BPPC/SDD-19

Page 1 of 19

SYSTEM DESIGN DESCRIPTION

LOW TEMPERATURE COOLING WATER
1.0

INTRODUCTION
This document presents a detailed description of the Low Temperature Water System for the 215
MW Bauang Diesel Power Plant. It includes the functions, criteria requirements, details of
components, instruments and controls, modes of operation and maintenance requirement for the
system.

1.1

System Function
The Low Temperature Water System provides the cooling requirement of Lube Oil Cooler, Charge
Air Cooler (2nd stage), Injector Water Cooler, Steam Drain Condenser. It also supplies water for
turbocharger washing operation.

1.2

Criteria Requirements
The system is designed in accordance with the following criteria:
1.2.1

General Requirements
A.
B.
C.

1.2.2

9-10
0.4% - 0.5% by wt.
38 oC - 45 oC

Engine Auxiliary Equipment Requirements (at full load)

A.
B.
C.
D.
E.
F.
G.

1.2.3

pH Value
Emulsion Oil (if added)
Water Temperature

Lube Oil Cooler (23E1) LT Water Flow

Charge Air Cooler LT Water Flow
Injector Water Cooler (22E1) LT Water Flow Total Flow at LT Water Flow Pump (19P1) Total Pressure (A, B and C)
Water Inlet Temperature at Radiator (19/21E1)
Water Outlet Temperature at Radiator
(19/21E1)

168 m3/hr
260 m3/hr
3
10 m /hr
438 m3/hr
3.5 bars
49.3 oC
-

38oC - 45oC

Steam Condensate Cooling Requirements (at full load)

A.
B.
C.

Condensate Cooling Radiator LT Water

Flow (0-19E1)
LT Water Pressure
LT Water Inlet Temperature at

50 m3/hr
1.5 bars

BPPC/SDD-19
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D.

1.3

Radiator (0-19E1)
LT Water Inlet Temperature at
Radiator (0-19E1)

52 oC

38oC - 45oC

Summary Description of the System

The Low Temperature Water System is a closed-type circuit and is divided into two (2) subsystems; a) Cooling System for Lube Oil Cooler (23E1), Charge Air Cooler (2nd stage) and
Injector Water Cooler (22E2). b) Cooling System for steam condensates recovery. The system also
supplies water during turbocharger washing operation.
1.3.1

The cooling system for engine auxiliaries is composed of LT Water Pump (19P1), Radiator
(19/21E) and LT Water Expansion Tank (19V1). Pipings, valves, instruments and control
are also provided for the system. During normal operation water is circulated by pump
(19P1) and flows to Charge Air Cooler (2nd stage), Injector Water Cooler (22E2) and Lube
Oil Cooler (23E1). The water then flows out of the engine auxiliaries and then cooled in the
radiator (19/21E1). LT Water Expansion Tank (19V1) ensures the circuit expansion and
the losses compensation. The venting holes of the Charge Air Cooler (2nd stage) are
connected with the expansion tank (19V1) bottom side via flow orifices.

1.3.2

Steam condensates recovery cooling system is composed of Water Cooling Condensate

Pump (0-19P1), Condensate Cooling Radiator (0-19E1), Condensate Water Expansion
Tank (0-19V1), pipings, valves, instruments and controls. Steam condensates that enter the
Steam Drain Condenser (0-32E2) is being cooled by the water circulated by pump (0-19P1).
Water then flows out of the condenser and enters the condensate radiator fan (0-19E1)
where it is cooled. Expansion tank (0-19V1) ensures the correct expansion and losses
compensation of the system. Make-up water is supplied by line 0-17-001-50-2 from Water
Treatment and Make-up Water System.

2.0

DETAILED DESCRIPTION OF THE SYSTEM

2.1

Components
2.1.1

LT Water Pump
Item No.
Quantity
Manufacturer
Operating Temperature
Water Density
Flow Rate
Suction Pressure
Delivery Pressure
Differential Pressure

19P1
21 (one per engine)
Sulzer Pompes
45 C
990 kg/m3
438 m3/h
0.8 bar
3.8 bar
3.0 bar

BPPC/SDD-19
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NPSH available
NPSH required
Rotating Speed
Input Power
Efficiency
No. of Bearing
Packing Gland Type
Suction Diameter
Delivery Diameter
Pump Material
Impeller
Shaft
Casing
Stuffing Box Packing
Coupling Type
Motor Data
Motor Type
Shaft Maximum Power
Shaft Minimum Power
Rotating Speed
Nominal Power
Nominal Speed
In
Max. Ambient Temperature
Relative Humidity
Insulation Class
Voltage
Phase/Frequency
Nominal Current
Power Factor
Efficiency
WR
Manufacturer
2.1.2

Ft20
Z20C13
Ft25
Carbon Ceramic
A65
MPTC
50 KW
46.50 kw
1780 rpm
63 KW
1775 rpm
6.7
40 C
TC
F
460V
3/60 HZ
60 A
0.85
94.1
3 kgm
Leroy Somer

LT Water Expansion Tank

Item No.
Quantity
Capacity
Tank Material

2.1.3

18 m. CL
4 m.CL
1750 rpm
46.5 KW
77 %
1
U3D
DN80PN10
DN65PN16

19V1
21
1 m3
ASTM A283 GRADE C

Radiator
Item No.

19/21E1

BPPC/SDD-19
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Quantity
Manufacturer
Operating Conditions
Fluid
Inlet Temperature
Outlet Temperature
Flow Rate
Density
Specific heat
Service Pressure
Calorific Power
Construction Code
Design Pressure
Test Pressure
Pressure Drop
Sooting Factor
Log. Middle Temp. Diff.
Surface tube/pipe area
Surface plates area
Exchange factor for bare pipe
Exchange factor for rad. plates
No. of Bundle
Width of Bundle
Bundle in parallel
Tubes/Bundle
Passes/Bundle
Sheets/Bundle
ND and Pipe Length
Tube Material
Radiating Plate
Radiating Plates Pitch/Material
Ventilating Fan Data
Type
Flow Rate
Rotating Speed
No. of Fan
Fan Power
Loud Power
Type of Transmission

Fan Motor Data:

Type
Shaft Maximum Power

21
GEA
Tube
Shell
Water
Air
49.3 C
38 C
45 C
45.1 C
3
448 m /h
989 kg/m3
0.998
0.24
1.8 bar
2472 KW
TEMA
4 bar
6 bar
0.69 bar
19 mm
-4
1.10
5.5 C
380 m
6310 m
909 kcal/mh C
54.85 kcal/mh C
3
2500 m.
3
390
2
5
11.9 mm x 8400 mm
Copper
Continuous
2.5/Copper
Axial
17.1 m3/s
860 rpm
15
7.8 KW
97.5 db
Direct

160 LU
7.8 KW

BPPC/SDD-19
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Rotating Speed
Starting Frequency/h
Nominal Power
Nominal Speed
In
Cn
Maximum Ambient
Temperature
Relative Humidity
Insulation Class
Voltage
Phase/Frequency
Nominal Current
Phase Factor
Efficiency
2.1.4

860 rpm
6
9 kw
860 rpm
3.8
1.7

38 C
90%
F
460 V
3/60 Hz
14.0
0.66
84.2%

Water Cooling Condensate Pump

Item No.
Quantity
Manufacturer
Operating Temperature
Water Density
Flow Rate
Suction Pressure
Delivery Pressure
Differential Pressure
NPSH available
NPSH required
Rotating Speed
Input Power
Efficiency
No. of Bearing
Packing Gland Type
Suction Diameter
Delivery Diameter
Pump Material
Impeller
Shaft
Casing
Stuffing Box Packing
Coupling Type
Motor Data
Motor Type
Shaft Maximum Power

0-19P1
3
Sulzer Pompes
45 C
990 kg/m3
50 m3/h
1 bar
2.5 bar
1.5 bar
18 m. CL
2.5 m.CL
1750 rpm
2.85 KW
72 %
1
Mechanical
DN80
DN65
Ft20
Z20C13
Ft25
Carbon Ceramic
A28
-

LS112M
3.2 KW

BPPC/SDD-19
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Shaft Minimum Power

Rotating Speed
Nominal Power
Nominal Speed
In
Cn
Max. Ambient Temperature
Relative Humidity
Heating
Insulation Class
Voltage
Phase/Frequency
Nominal Current
Phase Factor
Efficiency
WR
Protection Class
Manufacturer
2.1.5

2.85 kw
1730 rpm
4.8 KW
1750 rpm
6.27
2.4
50 C
100%
Class B
F
460 V
3/60 HZ
9A
0.82
83%
0.0284
IP55
Leroy Somer

Condensate Water Expansion Tank

Item No.
Quantity
Capacity
Tank Material

2.1.6

0-19V1
3
1 m3
ASTM A283 GRADE C

Condensate Cooling Radiator

Item No.
Quantity
Manufacturer
Operating Conditions
Fluid
Inlet Temperature
Outlet Temperature
Flow Rate
Density
Specific heat
Service Pressure
Calorific Power
Construction Code
Design Pressure
Test Pressure
Pressure Drop

Tube
0.15

0-19E1
21
GEA
Shell
Water
52 C
45 C
50 m3/h
0.988 kg/m3
0.999
2 bar
402 KW
TEMA
4 bar
6 bar

Air
38 C
45.8 C
164800 m3/h
0.24

BPPC/SDD-19
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Sooting Factor
Log. Middle Temp. Diff.
Surface tube/pipe area
Surface plates area
Exchange factor for bare pipe
Exchange factor for rad. plates
No. of Bundle
Width of Bundle
Bundle in parallel
Tubes/Bundle
Passes/Bundle
Sheets/Bundle
ND and Pipe Length
Tube Material
Radiating Plate
Radiating Plates Pitch/Material
Ventilating Fan Data
Type
Flow Rate
Rotating Speed
No. of Fan
Fan Power
Loud Power
Type of Transmission
Fan Motor Data:
Type
Shaft Maximum Power
Rotating Speed
Starting Frequency/h
Nominal Power
Nominal Speed
In
Cn
Maximum Ambient
Temperature
Relative Humidity
Insulation Class
Voltage
Phase/Frequency
Nominal Current
Power Factor
Efficiency
WR2

1.10-4
6.4 C
61 m
1016 m
895 kcal/mh C
54 kcal/mh C
1
2373 m.
1
296
2
4
12 mm
Copper
Continuous
2.5/Copper
Axial
15.2 m3/s
860 rpm
3
4.5 KW
95 db
Direct
160 M
3.9 KW
865 rpm
6
6.2 kw
860 rpm
3
1.7
40 C
90%
F
460 V
3/60 Hz
14.0 A
0.66
81.4%
0.089

BPPC/SDD-19
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2.1.7

2.2

Pipings and Valves

a.

Piping Specifications is listed in Appendix 7.2.

b.

List of Valves is in Appendix 7.3.

Instrumentations, Controls, and Alarms

Instrumentations, controls, and alarms are installed to ensure safe and proper operation of the
system.
2.2.1

Instruments
A.

Pressure Indicators
A.1

LT Water Pump Suction P.I.

Item No.
Quantity
Manufaturer
Operating Pressure
Operating Temperature
Range
Type
Material
Mounting
Diameter
Connection Position
Protection
Measuring Element
Type
Accuracy
Max. Temp.

A.2

PI 1-7.19102.1-3
21
HAENNI
1.3 bar
45 oC
-1/+3 bar
Wall Mounting, 3 brackets
Stainless Steel
Local
100 mm.
Vertical
IP65

Bourdon
Class 1
50 oC

PI 1-7.19103.1-3
21
HAENNI
3 bar
45 oC
0/6 B
Wall Mounting, 3 brackets
Stainless Steel

LT Water Pump Discharge P.I.

Item No.
Quantity
Manufaturer
Operating Pressure
Operating Temperature
Range
Type
Material

BPPC/SDD-19
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Mounting
Diameter
Connection Position
Protection
Measuring Element
Type
Accuracy
Max. Temp.
A.3

Local
100 mm.
Vertical
IP65

Bourdon
Class 1
50 oC

Water Cooling Condensate Pump Suction P.I.

Item No.
Quantity
Manufaturer
Operating Pressure
Operating Temperature
Range
Type
Material
Mounting
Diameter
Connection Position
Protection
Measuring Element
Type
Accuracy
Max. Temp.

A.4

PI 0.19101.1-3
3
HAENNI
1 bar
45 oC
-1/+3 B
Wall Mounting, 3 brackets
Stainless Steel
Local
100 mm.
Vertical
IP65

Bourdon
Class 1
50 oC

Water Cooling Condensate Pump Discharge P.I.

Item No.
Quantity
Manufaturer
Operating Pressure
Operating Temperature
Range
Type
Material
Mounting
Diameter
Connection Position
Protection
Measuring Element
Type
Accuracy

PI 0.19102.1-3
3
HAENNI
1.5 bar
45 oC
0-6 Bar
Wall Mounting, 3 brackets
Stainless Steel
Local
100 mm.
Vertical
IP65

Bourdon
Class 1

BPPC/SDD-19
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Max. Temp.
B.

Pressure Switch
B.1

Water Cooling Condensate Pump P.S.

Item No.
Quantity
Manufaturer
Operating Temperature
Operating Pressure
Casing
Type
Material
Mounting
Scale
Maximum Pressure
Mechanical Differential
Switch
Type
Number of Switch
Capacity
Measuring Element
Process Connection

C.

50 oC

PSL 0.19101.1-3
3
Danfoss
45 oC
1.5 bar

IP67
AL
Support Plate
0-2.5 Bar
6 Bar
0.1 B (not adjustable)

SPDT
1
6A 440 V
PG 13.5

3/8" M. BSP

PT 1-7.19101.1-3
21
ENDRESS & HAUSER
45 oC
2.5 bar

40 Bar

Relative Pressure
0-10 B
Ceramic
1
/2" BSP

Synthetic
On panel

Pressure Transmitter
C.1

Low Temperature Water Inlet P.T.

Item No.
Quantity
Manufacturer
Operating Temperature
Operating Pressure
Measuring Element
Type
Range
Material
Connection
Max. Pressure
Casing
Material
Mounting

BPPC/SDD-19
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Electrical Connection Transmitter

Supply
Output
Accuracy
D.

Connector DIN 43650

12.5 to 30 V
4-20 mA
0.5%

Temperature Indicators
D.1
D.2
D.3
D.4
D.5
D.6

L.O. Cooler (23E1) Outlet

L.O. Cooler (23E1) Inlet
Radiator (19/21E1) Inlet
2nd Stage CAC Outlet
2nd Stage CAC Outlet
2nd Stage CAC Inlet
Quantity
Manufacturer
Casing
Type
Casing Material
Tube Material
Casing Dimensions
Connection
Mounting
Accuracy
Immersion Tube Diameter
Length under connection
Range

D.7
D.8

TI 1-7.19102.1-3
TI 1-7.19103.1-3
TI 1-7.19104.1-3
TI 1-7.19106.1-3
TI 1-7.19107.1-3
TI 1-7.19108.1-3
-

21
HAENNI

Brass
-

Dial
Stainless Steel
Dia = 80 mm.
with protection pipe 1/2" BSP
Local
Class 1
8 mm.
160 mm.
0-60 oC

Injector Water Cooler (22E2) Inlet T.I. 1-7.19112.1-3

Injector Water Cooler (22E2) Outlet T.I. 1-7.19113.1-3
Quantity
Manufacturer
Casing
Type
Casing Material
Tube Material
Casing Dimensions
Connection
Mounting
Accuracy
Immersion Tube Diameter
Length under connection
Range

21
HAENNI

Brass
-

Dial
Stainless Steel
Dia = 80 mm.
with protection pipe 1/2" BSP
Local
Class 1
8 mm.
63 mm.
0-120 oC

BPPC/SDD-19
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D.9

Steam Drain Condenser (0-32E2) Inlet T.I.

Item No.
Quantity
Manufacturer
Operating Temperature
Operating Pressure
Casing
Type
Casing Material
Tube Material
Casing Dimensions
Connection
Mounting
Accuracy
Immersion Tube Diameter
Length under connection
Range

D.10

TI 0-19103.1-3
3
HAENNI
45 oC
1.5 Bar

Brass
-

Dial
Stainless Steel
Dia = 80 mm.
with protection pipe 1/2" BSP
Local
Class 1
8 mm.
100 mm.
0-60 oC

Steam Drain Condenser (0-32E2) Outlet T.I.

Item No.
Quantity
Manufacturer
Operating Temperature
Operating Pressure
Casing
Type
Casing Material
Tube Material
Casing Dimensions
Connection
Mounting
Accuracy
Immersion Tube Diameter
Length under connection
Range

E.

TI 0-19104.1-3
3
HAENNI
50 oC
1 Bar

Brass
-

Dial
Stainless Steel

TE 1-7.19101.1-3

Dia = 80 mm.
with protection pipe 1/2" BSP
Local
Class 1
8 mm.
100 mm.
0-60 oC

Temperature Element
E.1

LT CAC Water Inlet T.E.

Item No.

BPPC/SDD-19
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Quantity
Manufacturer
Operating Temperature
Operating Pressure
Measuring Element
Type
Nature
Head
Type
Connection
Protection
Material
Length
Type and Dia. of
Connection
Thermowell
Type
Outside Dia.
Length in Process
Inside Thread
Process Connection
F.

21
CMR
45 oC
3 Bar

PT 100

Connector
53 2411

INOX
110 MM

M18 x 1.5
-

DGS
12 MM
110 MM
M18 x 1.5
1
/2" BSP

Item No.
Quantity
Manufacturer
Operating Pressure
Operating Temperature
Flow Rate
Valve Body
Connection

TCV 1-7.19103.1-3
21
Samson
2 Bar
55 oC
448 m3/h

Material
Seat/Plug
Seat Material
Plug Material
Stem Material
Ways Number
Drawing Type
Type
Actuator
Type

Sandwich
DN200/PN25
Carbon Steel

Temperature Control Valves

F.1

LT CAC Water Bypass TCV

Stainless Steel
SS
SS
2
VETEC
72.26 MAXIFLUX
-

S.320, Pneumatic

Assembly

BPPC/SDD-19
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Control Signal
DP Firm
Safety Valve Position
Positioner
Type
Control Type
Supply Pressure
Connection
Position Transmitter
Type
Output Signal
Accessories
Air Set

F.2

1.7 to 3.1 Bar

6 Bar
FC
-

Electro-Pneumatic: 3767
4-20 MA
3.6 Bar
1
/4" NPT

3767.060
4-20 MA
Type 708 + MANO (1/4" NPT
Connection)

LT Water Discharge TCV

Item No.
Quantity
Manufacturer
Operating Pressure
Operating Temperature
Flow Rate
Valve Body
Connection

TCV 1-7.19102.1-3
21
Samson
2 Bar
55 oC
448 m3/h

Material
Seat/Plug
Seat Material
Plug Material
Stem Material
Ways Number
Drawing Type
Type
Actuator
Type
Control Signal
DP Firm
Safety Valve Position
Positioner
Type
Control Type
Supply Pressure
Connection
Position Transmitter

Sandwich
DN200/PN25
Carbon Steel

Assembly

Stainless Steel
SS
SS
2
VETEC
72.26 MAXIFLUX
S.320, Pneumatic
0.9 to 1.7 Bar
6 Bar
FO
-

Electro-Pneumatic: 3767
4-20 MA
3.6 Bar
1
/4" NPT

BPPC/SDD-19
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Type
Output Signal
Accessories
Air Set

G.

Type 708 + MANO (1/4" NPT

Connection)

Level Indicators
G.1

LT Water Expansion Tank (19V1) L.I.

Item No.
Quantity
Manufacturer
Operating Temperature
Operating Pressure
Type
Mounting
Measuring Tube Material
Connection
Connection Material
Distance Flanges
Float Material
Range

G.2

LI 1-7.19101.1-3
21
BESTOBELL MOBREY
Atm
50 oC
Magnetic Level with Flaps
Indicator
Side-side
SS-304L
Flanges DN20 PN16 RF
Cadmied Plated Steel
800 mm
SS-316L
0-100%

Condensate Water Expansion Tank (0-19V1) L.I.

Item No.
Quantity
Manufacturer
Operating Temperature
Operating Pressure
Type
Mounting
Measuring Tube Material
Connection
Connection Material
Distance Flanges
Float Material
Range

H.

3767.060
4-20 MA

Level Switches

LI 0.19101.1-3
3
BESTOBELL MOBREY
Atm
50 oC
Magnetic Level with Flaps
Indicator
Side-side
SS-304L
Flanges DN20 PN16 RF
Cadmied Plated Steel
800 mm
SS-316L
0-100%

BPPC/SDD-19
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H.1

LT Water Expansion Tank LS

Item No.
Quantity
Manufacturer
Operating Temperature
Operating Pressure
Casing
Material
Connection
Mounting
Transmission Type
Float Material
Switch
Type
No. of Switch
Capacity
Gland Type

H.2

LSL 1-7.19101.1-3
21
BESTOBELL MOBREY
50 oC
Atm

Aluminum
Square Flanges 92 x 92 M
Side
Magnetic
Stainless Steel
-

Double Pole - Change Over Dry Contact

2 SPDT
8A, 440AC-1A, 240V DC
M25 ISO Standard

Condensate Water Expansion Tank LS

Item No.
Quantity
Manufacturer
Operating Temperature
Operating Pressure
Casing
Material
Connection
Mounting
Transmission Type
Float Material
Switch
Type
No. of Switch
Capacity
Gland Type

2.2.2

LSL 0.19101.1-3
3
BESTOBELL MOBREY
85 oC
Atm

Aluminum
Square Flanges 92 x 92 M
Side
Magnetic
Stainless Steel
-

Double Pole - Change Over Dry Contact

2 SPDT
8A, 440AC-1A, 240V DC
M25 ISO Standard

Controls
The LT Water Pump (19P1), Radiator (19/21E1), Water Cooling Condensate Pump (019P1) and Condensate Cooling Radiator (0-19E1) can be started/ stopped from the Local
Control Panel, BJ Panel, OCW Panel and OIS console.

BPPC/SDD-19
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Starting/stopping the pump/radiator from local control panel, the mode selector switch is
placed in LOCAL and press ON/OFF pushbutton switch.
In the BJ panel, each pump/radiator is provided with OFF-RUN-START control switch and
RUN/FAULT indicating lights. To start/stop the pump, the local control panel mode
selector is placed to REMOTE and placing the control switch to START/OFF position.
Operating the pump/radiator through OCW panel, the OCW selector switch should be in
LCO position, BJ control switch in RUN position and local control panel switch to
REMOTE position before pressing the Auxiliary Sequence Stop or Start pushbutton.
The pump/radiator can also be started/stopped at OIS console by placing the OCW selector
switch to RCO position, BJ control switch in RUN position and local control panel switch to
REMOTE position.
2.2.3

Alarms
The following illuminated annunciators are provided at the OCW.
a)
b)

LT Cooling Water Expansion Tank 19V1 Low Level

Water Tank 0.19V1-Low Level

3.0

MODES OF OPERATION

3.1

Start-up
The system is prepared for startup by performing valve lineups and checking circuit general
condition. Ensure that expansion tank (19V1) is in normal level through level indicator (LI 19101).
The pump (19P1) will be started at BJ panel. The circuit must be vented and checked for leaks.

3.2

Normal Operation
During normal operation, periodic checking/monitoring of LT water pump (19P1), water cooling
condensate pump (0-19P1) expansion tank level (19V1) and related instruments is necessary.
Unusual sound or heavy vibration on motors and pumps are also monitored for early detection of
abnormalities.

3.3

Shutdown

BPPC/SDD-19
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The system can be shutdown depending on the condition of the main engine. If the engine will not
be available for one to five hours after shutdown, the radiator fans (19/21E1) is stopped by pressing
push button OFF in its local control panel. Consequently, stop the LT water pump (19P1) by
placing its control switch to OFF position.

4.0

SAFETY PRECAUTIONS
No special hazards are considered to exist in this system beyond those associated with work near the
rotating equipment and heated boundaries.

5.0

MAINTENANCE
All instrumentations, controls and alarm components shall be tested and calibrated at regular
intervals. Manufacturer's recommendations for Preventive Maintenance and inspection should be
the minimum basis.

6.0

REFERENCES

6.1

Water Diagram Sector 1/2/3, 0-137-755-156/040/162

6.2

New Sulzer Diesel File No. 11/7B

6.3

New Sulzer Diesel File No. 8/1

6.4

NSD Power Plant Operation from OCW Control Panel Rev.0

7.0

APPENDICES

7.1

Low Temperature Cooling Water System (Schematic)

7.2

Piping Specifications

7.3

List of Valves

7.4

LT Water Pump (19P1) Wiring Diagram

7.5

Equipment Location Drawing