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Technical Specification
3 MAN Gensets 18V48/60TS plus mechanical & electrical auxiliaries
Revision History
Table of Contents
1 Design data and performance guarantees 1
1.1 Design data 1
1.2 Performance data 4
2 Diesel engine 5
2.1 Engine scope and special engine accessories 6
2.2 Engine System 6
2.3 Detailed Technical Specification of one engine 48/60TS 8
3 Generating set 10
3.1 Connecting elements 11
3.2 Genset 12
4 Mechanical scope 15
4.1 Auxiliary systems, engine related 15
4.2 Auxiliary systems, plant related 18
4.3 Exhaust gas system 21
5 Electrical scope 22
5.1 Control and monitoring system 22
6 Miscellaneous 30
6.1 Plant service and protection systems 30
6.2 Documentation 30
8 Services 34
8.1 Quality Management, Quality Assurance 34
8.2 Project engineering 35
8.3 Logistics 37
8.4 Site activities 37
8.5 Project services 40
12 General information 51
12.1 List of sub suppliers 51
12.2 References 52
12.3 Leaflets and brochures 57
1
Peak ground acceleration with a probability of 10% to be exceeded in 50 years and
a return period of 475 years based on reference ground with a shear wave velocity >
800 m/s
Permissible
frequency limits 105 Continuous power
100
Load [%]
95
90
-6 -4 -2 0 2 4 6
Engine speed / Nominal speed [%]
2 Diesel engine
General The MAN engine 18V48/60TS is a
description four stroke, medium speed Diesel
engine, two-stage turbocharged and
charge air cooled. The engine is pre-
pared for operation on HEAVY FUEL.
Compared to other medium speed
engines, covering the same power
range, the 18V48/60TS produces high
power from a compact, efficient de-
sign.
2
Dimensions and weight of the engine 48/60TS:
Height (H) 5355 mm
Length (L) 13148 mm
Width (B) 4700 mm
Weight (dry) 255000 kg
2
The dimensions and weight stated correspond to the engine only. All given masses
are without lube oil and cooling water. Dimensions and weights are given for guid-
ance only and are subject to change without notice.
010 3 Engines 18V48/60TS, suitable for operation on heavy fuel oil, as per following
MJA10 AV010 detailed Technical Specification
3 Generating set
General Our generating sets are designed for power generation in continuous, durable
description and safe operation. The area of application comprises ranges from supplies of
basic loads in public mains or coverage of peak loads to isolated applications
for industrial consumers.
The engine is rigidly mounted on a steel frame, acting as the lubricating oil
service tank, which is resiliently seated on a simple concrete foundation by
spring isolators. The alternator is connected to the engine by a flexible
coupling, rigidly mounted and grouted onto a separate and elevated concrete
foundation.
This genset design is prerequisite for our simple, small, single-floor power
house concept to get short assembly and commissioning periods at low cost.
Outline
dimensions
3
Dimensions and weight of the generating set:
Height (H) 6530 mm
Length (C) 18558 mm
Width (W) 4700 mm
Weight (dry) 375000 kg
3
The dimensions and weight stated correspond to the complete unit including alter-
nator. The total weight varies depending on the alternator make. All given masses
are without lube oil and cooling water. Dimensions and weights are given for guid-
ance only and are subject to change without notice. The length of the genset unit
depends on the alternator make.
3.2 Genset
against overvoltage
Droop current transformer installed in main terminal box
Star point current transformers for protection purposes installed in main
terminal box
Painting similar to engine colour
Foundation bolts
Final series test report according to manufacturers standard is included.
4 Mechanical scope
030.020.150 3 Lube oil replenishing and flow rate measuring device consisting of:
MJV23 CF010 Oval gear meter including pulse trigger
Solenoid valve
4.1.8 Insulation
040.050.080 1 Heavy fuel oil pressure limiting valve for installation in piping for heavy fuel oil
END55 AA040 inside the engine room.
5 Electrical scope
MEASURING:
1 Voltmeter
1 Voltmeter selector switch for generator, 3 positions
3 Ammeters
SYNCHRONISING:
1 Automatic synchronizing unit with black busbar possibility door mounted
1 Synchrocheck relais with black busbar possibility
1 Key selector switch "GCP-SCADA"
1 Selector switch for GCP synchronizing "AUTO-OFF-MANUAL"
1 LED synchronoscope with integrated synchronizing check relay
1 Double-voltmeter
1 Double-frequency meter
1 Push button "CB ON"
1 Push button "CB OFF"
1 Switch "frequency lower / 0 / frequency higher"
1 Switch "voltage lower / 0 / voltage higher"
ALTERNATOR PROTECTION:
digital protection relays, with following protection functions:
Stator earth fault (59N)
Directional earth fault (67N), with cable current transformer
Over-current (51)
Short-circuit (50)
Negative sequence (46)
Differential current (87 G)
Loss of excitation (40)
Reverse power (32)
Over-/under-frequency (81)
Under-voltage (27)
Over-voltage (59)
CONTROL:
AC Supply input for panel equipment (fan, socket, anti-condensation
heating).
AC Supply input from UPS for control
Necessary set of mcbs
Necessary set of contactors, relays, transducers, terminals a.s.o.
Fault indication light on roof
Interface to external control with pot. free contacts, digital in/outputs, pot.
free analogue inputs according interface list.
All devices marked on device and mounting plate acc. circuit diagram.
1 Panel inside fixed list of mcbs and related functions.
Emergency stop push button with interlocking relays with connection to the
positively driven contacts and external reset terminals in ECP, function:
engine shut down
Spare terminals 10% of installed
PLC Part:
with Siemens Simatic S7-400
1 Power supply unit
1 CPU
1 Communication processor for industrial Ethernet
*Digital input boards with 32 inputs.
*Digital output boards with 32 outputs.
*Analogue input boards with 16 inputs.
SOFTWARE:
consisting of:
Start/stop and monitoring program for genset auxiliaries (automatic /
manual)
Start and stop program for engine
Generator active power monitoring
Generator current monitoring
Generator voltage monitoring
Generator power factor monitoring
Generator frequency monitoring
Generator circuit breaker control / Synchronizing release
Engine load regulation
Engine analogue value monitoring
Storage of analogue values
Overload monitoring (> 100 % load, load reduction)
Alternator winding temperature protection (49)
(alternator equipped with 6 Pt100 sensors)
Alternator bearing temperature protection (39)
(bearing equipped with Pt100 sensor)
In case of trouble, the indication of arisen failures will be indicated in sequence
of incidence with additional indication of time, when it happened.
MEASURING:
For 1 outgoing to step-up transformer:
Voltmeter
Voltmeter selector switch, 3 positions
3 Ammeter
1 Power factor meter 0,5-1-0,5*
1 MW-meter for connecting on transducer*
1 Measuring transducer for active power*
1 Measuring transducer for reactive power*
1 Measuring transducer for current*
1 Measuring transducer for voltage*
1 Measuring transducer for power factor*
1 Measuring transducer for frequency*
* can be integrated in one device
SYNCHRONISING
1 automatic synchronizing unit for outgoing to grid,
1 automatic synchronizing unit for LV circuit breaker to station transformer
1 Key selector switch "CCP-SCADA"
1 Selector switch for CCP synchronizing: "AUTO-OFF-MANUAL"
1 LED synchronoscope with integrated synchronizing check relay
1 Double-voltmeter
1 Double-frequency meter
1 Mimic diagram equipped with position indicator and push buttons ON/OFF
for each MV circuit breaker (except alternator CBs) and synchronisable LV
CBs
1 Control switch "frequency lower / 0 / frequency higher"
1 Control switch "voltage lower / 0 / voltage higher"
PROTECTION
CONTROL:
consisting of:
AC supply input for panel equipment (fan, socket, anti-condensation
heating)
AC UPS input for control
Necessary set of mcbs with short circuit withstands 10kA for values <= 20A
and 15kA for values > 20A
Necessary set of contactors, relays, transducers, terminals a.s.o.
Horn for alarm door mounted, fault indication light on roof
Interface to external control with pot. free contacts, digital in/outputs, pot.
free analogue inputs according interface list
All devices marked on device and mounting plate acc. circuit diagram
1 Panel inside fixed list of mcbs and related functions
1 Set of push buttons: lamps test, horn off, reset etc.
1 Set of control lamps: common aux. fault etc.
1 Control equipment for detection of mains fault
PLC Part:
Hardware with Siemens Simatic S7-400
Consisting of:
1 Power supply unit
1 CPU41_
1 Communication processor for industrial ethernet
*Digital input boards with 32 inputs
*Digital output boards with 32 outputs
*Analogue input boards with 16 inputs
1 Siemens Operator Panel OP 677 19"
1 MPI connection from CPU to OP 677 19"
1 Profibus connection to CAP
1 Profibus connection to CAPP
Data link to Central Supervisory System: Ethernet.
Software:
consisting of:
Control (switch ON/OFF, interlocking, release) of all motor operated circuit
breakers in MV switch gear and LV main distribution
Control of all plant auxiliaries acc. to power station design "Automatic-
Manual"
Plant power management acc. to remote or local demand
Load sharing program for load balance of the engines, including monitoring
of nominal load and reverse power
Control for start and stop of the gensets depending on load demand.
Island operation features
Load shedding program, in case of overload and underfrequency
Control for earthing resistors with selector switch "Automatic-Manual"
Mimic diagram for earthing CB with control lamp "ON"
Control for interlocking of earthing CBs (only one CB is on)
Mimic diagram for all motor driven CBs
Hardware:
2 Server PC with CPU with appropriate performance and memory capacity,
with state of the art operating system, with hard disk, CD-ROM, interfaces 2
x serial, 1 x parallel, state of the art graphic board, 3 Ethernet connections
standard keyboard (english)
redundant remote control via modem
3 Operator Station PCs with CPU with appropriate performance and
memory capacity, with state of the art operating system, with hard disk, CD-
ROM, interfaces 2 x serial, 1 x parallel, USB, state of the art graphic board,
ethernet connection
standard keyboard (english) and mouse
19" Monitor (TFT)
one color inkjet desk top printer, DIN A4 with cut sheet feeder
one black/white laser desk top printer, DIN A4 with cut sheet feeder
Ethernet switches
Software:
for 3 generating sets installed on each PC, consisting of:
complete overview of the power station
presentation of genset with analog value indication
single line diagram of the power station
overview of the lube oil system
overview of the cooling water system
6 Miscellaneous
6.2 Documentation
8 Services
8.2.3 3D modelling
210.022 -1 1 3D modelling
Based on the engineering services mentioned above MAN Diesel & Turbo will
execute a 3D modelling for Powerhouse.
As an outcome of the finished 3D model following drawings will be provided.
General drawings for mechanical erection of the plant:
Equipment location plan
Support location plan
Main cable tray plans
Guidance drawings for the preparation of plant steel works:
Pipe support drawings
Additional steel support drawings
Drawings for preparation and execution of piping works:
Pipeline installation plans
System isometric drawings
Pipe isometric drawings
8.3 Logistics
8.4.2 Commissioning
Optional service
240.010 -1 1 Factory training (mechanical)
Basic mechanical training course for up to 6 plant operators at the PrimeServ
Academy. Duration of the training is 5 days, training without traveling
expenses, boarding and lodging. The training language will be English.
Seminar contents:
Welcome and general introduction:
Introduction to the specified engine type
Safety and special tools
Handling of manuals and work cards
Hydraulic tensioning tools
Running gear maintenance
Fuel injection system
Lube oil system
Pneumatic system
Engine starting system
Cooling water system
Operating data of systems on engine
Turbocharger basics
Turbocharger maintenance
Introduction to Engine Control System
Operation of Engine Control System
Operating and maintenance experience
Identifying minor faults and troubleshooting
Execution of maintenance tasks defined byMAN Diesel & Turbo
instructions.
The training is subject to our general terms and conditions published on our
homepage www.mandiesel.com.
Optional service
240.015 -1 1 Factory training (electrical)
Basic training in electrical operation up to 6 participants. The training consists
of 5 working days, training without traveling expenses, boarding and lodging.
A detailed training schedule for the training program will be elaborated by the
PrimeServ Academy at least fourteen days prior to course implementation. The
training language will be English.
The course includes theoretical training as well as field exercises:
Maintenance procedures on alternators, transformers, switchgears and DC
systems.
Review of single line diagrams, switchgear and relay maintenance and
trouble shooting,
Introduction to the instrumentation and control system, such as e.g. control
fundamentals, sensors, transmitters, instrumentation and control systems.
The course will be held by professional trainers, dedicated to training only,
using multi-media equipment. Each participant will receive a personal copy of
the full course documentation.
The training is subject to our general terms and conditions published on our
homepage www.mandiesel.com.
The costs of the services rendered shall be accounted on the basis of the costs
incurred for each MAN Engineer as follows:
For each working day (8 hours),
without Saturdays, Sundays and Holidays EUR 1,100.00
Daily allowance per calendar day
with free accommodation EUR 85.00
For each overtime hour in excess of the
daily working time of 8 hours,
as well as for each working hour
on Saturdays, Sundays and Holidays EUR 200.00
The costs of the services rendered shall be accounted on the basis of the costs
incurred for each MAN Technician as follows:
For each working day (8 hours),
without Saturdays, Sundays and Holidays EUR 880.00
Daily allowance per calendar day
with free accommodation EUR 85.00
For each overtime hour in excess of the
daily working time of 8 hours,
as well as for each working hour
on Saturdays, Sundays and Holidays EUR 160.00
Should any evaluation costs be made in the workshops, then these will be
added to the invoice.
Travelling time will be charged at above mentioned prices. Travelling and
accommodation costs will be invoiced as incurred.
Value added tax
The above mentioned rates, resp. expenses, are quoted without VAT. The
corresponding VAT (turnover tax) will have to be added to those amount
according to the legal regulations which apply.
Electrical:
Terminal boxes on the modules / auxiliaries / sensors for connection to the
power and control cables
9.2.5 Engineering
Civil: n/a
E&M: Inside power house
PIDs: For fuel, intake air, exhaust gas, cooling water, lube oil.
11.2.3 Miscellaneous
Anything not specifically mentioned in the quoted scope is not included.
Minor changes due to technical development, design and output are reserved.
11.3 Drawings
12 General information
12.2 References
Total
Customer Country No. x Engine
Power
Total
Customer Country No. x Engine
Power
Total
Customer Country No. x Engine
Power
Total
Customer Country No. x Engine
Power
Stationary Engine
Programme 2011
MAN Diesel & Turbo power plants are located in all
regions of the world – in deserts, on pack-ice, at
low altitude or in high mountain regions. Whether
located in an area with a climate of dry heat,
tropical air humidity, permanent frost or extreme
temperature fluctuations, our power plants always
provide reliable energy.
Our power plants are able to be operated on
various kinds of fuels with highest flexibility and
economy.
Power Plants
Energy wherever you need it.
MAN Diesel & Turbo is one of the world’s leading
suppliers of land-based and floating power plants
based on Diesel and gas engines. Over the last
century we have built thousands of Diesel power
plants worldwide. The experience we have gained
and the technology we have developed over that
time enables our specialists to tailor power plants
to the individual needs of customers all over the
world.
18V48/60TS
Two-stage turbocharged diesel engine
Brief description of the MAN Diesel & Turbo engine
type 18V48/60TS with technology information and
technical details as well as engine dimensions.
The first choice when it comes to economy and
ecology. With a power output range of 18,900 kW
to 21,600 kW, this reliable, high-output engine is
the four-stroke heart of medium and large diesel
power plants the world over.
A true “prime mover”.
TCA
The New Turbocharger Generation
MAN Diesel & Turbo has more than 60 years
unprecedented experience of producing
turbochargers with plain bearings and uncooled hot
gas casings.
The new series of TCA turbochargers are available
in 2 stroke and 4 stroke versions for diesel, dual fuel
and gas engines. They have been developed to
provide a robust and reliable platform for engine
applications ranging from 2,500 kW up to
35,400 kW output per turbocharger.
Courses 2011
MAN PrimeServ Academies
Customised training programmes from basic Diesel
engine maintenance to complete power plant
operation.
We offer training modules for your Plant Managers,
Maintenance Personnel, Operators and Control &
Instrumentation staff.
In-factory and at-site courses for increased
productivity and enhanced quality.
TECHNO-COMMERCIAL OFFER
COGENERATION – 2.35MW
28.05.2013
1 GENERAL
2 SCOPE OF SUPPLY
3 TECHNICAL SPECIFICATIONS OF BOILER
4 TECHNICAL SPECIFICATIONS OF TURBINE GENSET
5 PRICE SCHEDULE
6 GENERAL TERMS & CONDITIONS
1- GENERAL
One (3) nos. of ALFA LAVAL (AALBORG)WHRB with all other auxiliaries.
One (3) nos.of DAMPER, Electrically operated gas diverter damper.
One(1) no. of TRIVENI Turbine Generator Set with Steam turbine, Condensing System
and AC Generator with all other auxiliaries.
b Fuel HFO
CO2 5.50
O2 12.10
H2O 7.50
SOX 0.08
NOX 0.12
CO 0.01
N2 75
TECHNICAL SPECIFICATIONS OF COGENERATION POWER PLANT
√-IncludedinMPPLScope X-ExcludedfromMPPLScope
Fabrication
Basic Detailed Sup
ItemDescription Supply Site &
Engineering Engineering Com
Erection
VILWORKANDRELATEDACTIVITIES
asteHeatRecoveryBoilers √ √ X X
ilerfeedwaterPumps √ √ X X
cessories&AuxiliariesPackageforWasteHeatRecoveryBoiler √ √ X X
eamTurbinePackage √ √ X X
aterCooledCondenserPackage √ √ X X
ndscaping,Roadandrelatedactivities √ √ X X
ilerWaterTreatmentPlant&ETP √ √ X X
ow downpit,NeutralizationPit,EarthingPit √ √ X X
uck ableroadup tofoundation √ √ X X
ASTEHEATRECOVERYBOILER PACKAGE
ainHeatRecoveryBoiler- 3 No’s √ √ √ X
essurePart √ √ √ X
ilerCasing √ √ √ X
uctureandSupport √ √ √ X
aterCooledCondenserPackage √ √ √ X
undationBolts √ √ √ X
otblowersfortubecleaning √ √ √ X
struments,MountingsandControlsof WHRB √ √ √ X
haustandbypassgasDivertervalveforgasisolation √ √ √ X
rewAirCompressorforInstrumentair √ √ X X
aterTreatment PlantforBoiler feedand cooling towermake-up. √ √ X X
mplecoolers √ √ √ X
owdownsystemforWHRB √ √ √ X
aerationsystemstankandChemicaldosing √ √ √ X
xiliariesandaccessoriesofWHRB √ √ √ X
EAMTURBINEANDAUXILIARIES PACKAGE
eamTurbinewithGenerator √ √ √ X
aterCooledCondenserPackage √ √ √ X
olingTowerPackageforMainandAuxiliary √ √ √ X
ushingLubricantsOilandfirstfillofchemical √ √ √ X
ECTRICAL&INSTRUMENTATION PACKAGE
steamandwatercontrolvalveassemblies √ √ √ X
strumentation and control cabling for Wasteheat driven power plant
√ √ √ X
thin battery limit.
rbine and Generator Protection Panels (NGR, Relay metering control &
√ √ √ X
nch panel,Turbine control panel, AVR panel).
ectricalinspectorateclearancesifany √ √ X X
earances/approvalsstatutorybodyfromproposedSEBorPoweranyotherPlant. √ √ X X
cumentation support for the inspection /
√ √ √ X
proval,statutoryapprovalsetc.ofelectricalinspectorate
art-up,GenerationCumPower
acuationsystem:-
kVPowerPlantSwitchgearSystemwithinbattery limit √ √ √ X
Cable
cablewithinbatterylimit. √ √ √ X
VSwitchgearSystemforpowerplantwithinbatterylimit
KVIndoorMVSwitchgearSystem √ √ √ X
Vcableandcabletraywithinbatterylimit √ √ √ X
tterybackupforMVswitch gearchargersystem&EOP(1starter)
√ √ √ X
PINGWITHSUPPORTINGSTRUCTURE PACKAGE
eam&FeedWaterPiping √ √ √ √
ndensatePiping √ √ √ √
strumentair,DrainandVentPiping √ √ √ √
olingWater&CondensatePiping √ √ √ √
pansionLoops/BellowsinabovePiping √ √ √ √
pportingstructureforabovePiping √ √ √ √
SULATIONANDCLADDINGPACKAGE
sulationandCladdingforWHRBPackage
cludingmainWasteheatrecoveryboilers, √ √ √ √
Atank,Blowdowntank,Dampers,Ductotheraccessoriesinboiler package
sulationandCladdingforDuctingPackage √ √ √ √
sulationandCladdingforPipingPackage √ √ √ √
sulationGeneratorandsetPackageCladdingforTurbine& √ √ √ √
SCOPE – EXCLUDED
Construction: AV-6N exhaust gas boiler is a water tube exhaust gas boiler, optimized for
heat recovery from diesel engine exhaust gas. The boiler generates superheated steam for
steam turbine application.
The boiler consists of following heating sections: Super heater, evaporator and economizer.
The exhaust gas inlet is in the upper part and the outlet in the lower part of the boiler, i.e.
exhaust gas flows downwards.
The extended heat transfer surfaces consist of horizontal plain steel tubes equipped with
steel fins. These water tubes are connected to inlet and out manifold pipes. The tubes are
twin tube construction of material P235GH/EN10217-2 or equal and the size of the tube is
φ38mm. The minimum wall thickness is 3mm.
Special attention is paid to the flexible construction of the heating surface where the tubes
can freely expand to minimize thermal stresses.
The heat surface is surrounded with welded steel cover casing, stiffened by steel bars and
connected to upper/lower exhaust gas chambers. Material of steel construction is S235JRG2
or equal.
Soot blowers: The boiler is equipped with three (3) automatic rake soot blowers. The soot
blowers are operated one at a time when the engine is running. Steam soot blowing is used
to prolong the interval of manual water washing.
Water washing: The off-service manual water washing is very important and recommended
to be made as minimum during every major engine shut-down and can be executed through
the service hatches.
The washing water drain connection at boiler bottom is equipped with a camlock system.
The connection is normally closed with a cap. During the water washing, the connection is
locked to a plastic drain hose (common hose included).
System Connections: The individual AV-6N exhaust gas boiler is to be connected to its own
steam drum and to the common feed water tank via feed water piping. The individual AV-
6N exhaust gas boiler is also to be connected to a common steam line.
Operational description (individual boiler): The feed water is pumped with feed water
pumps through the economizer into the steam drum. The water recirculation between the
steam drum and the evaporator is maintained by natural circulation. The evaporated
(saturated) steam is separated in the steam drum and directed through the super heater
into the steam header and further as the combined superheated steam flow to steam
turbine.
Note: Feed water tank heating is included; boiler steam flow data is stated after deduction
of heating steam.
The stated values are valid with clean heating surfaces. Aalborg Industries guarantees the
indicated steam flow at the design point when the boiler is operated and maintained clean
according to the AI instructions and O & M manuals.
When defining the steam capacity the exhaust gas mass flow of the engine is determined by
calculations, meaning and no separate flow-measuring device is included in the scope of
supply.
The exhaust gas boiler is delivered as a complete construction with loose packed insulation
material including the following items;
Exhaust gas chambers with flanged connections
Top casing prepared for site-installation of stem drum
Flanged inlet/outlet connections for water side
Insulation flat bar supports
Maintenance/service hatches
Supporting and lifting lugs
Water washing cam lock drain with common plastic hose of 20m*)
Valves and fittings (closing valves, thermometers, pressure gauges pressure
difference gauge) with bolts, nuts, gaskets and counter-flanges*)
Soot blowers*)
Prefabricated boiler pipes with site allowance; rises, down comer, economizer outlet
and superheating inlet pipe*)
Exhaust gas counter flanges (incl. gasket, bolts and nuts*))
Feed water control as unit*)
2.) STEAM DRUM – 3 No
Construction: UNEXTM HK is an all-welded steam drum consisting of steel cylinder and dished
ends. Material of steel construction is P265GH/EN10028-2 or equal.
Note: Steam turbine pressure fluctuation range should be checked against the above design
pressure and when presetting the safety valve opening pressure.
The steel construction of HK steam drum is delivered as a complete unit with insulation
including the following items
o Stands for installation
o Fittings with flanged connections
o Man hole for maintenance/service
o Lifting lugs
o Valves and fittings according to the following instrumentation list *)
Steam outlet closing valve
Safety valve (with a spare connection)
level gauge
automatic FW control with valves and water level alarms
manual bottom blow down/drain
manual scum blow out valve
sample cooler
venting
pressure gauge
pressure switch for high pressure alarm
pressure transmitter for bypass damper control
The steam header is used to collect steam from individual exhaust gas boiler for further
distribution to steam turbine.
The steam header is delivered without insulation. Unused standard connections are
equipped with blind flanges. All valves and instruments are delivered loose.
Manual blow-out valves for the incoming boiler steam lines are included as loose.
The containerized modular includes ready installed components as specified in items (ITEM
3) and necessary fittings including all piping and cabling work inside a 40’ container (not
classified)
Hot surfaces inside the container are insulated and covered with aluminum plates. Valves
are insulated or contact protected, if they are close to general walkways or service areas.
The container is equipped with one double door at the other end, one service door at the
side and ventilation hatch with fan.
The delivery consists of 2 feed water pumps; both sufficient for pumping feed water for 3
exhaust gas boilers at nominal capacity. The both pumps have 100% of needed capacity.
The other pump is a spare.
The indication of the emergency low level of feed water tank is used to stop the feed water
pumps
Technical data
Type Vertical centrifugal pump
Capacity 10.2 m3/h ; 13 bar
Motor 7kWe
Shaft sealing Mechanical
The delivery includes the necessary control system with all required components for
controlling and operating the steam heat recovery system according to Aalborg Industries
standard.
The control system consists of one common control panel with Siemens MP277 &WInAC MP
2007 control logic.
The boiler water regulating and control system is based on direct measurement of the water
level by conductivity and capacitance method. The system consists of two electrodes and
electric controllers.
This system controls feed water control valves (open/close) and gives an alarm signal of high
and low water level as well as emergency low water level alarm.
The feed water tank’s regulating and control system is based on direct measurement of the
water level. This system control makeup water value (open/close) and gives an alarm signal
of high and low water level as well as emergency low water level alarm. The emergency low
water level of the feed water tank stops also the feed water pumps.
Protection switches
Contractors
Main switch
Operation switches for pumps:
Indication lamps
- Pump 1 is operating
- Pump 2 is operating
- Pump failure
The capacity of the exhaust gas boiler is controlled by PID-controller which gets the pressure
signal from the pressure transmitter installed to the respective steam drum. PID-controller
gives control signal to the modulating by pass damper. Set point of the PIC-controller is 16
bar(a)
Dosing pump
Suction filter
Dosing nozzle
Plastic tank of 100 liters
Note: A steam turbine application sets strict requirement for the water quality and
therefore the combined cycle plants usually are equipped with special treatment plants for
securing high quality water.
Blow out procedures must be executed periodically for any type of steam boiler to remove
concentrations of solids, which would otherwise buildup in the boiler water.
The blow down tank is designed to safety handle those hot discharge with a self-acting
temperature control of cooling water.
The feed water tank is used to secure the feed water reserve for the exhaust gas boiler
system. Water in the tank consists of condensate and fresh make-up water, which are
mixed in tank together with boiler water light-adjustment chemicals
Temperature control Feed water is kept hot in order to reduce the amount of oxygen in
boiler water.
Total volume 16 m³
Operation temperature 134 ºC
Operation pressure 3 bar (a)
Design pressure 4 bar(g)
Design:
Type : Multistage, impulse, nozzle governed
Condensing
Casing split : Horizontal
Rotor type : Solidly forged & machined rotor with integral
disks.
Shaft seal : Labyrinth
No. of governing valves : Three (Inlet)
One/(Extraction)
Bearing support : Double pedestal
Rated power : 2350 KW
Oil System
- Oil:
Governing oil pressure : 5.5 kg/cm²g
Lube oil pressure : 1.5 KG/Cm²g
Oil type : Servo prime ISO VG-46 /57 /68
Oil quantity for initial fill
And flushing : 5100 L
Oil reservoir capacity : 3200 L (integral)
Retention time : 5 minutes
Material of oil reservoir : Carbon steel
Material of oil piping from
Pumps to filter : Carbon steel
Material of oil piping from
Filters to bearings : SS 304
Material of oil piping from
Bearing to reservoir : Carbon Steel
- Oil cooler:
Design code : HEI/TEMA
Type : Plate Hear Exchanger
Oil inlet temperature : 60 ºC
Oil outlet temperature : 46 ºC
Plate material : SA 240 Gr.316
Oil flow capacity : 550 Liters /minute
Mounting : Saddle support
Bearings:
- Journal bearings :
Type : Tilting pad
Material : White metal with steel Babbitt
- Thrust Bearings
Type : Tilting Pad
Material : White metal with steel Babbitt
Governing system
- Governor:
Type : Electronic (Wood ward)
Inputs (critical) : 2 Speeds from MPU -1 & 2
Control range : 80 to 110% of rated speed
Control accuracy : As per NEMA class D
Speed droop : 3 to 6% (Programmable)
Power supply : 110 V DC
Accessories : 2 Magnetic speed pick-ups(MPU)
1 electro-hydraulic actuator
- Hydraulic Accumulator
Type : Bladder
Working fluid : Pre-charged Nitrogen
Capacity : 20 liters
GEARBOX
Design:
Type : Double helical, single reduction
S.F. : 1.3
Accessory : Air breather
COUPLINGS:
- High Speed Coupling
Type : Flexible element
- Low Speed Coupling
Type : Flexible element with Shear pins
ACCESSORIES
- Barring gear:
Type : Auto disengage
Driver : AC Motor
EXPANSION BELLOW
Type : Rectangular with flow liner
Design code : Universal type rectangular expansion joints
Material of bellows element SS-304
Material of liner : SS-304
Material of flanges : Is-2062
3.) ELECTRICAL
AC GENERATOR
Design:
Rated output : 2350 kW
Rated voltage : 11KV +/- 10%
Rated frequency : 50Hz +/- 5%
Combined variation of
Voltage & frequency : +/- 10%
Rated p.f : 0.8 (lag)
No. of phases : 3 phase,
No. of terminals : 3 for phase & 3 for neutral
Connection : Star
Rated speed /No. of pole : 1500 rpm / 4 pole
Short circuit ratio : More than 0.5
Ambient temperature : 45 Deg.C
Excitation : Brush less
Rotor : cylindrical
Cooling method : CACW
Mounting : Horizontal
Insulation : class F (both rotor and stator)
Temperature rise : Class B limits(both rotor and stator)
Enclosure : IP-54(Stator) & IP-54 (Exciter)
Duty : Continuous and suitable for parallel operation
Rotation : To suit driver output
Noise level : 90 dB(A)
Terminal box : To suit HT cables
Reference standard : Is -4722
Harmonic loading : As per IEEE 519
Bearings:
Type : Sleeve
Accessory : Temperature gauge
Air coolers:
Cooling method : CACW
Capacity : 2 x 60%
Cooler tube material : Admiralty brass
Mounting : Top
Anti Condensation heaters
Type : Resistance heating
Power supply : 230 V, single phase
Design:
Control type : Analog
Control modes : 1 auto +1 manual
Voltage adj. Range : +/- 10%
Regulation : +/- 0.5%
Dead time : Less than 30 mS
Features:
- Compounding
- Auto PF controller
- Remote voltage control
- Auto- Manual follow-up
- Under frequency protection
- Field flashing provision
AVR cum excitation panel shall be complete with generator voltmeter, field voltmeter, field
ammeter, PF meter, Auto/Manual selector switch, AC supply & DC supply on /off control
switches, indicating lamps and space heater with thermostat.
The Panel shall be complete with AC supply & DC supply on / off control switches, indicating
lamps and space heater.
B TURBINES
1] Steam Turbine: Multistage, impulse, nozzle Euro 2,975,000.00
governed condensing 2350 KW.
2] Steam surface Condenser (TWO MILLION NINE
3] AC Generator 2350kW
4] AVR Cum Excitation Panel SEVENTY FIVE
5] Generator Relay Panel THOUSAND EUROS
6] Generator Control (Metering Cum Synchronizing) ONLY)
Panel
7] Neutral Grounding Resistor Panel
8] Turbine Control Panel
9] 11KV panel
Auxiliaries
1.Exhaust Duct and supports/expansion joints
2. Steam & water Pipeline and fittings
C 3. Cabling
4. Insulation.& cladding
5. support structural frame
The scope of work shall comprise of Works to be performed in accordance with The Scope of
supply provided.
The Contract Price shall be payable at the time and in the manner provided in PRICE
SCHEDULE.
The Contract commencement date (CCD) shall be the date of signing of this Contract.
The Effective Date of this Contract (EDOC) shall occur on the fulfillment of each of the
following:
In case any of these above conditions are not fulfilled within 120 (One hundred and
twenty) days from the date of signing of the Contract, the Parties to this Contract shall
meet and discuss the further course of action.
This quotation is based on the following assumptions regarding the project execution time
table:
Delivery of equipment : 8 month
Commissioning of the installed equipment : 12 month
We have calculated our prices on the assumption that payment will be effected out of an
irrevocable documentary credit, free of charge to us, opened through a Local National bank
confirmed by a German National bank acceptable to us.
The warranty will be valid for 12 months from the date of commissioning or 18 months from
the date of shipment or 8000 working hours for the Power Plant whichever is earlier.
We agree to repair or replace at our option any defective part in the equipment of our own
manufacture, where defects develop under use and arise solely from faulty material or
workmanship, and provided that the equipment is used as per our recommended operating
and maintenance procedures.
In the case of goods not of our manufacture, you are entitled to the benefits of the warranty
given to us in respect thereof, and our liability in respect of such goods is limited to the
warranty given by the respective manufacturer.
The defective parts replaced by us shall become our property. The replacements, if any will
be delivered on the same basis as the main equipment. W shall not be liable for any
consequential damage or loss incurred during warranty claims.
7.0 Validity
8.0 Cancellations
MPPL is entitled for full compensation of all raised material, manufacturing, engineering,
and administration costs in the event that the project or any parts of it is cancelled or
considerably postponed or the Contract is terminated. All such costs will be paid by REATL.
MPPL also entitled for full compensation of bank charges on PERFORMANCE SECURITY
GUARANTEE (PSG), if the project or any part of it has been cancelled or considerably
postponed or the Contract is terminated. The Performance security Guarantee should be
returned immediately to MPPL
Attached
10.0 Confidentiality
Please note that the contents of this letter and the documents included in our offer are to be
treated as strictly confidential and none of the information to be disclosed to any third
party.
We trust that our offer will meet your requirements and should you have any questions, or
require any additional information, please do not hesitate to contact us.
________________________
Rajakumar
Director
Annexure – 2(c)
Engine Catalogue
18V48/60TS
Two-stage turbocharged diesel engine
MAN Diesel & Turbo
The responsible way in leading technology
MAN Diesel & Turbo is the world’s leading designer and manufacturer of low and
medium speed engines. Our involvement with electrical power generators goes
back to 1904 when we supplied the first ever diesel generator sets to the Kiev Tram
System.
Since those early days, MAN Diesel & Turbo has never lost its technological pre-
eminence in the large engine field. Likewise, our engines have never relinquished
their status as the most efficient combustion engines available.
More than ever before, MAN Diesel & Turbo’s development focus is on the environ
mental performance of our engines. Using our unrivalled grasp of large engine
technology, we aim to make our engines progressively cleaner, more powerful and
more efficient.
With our firm commitment to reducing emissions while increasing fuel efficiency
and power density, and with our active partnership with environmental institutions
and development banks, we intend to be part of the global emissions solution.
Two turbochargers in sequence provide a new dimension in engine performance The diesel engine 18V48/60TS
The 48/60 type diesel engine is a perfect example of For the two-stage turbocharged 18V48/60TS, only a
and operational flexibility. A wide load range from 1,050 to 1,200 kW/cyl., a specific proven technology and robust design. Over 800 units few modifications were made to the standard engine:
fuel oil consumption of 171 g/kWh at 1.050 kW/cyl. and reduced NOx emissions set have been sold since the product was launched in
1988. They are now operating in a range of applica- n Adapted fuel injection nozzles
a new benchmark for four stroke diesel engines. tions in power generation and marine propulsion. n Three-ring piston with higher compression ratio
Thanks to its high efficiency, the 18 cylinder engine is n Modified camshaft for enhanced Miller timing
the 48/60 engine family’s best-selling configuration. n Additional exhaust gas bypass valve to avoid
Turbochargers from MAN Diesel & Turbo smoke during engine start-up
Turbochargers are the core of this innovative new a limited pressure ratio. A specially designed com-
concept – and MAN Diesel & Turbo is the only engine pressor, as in the TCA88/RCF23, can increase the TC Efficiency
manufacturer that also designs and builds turbo- pressure ratio – but also has the effect of decreasing
2-Stage operation
chargers. This unique expertise translates into ex- efficiency. The only solution to this dilemma is two- 0,78
ceptional efficiency and reliability. stage turbocharging, also known as sequential tur- 0,76
The idea is simple: just place two of MAN’s most The 18V48/60TS deploys MAN Diesel & Turbo’s tried 0,70
TCA88/RCF23
TC efficiency tot-tot
efficient turbochargers upstream from the engine, and tested TCA88 and TCA77 standard turbocharg- 0,68
one after the other. The result: the engine gets twice ers in sequence. The TCA88 is located upstream and 0,66
the charge air pressure, while turbocharger efficien- provides the low pressure turbocharger, while the 0,64
cy is increased significantly. TCA77 forms the high pressure turbocharger, next to 0,62
Standard components, proven design Lowest fuel oil consumption or NOx emissions Effects of Two-Stage Turbocharging
The overall design of the two-stage turbocharged The excess combustion air from the turbochargers Two-stage turbocharging is a modular system: its 1200
The low pressure turbocharger is located upstream As a result, the 18V48/60TS diesel engine’s extrem- Like the 48/60 series standard engines the two-stage Op. mode 1 2 3 4
from the engine, on its own steel frame. The combus- ely low specific fuel oil consumption of 171 g/kWh turbocharged 18V48/60TS can be operated with a
1850
tion air and exhaust gas piping between both turbo- makes it the most cost-effective in its class. wide range of different fuels: 1850
1800
chargers is fitted with compensators, ensuring com-
1750
Alternatively, the excess combustion air can be n Heavy fuel oils with a viscosity up to 700 cst
Fuel consumption
177
advantage of the extremely low fuel oil consumption
175 174
and giving them the possibility of a spinning reserve
173 172
g/kW/h
up to 21,600 kW. 171
171
A B
C W
18V48/60TS engine Engine type: 18V48/60TS General definition of diesel engine ratings
according to ISO 3046-1: 2002
Operation mode Engine cycle: four-stroke
Performance data Unit 1 2 3 4 Turbocharging system: 2-stage, constant pressure ISO Reference conditions:
n Low pressure TC type: MAN TCA88
Power per cylinder kW 1050 1100 1150 1200 n High pressure TC type: MAN TCA77 n Air temperature: +25°C (77F)
Tot. engine power kW 18,900 19,800 20,700 21,600 n Air pressure: 1000 mbar
Tot. el. genset power kW 18,428 19,305 20,183 21,060 Number of cylinders: 18 n Cooling water temperature upstream
Spec. fuel oil consumption Bore: 480 mm of charge air cooler: +25°C (77F)
acc. to ISO 3046, without pumps, g/kWh 171 172 174 177 Stroke: 600 mm n Relative air humidity: 30%
mech. Power output, +5% tolerance Swept volume per cyl.: 108.6 dm³
Heat Rate Engine speed 50/60Hz: 500/514 rpm Figures are given with a tolerance of 5%, except for
acc. to ISO 3046, without pumps, kJ/kWh 7,305 7,350 7,430 7,560 Mean piston speed: 10.0/10.3 m/s the lubrication oil consumption, which is given with a
mech. Power output, +5% tolerance tolerance of 20%.
NOx emissions (dry at 15% O2) mg/Nm3 1850 1740 1580 1480 Nom. generator efficiency: 97.5%
Mean effective pressure bar 23.2/22.6 24.3/23.7 25.4/24.7 26.5/25.8
Spec. lube oil consumption g/kWh 0,60 0,60 0,60 0,60 Cooling: Abbreviations:
Cylinder cooling: HT cooling water
A B C H W LP-TC charge air cooler: 2-stage HT and LT cooling water TC Turbocharger
HP-TC charge air cooler: 2-stage HT and LT cooling water HP High pressure
Dimensions (mm) 9625 5410 24510 9023 4694 LP Low pressure
Starting method: compressed air with HT High temperature
blower for low part load LT Low temperature
Dry mass (t) 407 407 407 407 407 operation up to 25% load
powerplant-aug@mandieselturbo.com
86224 Augsburg, Germany
www.mandieselturbo.com
Fax +49 821 322-3382
Phone +49 821 322-3897
MAN Diesel & Turbo
Annexure - 3
Fuel Specification
Fuel system related characteristic values:
The fuel system is designed to operate based on the following fuel oil
specification based on ISO 8217-2010:
Current fuel oil characteristics are not sufficient for estimating the combustion
properties of the fuel oil. This means that service results depend on oil
properties which cannot be known beforehand. This especially applies to the
tendency of the oil to form deposits in the combustion chamber, gas passages
and turbines. It may, therefore, be necessary to rule out some oils that cause
difficulties.
The fuel must be free of admixtures not based on mineral oil, such as coal oil
or vegetable oils, free of tar oil and lubricating oil, free of any chemical waste,
solvents and polymers.
Annexure - 4
The Greenery layout
Annexure - 5
Land Use Map
Annexure - 6
Land Development Map
Annexure - 7
Drainage Layout
Annexure - 8
Oily Water Separation System
EcoStream
The EcoStream bilge water treatment system from Alfa Laval is a reliable
fully automated, single-stage centrifugal separation system to clean oily
wastewater on board vessels at sea and at land-based power plants.
3 Summary
10 Equipment
Operating principle
Key components
13 Optional components
14 Flow diagram
16 Retrofitting
16 Documentation
16 Classification
Summary
Bilge water must be treated to reduce the oil content to levels that meet
international regulations for release into the environment. This is critical
to keeping the world’s oceans and their vast marine ecosystems healthy
and productive.
The Alfa Laval EcoStream bilge water treatment system Benefits for owners and operators
is a centrifugal separation system for bilge water treatment • Reduced operating costs thanks to low maintenance,
that has been approved by the International Maritime automated control, no waste disposal and an absence
Organization. of filter elements that require replacement.
This system generally cleans bilge water to less than five • Reliable, always-available system. Operates continuously,
parts per million (ppm) oil in water. It operates at flow rates of regardless of variations in feed, oil shocks and rough
up to 2,000 liters per hour to meet even the toughest bilge weather conditions.
water treatment applications.
• Easy to operate. Automated control and monitoring system
As a major equipment and technology supplier to the integrates with existing Alfa Laval systems, providing a
marine industry, Alfa Laval understands the requirements single user-friendly interface.
of all treatment systems on board vessels.
• Safe operation. A key lock switch can be set in manual
We use equipment and technology know-how to build or locked position to ensure that only the individual
solutions of all kinds for cost-effective and efficient operation responsible for environmental compliance may authorize
of vessels – from engine room applications including oil treat- overboard discharge.
ment and fuel conditioning to waste disposal applications,
including bilge water treatment.
Benefits for designers of ships and power plants
Our aim is to work continuously to improve customer • Compact, modular, easy-to-install system saves time,
processes – time and time again. space and money.
This document provides technical information about • Continuous, single-stage operation requires less holding
the Alfa Laval EcoStream bilge water treatment system. tank volume and provides more space for payload.
It includes information about the bilge water separation
process, advances in system design, system benefits • Easy integration with existing communications systems
and a description of equipment. on board.
The Queen Mary 2 is equipped with two EcoStream bilge water treatment systems.
Alfa Laval
EcoStream.
Treatment methods must meet individual ship requirements Conditioning Module and Separation Unit controllers,
and demands for safety, reliability, compactness, automation, facilitating ease of operation.
low maintenance and the ability to withstand rough weather
conditions. In addition, performance of the treatment system Easy to access and maintain
can vary depending on the oil content and the size of the Built-in service areas facilitate inspection and maintenance.
droplets or particles present in the water and on various A central pillar houses all motor starters and the advanced
operating conditions. process controller, making the EcoStream unit easier to
service and easier to operate than other units available.
Centrifugal separation has proven to be a reliable, efficient
and flexible method for continuous removal of oil and other More uptime, less maintenance
contaminants suspended in the bilge water on board ships Maintenance-free components, automation and remote con-
and at land-based power plants. trol increase operating time and decrease service disruptions.
Durable components contribute to longer service intervals
between inspections.
Overview
The EcoStream bilge water treatment system from Alfa Laval Lower installation and operating costs
is a centrifugal separation system for treatment of large bilge Thanks to pre-testing, installation requires less time and
water volumes at sea. EcoStream operates at flow rates of money than installation of separate components. Automation
between 1,500 and 2,000 liters per hour and usually cleans and remote control reduce operating costs.
bilge water to less than 5 ppm.
Technical support
EcoStream is easy to install for any new or existing All spares, service and sales engineers are available through
installation. It does not require large bilge water holding the Alfa Laval International Service Network.
tanks. This increases payload capacity. Compared to con-
ventional bilge water systems, EcoStream significantly
reduces operating costs, thanks to automation and remote
control. In addition, there is no expensive filter element
replacement required.
System benefits
Compact, modular and flexible design
This provides great flexibility to install the unit in a convenient
location. A wide range of options for functionality, remote
control and other features adds more flexibility.
635 mm
Easy to install
This simple, plug-and-play installation of this factory-tested
1450 mm
Regardless of its source, bilge water must be treated to Alfa Laval’s bilge water treatment solution is superior to many
reduce the oil content to levels that meet international regula- competing technologies with respect to the volumes of waste
tions for release into the environment. This is critical to generated.
keeping the world’s oceans and their vast marine ecosystems
healthy and productive.
What is bilge water?
Efficient bilge water treatment minimizes the impact of ship Bilge water collects in a ship’s bilge wells, which are located
propulsion on the marine environment as well as the heavy in the lowermost part of the vessel just above the hull. The
fines that ship operators can face for pumping oily bilge water wells receive water and mechanical fluids from operational
overboard. sources, such as technical rooms, propulsion systems and
different machinery.
Efficient treatment also reduces the need for and cost of
waste disposal ashore. Over the years, waste disposal costs Bilge water also contains fluids from machinery spaces,
have continued to climb as local authorities enforce stricter internal drainage systems, sludge tanks and various other
laws for the land-based companies that process this waste. sources.
Tank Condensate
overflows from air coolers
Incidents
Clean water
overboard
Bilge
pump
Bilge water
composition.
Fresh water
Water
Seawater
Hydraulic oil
Organic
Particles
Inorganic
Emulsifying, corrosive
Chemicals
Other
The definition of bilge water is thus much wider in scope Bilge water legislation
than merely the contents of a ship’s bilge, the enclosed area Bilge water treatment is an environmental application that
between the frames where the sides of the vessel curve in to must meet stringent requirements of international legislation.
form the bottom. Disposal of untreated bilge water into our oceans is strictly
prohibited by international law and subject to heavy fines,
In simple terms, bilge water contains two types of sub- especially in sensitive waters.
streams: (1) flows that are reasonably continuous and pre-
dictable, and (2) flows that are intermittent in nature and diffi- Current MARPOL legislation stipulates that separated bilge
cult to foresee. The first category includes water from the water containing 15 ppm or below oil in water can be dis-
separator sludge tank and water from cleaning activities in posed into international waters. Some national, regional and
the ship’s engine room. The second category may include local authorities, especially those governing sensitive waters,
soot water, leakage and incident spills from tanks and have more stringent regulations. In the United States and in
machinery spaces. the Baltic and North Seas, for instance, disposal of separated
bilge water is only permitted at least 12 nautical miles from
Bilge water is thus composed of a mixture of water, deter- shore.
gents and other chemicals, fuel oil, lubricating oil, hydraulic
oil, cat fines, oil additives, soot and dirt. This mixture is col- The International Maritime Organization (IMO) resolution
lected in the bilge water holding tank, which generally is MEPC 107(49) specifies how to type approve equipment
maintained at an elevated temperature. This high temperature used on board ships. The resolution complies with the
facilitates primary gravity separation, preferably of the two- or European Marine Equipment Directive, MED 96/98/EC.
three-stage type, in the bilge water tank. Here, oil rises to the
top and particles settle on the tank bottom, generally dividing Many manufacturers have succeeded in meeting the speci-
bilge water into three distinct layers in the tank: fied requirements for equipment certification, but much of
this equipment falls short of delivering the high separation
• Top layer efficiency required under real operating conditions for bilge
This contains most of the oil and organic solvents and con- water discharge.
stitutes a small portion of the total tank volume. Skimming
this top layer for separate treatment is recommended.
• Bottom layer
This contains solids and heavy sludge, which should also
be removed for separate treatment.
What are emulsions and suspensions? What used to be lubricating and hydraulic oils of relatively
By definition, an emulsion is a mixture of two immiscible elemental composition, based on simple mineral oils, are now
liquids. An oil-in-water emulsion consists of small oil droplets complex formulations, sometimes based on synthetic oils and
dispersed in a continuous water phase. A suspension is a incorporating a variety of additives.
mixture in which solid particles are dispersed in the con-
tinuous water phase. Modern lubricating and hydraulic oils have a greater ability to
take up water due to the action of detergents. Likewise,
Emulsions, or small droplets of one liquid (the dispersed cleaning chemicals have a great ability for oil and dirt uptake.
phase), can form in the other liquid (the continuous phase)
under agitation, such as during pumping or throttling in Stabilizers may also occur naturally in the oil. These stabilizers
valves. Droplets of oil dispersed in water generally coalesce, concentrate at the oil-water interface and lower the interfacial
or combine, into larger droplets because oil is not soluble tension, thus stabilizing the liquid mixture.
in water.
Some chemical residuals generally end up in a vessel’s waste
Increasing the droplet size helps facilitate separation. treatment system or holding tank. The bilge water treatment
The presence of surfactants, such as detergents, soaps system, in particular, processes a heavy load of chemical
and other surface-active compounds, however, may residuals.
contribute to stabilization of small oil droplets. This
makes separation very challenging. High centrifugal force Chemical usage in the engine room inevitably causes the for-
is then required to separate the small droplets that do mation of stable emulsions and suspensions as well as some
not spontaneously separate when subjected to gravita- form of environmental impact. Most chemical manufacturers
tional force. claim that their products do not stabilize emulsions in bilge
water. But the use of surface-active chemicals make many
Emulsion stabilizers may consist of: products contribute to the formation of stable emulsions.
• Low molecular weight surface-active compounds, or Usage of chemicals always causes some type of compromise
surfactants, that reduce the surface tension of the oil-water between cleaning efficiency and separation efficiency on the
interface and thereby create small droplets that contribute one hand and environmental friendliness on the other.
to emulsification.
Alfa Laval strongly recommends the use of quick-separating,
• Polymers and other macromolecules form a film around environmentally friendly and non-toxic detergents. Choosing
the emulsion droplet to establish a physical barrier to chemicals that are compatible, non-toxic, biodegradable and
coalescence and thereby stabilize emulsions further. non-emulsifying, helps prevent problems downstream.
Water
Solids
Feed
Mechanisms for emulsion breakdown • Flocculation is a process by which two or more particles
There are different mechanisms for emulsion destabilization aggregate without losing their individual identities.
and breakdown, including coalescence and flocculation.
– A high centrifugal force induced in a centrifugal separator
• Coalescence is a process where two or more droplets greatly contributes to the flocculation of small particles.
collide, resulting in the formation of one larger droplet.
– A high alkaline pH value promotes flocculation. The pH
– A high centrifugal force induced in a centrifugal separator value provides a measure on a scale from 0 to 14 of the
greatly contributes to the coalescence of small droplets. acidity or alkalinity of a solution.
– Elevated temperature accelerates the rate of coalescence – Chemical flocculants decrease or cancel the repulsive
by increasing the probability of the droplets to collide and electrostatic forces between particles in a suspension,
by decreasing the viscosity of the continuous phase. thus promoting flocculation.
What parameters affect separation efficiency? The expression states that the greater the difference in density,
Centrifugal separation relies on the difference in density among the greater the efficiency. However, the density difference is not
the various components present in emulsions or suspensions. the most important parameter affecting the separation efficiency.
Stokes’ Law (below) describes the settling velocity (vg ) of a The sedimentation velocity increases exponentially with the
particle or droplet when subjected to gravitational force, such as droplet, or particle, size. This means that the smaller the droplet
static settling in a tank, which in turn determines the separation or particle, the more challenging the separation task.
efficiency. The general formula is:
For separation of small droplets and particles, which are found
in the stable emulsions and suspensions in bilge water, gravity
d 2 (ρd – ρc) alone is not sufficient. In a centrifuge, the term (g) in the expres-
νg = g sion is replaced by (w2r), the centrifugal force, which is several
18 µc
thousand times greater than the acceleration due to gravity.
Therefore, even droplets and particles that are only a few
νg the sedimentation velocity due to gravity micrometers in size can be efficiently separated.
d the diameter of the dispersed droplet/particle
ρd the density of the dispersed phase Another important factor that has a positive effect on separation
efficiency is low viscosity. The viscosity of the continuous phase
ρc the density of the continuous phase
affects sedimentation velocity, which increases in inverse propor-
µc the viscosity of the continuous phase tion to the viscosity. Therefore, any medium with low viscosity,
g the gravitational acceleration such as a continuous water phase, facilitates separation.
Equipment
Environmental protection requires reliability. This is how Alfa Laval
has met the bilge water treatment challenge.
Bilge water then passes through a dual basket strainer which Forwarding pump
traps large particles from the fluid before entering a heat An eccentric screw pump with variable frequency drive
exchanger, which raises the fluid temperature to required control.
levels, generally between 60° and 95°C, for optimum separa-
tion efficiency. Strainer
A dual basket strainer of mesh size 1.5 mm.
A three-way changeover valve then directs the fluid to the
separation stage if all process conditions, such as feed Heat exchanger
temperature, feed pressure and separator speed, fall within A shell-and-tube heat exchanger using steam as its heating
preset process values. If any process condition is not met, medium.
the valve re-circulates the fluid back to the bilge water
settling tank. Three-way changeover valves
Two three-way changeover valves handle bilge water at
A high-speed centrifugal separator continuously processes critical junctions.
large volumes of bilge water. The oil outlet continuously dis-
charges out-separated oil and emulsions. Solids that collect Constant pressure valve
at the separator bowl periphery are discharged intermittently A fast-acting, high-precision constant pressure modulating
to a cyclone, which reduces the velocity and energy of the valve handles the required backpressure with accuracy.
discharged volume. Discharge occurs at preset intervals,
which is generally set at 20 minutes, depending on the Transmitters
installation. Solids are then directed to a sludge, or waste Electronic transmitters monitor temperature and pressure.
oil, collecting tank.
Separator
A built-in water pump, or paring disc, continuously dis- The BWPX 307 high-speed centrifuge uses the most modern
charges separated bilge water through the water outlet. fluid dynamics technology for high separation efficiency.
The destination of the separated bilge water depends upon
its oil content, which is continuously monitored at an iso- Control cabinet
kinetic sampling point by an oil-in-water monitor. Two separate compartments houses the process controller
and the electric power functions.
If oil content is less than or equal to 15 ppm, the separated
bilge water can be pumped either directly overboard or to a Process controller
‘clean’ bilge water holding tank for discharge overboard later. The EPC 50 process controller facilitates monitoring and
If oil content exceeds 15 ppm, the effluent is re-circulated, control of all EcoStream functions, which are displayed in
preferably to the cleanest part of, the bilge water settling tank clear text and on a mimic display.
for re-processing.
Oil-in-water monitor
As an alternative, separated bilge water with an oil content Certified according to IMO resolution MEPC 107(49), this
just above 15 ppm can be directed to an ‘almost’ clean bilge in-line unit accurately measures the content of oil in water.
Pump unit
The pump unit consists of a stand-alone compact pump
module, which is designed for ease of installation and ease
of accessibility for maintenance.
A speed sensor and an optional unbalance sensor monitor Whenever solids or sludge are discharged from the separator
the mechanical status of the separator. A cyclone, installed bowl, additional air pressure is applied to the valve to prevent
in the sludge outlet, provides ventilation and reduces the any untreated bilge water from penetrating and polluting the
velocity and energy of the discharge volume. system downstream.
Transmitters
Electronic transmitters provide accurate readings for pressure
and temperature and improve control to achieve high separa-
tion efficiency.
Sampling cocks
Situated before the separation stage and after the three-way
changeover valves, these sampling cocks enable analysis
of bilge water samples and provide an alternative way to
measure the accuracy of the oil-in-water monitor.
Control cabinet
Centrally located to monitor all EcoStream functions, the
control cabinet has two separate compartments. The lower
compartment contains all electric power functions, such as a
multi-transformer, for power supplies in the range of 230 to
690 V, all motor starters, pump unit speed control, power
supply for the optional chemical dosing unit and all pneumatic
control devices. The upper compartment contains the
Alfa Laval EPC 50 computer-based process controller and
operator panels.
Process controller
The EPC 50 is the latest generation of the Alfa Laval com-
puter-based process controller. Easy to operate, the unit pro-
vides fully automated advanced monitoring and control of all EPC 50 process controller.
EcoStream functions. To assist with trouble tracing, an alarm
log registers the last 31 alarms. It also records time when the
alarm appeared, time until the alarm was reset and the
sludge discharge time interval. More process data are easily accessible by simply pressing
a button. These include feed temperature, feed pressure,
The process controller has several built-in self-cure functions water outlet pressure, oil content in cleaned water, separator
that automatically activate to ensure continued operation bowl speed and total operating hours. All critical process
should a system problem occur. A proportional integral (PI) parameters and operation mode, including start-up, standby,
temperature controller accurately maintains the temperature pre-production, production and stop, are displayed in
set point for separation within ± 2°C, even under variable clear text.
bilge water feed conditions.
A key lock switch that controls discharge of separated water
Standard hardwired input and output signals include: is also located on the panel. Bypass, or locked, position re-
• Emergency stop button, circulates separated bilge water, regardless of its oil in water
• Emergency shut down (ESD), content. Inserting the key enables selection of automatic
• Process shut down (PSD), position, which directs bilge water with oil content of 15 ppm
• Common alarm indication, and, for discharge overboard.
• Process status indication.
It is also possible to set the limit for overboard discharge
The EPC 50 process controller is based on the same hard- lower than 15 ppm – at five ppm, for instance. This enables
ware used in other Alfa Laval units, making it easy to use for safe discharge in environmentally sensitive waters, where
operators who are already familiar with this equipment. lower oil in water content is required by regulatory bodies.
Operator panels Located next to the LED panel, the operator panel controls
A push button and light-emitting diode station displays the the feed rate of the variable frequency drive feed pump.
status of cleaned bilge water for discharge overboard and for
re-circulation, the pumping stage, the electric motors,
optional chemical dosing units and optional automatic
cleaning unit for the oil-in-water monitor.
Optional equipment
The EcoStream system offers these equipment options to provide
greater flexibility.
• Chemical dosing unit The CIP unit reduces downtime and maintenance man-
Under extreme conditions, centrifugal force alone may not hours and saves money. It also minimizes the potential risk
be sufficient to deliver high separation efficiency for satis- for mechanical damage of vital bowl parts.
factory treatment of the bilge water. This is usually the case
when large quantities of suspended solids, such as soot or • Automatic cleaning device for the oil-in-water monitor
detergents, are present in bilge water. An automatic pneumatic cleaning device for the oil-in-water
monitor is available as an alternative to manual cleaning of
For these conditions, an optional chemical dosing unit effi- the measuring cell in the oil monitor.
ciently handles strongly emulsified oil as well as suspended
colloids. The cleaning device activates at every sludge discharge,
ensuring accurate monitoring of oil content by continuously
Chemicals should only be added when a combination cleaning the measuring cell in the oil monitor.
of high separation temperature (95°C) and low flow rate
(1,500 liters per hour) is insufficient to separate bilge water • Serial bus connection
to contain 15 ppm or less oil in water. Fully remote operation of the EcoStream is possible by
connecting the process controller via serial bus to an
Alfa Laval recommends the use of safe and environmentally external computer or communications system.
friendly Alpacon chemicals, MP 300/302. The combination
of these water-based additives promotes demulsification This provides complete coordination with a Central Control
and flocculation to achieve clean water with less than System (CCS) or a plant’s Integrated Administration and
15 ppm for more difficult feed compositions. Control System (IACS). Proprietary field bus interface
boards, according to Profibus DP or Modbus RTU stan-
• Automatic self-cleaning filter dards, are installed in the process controller. This enables
If the feed water is expected to have a high solids or fiber communication to external automation systems. Most local
content, installation of an automatic, self-cleaning filter is functions can be replicated with the use of the field bus in-
recommended. This may be necessary, for instance, if the terface boards.
risk of overflow from black and grey water tanks into the
bilge wells exists. Please contact Alfa Laval if other protocol boards,
such as CANopen, DeviceNet or InterBus, are required.
Removing fibers and other coarse solids helps prevent Customers assume responsibility for coordination of pro-
clogging of passages, such as the distribution holes in the gramming on the remote side through their automation
separator disc stack. This prolongs service and maintenance providers. Alfa Laval provides documentation describing
intervals, which may otherwise be unacceptably short. the protocol for the system developers.
• Cleaning-in-place unit
An optional cleaning-in-place (CIP) unit is available to
enable cleaning of separator bowl parts without dis-
mantling the separator.
Flow diagram
Two-stage bilge water Automatic self-cleaning filter Steam pre-heater
settling tank (optional) Raises temperature of the liquid
Pre-heats the bilge water. Removes coarse solids and fibers. to the required treatment tem-
perature.
Chemical dosing units (optional) Pressure transmitters
Enhances separation efficiency if Measures the pressure in the water Temperature transmitters
stable emulsions are present. inlet and outlet and signals this in- Measures the temperature of the
formation to the process controller, liquid from the pre-heater and
Feed pump with which monitors pressure to ensure signals the process controller.
variable speed control remains within acceptable limits.
Transfers liquid to the steam Temperature controller
pre-heater. Dual basket strainer Alerts operator when the tempera-
Traps large particles from the fluid ture exceeds, or falls below, a pre-
before entering the heater. set limit and acts as a backup to
provide temperature control should
the temperature transmitter fail.
Feed recycling
Alpacon Alpacon
MP 300 MP 302
VFD
PT
Feed inlet
PT Clean water
outlet
Ventilation QT
QC
TC
TT TT
Sludge outlet
Retrofitting Documentation
EcoStream is ideal for replacing older bilge water Alfa Laval supplies each EcoStream bilge water treat-
treatment systems. Its compact size easily fits into ment system with full documentation either as paper
any available space. copies or as PDF (Portable Document Format) files on
a CD-ROM. The instruction manual, which can also
To facilitate transport through small passageways, be made available in most major languages, covers:
EcoStream can also be divided into four parts:
• Safety
• A separator with a frame, • System description
• Valve and piping rack, • Operating instruction
• Feed pump, and, • Parameter list
• Control cabinet. • Alarms and fault finding
• System reference/installation instructions
• Separator manual
• Spare parts catalogue
• Component descriptions
Any comments regarding possible errors and omissions or suggestions for improvement
of this publication would be gratefully appreciated.
Copies of this publication can be ordered from your local Alfa Laval company.
www.fotoskrift.se
EMD00050EN 0412
Annexure – 9(a)
Elevation & Layout of FGD Plant
Annexure – 9(b)
Technical Description of FGD Plant
Specification for FGD System
Scope of Supply and Services
Dhaka Southern Power Generations Ltd.
55 MW HFO Power Plant
Nababgonj,Dhaka.
November 2013
3
1 Project Profile
Your company has 3 fuel boiler, dust removal equipment, but you have no
desulfurization equipment. Therefore SO2 is out of gauge and need to revise. After our
careful consideration, we decided to adopt to add a set of desulfurization dust removal
equipment to back of the fan. In principle, this project adopts the single (sodium) process,
equipment adopts desulfurization tower desulfurization system, so as to meet the local
environmental allowed emissions and ensure the desulfurization effect. Below we will quote
according to the single boiler design.
The technology is mature, with high absorption, high efficiency of utilization, low
operation maintenance cost etc. It provided advanced equipment and materials, ensure to meet
the latest industrial standard requirements of the quality , services and the equipment.
Furnace flue gas outlet temperature<350OC (Guide equipment import of flue gas
temperature)
So2 content≤2500-3700mg/m3。
《Industrial boiler and furnace wet flue gas desulfurization engineering technical
specifications》(HJ462 -2009)
(GB50264-97)
《pipe supports and hangers third part:Intermediate fittings and architectural structure
fittings》(GB/T17116.3-1997)
《Water supply and drainage pipeline engineering construction and acceptance specification》
(GB50268-97)
《Equipment and flue of the general principles of the thermal insulation technology》
(GB4272-92)
ringelman emittance<1level.
2.5 Scope of Supply
The flue gas furnace production line (desulfurization) complete set of equipment
efficient desulfurization tower, the new equipment export increase pipeline and fan
connection. After the transformation, all things keep the same, just change the flue gas system,
desulfurization tower system, desulfurizer preparation system and other systems’ carry
information, design, construction, manufacture, installation, debugging and training. Reform
its internal structure, etc.
3 Technical Principle:
Single process uses NaOH or Na2CO3 alkali liquor to absorb SO2, produce HSO32-、SO32-and
desulfurizing process
Single alkaline process desulfurization serves caustic soda flakes seriflux as the main
desulfurization agent, soda is continuously recycling. Because of this, the system will not
appear scaling blocking phenomenon, so the operation is safe and reliable.
Due to the quick rate of sodium alkali absorption and SO2 reaction, comparing with
calcium base, it can achieve a very high SO2 removal rate in smaller liquid gas ratio
condition.
After high atomization nozzle, doctor solution will blow into small droplets, and
will have full contact with SO2. the dust in the flue gas was set down, SO2 is
piecewise desulfurization neutralization, so as to achieve the effect of
desulfurization
integration
This technology fully ensure the new and old equipment is mixture with flue gas
and doctor solution. After absorption, adsorption and chemical reaction, it can
completely remove the flue gas dust and sulfur dioxide emissions, to meet environmental
protection requirements. The equipment was awarded the national patent in 2010.
The design using sodium as the circulation desulfurization agent and efficient
absorption tower,has low liquid gasrate, low circulation,and the desulfurization agent
For the absorption efficiency of sodium alkali desulfurization agent is much higher
than albany grease, at the same time, using the high absorption tower design, its
desulfurization efficiency is 90 ~ 97%.
4. Process design
The project adopts advanced technology, stable operation of sodium - alkali TFGD,
taking the new and high efficiency desulfurization dust removal technology. Below is the
overall design principle:
1) To meet the environmental emissions standards and design index and client's
requirements;
6) This system is fully considered the change of SO2(that is, the range change of
Content Unit
Data Remark
3.5×14m XGP-20
thionizer specification
m 2.5X14m Twin Composite efficient
(Diameter x height)
Towers desulfurization tower
Tower gas rising velocity m/s 2.5
Exhaust gas of dust removal, desulfurization equipment is from the original equipment
out into efficient desulfurization case for flue gas treatment. Flue gas is through the high
efficiency desulfurization tower efficient filter layer. And this filter layer with special design,
flue gas going through the filter layer, enhance the efficiency of absorption. And after
desulfurization tower top three layers of atomized spray absorption area, desulfurization agent
atomized into tiny droplets collision adsorption, absorption of SO2, complete gas
desulfurization dust absorption, and then into the efficient desulfurization tower at the back of
the mist device. The flue gas of the droplet capture down, mist eliminator is equipped with
flushing device, timing to wash. Flue gas is through the mist eliminator (vice tower) to
remove the liquid gas after the reconstruction in a period of pipeline to gas pipeline
Single (sodium) process mainly includes:1 Flue gas piping system、2 clarification
4.3 Formulate
Dust gas by the transformation of the original equipment out enter the sulfur
removal system. Exhaust gas is through efficient desulfurization tower, dehydrator (vice
towe) equipment,finishing the flue gas desulfurization dust cleaningand then through the
made of steel structure,among import and export pipeline desulfurization take the
preservative treatment. The increasing pipeline internal all take the preservative
treatment.
(1)Pipeline
pressure, flow rate and the content of pollutants)to design the pipe.
Pipeline design can bear below load:self weight of pipeline、wind load、snow load、
seismic load、dust accumulation、the weight of the lining and so on。Some places add line
support.
Pipe is a gas tightness of welding structure,and all non flange connection interface are
continuous welding,complying with the above rules.
Piping layout can ensure condensate emissions,won't have water or condensate
fluid accumulation.So pipeline can provide the measures accumulation of low point
drainage and prevention condensate. In any case expansion joint and damper are not
size or try to reduce the size of reinforcement。And add the beauty of outer appearance.
will minimize piping system pressure drop, and its layout,sharp and internal parts(Such as
1)、design consideration
2)、design objective
1、desulfurization efficiency≥90%。Ringelmann shade scale≤1 Dust emissions<
100mg/m³
Sulfur emissions<100~250mg/m³
2、Equipment service life≥15years.
3)、design parameter(Provided by manufacturer)
1、Furnace shape:oil burning boiler
2、Treatment medium: SO2 produced from the furnace.
3、Day of working time 24 hours
4、Equipment flue gas inlet temperature:≤350℃
3
5、Gas flow:managing gas flow:80000-90000m /h(working condition)
6、 Sulfur inlet concentration<2500mg/m³-3600mg/m³
7、Sulfur out concentration<100-250mg/m³
4)、Design Philosophy
1、Adhere to the advanced ,reliable economic principle, so as to meet the domestic
advanced level
(shower nozzle, effuser, etc.) are made of strong corrosion resistant material.
4、The dust removal system installation, operation does not affect the original
ZL200920119623.5
safety norms.
6、 The main part of the dust removal system (dust desulfurization equipment) is
transformed in the original equipment, increasing the length of 400 mm 6 branches filter layer
and open the roof.
equipment connected air duct),a new efficient desulfurization tower,a mist eliminator,
4、The scheme does not include pool, supplement water and so on.
13~15m/s and through the pipe flow calculation,the diameter of the pipe system
isφ1500mm.
experience,according to the principle of seeking truth from facts, learning from others's
strong points to offset one's weakness and optimal design,Below is the technical design
big flow theory,reducing operation cost,to ensure the normal work of the furnace.
3. System air flow:Flue gas inlet temperature≤350℃ and local atmospheric pressure
the management it should achieve all aspects of requirements of the environmental protection
requirement and our work experience and other examples,we decide to take the technology of
TFGD,to manage SO2, and the purpose is to effectively remove a large amount of SO2. The
back).
Inside of the equipment added garden shape desulfurization layeran and the filter layer
devices which produced by ourselves. This filter layer is made by several small circular
support arm, and according to the characteristics of the fixed Angle, when the gas go through
the circular support arm, because of the wind movement characteristics, turn round, so the
contact surface will become bigger. And the circular surface is a lye, so gas and lye contact
surface will increase, contact time lengthen, and flue gas of sulfur of molecules and molecules
of the alkali lye can be fully in close, it is in the equipment structure to ensure the
desulfurization effect
So that the old water film is only by a cyclone principle into relying on a variety of
principle of comprehensive dust desulfurization and dehydration of new equipment, greatly
improving the sulfur removal effect, and now the new high efficiency desulfurization
equipment on modelling is not granite form, but external for steel plate, internal for corrosion
resistant material.
External is steel plate for 316 L stainless steel internal corrosion resistant materials
(divided into two layers: a layer for steel structure, the steel plate thickness, a layer of 8 mm a
layer of stainless steel 316 L, thickness of 2 mm) of several single formation, after a series of
desulfurization flue gas temperature dropped to 80-120 range.
In the installation,the equipment manufacturer firstly make every good single day,
and then to the scene to organic every single according to the need for flange
connection.After combination, enter pipe installation and duct connection work. So in
equipment installation, process, it greatly reduces the time; in equipment manufacturing,
it also reduces a lot of joint.When designing, I design the tower have each two filter
layer, three distributor, each layer of distributor layer has valve, a dehydrator (vice
tower). After water separation, the clean gas go through chimney into the atmosphere.
In the above equipment structure, it divides spillway hole and cleaning eye, air inlet,
spray layer, the filter layer, water pipe, ladder stand and platform eight parts. Leave clean
window in part of the window to clean up, there are clear when open, need not when closed.
clean simple, low operating cost.It is the best equipment,also is the most commonly used
among all kinds of boiler and furnace and smelting furnace.
establishment of contract.
8)、Operating expense
This set of equipment does not exist maintenance,observing two to three times
every week,mainly observing the bottom water situation. Water is recycled,if below the
water level,moisturizing. Temperature is not high, flue gas with water is few, so water is
5. Other system
Other system includes process water 、 accident slurry system 、 drainage 、 fire
Due to the desulfurization system circulating fluid containing ash and particles, the
installation structure is reasonable, and we design to residue precipitation in pipe, and also use
the water flow in channel to add alkali content, like this: it can achieve dosing mixing effect.
It is also available to clean up powder sediment in the channel (very simple). So the water in
pool is very clean, no cleaning.
gutter inlet, inspection well and then flow to our existing drainage system.
All equipment of this system does not contain the electrical system.
Anti-corrosion design.
The surface of all piping and box tank should besmear brushes anti-corrosive primer. To
not heat preservation and medium temperature less than 130℃ heat preservation of equipment
pipelines and accessories, support post, escalator platform to besmear brushes anticorrosive
paint, paint color should be coordination with the main project.
②Corrosion Prevention
Corrosion Prevention Range : All desulfurization serous or sodium alkali contact
equipment, pipeline and cell body may contact with low temperature saturated and flue gas
condensate, pipes have to take anticorrosion measures as follows:
6. After-sales service
For this project, our company promised the following items e:Product technical
debugging and the whole process of production. All equipment will be inspection and
acceptance according to relevant standards. After the acceptance, the equipment will be with
manufacturer's certificate. After reach the standard of equipment installation debugging,we
will delivery user management to use.
2、 Before installation,our company will provide the user the equipment installation
diagramand drawings. You can send technical person to the site for installation, serious
investigation, accurate to installation termination.
maintenance, according to the specified time, place, we will seriously to the scene for user
training operation and management personnel, And prepare relevant training maintenance
operation data, puts forward fault hair color’s causes and treatment methods, combining
theory and practical operation for equipment operation training
to attempt.
personnel for user, completes the training plan, schedule, method and time.
6、 The user operation and maintenance worker training general arrange in the
period of equipment installation and operation, the time is about 5 to 7 days. It is for
management personnel to can fully understand the performance of the equipment,
maintenance and knowledge.To ensure that equipment in the commissioning period and
the future operation process, each user should master all the operation function and the
equipment failure causes and simple maintenance methods.
and reference. After the operation to the delivery of the buyer's use. To ensure achieve
GB8978-1996 <integrated emission standard> of the second kind of pollutants emission
concentration and standard.
acceptance, cooperating with users and local departments in the equipment 。 And
according to the design requirements, the company worked out the project schedule,
debugging program, debugging main point and safety measures, etc.
2. According to the whole system equipment for installation check, equipment structure
layout and pipeline rout, node seal degree sealing, equipment operation has abnormal noise,
electric machine instrument performance is reasonable.If you find any unreasonable points,
pur company will be responsible for correcting until the user feel satisfied.
auxiliary material production of customers list, in order to remove the worry of user in
equipment maintenance, to ensure that the supplied goods operates continuous normal, free to
provide relevant technical data.
2、All the equipment are implement three guarantees. Guarantee period is for one year,
and during the warranty period, the company will provide free repair for the product quality.
For not belong to a responsibility or the warranty equipment repair, we only take cost of
production. And we only accept costs when the time is more than warranty period
maintenance.
3、For users that put forward relevant technical consulting requirements,we will reply
within 24 hours. In the domestic, we will catch the field to solve, service item will be within
24 hours to make a decision, and 48-72 hours to the county to solve the problem.
communication, taking a product quality tracking service, in order to improve the economic
benefit of the normal operation of production.
For above terms, welcome the user to supervise the implementation, and put forward
your valuable opinions and suggestions, so we can improve the product quality and after-sales
service.
Annexure - 10
Air Modeling Report
STACK EMISSION DISPERSION
MODELING OF
DHAKA SOUTHERN POWER
GENERATIONS LTD.
At
Nawabganj, Dhaka.
Prepared By:
November, 2013
TABLE OF CONTENTS
1. INTRODUCTION 2
2. METHODOLOGY 2
2.1 About AERMOD View 2
2.2 Meteorological Condition 3
3. STANDARDS AND GUIDELINES 6
4. SOURCE PARAMETERS 6
5. BACKGROUND POLLUTANT LEVELS 6
6. MODELING RESULTS 7
7. CONCLUSION 8
8. REFERENCES 32
AECL/AEDM/DSPGL/2013 Page 1 of 33
1. INTRODUCTION
It orders to estimate the pollutant concentration from a point source emission, USEPA
AERMOD view 8.0.5 model have been used. AERMOD view is a Gaussian plume model
that incorporates source-related factors, meteorological factors, receptors, terrain and
building downwash factors to estimate pollutant concentration from continuous point source
emission. The following report describes the prediction of emission of NO₂ from the gas fired
engine generated power plant and it’s impact on ambient air quality within 5 Km radius.
2.0 METHODOLOGY
Features
Create impressive presentations of the model results with the easy and intuitive graphical
interface of AERMOD View. We can customize the project using display options such as
transparent contour shading, annotation tools, various font options, and specify compass
directions.
Import base maps in a variety of formats for easy visualization and source
identification.
Use the major digital elevation terrain formats - USGS DEM, NED, GTOPO30 DEM,
UK DTM, UK NTF, XYZ Files, CDED 1-degree, AutoCAD DXF.
Interpret the effects of topography by displaying the model results with 3D terrain us-
ing the powerful 3D visualization built right into the interface.
Complete building downwash analysis effectively and quickly using the necessary
tools that AERMOD View provides.
Prepare meteorological data quickly and accurately using AERMET view by the step-
by-step meteorological pre-processing interface.
AECL/AEDM/DSPGL/2013 Page 2 of 33
Take advantage of AERMOD View's integrated post-processing with automatic con-
touring of results, automatic gridding, blanking, shaded contour plotting and posting
of results.
All the required information was obtained from manufacturer specification. Discharge
concentration was estimated at 500m increments from the plant up to 5 km radius.
The Nawabganj, Dhaka area where the power plant is located has a sub-tropical climate and
is under the influence of the strong southwest or summer monsoon and weak northeast or
winter monsoon. It has been understood from last few years of air quality monitoring, the air
quality level of the area greatly influenced by the Asian monsoon. The air quality
characteristic over the area and it’s surrounding shows distinct seasonal variations, with high
pollution episode observed during winter, while summer has relatively cleaner ambient air.
During dry winter and part of the post-monsoon season, the strength of north, northwest
wind coming from India, Nepal and Southeast China to the Bay of Bengal through
Bangladesh may transport the air pollutants to the city. Moreover, during dry season the
wind speed is so low that the pollutants emitted from the local sources cannot travel away
from the city.
The use of site-specific meteorological data has been collected from the World Meteorologi-
cal Organization (WMO) who has provided 1 Year of MM5-Preprocessed site specific Mete-
orological data for the period of Jan 01, 2011 to Dec 31, 2011 at Latitude: 22°14'17.94"N,
Longitude: 91°48'47.76"E , Time Zone: UTC +6. These data contain hourly value of wind
speed & direction, wind velocity, surface roughness, bowen ratio, albedo, temperature & ref-
erence height, precipitation rate, relative humidity, surface pressure and cloud cover over the
period mentioned above. The data then have been analysed and processed through MET
processing model AERMET View which uses Samson format to process the data and create
surface met data file & profile met data file computable to the USEPA AERMOD view disper-
sion model. These surface met data file & profile met data file were then used in AERMOD
view as Met input data for calculation.
The wind rose plots were drawn from the AERMET view met processor model and shows
distinct four wind directional patterns representing four seasons in a year as per air blowing
to and from (Figure 2.1 & 2.2). The mixing height in the boundary layer is one of the
important factors to assess the influence of meteorology on the dispersion of pollutants.
AECL/AEDM/DSPGL/2013 Page 3 of 33
Figure 2.1: Seasonal wind direction (Pre-monsoon, Monsoon, Post-monsoon and winter
respectively) blowing to the project location based on Samson data processing obtained
from AERMET view.
AECL/AEDM/DSPGL/2013 Page 4 of 33
Figure 2.2: Seasonal wind direction (Pre-monsoon, Monsoon, Post-monsoon and winter
respectively) blowing from the project location based on Samson data processing obtained
from AERMET view.
AECL/AEDM/DSPGL/2013 Page 5 of 33
3.0 STANDARDS AND GUIDELINES
Since HFO will be used for the proposed engine power plant, the principal air pollutant of
concern is nitrogen dioxides (NO₂) and Sulphur Di-oxide (SO2). The guideline value for NO₂
& SO2 in case of ambient air is shown in Table 3.1.
Table 3.1: Ambient air quality guideline for SO2 & NO₂.
The exhaust specifications and stack parameters for the proposed HFO generator is used as
input to USEPA AERMOD view model. The model calculates the values of 3 HFO
generators as point source of PM10, SO 2 & NO2 emissions. The parameters and
corresponding values are summarized in Table 4.1.
Table 4.1: The exhaust specifications and stack parameters (for each stack)
Parameters Values
Stack height (m) 32
Stack inside diameter (m) 4.5
Stack exit velocity (m/s)
Exhaust temperature (K) (195+273) = 468
Exhaust flow rate (m3/sec) 14.22
NOx emission rate as NO2 (gm/sec) 10.01
SO2 emission rate (gm/sec) 49.33
PM emission rate (gm/sec) 7.64
Ambient temperature (K) 273
This information was needed for the purpose of estimating the worst-case combined impact
of the proposed power plant and existing pollutant sources, which can then be compared to
the air quality objectives. There was no long-term data available for the area of concern. A
AECL/AEDM/DSPGL/2013 Page 6 of 33
limited monitoring was conducted by AECL (sampling & analysis has been done by AECL
Lab team on 03/11/2013 to 05/11/2013) for obtaining 24-hour average of pollutant
concentrations at different distances from the project site. The data are given in Table 5.1.
The modelling was conducted for the 3 individual engines releasing gaseous
emission as point source with simple terrain using USEPA AERMOD view version
8.0.5 model. The model assumes the stack tip downwash with receptors on flat
terrain and no flagpole receptor heights. The PM10, NO2 & SO2 concentration
contour have been analysed with 500 m interval with a radius of 5000m from the
point source.
NO2 concentration:
The NO2 concentration contour of 24 hour and annual average of have been
analysed. The maximum of 24 hour concentration of NO 2 (30-50 µg/m3) has been
predicted at a radius of 200mnorth & south and 1000m north & south to the project.
The concentrations are found below 10-30 µg/m3 within 1000m north & south and
around up to 5000 to the other sides. The maximum annual concentration of NO2
has been detected as 3-5 µg/m3 at 500m around the project side and the
concentrations are within 0.5-3 µg/m3 on the either sides up to 5000m from the
project.
AECL/AEDM/DSPGL/2013 Page 7 of 33
SO2 concentration:
The SO2 concentration contour of 24 hour and annual average of have been
analysed. The maximum of 24 hour concentration of SO2 (100-300 µg/m3 ) has been
predicted at a radius of 500m north & south and 2000m northwest & northeast to the
project, whereas the concentrations are within 50-100 µg/m3 at a radius of 500-
1000m north & south and up to 5000m to the other sides. The maximum annual
concentration of SO2 has been detected as 20-50 µg/m3 at 500m around the project
site, whereas the concentrations are within 5-20 µg/m3 on the either sides at around
1000 m north & south and up to 5000m at the other sides to the project.
PM10 concentration:
The PM10 concentration contour of 24 hour and annual average of have been
analyzed. The maximum of 24 hour concentration of PM10 (10-40 µg/m3) has been
predicted at a radius of 200-500m north & south and up to 5000m east & west to the
project site. The concentrations are found below 10 µg/m3 at the other sides of the
project site beyond 500m. The maximum annual concentration of PM10 has been
detected as 3-8 µg/m3 at 500m around the project side and the concentrations are
below 3 µg/m3 at all the sides which is coming down to 0.3 µg/m3 from 500m 5000m
surrounding the project.
7.0 CONCLUSION
NO2 Concentration:
There is no IFC/WHO and Bangladesh standard set for 24 hour concentration for
NOx. The maximum yearly concentration of NOx have been detected (max 5 µg/m3)
well below the IFC/WHO and Bangladesh standard at all sides at any radius around
the project.
SO2 Concentration:
There is no IFC/WHO annual standard set for SO 2 for ambient air quality, the 24
hour concentration of SO2 have been found (100-300 µg/m3 ) above the IFC/WHO
standard (20 µg/m3) but below the Bangladesh standard (24 hour average 365 µg/m3
and annual average 80 µg/m3) at all sides of the proposed project. The plant would
have a FGD, in which the emission level for SO2 will further be reduced by 90% and
thus will come down to 10-30 µg/m3 (24 hour average) and 0.20-0.50 µg/m3 (annual
average) which all will comply the both the IFC/WB standard and Bangladesh
NAAQS standard.
AECL/AEDM/DSPGL/2013 Page 8 of 33
PM10 Concentration
The IFC/WHO and Bangladesh standards for 24 hour PM10 concentrations are (50
µg/m3 and 150 µg/m3 respectively) and annual concentrations (max 20 µg/m3 and 50
µg/m3 respectively). The 24 hour and annual PM10 concentrations have been found
below Bangladesh and IFC/WB standard at all the sides of the project. Further, on
installing FGD, it will also substantially reduce PM emission (>50%) as it uses a wet
scrubbing process.
AECL/AEDM/DSPGL/2013 Page 9 of 33
Figure 6.1: Emission contour map showing the NOx concentration (24 hour average) at 5000m surrounding the project location
AECL/AEDM/DSPGL/2013 Page 10 of 33
Figure 6.2: Emission contour map showing the NOx concentration (Annual average) at 5000m surrounding the project location
AECL/AEDM/DSPGL/2013 Page 11 of 33
Figure 6.3: Emission contour map showing the SO2 concentration (24 hour average) at 5000m surrounding the project location
AECL/AEDM/DSPGL/2013 Page 12 of 33
Figure 6.4: Emission contour map showing the SO2 concentration (Annual average) at 5000m surrounding the project location
AECL/AEDM/DSPGL/2013 Page 13 of 33
Figure 6.5: Emission contour map showing the PM10 concentration (24 hour average) at 5000m surrounding the project location
AECL/AEDM/DSPGL/2013 Page 14 of 33
Figure 6.6: Emission contour map showing the PM10 concentration (Annual average) at 5000m surrounding the project location
AECL/AEDM/DSPGL/2013 Page 15 of 33
The following are the emission concentration plots in different directions of the power project at 24 hour and annual average of NO2
concentration:
Figure 6.7a: NO2 Emission concentration plots (24 hour average) at 5000m east to the project location
AECL/AEDM/DSPGL/2013 Page 16 of 33
Figure 6.7b: NO2 Emission concentration plots (24 hour average) at 5000m north to the project location
AECL/AEDM/DSPGL/2013 Page 17 of 33
Figure 6.7c: NO2 Emission concentration plots (24 hour average) at 5000m south to the project location
AECL/AEDM/DSPGL/2013 Page 18 of 33
Figure 6.7d: NO2 Emission concentration plots (24 hour average) at 5000m west to the project location
AECL/AEDM/DSPGL/2013 Page 19 of 33
Figure 6.8a: NO2 Emission concentration plots (Annual average) at 5000m east to the project location
AECL/AEDM/DSPGL/2013 Page 20 of 33
Figure 6.8b: NO2 Emission concentration plots (annual average) at 5000m north to the project location
AECL/AEDM/DSPGL/2013 Page 21 of 33
Figure 6.8c: NO2 Emission concentration plots (Annual average) at 5000m south to the project location
AECL/AEDM/DSPGL/2013 Page 22 of 33
Figure 6.8d: NO2 Emission concentration plots (Annual average) at 5000m west to the project location
AECL/AEDM/DSPGL/2013 Page 23 of 33
Figure 6.9a: SO2 Emission concentration plots (24 hour average) at 5000m east to the project location
AECL/AEDM/DSPGL/2013 Page 24 of 33
Figure 6.9b: SO2 Emission concentration plots (24 hour average) at 5000m north to the project location
AECL/AEDM/DSPGL/2013 Page 25 of 33
Figure 6.9c: SO2 Emission concentration plots (24 hour average) at 5000m south to the project location
AECL/AEDM/DSPGL/2013 Page 26 of 33
Figure 6.9d: SO2 Emission concentration plots (24 hour average) at 5000m west to the project location
AECL/AEDM/DSPGL/2013 Page 27 of 33
Figure 6.10a: SO2 Emission concentration plots (annual average) at 5000m east to the project location
AECL/AEDM/DSPGL/2013 Page 28 of 33
Figure 6.10b: SO2 Emission concentration plots (annual average) at 5000m north to the project location
AECL/AEDM/DSPGL/2013 Page 29 of 33
Figure 6.10c: SO2 Emission concentration plots (annual average) at 5000m south to the project location
AECL/AEDM/DSPGL/2013 Page 30 of 33
Figure 6.10d: SO2 Emission concentration plots (annual average) at 5000m west to the project location
AECL/AEDM/DSPGL/2013 Page 31 of 33
8. REFERENCES
1. Screening Procedures for Estimating the Air Quality Impact of Stationary Sources,
Revised, EPA-450 R-92-019.
2. Bilkis A. Begum, Naima A. Khan, M. Khabir Uddin and Swapan K. Biswas,
.Characteristics and short-range transport of particulate matter from Dhaka-Aricha highway..
J.of Bangladesh Chemical Society, 22(1), 2009, 18-34.
3.Bilkis A. Begum, Swapan K. Biswas, Andreas Markwitz and Philip K Hopke, .Identification
of sources of fine and coarse particulate matter in Dhaka Bangladesh.. Aerosol and Air
Quality Research, 10, 2010, 345-353.
4. IFC Environmental Health and Safety Guidelines. 2007
5. Air/Superfund National Technical Guidance Study Series, Volume 4: Guidance for Ambi-
ent Air Monitoring at Superfund Sites, Revised EPA Number: 451R93007, NTIS number
PB93-199214
6. Jindal, M., Heinold, D., 1991, "Development of Particulate Scavenging Coefficients to
Model Wet Deposition from Industrial Combustion Sources". Paper 91-59.7, 84th Annual
Meeting – Exhibition of AWMA, Vancouver, BC, June 16-21.
7. Ontario Ministry of the Environment, July 2005. Air Dispersion Modelling Guideline for On-
tario, Version 1.0. PIBS#5165e. Ontario Ministry of the Environment, Toronto, Ontario.
8. U.S. Environmental Protection Agency, 1985. Guideline for Determination of Good Engi-
neering Practice Stack Height (Technical Support Document for the Stack Height Regula-
tions). Revised EPA-450/4-80-023R. U.S. Environmental Protection Agency, Research Tri-
angle Park, North Carolina 27711.
9. U.S. Environmental Protection Agency, 1986. User’s Guide to the Building Profile Input
Program. Revised EPA-454/R-93-038. U. S. Environmental Protection Agency, Research
Triangle Park, NC.
10. U. S. Environmental Protection Agency, 1987. Guidelines on Air Quality Models (Re-
vised) and Supplement A. EPA-450/2-78-027R. U. S. Environmental Protection Agency, Re-
search Triangle Park, NC.
AECL/AEDM/DSPGL/2013 Page 32 of 33
Annexure - 11
Noise Modeling Report
Noise modeling of 55 MW Power Project of
Dhaka Southern Power Generations Ltd.
Table of Contents
1. Noise Pollution
2. Impact on Noise Quality
3. Noise Modeling input data
4. Noise Modeling
5. Noise Modeling Result
6. Resultant noise emission
AECL/NM/DSPGL/2013 Page 1 of 6
1.0 Noise pollution
The word "noise" comes from the Latin word "nausea" meaning Sea sickness. Noise
is among the most pervasive pollutants today. Noise pollution can be caused by
many sources including highways, vehicles, factories, engines, machine, aircraft,
helicopters, industrial development and construction work. Noise negatively affects
human health and well-being. Problems related to noise include stress, sleep loss,
distraction, and a general reduction in the quality of life. Noise pollution can be also
harmful to animals. High enough levels of noise pollution may interfere with the
natural cycles of animals. Noises are irregular and disordered vibrations including all
possible frequencies. The intensity of a sound I can be expressed in decibels with
the standard equation:
L=10 log(I/I0)
where I0 is the quietest sound most people can hear, the threshold of hearing 10-
12Wm-2. When the ratio is between two field strength (so that the power being
transmitted is proportional to the square of the pressure, the formula is:
LdB=10 log[p2/(p0)2]
The decibel unit is often used in acoustics to quantify sound levels relative to some 0
dB reference. The reference may be defined as a sound pressure level (SPL),
commonly 20 micropascals. The reference sound pressure (corresponding to a
sound pressure level of 0 dB) can also be defined as the sound pressure at the
threshold of human hearing, which is conventionally taken to be 20 micropascals. It
can therefore be seen that a ratio expressed in decibels. A-weighted decibels are
abbreviated dB(A) . When acoustic measurements are being referred to, then the
units used will be dB SPL (sound pressure level) referenced to 20 micropascals = 0
dB SPL.
The intensity of two sounds L1 and L2 can be added in decibels with the standard
equation:
LdB=10 log[(p1/p0)2+[(p2/p0)2]
and then,
In this way, decibels from two different sources can be added. CUSTIC Software will
consider this method of calculation.
AECL/NM/DSPGL/2013 Page 2 of 6
2.0 Impact on Noise Quality
The main sources of noise during operations of the power plant will be from the 3
exhaust stack of the HFO engine generator. The generators will be fitted with a
silencer prior to disperse the emission through stack. The power house building will
adopt modern building design and the use of sound absorbing materials to minimize
noise and vibration from the powerhouse.
The generator room will have internal noise level of around 107 dBA at 1m distance
from each reciprocating engine and the noise level at the steam turbine unit is 90
dBA, the combined noise effect from the 3 engines and turbines can be found by
applying the formula of (∑L = 10. Log10 (10L1/10 + 10L2/10) dBA, in which the
equivalent noise will be 112 dBA from all engines & turbines, which will be minimized
by sophisticated acoustic power house building design so as to minimize the noise
emission up to standard. The generators and turbines are enclosed in buildings
acoustically designed, providing Styrofoam filler of 100 mm width in between 150
mm thick brick walls both side (sandwich type).
The Styrofoam filter and brick wall will absorb noise as following:
It is estimated that the noise abatement measures of the power house building will
be capable to absorb around 90 dBA noise from the engine room, but the maximum
engine room noise is around 112 dBA near the generators & steam turbine, the
further noise emission simulation from the power house building will be determined
by the modelling calculation.
The individual reciprocating engine stack will emit a noise level of 65 dBA after
providing the silencer (25 dBA abatement from the steam turbine exhaust). Further
noise emission simulation from the stack will be determined by the modelling
calculation.
The following input data has been used for the modeling:
AECL/NM/DSPGL/2013 Page 3 of 6
A. Internal point source
4. Noise Modeling
Canarina CUSTIC 3.2 software for noise pollution modelling is used for the
assessment of the noise propagation of this power project. The CUSTIC Software
allows us to create robust and useful numeric simulations that fully make use of the
graphical user interface, with a certain security that the software CUSTIC 3.2 is one
of the best tool, to carry out numeric simulations of noise pollution.
The cumulative impact from the stationary noise sources at proposed project site has
been predicted using the above model. It was found that the ambient noise is higher
than predicted levels therefore, due to the masking effect, an increase is not
expected.
At 112 dBA equivalent noise output from the 3 engines and turbines and equivalent
noise absorption of 90 dBA by the Styrofoam and brick wall, the resultant noise
emission simulation has been done by the model and the predicted noise output is
as below:
AECL/NM/DSPGL/2013 Page 4 of 6
Fig 1: Plot of output noise power level in dBA vs Radius in meter (Internal Engine room noise)
At 65 dB noise output from the each stack after silencer, the resultant noise emission
simulation has been done by the model and the predicted noise output is as below:
AECL/NM/DSPGL/2013 Page 5 of 6
Fig 2: Plot of output noise power level in dB vs Radius in meter (external stack noise)
The resultant noise emission from the internal and external sources of the power
plant has been calculated by the equivalent noise summation formula and the
resultant noise has been given below:
AECL/NM/DSPGL/2013 Page 6 of 6
Annexure - 12
NOx & SO2 Calculation
Exhaust flow rate calculation:
So, the Exhaust flow rate is 51209 m 3/hr at 573 OK = 14.22 m3/sec
Now the NOx emission rate is 1480 x 6.77 = 10019.6 mg/sec = 10.01 gm/sec