ESIA of DSPGL

Annexure - 1

Project layout plan

Annexure – 2(a)

HFO Engine Specification

MAN Diesel & Turbo

Our Reference 5301959-01-B001 Date 2012-02-21 5301959-01-B001 Technical specification Rev000 Page i

Nababganj Power Plant - 55MW Bangladesh

Technical Specification 3 MAN Gensets 18V48/60TS plus mechanical & electrical auxiliaries

MAN Diesel & Turbo

Our Reference 5301959-01-B001 Date 2012-02-21 5301959-01-B001 Technical specification Rev000 Page ii

Revision History

Revision Description Date Author

5301959-01-B001 Technical Specification 3x18V48/60TS 2012-02-21 Nikhil Ghag

MAN Diesel & Turbo

Our Reference 5301959-01-B001 Date 2012-02-21 5301959-01-B001 Technical specification Rev000 Page iii

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

7 Tools, spare and wear parts 31 7.1 Tools and spares 31

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

9 Requirements and limitations 43 9.1 Quality requirements for operating media 43 9.2 Limits of supply 46

10 Operation and maintenance 48 10.1 MAN Diesel & Turbo Service Worldwide 48

11 Standards, Guidelines and Drawings 49 11.1 Applicable standards 49 11.2 General guidelines 49 11.3 Drawings 50 11.4 Division of Works 50

12 General information 51 12.1 List of sub suppliers 51 12.2 References 52 12.3 Leaflets and brochures 57

Nababganj Power Plant - 55MW Section 1 - Design data and performance guarantees

Our Reference 5301959-01-B001 Date 2012-02-21 5301959-01-B001 Technical specification Rev000 Page 1 of 58

1 Design data and performance guarantees

Our quotation is based on following design data as well as the:

- Drawing of generating set: 11745001770_01_A_Genset Drawing 18V4860TS

1.1 Design data

1.1.1 Site conditions

Site conditions All offered equipment is designed to operate within the following ambient conditions:

Altitude above sea level 23 m

Wet bulb temperature 29 °C

Minimum ambient air temperature 10 °C

Maximum ambient air temperature 40 °C

Operation outside of these limits without guarantee.

1.1.2 Generating sets

Generating sets Under consideration of your request, this quotation provides for 3 generating sets based on the MAN 18V48/60TS engine.

Number of generating sets 3

Engine type 18V48/60TS

Engine speed 500 min-1

Lube oil pump engine driven

HT cooling water pump engine driven

LT cooling water pump engine driven

Electrical system

The offered equipment is based on the following electrical values:

Operation mode GRID ONLY

Frequency 50 Hz

Power factor cos phi (lagging) 0.8

Medium voltage 11 kV

Low voltage 400 V



1.1.3 Other design data

Foundation Soil bearing capacity 200 kN/m2

Earthquake design according to Peak Ground Acceleration

PGA1 0.2 g

Lube oil Engine lube oil has to be in accordance to the requirements as stated in section 9.1

Requirements for viscosity:

Viscosity-class (40°) SAE40

Cooling method Features of the cooling water system:

Type of cooling system RADIATOR

Heavy fuel oil The fuel oil system is designed based on heavy fuel oil in accordance to the requirements as stated in section 9.1.5.

Alternatively the engines can be operated on diesel fuel oil in accordance to the requirements as stated in section 9.1.4 for up to 72 hours at a time.

Intake air Ambient air free of dust, salt and sand

Power house ventilation

Design temperature rise inside power house 17 K

The temperature rise to be measured between ventilation outlet und inlet.

The power house ventilation air is blown directly onto the alternator.

The alternator design temperature is 43 °C.

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

Table 1: Diagram of permissible frequency and load limits

Table 1 shows that the maximum continuous engine output is ensured at a mains grid frequency exceeding up to max. +3%, whereas at a frequency drop to max. -5%, the power output is continuously reduced to 95% MCR. We permit operation of the engines up to +5% frequency fluctuation for maximum 120 seconds. In any case, the maximum permissible mains grid frequency deviation is ±5%.

Load application

When load is suddenly applied to a generating set there will be a transient deviation in voltage and frequency. The maximum permissible load increase is limited to steps of 25% of the nominal power of all generating sets in operation. Further it depends on the base load before load increase.

The offered generating sets comply with ISO 8528-5 class G2.

90

95

100

105

-6 -4 -2 0 2 4 6

Engine speed / Nominal speed [%]

Lo

ad

[%

]

Continuous power



1.2 Performance data

Site Reference conditions

The values given here are for information only and without guarantee.

Our stated performance data is based on the design data as per section 1.1 and calculated for the following reference conditions:

Air Inlet temperature (before air inlet filter) 35 °C

Air Inlet pressure (before air inlet filter) 1011 mbar

Charge air temperature before cylinder 54 °C

Exhaust gas back pressure 30 mbar

Intake air pressure loss 20 mbar

In case the site conditions / technical parameters at performance test are different from the site reference conditions defined above, the performance guarantees will be adapted in accordance to MAN standard procedure.

Measuring tolerances

Tolerances in the measuring equipment shall be considered additionally and are not included in the guarantee figures stated below. Tests will be done according to ISO 15550:2002 (ISO 3046-3:1989).

1.2.1 Continuous power of the generating set

Data will follow

1.2.2 Specific fuel oil consumption (SFOC)

Data will follow

1.2.3 Lubricating oil consumption

Data will follow

Nababganj Power Plant - 55MW Section 2 - Diesel engine


2 Diesel engine

General description

The MAN engine 18V48/60TS is a 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.

Technical data The technical data is summarised in the following table:

Cylinder bore 480 mm

Piston stroke 600 mm

Engine speed 500 min-1

Piston speed 10.00 m/s

Mean effective pressure 23.21 bar

Power per cylinder 1050 kW/cyl

Power of the engine (at crankshaft) 18900 kWm

Continuous development

The engine familiy has a well proven service record in marine propulsion, marine auxiliary genset and stationary power generation. 48/60TS engines from MAN have been in service since 1989 and are subject to continuous development to ensure reliability under the most severe service conditions. Each 18V48/60TS engine is engineered to optimise its performance to ensure that your individual requirements are met.

Outline dimensions

Dimensions and weight2 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.



2.1 Engine scope and special engine accessories

Item Q’ty Description

2.2 Engine System

2.2.1 Engine System

010 MJA10 AV010

3 Engines 18V48/60TS, suitable for operation on heavy fuel oil, as per following detailed Technical Specification

2.2.2 Turbocharger off engine

010.202 3 Turbocharger off engine

2.2.3 Lubrication system

010.220.010 MJV21 AP050

3 Engine attached lube oil pump(s)

Capacity approx. 504 m³/h including pressure control valve and connecting pipe between pumps

2.2.4 Cooling water system

010.230.010 MJG31 AP030

3 Engine attached HT cooling water pump

Capacity approx. 220 m³/h

010.230.020 MJG32 AP030

3 Engine attached LT cooling water pump

nominal capacity 280 m³/h. The cooling water flow through the charge air cooler will be adapted to 280 m³/h by installation of orifices.

2.2.5 Special equipment of the engine

010.250.030 3 Slow-turn facility on the engine.

The engine is automatically turned slowly prior to engine start with being monitored by the engine control. If the engine does not reach the expected number of crankshaft revolutions within the specified period of time, an error message is issued. Slow-turn serves as an indication that there is liquid (oil, water, fuel) in the combustion chamber.

2.2.6 Engine control and monitoring

010.290.420 3 Sensors / cabling for TC off engine




2.2.7 Factory Acceptance Test (FAT)

010.330.020 1 Factory Acceptance Test of the engine

The test will be done with the MAN Diesel & Turbo testbed equipment and installations but without other offered equipment.

Pre tests:

Checking of systems and installations

Testing of monitoring and safety equipment

Running-in and adjusting

Running up to 100% load

Adjusting of ignition pressure

Adjusting of governor

Checking of all operation data

Workshop test procedure:

Starting tests approx. 15 min.

Warming up to 100% load approx. 25 min.

Continuous power of 100% load 60 min.

Continuous power of 85% load 30 min.

Governor test approx. 15 min.

For the FAT Diesel fuel and lube oil will be used in line with the MAN Diesel & Turbo standards. The test will be executed according to the actual conditions prevailing at our workshop. The operating values to be expected at site can be calculated by using well-proven methods on basis of the main operating values as certained on the test bed. The measuring parameters, including relevant accuracies, are based on ISO 3046.

Extension or changes of our test programme would result in additional cost and have to be clarified upon request.



2.3 Detailed Technical Specification of one engine 48/60TS

Design features One-part crankcase with safety valves on crankcase covers

Crankshaft made of forged steel with torsional vibration damper at free end

Main bearings and big-end bearings with two-part thin-walled bearing shells and main bearings cross-braced by tie-rods

Connecting rod (splitted with flange) drop-forged of steel

Three-ring piston with forged steel crown and nodular cast-iron skirt

Cast-iron cylinder liners with fire band ring

Nodular cast-iron cylinder head with armour-plated inlet and exhaust valves, valve seat rings for the inlet and exhaust valves. Valve rotators on the inlet and exhaust valves. Indicator valve on each cylinder

Multi-part camshaft for enhanced Miller timing

Pipes on the engine with counter flanges or connecting screws

Fuel injection system

Injection pump on each cylinder

Rocking levers between camshaft and pump plungers, on an excentric shaft, adjustable from outside for optimising the injection timing

Variable injection timing (VIT), with automatic adjustment

Injection pipes, double walled

2 buffer pistons at the fuel admission and return pipes

Speed control Woodward EM300 electronic speed governor with actuator

Electric speed transmitter for engine speed and turbocharger speed

Electro-pneumatic emergency shutdown device on the engine for manual remote emergency stop and for automatic stop at over speed and other stop criteria within the safety system

Turbo charging and charge-air cooling

2 exhaust gas turbocharger, type TCA88 and TCA77 mounted at the FREE END. Lube oil run down tank, decoupled from turbocharger. Washing device (wet) for the exhaust gas turbine and compressor.

2 Charge-air cooler in fresh water and two-stage design; with counter flanges, standard design for top removalAir pipe sound insulated between compressor and charge air cooler (including air intake casing)

Exhaust gas piping on the engine, uncooled, thermally insulated and lagged

Platform Brackets on the engine for attaching the main gallery supports

Operation and control

Engine safety and control system SaCoS_one

comprising of:

Control unit, resiliently mounted on engine, consisting of high integrated control modules, one for safety system and one for alarm handling and control, including the following functions:

Splash oil temperature monitoring

Main bearing temperature monitoring

Lube oil temperature and pressure monitoring

Cooling water temperature and pressure monitoring

Charge air temperature and pressure monitoring

Exhaust gas temperature monitoring

Speed monitoring and overspeed protection

Engine control



Electronic speed governing

Interface cabinet, as floor-standing cabinet for engine room installation (standard colour RAL7035), including gateway module for plant communication via interfaces to

Plant automation system

Power supply

Power management and starters for cylinder lubrication

Power management and starters for valve seat lubrication

HT, LT and CHATCO temperature control

Oil mist detector, make Schaller VN115

Temperature measuring

Thermocouples for measuring the exhaust gas temperature after each cylinder, before and after turbocharger, with terminal box and cabling on the engine.

Start and stop equipment

Compressed air starting equipment with main starting valve and with starting valve on each cylinder of one cylinder bank

Lubricating and cooling

Cylinder lubrication oil pump with attached electrical motor (IP 55)

Forced-feed lubrication for all bearing points of running gear, camshaft, timing gear, governor drive and turbocharger

Pressure control valve for engine lube oil

Cylinders, cylinder heads, fuel injection valves, and charge-air cooler are water-cooled, pistons are oil cooled

Flywheel and turning gear

Flywheel with toothing, without protection cover

Bolts connecting the flywheel with the crankshaft

Turning gear for the running gear, with electric motor (reversible; IP 54)

Push button switching equipment, control cable

Starting interlock when turning gear engaged, with limit switch (not cabled; 24 V DC; IP 65) for display

Engine painting The outer surface of the engine is covered with paint “white aluminium” RAL 9006. Painting consists of one finishing coat, approx. 20 µm.

Acceptance Works acceptance / factory approval.

Calculation Torsional vibration calculation

Nababganj Power Plant - 55MW Section 3 - Generating set


3 Generating set

General description

Our generating sets are designed for power generation in continuous, durable 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

Dimensions and weight3 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.




3.1 Connecting elements

3.1.1 Coupling arrangement

020.010.010 3 Flexible coupling

The flexible coupling is mounted between engine flywheel and alternator shaft. The scope includes a connection hub for the alternator shaft and fixing bolts for connection to the flywheel.

A standard coupling is used. Size and rubber quality are determined by the torsional vibration calculation.

020.010.040 3 Cover for flywheel and coupling

3.1.2 Engine seating

020.020.020 3 Engine seating

Set of foundation bolts for ridgid seating of the engine.

3.1.3 Pipe adapters

020.030.025 3 Flexible pipe connections for the engine

020.030.080 3 Rubber expansion joint for intake air duct

to be installed upstream of turbocharger, delivered with counterflange

020.030.090 3 Adapter for exhaust gas duct

to be installed downstream of turbocharger, without counter flange

3.1.4 Low pressure turbo charger ducts

020.035.010 -1 3 Intake air ducting

interconnecting ducts for intake air between low pressure- and high pressure turbo charger

020.035.020 -1 3 Exhaust gas ducting

interconnecting ducts for exhaust gas between low pressure- and high pressure turbo charger

020.035.030 -1 3 Miscelleanous piping

consisting of lube oil, cooling water and starting air piping for the turbo charger unit off engine, including steel structure for T/C support




3.2 Genset

3.2.1 Alternator system

025.020.010 -1

MJA10 AG011

3 Three phase synchronous alternator

Design:

The stator frame is a rigid, welded steel structure construction. The stator core is built of thin electric sheet steel laminations which are insulated on both sides with heat-resistant inorganic resin. The radial cooling ducts in the stator core insure uniform and effective cooling of the stator.

The rotor consists of a forged steel shaft, a hub and sheet steel poles fixed on the hub. The pole laminations are pressed together with steel bars fixed to the end plates.

The windings, epoxy resin impregnated, are provided with very strong bracing which withstands all expected mechanical and electrical shocks and vibrations.

Engine-independent, self lubricated bearing design, to avoid possible lube oil contamination by the engine.

The alternator is self-ventilated and needs no external forced air flow. The surrounding air is used for cooling. The cooling air is drawn in through air filters and blown out to the surrounding environment.

Rated technical data:

Output approx. 22988 kVA

Voltage 11 kV

Current approx. 1207 A

Frequency 50 Hz

Power factor 0,8

Temperature rise stator/rotor F/F

Insulation class F

Mounting design IM1101 or IM7301

Protection class alternator IP23

Protection class terminal box IP54

Cooling method IC0A1 (Air cooled)

Operation S1, continuous

Operation mode Grid parallel

Applicable standard IEC 60034

The alternator is optimized for voltage-stability in case of load variation.

Accessories:

Anti-condensation heater

Pt100 sensors for winding temperature detection

Pt100 element and lubrication oil sight-glass for monitoring, for each bearing

Main terminal box (terminals U/V/W/N) and auxiliary terminal box (for accessories) inclusive suitable cable glands for bottom entry

Brushless self-excitation system including rotating diodes and protection




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.

025.020.050 3 Automatic voltage regulator (AVR)

Digital excitation control system type Basler DECS 200 is installed on a mounting plate integrated in the Genset Interface Panel (GIP).

Features:

Voltage regulation within 0.25% from no-load to full-load

Proportional (P), integral (I) and derivative (D) stability control

Underfrequency limiter or V/Hz ratio limiter

Paralleling compensation of two or more generators using reactive droop

Manual and automatic channel

Several protection functions

Diode monitoring function is included

Serial bus coupling for read out of different measuring values

3.2.2 Foundation system

025.030.010 3 Steel foundation frame

The engine is rigidly mounted and bolted on a steel foundation frame which is resiliently seated on the foundation. The steel foundation frame is used as lube oil service tank.

025.030.030 3 Grouting material for seating of alternator

025.030.050 3 Foundation frame seating

Spring elements for resilient, vibration-isolated mounting of the steel foundation frame with engine on the concrete foundation including equipment for lining (balancing aids) and fixing.

3.2.3 Genset addons

025.035.010 3 Frame auxiliaries and frame assembly

Engine and steel foundation frame are mounted at the MAN Diesel & Turbo workshop. Attachment of turning gear, terminal boxes, piping and cabling is included. Additionally an installation drawing is provided.

025.035.060 3 Lube oil tank level monitoring




3.2.4 Genset service platforms

025.040.010 3 Engine service platform

Free standing engine service platform, with floor plates, railing, stair and fasteners.

025.040.020 2 Interconnecting bridges for engine service platforms, with railing

025.040.050 1 Service platform for turbocharger

Nababganj Power Plant - 55MW Section 4 - Mechanical scope


4 Mechanical scope


4.1 Auxiliary systems, engine related

4.1.1 Lube oil service system

030.020.010 -1

MJG32 AP040

3 Lube oil module

consisting of:

Lube oil heat exchanger

Lube oil automatic filter

Lube oil priming pump with e-motor

lube oil temperature regulating valve

Terminal box

The above equipment is mounted on a frame with corresponding fittings completely piped and wired.

030.020.150 MJV23 CF010

3 Lube oil replenishing and flow rate measuring device consisting of:

Oval gear meter including pulse trigger

Solenoid valve

030.020.160 GBK37 AT020

3 Lube oil separator module

consisting of:

Separator, self-cleaning, capacity min. 4725 l/h with motor

Switch cabinet, complete with control and power part as well as temperature control and temperature switch

Steam heated lube oil preheater with safety valve and insulation

Sludge collector and sludge pump

Supply pump, not fitted

030.020.280 MJV28 AN010

3 Oil mist eliminator

The vent gases originate from the following:

Crankcase: Gases from the combustion chamber leak past the piston rings

Turbocharger vent: The bearing housing of the turbocharger is pressurized to prevent the hot exhaust gases entering the bearing housing. It is pressurized by letting some of the gases from the compressor side of the turbocharger into bearing housing. This process can not be controlled precisely so some of the gases are vented via a pressure regulating value to the atmosphere.

The oil mist eliminator reduces the air emissions from the vents of the engine crankcase chamber and the turbocharger.




4.1.2 HT cooling water service system

030.030.035 MJG31 AP020

3 Cooling-down pump, free-standing

capacity 30 m³/h, with e-motor 2.5 kW

030.030.040 MJG31 AA010

3 HT cooling water temperature regulating valve

with electric actuator, to be fitted in the cooling water pipe to radiator and resistance thermometer Pt 100 to be fitted in HT cooling water pipe downstream the mixing point.

030.030.050 3 Resistance thermometer for HT cooling water, loose supply

030.030.060 MJG31 BB010

3 Cooling water expansion tank

The tank is designed with two separate compartments for HT and LT circuit, capacity 1000/500 l, with mechanical level indicator and minimum alarm contact

4.1.3 Low temperature cooling water system

030.040.050 MJG32 AA025

3 LT cooling water temperature control valve

DN200, with electric actuator and resistance thermometer Pt100 to be installed in LT cooling water pipe downstream the mixing point

030.040.063 MJG32 AA010

6 Charge air temperature control valve (CHATCO)

030.040.066 MJG32 AA015

6 Resistance thermometer for charge air temperature

4.1.4 Two circuit radiator cooling system

030.050.010 -1

MJG31 AC020

3 Two-circuit radiator cooling system

The engines are cooled with outside mounted, horizontal type radiators with electrically driven induced draft fans with space heaters.

Scope of supply:

Radiator cooler with separate cooling circuits for high and low temperature cooling water

Frame material: Hot dipped galvanized steel.

Tube material: copper

Fin material: Aluminum

The radiator coolers are designed for a minimum temperature of 10°C (without glycol) and a maximum ambient temperature of 40 °C.

Supply without steel supporting structure.

Each engine is cooled by separate radiator units.

Noise power level of the radiators for one engine is 107 dB(A).




4.1.5 Fuel oil service system

030.110.140 3 Fuel oil booster module

designed as single-module, acting engine related, consisting of:

Flow rate measuring device, volumetric type

Mixing tank

Booster pump with motor and safety valve

Stand-by booster pump with motor end safety valve

Fuel oil cooler for Diesel fuel oil

Duplex filter approx. 0.034 mm serving as indicator filter, with manual change-over and differential pressure contact indicator

Pressure compensation tank

Control cabinet

The above equipment mounted on a frame, complete with pipes, with leakage oil pan, fittings, valves, insulation and fixing bolts.

4.1.6 Combustion air system

030.120.010 MJQ61 AC020

3 Intake air filter unit

consisting of:

Vertical weather louvre

Pocket filters (dry filters)

Filter house

Difference pressure transmitter

Transition piece with integrated silencer for a noise attenuation of approx. 40 dB(A) and flange(s) to intake air duct

030.120.050 3 Intake air duct upstream of turbocharger

including supports

4.1.7 Engine exhaust gas system

030.130.020 3 Expansion joint for exhaust gas duct

to be installed after adapter, without counter flange

030.130.030 3 Exhaust gas duct inside power house

with bend and supports, without wall sockets, without counterflange

4.1.8 Insulation

030.160.010 3 Insulation material for exhaust gas duct inside powerhouse

for heat insulation of the exhaust gas adapter, compensator and duct inside power house, with jacketing, supplied loose.




4.2 Auxiliary systems, plant related

4.2.1 Lube oil supply system

040.010.020 EGD51 AP040

1 Leakage oil module,

This module collects the fuel oil leakage quantities of the engine and of the fuel oil module.

The leakage oil module is equipped with:

Leakage oil tank, 500 l capacity, with level indicator and level switch

2 Discharge pumps for fuel oil

Terminal box

The above equipment is mounted on a frame completely piped and wired.

040.010.030 MJV23 AA010

1 Lube oil supply pump

capacity 3 m³/h, with e-motor 2 kW. The pump is used to supply lube oil from the storage tank to the service tank.

040.010.040 MJV23 AP060

1 Lube oil transfer pump

capacity 10 m³/h, with motor 4 kW and attached pressure relief valve. The transfer pump is used to refill the foundation frame (lube oil service tank) with the lube oil stored in the maintenance tank.

4.2.2 HT cooling water supply system

040.030.010 -1

MJG31 AC010

1 Preheater set for cooling water

If, after a longer engine shut down, the temperature of the cooling water is below 20°C, preheating is necessary before the start-up of the engine.

A preheater set delivers the necessary energy. A circulating pipe interconnects the preheating set with the engine.

Cooling water preheating module, consisting of:

Continuous flow water heater (steam heated)

Temperature regulator

Terminal box

4.2.3 Main water supply and condensate system

040.040.010 GBK35 BB050

1 Cooling water collecting tank

capacity 10000 l with mechanical level indicating.

040.040.020 GBK35 AP010

1 Cooling water replenishing pump

capacity 3 m³/h, with e-motor 2 kW and expansion pot, capacity 200 l.




4.2.4 Fuel injection nozzle cooling system

040.045.010 MJG32 AP020

3 Nozzle cooling water module

consisting of:

Nozzle cooling water circulation pump with motor

Expansion tank

Heat exchanger (connected to LT circuit)

Temperature regulating valve

Safety valve

The above mentioned eqiupment is mounted on a frame with corresponding fittings, completely piped and wired.

4.2.5 Fuel system, plant related

040.050.070 EGD53 AA010

1 Diesel oil pressure limiting valve

to be mounted in the Diesel oil piping inside engine room.

040.050.080 END55 AA040

1 Heavy fuel oil pressure limiting valve for installation in piping for heavy fuel oil inside the engine room.

4.2.6 Fuel oil treatment and supply unit

040.060.010 EPN54 AC201

1 Heavy fuel oil separator module

consisting of:

Separator (self-cleaning), effective separator capacity min. 13422 l/h, with motor

Switch cubicle complete with control and power part, as well as temperature control and temperature switch

Steam heated fuel oil pre-heater with safety valve and lagging

Sludge collector and sludge pump

Flexible pipe connections

Supply pump, not fitted, with dirt trap.

040.060.015 1 Heavy fuel oil separator module (stand-by)

consisting of:

Separator (self-cleaning), effective separator capacity min. 13422 l/h, with motor

Switch cubicle complete with control and power part, as well as temperature control and temperature switch

Steam heated fuel oil pre-heater with safety valve and lagging- Sludge collector and sludge pump

Flexible pipe connections

Supply pump, not fitted, with dirt trap.




040.060.040 END55 AP030

1 Set of heavy fuel fuel oil supply pumps

(1x for service + 1x as stand by)

capacity approx. 20 m³/h each, with motor 15 kW, with dirt trap and safety valve.

040.060.050 EGD53 AP020

1 Set of Diesel oil supply pumps,

(1 x service + 1 x stand-by), capacity approx. 25 m³/h each, with motor 11 kW, with dirt trap and safety valve.

040.060.060 EGD53 AT050

1 Heavy fuel oil filter module

consisting of:

Automatic backwash filter for fuel oil approx. 0.025 mm, with attached differential pressure contact indicator, steam heated

Flushing tank

The above equipment mounted on a frame, complete with pipes.

040.060.080 1 Diesel oil duplex filter

mesh width 0.025 mm with attached differential pressure contact indicator

4.2.7 Starting air system

040.070.010 SCB71 BB010

2 Starting air receiver

capacity 5000 l, working pressure 30 bar, with valve head, fittings, pressure gauge, supports and retaining bracket. The starting air receivers are connected in parallel, each one can be isolated from the system by shut-off valves.

The capacity of the starting air receivers is designed for 3 starts of one engine without refilling. After a longer standstill of the engine a slow turn manoeuvre is required which needs additional starting air. 1 slow turn manoeuvres are considered in dimensioning of total capacity of the starting air receivers.

040.070.030 SCA71 AT020

2 Automatic draining equipment for starting air receiver

040.070.040 SCA71 AN010

1 Compressor module

consisting of 2 compressors with eletric motor, 30 bar pressure, capacity 172 m³/h each at 20°C and 1013 mbar barometric pressure, with suction filter, air cooled, intermediate and final cooler, oil and water traps, electro-magnetic water drain and switch and control device.

Module complete with three-phase motor 45 kW, flywheel and flexible coupling.

Equipment mounted on a skid for resilient mounting.

040.070.060 QFA71 AA010

2 Pressure reducer for control air

with water trap, dirt trap and safety valve. One in operation plus one in stand-by.

The pressure reducer is installed in the 30 bar air line, the pressure is reduced to 7 bar for providing control air to the engine and accessories.




040.070.070 QFB72 AT020

1 Control air drier

Dehumidification of the control air. Complete system with

thermometer for dew point temperature indication

automatic condensate discharge

040.070.080 QFB72 BB010

1 Control air tank for pump house

content 120 l, vertical tank with safety valve, pressure gauge and shut-off valve.

The control air tank to be installed in the pump house.

040.070.140 -1 3 Start-up air blower

4.3 Exhaust gas system

4.3.1 Exhaust gas silencer

060.005.010 MJR65 BS010

3 Exhaust gas silencer:

Silencer for installation outside of the power house,

Technical features:

Reactive and/or absorptive attenuation principle

Noise attenuation approx. 25 dB(A)

Total pressure loss < 10 mbar

Material of main components S235JR

Absorptive material, if any, within special cushions retained by perforated plates

Scope of supply for silencer including:

Corrosion protection of non-insulated external surfaces

Support brackets and fixing accessories for installation on roof or in steel structure

Delivery loose, without counterflange and insulation material

Insulation works by Third Parties according to engineering specification

4.3.2 Insulation material for exhaust gas duct

060.140.020 3 insulation material for silencer

incl. insulation material and sheathing

Nababganj Power Plant - 55MW Section 5 - Electrical scope


5 Electrical scope


5.1 Control and monitoring system

5.1.1 Genset Interface Panel (GIP)

070.010 -1 3 Genset Interface Panel (GIP)

The genset interface panels are arranged for floor mounting with cable insert from backside into plinth. Design as steel frame construction, totally closed, front door with rubber gasket. The panels are equipped with fans, thermostat, air filters and anti-condensation heating. The panels are with panel light and electrical outlet.

Dimensions of each panel:

Width approx. 800 mm

Height approx. 2,000 mm

Depth approx. 600 mm

Plinth approx. 200 mm

protection class IP 42

structural painted to RAL 7035

plinth painted to RAL 7022

labels: white, with black standard-type letters, design according to DIN EN 60439-1, IEC 60439-1 and ISO 8528, Part 4.

Control equipment:

AC power supply input for panel equipment

AC UPS power supply input for control and generation of DC 24V

1 x AC UPS Voltage / DC 24 V power supply unit for PLC equipment

Emergency stop push button with interlocking relais with positively driven contacts and external reset terminals. Function: engine shut down and engine aux. stop

PLC equipment (Siemens ET200)

1 PROFIBUS connection to Interface Cabinet

1 PROFIBUS connection to EAP (Engine Auxiliary Panel)

1 Interface module to EDS-D system

Integrated devices:

AVR with power factor regulation (item 025.020.050)

1 EDS-D system

5.1.2 Genset control panel (GCP)

070.020 -1 3 Genset control panel (GCP)

arranged for floor mounting, metal enclosed cubicle, steel frame construction, totally closed with ventilation slots, front door with rubber gasket

Dimensions each panel:




Width: approx. 800 mm

Height: approx. 2000 mm

Depth: approx. 600 mm

with panel fan incl. thermostat and filter for each panel

with panel light, incl. electrical outlet

with heating resistance humidity controlled

protective system IP 42


instruments: frame size: 96 x 96 mm, scale 90°, class 1,5

labels: white, with black standard-type letters, design according to DIN EN 60439-1, IEC 60439-1 and ISO 8528, Part 4.

located in control room, cable insert from bottom

MEASURING:

1 Voltmeter

1 Voltmeter selector switch for generator, 3 positions

3 Ammeters

1 Power factor meter 0,5-1-0,5*

1 MW-meter for connecting on transducer*

1 MWh-meter with pulse output*

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

1 Set of test terminals for performance test

1 Set of measuring and control circuit MCBs

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"




1 Mimic diagram equipped with position indicator for generator circuit breaker

1 Mimic diagram equipped with position indicator for alternator earthing CB with push buttons "ON / OFF"

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)

Over-excitation (24) realized in AVR

Loss of excitation (40) realized in AVR as backup

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.




1 PROFIBUS connection to ECP (Engine Control Panel)

1 Siemens Operator Panel

1 MPI connection from CPU to Operator Panel

*Number of boards as required (15 % spare).

Data link to Central Supervisory System / Common Control Panel: Ethernet

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.

5.1.3 Common control panel (CCP)

070.030 -1 1 Common control panel (CCP)

arranged for floor mounting, metal enclosed cubicle, steel frame construction, totally closed with ventilation slots, front door with rubber gasket.

Dimensions:

Width approx. 2000 mm

Height approx. 2000 mm

Depth approx. 600 mm

with panel fan incl. thermostat and filter

with panel light, incl. electrical outlet

with heating resistance thermostat controlled

protective system IP 4x





instruments: frame size: 96 x 96 mm, scale 90°, class 1,5

labels: white, with black standard-type letters,

design according to DIN EN 60439-1, IEC 60439-1 and ISO 8528, Part 4.

Located in control room, cable insert from bottom

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

for 1 MV bus bar:

1 Voltmeter

1 Voltmeter selector switch, 3 positions

1 Measuring transducer for voltage

1 set of test terminals for performance test

1 set of measuring and control circuit MCBs

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




1 multi function protection relay for station transformer, with:

Short-circuit (50)

Overcurrent (51)

Earth fault (50N/51N)

1 multi function protection relay for outgoing feeder to step-up transformer, with:

Short-circuit (50)

Overcurrent (51)

Earth fault (50N/51N)

Over/under voltage (59/27)

Over/under frequency (81)

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.

*Number of boards as required (15 % spare)




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

5.1.4 Operation and monitoring system

070.040 -1 1 CENTRAL SUPERVISORY SYSTEM

Automation control system for supervision and control with 2 Server PCs and 3 Operator Station PCs for supervision:

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




overview of the fuel system

overview of the intake air system

overview of the exhaust gas system

overview of the steam generation system

presentation of these values in monthly bar diagram

presentation of 32 analog values as a line diagram of the last 24 hours (8 values in one diagram simultaneously)

presentation of 32 stored analog values as a line diagram at days before (8 values in one diagram simultaneously)

documentation of fault indications and operation signals as short term / long term history.

5.1.5 Plant sensors for piping

070.060.010 -1 1 Plant sensors for piping

Sensors and instrumentation for visualization of operating conditions transmitted via electrical signals (no local sensors without any wiring)

Scope of supply:

Sensors and instrumentation connected to pipes (connecting pipes between modules) which are not included neither in the scope of the Diesel engine nor in any module or component of the plant.

Nababganj Power Plant - 55MW Section 6 - Miscellaneous


6 Miscellaneous


6.1 Plant service and protection systems

6.2 Documentation

170.010.010 -1 3 Engine, turbocharger and plant documentation

in paper edition, consisting of:

Operating instructions and maintenance schedule for engine and turbo-charger

Working Instructions

Spare parts catalogue

Tools and spare parts list

Workshop test acceptance certificate for engine and turbo-charger

Set of documentation for the plant accessories and

Set of documentation for control and monitoring accessories (after commissioning)

Additionally the above mentioned documents will be handed over in PDF-format on CD or DVD. The documentation will be in English language and in MAN Diesel & Turbo Standard format (duplex printed).

Nababganj Power Plant - 55MW Section 7 - Tools, spare and wear parts


7 Tools, spare and wear parts


7.1 Tools and spares

7.1.1 Engine tools

015.010.010 1 Set of standard and special tools for the engine

required for servicing and inspection of the engine, consisting of:

BASIC TOOLS

Eye bolt, socket wrench insert with adapters, screw driver inserts, torque spanners

HYDRAULIC TOOLS

Pneumatically driven hydraulic high-pressure pump with hyraulic bolt tensioning devices

MEASURING TOOLS

Valve seats in the inlet and exhaust valve seat rings

Elongation of the connecting rod bolts

TOOLS FOR INJECTION

Adjusting device for the fuel injection pumps

Hydro pneumatic injection tester and cleaning tool for the fuel injection valves

TOOLS FOR GOVERNOR

Tools for the speed governor

GENERAL

Piston ring expander

Cleaning device for the injection and starting valve seats in the cylinder heads

DEVICES

Hydraulic lifting and lowering device for the main bearing caps

Supporting device for the running gear

Mounting and removing devices for:

Valves in the cylinder heads

Inlet and exhaust valve springs

Fuel injection pumps and their drive

Springs of the fuel injection pumps

Sealing rings of the fuel injection pump elements

Pistons including insertion bush

Cylinder liners

Fire ring

Connecting rod bearing caps

Crankshaft and connection rod bearing shells

Connecting rods

Suspension devices for:




Rocker arm casing

Cylinder head

Fuel injection pumps

Connection rod shank

MILLING AND GRINDING TOOLS

Milling device for the fuel injection valve seat in the cylinder heads

015.010.020 1 Crank web deflection measuring device

015.010.080 1 Electric valve cone grinder

for the exhaust valves, make HUNGER

015.010.090 1 Electric valve seat grinder

for the inlet and exhaust valve seats (alternating current 230V)

015.010.110 1 Electronic firing pressure gauge 250 E

015.010.182 1 Assembly and reversing device for the cylinder heads

015.010.370 1 Set of tools for turbocharger

including 1 set of blocking / closing device

7.1.2 Engine spare and wear parts

015.020.010 1 Set of spare parts for turbocharger

015.020.020 3 Set of engine standard spare parts

for engine type 18V48/60TS, consisting of:

Piston:

1 Set of compression and oil scraper rings

Cylinder head:

1 Valve seat insert for inlet valve with round seal ring

1 Valve seat insert for exhaust valve with round seal ring

1 Valve guide with round seal ring

Inlet valve:

1 Inlet valve, complete

Exhaust valve:

1 Exhaust valve, complete

Operation/Monitoring:

1 Three-way solenoid valve

1 Pressure reduction valve

Fuel injection pump with drive:

1 Pump plunger with barrel (pump element)

1 Set of seal rings for fuel injection pump

Fuel injection valve:

1 Fuel injection valve, complete




3 Fuel injection nozzles with needle and guide

3 Sets of round seal rings for injection valve

Fuel injection pipe:

1 Fuel injection pipe with connection parts (without threaded piece)

Seals and round seal rings:

1 Set of seals and seal rings for 1 cylinder

Sealing material:

1 Set of sealing material.

015.020.070 1 Spare parts for operating and monitoring the engine

015.020.140 1 Set of spare parts for SACOS

015.020.170 1 Spares for oil mist detector

7.1.3 Plant tools

015.030.025 1 Tools for nozzle cooling water unit

015.030.090 1 Mobile strainer cleaning unit

for lube oil and heavy fuel oil automatic filter, consisting of:

Tank

High-pressure pump

Pump protecting filter

Microfilter

Cleaning gun with high-pressure hose

Cleaning liquid

7.1.4 Plant spares

015.040.020 -1 1 Set of spare parts for alternator

consiting of:

1 Set of diodes; varistor (for one generator)

1 PC PT100 for bearing

Nababganj Power Plant - 55MW Section 8 - Services


8 Services


8.1 Quality Management, Quality Assurance

8.1.1 man hours Quality Planning

205.010 -1 1 Establishing of a Quality Plan

MAN Diesel & Turbo has implemented a Quality Management System that conforms to ISO 9001 and ISO 14001 environmental standards. The integrated quality and environmental management manual is applied to all internal process steps to assure MAN Diesel & Turbo's grade of quality for our engines as well as for equipment delivered by subsuppliers.

An individual quality plan will be issued, containing order-specific outlines of the quality standard related to quality assurance and quality documentation. In addition, individual processes are scheduled, deliveries are defined and test plans are assigned to the components to be suppiled. Factory/Site Acceptance Tests follow the individual items of this plan.

The electronic version of the documentation shall consist of:

Project specific Quality Plan

Inspection and Test Plans

Inspection and Test Records

The above mentioned documents will be handed over in PDF format on CD/DVD. The documents will be in English language and in MAN Diesel & Turbo standard format.




8.2 Project engineering

8.2.1 System engineering

210.015.010 -1 1 System engineering

MAN will engineer the standard systems of the power plant and supply the design data required for specification of the concerned equipment

Design of the lube oil, cooling water, fuel, intake air and exhaust gas systems

Heat recovery system for auxiliary consumption

Adaption of the engine configuration to site conditions

The results of the system engineering are dimensioning data such as consumption, pressures, flow rates, temperatures, etc. and technical requirements at interfaces which will be used for ordering of the equipment.

MAN will execute P&I Diagrams of all mediums required for the operation of the electrical power generating equipment (i.e. lube oil, cooling water, fuel) including all relevant pipe sizes.

210.015.020 -2 1 Basic Design criteria - Engineering Tankfarm

Basic dimensioning of tanks

Definition of heating requirements

Recommendation for tanks incl. generic standard drawings for tanks and heating device

Recommendation for instrumentation of tanks

8.2.2 Mechanical project engineering

210.020 -1 1 Mechanical project engineering

MAN will execute following order drawings:

Power house layout drawing




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

8.2.4 Calculation of genset foundation

210.033.010 1 Design of the genset foundation base

Based on the genset foundation drawing mentioned above, MAN will execute civil design works for the genset foundation.

As an outcome of the civil design works MAN will prepare following documentation:

General arrangement drawing

Reinforcement drawing

Steel bending and quantity list

Foundation calculation

Short construction manual.

Calculation of the foundation is based on the soil bearing capacity as per section 1 and does not consider engineering or design for piling.

8.2.5 Engineering of auxiliaries

210.040 -1 1 Engineering of auxiliaries

Based on the standard system engineering mentioned above, MAN will define and engineer all offered equipment.




8.2.6 Electrical engineering

210.060 -1 1 Electrical engineering

establishing of the electrical documentation of the plant, consisting of:

Technical specification of electrical equipment

Electrical cabinet drawings

PLC architecture / schematic diagrams

Single-line diagrams for MV and LV system

List of measuring and control devices (plant)

List of Electrical Consumers

8.3 Logistics

8.3.1 Transportation of equipment

220.020.050 -1 1 Sea transport to CIF Mongla, not unloaded

220.020.090 -1 3 Engine lifting device (on loan basis)

MAN Diesel & Turbo will deliver the engine together with an engine lifting device. This equipment is required for transport and installation purpose only and shall be returned to MAN Diesel & Turbo once installation of the engines / generating sets is over.

The customer shall cover the cost for return transport to MAN Diesel & Turbo's workshop in Augsburg and shall also arrange for temporary import permission of the device (if necessary).

8.4 Site activities

8.4.1 Supervision of installation

230.030.040 -1 34 man days monitoring of mechanical installation

The MAN Advisor joins the placing of the gensets on the foundation, alignment as well as installation of the offered auxiliary equipment to implement the MAN Diesel & Turbo quality standard. After completion, a final check of all systems will be done.

230.030.060 -1 13 man days of electrical equipment erection




8.4.2 Commissioning

230.110.010 -1 75 man days commissioning of engine by technician

The technician will assist the commissioning engineer in performing all mechanical pre-tests, signal testing, starting up the genset, collecting of operational data and adjusting of engine parameters.

230.110.020 -1 75 man days commissioning of engine by engineer

The commissioning engineer will perform all mechanical and electrical pre-tests and starting up of the individual auxiliary systems. The commissioning engineer is responsible for running-in the engine according to manufacturers instructions. He verifies functional tests of the engine and plant control and safety system. Additionally he will assist the measurement team during the execution of performance tests.

230.110.040 -1 75 man days commissioning LV/Control (SaCoS)

230.110.200 -1 15 man days commissioning alternator

One commissioning engineer from the manufacturer will commission the alternator according to the manufacturers instruction. He will check the correct installation as well as the function of the alternator protection and control system.

230.110.210 -1 9 man days commissioning lube oil seperators

230.110.210 -2 6 man days commissioning separators

One commissioning engineer will verify the correct installation and set the separator into operation according to manufacturers instruction.




8.4.3 Site Acceptance Test (SAT)

230.120.010 -1 3 Performance test

Specialists from MAN Diesel & Turbo will perform measurements to demonstrate the guaranteed values according to MAN Diesel & Turbo test procedures. The measurements will be done by our engineers in cooperation with the customers operating personnel.

Output at site: Measurements are taken at by using an external high precision power meter Type Zimmer LMG 450.

Fuel oil consumption: Measurements and calculations of the fuel oil consumption will be carried out in line with ISO 3046, ISO 15550 and MAN standard procedures. Measuring equipment is an external high-precision mass flow meter type Endress+Hauser Promass 83, which is temporarily installed on the fuel oil booster module. The duration of the test has to be adapted to the local availability of constant load. As a guideline, 3 tests of 2 hours each could be performed. The determination of the lower calorific heat value of the fuel oil used will be carried out at the MAN laboratory in Augsburg.

Lube oil consumption: The measurements and calculations of the lube oil consumption will be carried out in line with ISO 3046, ISO 15550 and MAN standard procedures (engine running in). Due to the required measuring time being minimum 24 hours, lube oil consumption measurement will continue after the fuel consumption test.

230.120.040 -1 9 man days exhaust gas emission test

MAN Diesel & Turbo will carry out tests and measurements to verify compliance of the engine emissions with the contractually specified criteria. This is done by MDT own staff.




8.5 Project services

8.5.1 Factory training (mechanical)

240.010 -1

1

Optional service

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.




8.5.2 Factory training (electrical)

240.015 -1

1

Optional service

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.




Additional site activities

The above mentioned site services are based on our experience and cover the normal supervision duration of a standard power plant. In case this project requires additional supervision or commissioning services, we are able to offer further supervision services based on the following conditions.

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.

Nababganj Power Plant - 55MW Section 9 - Requirements and limitations


9 Requirements and limitations

9.1 Quality requirements for operating media

MAN Diesel engines are designed for continuous operation on the operation media as listed below. Project specific system layout for the respective operating media are mentioned in the respective chapters of our offer.

Compliance with environmental regulations (e.g. World-Bank Guidelines for stack emissions) cannot be stipulated and has to be checked for the operating media that will be used for the project.

9.1.1 Lube oil

Use of engine lube oils according to the approval list of MAN Diesel & Turbo. More detailed information on the lube oils approved by MAN Diesel & Turbo is available in the engine manuals.

Requirements for viscosity:

Viscosity-class (40°) SAE40

Requirements for Base Number (BN):

TBN (Total Base Number),

if sulphur concentration < 1.5% wt. 30 mg KOH/g oil

if Sulphur concentration > 1.5% wt. 40 mg KOH/g oil

Please note that our cooling systems are designed to operate with the above mentioned lube oil class SAE40 only. Operation of the plant with other lube oils requires a detailed modification in the cooling systems and additional equipment cost.

9.1.2 Cooling water

The engine and radiator cooling water must be carefully selected, treated and controlled. The treatment with an anti-corrosion agent has to be effected before the first commissioning of the plant. During subsequent operations the concentration specified by the engine manufacturer must always be ensured. The MAN operating instructions contain the additive brands that are approved by the manufacturer.

The characteristics of the water used for engine cooling must be within the following limits:

Type of water preferably distilled water or freshwater, free from foreign matter

Total hardness4 < 10°dH

pH-value 6.5 - 8

Chloride ion content max. 50 mg/l

Silicid acid max. 50 mg/l

Not to be used: Sea water, brackish water, brines industrial waste water and rain water

4 1 °dH (German hardness) = 10 mg CaO in 1litre water

= 17.9 mg CaCO3/litre = 0.357 mval/litre = 0.179 mmol/litre



9.1.3 Water for separators

The water for separator operation must be carefully selected, treated and controlled. The characteristics of the water used must be within the following limits:

Type of water preferably distilled water or freshwater, free from foreign matter

Total hardness5 < 6°dH

pH-value > 6.5

Chloride ion content < 50 mg/l

TSS < 10 mg/l

Not to be used: Sea water, brackish water, brines industrial waste water and rain water

9.1.4 Diesel fuel oil

9.1.4.1 Fuel system related characteristic values

Diesel fuel oil (DFO) – based on ISO F- DMB. (ISO 8217-2010)

The usability of the DFO depends on its conformity with the key properties listed below:

Lower calorific value (LCV)

Density at 15° C

Kinematic viscosity at 40°C

Pour Point, winter quality

Pour Point, summer quality

Flash point (Pensky Martens)

Total sediment fraction

Water content

Sulphur content

Ash content

Coke residue (MCR)

Cetane number or cetane index

Hydrogen sulphide

Total acid number

Oxidation stability

Lubricity (wear scar diameter)

Copper-strip test

42,250 kJ/kg

900 kg/m3

2.0 … 11 mm2/s

< 0 °C

< 6 °C

> 60 °C

0.10 % wt.

< 0.3 % vol.

< 2.0 % wt.

< 0.01 % wt.

< 0,3 % wt.

> 35

< 2 mg/kg

< 0.5 mg KOH/g

< 25 g/m3

< 520 µm

< 1

If the above mentioned fuel oil specification is not met, it can only be used in case of fuel treatment.

9.1.4.2 Diesel fuel oil properties related to site conditions

Required kinematic viscosity at engine inlet: 2,5 … 14 mm2/s

To meet the Diesel oil requirements at engine inlet the Diesel oil provided must be in a range between minimum viscosity and maximum viscosity as specified

5 1 °dH (German hardness) = 10 mg CaO in 1litre water

= 17.9 mg CaCO3/litre = 0.357 mval/litre = 0.179 mmol/litre



bellow, considering project-specific ambient conditions (minimum air temperature Tamb min. / maximum air temperature Tamb max. plus ΔT = 10 K):

Min. kinematic viscosity: 2.5 mm2/s at 50 °C

Max. kinematic viscosity: 14 mm2/s at 10 °C

MDT is recommending a fuel management suitable for seasonally occurring temperatures, i.e. subsequently to the requirements above it might be necessary to provide two different Diesel oil qualities for summer season and winter season.

In case the viscosity limits as stated above cannot be met, a special Diesel oil cooling system respectively a Diesel oil heating system is required and can be offered upon request.

9.1.5 Heavy fuel oil

The HFO specified in the following chapters is the worst-case fuel that Diesel engines can operate satisfactorily.

9.1.5.1 Fuel system related characteristic values

The fuel system is designed to operate based on the following fuel oil specification based on ISO 8217-2010:

Lower calorific value (LCV) 40230 kJ/kg

Viscosity (at 50°C) up to 180 mm2/s

Density (at 15°C) max. 1010 kg/m3

Sulphur content up to 3.4%-wt.

Ash content up to 0.15%-wt.

Flash point min. 60 °C

Pour point max. 30 °C

Coke residue (Conradson) max. 20 % wt.

Vanadium max. 450 mg/kg

Water max. 0.5 % vol.

Sediment (potential) max. 0.1 % wt.

Aluminium and silicon (total) max. 60 mg/kg

Total acid number max. 2.5 mg KOH/g

Hydrogen sulphide max. 2 mg/kg

Asphaltene content max. 2/3 of coke residue % wt (Conradson)

Sodium Sodium < 1/3 vanadium, Sodium < 100 mg/kg

CCAI number max. 870

Current fuel oil characteristics is 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.



9.1.5.2 Treated heavy fuel oil at engine inlet

Inorganic foreign particles <20 mg/kg (incl. catalyst residues) (aluminium + silicon content < 15 mg/kg)

particle size: < 5 m

Water < 0.2% vol.

9.1.6 Intake air

The quality and the condition of the intake air (combustion air) exert great influence on the engine output as well as on the engine's lifetime.

For this reason, effective cleaning of the intake air and regular maintenance/cleaning of the air filter are required.

The concentrations before the turbocharger inlet must not exceed the following limiting values:

Dust (sand, cement, CaO, Al2O3 etc.) max. 5 mg/Nm³

Chlorine max.1.5 mg/Nm³

Sulfur dioxide (SO2) max.1.25mg/Nm³

Hydrogen sulphide (H2S) max.15 mg/Nm³

9.2 Limits of supply

9.2.1 General remark

The “Limits of Supply” are to be read in connection with the offered scope of supply as per the technical specification.

All equipment comes with steel frames or mounting plates and with bolts, studs and screws to install the equipment on the foundations or elevated platforms / walkways.

Any steel supporting structures, steel mounting elements, etc. necessary to install the equipment / modules / auxiliaries are not included in the scope of supply of MAN Diesel & Turbo.

9.2.2 Generating sets

Mechanical:

Pipe connection terminal on the engine to connect the engine to various pipes

Electrical:

Terminal box of the alternator

Civil:

Steel foundation frame with frame stoppers and leveling screws; grouting material (pagel)



9.2.3 Engine and plant related auxiliaries, modules, equipment and tanks

Mechanical:

Flanges and counter flanges on the modules / auxiliaries / equipment for connection to the various system pipes (e.g. fuel, lube oil, water, sludge, steam, condensate, pressurized air)

Electrical:

Terminal boxes on the modules / auxiliaries / sensors for connection to the power and control cables

9.2.4 Electrical equipment / Engine and plant control system

Connectors on Genset Interface Panel (GIP) and Genset Control Panel (GCP) for bus cables (Profibus)

Connectors for power supply on GIP and GCP

9.2.5 Engineering

Civil: n/a

E&M: Inside power house

PIDs: For fuel, intake air, exhaust gas, cooling water, lube oil.

Nababganj Power Plant - 55MW Section 10 - Operation and maintenance


10 Operation and maintenance

10.1 MAN Diesel & Turbo Service Worldwide

For all engines delivered by us or built according to our design, MAN Diesel & Turbo offers high-quality service 24 hours a day and around the world. Therefore, our customers may rely on assistance through our service team during the entire life-time of their engine plant.

The scope of services and products covered by the MAN Diesel & Turbo Service network comprises the following essential features:

All over the globe, along the major shipping routes as well as in the most thriving economies, the MAN Diesel & Turbo Service team is near you! This ensure 32 service centres, 49 authorised workshops, 24 spare parts stocks and 70 agencies, which provide the best possible care for your plant.

If necessary, a swift, around-the-clock spare parts supply permits delivery of parts, usually within one day from the receipt of your order.

Our specialists, located both at our global service bases and in our Augsburg headquarters, offer free-off-charge counselling by phone. From among them, a stand-by team of particularly experienced service personnel will render competent assistance; 24 hours a day and 365 days a year!

Original, high-quality spare and wear parts ensure the safe, reliable and economic operation of your engine plant; at a reasonable price! This also applies to our inexpensive reconditioning service.

If you wish to combine utmost operational reliability with certainty regarding the future working expenses of your plant, you may take advantage of our maintenance and operation contracts. We provide the required exchange parts as well as the connected services over the requested contract period at exactly calculated costs.

Even the best state-of-the-art engines require a qualified service, which we have been offering for over a century, now.

Make use of our experience!

Nababganj Power Plant - 55MW Section 11 - Standards, Guidelines and Drawings


11 Standards, Guidelines and Drawings

11.1 Applicable standards

All materials, equipment and services mentioned in this quotation comply with the respective standards and codes of the country of manufacture.

In particular, equipment supplied from EU countries complies, as far as applicable, with the following standards and codes:

ISO International Standards Organisation

IEC International Electro technical Commission

EN standard - European Institute for Standardisation

Manufacturer’s QA/QC System

Manufacturer's standards

11.2 General guidelines

11.2.1 Heat exchangers for engine cooling

The heat exchangers offered are suitable for non-aggressive raw water (fresh water). If aggressive raw water is used (e.g. brackish water, industrial waste water) we are unable to accept any warranty for the heat exchangers, pumps, pipes and other units in contact with such water.

Water treatment, mains water supply

For the first filling of the system, water used in the cooling system has to meet the requirements listed in chapter 9. The treatment, kind and amount of added chemicals are related to the water quality available at site.

The water shall be available at the plant premises with a pressure of 4-6 bar.

11.2.2 Painting of the supplied equipment

Auxiliary equipment is delivered in the original colour as supplied by the sub supplier, if not specified in this document otherwise.

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.

11.2.4 Required information from the customer

In case of order the customer shall supply to MAN Diesel & Turbo the following documents and information in due time:

Actual site plan and arrangement drawing showing the exact location and dimension of the area of the power plant and the neighbouring installations

Main wind directions and seismic activities to be considered

Minimum load bearing capacity of power plant subsoil or soil investigation report

List of electrical consumers to be provided locally by customer

Sample of heavy fuel oil, raw water

Nababganj Power Plant - 55MW Section 11 - Standards, Guidelines and Drawings


11.3 Drawings

11.3.1 Drawing of generating set Drawing: 11745001770_01_A_Genset Drawing 18V4860TS (Rev. A, Dtd. 06.06.11)

11.4 Division of Works 5301959-01-B001 DOW Rev000

Nababganj Power Plant - 55MW Section 12 - General information


12 General information

12.1 List of sub suppliers

This list includes a selection of the major equipment components and the respective sub-suppliers selected and approved by MAN Diesel & Turbo. Further sub-suppliers may be considered after MAN Diesel & Turbo quality auditing. In any case MAN Diesel & Turbo reserves the right to select the sub-supplier at its discretion.

12.1.1 Generating set

Alternator ABB, Hyundai, Indar, WEG GermanyCummins, Jeumont

Flexible coupling VULKAN, Centa

Anti vibration mountings GERB

12.1.2 Lube oil system

Lube oil module Auramarine, MAS, Alfa Laval, GEA Westfalia Separator

Lube oil flow rate measuring device Endress & Hauser, Bopp & Reuther

Lube oil separator module GEA Westfalia Separator, Alfa Laval

Lube oil transfer pump Kracht, Rickmeier

12.1.3 Cooling water system

Cooling water pre-heater set ELWA, Midland Combustion

Nozzle cooling water module ELWA

Radiator cooling system Ecodyne, Alfa Laval Vantaa, Thremofin, Friterm, GEA Ergé-Spirale

12.1.4 Fuel oil system

Diesel fuel oil supply pumps KRAL, Imo Pump, LEISTRITZ

Heavy fuel oil supply pumps KRAL, Imo Pump, LEISTRITZ

Heavy fuel oil filter module Alfa Laval Moatti, BOLL & KIRCH, Filtrex

Diesel oil filter module Alfa Laval Moatti, BOLL & KIRCH, Filtrex

Fuel oil separator module Alfa Laval, GEA Westfalia Separator

Leakage oil module Hydac, MAS

12.1.5 Intake air system

Intake air filter unit AAF International, GEA Delbag, ALS

http://www.vulkan24.com/

http://www.gerb.com/

http://www.boppureuther.com/

http://www.boppureuther.com/

http://www.westfalia-separator.com/

http://www.alfalaval.com/ecoreJava/WebObjects/ecoreJava.woa/wa/showNode?siteNodeID=3248&contentID=32414&languageID=45

http://www.rickmeier.com/

http://www.elwa.com/

http://www.elwa.com/

http://www.kral.at/

http://www.kral.at/

http://www.bollfilter.de/

http://www.bollfilter.de/

http://www.aafintl.com/



12.1.6 Compressed air system

Starting air compressor Sauer & Sohn, Neuenheuser, Kaeser

Starting air receiver Römer

Compressor unit for working air Sauer & Sohn, Neuenheuser, Kaeser

12.1.7 Exhaust gas system Expansion joint for exhaust gas KE-Burgmann, Stenflex, Witzenmann

12.1.8 Electrical equipment

Engine and alternator control system Kuhse, Woodward, Siemens Pakistan, Natus

12.2 References

MAN Diesel & Turbo can look back on nearly 120 years of experience in the manufacture and operation of Diesel engines. It was at MAN in Augsburg that, between 1893 and 1897, Rudolf Diesel's groundbreaking idea, the Diesel engine, was developed to the point where it was ready to go into service.

MAN Diesel built the world’s first large scale Diesel power station in Kiev in 1904 and supplied engines for the first ocean-going Diesel engine-powered vessel in 1912.

To date MAN Diesel &Turbo SE has installed approx. 26,900 medium speed engines with an output of approx. 56,000 MW all over the world.

References of engines from the current programme:

Engine type No. of engines Total Power

16/24 2,525 1,486 MW

21/31 1,454 2,074 MW

27/38 2,176 5,144 MW

28/32 5,106 8,201 MW

28/33 52 400 MW

32/40 3,006 13,572 MW

32/44CR 44 260 MW

48/60 784 9,411 MW

51/60DF / 51/60G 19 254 MW

http://www.kuhse.de/



58/64 462 4,903 MW

Others 11,231 10,283 MW

Please find below a reference list of selected power plant installations.

Customer Country No. x Engine Total

Power

VINLEC Extension St. Vincent 2 x 9L32/40 9.0 MW

Guadeloupe France 9 x 18V48/60 170.1 MW

Breitener Gas Conversion Brazil 1 x 18V51/60DF 17.5 MW

Stelco IV Maldives 2 x 18V32/40 18.0 MW

Yanbu Cement Extension Saudi Arabia 6 x 12V48/60 75.6 MW

Komsilga Burkina-Faso 1 x 18V48/60 18.9 MW

Extension Owen Springs Australia 1 x 12V51/60DF 11.7 MW

Karadeniz Power Ship #1 Turkey 6 x 18V51/60DF 3 x 14V48/60

149.4 MW

EDF Extension Martinique 6 x 18V48/60 113.4 MW

AL TAKAMOL Egypt 5 x 18V32/40CD 45.0 MW

PLC MEZHREGIONENERGO Russia 1x 18V32/40PGI 8.1 MW

ENDESA GENERACION Spain 1 x 12V48/60 12.6 MW

HUB POWER Pakistan 11 x 18V48/60 207.9 MW

ELECTRAWINDS Belgium 2 x 18V32/40 18.0 MW

Endesa Spain 1 x 9L21/31 1.9 MW

CENTRAIS ELETRICAS Brazil 2 x 9L32/40 9.0 MW

CENTRAIS ELETRICAS Brazil 38x 18V32/40 342.0 MW

OKINAWA Electric Japan 1 x 18V48/60 18.9 MW

Asian Colour Coated Ispat Ltd. India 2 x 16V28/32S 7.5 MW

Honda Siel Cars India 1 x 8L27/38 2.6 MW

Asian Colour Coated Ispat Ltd. India 1 x 18V28/32S 4.2 MW

Grasim Industries India 1 x 8L27/38 2.6 MW

POWER AND WATER Australia 2 x 12V51/60DF 24.0 MW

Ambatovy Madagascar 3 x 7L27/38 6.7 MW

STX Dalian South Korea 2 x 6L27/38 4.0 MW

STX Dalian South Korea 2 x 8L27/38 5.3 MW

Electric Power Develop. Co Ltd Japan 3 x 18PA 6 15.9 MW

VOESTALPINE Stahl Austria 2 x 12V32/40DF 9.6 MW

National Electricty Corporation Sudan 2 x 18V28/32S 8.5 MW

EDA, Electricidade dos Acores Portugal 1 x 7L32/40 3.5 MW

CARIBBEAN UTILITIES Cayman Is. 1 x 14V48/60 14.7 MW

UNE Cuba Energoimport Cuba 11 x 9L28/32H 20.8 MW




Power

UNE Cuba Energoimport Cuba 1 x 18V28/32S 4.1 MW




BEC Cat Island Bahamas 2 x 9L28/32H 3.8 MW

BEC Hatchet Bay Bahamas 4 x 18V28/32S 16.2 MW

PPC - Grecce Islands Greece 1 x 12V32/40 6.0 MW

Grønlands Energiforsyning Greenland 1 x 18V28/32S 4.2 MW

Grand Bahama Power Bahamas 1 x 18V48/60 18.9 MW

EDF – Port Est, La Reunion France 9x18V48/60 170.1 MW

EDA, Electricidade dos Acores Portugal 2x5L21/31 2.0 MW

EDF – Bellefontaine, Martinique France 6x18V48/60 113.4 MW

Grønlands Energiforsyning Greenland 1x18V28/32S 4.2 MW

Geoterm El Salvador 4 x 18V48/60 75.6 MW

Electrawinds, Brugge Belgium 2 x 18V48/60 37.8 MW

Belco Bahamas 4 x 12V48/60 50.4 MW

Energetica Camacari Muricy Brazil 8 x 18V48/60 151.2 MW

Atlas Power Pakistan 11 x 18V48/60 213.6 MW

BEC Bimini Bahamas 2 x 9L32/40 9.0 MW

BEC Cat Island Bahamas 2 x 9L32/40 9.0 MW

Tortola Brit. Virgin Island

4 x 18V32/40 36.0 MW

BLM-Suez Panama 10 x 18V32/40 90.0 MW

Barcelona Airport Spain 5 x 18V32/40DF 36.0 MW

IGI Termoindustriale Italy 1 x 18V32/40 9.0 MW

OXON Termoindustriale Italy 1 x 18V32/40 9.0 MW

Isolux Ecuador 2 x 12V32/40 12.0 MW

Milos Greece 2 x 12V32/40 12.0 MW

PAMPA Energia S.A. Argentina 2 x 18V32/40 16.2 MW

ADANAC Ruby Creek USA 4 x 18V32/40 36.0 MW

Ingemas Senegal 4 x 18V32/40 36.0 MW

Surimane Phase 3 N.V.Energiebedrijven Suriname

Suriname 1 x 18V32/40 9.0 MW

Ceuta ENDESA

Spain 3 x 12V48/60 37.8 MW

Mosoblenergogas Russian Federation

2 x 18V32/40PGI

16.0 MW

Melilla ENDESA

Spain 3 x 12V48/60 37.8 MW




Power

Arabian Cement Co. Ltd. Saudi Arabia

3 x 18V48/60 56.7 MW

INCA Santo Domingo

Dominican Republic

2 x 9L32/40 9.0 MW

UNE 2 Energoimport de la Habanna

Cuba 7 x 18V48/60 132.2 MW

UNE 3 Energoimport de la Habanna

Cuba 1 x 18V32/40DF 6.9 MW

SONABEL La Soc. Nat. d’Electricité

Burkina Faso

1 x 18V48/60 18.9 MW

Chekka Holcim Leban S.A.L.

Lebanon 1 x 18V48/60 18.9 MW

Sepcol Southern Electric Power Co.Ltd.

Pakistan 1 x 18V48/60 5 x 18PC4.2

128 MW

Ibiza ENDESA for Gas y Electricidad S.A.

Spain 4 x 18V48/60 75.6 MW

Sharourah Al-Saleem / Saudi Electric Comp.

Saudi Arabia

3 x 12V48/60 2 x 12V48/60

63.0 MW

Fortune Electric, Taipei Taiwan Power Co.

Taiwan 4 x 9L32/40 18.0 MW

NATCO Public Electric Comp.

Yemen 1 x 16V32/40 1 x 12V32/40

20.0 MW

Surimane N.V.Energiebedrijven Suriname

Suriname 2 x 18V32/40 17.2 MW

Shuaiba ABB / Public Authority for Industry

Kuwait 1 x 9L48/60 9.4 MW

GECSA Genedora Electrica S.A.

Guatemala 2 x 18V32/40 19.0 MW

White Nil Petroleum Operating Company

Sudan 5 x 18V32/40 54.0 MW

Choloma I–III Energia Renovables S.A.

Honduras 14 x 18V48/60 265 MW

Los Guinchos, Las Palmas ENDESA for UNELCO

Spain 4 x 12V48/60 50.4 MW

Las Salinas, Fuerteventura ENDESA for UNELCO

Spain 3 x 18V48/60 56.7 MW

Punta Grande, Lanzarote ENDESA for UNELCO

Spain 5 x 18V48/60 94.5 MW

Weipa Comalco Aluminium Ltd.

Australia 6 x 9L32/40 27.0 MW

Pico / Belo Jardim Electricidade dos Acores

Portugal 1 x 7L32/40 2 x 12V48/60

4 x 9L40/54

58.5 MW




Power

Grand Bahama Grand Bahama Power Comp.

Grand Bahama

1 x 18V48/60 18.9 MW

Caracol Knits Ingemas, Gijon

Honduras 1 x 12V48/60 12.6 MW

St. Vincent Vinlec

St. Vincent 2 x 9L32/40 9.0 MW

Pembroke / Bermunda Bermuda Electric Light Comp. Ltd.

Bermuda 2 x 14V48/60 29.4 MW

Benue Cement Company (BCC) Nigeria 5 x 18V32/40 45.0 MW

Comp. des Pétroles Libya 2 x 18V32/40 17.0 MW

Pedregal Power Company Panama 3 x 18V48/60 56.7 MW

Caribbean Utilities Comp. Ltd. Grand Cayman

Cayman Islands

2 x 14V48/60 1 x 12V48/60

38.0 MW

Aqualectra, Curacao Netherlands Antilles

4 x 18V32/40 34.5 MW

China National Offshore Oil Corp. (CNOOC)

China PR 5 x 16V32/40 5 x 16V32/40

76.8 MW

Poplar Bluff / Mississippi USA 3 x 18V32/40DF 21.0 MW

Consorcio Breitener for Forteleza Power Station

Brasil 8 x 18V48/60 2 x 16V32/40

167 MW

Peng Hu TATUNG Co.

Taiwan 8 x 9L58/64 4 x 12RK270

125 MW

Habas Kasimpasa Turkey 3 x 18V48/60 57.0 MW

Esemboga Ankara Enerji Uretim A.S.

Turkey 7 x 16V32/40 53.8 MW

Mineracao Rio Do Norte S.A. Brasil 5 x 9L48/60 47.0 MW

Dohuk, Erbil, Sulaimaniyah UNDP for Local Electricity Authority,

Iraq 3 plants with 4 x 16V32/40

92.0 MW

Union Fenosa S.A. Dominican Republic

5 x 18V48/60 94.5 MW

Power Barge Esperanza Puerto Quetzal Power Ltd.

Guatemala 7 x 18V48/60 132 MW

Nouakchott SONELEC

Mauretania 2 x 9L48/60 4 x 52/55B

54.0 MW



12.3 Leaflets and brochures

Following brochures are available on our homepage in electronic format or can be handed out as hardcopy upon your request.

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.

Powering the World

Brochure with general information about the MAN AG Group of companies and specially MAN Diesel SE, its history, product portfolio and worldwide services.

MAN Diesel, the "birthplace of the Diesel engine", is one of the world's leading suppliers of large-bore Diesel engines for marine application, energy production, railways and heavy duty vehicles. In addition, MAN Diesel & Turbo also build turnkey power stations and complete propulsion systems for ships.

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.

http://viewer.zmags.com/publication/f81592fd

http://man.cwshops.com/shop/images/artikel/pdf1/34210001.pdf

http://compass1.md-man.biz/businessunit/PowerPlants/PS Sales/PST-Tendering/MAN Diesel Brochures/Power Plants - Energy wherever you need it.pdf



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.

http://man.cwshops.com/shop/images/artikel/pdf1/34210011.pdf

http://compass.md-man.biz/businessunit/PrimeServ/AQ/Documents/MDT_Courses2011.pdf

Annexure – 2(b)

Co-generation Engine Specification

MAGNUS POWER PRIVATE LIMITED BANGALORE – INDIA

RUPALI ENGINEERING & TRADERS

LIMITED

TECHNO-COMMERCIAL OFFER

COGENERATION – 2.35MW

28.05.2013

(3X18V48/60TS MAN POWER PLANT)

TABLE OF CONTENTS

COGENERATION POWER PLANT 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

The Cogeneration Power Plant includes a well designed:

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.

Sl No. Description Parameters

1 Plant Location Bangladesh

2 Details of each engine

a Engine Capacity (MWm) MAN-18V48/60 TS 18.9

b Fuel HFO

c Exhaust Gas Flow (Kg/hr) 122000

d Exhaust Gas Temperature (Deg C) 300

e Exhaust Gas Composition (V/V%)

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

Sl No. Description Unit Qty

1 Exhaust gas flow in HRU (for one engine) Kg/hr 122000

2 Exhaust gas temperature HRU (for one engine) Deg.C 300

3 GENERAL INPUT DATA

A Number of boilers 3

Forced cir. LP evaporator with cir. pumps, 2 pcs

B HP-evaporator Natural circ

C Number of steam drums 3

D Superheater YES

E HP economizer YES

F LP evaporator/preheater YES

G Hot water section NO

H By pass Modulating

I Automatic rake soot blowers 9 PCS

J Exhaust gas pipe diameter DN 1600

4 THERMAL INPUT DATA

A Exhaust gas flow/engine 33.9 kg/s 122 000 kg/h

B Exhaust gas temperature IN 300.0 0C

C Exhaust gas temperature OUT, ECO 204.6 0C

D Exhaust gas temperature OUT, LP 194.9 0C

E Temperature in feed water tank 135 0C NOTE:

F Condensate temperature 80.0 0C F. W. Tank heating included Boiler steam flow data is Stated after deduction of Heating steam

G Condensate return % 97.0 %

H Make-up water temperature 30

I HP evaporating pressure 16.1 bar(a)

J Steam pressure after superheater 16.0 bar (a)

5 OUTPUT DATA (With clean heating surface) per boiler

A Capacity HP 4048 Kw

B Steam flow per boiler HP 6071 kg/h

C Steam Temperature HP 2800C

D Exhaust gas pressure drop (clean) 1130 Pa

6 PRELIMINARY DIMENSIONS( BOILER)

A Length 5460 mm

B Width 2690 mm

C Total height (incl. drum) 11410 mm

D Total water volume (boiler/drum/pipes) 4.1/3.8/1.m3

E Max weight (full of water) 69299 kg

7 Power Generation Equipment

Turbine –steam turbine- multistage –condensing

A Gross Electric Power Generation kWe 2350

B Power generation Voltage/Frequency kV/Hz 11/50

2 – SCOPEOF SUPPLY

√-IncludedinMPPLScope X-ExcludedfromMPPLScope

Sl.No. ItemDescription Basic

Engineering Detailed

Engineering Supply

Fabrication Site &

Erection

Supervisionof Commissioning

A CIVILWORKANDRELATEDACTIVITIES

1 WasteHeatRecoveryBoilers √ √ X X X

2 BoilerfeedwaterPumps √ √ X X X

3 Accessories&AuxiliariesPackageforWasteHeatRecoveryBoiler √ √ X X X

4 SteamTurbinePackage √ √ X X X

5 WaterCooledCondenserPackage √ √ X X X

6 Landscaping,Roadandrelatedactivities √ √ X X X

7 BoilerWaterTreatmentPlant&ETP √ √ X X X

8 Blow downpit,NeutralizationPit,EarthingPit √ √ X X X

9 Truck ableroadup tofoundation √ √ X X X

B WASTEHEATRECOVERYBOILER PACKAGE

1 MainHeatRecoveryBoiler- 3 No’s √ √ √ X √

2 PressurePart √ √ √ X √

3 BoilerCasing √ √ √ X √

4 StructureandSupport √ √ √ X √

5 WaterCooledCondenserPackage √ √ √ X √

6 FoundationBolts √ √ √ X √

7 Sootblowersfortubecleaning √ √ √ X √

8 Instruments,MountingsandControlsof WHRB √ √ √ X √

9 ExhaustandbypassgasDivertervalveforgasisolation √ √ √ X √

10 ScrewAirCompressorforInstrumentair √ √ X X √

11 WaterTreatment PlantforBoiler feedand cooling towermake-up. √ √ X X √

12 Samplecoolers √ √ √ X √

13 BlowdownsystemforWHRB √ √ √ X √

14 DeaerationsystemstankandChemicaldosing √ √ √ X √

15 AuxiliariesandaccessoriesofWHRB √ √ √ X √

C EXHAUSTGASDUCTINGAND SUPPORTING STRUCTURE PACKAGE

1 DuctingfromHeatSourcetoDiverterdamper √ √ √ X √

2 DuctingfromDampertoWHRBInlet √ √ √ X √

3 DuctingfromWHRBOutlettoExistingDuct √ √ √ X √

4 SupportingstructureforDucting √ √ √ X √

D STEAMTURBINEANDAUXILIARIES PACKAGE

1 SteamTurbinewithGenerator √ √ √ X √

2 WaterCooledCondenserPackage √ √ √ X √

3 CoolingTowerPackageforMainandAuxiliary √ √ √ X √

4 FlushingLubricantsOilandfirstfillofchemical √ √ √ X √

E ELECTRICAL&INSTRUMENTATION PACKAGE

1 Allsteamandwatercontrolvalveassemblies √ √ √ X √

2 Instrumentation and control cabling for Wasteheat driven power plant within battery limit.

√ √ √ X √

3 Turbine and Generator Protection Panels (NGR, Relay metering control & synch panel,Turbine control panel, AVR panel).

√ √ √ X √

4 Electricalinspectorateclearancesifany √ √ X X √

5 Clearances/approvalsstatutorybodyfromproposedSEBorPoweranyotherPlant. √ √ X X √

6 Documentation support for the inspection / approval,statutoryapprovalsetc.ofelectricalinspectorate

√ √ √ X √

7 Start-up,GenerationCumPower Evacuationsystem:-

A 11kVPowerPlantSwitchgearSystemwithinbattery limit √ √ √ X X

1 LTCable

A LTcablewithinbatterylimit. √ √ √ X X

8 MVSwitchgearSystemforpowerplantwithinbatterylimit

A 11KVIndoorMVSwitchgearSystem √ √ √ X X

B MVcableandcabletraywithinbatterylimit √ √ √ X X

C BatterybackupforMVswitch gearchargersystem&EOP(1starter) √ √ √ X X

F) PIPINGWITHSUPPORTINGSTRUCTURE PACKAGE

1 Steam&FeedWaterPiping √ √ √ √ √

2 CondensatePiping √ √ √ √ √

3 Instrumentair,DrainandVentPiping √ √ √ √ √

4 CoolingWater&CondensatePiping √ √ √ √ √

5 ExpansionLoops/BellowsinabovePiping √ √ √ √ √

6 SupportingstructureforabovePiping √ √ √ √ √

G) INSULATIONANDCLADDINGPACKAGE

1 InsulationandCladdingforWHRBPackage includingmainWasteheatrecoveryboilers, D.Atank,Blowdowntank,Dampers,Ductotheraccessoriesinboiler package

√ √ √ √ √

2 InsulationandCladdingforDuctingPackage √ √ √ √ √

3 InsulationandCladdingforPipingPackage √ √ √ √ √

4 InsulationGeneratorandsetPackageCladdingforTurbine& √ √ √ √ √

SCOPE – EXCLUDED

Sl. No. DESCRIPTION

B

1 Cold start up power

2 Water treatment plant for boiler water and cooling water topping up

3 Required land, landscaping, road and related activities

4 Effluent treatment Plant

5 Statutory approvals

6 Freight & Transit Insurance

7 Street Illumination system and Illumination outside battery limit of Proposed power plant

8 Pollution and Factory approval

9 Any Electrical system analysis and study

10 EPABX System

11 Emergency shutdown system

3 – TECHNICALSPECIFICATIONS OF HEAT RECOVERY BOILER – ALFA LAVAL 1.) EXHAUST GAS BOILER, AV-6N / NATURAL CIRCULATION – 3 No

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 Individual steam drums to be connected to individual exhaust gas boilers. 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

3.) STEAM HEADER – 1 No The steam header is used to collect steam from individual exhaust gas boiler for further distribution to steam turbine.

Steam from exhaust gas boilers (1) with closing valves

Stem from oil fired boiler, with closing valve

Steam to consumers, with closing valve

Steam to consumers, with closing valve

Steam to feed water tank, with closing valve

Pressure gauge with cock

Pressure transmitter with cock for bypass damper control

Condensate/Drain with steam trap and closing valves 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.

4.) AUXILIARY CONTAINER, AIC-20/COMMON SYSTEM – 1 No

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) Note: Feed water tank is to be site-installed on top of the container on a separate supporting. The tank foundation supporting and service platform. Connecting pipes between the feed water tank and container (prefabricated with work allowance) are supplied loose and will be installed at site by the KPPGL. Chimney (height 10m without insulation) and foundation anchoring for chimney are included as loose supply. 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. 5.1 FEED WATER PUMPS – 2 Nos 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 5.2) Local PLC control system, Siemens TCP/IP – 1 No 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 following alarms are available for remote monitoring

Common alarm

Pressure alarm high

Steam pressure at the common steam header

Steam temperature at the common steam header

Bypass damper position The control system consists of one common control panel with Siemens MP277 &WInAC MP 2007 control logic. 5.4.1) Drum water regulating and control system 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. 5.4.2) Feed water regulating and control system – 1 Set

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.

5.4.3) Starter for feed water pump

The starter includes the following components:

Protection switches

Contractors

Main switch

Operation switches for pumps:

Indication lamps - Pump 1 is operating - Pump 2 is operating - Pump failure

5.4.4) Capacity control of the exhaust gas boilers

Stem production of the boiler is controlled according to pressure in the system

Normal pressure range of the system is between 13,5 …16 bar(a)

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)

6.) Chemical dosing unit – 1 No

This unit is mean for adding chemicals into the feed water system for mild after-treatment and oxygen removal.

The system includes following:

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.

7.)BLOWDOWN TANK, BDT-150 – 1 Nos

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.

8.) PRESSURIZED FEED WATER TANK, PSVS-16 – 1 No

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

Construction NEX ™ PSVS is an all-welded horizontal feed water tank consisting of horizontal steel cylinder and dished ends. Material of steel construction is P265GH/ EN10028-2 or equal

Condensate line is connected to the tank and added make-up water to the stainless steel deaerator which is installed on the top of feed water tank.

Temperature control Feed water is kept hot in order to reduce the amount of oxygen in boiler water.

The temperature in the feed water tank is maintained by an automatic temperature control value. This is backup system activated by low set point of feed water tank temperature whilst the exhaust gas preheating is the primary heating method. As the heat transfer from the exhaust gas preheater is proportionally to temperature of the water flow, increasing temperature will automatically be controlled by respectively reduced heal transfer to feed water tanks circuit.

Technical data

Total volume 16 m³

Operation temperature 134 ºC

Operation pressure 3 bar (a)

Design pressure 4 bar(g)

The steel Construction for PSVS-pressurized feed water tank is delivered as a complete unit with insulation including the following items.

Stands for installation

Fittings with flanged connections

Man hole or maintenance /service

Lifting lugs

Deaerator

Valves and fittings according to the following instrumentation list*)

- Feed water outlet closing valve - Safety valve - Automatic makeup water regulating and control with

valves and water level alarms(integrated level indicator)

- Manual bottom blow down/drain - Manual scum blow out valve - Sample cooler - Venting - Thermometer - Automatic stem injection control for maintaining the

set temperature.

9.ELECTRICALLY OPERATED GAS DIVERTER DAMPER

Medium : Exhaust gas

Flow rate : 129900 Kg/hr

Temperature : 400⁰C

Pressure : 300mmWC

Damper size : 1650 sq.mm

Blade type : Single type

Sealing efficiency : 99.5% on C/s area

Operation : Electrical

Duty : Modulating

4 – TECHNICALSPECIFICATIONS OF TURBINE GENERATOR SET – (TREVENI)

1.) STEAM TURBINE

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 - Main oil pump: Type : Gear (positive displacement) / Screw Operating speed : 1500 rpm Capacity : -/minute Driver : Gearbox low speed shaft Material of body : CI Material of end cover : CI Material of drive gear : EN 36 /EN 40 - Auxiliary oil pump: Type : Gear (positive displacement)/screw Operating speed : 1500 rpm

Capacity : 350 L / Minute Drive : AC motor Material of body : CI Material of end Cover : CI Material of drive gear : EN 36 EN 40 - Emergency oil pump Type : Gear (Positive displacement) Operating speed : 1500 rpm Capacity : 48 L / minute Driver : DC motor Material of body : CI Material of end cover : CI Material of drive gear : EN36 /EN40 - 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 - Lube oil Filter Element type : Micro –felt Oil flow Capacity : 350 liter/minute Oil filtration Capacity : 10-15 microns Mounting : Foot - Oil Vapor Extractor Type : Centrifugal Capacity : 400m³/Hr Driver : AC Motor Mounting : Flange 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 - Governing oil filter Element type : Micro-felt Oil flow capacity : 35 Liters /minute Oil filtration Capacity : 10-15 microns 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 - Gland vent condenser Type : Shell and tube Tube material : Admiralty brass Shell & end cover material Carbon Steel Tube sheet material : IS-2002 Accessory : Motor driven centrifugal air blower Driver for air blower : AC Motor Noise level : 90 dB(A)

2.) CONDENSING SYSTEM

STEAM SURFACE CONDENSER Type : Shell and tube Capacity : To suit exhaust flow Construction : Divided water box Cleanliness factor : 0.85 Hot well retention time : 2 minutes Tube fixing : Expanded joints Tube material : SS 304 FRW(22 Bwg) Tube sheet material : IS-2062 Gr.B Water box & Shell material IS-2062 Gr.B STEAM JET AIR EJECTORS Suction medium : Air / Vapour System elements : Twin Stage, 2 x100% main ejectors Single stage, 1x 100% start-up ejector 1x100% inter/after condenser Accessory : Integral steam strainers Time to reach 60% vacuum With start-up ejector : 20 minutes Material of nozzle : AISI-304 Material of shell & diffuser CS Material of tubes : SS-304 ERW Material of tube sheet : IS-2026 Material of silencer : CS CONDENSATE EXTRACTION PUMPS Type : Centrifugal Mounting : Horizontal Suction pressure : Same as condenser pressure Discharge pressure : 80 MWC Operating speed : 2900 RPM Driver : AC motor(415 V, 3 Phase) Type of bearings : Anti – friction Type of seal : Mechanical Type of coupling : Flexible Type of lubrication : Oil Material of casing : CI Material of impeller : CF8M Material of shaft : C45 Material of shaft sleeve : AISI 316 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 Lube oil system: Type Forced feed Source : Turbine lube oil system 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 Water leakage detector Location : Bottom of cooler Quantity : 1No. per cooler AVR CUM EXCITATION PANEL 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. TURBINE CONTROL PANEL Turbine control panel shall house the following: - Electronic governor with keyed-in operating program - Condenser hot well level indicator cum controller - Relay based hard wired turbine safety interlocks and trip logic

- Remote controls comprising of selector switches, ammeters, push buttons & Indicating lamps for:

AOP motor

EOP motor

CEP-1,2 motor

Barring gear motor

Air blower motor

Vapour extractor motor - Push buttons for turbine speed raise and lower - Turbine remote trip/reset push buttons - Temperature scanner for Monitoring turbine and gearbox bearing temperature

- Alarm annunciator for Turbine fault monitoring. The Panel shall be complete with AC supply & DC supply on / off control switches, indicating lamps and space heater. TURBINE GAUGE PANEL Turbine gauge panel shall house the following gauges:

- Pressure gauges for: Inlet steam HP Wheel case Bleed steam Exhaust steam Lube oil Control oil - temperature gauges for:

Inlet steam Bleed steam

5 - PRICE SCHEDULE- THREE BOILER SYSTEM

Sl No. DESCRIPTION EURO’S

A BOILER

1] 3nos Exhaust Gas Boiler, AV-6N/Natural circulation 2]3nos Modulating Bypass Damper, DN 1600 3] Steam Drum 4] Steam Header 5] Auxiliary Container, AIC-20/ Common System 6] Blow down Tank, BDT-150 7] Pressurized Feed Water Tank, PSVS-16 8] Condensate Tank C-6 9] Standard Spare parts for Commissioning 10] General Input Data 11] Thermal Input Data 12] Output Data [with clean heating surface] 13]cooling tower

Euro 2,975,000.00

(TWO MILLION NINE

SEVENTY FIVE

THOUSAND EUROS

ONLY)

B TURBINES

1] Steam Turbine: Multistage, impulse, nozzle governed condensing 2350 KW. 2] Steam surface Condenser 3] AC Generator 2350kW 4] AVR Cum Excitation Panel 5] Generator Relay Panel 6] Generator Control (Metering Cum Synchronizing) Panel 7] Neutral Grounding Resistor Panel 8] Turbine Control Panel 9] 11KV panel

C

Auxiliaries 1.Exhaust Duct and supports/expansion joints 2. Steam & water Pipeline and fittings 3. Cabling 4. Insulation.& cladding 5. support structural frame

D

Erection & commissioning: Erection & Commissioning- supervision - AALBORG Engineers Erection & Commissioning supervision - Triveni Engineers

E FRIGHT AND INSURANCE - CHITTGONG PORT (CIF)

Euro 160,000.00 [ONE HUNDRED SIXTY

THOUSAND EUROS ONLY]

6 - TERMS AND CONDITIONS OF SALE

Scope of Supply

The scope of supply is limited to the equipment as listed in our specification

1.0 Scope of Work

The scope of work shall comprise of Works to be performed in accordance with The Scope of

supply provided.

2.0 Contract Price

The Contract Price shall be payable at the time and in the manner provided in PRICE

SCHEDULE.

3.0 Effective Date of the Contract-(EDOC)

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:

a) Signing of the Contract. b) Advance Payment and Letter of Credit establishment

c) Approval to proceed with placement of Orders for major equipments.

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.

4.0 Project Execution

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 5.0 Payment Terms

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 price is payable as follows:

20% down payment with placement of the order.

80% against irrevocable first class bank letter of credit.

6.0 Warranty

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.

The provisions contained in this clause are not applicable

a. In case of normal wear and tear b. In case of damage due to negligence or improper handling or repairs/alterations carried out

without our approval or due to damage by any cause beyond our control. c. If the purchaser has not notified us in writing within a week from the occurrence of any

defect. d. If the DG set is run after raising a warranty claim but without awaiting our prior

permission/clearance to restart.

7.0 Validity

Unless withdrawn the offer will remain valid till 30.06.2013

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

9.0 The General Terms and Conditions of Sale:

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.

For Magnus Power Pvt. Ltd.,

________________________ Rajakumar Director

Annexure – 2(c)

Engine Catalogue

18V48/60TSTwo-stage turbocharged diesel engine

318V48/60TS – Four-stroke diesel engine

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.

MAN Diesel & Turbo The responsible way in leading technology

4 18V48/60TS – Four-stroke diesel engine 518V48/60TS – Four-stroke diesel engine

The Best in its Class18V48/60TS

Turbochargers from MAN Diesel & Turbo

Turbochargers are the core of this innovative new

concept – and MAN Diesel & Turbo is the only engine

manufacturer that also designs and builds turbo-

chargers. This unique expertise translates into ex-

ceptional efficiency and reliability.

Two-stage turbocharging

The idea is simple: just place two of MAN’s most

efficient turbochargers upstream from the engine,

one after the other. The result: the engine gets twice

the charge air pressure, while turbocharger efficien-

cy is increased significantly.

A single turbocharger, such as MAN Diesel & Turbo’s

well known TCA88, is highly efficient; however, it has

A New Dimension

a limited pressure ratio. A specially designed com-

pressor, as in the TCA88/RCF23, can increase the

pressure ratio – but also has the effect of decreasing

efficiency. The only solution to this dilemma is two-

stage turbocharging, also known as sequential tur-

bocharging (STC).

The 18V48/60TS deploys MAN Diesel & Turbo’s tried

and tested TCA88 and TCA77 standard turbocharg-

ers in sequence. The TCA88 is located upstream and

provides the low pressure turbocharger, while the

TCA77 forms the high pressure turbocharger, next to

the engine. In this configuration, both turbochargers

can achieve pressure ratios over 6 bars and efficien-

cies of more than 76 per cent.

The diesel engine 18V48/60TS

The 48/60 type diesel engine is a perfect example of

proven technology and robust design. Over 800 units

have been sold since the product was launched in

1988. They are now operating in a range of applica-

tions in power generation and marine propulsion.

Thanks to its high efficiency, the 18 cylinder engine is

the 48/60 engine family’s best-selling configuration.

Two turbochargers in sequence provide a new dimension in engine performance

and operational flexibility. A wide load range from 1,050 to 1,200 kW/cyl., a specific

fuel oil consumption of 171 g/kWh at 1.050 kW/cyl. and reduced NOx emissions set

a new benchmark for four stroke diesel engines.

For the two-stage turbocharged 18V48/60TS, only a

few modifications were made to the standard engine:

n Adapted fuel injection nozzlesn Three-ring piston with higher compression ration Modified camshaft for enhanced Miller timingn Additional exhaust gas bypass valve to avoid

smoke during engine start-up

2-Stage operation

p_out / p_in compressor

TC

eff

icie

ncy

to

t-to

t

0,78

0,76

0,74

0,72

0,70

0,68

0,66

0,64

0,62

0,601,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5 6,0

TCA88

TCA88/RCF23

TCA88+TCA77

TC Efficiency

Low pressure Turbocharger

High pressure Turbocharger


Standard components, proven design

The overall design of the two-stage turbocharged

18V48/60TS has been kept as simple as possible.

Apart from the modifications described above, the

engine is standard, with the high pressure turbo-

charger directly mounted to it.

The low pressure turbocharger is located upstream

from the engine, on its own steel frame. The combus-

tion air and exhaust gas piping between both turbo-

chargers is fitted with compensators, ensuring com-

plete insulation from vibrations.

An air blower is situated below the steel frame of the

low pressure turbocharger. Active during engine

start-up and low part-load operation (up to 25 per

cent load), it avoids smoke emissions caused by the

lack of combustion air from the turbochargers in this

operation range.

Lowest fuel oil consumption or NOx emissions

The excess combustion air from the turbochargers

provides greater operational flexibility. The high

charge air pressure can be used for enhanced Miller

Cycling, delivering significant fuel savings and further

reducing NOx emissions.

As a result, the 18V48/60TS diesel engine’s extrem-

ely low specific fuel oil consumption of 171 g/kWh

makes it the most cost-effective in its class.

Alternatively, the excess combustion air can be

leveraged to significantly increase the engine’s

power output, up to 1200 kW/cylinder. Although this

does not save as much fuel, it does allow for a great-

er reduction of NOx emissions within a wide opera-

tion range. NOx emissions of 1480 mg/Nm³ make the

18V48/60TS the cleanest diesel engine in its power

range.

Two-stage turbocharging is a modular system: its

design enables most MAN Diesel & Turbo power

plants to be retrofitted with this solution.

Flexibility in fuels, flexibility in operations

Like the 48/60 series standard engines the two-stage

turbocharged 18V48/60TS can be operated with a

wide range of different fuels:

n Heavy fuel oils with a viscosity up to 700 cstn Marine diesel and gas oil

Due to the unique features of two-stage turbocharg-

ing, the 18V48/60TS can be operated continuously

at shaft power outputs from 18,900 up to 21,600 kW.

For example, this allows power producers to operate

the engines at a normal load of 18,900 kW – taking

advantage of the extremely low fuel oil consumption

and giving them the possibility of a spinning reserve

up to 21,600 kW.

Po

wer

ou

tpu

t kW

/Cyl

.N

Ox m

g/N

m3

@15

%O

2

Effects of Two-Stage Turbocharging

Op. mode

1200

1150

1100

1050

1000

1850

1800

1750

1700

1650

1600

1550

1500

1 2 3 4

Fuel

co

nsu

mp

tio

n g

/kW

/h

177

175

173

171

1 2 3 4Op. mode

Standard Components, Proven Design

1050

1850

171

1100

1740

172

1150

1580

174

1200

1480

177

H

WA B

C


18V48/60TS Technical DataOverview

18V48/60TS engine

Performance data

Power per cylinder

Tot. engine power

Tot. el. genset power

Spec. fuel oil consumption

acc. to ISO 3046, without pumps,

mech. Power output, +5% tolerance

Heat Rate

acc. to ISO 3046, without pumps,

mech. Power output, +5% tolerance

NOx emissions (dry at 15% O2)

Mean effective pressure

Spec. lube oil consumption

Dimensions (mm)

1

1050

18,900

18,428

171

7,305

1850

23.2/22.6

0,60

B

5410

2

1100

19,800

19,305

172

7,350

1740

24.3/23.7

0,60

C

24510

3

1150

20,700

20,183

174

7,430

1580

25.4/24.7

0,60

H

9023

4

1200

21,600

21,060

177

7,560

1480

26.5/25.8

0,60

W

4694

Unit

kW

kW

kW

g/kWh

kJ/kWh

mg/Nm3

bar

g/kWh

A

9625

Operation mode

Dry mass (t)

407 407 407 407 407

Engine type: 18V48/60TS

Engine cycle: four-stroke

Turbocharging system: 2-stage, constant pressuren Low pressure TC type: MAN TCA88n High pressure TC type: MAN TCA77

Number of cylinders: 18

Bore: 480 mm

Stroke: 600 mm

Swept volume per cyl.: 108.6 dm³

Engine speed 50/60Hz: 500/514 rpm

Mean piston speed: 10.0/10.3 m/s

Nom. generator efficiency: 97.5%

Cooling:

Cylinder cooling: HT cooling water

LP-TC charge air cooler: 2-stage HT and LT cooling water

HP-TC charge air cooler: 2-stage HT and LT cooling water

Starting method: compressed air with

blower for low part load

operation up to 25% load

General definition of diesel engine ratingsaccording to ISO 3046-1: 2002

ISO Reference conditions:

n Air temperature: +25°C (77F)n Air pressure: 1000 mbarn Cooling water temperature upstream

of charge air cooler: +25°C (77F)n Relative air humidity: 30%

Figures are given with a tolerance of 5%, except for

the lubrication oil consumption, which is given with a

tolerance of 20%.

Abbreviations:

TC Turbocharger

HP High pressure

LP Low pressure

HT High temperature

LT Low temperature

10 18V48/60TS – Four-stroke diesel engine

World Class ServiceExpert advice and assistance

PrimeServ – peace of mind for life

With more than 150 PrimeServ service stations and

service partners worldwide and our growing network

of PrimeServ Academies, MAN Diesel & Turbo is

committed to maintaining the most efficient, acces-

sible after-sales organisation in the business.

PrimeServ’s aim is to provide:n Prompt, OEM-standard service for the complete life

cycle of an installation n Training and qualification of service personnel at

our PrimeServ Academies to maximise the plant’s

avai lability and viabilityn Rapid, global availability of genuine, quality-as-

sured MAN Diesel & Turbo spare parts via local

outlets or our 24 hour hotline.

PowerManagement by MAN Diesel & Turbo

Complementing the PrimeServ after-sales offering is

the MAN PowerManagement concept.

MAN PowerManagement packages provide integrated

support solutions for all aspects of running a power or

co-generation plant. Individually negotiated agreements

can cover assistance with – or delegation of – the ma n-

agement of all mechanical, electrical and thermal equip -

ment. This gives the power plant operator comprehensive

access to the technology, experience, best practices

and professional resources of MAN Diesel & Turbo.

In short: PowerManagement by MAN Diesel & Turbo

allows you to benefit from our specialist expertise in

running a power plant while you concentrate on your

core business.

MAN Diesel & Turbo

86224 Augsburg, Germany

Phone +49 821 322-3897

Fax +49 821 322-3382

[email protected]

www.mandieselturbo.com

All d

ata provid

ed in this docum

ent is non-bind

ing. This data serves inform

ational purp

oses only and is especially not guaranteed in any w

ay. Dep

ending on the sub

sequent sp

ecific

individ

ual projects, the relevant d

ata may b

e subject to changes and w

ill be assessed and d

etermined ind

ividually for each p

roject. This will d

epend on the p

articular characteristics of

each individ

ual project, esp

ecially specific site and op

erational conditions · C

opyright © M

AN

Diesel &

Turbo · D

2366483EN

Printed in G

ermany G

MC

-AU

G-06110.3

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: Lower calorific value (LCV) 40230 kJ/kg Viscosity (at 50°C) up to 180 mm2/s Density (at 15°C) max. 1010 kg/m3 Sulphur content up to 3.4%-wt. Ash content up to 0.15%-wt. Flash point min. 60 °C Pour point max. 30 °C Coke residue (Conradson) max. 20 % wt. Vanadium max. 450 mg/kg Water max. 0.5 % vol. Sediment (potential) max. 0.1 % wt. Aluminium and silicon (total) max. 60 mg/kg Total acid number max. 2.5 mg KOH/g Hydrogen sulphide max. 2 mg/kg Asphaltene content max. 2/3 of coke residue % wt (Conradson) Sodium Sodium < 1/3 vanadium, Sodium < 100 mg/kg CCAI number max. 870 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

Technical information for bilge water treatment

Inside view

3 Summary

4 The EcoStream bilge water treatment systemOverviewSystem requirementsSystem benefits

6 Towards cleaner oceansWhat is bilge water?Bilge water treatmentBilge water legislation

8 Stable emulsions in bilge waterWhat are emulsions and suspensions?Chemical usage aids stabilizationEffect on separation performanceMechanisms for emulsion breakdown

10 EquipmentOperating principleKey components

13 Optional components

14 Flow diagram

16 Retrofitting

16 Documentation

16 Classification

16 Spare parts, service and support

The EcoStream bilge water treatment system from Alfa Laval is a reliablefully automated, single-stage centrifugal separation system to clean oilywastewater on board vessels at sea and at land-based power plants.

Alfa Laval EcoStream

2 Alfa Laval Marine & Diesel Equipment

SummaryBilge water must be treated to reduce the oil content to levels that meetinternational 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 is a centrifugal separation system for bilge water treatmentthat has been approved by the International MaritimeOrganization.

This system generally cleans bilge water to less than fiveparts per million (ppm) oil in water. It operates at flow rates ofup to 2,000 liters per hour to meet even the toughest bilgewater treatment applications.

As a major equipment and technology supplier to the marine industry, Alfa Laval understands the requirements of all treatment systems on board vessels.

We use equipment and technology know-how to buildsolutions of all kinds for cost-effective and efficient operationof vessels – from engine room applications including oil treat-ment and fuel conditioning to waste disposal applications,including bilge water treatment.

Our aim is to work continuously to improve customerprocesses – time and time again.

This document provides technical information about the Alfa Laval EcoStream bilge water treatment system. It includes information about the bilge water separationprocess, advances in system design, system benefits and a description of equipment.

Benefits for owners and operators• Reduced operating costs thanks to low maintenance,

automated control, no waste disposal and an absence of filter elements that require replacement.

• Reliable, always-available system. Operates continuously,regardless of variations in feed, oil shocks and roughweather conditions.

• Easy to operate. Automated control and monitoring systemintegrates with existing Alfa Laval systems, providing asingle user-friendly interface.

• Safe operation. A key lock switch can be set in manual or locked position to ensure that only the individualresponsible for environmental compliance may authorizeoverboard discharge.

Benefits for designers of ships and power plants• Compact, modular, easy-to-install system saves time,

space and money.

• Continuous, single-stage operation requires less holdingtank volume and provides more space for payload.

• Easy integration with existing communications systems on board.

Alfa Laval Marine & Diesel Equipment 3


The Queen Mary 2 is equipped with two EcoStream bilge water treatment systems.



Alfa Laval EcoStream.

The Alfa Laval EcoStream bilge water treatment systemCleaning of bilge water poses distinct challenges. Not only does the composition and flow of bilge water constantly change, making continuous and efficient treatment difficult, but treatment on board also presents another set of constraints.

Treatment methods must meet individual ship requirementsand demands for safety, reliability, compactness, automation,low maintenance and the ability to withstand rough weatherconditions. In addition, performance of the treatment systemcan vary depending on the oil content and the size of thedroplets or particles present in the water and on variousoperating conditions.

Centrifugal separation has proven to be a reliable, efficientand flexible method for continuous removal of oil and othercontaminants suspended in the bilge water on board shipsand at land-based power plants.

OverviewThe EcoStream bilge water treatment system from Alfa Lavalis a centrifugal separation system for treatment of large bilgewater volumes at sea. EcoStream operates at flow rates ofbetween 1,500 and 2,000 liters per hour and usually cleansbilge water to less than 5 ppm.

EcoStream is easy to install for any new or existinginstallation. It does not require large bilge water holding tanks. This increases payload capacity. Compared to con-ventional bilge water systems, EcoStream significantlyreduces operating costs, thanks to automation and remotecontrol. In addition, there is no expensive filter elementreplacement required.

EcoStream enables cleaning of bilge water under a widerange of real operating conditions. It complies with the Marine Environment Protection Committee Resolution, MEPC 107(49), of the International Maritime Organization(IMO), MED 96/98/EC. EcoStream is not only certified bythese organizations, but has proven its high level of per-formance under real operating conditions, normally below5 ppm – even when subjected to oil shock or rough weather.

System benefitsCompact, modular and flexible designThis provides great flexibility to install the unit in a convenientlocation. A wide range of options for functionality, remotecontrol and other features adds more flexibility.

Easy to installThis simple, plug-and-play installation of this factory-testedmodule makes it easy to install. Pipe connections locatedunderneath the unit make EcoStream easy to install.

Faster, more secure commissioningPre-tested, pre-installed and pre-approved components for allsystem functions make commissioning quick, easy and muchless expensive than buying separate components anddesigning a bilge water treatment system.

Easy to operateAutomation and remote control make EcoStream a user-friendly, start-and-forget system. The process controller also shares the same user interface as the Alfa Laval Fuel

Conditioning Module and Separation Unit controllers,facilitating ease of operation.

Easy to access and maintainBuilt-in service areas facilitate inspection and maintenance. A central pillar houses all motor starters and the advancedprocess controller, making the EcoStream unit easier toservice and easier to operate than other units available.

More uptime, less maintenanceMaintenance-free components, automation and remote con-trol increase operating time and decrease service disruptions.Durable components contribute to longer service intervalsbetween inspections.

Lower installation and operating costsThanks to pre-testing, installation requires less time andmoney than installation of separate components. Automationand remote control reduce operating costs.

Technical supportAll spares, service and sales engineers are available throughthe Alfa Laval International Service Network.



Dimensions

1768

mm

750 mm

1070 mm

1810 mm

1450

mm

635

mm

Access area

Towards cleaner oceansBilge water generated on board ships is a major environmental concern for the shipping industry.

Regardless of its source, bilge water must be treated toreduce the oil content to levels that meet international regula-tions for release into the environment. This is critical tokeeping the world’s oceans and their vast marine ecosystemshealthy and productive.

Efficient bilge water treatment minimizes the impact of shippropulsion on the marine environment as well as the heavyfines that ship operators can face for pumping oily bilge wateroverboard.

Efficient treatment also reduces the need for and cost ofwaste disposal ashore. Over the years, waste disposal costshave continued to climb as local authorities enforce stricterlaws for the land-based companies that process this waste.

Alfa Laval’s bilge water treatment solution is superior to manycompeting technologies with respect to the volumes of wastegenerated.

What is bilge water?Bilge water collects in a ship’s bilge wells, which are locatedin the lowermost part of the vessel just above the hull. Thewells receive water and mechanical fluids from operationalsources, such as technical rooms, propulsion systems anddifferent machinery.

Bilge water also contains fluids from machinery spaces, internal drainage systems, sludge tanks and various othersources.



Cleaning andmaintenance

Drainsand leaks

Water from purifiersludge tanks

Water from wasteoil tank

Condensatefrom air coolers

Bilgepump

Tankoverflows

Incidents

Bilge well

Clean wateroverboard

Bilge water tanks Bilge watertreatment

Bilge well

Bilge water containsa mixture of waterand fluids from various sources onboard that is treatedfor clean waterdischarge overboard.

The definition of bilge water is thus much wider in scope than merely the contents of a ship’s bilge, the enclosed areabetween the frames where the sides of the vessel curve in toform the bottom.

In simple terms, bilge water contains two types of sub-streams: (1) flows that are reasonably continuous and pre-dictable, and (2) flows that are intermittent in nature and diffi-cult to foresee. The first category includes water from theseparator sludge tank and water from cleaning activities inthe ship’s engine room. The second category may includesoot water, leakage and incident spills from tanks andmachinery spaces.

Bilge water is thus composed of a mixture of water, deter-gents and other chemicals, fuel oil, lubricating oil, hydraulicoil, cat fines, oil additives, soot and dirt. This mixture is col-lected in the bilge water holding tank, which generally ismaintained at an elevated temperature. This high temperaturefacilitates primary gravity separation, preferably of the two- orthree-stage type, in the bilge water tank. Here, oil rises to thetop and particles settle on the tank bottom, generally dividingbilge water into three distinct layers in the tank:

• Top layerThis contains most of the oil and organic solvents and con-stitutes a small portion of the total tank volume. Skimmingthis top layer for separate treatment is recommended.

• Middle, or main, layer This aqueous phase contains water polluted by oil, chemi-cals and particles in emulsified form. This is fed to the bilgewater treatment system.

• Bottom layerThis contains solids and heavy sludge, which should alsobe removed for separate treatment.

Bilge water legislationBilge water treatment is an environmental application thatmust meet stringent requirements of international legislation.Disposal of untreated bilge water into our oceans is strictlyprohibited by international law and subject to heavy fines,especially in sensitive waters.

Current MARPOL legislation stipulates that separated bilgewater containing 15 ppm or below oil in water can be dis-posed into international waters. Some national, regional andlocal authorities, especially those governing sensitive waters,have more stringent regulations. In the United States and inthe Baltic and North Seas, for instance, disposal of separatedbilge water is only permitted at least 12 nautical miles fromshore.

The International Maritime Organization (IMO) resolutionMEPC 107(49) specifies how to type approve equipment used on board ships. The resolution complies with theEuropean Marine Equipment Directive, MED 96/98/EC.

Many manufacturers have succeeded in meeting the speci-fied requirements for equipment certification, but much of this equipment falls short of delivering the high separationefficiency required under real operating conditions for bilgewater discharge.



Water

Oil

Particles

Fresh water

Seawater

Heavy fuel oil

Lube oil

Hydraulic oil

Organic

Inorganic

Emulsifying, corrosive

Other

Emulsions,suspensions

Chemicals

Bilge watercomposition.

What are emulsions and suspensions?By definition, an emulsion is a mixture of two immiscibleliquids. An oil-in-water emulsion consists of small oil dropletsdispersed in a continuous water phase. A suspension is amixture in which solid particles are dispersed in the con-tinuous water phase.

Emulsions, or small droplets of one liquid (the dispersedphase), can form in the other liquid (the continuous phase)under agitation, such as during pumping or throttling invalves. Droplets of oil dispersed in water generally coalesce,or combine, into larger droplets because oil is not soluble in water.

Increasing the droplet size helps facilitate separation. The presence of surfactants, such as detergents, soaps and other surface-active compounds, however, maycontribute to stabilization of small oil droplets. This makes separation very challenging. High centrifugal force is then required to separate the small droplets that do not spontaneously separate when subjected to gravita-tional force.

Emulsion stabilizers may consist of:

• Low molecular weight surface-active compounds, orsurfactants, that reduce the surface tension of the oil-waterinterface and thereby create small droplets that contributeto emulsification.

• Polymers and other macromolecules form a film around the emulsion droplet to establish a physical barrier tocoalescence and thereby stabilize emulsions further.

• Fine particles can accumulate and adsorb at the oil-waterinterface to form a physical barrier around the emulsiondroplets.

Chemicals usage aids stabilizationEmulsion stabilizers may originate from a variety of sources inthe engine room – from the use of cleaning detergents, fromlube oil additives and so on. Clearly, the use of chemical sub-stances on board is excessive.

Chemicals on board are used for: cleaning and maintenance,treatment of water, improving fuel quality, and improving thequality of lubricating oil.

What used to be lubricating and hydraulic oils of relativelyelemental composition, based on simple mineral oils, are nowcomplex formulations, sometimes based on synthetic oils andincorporating a variety of additives.

Modern lubricating and hydraulic oils have a greater ability totake up water due to the action of detergents. Likewise,cleaning chemicals have a great ability for oil and dirt uptake.

Stabilizers may also occur naturally in the oil. These stabilizersconcentrate at the oil-water interface and lower the interfacialtension, thus stabilizing the liquid mixture.

Some chemical residuals generally end up in a vessel’s wastetreatment system or holding tank. The bilge water treatmentsystem, in particular, processes a heavy load of chemicalresiduals.

Chemical usage in the engine room inevitably causes the for-mation of stable emulsions and suspensions as well as someform of environmental impact. Most chemical manufacturersclaim that their products do not stabilize emulsions in bilgewater. But the use of surface-active chemicals make manyproducts contribute to the formation of stable emulsions.

Usage of chemicals always causes some type of compromisebetween cleaning efficiency and separation efficiency on theone hand and environmental friendliness on the other.

Alfa Laval strongly recommends the use of quick-separating,environmentally friendly and non-toxic detergents. Choosingchemicals that are compatible, non-toxic, biodegradable andnon-emulsifying, helps prevent problems downstream.

Effect on separation performanceThe formation of stable emulsions and suspensions affectsseparation efficiency. Many conventional technologies fail tosplit stable emulsions and remove suspended colloidal parti-cles from the water phase. This often results in equipmentmalfunction because separation of oil below 15 ppm is notachieved or because of clogging from excessive solids.

Understanding the factors that contribute to the formationand breakdown of stable emulsions is essential to under-standing why centrifugal bilge water treatment systems canefficiently separate bilge water, despite a high concentrationof stable emulsions.

Stable emulsions in bilge waterSeparation of oil and particles from bilge water is becoming increasinglychallenging, due to the presence of stable emulsions and suspensions. Emulsion and suspension formation and stability are of major concern in the context of bilge water treatment.



Mechanisms for emulsion breakdownThere are different mechanisms for emulsion destabilizationand breakdown, including coalescence and flocculation.

• Coalescence is a process where two or more dropletscollide, resulting in the formation of one larger droplet.

– A high centrifugal force induced in a centrifugal separatorgreatly contributes to the coalescence of small droplets.

– Elevated temperature accelerates the rate of coalescenceby increasing the probability of the droplets to collide andby decreasing the viscosity of the continuous phase.

– Chemical demulsifiers decrease or cancel the repulsiveelectrostatic forces between droplets in an emulsion,causing droplet coalescence.

• Flocculation is a process by which two or more particlesaggregate without losing their individual identities.

– A high centrifugal force induced in a centrifugal separatorgreatly contributes to the flocculation of small particles.

– A high alkaline pH value promotes flocculation. The pHvalue provides a measure on a scale from 0 to 14 of theacidity or alkalinity of a solution.

– Chemical flocculants decrease or cancel the repulsiveelectrostatic forces between particles in a suspension,thus promoting flocculation.



What parameters affect separation efficiency?Centrifugal separation relies on the difference in density amongthe various components present in emulsions or suspensions.

Stokes’ Law (below) describes the settling velocity (vg) of aparticle or droplet when subjected to gravitational force, such asstatic settling in a tank, which in turn determines the separationefficiency. The general formula is:

νg = d2 (ρd – ρc)

g18 µc

νg the sedimentation velocity due to gravity

d the diameter of the dispersed droplet/particle

ρd the density of the dispersed phase

ρc the density of the continuous phase

µc the viscosity of the continuous phase

g the gravitational acceleration

The expression states that the greater the difference in density,the greater the efficiency. However, the density difference is notthe most important parameter affecting the separation efficiency.

The sedimentation velocity increases exponentially with thedroplet, or particle, size. This means that the smaller the dropletor particle, the more challenging the separation task.

For separation of small droplets and particles, which are found in the stable emulsions and suspensions in bilge water, gravityalone is not sufficient. In a centrifuge, the term (g) in the expres-sion is replaced by (w2r), the centrifugal force, which is severalthousand times greater than the acceleration due to gravity.Therefore, even droplets and particles that are only a fewmicrometers in size can be efficiently separated.

Another important factor that has a positive effect on separationefficiency is low viscosity. The viscosity of the continuous phaseaffects sedimentation velocity, which increases in inverse propor-tion to the viscosity. Therefore, any medium with low viscosity,such as a continuous water phase, facilitates separation.

Flocculation of particles Coalescence of droplets

Feed

Water

Solids

Oil

High centrifugal force inthe separator contributesto coalescence andflocculation, which aidemulsion breakdown.

EquipmentEnvironmental protection requires reliability. This is how Alfa Laval has met the bilge water treatment challenge.

Operating principleA positive displacement feed pump with variable frequencydrive control directs oily water from the bilge water settlingtank or equivalent to the system. The pump provides a feedrange of between 1,500 and 2,000 liters per hour. Theprocess liquid should always maintain a pH value above five.An optional chemical dosing unit can be connected after thepumping stage although chemicals usually are not required to accomplish efficient bilge water treatment.

Bilge water then passes through a dual basket strainer whichtraps large particles from the fluid before entering a heatexchanger, which raises the fluid temperature to requiredlevels, generally between 60° and 95°C, for optimum separa-tion efficiency.

A three-way changeover valve then directs the fluid to theseparation stage if all process conditions, such as feedtemperature, feed pressure and separator speed, fall withinpreset process values. If any process condition is not met,the valve re-circulates the fluid back to the bilge water settling tank.

A high-speed centrifugal separator continuously processeslarge volumes of bilge water. The oil outlet continuously dis-charges out-separated oil and emulsions. Solids that collectat the separator bowl periphery are discharged intermittentlyto a cyclone, which reduces the velocity and energy of thedischarged volume. Discharge occurs at preset intervals,which is generally set at 20 minutes, depending on theinstallation. Solids are then directed to a sludge, or waste oil, collecting tank.

A built-in water pump, or paring disc, continuously dis-charges separated bilge water through the water outlet. The destination of the separated bilge water depends uponits oil content, which is continuously monitored at an iso-kinetic sampling point by an oil-in-water monitor.

If oil content is less than or equal to 15 ppm, the separatedbilge water can be pumped either directly overboard or to a‘clean’ bilge water holding tank for discharge overboard later.If oil content exceeds 15 ppm, the effluent is re-circulated,preferably to the cleanest part of, the bilge water settling tankfor re-processing.

As an alternative, separated bilge water with an oil contentjust above 15 ppm can be directed to an ‘almost’ clean bilge

water holding tank in order to avoid re-contamination. Thishelps make bilge water handling more efficient.

Key componentsEcoStream makes the best use of available space andprovides flexibility and easy access for operation and main-tenance. These key EcoStream components are more fullydetailed later in this section:

Forwarding pumpAn eccentric screw pump with variable frequency drivecontrol.

StrainerA dual basket strainer of mesh size 1.5 mm.

Heat exchangerA shell-and-tube heat exchanger using steam as its heatingmedium.

Three-way changeover valvesTwo three-way changeover valves handle bilge water atcritical junctions.

Constant pressure valveA fast-acting, high-precision constant pressure modulatingvalve handles the required backpressure with accuracy.

TransmittersElectronic transmitters monitor temperature and pressure.

SeparatorThe BWPX 307 high-speed centrifuge uses the most modernfluid dynamics technology for high separation efficiency.

Control cabinetTwo separate compartments houses the process controllerand the electric power functions.

Process controllerThe EPC 50 process controller facilitates monitoring andcontrol of all EcoStream functions, which are displayed inclear text and on a mimic display.

Oil-in-water monitorCertified according to IMO resolution MEPC 107(49), this in-line unit accurately measures the content of oil in water.



Components in the system

Pump unitThe pump unit consists of a stand-alone compact pumpmodule, which is designed for ease of installation and ease of accessibility for maintenance.

Thanks to its variable speed control, this screw pump easilyhandles changing fluid capacities and enables adjustment ofthe feed rate setting during operation. The feed rate rangesbetween 1,500 and 2,000 liters per hour.

To protect the pump from dry running, the unit is equippedwith a water-priming device, which is automatically activatedupon startup. This water-priming device may also be acti-vated manually, whenever necessary. The pump has a pres-sure relief valve, pressure gauges and a non-return valve onthe discharge side.

StrainerTo trap large foreign particles suspended in the bilge waterthat may cause unnecessary operational disturbances, a dualbasket strainer with a mesh size of 1.5 mm is installed as asafety measure.

Heat exchangerThis shell-and-tube heat exchanger uses steam as theheating medium. All heater parts that come into contact withthe bilge water are made of cupronickel, a corrosion-resistantalloy. A proportional integral (PI) temperature controller accu-rately maintains the temperature set point within ± 2°C, evenunder variable bilge water feed conditions. This is especiallyimportant to achieve high separation efficiency. Installation ina horizontal position reduces the risk for build up of conden-sate and provides easy access for maintenance.

Separation unitThe BWPX 307 high-speed centrifuge utilizes the latestachievements in modern fluid dynamics technology. Designedfor continuous, high-efficiency separation of large bilge watervolumes, the centrifuge handles throughput capacities of1,500 to 2,000 liters per hour. Its unique design providesreliable operations, even when subject to oil shocks andrough weather conditions.

The patented Alfa Laval disc inlet, Optiflow, gently acceleratesbilge water into the separator bowl with a minimum ofshearing and foaming. This greatly improves separation effi-ciency by preventing the splitting of drops and the formationof further emulsions.

The new disc-stack design provides the maximum surfacearea possible for separation. Specially designed concentratordistribution holes and caulk configuration further optimizeseparation efficiency.

A speed sensor and an optional unbalance sensor monitorthe mechanical status of the separator. A cyclone, installed in the sludge outlet, provides ventilation and reduces thevelocity and energy of the discharge volume.

Oil-in-water monitorThis in-line unit monitors the oil content of separated bilgewater in compliance with IMO Resolution MEPC 107(49). It is capable of monitoring oil content from zero to 30 ppm at sample temperatures of up to 65°C.

To minimize response time, the iso-kinetic sampling point ofthe monitor is located as close as possible to the separationstage. Before processing occurs through the monitor, thesample passes through a cooler, which is used when separa-tion temperature exceeds 65°C, to prevent damage to themonitor from excessive heat.

Two independent alarm circuits come with a factory setting of15 ppm, but may be set independently to indicate oil contentin water ranging from two to 15 ppm. An alarm setting above15 ppm is impossible.

Three-way changeover valvesTwo pneumatically activated three-way changeover valvesregulate bilge water at critical junctions. The first directs bilgewater to the separation stage for treatment, and then re-circulates bilge water that does not meet pre-set conditionsback to the bilge water settling tank. The second routesseparated bilge water with oil content that is less than orequal to 15 ppm to a holding tank for discharge overboardlater or pumps the water directly overboard.

During an alarm situation when any preset condition is notmet, loss of operating air pressure or power failure, the three-way changeover valves automatically shift to re-circulationmode, thus preventing overboard discharge of any bilgewater with oil content exceeding 15 ppm.

Constant pressure valveThis fast-acting, high-precision constant pressure modulatingvalve prevents the formation of air bubbles during the separa-tion stage and thereby helps insure the accuracy of the oil-in-water monitor. It is installed after the separator.

Whenever solids or sludge are discharged from the separatorbowl, additional air pressure is applied to the valve to preventany untreated bilge water from penetrating and polluting thesystem downstream.



Oil-in-water monitor according to IMO resolution MEPC 107(49).

TransmittersElectronic transmitters provide accurate readings for pressureand temperature and improve control to achieve high separa-tion efficiency.

Sampling cocksSituated before the separation stage and after the three-waychangeover valves, these sampling cocks enable analysis of bilge water samples and provide an alternative way tomeasure the accuracy of the oil-in-water monitor.

Control cabinetCentrally located to monitor all EcoStream functions, thecontrol cabinet has two separate compartments. The lowercompartment contains all electric power functions, such as amulti-transformer, for power supplies in the range of 230 to690 V, all motor starters, pump unit speed control, powersupply for the optional chemical dosing unit and all pneumaticcontrol devices. The upper compartment contains theAlfa Laval EPC 50 computer-based process controller andoperator panels.

Process controllerThe 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 allEcoStream functions. To assist with trouble tracing, an alarmlog registers the last 31 alarms. It also records time when thealarm appeared, time until the alarm was reset and thesludge discharge time interval.

The process controller has several built-in self-cure functionsthat automatically activate to ensure continued operationshould a system problem occur. A proportional integral (PI)temperature controller accurately maintains the temperatureset point for separation within ± 2°C, even under variablebilge water feed conditions.

Standard hardwired input and output signals include:• Emergency stop button,• Emergency shut down (ESD),• Process shut down (PSD),• Common alarm indication, and,• Process status indication.

The EPC 50 process controller is based on the same hard-ware used in other Alfa Laval units, making it easy to use foroperators who are already familiar with this equipment.

Operator panelsA push button and light-emitting diode station displays thestatus of cleaned bilge water for discharge overboard and forre-circulation, the pumping stage, the electric motors,optional chemical dosing units and optional automaticcleaning unit for the oil-in-water monitor.

A mimic display continuously indicates the operation mode of:• Feed to the separation unit or re-circulation,• Cleaned water for discharge overboard or re-circulation,• Pressure and temperature transmitters.

More process data are easily accessible by simply pressing a button. These include feed temperature, feed pressure,water outlet pressure, oil content in cleaned water, separatorbowl speed and total operating hours. All critical processparameters and operation mode, including start-up, standby,pre-production, production and stop, are displayed in clear text.

A key lock switch that controls discharge of separated wateris also located on the panel. Bypass, or locked, position re-circulates separated bilge water, regardless of its oil in watercontent. Inserting the key enables selection of automaticposition, which directs bilge water with oil content of 15 ppmfor discharge overboard.

It is also possible to set the limit for overboard dischargelower than 15 ppm – at five ppm, for instance. This enablessafe discharge in environmentally sensitive waters, wherelower oil in water content is required by regulatory bodies.

Located next to the LED panel, the operator panel controlsthe feed rate of the variable frequency drive feed pump.



EPC 50 process controller.

Optional equipmentThe EcoStream system offers these equipment options to provide greater flexibility.

• Chemical dosing unitUnder extreme conditions, centrifugal force alone may notbe sufficient to deliver high separation efficiency for satis-factory treatment of the bilge water. This is usually the casewhen large quantities of suspended solids, such as soot ordetergents, are present in bilge water.

For these conditions, an optional chemical dosing unit effi-ciently handles strongly emulsified oil as well as suspendedcolloids.

Chemicals should only be added when a combination of high separation temperature (95°C) and low flow rate(1,500 liters per hour) is insufficient to separate bilge waterto contain 15 ppm or less oil in water.

Alfa Laval recommends the use of safe and environmentallyfriendly Alpacon chemicals, MP 300/302. The combinationof these water-based additives promotes demulsificationand flocculation to achieve clean water with less than15 ppm for more difficult feed compositions.

• Automatic self-cleaning filterIf the feed water is expected to have a high solids or fibercontent, installation of an automatic, self-cleaning filter isrecommended. This may be necessary, for instance, if therisk of overflow from black and grey water tanks into thebilge wells exists.

Removing fibers and other coarse solids helps preventclogging of passages, such as the distribution holes in theseparator disc stack. This prolongs service and maintenanceintervals, which may otherwise be unacceptably short.

• Sludge removal kit (SRK)When installation of EcoStream on top of a sludge-collecting tank is impossible, an optional sludge removal kit(SRK) is available.

As part of the oily water pre-treatment stage, this small,intermediate sludge tank comes equipped with a pneu-matically driven sludge removal pump, level controller and level switch.

• Cleaning-in-place unitAn optional cleaning-in-place (CIP) unit is available toenable cleaning of separator bowl parts without dis-mantling the separator.

The CIP unit reduces downtime and maintenance man-hours and saves money. It also minimizes the potential riskfor mechanical damage of vital bowl parts.

• Automatic cleaning device for the oil-in-water monitorAn automatic pneumatic cleaning device for the oil-in-watermonitor is available as an alternative to manual cleaning ofthe measuring cell in the oil monitor.

The cleaning device activates at every sludge discharge,ensuring accurate monitoring of oil content by continuouslycleaning the measuring cell in the oil monitor.

• Serial bus connectionFully remote operation of the EcoStream is possible byconnecting the process controller via serial bus to anexternal computer or communications system.

This provides complete coordination with a Central ControlSystem (CCS) or a plant’s Integrated Administration andControl System (IACS). Proprietary field bus interfaceboards, according to Profibus DP or Modbus RTU stan-dards, are installed in the process controller. This enablescommunication to external automation systems. Most localfunctions can be replicated with the use of the field bus in-terface boards.

Please contact Alfa Laval if other protocol boards, such as CANopen, DeviceNet or InterBus, are required.Customers assume responsibility for coordination of pro-gramming on the remote side through their automationproviders. Alfa Laval provides documentation describing the protocol for the system developers.





Flow diagram� Two-stage bilge water

settling tankPre-heats the bilge water.

� Chemical dosing units (optional)Enhances separation efficiency ifstable emulsions are present.

� Feed pump with variable speed controlTransfers liquid to the steam pre-heater.

� Automatic self-cleaning filter(optional)Removes coarse solids and fibers.

� Pressure transmittersMeasures the pressure in the waterinlet and outlet and signals this in-formation to the process controller,which monitors pressure to ensureremains within acceptable limits.

� Dual basket strainerTraps large particles from the fluidbefore entering the heater.

� Steam pre-heaterRaises temperature of the liquid to the required treatment tem-perature.

� Temperature transmittersMeasures the temperature of theliquid from the pre-heater andsignals the process controller.

Temperature controllerAlerts operator when the tempera-ture exceeds, or falls below, a pre-set limit and acts as a backup toprovide temperature control shouldthe temperature transmitter fail.

PT

Feed inlet

Recycling to tank

Feed recycling

Frombilge wells

From drainsand leaks

AlpaconMP 300

AlpaconMP 302

VFD

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�

�

�

�

�



Three-way changeover valvesDirects bilge water from the tank to the separation stage and fromthe separation stage either to pump for discharge overboard if it contains less than 15 ppm oil in water or back to the bilge watersettling tank if these conditions are not met.

� CycloneReduces the velocity and energy ofthe discharged volume of solidsbefore reaching the sludge outlet.

� BWPX 307 high speed centrifugal separatorContinuously separates largevolumes of bilge water.

� Oil-in-water monitorContinuously measures oil contentof cleaned bilge water and com-pares these measurements to apre-set value.

� Constant pressure modulating valvePrevents the formation of air bub-bles during the separation stageand thereby helps insure the accu-racy of the oil-in-water monitor.

Intermediate sludge tank withsludge pump (optional)Temporarily stores sludge for wasteprocessing on shore.

Sludge outlet

PT Clean wateroutlet

QC

Ventilation QT

TT

TC

TT

�

�

�

�

�

�

�



EcoStream is ideal for replacing older bilge watertreatment systems. Its compact size easily fits into any available space.

To facilitate transport through small passageways,EcoStream can also be divided into four parts:

• A separator with a frame,• Valve and piping rack, • Feed pump, and,• Control cabinet.

Alfa Laval supplies each EcoStream bilge water treat-ment system with full documentation either as papercopies or as PDF (Portable Document Format) files ona CD-ROM. The instruction manual, which can alsobe made available in most major languages, covers:

• Safety• System description• Operating instruction• Parameter list • Alarms and fault finding• System reference/installation instructions• Separator manual• Spare parts catalogue• Component descriptions

Documentation

Alfa Laval ensures that the EcoStream fulfils therequirements of all major classification societies. Upon request, Alfa Laval delivers the EcoStream withan individual test certificate. This includes approval bythe society of the main components as well as work-shop testing of the complete module. Several keycomponents are also type approved by the leadingclassification societies.

Alfa Laval provides spare parts kits for all service andmaintenance needs. Global technical service, trainingand support are available throughout the lifetime of the EcoStream.

Retrofitting

Classificationsociety approval

Spare parts,service andsupport

Alfa Laval reserves the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or suggestions for improvementof this publication would be gratefully appreciated.

Copies of this publication can be ordered from your local Alfa Laval company.

Published by: Alfa Laval Tumba ABMarine & Diesel EquipmentSE-147 80 TumbaSweden

© Copyright Alfa Laval Tumba AB 2004.

EMD00050EN 0412

Alfa Laval in brief

Alfa Laval is a leading global providerof specialized products and engi-neering solutions.

Our equipment, systems and servicesare dedicated to helping customersto optimize the performance of theirprocesses. Time and time again.We help our customers to heat, cool,separate and transport productssuch as oil, water, chemicals, bever-ages, foodstuff, starch and pharma-ceuticals.

Our worldwide organization worksclosely with customers in almost 100countries to help them stay ahead.

How to contact Alfa Laval

Contact details for all countries arecontinually updated on our web site.Please visit www.alfalaval.com toaccess the information.

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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 PlantNababgonj,Dhaka.

November 2013

3

1 Project Profile

Your company has 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.

2 Design Basis and Indicators

2.1 Flue Gas Parameters

Flue Gas（for one furnace）80000-90000 m3/h

Furnace flue gas outlet temperature＜350O

C （Guide equipment import of flue gas

temperature）

So2 content≤2500-3700mg/m3。

2.2 Desulfurization Agent Quality

Main Desulfurization Agent：90％caustic soda flakes；

2.3Codes and Standards

《The Integrated Emission Standard of Air Pollutants》（GB16297-96）

《Industrial furnaces standards for the discharge of atmospheric pollutants》（GB9078-1996）

《Industrial boiler and furnace wet flue gas desulfurization engineering technical

specifications》（HJ462 -2009）

《Standard of noise at boundary of industrial enterprises》（GB12348-90）

3

USER

Sticky Note

MigrationConfirmed set by USER

《GBZl》（GBZ1-2002）

《Concrete structure design code》（GBJ10-89）

《Welds technical specification for concrete structures》（JGJ/T114-97）

《Industrial metal pipeline design specifications》（GB80316-2000）

《 Industrial equipment and pipeline insulation engineering design specifications 》

（GB50264-97）

《Pipe rack first part: technical specifications》（GB/T17116.1-1997）

《Pipe rack second part: pipe connection parts》（GB/T17116.2-1997）

《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）

《Water structure construction and acceptance specification》（GBJ141-90）

《Stationary steel straight ladder》（GB4053.1-93）

《Stationary bevel steel ladder》（GB4053.2-93）

《Stationary industrial protective barrier》（GB4053.3-93）

《Fixed steel industrial platform》（GB4053.4-93）

《Industrial enterprise lighting design specifications》（GB50034-92）

《Low voltage distribution design specifications》（GB 50054-95）

《General electric equipment distribution design specifications》（GB 50055-93）

《Building structure load standard》（GBJ9-87）

《Building ground design specifications》（GB50037-1996）

《Architectural lighting design standards》（GB50033-2001）

《Building lightning protection design specifications》（GB 50057-94）

《Earthquake Resistant Design Code》（GB50011-2001）

《Structure seismic design code》（GB50191-93）

《Industrial equipment pipeline anticorrosion engineering construction

and acceptance specification》（HGJ229-91 ）

《Fluid delivery with stainless steel seamless steel pipe》（GB/T14976-94）

《Fluid delivery with seamless steel tube》（GB/T8163-1999）

《Stainless steel seamless steel pipe》（GB2270-80）

《Steel welding atmospheric vessel》（JB/T4735-1997）

《Stell Buildings and Bridges》（GBJ17-91）

《Equipment and flue of the general principles of the thermal insulation technology》

（GB4272-92）

《Code for design of building》（GBJ7-89）

《Steel structure construction and acceptance specification》（GB 50205-95）

2.4 Design Objective

According to the national 《 Industrial stoves standards for the discharge of

atmospheric pollutants》（GB9078-1996）, Considering the total quantity control and the

improvement of environmental protection standard，The desulfurization process designs

desulfurization efficiency≥90％，the emission concentration of SO2≤100 mg/Nm3，

ringelman emittance＜1level.

2.5 Scope of Supply

The flue gas furnace production line (desulfurization) complete set of equipment

management，that is：the original equipment modification installed internals, increase a new

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：

3.1 Desulfurization adopts TFGD

Single (sodium) process is to use soluble alkaline clear liquid（main：NaOH or

Na2CO3）as an absorbent to absorb SO2.Because in the process of absorption liquid, it

use the same type of alkali, so called single process.

3.2 Desulfurization principle

Single process uses NaOH or Na2CO3 alkali liquor to absorb SO2, produce HSO32-、SO3

2-and

SO42-，reaction equation as below:

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.

3.3 Dust Removal Principle and Original Equipment Modification

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

Remark；The production does not suitable for TFGD desulfurization,because

TFGD exists the risk of Blocked.

3.4 Technics Characteristic

a、 Advanced technology, complete set of equipment, set sulfur removal

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.

b、Low operating cost

The design using sodium as the circulation desulfurization agent and efficient

absorption tower,has low liquid gasrate, low circulation，and the desulfurization agent

and electric water consumption is low.

c、System stable operation

Using sodium as the circulation desulfurization agent in the circulation process is

without scale and blocking phenomenon to water pump, piping, equipment, and the

system can be stable operation.

d、High Desulfurization efficiency

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；

2) To use a set of composite desulfurization tower and a set of utility system

configuration;

3) In the premise of guarantee system reliability, rational distribution, and as far as

possible to use of the existing flue, reducing investment cost and floor space;

4) Saving energy and reducing consumption, under the precondition of meeting the

indicators and sulfur removal system to ensure the best absorption liquid gas ratio and other

control parameters, in order to decrease the desulfurization agent consumption, energy and

water consumption.

5) Not set up the bypass flue;

6) This system is fully considered the change of SO2(that is, the range change of

1500～2300mg/m3），and combined with the gas flow parameters 50～100％ to design.

4.1 Process design parameters (sulphur content 5-2%)

Content Unit

Data Remark

Inlet flue gas temperature C ≤350 Fan outlet temperature

Gas flow m3/h

80000-90000

Provided by the

manufacturer

SO2 concentration mg/ m3 2500-3600mg/m3

thionizer specification

(Diameter x height) m

3.5×14m

2.5X14m Twin

Towers

XGP-20

Composite efficient

desulfurization tower

Tower gas rising velocity m/s 2.5

liquid-gas ratio L/m3

4

Export so2 concentration mg/Nm3 ≤100～250

The amount of caustic soda

consumption kg/h 12-15

Export flue gas to carry water

content mg/m

3 ≤75

Desulfurization system

pressure drop Pa ＜900

Spray tower

desulfurization

resistance

System added water Kg/h 6

Absorption tower design

service life annual ＞15

Production staff person/ class observation every week

and clearing channel

System installed power kW 30

power consumption kWh 15 service power of the

system

desulfurization efficiency % ＞90

4.2 Process overview

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

system（thionizer、pool）、3 Desulfurization agent preparation system、4 Circulating water

tank system、5、other system.

4.3 Formulate

4.3.1 Flue gas system

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

fan and chimney to high emission

Desulfurization main equipment’s side is not setting bypass flue. Pipeline are all

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

According to the possibility of the worst operating conditions（e.g.：temperature,

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

arranged in low point。

Pipe external will fully reinforcement and support, in order to prevent the chatter and

vibration, and to meet stable operation in all sorts of flue gas temperature and pressure

(including stratification and uneven).

All the way of anti-corrosion protection should only use external reinforcement, do

not use internal stiffeners or support

Pipe external reinforcement uniform spacing arrangement.Use reinforced uniform

size or try to reduce the size of reinforcement。And add the beauty of outer appearance.

When arranging the reinforcement,we need to consider preventing water

All piping in the appropriate position is equipped with a sufficient number and size of

manhole door and soot cleaning hole, so that the pipeline (including expansion joint and

damper) can be maintenance and check and remove soot formation. The design of the pipeline

will minimize piping system pressure drop, and its layout,sharp and internal parts（Such as

turning guide plate）have optimization design.

4.3.2 Flue gas desulfurization dust removal system

1）、design consideration

See above：codes and standards

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℃

5、Gas flow：managing gas flow：80000-90000m3/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

2、Environmental protection standard is stricter than state specified standard.

3、All equipment are based on domestic processing production, important parts

(shower nozzle, effuser, etc.) are made of strong corrosion resistant material.

4、The dust removal system installation, operation does not affect the original

production facility structure and process.

5、The sulfur removal technology is advanced：taking the integration of sulfur

removal which was produced by our company:“A new efficient desulfurization

tower”.The project has been granted the national patent，PATENT NO：

ZL200920119623.5

System configuration is reasonable and complete，complying with the relevant state

safety norms.

Safe and reliable operation，convenient maintenance，low operating cost，the

reasonable and reliable connection，and can quickly input and switching.

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.

7、Steel structure joint parts adopt standard joint.

5）、Dust removal system design and limit of works area

1、Equipment pipeline door system design

2、Desulfurization dust removal equipment design：including pipeline（remark：

equipment connected air duct），a new efficient desulfurization tower，a mist eliminator，

and to rebuild original dust removal equipment.

3、The range of construction scheme is

for fuel boiler flue gas purification and removal sulfur project design, equipment

production, transportation, guide installation and debugging, training and comprehensive

work

4、The scheme does not include pool, supplement water and so on.

6）、Desulfurization system design and Equipment Selection

1、Desulfurization system process

According to our company’s experience, in order to achieve relatively satisfied result.

Below is the technological process:

Original dust removal equipment→draught fan→Efficient desulfurization dust

removal equipment dehydrator→chimney net gas emission

Determination of the pipeline system：According to the economic flow velocity

13～15m/s and through the pipe flow calculation，the diameter of the pipe system

isφ1500mm.

2、Desulfurization system design features

According to client's requirement，combining with our successful examples and

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

for flue gas desulfurization system：

2.1 Desulfurization system is running in a negative state，maximum manage So2 in

the production process,in order to ensure not affect furnace work.

2.2 Sulfur removal system design、equipment selection emphasize low resistance、

big flow theory，reducing operation cost，to ensure the normal work of the furnace.

2.3 de-dusting、desulfurization equipment filter material is temperature resistance

350，filter material prevention corrosion.

2.4 To ensure the normal operation of desulphurization system，achieving

environmental protection standard.

2.5 Desulfurization system is running low resistance,and equipment floor space is

little.

2.6 The main equipment selection

3. System air flow：Flue gas inlet temperature≤350℃ and local atmospheric pressure

conditions，desulfurization system pipeline chose no air leakage rate, airflow is

80000-90000 m3/h.

3、1 Desulfurization equipment choice

According to the original parameters and the characteristics of the furnace，and after

the management it should achieve all aspects of requirements of the environmental protection

departments，that,is, sulfur dioxide emissions and Ringelmann coefficient. According to the

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

specific equipment include new efficient desulfurization equipment（dehydration unit in the

back）.

3、2 Water Pump：here，we will take engineering plastics submerged pump

feedwater（strong corrosion resistance），with two sets.

7）、Desulfurization dust removal equipment principle of work

New composite efficient desulfurization equipment

Composite high efficiency low resistance desulfurization dust removal equipment is in

the original granite water film dust removal and monomer desulfurization tower and turbulent

ball tower, on the basis of three kinds of equipment to improve.It will be recombination with

these three simple equipment, so as to make up the big resistance defect for the granite water

film spiral wind and spray tower and turbulent ball tower.

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.

The characteristics of the equipment：reliable operation, no maintenance, easy to use,

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.

Remark：Pool diagram will be supplied by our company within10days after

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

on a case-by-case basis. The main cost is adding alkaline，that is desulfurization cost.

This fee should according to the factory actual situation.

9) Project Implementation Plan

Since the project contract effective date，including equipment design, manufacture,

installation, the plan period is 55 days.

5. Other system

Other system includes process water、accident slurry system、drainage、 fire

protection and so on.

5.1 Process water system

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.

5.2 Drainage、Fire extinguishing system

a. Drainage：Rainwater of desulfurization island area collected by drainage ditch,

gutter inlet, inspection well and then flow to our existing drainage system.

b. Fire protection：using chemical fire extinguisher method.

5.3 Electric System

All equipment of this system does not contain the electrical system.

5.4 Equipment heat preservation paint

①Heat preservation and paint

Heat preservation range ： Pipeline is no need for heat preservation,but for

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

service and after-sales service and measures：

（一） Equipment installation commissioning training：

1、 Our company will undertake 1 complete set of equipment installation and

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.

3、 The company is responsible for equipment operation personnel training,

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

4、 To master relevant equipment structure principle，the most basic operation

to attempt.

5、 First， company will have training technical operation and maintenance

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.

7、Installation and construction according to the relevant state of industry standards

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.

（二） Equipment in auxiliary for general acceptance

1. The whole system equipment in the installation is completed for debugging and

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.

（三）、After-sale service：

1、First of all， to ensure that the user’s supply of spare parts and to provide relevant

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.

4 、 The normal operation of equipment in every three months for technical

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:

Adroit Environment Consultants Ltd (AECL)

10/17, Iqbal Road, Mohammadpur, Dhaka-1207, Bangladesh Tel: 8126082, 8152113, Fax: 880-2-8155542

E-Mail: [email protected], Web: www.aecl-bd.org

November, 2013

mailto:[email protected]

http://www.aecl-bd.org/

Page 1 of 33

AECL/AEDM/DSPGL/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

Page 2 of 33


1. INTRODUCTION

Air Emission Dispersion modelling uses mathematical formulations to characterize the

atmospheric processes that disperse a pollutant emitted by a source. Based on emissions

and meteorological inputs, a dispersion model can be used to predict concentrations at

selected downwind receptor locations. These air quality models are used to determine

compliance with National and international Ambient Air Quality Standards.

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 2.1 About AERMOD View AERMOD View is a complete and powerful air dispersion modelling package that seamlessly incorporates the popular U.S. EPA models, AERMOD, ISCST3, and ISC-PRIME into one interface without any modifications to the model. These models are used extensively to as-sess pollution concentration and deposition from a wide variety of sources. 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.

Specify model objects such as sources, receptors and buildings graphically.

Automatically eliminate receptors within the facility property line.

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.

http://www.epa.gov/ttn/scram/metobsdata.htm

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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.

The dispersion modelling was conducted to appraise environmental impact assessment

(EIA) for the proposed HFO fired reciprocating engine power plant. In the study, the SO2 &

NO₂ emissions for the HFO fired engine discharged through stack was modelled to obtain

maximum possible concentration. This model was also tested in case of area source and

showed good correlation with the measured data under Bangladesh condition.

Information required for the model includes:

a) Pollutant emission rate

b) Stack exhaust exist temperature

c) Stack exhaust exist velocity flow

d) Stack diameter

e) Meteorological data

All the required information was obtained from manufacturer specification. Discharge

concentration was estimated at 500m increments from the plant up to 5 km radius.

2.2 Meteorological Condition

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.

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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.

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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.

Page 6 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.

Pollutants Average period Standard in µg/m3

BNAAQS*** WHO/IFC 2007* US EPA

NO2 1 hr 200** 188

Annual 100 40** 200

SO2 24 hr 365 20

Annual 80

PM10 24 hr 150 20

Annual 50 50

* IFC Environmental Health & Safety Guidelines 2007

** Ambient air quality standard for small combustion facility

***Bangladesh National Ambient Air Quality Standard

4.0 SOURCE PARAMETERS

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, SO2 & 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

5.0 BACKGROUND POLLUTANT LEVELS

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

Page 7 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.

Table 5.1: The average concentrations at different distances

SN Description Ambient Air Pollution Concentration in micro gram/cubic meter.

PM2.5 PM10 SPM SO2 NOX CO

Method of analysis Gravimetric Gravimetric Gravimetric West-Geake Jacob and

Hochheiser Indicator Tube

Test Duration (Hours) 24 24 24 24 24 24

Bangladesh (DoE) Standard for ambient Air 65 150 200 365 100 10000

WHO /World Bank Standard 25 50 NF 20 NF

1

Test result (Concentration present) in Project

West-North corner near boundary area.

(Date :03/11/2013) 27 67 143 12 21 170

2



(Date :04/11/2013) 31 77 159 14 26 180

3



(Date :05/11/2013) 25 65 147 17 23 190

Remarks

Pollution source from normal activities

Note: 1. Fine Particulate Matter (PM2.5). 2. Respirable Dust Content (PM10). 3. Suspended Particulate Matter (SPM).

4. Oxides of Nitrogen (NOX). 5. Sulphur Di-Oxide (SO2). 6. Carbone Mono-Oxide (CO).

The weather was sunny and the wind direction was from the north-west to south-east corner.

6.0 MODELING RESULTS 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 NO2 (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.

Page 8 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 SO2 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.

Page 9 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.

Page 10 of 33


Figure 6.1: Emission contour map showing the NOx concentration (24 hour average) at 5000m surrounding the project location

Page 11 of 33


Figure 6.2: Emission contour map showing the NOx concentration (Annual average) at 5000m surrounding the project location

Page 12 of 33


Figure 6.3: Emission contour map showing the SO2 concentration (24 hour average) at 5000m surrounding the project location

Page 13 of 33


Figure 6.4: Emission contour map showing the SO2 concentration (Annual average) at 5000m surrounding the project location

Page 14 of 33


Figure 6.5: Emission contour map showing the PM10 concentration (24 hour average) at 5000m surrounding the project location

Page 15 of 33


Figure 6.6: Emission contour map showing the PM10 concentration (Annual average) at 5000m surrounding the project location

Page 16 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

Page 17 of 33


Figure 6.7b: NO2 Emission concentration plots (24 hour average) at 5000m north to the project location

Page 18 of 33


Figure 6.7c: NO2 Emission concentration plots (24 hour average) at 5000m south to the project location

Page 19 of 33


Figure 6.7d: NO2 Emission concentration plots (24 hour average) at 5000m west to the project location

Page 20 of 33


Figure 6.8a: NO2 Emission concentration plots (Annual average) at 5000m east to the project location

Page 21 of 33


Figure 6.8b: NO2 Emission concentration plots (annual average) at 5000m north to the project location

Page 22 of 33


Figure 6.8c: NO2 Emission concentration plots (Annual average) at 5000m south to the project location

Page 23 of 33


Figure 6.8d: NO2 Emission concentration plots (Annual average) at 5000m west to the project location

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Figure 6.9a: SO2 Emission concentration plots (24 hour average) at 5000m east to the project location

Page 25 of 33


Figure 6.9b: SO2 Emission concentration plots (24 hour average) at 5000m north to the project location

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Figure 6.9c: SO2 Emission concentration plots (24 hour average) at 5000m south to the project location

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Figure 6.9d: SO2 Emission concentration plots (24 hour average) at 5000m west to the project location

Page 28 of 33


Figure 6.10a: SO2 Emission concentration plots (annual average) at 5000m east to the project location

Page 29 of 33


Figure 6.10b: SO2 Emission concentration plots (annual average) at 5000m north to the project location

Page 30 of 33


Figure 6.10c: SO2 Emission concentration plots (annual average) at 5000m south to the project location

Page 31 of 33


Figure 6.10d: SO2 Emission concentration plots (annual average) at 5000m west to the project location

Page 32 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.

Annexure - 11

Noise Modeling Report

Noise modeling of 55 MW Power Project of

Dhaka Southern Power Generations Ltd.

Page 1 of 6

AECL/NM/DSPGL/2013

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

Page 2 of 6

AECL/NM/DSPGL/2013

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 frequency range of sound audible to humans is approximately between 20 and 20,000 Hz. The amplitude range of sound for humans has a lower limit of 0dB, called the threshold of hearing. Sound is technically at its upper limit at 194.09 dB. Sounds begin to do damage to ears at 85 dB and sounds above approximately 130 dB. 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, LdB=10 log[10L1/10+ 10L2/10] In this way, decibels from two different sources can be added. CUSTIC Software will consider this method of calculation.

Page 3 of 6

AECL/NM/DSPGL/2013

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.

A. Engine room noise:

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:

Material Thickness,

mm

Approximated noise

absorption capacity, dBA

Styrofoam (Acrylic -Poly-

Methyl-Meta-

Acrylate (PMMA)

100 90

Brick with or without plaster 150 40

Total Equivalent noise 90

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.

B. External noise emission:

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.

3. Noise Modeling input Data: The following input data has been used for the modeling:

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AECL/NM/DSPGL/2013

A. Internal point source Equivalent Noise Power: 112 dBA (from 3 engines and turbines) Total External surface area: 1640 sq.m Noise insulation : 90 dBA Engine room noise: 107 dBA Turbine Noise : 90 dBA B. External point source Noise Power: 65 dBA (Single stack point) Total stack: 3 Numbers Stack height : 32m Terrain: Flat Terrain without sound attenuation Height of noise calculation: Surface height 4. Noise Modeling Noise Modeling Software: CUSTIC 3.2 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. 5. Noise Modeling Results A. Internal Noise Modelling result 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:

Radius, m 30 50 100 200 300 400

Output Sound power level in dBA

25.03 20.85 16.89 12.52 8.34 4.17

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AECL/NM/DSPGL/2013

Fig 1: Plot of output noise power level in dBA vs Radius in meter (Internal Engine room noise)

B. External Noise Modelling result 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:

Radius, m 30 50 100 200 300 400

Output Sound power level in dBA

27.70 23.09 18.48 13.86 9.24 4.62

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AECL/NM/DSPGL/2013

Fig 2: Plot of output noise power level in dB vs Radius in meter (external stack noise)

6. Resultant noise emission from External and Internal Sources 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:

Radius, m 30 50 100 200 300 400

Output Sound power level in dBA (Internal noise)

25.03 20.85 16.89 12.52 8.34 4.17

Output Sound power level in dBA (External noise)

27.70 23.09 18.48 13.86 9.24 4.62

Equivalent Noise emission (internal & external)

29.58 25.12 20.77 16.25 11.82 7.41

Annexure - 12

NOx & SO2 Calculation

Exhaust flow rate calculation:

Exhaust Flow rate: 127 Tons/hour at 573 OK The density of air at 300 OK is 1.3 kg/cu.m The density of air at 598 OK is 2.48 kg/cu.m (Using V1/T1 = V2/T2)

So, the Exhaust flow rate is 51209 m3/hr at 573 OK = 14.22 m3/sec

NOx emission rate calculation:

1. Nox emission concentration: 1480 mg/Nm3

2. Exhaust flow rate: 51209 m3/hr 3. Stack temperature: 300 0C = 300+273 = 573 OK

Using V1/T1 = V2/T2

Where V1 = 51209 m3/hr, T1 = 573 OK, V2 =? & T2 = 273 OK

Using the formula: V2 = 24398 Nm3/hr = 6.77 Nm3/sec

Now the NOx emission rate is 1480 x 6.77 = 10019.6 mg/sec = 10.01 gm/sec

SO2 emission rate calculation:

Fuel Consumption = 68800 tons/year

Sulphur content in the fuel = 3.4%

Total Sulphur content per year = 68800 x 3.4/100 = 2339 tons/year

Total SO2 emission rate per year = 4678 tons/year = 148 gm/sec Total SO2 emission rate per year through one stack = 148/3 = 49.33 gm/sec

Annexure - 13

Land lease Agreement

Annexure - 14

Ambient Noise Quality Test Report

Annexure - 15

Ambient Air Quality Test Report

Annexure - 16

Site Clearance Certificate

Annexure - 17

Electrical Interconnection for power

Evacuation

Annexure - 18

Elevation Survey Report of the Site

.the Existing Roadthesame tom

Annexure - 19

Fuel Transmission Line

Annexure - 20

General Arrangement of Pontoon

Annexure - 21

Contour Map of River & Road Site

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