Diesel Power Generation Plants with

Multiple Machines in Parallel and on

the Electrical Power Grid

Technology Training that works

 Learning objectives
• Industrial applications
• Power generation plant applications
• Essential subsystems in a Engine based power plant
• Single and multiple sets
• Fuel storage requirements
• Air Intake system
• Exhaust system
• Auxiliary power requirements
• Typical power schemes
• Typical power plant layout

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 Application of Diesel Generators in Industry
• Mainly used for emergency power assistance
• Loads will typically consist of:
– Critical drives
– Battery charges/UPS equipment
– Emergency lighting
– Safety related equipment (fire fighting, cooling water)
• Any other facility requiring power without long interruption if
mains power fails

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 Application of Diesel Generators in Industry
• Supplementing regular power source
• Areas with weak grids of inadequate capacity
• Unreliable power supply
• Aim is to continue with production to full capacity
• Shortfall from external power source is made up
• Base load operation (in parallel with grid) is NOT the objective in
such a case

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 Power generation applications
• Non-industrial power generation application for small
towns and communities
• Lack of other resources
– Hydro-electric power or other means is not possible
• Long distance from existing grid resources
– Uneconomical to establish T&D infrastructure
• Small capacity requirements
– Thermal /nuclear generation unviable for such capacity
• Multiple generators for reliability

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 Power plants using Diesel Generation
• A power plant contains all essential facilities for operation and
supply of power
• Main component is naturally the engine-generator
• Will also include other facilities such as:
– Fuel storage, cooling equipment, lubrication systems, auxiliary ac and
dc power, switchgear for generator and auxiliaries, minor repair and
maintenance facilities
– Control and instrumentation of the engine
– Synchronising facility where needed
– Associated power off take/distribution switchgear

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 Engine generator
• Usually supplied as a complete unit
• A common base-frame/skid with engine generator
and mounted auxiliaries
• Sometimes portable units for small capacities
• Can be complete with generator control,
switchgear
• Requires hook up to external facilities located
outside the base-frame

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 Typical Portable Generator Set

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 Layout of a small DG installation

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 Layout of a large DG installation

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 Salient aspects of large DG plants
• Heat recovery boiler located on roof as a part of the stack
system
• Feed water tank for boiler
• Overhead crane in DG hall (Electrically operated where
required)
• Heat exchangers/cooling towers outside the building (one
for each unit) for radiator water cooling
• Air filter at intake point with silencer
• Fuel treatment plant and fuel circulation system
• Lube oil tank below grade level

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 Fuel storage system-Typical

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 Fuel storage-salient features
• Storage capacity of 15 days to 30 days of consumption
• Metal storage tanks (separate for each fuel) for fuel and lube
oil
• Tank farm with dyke for containment
• Local codes for flammable/explosive substances to be adhered
to
• Truck unloading and receiving arrangement with measuring
facility
• Fire hydrants and foam type extinguishers

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 Air intake
• For combustion air to the engine
• Intake filter facing outside
• Oil wetted filters for large ratings
– Viscous oil used captures fine dust
• Silencers required to limit noise to 40 dB (A) as air velocity can
be high
• Compressor unit of Turbocharger at intake point with an after
cooler
• Isolation using bellows between intake system and turbocharger

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 Exhaust system components
• Turbo-charger (recovers exhaust gas energy)
• Ducting from engine exhaust with expansion bellows
• Silencer
• Waste heat recovery boiler
• Chimney
• Exhaust gas quality measurement devices
• Lightning protection/aviation obstruction lights for
chimney

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 Typical exhaust system

Plan view

Section

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 Auxiliary power system
• Auxiliary power is about 3 to 4% of DG output
• Main auxiliaries
– Lube oil pump
– Engine cooling water pumps
– Fuel injection pumps
• Auxiliary source: DG Plant power
• Auxiliary transformer for HV alternators
• Redundancy for aux. power to meet failures

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 Auxiliary loads (Fuel system)
• Fuel oil unloading pumps
• Fuel oil separators or purifiers
• Fuel oil transfer pumps
• Fuel oil Booster pumps
• Return oil pumps
• Lube oil unloading pumps
• Lube oil separator units
• Pre lube oil pumps
• Sludge transfer pumps
• Oily water transfer pumps

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 Other auxiliary loads
• Starting air compressor
• Instrument air compressor
• DG hall ventilation system consisting supply and exhaust fans
• Plant water system motors
• Plant lighting loads
• Workshop Equipment Loads
• Air conditioning loads for control room
• Switchyard equipment and Plant HT and LT switchgear power requirement

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 Important aspects in planning
• What is the objective of the generation?
• What will be the voltage of the generators?
• Generator location and hook up with the system
• What is the capacity requirement?
• Multiple generators to be provided? (Synchronising and load
sharing)
• Sizing of generator units
• Special conditions to be looked at (de-rating may be necessary)
– Large drives to be started on the generator
– High non-linear load component
– Unbalanced loads to supplied

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