Specification :

BPQL091012.001 REV0
Industrial and Marine Power Services Ltd Whisby Way North Hykeham Lincoln England0 LN6 3LQ
1250 kVA Gas-engined Generator with Heat Recovery
Machine spec. reference SGM 1250 Fuel Natural gas similar to British n.g. Engine Perkins 4016 E61 TRS Cylinder Arrangement V-16 T/ C and I/ C Machine running speed 1500 rpm Compression ratio 12: 1 Swept volume 61.1 litres Combustion air flow 80 cu.m / minute Engine flywheel power 1042 kW Engine efficiency 40.5% Fuel input 2574 kW ( 270 m3/ hour) Oil consumption ( after bedding) 0.25 g/ kWh Sump capacity 286 litres Electrical system 400 v / 3 ph / 50 Hz Alternator Leroy Somer Alternator efficiency 96.0% at 0.8 p.f. 95.6% at 0.8 p.f. Electrical output 1, 250 kVA at 0.8 p.f. Heat Recovery Engine exhaust 650 kW Engine jacket and lub. oil 548 kW Heat rejected from intercooler ( not recoverable) 93 kW Heat rejected from container 185 kW Secondary cooling water " on" temperature assumed 70oC Secondary circulating water flowrate 900 l/ minute Secondary cooling water outlet temperature produced 90oC Gas pressure assumed at 20 to 50 mbar Engine rating conditions Sea level 25oC 80% RH Alternator rating conditions Sea level 40oC Radiators rated to 35oC ambient temperature. Cooling systems utilise 50% glycol solution
2. Scope of Supply
2.1 General Specification
The unit offered is a combined heat and power module with all components incorporated into an ISO frame container.
Although there are space constraints within such a container, the ISO unit allows for convenient shipment.
The prime mover is a reciprocating engine fuelled by natural gas ( methane) and drives a synchronous alternator. The engine is started by lead acid battery and starter motor, electrical system 24v. Once the engine has fired, it runs up to synchronous speed under control of an electronic governor. When up to speed and stable, motorised circuit breaker closes to allow the machine to export power to local distribution. If the machine is to be paralleled with another machine, synchronising and load sharing input connections will be necessary.
Voltage is controlled by automatic voltage regulator.
Shutdown functions: -
Engine faults - Low oil level
- Low jacket water level
- Low oil pressure
- High jacket water temperature
- Intercooler faults
Generator overload
Overspeed
Low/ High gas pressure
Heat is collected from the engine’ s oil and the primary cooling water ( engine jacket) , being given up in water/ water heat exchangers to secondary circulating water. Additional heat is recovered from engine exhaust.
Intercooler heat is also collected, but is dumped in a local radiator.
Industrial grade engine exhaust silencer provided.
Engine is fitted with automatic oil make-up system and separate oil storage tank. An on-board pump is also fitted for oil draining.
2.2 Engine/ alternator
Prime movers, though specially developed for gas burning, have as their basis compression ignition engines. With spark plugs, electronic ignition system, modified pistons to give a lower compression ratio and thus freedom from detonation, the resulting engines are extremely tough units with block, heads and bottom end designed for the heavy loads of the CI type of engine and the top end modified to withstand the higher temperatures of an SI engine.
Engines are directly coupled via flexiplate coupling to single bearing, self excited alternators. Alternator rated at Class H temperature rise.
Engine/ alternator assembly is mounted to a substantial steel bedplate with anti-vibration mounts designed for 90% isolation.
2.3. Container
A 6 m ISO container will not be large enough to contain this machine so we intend to use a 12 m long, " one trip" container.
It will be split into three " rooms" . This is to minimise the amount of internal wall requiring sound insulation. The three rooms will be
1. Heat recovery and radiators. Access via the container' s hinged doors, plus a personnel door. Intake louvres for air separately provided.
2. Main engine and alternator room with doors to rooms at each end.
3. Control panel room with external personnel access door.
The engine room part will have a removable roof section to allow large components to be removed for major work.
Sound insulation consists of rockwool infill covered with pre-galvanised mild steel inner skin.
The acoustic media is inert, incombustible, non hygroscopic and vermin proof mineral wool with a superficial density of not less than 45 kg/ m3 and packed under a 10% compression to prevent settlement.
Cooling of the whole unit will use the air flow generated by the intercooler radiator fan. Air change rate is designed to remove the waste heat radiated by the engine / alternator unit. Air route from the heat recovery room via the main plantroom and thence to atmosphere.
2.4. Heat Recovery System
There are three sources of heat from the engine; intercooler cooling, exhaust heat recovery and the engine jacket and lubricating oil.
The engine fuel/ air mixture is cooled after the turbocharger by a two-stage cooling water circuit. The first stage is cooled by jacket water, but the second stage has its own circuit fitted with its own pump, thermostat and radiator matrix. Because the intercooler has to operate at a temperature close to ambient, it is not usually possible to recover this heat.
Exhaust gas heat recovery unit is a shell and tube unit. The exhaust discharge temperature is generally maintained above dew point to prevent condensation and to avoid an obvious plume, though in very cold ambients this is impossible to prevent.
Engine jacket water from the engine is pumped to the exhaust heat recovery unit prior to giving up the combined heat sources in the main heat exchanger.
Thermostats are fitted where necessary to ensure that overcooling does not occur.
Technical schedule gives typical heat recovery figures, with a tolerance of 7% . The different sources of heat can be separately recovered and used in independent circuits if necessary. If this option were of interest, extra cost may be implied.
Heat dump systems consist of electric fan cooled radiators. Control of the heat dump system is given from the panel logic controller using fan starters, temperature probe and 3 port valve.
Pipework is generally carried out using BS 1387 pipe for threaded pipe using BS21 threads up to 50 mm, for larger pipe, welded with fittings to BS 1965
2.5 Gas Train
The gas train is designed in accordance with British Regulations for gas supply. From an isolating ball valve, gas flows via a 50 micron filter to duplicated solenoid valves. From the valves, gas passes to a plc controlled pressure regulator which maintains a constant supply pressure into the gas/ air mixing system.
The solenoid valves fail closed and the majority of engine and electrical faults will close these valves.
The gas train is also fitted with high and low gas pressure switches.
2.6 Control Panel
The machine is controlled from its own panel based on proprietary plc based unit
( Deepsea electronics) . It is assumed as being started locally on the panel.
Machine configured for paralleling with other machines ( gas engined only) .
Paralleling through motorised CB.
MCBs for auxiliary circuits - engine cooling water pumps
- Intercooler water pump
- Radiator fan( s)
All instrumentation is provided on an LCD panel, which continuously reports on machine operational state and gives readout of any shutdown functions.
2.7 Demarcations
2.7.1 Secondary c.w.
Flanged terminations at container wall. Secondary circulating water pump not included.
Local isolating valves by others.
2.7.2 Gas
Termination at container wall. Gas to be maintained in the pressure range 100 to 200 mbar under all conditions of loading.
Site isolating valve by others
2.7.3 Electricity
Connection at 400 v / 3 ph / 50 Hz to MCB assumed by others. Gland plate supplied in floor of container.
Any connections for SCADA, call-to-run etc. by others.
Load sharing and synchronising connections provided at weatherproof socket at wall of container.
2.8. Options and summary of supply scope
Acoustic enclosure
ISO container Included
Stainless steel silencer
Bulk Lub. Oil tank and auto fill Included
Alternator rated to class F temperature rise
Alternator PMG excited
Alternator anti-condensation heater Included
Power factor regulator
Low engine water level switch Included
Low sump oil level protection switch Included
Engine jacket heater
Secondary Water Pump
Exhaust heat recovery Included
Heat Dump System Included
Gas Pressure Booster
Gas metering
Heat meter
Gas detection system
Remote monitoring
Tests Engine test at manufacturer’ s works ( unwitnessed) Included
Alternator test at manufacturer’ s works ( unwitnessed) Included
Panel functional tests ( works) Included
Site tests and commissioning
Delivery
Unloading and placing
Mechanical installation
Electrical installation
Non-included items can be included, at extra cost, on request.