173-Gas Substations Project Guide

QSV 81-91G
Gas Power Plant Project Guide
Foreword
This Power Plant Project Guide describes CHP power plants and gas fueled power plants built around our new generation of lean-burn gas engines. The project guide is intended for use in presale activities and also as support for final design of power plants from 1 to 20MW. Parts of this document, such as equipment description and auxiliaries data sheets may be reproduced and disclosed to clients. The content of this document is based on the most current information at the time of publication and is subject to change without notice.
Cummins Power Generation Manston Park Columbus Avenue Manston Ramsgate Kent CT12 5BF U.K. Telephone +44 (0) 1843 255 000
Technical data contained in this publication is not contractual and may change without prior notice. Issue 2.0 / March.2001 Page 1
QSV 81-91G
Contents Foreword 1. General 1 6
Introduction ....................................................... 6 Quality assurance .............................................. 6 World electricity supplies.................................. 7 Standards .......................................................... 10
Prime movers.................................................................. 10 Generators ...................................................................... 10 Electrical Equipment ..................................................... 10
2. Generating sets Gas engine
11 11
Reference conditions ...................................................... 11 De-rate factors ................................................................ 11 Engine components ........................................................ 11 Engine block ................................................................... 11 Cylinder head ................................................................. 11 Crankshaft ...................................................................... 12 Connecting rod ............................................................... 12 Main bearings and conrod big end bearing ................ 12 Cylinder liner ................................................................. 12 Piston ............................................................................... 12 Piston rings ..................................................................... 12 Camshaft and valve mechanism ................................... 12 Flywheel housing............................................................ 13 Free end cover ................................................................ 13 Oil sump .......................................................................... 13
3 Combustion 4 Gas Definition
14 16
QSV 81-91G design: open chamber ............................. 14 Exhaust Gas composition .............................................. 15 Combustion process ....................................................... 15 Heat value ....................................................................... 16 Gas density ..................................................................... 16 Methane number ............................................................ 16 Current Methane Numbers (MN) ................................ 16 Natural gas ..................................................................... 17 Gas quality requirements .............................................. 17
Technical data contained in this publication is not contractual and may change without prior notice. Page 2 Issue 2.0 / March.2001
QSV 81-91G
5 Engine Lubricant & Coolant Definition

Lube Oil Definition ........................................................ 18 Lube Oil Quality ............................................................ 18 Lube Oil Grade (weight) ............................................... 18
18
Coolant Treatment ........................................... 19

General ........................................................................... 19 Water or Coolant & Inhibitors Preparation................ 20 Antifreeze composition .................................................. 22
6 Boiler Water Treatment 7 Alternator
23 25
Boiler Operation ............................................................ 23 General ........................................................................... 25 Winding and Electrical Performance........................... 25 Generator design ............................................................ 25 Voltage regulator functions ........................................... 28
8 Genset Control Panel (GCP)
29
Gas engine control ......................................................... 29 Generator control........................................................... 29 GCP System Configuration ........................................... 30 PC Based H.M.I. (Touchscreen) ................................... 30 PowerCommand Supervisor ..................................... 31 AC Generator protection devices ................................. 32
9 Generator Load Acceptance 10 Generator Set Arrangement 11 Generator Set Handling 12 Turnkey Power Plant 11 Safety Equipment 13 Generator set foundations 14 Maintenance facilities 15 Electrical systems
33 34 36 38 38 39 39 40
Generator Set Connections ........................................... 35
Power Plant Buildings (General) .................................. 38 Fire, Smoke and Gas Leakage Detection. .................... 38 Electromagnetic Interference........................................ 39
Baseload applications .................................................... 41 Isolated System - Medium Voltage Generation ........... 42 Power distribution equipment ...................................... 43 Neutral Grounding System ........................................... 44
QSV 81-91G
16 Power Plant Control Features 45 17 Low voltage supplies 47 18 Power Plant Earthing System 48
Typical Earthing Arrangement..................................... 49
19 Mechanical systems
50
Starting system ............................................................... 51 Lubricating oil system ................................................... 52 Cooling systems (without heat recovery) ............................................. 53 Cooling systems (with heat recovery) .................................................. 53 Radiator system.............................................................. 54 Raw water system .......................................................... 55 Tower system .................................................................. 56
20 Charge air system 58 21 Exhaust gas system (without cogeneration system) 59 22 Ventilation and noise control 60
Sizing ............................................................................... 60 Noise control ................................................................... 60
23 Cogeneration systems 24 Partnership 25 Units,Formulae
61 62 63
Key drivers and competitive advantages ..................... 61 Basic knowledge ............................................................. 61 Engineering .................................................................... 62 Maintenance ................................................................... 62 Operation of the power plant........................................ 62 Power imperial measurements ...................................... 63 Energy measurements ................................................... 63 Refrigeration .................................................................. 63 Conversion factors ......................................................... 64 Area ................................................................................. 65 Volume ............................................................................ 65 Mass ................................................................................ 65 Force ................................................................................ 65 Pressure, stress ............................................................... 65 Temperature ................................................................... 66 Power .............................................................................. 66
QSV 81-91G
Energy ............................................................................. 66 Specific energy (mass) ................................................... 66 Specific energy (volume) ............................................... 67 Specific heat capacity (mass) ........................................ 67 Specific heat capacity (volume) .................................... 67 Water hardness .............................................................. 67 Miscellaneous ................................................................. 67 Formulae ......................................................................... 68
26 Mechanical data
69
QSV 81-91G gas regulating unit ................................... 69 Compressed Air Production Unit ................................. 70 Air Storage Unit ............................................................. 71
QSV 81-91G
1. General
Introduction
The Cummins QSV 81G-91G gas engines, built in the United Kingdom, are used as prime movers for gas fuelled power plants and are designed for powering: Cogeneration plants in sensitive environmental areas; Cogeneration plants for hospitals, office complexes and factories; Power plants for IPP (Independent Power Producers) and industrial parks. Power from Flare Gas Power from Waste Flammable Gases
Quality assurance
The quality of the products is ensured by a quality assurance program, as described in Quality Assurance Manual and Quality Instructions. These meet the requirements of the ISO 9001 International Quality Standard. All activities in the operations are evaluated and revised continuously through internal and external quality reviews. Cummins develops and maintains a world-wide, high quality service network which ensures optimum operation of delivered products under all circumstances by means of preventive and corrective service, spare parts supply, training of operating staff and technical support and information.
The Cummins turnkey solutions are designed for low capital investment with reduced lead-times, ideally suited to satisfying short and long term needs. When designing power plants, fundamental design information is important. Environmental conditions such as noise level, emissions and pollution will affect the design parameters and the elements and ground conditions may impact the overall scheme. This document is intended to give guidance in the proper application of the product. For more detailed assistance, contact the Cummins Power Generation at Manston England.
QSV 81-91G
World electricity supplies

Country
Abu Dhabi (United Arab Emirates) Afghanistan Algeria Angola Antigua Argentina Australia Austria Bahamas Bahrain Bangladesh Barbados Belgium Belize Benin (Dahomey) Bermuda Bolivia Botswana Brazil Brunei Bulgaria Burkina-Faso (Upper-Volta) Burma Burundi Cambodia (Khmer Republic) Cameroon Canada Canary Islands Cape Verde Islands Cayman Islands Central African Republic Chad Chile Christmas Islands Colombia Congo-democratic Republic of (Zaire) Congo-Republic of Costa Rica Cuba Cyprus Czechoslovakia Denmark Dominica (Windward Islands) Dominican Republic Dubai (United Arab Emirates) Ecuador Egypt (United Arab Republic) Eire (Republic of Ireland) El Salvador Ethiopia Faeroe Islands (Denmark) Falkland Islands (UK) Fiji Finland France French Guiana French Polynesia Gabon Gambia Germany (BRD) Germany (DDR)
Frequency (Hz) Supply Voltage Levels in Common Use (V)

50 50; 60 50 50 60 50 50 50 60 50; 60 50 50 50 60 50 60 50; 60 50 50; 60 50 50 50 50 50 50 60 50 50 60 50 50 50 60 50 50 60 60 50 50 50 50 60 50 60 50 50 60 50 50 50 50 50 50 50 60 50 50 50 50 11 kV;415/250 380/220; 220 10 kV; 5.5 kV; 380/220; 220/127 380/220; 220 400/230; 230 13.2 kV; 6.88 kV; 390/225; 339/220: 220 22 kV; 11 kV; 6.6 kV; 440/250; 415/240; 240 20 kV; 10 kV; 5 kV; 380/220; 220 415/240; 240/120; 208/120; 120 11 kV; 400/230; 380/220; 230; 220/110 11 kV; 400/230; 230 11 kV; 3.3 kV; 230/115; 200/115 15 kV; 6 kV; 380/220; 2201127, 220 440/220; 220/110 15 kV; 380/220; 220 4.16/2.4 kV; 240/120; 208/120 230/115; 400/230/220/110 380/220;220 13.8 kV; 11.2 kV; 380/220,220/127 415/230 20 kV; 15 kV; 380/220; 220 380/220; 220 11 kV; 6.6 kV; 400/230; 230 380/220; 208/120; 120 15 kV; 320/220; 220 12.5/7.2 kV;4,16 kV 600/347; 240/120; 208/120; 600; 480; 240 380/220; 230 380/220; 127/220 480/240; 480/227; 240/120; 208/120 380/220 380/220; 220 7.2 kV;380/220; 220 13.2 kV; 240/120; 120 380/220; 220 380/220; 220 240/120; 120 440/220; 220/110 11 kV; 415/240; 240 22 kV; 15 kV; 6 kV; 3 kV; 380/220; 220 30 kV; 10 kV; 380/220; 220 400/230 220/110; 110 6.6 kV; 330/220; 220 240/120; 208/120; 220/127; 220/110 11 kV; 6.6 kV; 380/220; 220 10 kV; 380/220; 220 14.4 kV; 2.4 kV; 240/120 380/220; 220 380/220 415/230; 230 11 kV; 415/240; 240 660/380; 500; 380/220; 220 20 kV; 15 kV; 400/230; 380/220; 380; 220; 380/220 220; 100 380/220 400/230; 230 20 kV;10.5 kV; 10 kV; 6 kV; 400/230; 380/220; 220 10 kV; 6 kV; 660/380; 380/220; 220/127; 220; 127

Country
Ghana Gibraltar Greece Greenland Grenada (Windward Islands) Guadeloupe Guam (Mariana Islands) Guatemala Guyana Haiti Honduras Hong Kong (and Kowloon) Hungary Iceland India Indonesia Iran Iraq Israel Italy Ivory Coast Jamaica Japan Jordan Kenya Korea Republic (South) Kuwait Laos Lebanon Lesotho Liberia Libyan Arab Republic Luxembourg Macao Malagassy Republic (Madagascar) Malawi Malaysia (West) Mali Malta Manila Martinique Mauritania Mauritius Mexico Monaco Montserrat Morocco Mozambique Muscat and Oman Naura Nepal Netherlands Netherlands Antilles New Caledonia New Zealand Nicaragua Niger Nigeria Norway 50 50 50 50 50 50; 60 60 60 50 60 60 50 50 50 50; 25 50 50 50 50 50 50 50 50; 60 50 50 60 50 50 50 50 60 50 50 50 50 50 50 50 50 60 50 50 60 50 60 50 50 50 50 50 50 50; 60 50 50 60 50 50 50
QSV 81-91G
440/250; 250 415/240 22 kV; 20 kV; 15 kV; 6.6 kV; 380/220 380/220 400/230; 230 20 kV; 380/220; 220 13.8 kV; 4 kV; 480/277; 480: 240/120; 207/120 13.8 kV; 240/120 220/110 380/220; 230/115; 230; 220; 115 220/110; 110 11 kV; 346/200; 200 20 kV; 10 kV; 380/220; 220 380/220; 220 22 kV; 11 kV; 440/250; 400/230; 460/230; 230 380/220; 2201127 20 kV; 11 kV; 400/231; 380/220; 220 11 kV; 380/220; 220 22 kV; 12.6 kV; 6.3 kV; 400/230; 230 20 kV; 15 kV; 10 kV; 380/220; 220/127; 220 380/220; 220 4/2.3 kV; 220/110 6.6 kV; 200/100; 22 kV; 6.6 kV; 210/105; 200/100; 100 380/220; 220 415/240; 240 200/100; 100 415/240; 240 380/220 380/220; 190/110; 220;110 380/220; 220 12.5/7.2 kV; 416/240; 240/120; 208/120 400/230; 220/127; 230;127 20 kV; 15 kV; 380/220; 220 380/220; 220/110 5 kV; 380/220; 220/127 400/230; 230 415/240; 240 380/220; 220/127; 220; 127 415/240 20 kV; 6.24 kV; 3.6 kV; 240/120 220/127; 127 400/230; 230 13.8 kV; 13.2 kV; 480/277; 220/127; 220/120 380/220; 220/127; 220; 127 400/230; 230 380/220; 220/127 380/220 415/240; 240 415/240 11 kV; 400/220; 220 10 kV; 3 kV; 380/220; 220 380/220; 230/115; 220/127; 208/120 220 11 kV; 415/240; 400/230; 440; 240; 230 13.2 kV; 7.6 kV; 240/120 380/220; 220 15 kV; 11 kV; 400/230; 380/220; 230; 220 20 kV; 10 kV; 5 kV; 380/220; 230
QSV 81-91G
Country
Pakistan Panama Papua New Guinea Paraguay Peru Philippines Poland Portugal Portuguese Guinea Puerto Rico Qatar Reunion Romania Rwanda Sabah Sarawak (East Malaysia) Saudi Arabia Senegal Seychelles Sierra Leone Singapore Somali Republic South Africa Spain Spanish Sahara Sri Lanka (Ceylon) St. Helena St. Kitts Nevis Anguilla St. Lucia Saint Vincent Sudan Surinam Swaziland Sweden Switzerland Syrian Arab Republic Taiwan (Republic of China) Tanzania (Union Republic of) Thailand Togo Tonga Trinidad and Tobago Tunisia Turkey Uganda United Kingdom Uruguay USA USSR (former republics of) Venezuela Vietnam (Republic of) Virgin Islands (UK) Virgin Islands (US) Western Samoa Yemen-Northern (Sana'a) Yemen-Southern (Aden) Yugoslavia Zambia Zimbabwe

50 60 50 50 60 60 50 50 50 60 50 50 50 50 50 50 60 50 50 50 50 50 50; 25 50 50 50 50 50 50 50 50 50; 60 50 50 50 50 60 50 50 50 50 60 50 50 50 50 50 60 50 60 50 60 60 50 50 50 50 50 50 400/230; 230 12 kV; 480/227; 240/120; 208/120 22 kV; 11 kV; 415/240; 240 440/220; 380/220; 220 10 kV; 6 kV; 225 13.8 kV; 4.16 kV; 2.4 kV; 220/110 15 kV; 6 kV; 380/220; 220 15 kV; 5 kV; 380/220; 220 380/220 8.32 kV; 4.16 kV; 480; 240/120 415/240; 240 110/220 20 kV; 10 kV; 6 kV; 380/220; 220 15 kV; 6.6 kV; 380/220; 220 415/240; 240 4151240; 240 13,8 kV; 380/220; 220/127; 127 220/127; 127 415/240 11 kV; 400/230; 230 22 kV; 6.6 kV; 400/230; 230 440/220; 220/110; 230: 220; 110 11 kV; 6.6 kV; 3.3 kV; 433/250; 400/230; 380/220; 500; 220 15 kV; 11 kV; 380/220; 220/127; 220; 127 380/220; 110; 127 11 kV; 400/230; 230 11 kV; 415/240 400/230; 230 11 kV; 415/240; 240 3.3 kV; 400/230; 230 415/240; 240 230/115; 220/127; 220/110; 127; 115 11 kV; 400/230; 230 20 kV; 10 kV; 6 kV; 380/220; 220 16 kV; 11 kV; 6 kV; 380/220; 220 380/220; 200/115; 220; 115 22.8 kV; 11.4 kV; 4.16 kV; 380/220; 220/110 11 kV; 400/230 380/220; 220 20 kV; 5.5 kV; 380/220; 220 11 kV; 6.6 kV; 415/240; 240; 210 12 kV; 400/230; 230/115 15 kV; 10 kV; 380/220; 220 15 kV; 6.3 kV; 380/220; 220 11 kV; 415/240; 240 22 kV; 11 kV; 6.6 kV; 3.3 kV; 400/230; 380/220; 240; 230; 220 15 kV; 6 kV; 220 480/277; 208/120; 240/120 380/230; 220/127 and higher voltages 13.8 kV; 12.47 kV; 4.8 kV; 4.16 kV; 2.4 kV; 240/120; 208/120 15 kV; 380/220; 208/120; 220; 120 208; 120 110/220 415/240 440/250; 250 400/230 10 kV; 6.6 kV; 380/220; 220 400/230; 230 11 kV; 390/225; 225
QSV 81-91G BS 162 1661 Electrical Power Switchgear and Associated Apparatus.
BS 2757 Insulation BS 5424 Part 1 1977 - Contractors.
Standards
Our equipment is designed and manufactured in accordance with the following International Standards Codes:
Prime movers
ISO 3046 (BS 5514 ) - Specification for reciprocating internal combustion engines, parts 1 to 6. ISO 8528 Reciprocating internal combustion engine driven alternating current generating sets, parts 1 to 10 EEC Directive 84/536/EEC - Noise from construction equipment - power generators. The engine and its auxiliaries are manufactured and/or controlled under a registered quality control system approved to ISO 9001.
Generators
IEC 34-1 Rotating electrical machines BS2615 The Electrical Performance of Rotating Electrical Machinery BS 4999(IEC 341) General requirements for rotating electrical machines. BS 5000(IEC 341)Rotating electrical machines of particular types or for particular applications. NEMA MG 1 Motors and generators EN 50081(BS EN 500812)Electromagnetic compatibility. Generic emission standard. EN 50082(BS EN 500822)Electromagnetic compatibility. Generic immunity standard. The generator and its control system are manufactured under a registered quality control system approved to ISO 9001.
Electrical Equipment
IEC 4391(BS EN 60439)(EN 604392) Specification for low-voltage switchgear and control gear assemblies. IEC 9471(BS EN 60947)(EN 609472) Specification for low voltage switchgear and control gear. IEC 3641(BS 7671) Requirements for electrical installations. IEE Wiring Regulations (sixteenth edition). EC 439(BS 5486) Factory Built assemblies of Low Voltage Switchgear and Control Gear. EC 479 Effects of Current Passing through the Human Body BS3950 Electrical Protective Systems for A.C Plant BS 159 1957 Busbars and Busbar Connections.
QSV 81-91G
2. Generating sets
Reference conditions
The output of the engines conforms to ISO 3046/1. Where ambient conditions exceed the reference conditions the engine will de-rate for temperature and altitude at the rates defined in the data sheets. COP refers to engine operating for baseload duty with a continuous 100% load. No overload is permitted. Prime duty refers to operation in island mode with a fluctuating load where the average load factor is 75%.
Gas engine
Engine components
The engines are four stroke high speed, spark ignited lean burn gas engines. Lean burn design increases performance and reduces emissions. All main auxiliaries and ducts are integrated, allowing easy maintenance by large inspection doors.
Engine block
The engine block is cast in one piece in modular cast iron. It has a stiff and durable design to absorb internal forces and to enable resilient mounting. The engine has an underslung crankshaft held in place by main bearing caps. The main bearing caps are nodular cast iron and are guided laterally by the engine block and axially by a locating pin. They are fixed by two hydraulically pretensioned studs and secured by lateral screws. The supercharge air duct is integrated between the cylinder banks disposed in a V angle of 60. The jacket cooling water supply to the cylinder heads and the return are integrated in the engine block. The lubricating oil supply to the bearings and the piston cooling occurs through a drilled channel in the middle of the engine block. There is one camshaft for each of the two cylinder banks bearing valve cams. The bearing housings are fully integrated into the engine block and located on the outside of the cylinders. There are large crankcase openings as well as openings for the camshafts on both sides of the engine block.
De-rate factors
The performance of gas engines is affected by the reduction in oxygen mass entering the cylinders at altitudes and higher temperatures. The output rating is set at 1000 metres and 35C respectively. Where the engine draws its aspiration air from inside a building or enclosure the effect of the rise in temperature due to the heat rejection from engine block, alternator carcass, exhaust and cooling pipework must be taken into consideration. The quality of the gas is another factor which will cause the engine output to be de-rated. The engines have different variants, with the same standard power output, which will operate on a methane index from 50 upwards. You should consult Cummins Power Generation at Manston England for guidance on operation on a gas with a methane index below 50. The low temperature cooling circuit is designed for a return temperature of 50C. It is permissible for this temperature to increase to 60C but the engine output will be de-rated. You should consult Cummins Power Generation at Manston England for guidance on the de-rate factor.
Cylinder head
The cylinder head is made of special cast iron. The thermally loaded flame plate is efficiently water cooled. The intermediate deck improves the cylinder head cooling as well as absorbing the mechanical loads on the cylinder head. The high and stiff design of the cylinder head allows it to be fixed by only four hydraulically tightened studs. The cylinder head features two inlet and two exhaust valves per cylinder. The exhaust valve seat is water cooled. The valves have stellite-coated seat faces and chromiumplated stems.
Gas Power Plant Project Guide Cylinder liner
QSV 81-91G
Crankshaft
The crankshaft is forged in one piece in a high tensile steel. All the crankshaft surface is nitrided. Journals and crankpins end on recessed fillets. The crankshaft fulfils all classification societies requirements. The two counterweights per crankthrow are each bolted on by three screws. They are positioned by locating pins which prevent any fretting corrosion. The main drive crankshaft pinion is shrunk on the flywheel end, to drive camshafts. Correct toothing allows operation without axial efforts on thrust bearings. The gear wheel for coolant, lubricating oil pump drive, and torsional vibration damper are bolted on to the free end.
The cylinder liner is made of centrifugally cast, cast iron, and surface finished by lapping. The jacket water is sealed by two O-rings in the lower part, and a metal to metal seal face under the mating flange. An anti-polishing ring is inserted at the top of the liner, allowing heavy duty operation with minimised wear.
Piston
Piston is made of a steel open combustion chamber and an aluminium skirt. The piston cooling is from oil nozzles fed by the main oil duct of the cylinder block. The piston ring grooves are hardened.
Connecting rod
The connecting rod is forged in one piece and the big end has a serrated split. The cap is hydraulically tightened by two studs. The connecting rod passes through the liner for maintenance. The cap is installed and tightened from the side where the cylinder is situated, opening one inspection door. The oil supply for the small end bush lubrication passes through a drilling in the connecting rod.
Main bearings and conrod big end bearing

The main bearing consists of two thin prefinished bearing shells. Both shells are peripherally slightly longer than the housing thus providing the shell fastening and seating. The main bearing located closest to the flywheel is provided with four thrust washers for the axial guidance of the crankshaft. The flywheel is bolted and secured by pins on the crankshaft end.
Piston rings
The piston ring set includes two chromium plated compression rings and one spring loaded oil scraper ring. All piston rings are situated in the steel crown.
Camshaft and valve mechanism

The camshafts are made up of sections, which are flanged together. The cam profiles and bearing surfaces are case hardened. The camshaft turns in bushings force-fitted into the engine block. The valve tappets are of piston and roller type and are located in the housing for the spark control devices.The camshaft drive is fully integrated into the engine block, at the flywheel end.
conrod
QSV 81-91G
Flywheel housing
The flywheel housing includes several functions. It supports the flange mounted generator as well as starter, barring devices, some governing accessories and ducts.
Free end cover

The torsional vibration damper is fully enclosed in the free end cover. All engine driven pumps are installed on the free end cover. There are, as standard, the twin cooling water pump and the pump unit including engine driven main lubricating oil pump and electric pre-lubricating pump.
Oil sump
Oil sump is bolted under cylinder block. Its capacity is intentionally increased in relation to engine power, allowing the oil charge intervals to be extended.
QSV 81-91G
3 Combustion
Combustion is a chemical reaction between fuel and oxygen. If the amount of air brought into the cylinder is perfect for complete combustion of the fuel, then the combustion is called stoichiometric i.e. complete. If an excessive amount of air is introduced, the combustion is called lean. Lean burn engines benefit from lower combustion temperatures and a consequent reduction in the formation of nitrogen oxides (NOx ) The characteristic of lean burn air-fuel ratio is called lambda l, defined from following formula:
l= (m air/ m gas) actual
(m air/ m gas) stoichiometric
QSV 81G-91G engines are spark ignited and operate with a lean-burn.
QSV 81-91G design: open chamber

The design comprises a simple open combustion chamber, housed in the piston crown. The flame plate of cylinder head is regular, the spark plug is centrally located. Air and gas is mixed prior to the turbocharger, using a governor controlled gas nozzle operating in a venturi. The fuel - air mixture is controlled at l = 1.7 QSV 81 G top section view
QSV 81-91G
Exhaust Gas composition

Exhaust gas composition will depend upon fuel gas composition and combustion fuel to air ratio. The table below depicts the exhaust gas composition for pure methane as the fuel gas controlled at l = 1.7
Combustion process
Any chemical reaction requires an energy source to initiate combustion. The spark plug performs this function. For engines operating on the pre-chamber principle the combustion process is enhanced by the pre-mixing of air and fuel thereby injecting a more concentrated mixture into the combustion chamber. This controls the speed of ignition and reduces the occurrences of knocking, also known as detonation. Knocking (detonation) occurs, either when the air/fuel blend comes into contact with the hot parts of the combustion chamber and self ignites or, as a result of ignition taking place at excessive speed. Combustion becomes noisy and harmful shocks are exerted on to the piston, rod and crankshaft. To prevent knocking, the combustion process must be controlled to keep within the optimum operating window. Charge air temperatures and volume, together with air to fuel ratio and compression ratio, are constantly monitored. The microprocessor based engine controller regulates the fuel flow and air/gas mixture and the ignition timing to prevent knocking.
Gas component Nitrogen Oxy gen W ater vapour Carbon dioxide M olecular weigh Density Spec ific heat cp Spec ific heat cp
Form ula
Content vol-%
N2 72.70% O2 8.10% H2O 13.70% CO2 5.50% kg/km ol 28 kg/Nm3 1.24 120-450 C 1.10 k J/(kg K) 25-120 C 1.05 k J/(kg K)
Diagram of combustion limits
QSV 81-91G
4 Gas Definition
Gaseous fuel is a mixture of combustible and inert gases which have different physical properties. Many of the fuel gas properties can be determined from those of the component gases. The table below gives some physical characteristics of gases contained in natural gas. Heat values are sometimes given in kWh/Nm3 or MJ/Nm3 or MJ/Sm3 (e.g. in Italy) or BTU/SCF (in the US). Note that standard (S) refers to an ambient temperature of 15 oC. (e.g. 1 Sm3=(273+15)/273 Nm3=1.055 Nm3)
Gas density
Gas Methane Ethane Propane Butane Pentane Hexane Heptane Octane Hydrogen Carbon dioxide Carbon monoxide Oxygen Nitrogen Hydrogen sulphide LHV Formula Mol weight 3 kg/kmol MJ/Nm CH4 C2H6 C3H8 C4H10 C5H12 C6H14 C7H16 C8H18 H2 CO 2 CO O2 N2 H2S 16,0 30,1 44,1 58,1 72,1 86,2 100 116 2,02 44,0 28,0 32,0 28,0 34,1 35,3 63,5 90,0 117 144 165 190 216 10,6 0 12,5 0 0 23,1 Density 3 kg/Nm 0,71 1,34 1,99 2,63 3,30 4,44 5,15 5,86 0,09 1,95 1,23 1,41 1,23 1,52
Fuel gas density is dependent on gas composition and varies from case to case. It is a function of temperature and decreases for increasing temperature. Usually, references to gas density assume normal conditions of 0C and 101.3 kPa unless otherwise specified. Gas density is expressed in kg/Nm3 (SI-unit).
Methane number
Methane number (MN), sometimes called methane index, can be assigned to any gaseous fuel indicating the percentage by volume of methane blend with hydrogen that exactly matches the knock intensity of the unknown gas mixture under specific operation conditions in a knock test engine. Therefore, the MN gives a scale for evaluation of the resistance to knocking of a gaseous fuel. The Methane number can be used to determine fuel gas suitability as an engine fuel. MN is an index and has no units.
N = normal, and is at an ambient temperature of 0C, at a pressure of 101.3 kPa gauge.
Heat value
The heat value of the fuel is a measure of its energy content. When dealing with the QSV engines, the lower heat value (LHV) is used when presenting fuel consumption and efficiencies. Normally, the value is given in MJ/Nm3 (SI-unit). Sometimes natural gas suppliers give sales unit price per energy unit at higher heat value (HHV). Use of the HHV gives a seemingly lower fuel price. As HHV includes the vaporization or latent heat of the generated vapour there is a relation between HHV and LHV: LHV/HHV=0.9 or HHV=LHV + water mass * vapourization enthalpy.
Current Methane Numbers (MN)

Most natural gases have methane numbers from 70 to 97. Incombustible gases like CO2 and N2 also increase the MN.
G as M e th a n e E th a n e P ro p a n e B u ta n e C a rb o n m o n o x id e H y d ro g e n
F o rm u la C H4 C2H6 C3H8 C 4 H 10 CO H2
M e th a n e N um ber 100 44 33 10 75 0
QSV 81-91G
Natural gas
The composition of natural gas varies greatly according to the production field. Gases having a composition as shown in the table below are called natural gas. Special attention must be given for lean burn gas engine use, if the applied natural gas composition deviates from these guidelines.
Generic composition of natural gas Gas quality requirements

To ensure the correct operation and output of the engine, the fuel gas has to meet the criteria given in table below. If the fuel gas does not meet the requirements, the engine must be derated according to the generating set data sheet. Please consult Cummins Power Generation at Manston England for advice on fuel gas compositions and application.
G as M e th a n e E th a n e P ro p a n e B u ta n e H y d ro g e n C a rb o n d io x id e O xygen N itro g e n O th e rs
F o rm u la CH4 C 2H 6 C 3H 8 C 4H 10 H2 CO2 O2 N2
C o n te n t v o l-% 7 5 -9 9 0 -5 0 -3 0 -2 0 0 -1 0 0 -0 .2 0 -1 5 0 -5
Gas Gas heat value(LHV) Gas density Methane number Methane content Ethane Hydrogen sulphide Max. gas temp.
unit/formula
4 MJ/Nm3
criteria 30-40 0,7-0,9 >70 >75% <10% <0.01% 50
kg/Nm MN CH C2H6 H2S C
Indicative analysis of main natural gases Warning! these values are indicative only, please do not use for contractual documents!
Gas
Algeria - Arzew
CH4 %
vol
C2H6
% vol
C3H8
% vol
C4H10
% vol
C5H12
% vol
C6H14
% vol
CO2 % N2 %
vol vol
LHV
(MJ/Nm3)
Density
(kg/Nm3)
Methane Index
Algeria - Skikda Brazil Recife Brazil Rio de Janerro Denmark France Algeria France Ekofisk France Groninigue France Lacq France Russia Germany Korea- Hung Kuk Netherlands North Sea North Sea Troll Norway Ekofisk Norway North Sea Russia Thailand USA Tex Venezula
88.6 90.9 80.4 86.8 91.2 89.3 85.3 81.3 97.3 93 74.7 89.4 81.3 88.2 85.1 86 94.4 98 80.3 80.9 82.7
8.2 7.2 14.3 9.8 4.8 6.2 8.4 2.9 2.1 3 0.1 7.8 2.9 5.4 9.6 7.7 3.1 0.6 9.7 6.8 8.9
2 0.9 0.9 2.1 1.7 0.6 2.9 0.4 0.2 0.8 0 2.1 0.4 1.2 3 2.9 0.5 0.2 1.8 2.7 0.9
0.6 0.1 0 0.2 1.1 0.1 0.9 0.2 0.1 0.3 0 0.7 0.1 0.4 0.6 0.8 0.2 0.1 0.7 1.1 0.3
0 0 0 0.01 0 0 0.2 0 0 0.1 0 0.02 0.1 0.2 0.1 0.3 0.2 0 0.2 0.5 0.1
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.09
0 0 2.9 0.36 0.7 0 1.8 1 0 0.3 18 0 0.9 1.4 0.3 1.6 1.1 0.1 6.1 0.1 6.9
0.6 0.9 1.5 0.63 0.5 3.8 0.5 14.2 0.3 2.5 7.2 0 14.3 3.2 1.3 0.7 0.5 1 1.2 7.9 0.1
39.7 38.3 38.9 39.8 38.8 36.8 40.2 31.9 36.6 36.6 27.8 40.0 31.7 37.1 40.4 40.0 36.9 35.9 37.9 38.1 36.9
0.81 0.78 0.86 0.82 0.8 0.79 0.86 0.84 0.74 0.77 1.00 0.81 0.83 0.81 0.84 0.85 0.77 0.73 0.90 0.87 0.88
73.1 79.6 75 73.8 74.9 82.2 70.5 89.0 90.6 84.3 105.9 72.6 90.8 79.4 69.9 70.8 85.8 94.4 76.0 69.2 81.5
QSV 81-91G
5 Engine Lubricant & Coolant Definition

Lube Oil Definition
High-quality lubricants shall be used for the lubrication of QSV 81G-91G engines. Products from well-known companies who can assure a consistent supply of quality oils, and who can also provide oil analysis from engines in operation, are preferred. The selected oil must have enough heat resistance not to form ash deposits at the temperature to which it is exposed. It must also maintain a satisfactory oil film between the moving components.
Brand name & characteristics
Producer
For continuous duty
grade
TBN
sulphated
ash%
Lube Oil Quality

The gas engine lube oils are specially formulated. Never use a diesel engine lubricant in a gas engine as it could cause damage to the engine. The gas engine oil contains adequate additives to prevent the lubricant base being degraded by high temperatures and water vapour. Oils listed below are defined as suitable for use in Cummins natural gas lean burn engines. TBN of regular gas engines lubricants is near 5. It is sufficient to prevent bearing corrosion against most natural gases whose H2S content is below 0.01% in volume. Above this, gas treatment or special lube oil formulation is recommended. A TBN over 6 may cause piston fire ring blocking due to excessive calcium deposits in the grooves. For the same reasons, sulphated ash content of oil should be lower than 0.5%.
Engines operated with natural gas, H2S content< 0.01 vol. MOBIL MOBIL ELF SHELL ESSO
( EXXON)
Pegasus 805 Pegasus 705 Nateria MH 40 Mysella LA Estor SHPC
SAE 40 SAE 40 SAE 40 SAE 40 SAE 40
6.2 5.3 5.2 5.0 5.1
0.50 0.46 0.45 0.45 0.48
Lube Oil Grade (weight)

A monograde SAE 40 is required, as a minimum weight. This is necessary to ensure oil film resistance under high temperature operation.
Other Lubricants From time to time, other oils will be approved and added to the list, where a specific oil is specified, contact Cummins Power Generation at Manston England.
QSV 81-91G
Coolant Treatment
General
CHP systems comprise various water loops whose operating conditions are different. To safeguard the engine longevity it is better to separate the engine water system from the other water loops, This allows close control of the engine cooling water condition. The steam boiler water treatment is peculiar to the boiler, and should never be circulated in the engine. The purposes of water treatment are to prevent: - Furring of heat exchange surfaces due to the mineral content of the water, - Corrosion of metals due to dissolved oxygen and carbon dioxide, - Cavitation due to boiling point, and/or pump impeller pressure drop, - Freezing if coolant & engine is exposed to frost. We have defined for our CHP plants, a number of categories of water treatment processes, from existing commercially available products. Two criteria are preeminent to determine the category of treatment: - the nature of the materials inside the circuit. - the highest water circuit wall/surface temperature. Categories are as follows: A for anticorrosion products, without antifreeze addition B for anticorrosion products with antifreeze addition C for steam boiler feedwater products In these categories, two grades are proposed : - Grade 1 for upgrade products used in severe conditions in primary circuits; - Grade 2 or 3 for regular products used in secondary circuits. Primary circuits are the ones in contact with engine internal parts, and the exhaust heat exchangers. Secondary circuits are the heat transfer circuits, not in contact with fired parts. Tables in Cogeneration Chapter indicate the recommended product category and grade for each loop of the CHP plant. Upgrade Corrosion Inhibitors (Category A Grade/-A1) Engine circuits are to be treated only with recommended chemical (s), suitable for engine conditions, aluminium protection and passage through exhaust heat exchangers (high wall temperature). Regular Corrosion Inhibitors (A2) Other circuits which are made of various metals, aluminium excepted, may be treated with regular products of A2 category, if they are not passing through exhaust heat exchangers, whose wall temperature is high. We recommend stainless steel plate heat exchangers for engine HT water and lube oil interface. They can be used in contact with regular products. Products which form a protective layer are suitable, provided that this layer may be cleaned or dissolved if it tends to reduce the performance of exchangers. Soluble oils are not recommended. The Floating anode (Nitrite- chromates) product demands a precise understanding of metals in the circuit and a frequent check of concentration. They are either toxic or unstable and forbidden for use in certain countries. We do not recommend their use. Heating Circuit Corrosion Inhibitors (A3 category) The circuits entirely made of carbon steel, bronze and passivated copper may be treated with A3 category products. Trisodic phosphate, morpholine or any other chemical formulated to maintain the PH value over 8,5

are suitable. This treatment is not suitable where other metals are present in the engines, or when fluid speed is over 1m/s. Upgraded Inhibitor & Antifreeze Coolant for CHP (Category B Grade/-B1) The B1 category coolant is the recommended product for engine protection and use in exhaust heat exchangers whose wall temperature is elevated. It is efficient where aluminium is present. Use of a regular automotive coolant may cause floculation, deposits, glycol decomposition or exchanger deterioration. The proposed ELF Coolelf CHP supra is particulaly suitable for the CHP plants in hot countries. However, 20% Monoethylene glycol is included, not for freezing, but to dissolve and stabilize the anticorrosion organic complex. Engine Inhibitor & Antifreeze Coolant (B2) The B2 category coolant is the recommended product for engine protection but not for use in exhaust heat exchangers, whose wall temperature is elevated. It is efficient where aluminium is present. Regular Inhibitor Antifreeze Coolant (B3 category) The B3 coolant is suitable for hot water loops which are not passing through the engine and/or exhaust exchanger and are not in contact with aluminium parts.
QSV 81-91G
- Chlorides contents < 60 mg/liter of NaCl. - Sulphates contents < 40 mg / liter of SO4Ca Above these figures, use softened or demineralized water, or ready-to use soloutions. Basically we recommend the use of demineralized water for dilution, or ready to use products.
Coolant Preparation For antifreeze based coolant preparation a maintenance tank, where water and treatment chemicals are mixed together is proposed. A pump and piping system to connect pump, tank, and circuits together for filling, dilution and maintenance can then be designed and installed. The tank should be sized to hold the circuit contents.
Rules of Thumb: - Use of distillated water or rain-water without treatment is strictly forbidden, even for short duration tests. - Life-time of antifreezed coolant of grade 1 is about 3 years in air-tight circuits. - An analysis of coolant quality is recommended every three months, whatever its nature. Quick-check sets are available from the chemical suppliers. -If the cogeneration loop is part of an existing system, it is advisable to check its cleanliness to prevent central heat exchanger fouling. -If new chemical products are installed in existing systems, it is advisable to flush and thoroughly clean the systems, to remove all traces of the old chemicals.. -Chosen product shall not be toxic if it is to be used in heat exchangers through which drinkable water is passing. Point of Warning LT water and HT water in the engine circuit shall be protected using the same chemical, as these circuits are in mixed inside the engine if the doulble impellor, engine driven pumps are fitted.
Water or Coolant & Inhibitors Preparation

If concentrated products are used, you have to use good quality water for coolant preparation or . The minimum quality requirements for anti-corrosion product efficiency are : - Water totally clean and limpid. - Total Hardness < 5.6 dH(1) (100 ppm as CaCo3). - Acidity 6.5 < pH < 7.5.
(1)
A total hardness up to 250 ppm as CaCO3 may be toleratedin the circuit,
but to top-up with this kind of water, to compensate for evaporation in service would cause deposits or saturate the furring inhibitors.
QSV 81-91G
Coolant Treatment Definition The table below defines the kinds of coolants to be used for safe operation. The ones defined for circulation in engine and exhaust exchanger shall be mandatorily used during warranty period. If other coolants should be used, a testing procedure shall be implemented, followed by corrosion checks, and chemical analysis.

Use of table below: Product indicated for grade 1 is suitable for use in all situations. Choice of different grades in a system would cause unschedulded coolant changes in loops, due to aging of lower grade coolants. Choose only tested products, to prevent equipment degradation, loss of time and money.
Product category working conditions

HIGH-GRADE INHIBITOR
Recommended brands Producer ROHM & HAAS Tradename Type of product
substite products
A1
REGULAR INHIBITOR
Engine circuits with copper , brass, soldering, aluminium, AND contact with very hot parts in exhaust exchanger. Hot water circuits WITHOUT contact with very hot parts in exhaust exchanger, WITHOUT contact with engine parts
RD 25
Anticorrosion, film Needs to be tested in generator, without antifreeze, accordancewith Cummins to be diluted @ 6-8% agreed procedures.
A2
HEATING CIRCUITS INHIBITOR
Others
Anticorrosion for circuits without aluminium, suitable for hot water in closed heating circuits.
A3
CHP
Hot water circuits entirely steel & bronze made, WITH contact with very hot Others parts in exhaust exchanger, WITHOUT contact with solders, aluminium and copper alloys Coolelf CHP supra Engine circuits with copper , brass, tin solder, aluminium, AND contact with very hot parts in exhaust exchanger. ELF Coolef supra; supra GF Glacelf supra
Anticorrosion , trisodic phosphate or morpholin, nitrites, borates, benzoates, or chromates based ,or floating anode principle, suitable for hot water in steel circuits. PH from 8.5 to 9.5
protection minus 7C, for hot countries protection minus 25C; minus 35C, ready to use to be diluted with demineralized water, protection down to minus 50C to be diluted with demineralized water, protection minus 35C protection minus 35C, ready to use protection minus 20C, ready to use protection minus 25C, ready to use
HIGH-GRADE COOLANT ANTIFREEZE
As above
B1
Diagel-6N
ENGINE COOLANT ANTIFREEZE
B2
Engine circuits with copper , brass, tin solder, aluminium, WITHOUT contact with very hot parts in exhaust exchanger.
ROHM & HAAS
Diamigel-6N Triagel-6N
As above
SHELL
REGULAR COOLANT ANTIFREEZE
Glycol Shell type D
B3
Hot water circuits WITHOUT contact with very hot parts in exhaust exchanger, WITHOUT contact with engine parts
Others
Automotive or industrial glycol based coolant. Should conform to ASTM D 3306, SAE J 1034, BS 6580, BS 5117, or NFR 15-601
QSV 81-91G
Key considerations for determining the suitability of other products The grade 2 and 3 products may be available locally. Generally, engine antifreeze solutions are formulated with anticorrosion, anti-cavitation and anti-furring additives.
Nitrites-borates based inhibitors (not recommended) Nitrite-borate, nitrite-sodium, nitrite-benzoate based corrosion inhibitors are the older formulas on the market. Efficiency is poor on aluminium and tin solderings, but good on other materials. They are unstable and necessitate frequent checks, concentration adjustments and total renewal. They have a reduced toxicity and are partially biodegradable. This is an advantage and a disadvantage: anaerobic bacteria may develop in closed circuits and form concentrations of ammonia. Copper alloys and aluminium are degraded, even if pH is under 9 (Over pH 9, copper degradation is greater and more rapid). Also, stress corrosion is possible on expanded tubes, and copper, bronze, or brass tubesheets. These products are generally used in automotive applications. If a nitrite based product is used for long time, it is necessary to clean the cooling circuit with approved and non-corrosive biocide. Rinsing of circuit and coolant preparation shall be performed using demineralized or bacteria-free water. Chromates (use forbidden : toxic) Chromate based products are very efficient but are highly toxic and, currently, their use is forbidden in Europe and U.S. Silicates : (forbidden in engine) Never use silicate based inhibitors in engine circuits : coolant velocity is too high (corrosion appears when velocity is over 2 m/s). Particular recommendations for ecology Water treatments are chemicals which may cause pollutions, or may contain non-degradable substances, such as glycol based formulas. Coolants containing antifreeze should be disposed of in a controlled manner. Operatives should wear the correct protective equipment when handling, even if product is not toxic.
Antifreeze composition
Monoethylene-Glycol antifreeze (MEG) is suitable for countries where lower temperatures are minus 35C; For arctic conditions, monopropylene-glycol (MPG) use is necessary to obtain protection down to minus 47C. (Consult the factory for these particular conditions). Never use Methyl Alcohol-based, nor Methoxy propanolbased antifreeze in coolant circuits. These products will damage hoses, synthetic rubbers and fluoroelastomer seals. Never mix different antifreezes in the same water circuit, since a concentration check is not possible by specific weight measurement. Never use automotive prepared coolants in engines, since they are made of poor quality antifreezes, recycled from industrial processes and containe impurities, various metals and toxics. They decompose in elevated temperatures, and corrosion evaluation by spectrography is affected by metal content. Organic polymers based inhibitors (suitable) This new generation of protection products are made of protective film generators, based on an organic chemical. They are biodegradable and environmentally friendly. They are active in the presence of aluminium and high wall temperatures. They are free of amines, phosphates, nitrite and borates. The B1 category product uses this kind of advanced product. Molybdates - phosphates based inhibitors (suitable) These products are suitable for engines circuits because they offer a good protection for multiple metals, including aluminium . Generally, they also contain an organic polymer which forms a protective layer on surfaces. They may not be suitable for use in exhaust heat exchangers becauses phosphates may precipitate when in contact with high temperature walls, and their use for this purpose should only be approved after satisfactory testing.
QSV 81-91G
6 Boiler Water Treatment

normally referred to as make up. Evaporation of water in boilers leads to the formation of scale and corrosion. The scale forms an insulating layer which reduces the heat transfer rate, so reducing efficiency. Also more importantly the scale raises the metal temperature, reducing its strength, which may lead to distortion and failure. Water can become acidic due to the presence of dissolved gases such as oxygen and carbon dioxide, or dissolved metallic salts such as magnesium chloride, and water in an acidic condition provides the electrolyte for corrosion to take place. Steam boiler water treatment is specially adapted for boilers, using strong bases which increase the pH to 10-12 to prevent the corrosion which occurs in acid middle. This treated water is not suitable for engine cooling and should never be used in engine water circuits. Properties of water Some properties of water are :pH is the acidity index of water. 7 is neutral, 2 is very acid, 12 is very alkaline. Alkaline Hardness - (temporary hardness) - due to bi-carbonates of calcium and magnesium which breakdown to form carbon dioxide and carbonates which deposit as soft scale and sludge. Non Alkaline Hardness (permanent hardness) - due to sulphates and chlorides of calcium and magnesium. Total Dissolved solids - all the substances, harmful or otherwise dissolved in the water. Steam boiler water shall be treated to prevent: - scale and sludge formation, - corrosion of metals, - priming ( water particles swept along by steam flow) Boiler Water Treatment Due to the wide range of water compositions the following information is given as an indication only. Each system will need a specific treatment regime which will ensure correct operation of the plant. Steam boiler water composition Some indications of steam boiler water composition are depicted in the table below. Generally, feed water is first demineralized, then treated with an additive, to raise the pH. Then an oxygen scavenger is added as the water enters the boiler.
Characteristics of water in acceptance the fire tubes boiler criteria between indicated limits minimum
boiler operating pressure up to 15 bar from 16 to 30 bar 11 to 11.7
PH @ 25C
11 to 12
ALK infrench degrees (ppm as Ca CO) 3
25 f (250 ppm) 140f (1400 ppm) 50 to 80 mg/l 200 mg/l 1.5
25 f (250 ppm) 120f (1200 ppm) 100mg/l 150 mg/l 1.5
maximum NA3 PO4 content SiO2 content in ppm ratio SiO mg/l on ALK F 2 NaOH free Total dissolved salts amount minimum maximum maximum maxi maxi
Boiler Operation
A power steam boiler is a steam generator. Steam passes from the boiler into the circuit, and returns at low pressure, or condensed. Some processes do not return condensate to the boiler, so losses occur. In this case the steam boiler water circuit needs to be replenished with new water,
just for PH adjustment, if any 8g/l
QSV 81-91G
High-grade integral treatment (C1 category) Treatment manufacturers propose liquid concentrate for water treatment which can be injected into the feed water by means of a dosing pump. In addition, the introduction of dispersants and protective film additives ensures cleanliness of internal surface and prevents blockage. They can be used with partially demineralized water or drinking water with a total hardness lower than 5f (50ppm as Ca CO3).
alkalinity, antioxygen content, and losses due to blowdown. This kind of treatment is more complicated, and needs operator know-how. It is mainly applied to steam processes without condensate return. Basic treatment of boiler water is made through the addition of trisodic phosphate (Na3PO4) to increase pH of boiler and precipitate calcium, and catalysated soda sulphite (Na2 SO3 7 H2O) to remove dissolved oxygen. We do not recommend the use of Hydrazine N2 H4 as an antioxygent as it is toxic. If more economical powdered products are to be used, it is necessary to install a mixing tank for powder mixing and a means of weighing for dosage.
Traditional treatment (C2 category)

This treatment is made from basic chemicals which are mixed in various proportions to reach equilibrium between
Product category
working conditions
Recommended brands Producer ROHM & HAAS Tradename Type of product

Anticorrosion, antioxygen, anti carbon dioxide, passivant film generator, to be diluted @1.5 per thousand sulfite, phosphates, dispersent, alkanilizent + anti-CO2 Trisodic phosphate (alcalinizent anti-furring), sodium sulfite (antioxygen) and specific amine (antiCO2)
substitution products
BOILER INTEGRAL
C1
BOILER
TRADITIONAL
Boiler with carbon steel, inox, copper , bronze, and feeding water circuits
B 108
Erpacalor DEGREMONT 339 + Erpamine 5
Needs to be agreed by boiler manufacturer if stainless steel is used in structural parts.
C2
Boiler with carbon steel, inox,copper , bronze, and feeding water circuits
CHEMICALS DEALER
C riteria for w ater an alysis and usual abbreviations

FR EN C H N AM E Potentiel en hydrogne D uret totale ( titre hydrotim trique) D uret tem poraire D uret perm anente Titre alcalim trique Titre alcalim trique com plet AB. PH TH _ P TA TAC EN G LISH N AM E acidity Total hardness Tem porary hardness Perm anent H ardness C austic alkalinity Total alkalinity AB. PH TH _ _ C .A. ALK G esam thrte Karbonathrte N ichtkarbonathrte p-W ert Alkalitt ( m - w ert) G ER M AN N AM E AB. PH G .H . K.H . N .H .K. p m
QSV 81-91G
7 Alternator
General
The alternator is an air-cooled synchronous machine, with a brushless excitation system, and can be supplied in a range of output voltages. For voltages that are not in the standard range, transformers etc are available. Construction form is IM 2001, i.e., built with two feet and one flange for fixing on engine end. Shaft end is cylindrical and keyed. For the QSV 81-91G generator sets we use 4 pole for 50 Hz 1500 rpm and 60 Hz 1800 rpm and 6 poles for 60 Hz 1200 rpm.
Waveform Distortion
Total harmonic distortion (THD) of the open circuit voltage waveform is in the order of 1.5%. Under 3 phase balanced, linear, load conditions the THD is in the order of 3.5%.
Generator design
Enclosure IP23 (NEMA1) is standard for all industrial alternators. The frame is made of welded steel, optimizing strength and power to weight ratio. Stator laminations are made of high quality Silicon electrical steel. Salient poles rotor is designed to withstand 150% of rated overspeed. Two bearing constructions (IM 20001) are available with SAE 00 adaptors. Alternators incorporate long life regreasable bearings. The cooling fan is cast aluminium. End brackets are made of welded plates with cast iron bearing housings, seals, and exciter stator support parts. On the drive end a cast voluted housing is used. Terminal Boxes Instrument and control connections are in segregated compartments, with external access for safety. Vibration Limits All alternator rotors are dynamically balanced to better than BS6861: Part 1 Grade 2.5 for minimum vibration in operation. Two bearing alternators are balanced with a half key.
Salient pole PMG alternator Winding and Electrical Performance

The stator winding in conjunction with carefully selected pole and tooth designs ensures optimum performance and low waveform distortion. A fully interconnected damper winding stabilises the rotor during load changes. Generators will sustain a maximum short circuit of around 250% (50Hz), 300% (60Hz), rated current under a three phase LL-L short circuit condition. The AVR will support this condition for eight seconds, at which point the AVR protection system will de-excite the machine. Current levels under 2 Phase L-L or 1 Phase L-N short circuit conditions are much higher than the above L-L-L levels, and must be removed from the generator by breakers within typically 5 seconds and 2 seconds respectively. The actual values are indicated in the generator data sheet. Radio Interference The absence of brushgear and the high quality AVR ensure low levels of interference with radio transmissions. Additional RFI suppression may be supplied if required. Telephone Interference THF (as defined by B54999 Part 40) is better than 2%. TIF (as defined by ASA C50.12) is better than 50.
QSV 81-91G
Insulation/Impregnation of windings Standard insulation classes for the alternators are class H for low voltage (400 - 480V), and F for medium & high voltage (4160 - 13800 V) .Please refer to data sheet for actual specifications. All wound components are impregnated with materials and processes designed specifically to provide protection against the harsh environments encountered in generator applications. Resins are selected and developed to provide the high build required for static windings and the high mechanical strength required for rotating components. A Hybrid System using the best features of Global VPI, and Resin Rich Technology is used, optimising insulation life in the slot section, with the advantages of VPI epoxy in the outhangs for strength, electrical properties and optimum protection. 5kV machines and above, have Corona Protection tapes applied. PMG excitation A Permanent Magnet Generator (PMG) excitation system is a standard feature designed to enhance reliability, response and stability. The PMG provides power via the AVR to the main exciter, giving a source of constant excitation power independent of generator output. The exciter output is then fed to the main rotor through a full wave bridge rectifier, protected by a surge suppressor. The AVR has in-built protection against sustained over-excitation caused by internal or external faults. This de-excites the alternator after a preset period. Over voltage protection is built-in and short circuit current level adjustment is an optional facility. Voltage Regulator (built-in version) The 3 phase RMS voltage sensing AVR provides very accurate vc!tage regulation, from no load to full load in-
cluding cold to hot variations for any power factor between 0.8 lagging and unity allowing for 4% engine speed variations. It is particularly suitable for non linear load applications. Three Phase Sensing Three phase sensing centres any voltage imbalance caused by load imbalance around the nominal voltage and helps to ensure trouble-free operation under the most demanding loads. Parallel Operation All alternators are well-suited for parallel operation (optional droop kit fitted) with the mains utility or with other generators. A fully interconnected damper winding reduces oscillations around the synchronisation point during paralleling. Advanced regulation features PMG alternators may be operated directly with the PowerCommand system which includes its own voltage regulator. See enclosed PowerCommand description for more information.
QSV 81-91G
Waveform Low voltage alternators for stationary applications, have a 2/3 pitch winding as standard, designed in order that the voltage waveform between phase and neutral at no load has no third harmonics. Radio Interference Radio interference (RFI) is guaranteed to be within the limits defined in the international standard CISPR. Overload Capacity The stator winding withstands high overloads for short durations, e.g. the continuous shortcircuit current can be over 3 times the rated current for approx. 10 seconds. The stator winding supports also withstand the stresses caused by the maximum asymmetrical short-circuit current. Unbalanced Load The AC generators can operate on an asymmetric network provided that none of the phase currents exceed the rated current with an unbalanced current of 30 %. Stator The frames are made of welded steel and are heavily ribbed to prevent deformations. The upper part supports the main terminal box. The magnetic circuit consists of low-loss silicon magnetic laminations, securely wedged to the frames ribs. Rotor This consists of a shaft, main rotating exciter winding, a fan, a balancing disc, an exciter armature and a rotating rectifier bridge. The shaft is made of carbon steel, forged or laminated according to its size. The rotor is of salient pole design manufactured with low magnetic loss laminations. The exciter coils are maintained in position by full length heat shrink wedges which serve for thermal diffusion as well as opposing centrifugal forces. The fan and the balancing flywheel are keyed on the shaft. Dynamic balancing of the complete rotor and shaft is carried out on all alternators. Bearings Roller bearings are rigidly fixed to the stator end plate. Lubrication is performed by means of grease, with a used grease escape valve. New grease is inserted during operation causing the old grease to be evacuated. Fan Cooling The air inlet is located at the rear of the alternator and the air outlet at the driving end ; air escapes through the gap by means of the fan keyed on the shaft. If the alternator is to operate in a dusty environment, then filter elements can be fitted. Consult the Gas Projects team at Cummins UK, Manston Office for details as the alternator output will reduce. Stator winding Low voltage coils are wound with round enameled wires. Impregnation is done with polyester based varnish impregnated under vacuum. Medium voltage coils are built with fiberglass-lapped flattened enameled wires, the sections are isolated using mica products. Special precautions are taken to ensure perfect wedging of the sections and connections using insulating rings and inserts. Global impregnation with solventless polyester resin under vacuum and pressure provides the unit with a remarkable mechanical strength, a very high degree of insulation impervious to humidity, oil, fuel-oil, diesel fumes and industrial chemicals. Standard insulation classes for the alternators are class H for low voltage (400 - 480 V), and F for medium & high voltage (4.160 - 13.800 V).

Rotor winding The Rotor is built with rectangular copper enameled bars or insulated with two fiberglass layers and totally impregnated with solventless polyester resin under vacuum and pressure. Terminal box - Connection A large-sized and easily accessible terminal box is located at the alternator top. Inside, the six windings ends are wired to connecting bars (for low voltage) or to insulators (for medium and high voltage), thus allowing easy connection. Thermal protection PT 100 thermal sensors (100 ohms at 0C) are enclosed in the stator winding and implanted in the bearings. Output may be used either for temperature measurement or alarm and tripping. Brushless excitation Field flashing is ensured by residual magnetism, delivering minimal field to enable voltage regulator operation. Excitation alternating current is drawn off an inverted alternator keyed onto the rotor shaft. Inverted means that the armature is rotating, and field poles are fixed. The excitation current is rectified through a Graetz bridge of silicon diodes properly sized and protected by resistors connected in parallel on the alternator rotor windings. The rectifier is fixed onto the alternator rotor, and so named rotating rectifier. If out of control, the exciting system trends to minimal voltage output. Shunt regulator The regulator (6) is supplied by the generator output (1) and controls the excitation in the exciter field (5). The excitation current from the exciter armature (4) is rectified by the rectifier bridge (3) and supplies the alternator pole wheel (2). A three phase current booster is supplied, and a current transformer (dotted line on diagram) is allowed for parallel operation reactive power control. A potentiometer allows adjustment of the nominal voltage over a 5 % range.
QSV 81-91G
sharing of the reactive power. 2nd function : the second function also allows parallel operation with a much more powerful network with regulation of the AC generator power factor. 3rd function : the third function also offers voltage preequalization between the AC generator and the network before coupling. The rotor poles include a damper winding to assist in parallel operation. Regulation basic performances Following performances are typical and cannot constitute a contractual guarantee. Under steady conditions, the voltage is kept constant within 1% between 0 and 4/4 load, P.F 0.6 to 1 inductive, in cold or hot state, at rated speed within 5%. Output voltage is remotely adjustable by +/-5%. Under transient conditions, the alternator is able to return to nominal voltage under 0.5s. Please contact sales support for calculation of performance in regard with step reloading nature. Short-circuit current Compounding is designed so as to sustain a three-phase or single-phase current equal to 2 to 5 time rated current for a few seconds in the event of short-circuit, enabling proper operation of protections and ensuring selectivity in distribution systems. Generator protection Generator protections for isolated and paralleled operation are provided. Optional protections are to be defined according to bus specificities or local regulation. Power distribution system protections are defined by others, but they shall be communicated to project staff to check the effective selectivity in the whole system.
Voltage regulator functions

The function of the basic AVR is to keep the terminal voltage of the alternator constant at set point under various load conditions, when operating on isolated bus. AVR controls also the paralleled operation with other units in a power generation system, and with an infinite grid. To make paralleling possible, the AVR is equipped with a voltage droop circuit, which is enabled as soon as the generator is paralleled on live bus. When increasing reactive load, the terminal voltage decreases according to a predetermined characteristic. This reactive load sharing is important to prevent an imbalance and circulating currents in the system. Basic function : the regulator allows operation of a single AC generator by itself or parallel-coupled to AC generators of comparable power. A current transformer allows appropriate
QSV 81-91G
8 Genset Control Panel (GCP)

Genset control The genset control is microprocessor based and includes features for engine control, as well as generator and power plant interfacing controls. per ignition event, to each coil. It receives the feedback sensor signal from each coil and then adjusts energy delivery for each spark. The prognostic Diagnostic Module (PDM) outputs diagnostics of the spark plug and coil for each cylinder, and prognostics for trending the condition of these components. It also outputs faults of the coil section. SSM 558 is a governing system for controlling the airgas mixture. The gas rate is set by an electrically operated valve, controlled by the SSM 558, from the gas flow required. Valve position is determined from feedback. The engine governing system is controlled either by Woodward 723A or MCM 700 governing systems. The actuator is a PROACT III series.
Gas engine control

The CENSE control acquires data from analogue and logic sensors installed on the engine. Some of these parameters are for alarm and display purposes, others are for cylinder ignition tuning. CENSE data is sent to the MCM 700 for engine control. The Master Control Module MCM 700 receives (from Power Command Supervisor (PCS)) a power demand to set the active power of genset, and real time data from CENSE. The signals for start, stop and torque demand are transmitted to SSM558 and CCD/PDM The Capacitive Coil Driver (CCD) receives ignition data from the MCM, and interprets it to output cylinder individual voltage, containing one or multiple firing signals
Generator control
The standard PMG generator is controlled by the PCS device, and the shunt-booster generator is controlled by the autonomous Automatic Voltage Regulator (AVR) receiving feedback from built-in PTs and CTs. The GCP includes digital annunciator and parameters display, a programmable Logic Controller (PLC), genset protection devices, start, stop and paralleling controls.

Genset Control Panel specification The QSV G.C.P. is a micro-processor based system designed to interface directly with the engine or the monitoring components. The control panel provides extensive integrated system monitoring and control functions using the very reliable Power Command Supervisor TM. It further utilises a PLC to generate a range of communication protocols for both internal and external usage.
QSV 81-91G
Construction
The control system is housed in a rigid, free standing, metal enclosure designed to require front access only.
PC Based H.M.I. (Touchscreen)

The HMI is the Human Machine Interface. A microprocessor based graphic interface (touchscreen) package is provided to allow operator monitoring and control. Data from the genset is displayed to the operator in layered menus so that it is easy to understand and allows operators to easily learn the functionality and diagnostic facilities of the unit The touchscreen provides data and graphics on an EL monochrome display. The microprocessor is 80486SXLC2-50 technology and includes a DOS based operating system and Interact application software. It is complete with a real time clock, (month/day/year/hour/ min/sec) with separate battery backup and holds an extensive 5MB of FlashDisk memory. The screen is mounted on a console on the front of the GCP with gaskets between the touchscreen and the enclosure for environmental protection. The HMI is interconnected to the PLC via serial comms utilising a Modbus protocol.
GCP System Configuration

The Genset Control Panel can be located either locally at the genset or remotely, up to a distance of 100 metres, ie; in a control room environment. Standard components used to provide the system control comprise : Control batteries and charger , PC based HMI (touchscreen) , PLC based auxiliary control , PLC based CENSE interface , PowerCommand Supervisor, Aux AC enclosure (genset mounted) , Engine interface enclosure (genset mounted) . The system is intended for use in single or multi-set isolated bus or single set base load utility paralleling applications whilst providing both isolated bus paralleling control (set to set synchronising, isochronous KW and KVAR load sharing) and base load utility paralleling (synchronising to utility, base load KW control, VAR/PF control). It provides compatibility with master controllers for multi set utility paralleling applications requiring supervisory system control, ie, load demand, multi level load shed/add etc, whilst enabling data control and monitoring via an optional (Modbus) communications interface.
PC Based HMI (Touchscreen) Specification

Processor : 80486SXLC2-50, 8MB DRAM, 256 kB static RAM, 5 MB FlashDisk, 4 serial and 1 parallel interface (LPT1), CAN Bus interface, 2 PCMCIA type II slots. Screen Type : Amber electroluminescent (EL) flat panel. The screen surface is hard coated, durable and anti-glare to allow ease of use in any lighting condition and long life. A screen save facility is provided to enhance life and save power. Screen Size : 10.4 (264mm) diagonal with 640 x 480 pixel resolution. Operating System : DOS 6.22. Application Software : InteractTM Runtime System III. PLC Interface : Serial Communication port slot with Modbus Protocol. Protection : Nema 4.
Control Panel Environmental Hardening

The control system touchscreen, PCS and other optional door mounted equipment are provided with sealed front faces to minimise the effects of dust and moisture on the equipment. Operating range of the complete GCP is : Operating Temperature : 0 to +50 C Rating : IP54
QSV 81-91G
Temperature Rating : -5C to + 55C. External Optional Connectivity : VGA monitor, disk drive, mouse interface, IBM AT keyboard port.
PowerCommand Supervisor
This unit is a microprocessor based genset monitoring, metering and control system. It is integrated into the GCP and incorporates the following key features; Voltage Regulator Synchronizer (Freq, Phase & Volts) Iso-Bus kW and kVAR load sharing Utility Paralleling kW Load Control Utility Paralleling pF Control AmpSentryTM Alternator Protection Overload, Overcurrent [51], Short circuit [50], High AC Volts [59], Low AC Volts [27], Underfrequency [81u], Sync Check, Fail to Sync, CB Fail to Close, Reverse Power [32], Loss of Excitation [40],
Main Screen
The main screen is designed to enable the operator to determine the current genset status. It further allows access to the data embedded in the layered screens. Data Includes : Voltage per phase, Current per phase, Current per phase, kW, MW/hr, Frequency, Power factor, Oil pressure, Speed and Engine hours. Touchscreen activities allow the following access: Engine Data, Alternator Data, AC Auxiliaries mimic, Alarm Activities, GCP User Level Configuration, Related Plant Data The main screen is designed to include an alarm capability so that the operator is immediately advised of all alarm and shutdown conditions.
Alternator Statistics
This screen enables the operator to analyse the alternator data in more detail. Data includes : AC Voltage Phase - Phase, AC Voltage Phase - Neutral, AC Current per phase, Average AC current, AC Kilowatts, Percent power, AC Reactive power, AC Megawatt hours, Generator frequency, Alternator bearing temperature (drive end), Alternator bearing temperature (non drive end), Alternator winding temperature (red phase), Alternator winding temperature (blue phase), Alternator winding temperature (yellow phase).
Phase Rotation Alternator Metering
Enclosure Environmental Hardening

The front panel of the unit is formed by a single membrane that covers the entire surface. The facia is easy to clean and impervious to water spray, dust and oil/exhaust residue. Switches for control are incorporated into the door which is gasketted with a dual moisture and RFI/EMI gasket to protect internal components from airbourne contaminants.
QSV 81-91G
PowerCom m and Supervisor
AC Generator protection devices

One AC generator voltage multifunction protection relay includes the ANSI codes 27,59,81 (typical). One AC generator current multifunction protection relay includes the ANSI codes 32,40,46,50,51, 51N or 64 (typical). One differential protection relay ANSI 87G is available as option, and may be added in standard rack containing above listed protections. One synchroscope and synchronising check relay allows manual paralleleing. Alarms and signals
Controls and Adjustment Switches

An oil tight, three position switch starts and stops the generator set locally or enables start/stop control from a remote position. It provides the following functions: The OFF position de-energises all primary DC circuits. When the switch is in this position, the non-automatic indicator will flash continuously. The RUN position energises the control and initiates the genset starting operation. Note : the non-automatic indicator will flash when the switch is in the run position. The AUTO position enables the control to receive a start signal from a remote location.
Buzzer-type horn annonciator includes 16 alarm windows. Operators Controls:
1 Horn stop/Fault reset push button. 1 Lamps test push button. 1 set of engine start/stop push button. 1 set of speed/load - raise/lower push button. 1 set of set circuit breaker on/off push button. 1 running mode selector switch. (OFF/ MANU/AUTO)
1 selector switch for manual mode. (IDLE/ RATED SPEED/ SYNCHRO/LOAD)
Emergency Stop Switch

A two position safety mushroom head switch provides an easy and obvious means to immediately shut down the genset in the event of an emergency condition.
1 emergency stop push button with key.
System Control
Control arrows on the screen lead the operator to information. The control switches provide the operator with a positive indication that the switch is operated. The switches are totally sealed and designed to provide reliable service.
Menu selection Switches.

These four switches allow the operator to select menu-driven control and monitoring information.
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9 Generator Load Acceptance

Load Acceptance The ability of a gas engine to accept high impact loads is lower than that of a diesel engine, especially when operating in Island Mode. The table below gives a guideline for the step loading based upon the imposition of a resistive type load. Capacitive and inductive type loads and the starting of asynchronous motors have a variable effect on the load acceptance capability. The details of the characteristics of the motor to be started, such as start and run power factor and the type of starting method, should be advised to the Technical Support Group for assessment.
primemover
frequency & voltage build-up t1 (1)
t2
recovery time for Px reloading step 10 to 18s depending on step 10 to 12s depending on step
minimum delay between steps
step reloading value of
Px P5
t4
P1
30%
P2
55%
P3
75%
P4
85%
step (2) unloading speed excursion
step unloading recovery time tu 4 to 14s depending on step 0 to 13s depending on step
nu
4% maxi
QSV 81G
24s
15s
QSV 91G
24s
15s
30%
55%
75%
85%
steps of 5% up to 100%
6.5% maxi
(1) engine preheated. (2) for any load removal.

QSV 81-91G
10 Generator Set Arrangement

The following figures show generator set general outline dimensions.
QSV 81G LV genset
QSV 81G MV/HV genset
QSV 91G LV genset
QSV 81-91G
Generator Set Connections

The QSV 81G and QSV 91G generating sets are delivered as standard with flexible hoses and exhaust bellows.
The table below gives the dimension and the position of each engine connection.
408 402 451 456 403 454 G1 215 216 216 501
connection HT water inlet HT water outlet LT water inlet LT water outlet HT water venting pipe LT water venting pipe Gas inlet Oil filling Oil make-up Oil drainage Exhaust gas outlets
Port dimension position-> ND3" ND3" ND3" ND3" 3/4" BSP female 3/4" BSP female 80NB BS 4504 table 16/3 flange ND 1" ND 1" 250NB BS 4504 table 6/3 flange
QSV 81G
X - 197.50 - 48.50 - 48.50 - 197.50 Y 140 191 400 423 + + + + Z 680 680 680 680 X - 197.50 - 48.50 - 48.50 - 197.50
QSV 91G
Y 140 191 400 423 + + + + Z 680 680 680 680
-560 - 200 + 140 + 140 + 1050
-535 + 240 - 605 - 605 + 1375
-215 - 580 - 60 - 60 + 279 - 279
-560 - 200 + 140 + 140 + 1194
-535 + 240 - 605 - 605 + 1375
-215 - 580 - 60 - 60 + 279 - 279
QSV 81-91G
11 Generator Set Handling

Generator set handling The generator set is delivered in a shipping container. Lifting points on the baseframe are positioned so that the weight is evenly distributed. Distancers should be used when lifting to ensure that the slings do not damage the equipment. In any case, the sling should be arranged to limit the angle of lift to a maximum of 60C in all directions. The recommended length of slings is in the table. All weights in metric tonnes, tolerance +15% depending on optionnal features Holes in QSV frames: 50 mm Holes in spreader 52 mm
Generator sets to be handled Handling system weight capacity Characteristics Shackle Sling A Sling B Distance
QSV 81 - 91 G (16 to 21.5 tons) 16 to 30 tons Number 10 or 12 4 4 2 Type regular Length NA Force 15 tons
textile 2.5 to 3.2 m 15 tons preferred metal or 2.5 to 5 m 15 tons textile SMO 188 200 2 meters 17 tons
Sling B Spreader
Shackles
Sling A
Shackles
Shackles
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Intentionally blank page
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installation. It is also more suitable if the runs can be kept as straight as possible to reduce the back pressure. Flexible cables may be more expensive but more convenient in confined spaces.
12 Turnkey Power Plant

General
Cummins Power Generation will develop power stations from green field sites, taking responsibility for the preparation of the site, including all civil works from slab foundations, to cable and pipe trenching. The type of housing for the equipment depends on space constrictions, speed of putting into operation and the time-span of the project. A short term project with tight space restraints would benefit from a containerised solution, whereas the extended project term with lots of space would demand a brick or steel clad building.
Building regulations
Planning and building legislation varies throughout the world. However the principles behind such legislation are almost always the same and have therefore been given due consideration. These principles are : Location suitability and environmental friendliness
The zoning plan for a particular area dictates the function and general appearance (size and height etc....) of buildings in the area. Structural stability
Power Plant Buildings (General)

This section indicates the basic principles of erecting a steel or brick building. It is not intended as a definitive guide to building construction. The typical layout drawings contained within this section are meant for guidance purposes only. The design and layout of the building and its contents would be job specific.
The buildings structure must naturally withstand the pressures placed upon it by local conditions. Building regulations decides the loadings that the building must be designed with. Codes throughout the world differ in respect to requirements on structural stability and therefore the final structural arrangement of the building will differ. Extreme circumstances, such as risk for earthquake, storm, require special consideration.
Building Layout
The building is largely a reflection of the processes that exist inside it. The size will reflect the layout of the hardware, giving due consideration to the space required to install and maintain it and to provide adequate access for installation and removal for replacement and repair. The height should allow sufficient room for the suspension of exhaust silencers and pipework, and the trays or ladder racking for cables if trenching is not appropriate. The routing of water, lubricating oil and gas pipes will also have to be planned where they cannot be placed in a covered trench. The movement of ventilation and aspiration air should be carefully considered so that the point of introduction and discharge ensures the heat generated by the hardware is dispelled without short circuit. The air velocity, volume and acceptable temperature rise will determine the size of the apertures and the number and rating of the ventilation fans. Noise control treatment will be required wherever a breakout can occur. The walls and roof section will be treated with mineral fibre in-fill and the inlet and discharge air will pass through attenuation units. Doors will also be padded with mineral fibre.
13 Safety Equipment
Fire, Smoke and Gas Leakage Detection.
Gas leakage inside the building should be minimised through adequate ventilation. However, gas and fire detection equipment should be installed to ensure operator safety. In the event of fire or gas leakage, a signal will be sent to shut off the supply of gas and to shut down the generator set. Local and remote indication is given to ensure the evacuation of personnel and to initiate the fire fighting systems. The gas leakage is detected by sensors strategically positioned at high and low levels and adjacent to the ventilation air discharge. Fire is detected by temperature sensors placed at high level away from the hottest parts of the equipment, i.e turbochargers. Smoke is also detected with sensors positioned at high level adjacent to the ventilation discharge. Emergency stop push buttons are located adjacent at each point of entry, positioned at a convenient height and without obstruction and shrouded to prevent inadvertent activation. A central detection monitoring system will be installed with a maintained supply with batteries retaining charge for at
Piping, Ducting and Cabling

The shorter the runs of water, steam, oil and gas pipes and control and power cables, the more economical the
QSV 81-91G
least one month. A local audible alarm and trip signal are initiated and a visual alarm is displayed on the monitor. The signals can be transmitted via modem to remote locations. P(psi)

= W (kgs) (mm)
Electromagnetic Interference
The controls of a cogeneration plant incorporate sensitive microprocessor based electronics and can be effected by the electromagnetic interference generated by the alternator or the spark plugs. Any sensitive equipment should be housed in a metal enclosure and duly grounded.
The pressure imposed by the generator set weight must be less than the load carrying capacity of the supporting material. Seasonal and weather changes adversely affect mounting surfaces. Soil changes considerably while freezing and thawing. To avoid movement from seasonal change, extend foundations below the frost line.
Noise Attenuation
The airborne mechanical noise generated by the engine shall be contained within the building to levels acceptable to the local environment. Where more than one generator set is to be installed within the same building, an acoustic enclosure will surround the sets so that maintenance can be carried out whilst other sets continue to run.
Concrete Base
The base concrete slab should be designed to accept all the static and dynamic loads imposed by the generator set and all the associated plant equipment that is required. The slab must also be adequately supported by the soil or a robust structure such that it remains level.
Vibration Isolation
Vibration isolators giving 95% isolation will be positioned between the bedframe and the concrete floor. Higher efficiency isolation dampers are also available as an option. As vibration isolators amplify the effect of seismic shock, special isolators are required in earthquake sensitive areas. Consult your Technical support Group at the factory.
Engine type QSV 81G QSV 91G
Weight of the genset (kg) in operation 20,500 22,000
Dimensions of the foundation (mm) (concrete spec . weight : 2.4 A 6,500 6,500 B 1,900 2,000 C 700 700
14 Generator set foundations

The foundation slab should be able to support the static weight of the generator set with the weight distributed evenly across the isolators. If isolators are not used, the slab weight should be 125% of the generator set weight. In the following table, dimensions A and B should exceed the dimensions of the generator set by 300mm. The depth of the concrete base will depend on the composition of the soil. Firm, level soil, gravel or rock provides satisfactory support. Soil such as fine clay, loose sand, or sand near the ground water level is particularly unstable under dynamic loads and requires a more substantial foundation. The area of load bearing support is adjusted to according to the surface material. To determine the pressure (P) exerted by the generator set, divide the total wet weight (W) by the total surface area (A).
15 Maintenance facilities
To prevent further operational costs, a power plant should be designed to allow maintenance tasks to be performed with sufficient space to avoid use of special lifting equipment, stopping and removal of adjacent units, or partial building demolition. Each cylinder bank of the engine shall be provided with an overhead crane, to ensure fast and easy maintenance. The surrounding area of a building shall allow cranes to safely support the loads. The crane must be free to extend to reach the exhaust stack. Pipes, which run overhead, should not obstruct the maintenance or removal of the generator set. Trenches shall be well drained with metallic mesh fitted to prevent rodent intrusion. Storehouses shall be protected from large temperature variation, be free of dust, humidity and ultraviolet rays penetration (windows are painted blue and lighting is with incandescent bulbs).
QSV 81-91G
The standard voltage is 400V 50Hz and 480V 60Hz. The step-up to higher voltages is via a voltage transformer. The sets may be operated in island mode with a varying load. The number of sets required to support the load can be adjusted according to the load demands changes. The percentage of load at which additional sets will be called on or at which sets can be withdrawn can be adjusted to give optimum performance. The system can also signal the distribution to introduce or reject sections of the load to avoid the overloading of the system. Alternatively, the sets can be operated in conjunction with the utility supply either as a baseload where the system is set to allow the generator sets to produce 100% load continuously and export the excess to the utility, or, as a peaking system with the utility supplying a constant load and the generator sets following the fluctuation in load demand. In the event that the sets are providing baseload with the utility and the utility supply fails, the generating sets will continue to support the load. Once the utility supply is restored the generating sets will resynchronise and revert to exporting the excess. Individual sets can be used for baseload, peaking or automatic mains failure support.
16 Electrical systems
General
This section describes the power circuits associated with a power generation system. It includes: the low voltage protection and/or synchronising circuit breaker medium/high voltage protection breakers step-up voltage transformers Plant controls systems Neutral grounding system Auxiliary equipment control system Plant grounding system
If voltage > 13.8 kV

QSV 81-91G
Baseload applications
The single line diagram below shows a low voltage system supplying a load through step-up transformers. The width of the cubicle section is indicated. The overall width will differ according to the number of sections used but the single line will remain the same. Each generator set delivers power through a circuit breaker and an isolator which allows safe maintenance whilst the bus remains live. Whilst the isolator and generator protection breaker are open, the system is manually earthed. Current and voltage transformers are an integral part of the generating set. The auxiliary transformer with a 3 phase and neutral secondary circuit is protected by fuses and provided with an isolator which will open circuit in the event of a blown fuse. A dual switch grounding system ensures the grounding of any residual voltage. The output to distribution is protected through a circuit breaker and provided with an isolator for safe maintenance. The output bus can be manually earthed when the isolator and breaker are open. A measurement voltage transformer is provided for the grid supply. The primary side is provided with an isolator. The secondary is fitted with an interrupter protected by fuses. A phasing transformer is provided on the secondary to allow proper synchronisation. The neutral grounding is arranged to suit the type of application in relation to the grid.
to grid
Gas Power Plant Project Guide Isolated System - Medium Voltage Generation
The single line diagram below shows a medium voltage system supplying a load to an isolated grid. The width of the cubicle section is indicated. The overall width will differ according to the number of sections used but the single line will remain the same. Each generator set delivers power through a circuit breaker and an isolator which allow safe maintenance whilst the bus remains live. Whilst the isolator and the generator protection breaker are open, the system is manually earthed. Current and voltage transformers are an integral part of the generating set. A measurement voltage transformer is provided for each generator set. The primary and the secondary sides are protected by fuses and provided with an isolator. Current transformers are fitted in the alternator terminal box.
QSV 81-91G
A measurement voltage transformer is provided for the bus (not required for a dead bus). The primary side is protected by fuses and provided with an isolator. The secondary is fitted with an interrupter and protected by fuses. The auxiliary transformer with a 3 phase and neutral secondary circuit is protected by fuses and provided with an isolator on the primary side which will open circuit in the event of a blown fuse. A dual switch grounding system ensures the grounding of any residual voltage. The output to distribution is protected through a circuit breaker and provided with an isolator for safe maintenance. The output bus can be manually earthed when the isolator and breaker are open. Two neutral grounding systems are shown: Option A is a low impedance system; Option B is an artificial neutral point for multiple generator sets with a fault current limiting resistor on the secondary of the transformer.
QSV 81-91G Power distribution equipment

Medium Voltage Switchgear Medium voltage switchgear contains breakers for the generator sets output, measurement transformers for the common part of the governing systems, and tapping power switching. Location of the MV switchgear The switchgear is normally located in the main control building. It is important to install the equipment in such way that operation, maintenance and supervision can be performed safely and easily. See our installation documents for further information. Breaker Types The SF6 breaker is the most commonly used type in the medium voltage range. Standard breaker is of truck-type (can be withdrawn), making it easy to interchange and maintain. It has a high current breaking capacity. The isolating gas is SF6 (Sulphurhexafluoride). The load breaker is used for switching load currents . The LB (Load Breaker) is fitted with fuses for breaking short-circuit current. An arrangement is provided for tripping the breaker if one of the three fuses blows. The load breaker is normally used for protection of transformers or generator set output. Power distribution systems can be tailor-made to individual requirements. Busbar System The units in a MV switchboard are interconnected by a busbar system. The required area and rated current for the busbars, depends on the voltage, number of power generation units, connected short-circuit current, protection class of the switchgear and spare capacity required for future extension. Our advice is to prohibit aluminium busbars in humid, maritime, and tropical climates, and in acid industrial atmosphere. Use of tinned copper ends is recommended for all these situations.
The QSV generator set range follows the following parameters: Rated current 630A (busbar and breakers) Rated short circuit current 12.5 kA Voltage range 3.3 to 20 kV
Step-up transformer Some generator sets are installed with transformer installed close to generator, with a direct busbar or cable connected between generator and transformer. These transformers are self-cooled, and fully enclosed type. Combined DGPT2 oil pressure, temperature, and level protection is standard. Station auxiliary transformer For the power plant auxiliaries a tapping transformer, connected from the MV switchgear to a main LV distribution board, is used. This provides the power supply for the power plant various auxiliaries, such as heaters, pumps, radiator fans, compressors.... The transformer is of sealed oil cooling type, to be installed indoor or outdoor. A DGPT2 protection does not need an oil retention system. Location of the transformers Transformers are self cooled. When they are located in a switchgear room or in a separate area, it is important to provide the transformer with sufficient cooling air. The temperature rise of the air should not exceed 10C to provide an acceptable cooling capacity. Generally, an air flow of 5m3 per minute is regarded as an acceptable ventilation rate to account for 10 kW heat rejection.
Gas Power Plant Project Guide Neutral Grounding System

There are numerous methods for local neutral grounding of the generator. This depends on past practices, grounding philosophy and local electricity board regulations. Our recommendation is to ground the neutral through a
QSV 81-91G
low impedance grounding resistor that limits the earth fault current to about 5 to 15 Amps . This system is simple to achieve (if existing bus or grid allows) and ensures proper protection selectivity in most cases.
Common LV solution
Preferred HV solution
N.E.T.
N.G.R. .
Ie>100A e < 100A
Floating
Direct
Impedance
Resistance (low ohmic)
Resistance (high ohmic)
N EUTRAL
GROUNDING
PRINCIPLE
O PERATING
PRINCIPLE
P HASES
INSULATION
P ROTECTION
SELECTIVITY
H UMAN
BODY
D AMAGE
RESULTING OF FAULT
NEEDS
PROTECTION
neutral directly grounded.
lowers the fault overvoltage occurences.
low level is needed. phase/ground insulation shall be equal or higher than phase/phase insulation.
very good selectivity, 1 st step trips generator. determination and setting of first step is not easy, 2 nd step trips generator. simple protections may be used with good selectivity. 1 st step trips generator.
dangerous while fault is pending. safe if first step detection is well set. Fault searching shall be immediatly performed.
very important due to high fault current. equipment not damaged due to nil or limited current. (fault current lower than 3 amps) equipment is not heavely damaged, power is dissipated in impedance. (fault current is betwen 3 and 50 amps)
isolated neutral or neutral grounded through high impedance.
allows to continue operation with 1 st step fault pending.
neutral grounded through low impedance.
permanent fault current is limited, and internal surge is limited. Fault current is limited as soon as it appears. (suitable for extended distribution networks)
regular insulation system is suitable.
good protection by voltage limitation.
neutral grounded through a reactance system
regular insulation system is suitable.
selectivity is ensured if IL >>Ic network. 1 st step trips generator.
large voltage surge may be caused when fault is eliminated.
equipment may be damaged by surge.
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17 Power Plant Control Features

Synchronizing features Automatic synchronizing feature is included in our GCP, for each generator set, against offsite power. This feature measures live bus phasing, and frequency, and adjusts the speed of generator set to match them for synchronizing. Then the bus voltage is measured and a correction signal is sent to the generator voltage regulator to equalize voltages. As soon as these parameters are matched to within a preset tolerance, a signal is sent to the paralleling breaker for closure. Angle and voltage errors are preset to 50 % under the acceptable limits of the generator. We recommend to start and synchronize gas fueled generators with other power sources independently. Load control modes Load control of paralleled generator sets may be achieved in two ways : - The load is preset in the GCP, and is maintained as long as the generator set is operated in parallel : this mode is called Baseload. The output of the generator set does not change, output of power plant is multiple of operating generator sets. The common panel PSCP senses the load requirements automatically selects the number of generator sets needed to fulfil the load demand. or, - The load is proportionally shared among the paralleled generator sets (load sharing). The load on each generator set changes according to the station demand and/or according to the number of sets supplying the bus. The operator selects the gross output at the PSCP panel. Soft loading and unloading
The load can be gradually increased to a preset level to get a smooth load transfer when paralleling a generator set onto a live bus. When a generator set is going to be stopped, the load is gradually decreased to a preset level (gapload) before the generator set is separated from the parallel system. Automatic commands are generated by power plant digital control built in the PSCP panels and loading/unloading ramps are controlled by generator set GCP panels, or by the PowerCommand supervisor. Multiple generator set management This feature provides for automatic start and stop of generator sets depending on the actual load level and the loading set point. The paralleled generator sets may be controlled in load sharing or in baseload mode. When the load increases to a preset level, an automatic start command will be given to the next selected generator set. After synchronizing, the unit will share the load with the other units in the parallel system or deliver its baseload rating. The system will switch off generator sets when the load setting decreases, but only after confirming that the remaining generator sets will not be overloaded. These functions are supported by PSCP3 panels. Plant Power Management Power management is applicable for situations where a power plant is operated in parallel with other power sources, with or without a local consumer load. The global power output of the plant is managed under operator control, and the generator sets are operated in load sharing mode. Multiple generator set management feature is enabled as described above. These functions are supported by PSCP panels, or by the PowerCommand system .
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Information to Follow at a later date.
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18 Low voltage supplies

Auxiliaries are operated as shown in the table below. The step -down transformer is connected to live bus, allowing auxiliaries to be energized even if generator set is shutdown. Control panels are delivered with enclosed batteries and charger.
AUXILIARIES Control System Water Pre-Heat Pump & Pre-Heater Pre-Lubricating Oil Pump Fan Coolers / Water Circulation Pump Room Ventilation Fans / Louvres Starting Air Compressor Battery Chargers Lubricating Oil Transfer Pump Generator Space Heater
OPERATING SEQUENCE Stand By Starting Operation Shut Down UNINTERRUPTED 24 Volt Source Required Required If Possible Required If Possible If Possible Required If Possible Required Required Required Required Required Required Required Required Required If Possible Required If Possible Required If Possible
Auxiliaries power requirements The table below gives an indication to the power required to support a typical installation. It is meant to give a guide to the sizing of the power supply cable, trips etc, together with panel dimension. The actual power required may change according to specific project requirements, and equipment that is fitted.
A U X IL IA R Y IT E M P r e - L u b r ic a tio n P u m p W a te r P r e - H e a te r P r e - H e a tin g W a te r P u m p G e n e r a to r H e a te r A ir C o m p r e s s o r M o to r L u b r ic a tin g O il T r a n s f e r P u m p M a in te n a n c e W a te r P u m p R a d ia to r F a n s R a d ia to r F a n s ( L o w N o is e ) C o o lin g T o w e r L i g h tin g B a tte r y C h a r g e r s C o n tr o l P a n e l H e a te r
P o w e r C o n s u m p t io n ( k W ) Q SV 81G Q SV 91G 1 .3 1 .3 2 x 6 2 x 6 0 .3 0 .3 0 .5 0 .5 4 4 0 .7 5 0 .7 5 1 .5 1 .5 2 1 to 2 6 2 1 to 3 2 1 5 to 1 8 1 5 to 1 8 1 5 to 1 8 1 5 to 1 8 2 2 0 .3 0 .3 0 .0 7 5 0 .0 7 5
QSV 81-91G
19 Power Plant Earthing System

Grounding circuits purpose Grounding circuits are essential for power plant safety. They are essential if an electrical incident occurs, as for an extinguisher in case of fire. There are three main functions in power plant grounding circuits : - Personal and equipment protection against phase insulation fault, associated with detection relays or differential breakers. - Radio interference protection, to prevent perturbation of electronic sensitive equipment. - Generator protection by impedance neutral grounding (impedance limits the neutral fault current when generator is operated in abnormal condition). A lightning arrester should be connected to an individual earthing circuit to prevent any flashing of electronic components and/or personal injury, loss of life. Some local regulations require to interconnect ground bus and lightning grounding circuits. Neutral grounding Neutral grounding systems shall ensure the efficient protection of equipment and personnel. If neutral is directly grounded, the grounding electrode and wiring shall be able to sustain the full default current, which may be equal to one phase current. Details for neutral grounding of a substation or of a generator supplying a three phase+neutral grid are enclosed in IEEE 80 IEEE guide for safety in AC substation grounding. Requirements and neutral systems are previously described above in Power distribution equipment section.
Grounding impedance Impedance of grounding loop shall be as low as possible. Impedance value changes with the earth humidity ; for this reason, we recommend grounding in humid areas, at sufficient depth to ensure moisture during dry season and/ or freeze in winter. The grounding impedance objective value is to be determined following local regulations, determining maximum prospective touch voltage between ground and conductive parts connected to earthing system. Be aware that an inadequate local soil may require the electrodes to be installed at a long distance from power plant, resulting in extra-costs and efficiency diminution. Lightning protection The lightning protection requires a separate earth electrode, installed independently of the general earthing network. The shape of this electrode must take the high frequency currents of the lightning system to consideration. The earthing impedance shall be measured after installation is complete.
QSV 81-91G
Typical Earthing Arrangement
QSV 81-91G
20 Mechanical systems
General
The gas engine depends on the auxiliary systems in order to operate properly. The environmental conditions must be considered at an early stage and it is of utmost importance that all auxiliary systems are considered and optimized for their intended purposes at the project design stage. Piping should comply with the following good practice rules : 1) All pipe work should be installed with a slope of 1 cm/m in order to facilitate fluid-emptying, and venting of air pockets on system filling. Low points on the pipe work should be fitted with drain valves or plugs, both on fluid circuits and gas circuits. Shell and tube heat exchangers should be inclined by 1 cm/m, so that, the bundle can be emptied by blowing through a hole. The water circuit filling point should be at the lowest point, and the high parts fitted with a manual or automatic degasing system. The materials used for the pipe work and associated equipment should be resistant to the material that is being circulated. For example mild steel should not be used for demineralized water. The connections between the installation and the generator must be made using flexible sections, so as to absorb the vibrations and misalignments resulting from relative movement or expansion. The inside of lubricating oil pipes and gas pipes must be pickled and passivated, when situated downstream of the filters.
changed it can be pre-mixed in the tank to the correct strength before being pumped into the system. 9) Pipe work that is above 40 deg.C should be lagged to reduce heat loss, and to prevent personnel coming into contact with hot surfaces.
2)
3)
4)
5)
6)
7)
8)
Closed systems that are filled with a protective fluid, such as anti-freeze, should be easily drainable to a suitably sized tank. This will allow system maintenance to be carried out and the system refilled from the tank, also when the protective fluid needs to be
QSV 81-91G

the compressors should be fitted with a control system which cycles the lead compressor, and prevents all compressors starting when one engine is started. The compressors may be installed at a distance from the receivers but the supply line between receiver and starter motor should be kept to a minimum length to reduce pipe work losses and enusre maximum starting efficiency.
Starting system Air (Standard)

Each engine is supplied with three air receivers each of 200 litres which is adequate for at least 3 attempts to start, each attempt being of 12 seconds cranking with no fuel to vent the engine and exhaust, then up to 12 seconds cranking with fuel and ignition on.. The receivers are charged with air to 40 barg air pressure by an electric motor driven compressor which consumes 4 kWe, which is sized to refill the receivers in less than one hour. The receivers and compressors can be connected in parallel. However, if the generator sets are to be used for emergency purposes, we recommend that one receiver/ compressor unit is used for each generator. If the recieivers are connected in parallel, then the isolating valves should be kept closed, unless system problems occur. If the isolating valves are to be normally open, then
Electric (Option)
A single electric starter is fitted in ambients temperatures down to about 10C. In ambients below 10C a dual electric starter option is available. A dual (air/electric) start option is also available on request. Lead acid or nickel cadmium batteries are available together with connecting cables, lugs and a floor stand. The batteries are sized to permit 3 attempts to start in 0C ambient conditions. Power Command ControlTM system in the GCP incorporates a low battery voltage detection system, which checks the condition of the batteries at each start and gives an early warning of deterioration of the battery.
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Gas Power Plant Project Guide Lubricating oil system

Lubrication of the QSV Gas engines is performed by a single lube oil circuit, which is used both for lubricating parts in movement and cooling the pistons. An integrated lub-oil module ensures temperature regulation through a heat exchanger and thermostatic valve operated in mixing mode. Full-flow filtering of the oil through paper cartidges occurs just before the oil flow enters the engine. A parallel centrifugal filter is also fitted to the engine, and the element in this device can be cleaned during engine operation. The external lubricating oil system involves the following : a fresh lube oil storage tank (optional) a lubricating oil service tank, a waste lubricating oil tank (optional).
QSV 81-91G
oil, before sending it for recycling. To transfer used lube oil, an oil transfer caddy is available (optional). The suction of the mobile pump is connected to the sump and the oil pumped to the waste oil tank. This tank can then be emptied into barrels, or tanker for disposal.
External lubricating oil piping design rules

All the fresh lube oil pipes shall be mandatorily pickled inside, or made of cold drawn pickled pipes. In case of automatic filling, the lubricating oil service tank has to be located so that the tank base is between 1 and 4 m above floor level. This is to ensure an adequate gravity feed to the engine sump. Clear access to the transfer pump between storage and daytank should be maintained for maintenance purposes. A strainer and foot valve should be fitted on the lubricating oil storage tank suction. When the lubricating oil service tank is located lower than the storage tank, the use of a solenoid valve is necessary, to prevent siphonic action overfilling the service oil storage tank. If a bulk L.O. storage tank is not installed, the size of the lubricating oil service tank depends on the expected length of engine operating time without tank refilling.
The interconnecting pipe work to be made on site by the installer. The lube oil storage tank should be installed inside the power plant, in a cool area, free of excessive humidity. The lube oil service tank, which should be installed near the engine, supplies the sump by gravity through a manual filling valved connection, or optionally trough an automatic filling device fitted on to the oil sump. The automatic filling device is fitted with a sight glass which enables a visual check on the oil level within the engine sump. The waste lube oil tank is intended to recover the used lube
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QSV 81-91G Cooling systems (without heat recovery)

The cooling systems described below are installed if there is no cogeneration system.
When selected as an option, electrical pre-heating, which includes a small electrically driven circulating pump is fitted to the engine. This maintains the engine block at approximately 40 deg.C for easier cranking and starting.
Engine system
The internal cooling water system consists of two separate cooling circuits : the low temperature (LT) and the high temperature (HT) circuit. The low temperature circuit water cools the charge air cooler, (second pass), and the lubricating oil heat exchanger as standard. The high temperature cooling water cools the charge air (first pass), the cylinders (jacket water), cylinder heads and the exhaust system at cylinder head output. Both cooling water circuits are circulated by an engine driven pump as standard. The pump is a single shaft centrifugal pump with two impellers, one for the low temperature circuit and the other for the high temperature circuit. Each cooling circuit is controlled by thermostatic valve elements with wax sensors, which are fitted in the same casing, identified as the cooling water control unit, which is an assembly mounted on the rear side of the free end cover. The engine has two inlets/outlets for separated HT and LT circuits. Both HT and LT circuits shall be kept under a static pressure as defined in the generator set data sheet. The same coolant shall be used in both circuits; and a compensating pipe shall be routed between the HT and LT expansion tanks, as there is a leakage path between the two sections of the pump, from the HT to the LT circuit.. The heat rejected by the enigne circuits should be passed to suitably sized radiators, cooling towers, or some other form of heat sink. The requirements for the temperatures, flow rates and system external pressure drops are given in the relevant engine data sheet.
Cooling systems (with heat recovery)

The cooling systems described below are installed if there is a cogeneration system, which is using the engine heat for some purpose. If the engine is to be used in a cogeneration application it is beneficial to fit remote mounted electrically driven circulation pumps to the HT and LT cooling circuits, and remove the standard engine driven pumps and wax thermostats. This allows greater freedom in the design of the co-generation scheme, as the circuit pressure losses do not have to be designed to fit the requirements of engine driven pump. Also remote 3 way control valves, which are regulated by 3 term control loops, can be fitted to allow close control of system temperatures and hence provide efficient system operation. A 3 water circuit cooling engine option is available, where the lubricating oil module is removed from the LT circuit water flow, and receives cooling water from a separate source. Details of this option are avialable from Cummins Power Generation, Manston England. If the engine is required to operate during periods when the cogeneration system cannot provide the cooling load, then the heat rejected by the enigne circuits should be passed to suitably sized radiators, cooling towers, or some other form of heat sink. The requirements for the temperatures, flow rates and engine pressure drops are given in the relevant engine data sheet, or are avialable from Cummins Power Generation, Manston England. When selected as an option, electrical pre-heating, which includes a small electrically driven circulating pump is fitted to the engine. This maintains the engine block at approximately 40 deg.C for easier cranking and starting.
Gas Power Plant Project Guide Radiator system

Cooling systems using radiators are operated sealed, that is the system vent is sealed by a spring loaded valve, which will open at approximately 1 barg. Radiators are built in complete modules, ready to install on anchors, over paved or stoned areas. Fans are used to suck or blow air through a finned tube bundle. The radiator module is of copper tube/aluminium fins type as standard. In acid polluted atmoshere or coal power plants, it is necessary to use copper or coated aluminium fins. If cotton fibres are present in the radiator area, the preferred method of cooling is by a cooling tower with a special air filtering system. Radiator installation Radiators should be installed at sufficient distance from the power plant, to prevent exhaust gases recirculating through the radiator bundles. They should also be sited where the air flow is un-restricted, eg/ not below a roof parapet. If multiple radiators are installed, it is recommended to group them, ensuring that the lateral air inlet section is at least equal to the top surface area of the bundle. This arrangement ensures that hot air recirculating through the radiator is minimized. Degasing points are equipped with venting cocks. Draining points shall be provided at the lowest point of the installation. If a radiator is placed on the roof of a high building total
QSV 81-91G
static head shall be limited to that stated on the engine data sheet at engine level. If this criteria is exeeded, the radiator circuit shall be separated and interfaced with the engine through a pressure resistant heat exchanger. Expansion tank The expansion tank limits the internal pressure and allows air entry if necessary. The expansion tank has to be placed at the highest part of the circuit. When the radiators are placed remotely from the power plant, the expansion tank is installed in the generator set room. When the radiators are installed on the roof, the expansion tank remains on the radiator. The priming pipe must be connected close to the pump suction inlets. It must have a sufficient diameter to prevent cavitation (DN 50). If the expansion tank cannot be installed at the highest point, the pipework above the tank must be fitted with a breather. It is mandatory to provide a permanent breather in the ascendant sloping pipe between engine port and expansion tank. Maintenance water tank The maintenance water tank is used to store treated water for the engine cooling systems. It is made of a kit including a polyethylene tank, a portable electric pump and a set of flexible hoses. Clean water and chemicals can be added and mixed in the 1000 liters tank (by circulating the tank content). The unit can also retrieve and save the water when the engine needs to be emptied during maintenance or repair work. Additional tanks are available on request.
Expansion tank volume calculation
Litres per pipe D l/ N 25 40 50 65 80 10 12 15 1" 1" 2" 2" 3" 4" 5" 6" 0, 1, 2, 3, 5, 9, 14 20
Water expansion with maximum TC and l l t (0 30 50)

0,0 0,0 0,0 0,0 0 0 20 40 60 80 100 0
50 30
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Tank volume 1
2 litre litre litre litre litre
engin pipin miscellane radiat total %
%
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The above table is intended to determine the expansion rate versus the temperature, the circuit internal volume
and antifreeze concentration. Expansion tank capacity should be a minimum of three times the expansion volume.
QSV 81-91G Raw water system

A raw water cooling system may be the most cost effective solution when raw water is available in sufficient quantity and quality. If the raw water does not fulfill the required quality, a radiator or cooling tower is more suitable The raw water system makes it possible to use treated coolant in the engine circuit while using raw water in the final heat exchanger. The engine LT and HT cooling circuits are run in seperate circuits, each with its own expansion tank and cooler. The expansion tanks are linked by a compensation pipe at low level, to compensate any leakage across the double body pump. The engine coolants shall be treated following Cummins recommendations. Raw water open loop Raw water shall be pumped in sufficient volume through a compact heat exchanger. The raw water is taken from a pond freely filled by lake, river or sea water. Whatever the water nature, a stainless steel tube bundle shall be used in the exchanger. A coarse screen is to be used to stop large matter from the raw water entering the system. The feeding channel shall be concreted, and water speed should be limited to 0.3m/s (1ft/s). A sand trap (pond) is normally constructed on site and consists of a concrete or metallic chamber with a strainer plate disposed at the bottom, over a sand trap.

Water inlet, at low speed is disposed near the strainer surface, cleaning its surface continuously. Suction is at a distance avoiding the sand to be aspirated. A foot valve ensures pump priming. Generating sets operating in the centre of towns (or in deserts) may use raw water drawn off one well, and rejected into another. The distance between wells shall ensure that the recirculating water will come back cooled. For evaluation, 100 metres of distance is suitable for 0.3 to 1 MW generating set, 200 metres is adequate for 1-3 MW generating set. Raw water pump The raw water pumps transfer the water from the pond to the heat exchangers and then, the rejection line. The pump delivery volume to be the required flow when the engine is operated at maximum load , plus allowance for heat exchanger fouling. The pump is to be designed to deliver water even when the water contains sand, abrasive particles or algae. Engine cooling loop The engine cooling systems are similar to the ones using radiators, but the radiator is replaced by two easily cleaned heat exchangers. If the water is clear, plate heat exchangers are suitable. If there is earth, algae or particles in suspension, a stainless steel tubular heat exchanger is necessary.
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Gas Power Plant Project Guide Tower system

The cooling tower system makes it possible to use treated coolant in the engine circuits while using fresh water in the cooling tower. The engine LT and HT coolants are run with heat exchangers as final coolers. Each circuit is installed with an expansion tank. A level compensation pipe is installed between the expansion tanks to compensate for the small leakage across the double body engine driven pump. The engine coolants shall be treated following Cummins recommendations.
QSV 81-91G
An advantage with using the cooling tower is that the water within the tower can reach a temperature lower than the ambient temperature, due to a forced evaporation of the tower water. The evaporation losses must be compensated for by adding new water. To reduce the accumulation of salts and minerals in the cooling media, a percentage of the evaporation losses must be drained off. Typical concentration of dissolved solids in the cooling tower pond is 3500 ppm. Note:- A cooling tower will only work effectively when water can evaporate into the air passing through the tower. This will not be the case in a high humidity atmosphere. From this table, you can estimate the wet bulb temperature. Practical temperature of water exiting tower will be 10C above the wet bulb temperature.You can see,that the drier the air, the more evaporation takes place, and the cooling tower efficiency increases. For a tropical climate, or where the humidity is often near 100%, a cooling tower will not be efficient so a correctly sized radiator should be used, or a raw water source if available and suitable.
Cooling tower
The cooling water from the cooling tower is delivered by the circulating pump, and passes succesively through LT, then HT water heat exchangers, removing the engine heat, and then is distributed over the towers internal plate pack. Water is collected in a basin at the bottom of the cooling tower, where a pump recirculates it. A fan provides a forced draft through the cooling tower, cooling the water by evaporation.
Some worldwide temperatures are indicated below for weather evaluation, according to country. Be aware that on some days in the year, the temperatures indicated may be exceeded.
Air Temperature (deg.C) Relative Humidity (%) 10 20 30 40 50 60 70 80 90 100
Country (station) 30 35 40 45 50
Max Dry Bulb (deg.C) 35 40 34 34 34 39 32 33 37 32 38 44 33 30 36
Associated Wet Bulb (deg.C) 25 25 27 27 27 24 21 27 28 27 28 30 28 21 30
13.0 15.5 17.9 19.9 21.9 23.8 25.5 27.2 28.8 30.0
15.5 18.5 21.5 24.0 26.0 28.0 30.0 32.0
18.5 22.0 25.0 27.5 30.0 32.5
21.0 25.0 28.5 31.5
23.0 28.0 32.0
Algeria (Alger) Australia (Alice Springs) Brazil (Rio de Janeiro) China (Shanqai) Congo (Brazaville) Egypt (Cairo) France (Paris) Hong Kong (Hong Kong) India (Calcutta) Indonesia (Djakarta) Pakistan (Karachi) Saudi Arabia (Dharhan) Singapore (Singapore) Russia (Moscow) Vietnam (Da Nang)
QSV 81-91G
Particular attention shall be paid to the raw water which is added to the cooling tower circuit. If it contains earth, oxydes in suspension, installing plate type heat exchangers, in the cooling loop is the wrong choice, because the potential for rapid clogging of the tower water side. A shell and tube type heat exchanger with the tower water passing through the tubes, is more suitable because it is more easily cleaned. The raw water used in the tower should be filtered and treated to prevent algal formation, calcareous deposits and excessive salinity. Dosing pumps shall be installed on top-up water circuit, and the tower pond for the addition of treatment chemical addition. The water quality and the treatment chemicals required may determine the materials to be used for the cooling circuits and tower construction. Optional double pump unit The double pump unit transfers the water from the cooling tower basin to the heat exchangers and then, back to the cooling tower. One pump is operated to fulfill the cooling system required flow. If this pump fails, a flow detector placed in the common delivery line allows the generator set control system to start the other pump as backup. Integrated check valves in the double pump body prevents back circulation of water through the stopped pump.

Automatic change over of the pumps, every week, may be programmed using a suitable device. Engine cooling loops The engine cooling loops are similar to the ones with a radiator, but the radiator bundles are replaced by a pair of heat exchangers. Coolant in the engine circuits shall be treated according to our coolant requirements, with an anti-corrosion/anti cavitation chemical to prevent engine damage. The expansion tanks are traditionally located near the engine and equipped with two low level switches. The heat exchangers are installed near the engine and a maintenance area shall be reserved for cleaning. The tubular exchangers should be installed with a slight slope in fluid passage direction, to facilitate the draining of water and deposits. A maintenance tank is required for engine cooling loops, see radiator chapter.
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QSV 81-91G
21 Charge air system

The engine is turbocharged and the charge air temperature is reduced by a two stage air cooler, traversed by controlled temperature cooling circuit(s) water. If the plant is to operate at ambient temperatures below 0 deg.C, or above 40 deg.C then Cummins Power Generation should be contacted to ensure that the charge air system will operate correctly. If there are concerns regarding the condition of the intake air then consult Cummins Power Generation at Manston England. Optional air filtration If the air quality does not conform to these conditions, an increased efficiency filter has to be installed. Oil bath filters, with sliding media, are an option, together with cyclone and high efficiency replacable media types. Each application should be considered individually to ensure reliable operation of the engines. Intake air duct When external filtration is installed, an intake duct may be locally manufactured following these elementary rules. - Intake ducts shall be manufactured individually for each engine, a common duct may be made for two turbos of an engine, but a square tee connection should be avoided, preferring a low angle branch. - Internal parts of duct shall be rustproof or painted. - The duct shall be suitably supported. - A flexible connection must be used to connect the duct to the engine turbocharger, to prevent any stress on the inlet nozzle. The maximum allowed pressure drop through the intake air system, including clogged air filter, is indicated in generator set data sheets. It is recommended to design the system to reach half of the limit when the engine is operating at full load.
optional oil bath air filter
Intake air filtration

Generally, in the standard layout for power plants, the gas engine draws intake air from within the genset room. Standard duty filter elements are fitted to the engine air intakes, but a prefiltering system will need to be designed and installed if the environment is dusty or contaminated. The intake shall be equipped with necessary filters to remove particles that may cause deposit formations in the system or damage the engine. Basically, the engine is equipped with a dry type air filter, fixed directly on the turbocharger inlet. The highest possible dust concentration at turbocharger inlet is 3 mg/m3 and largest permissible particle size at turbocharger inlet is 5m. When environmental conditions are extremely dusty, (eg/ cement factory), the highest allowed particle concentration at the dry filter inlet are evaluated as follows:- 10 mg/m3 of cement dust, 5 mg/m3 of calcium hydroxide, 1.5 mg/m3 of chlorines, 20 mg/m3 of sulphur oxides.
QSV 81-91G

Exhaust lines of different engines shall not be mixed in a common stack, but routed separately in individual ducts, enclosed in a chimney. Sizing of the stack should result in a gas speed over 25m/s at the exit point, and/or conform to local regulations.. A suitable material for exhaust pipe construction is carbon steel sheet, and the recommended calculation temperature is 550C. Sliding supports shall be provided to allow for expansion, and fixed points should be situated in an opposite position to the compensators. Rain & condensate should not be able to biuld up in the exhaust, and permanent draining should be installed to prevent water entering the silencer and the engine. If the drains are not fitted with valves then a U water seal should be provided. Exhaust silencer The exhaust silencer is made of a carbon steel receiver containing a sound attenuator, and wave de-phasing system made of perforated steel sheet and heavy rockwool. It is asbestosfree. When two turbochargers are installed on the engine, it is mandatory to fix the delivered exhaust bellows directly onto the turbocharger outlet, and make any onward connection after the bellows to prevent any stresses being exerted on the turbocharger casing. Oxidisation catalyst If pollution levels required by local regulations are exeeded in HC or CO content, an oxidisation catalyst may be placed in the exhaust pipe, as close as possible to the engine outlet, before the silencer. If a reduction in pollutants is required then consult Cummins Power Generation in Manston England.
22 Exhaust gas system (without cogeneration system)

Exhaust gases from the turbochargers are discharged towards atmosphere through one or two silencers, depending upon noise emmission requirements. The stack should vent to a point which conforms to any local regulations, but generally the higher the better. Any vertical stacks must be adequately supported against wind loading. It is important to note that the turbocharger nozzles must always be free of loading, therefore the exhaust system must be supported independently of the engine. Stainless steel flexible exhaust bellows are delivered with each generator set, and shall be installed between the turbocharger and exhaust system. Exhaust duct It is of utmost importance that the entire exhaust line is designed properly to minimize flow restrictions, sudden direction change, or lines blowing in opposite directions. Maximum allowable pressure drop through the system is indicated in generator set data sheets. But it is recommended to design the system to reach half of the limit when operated at full load. The duct shall be gastight, to protect operators against toxic emissions in the generator set room (CO, CO2), and insulated to reduce the surface temperature to a safe level. The use of asbestos free materials is mandatory. Uninsulated exhaust lines situated outside shall not be routed near engine air intake or power plant ventilation entries, to prevent a rise in temperature of the intake air, which may result in a reduction in engine performance.
second silencer oxidisation catalyst first silencer
QSV 81-91G
To determine generator heat losses, calculate the difference between Electrical Power and mechanical output in the heat balance The exhaust line also causes thermal loss which may be determined from insulating system manufacturer indications. Coolant system pipes, etc also cause thermal loss to the genset room. The inlet/outlet temperature increase to take as a reference point is : 15C for temperate climate 10C for hot climate Prefiltering The room air should be pre-filtered if the site is polluted. Limits on pollution levels are detailed in the charge air system. Prefiltering panels should be dimensioned to allow ventilation operation with clogged media.
23 Ventilation and noise control

General principles The purpose of ventilation is: to remove the heat radiated by the engine and generator cooling; to keep the room pressurized if the surrounding air is polluted (in this case, a filtering system shall be installed). -to provide aspiration air for the engine. -to remove any fumes and gases that may be present. A ventilation system designed to create overpressure in power plants has benefits as follows. - The ventilation air can easily be filtered. - The air stream can be directed. - More pressure in the air intake of the engine. Ventilation of genset room Genset room is well ventilated to deliver fresh air near to the engine intakes and step-up transformer area. Soundproofing of this ventilation system is normally required. Generally the ventilation air enters at one end of the power plant and is blown axially, to exit at the opposite end. Air is admitted in the coldest area, and exhausted in hottest area ( e.g. boiler side) If necessary, extraction ventilators are installed at the exhaust end, to increase efficiency. To cool the boiler surroundings, a small size ventilator may be installed at low level, to allow fresh air entrance and better circulation.
Noise control
The air is aspirated or evacuated through air inlet/outlet louvres and sound attenuation baffles, sized from noise level specification. If a high noise attenuation requirement is pending, ventilation inlet and outlet apertures shall be equipped with high absorption sound traps. They shall be determined according to attenuation rate, and noise source frequency spectra. All the noise attenuation shall be situated inside the building, to prevent noise passage through non - soundproofed ducts. Doors should be stuffed and windows should be equipped with rubber gaskets to prevent vibration and noise passage. Pipe penetrations shall be closed.
Sizing
The engine heat emissions are given in the generator set data sheet.
QSV 81-91G

In a water / water heat exchanger the minimum temperature difference between the flows is 5 C, but 8 to 10 deg.C is a more practicable value. For an exhaust gas / water heat exchanger the minimum temperature difference is 30 C. If the scheme is not simple, or there are unknown factors or conditions, consult Cummins Power Generation at Manston England. Steam production guidelines Steam production is generally carried out in a multiple generator power plant. Boiler and feed water preheating may be carried out using LT, HT and exhaust, depending upon the feed water temperatures. Steam generation is used for industrial processes, like drying, heating at high temperatures or chemical applications. Steam is produced in the boiler which may be equipped with economisers to preheat the feed water. Feed water treatment etc, shall be part of the boiler supply, to ensure its safe operation. For a multi engine power plant, the cost effective solution is to collect the exhaust gases and to use a single boiler. The steam generators are submitted to local construction codes, generally issued of the well-known ASME code. If the local code is very different, we advise to buy the boiler locally. In standard form, the steam delivered is saturated but superheated steam can be produced for high temperature needs. The usual operating pressure range is 5-12 bar. The highest advised service pressure, with a reasonable output, in cogeneration with gas engines is 15 bar. The boilers may be designed for higher pressures, but CHP efficiency reduces and boiler price increases. Hot water production guidelines Hot water is heated by exhaust gases and by engine cooling fluids, the LT water, may be included if the process water is cold enoough to produce a low return temperature of 50C maximum for the QSV 81 - 91G LT inlet. Hot water processes may allow the clients water to circulate directly in engine recovery systems, or comprise of an intermediate cogeneration loop with heat exchangers. The compensation radiators reject excess heat, and shall be filled with antifreeze/corrosion protection dependant upon the ambient conditions.
24 Cogeneration systems
Power plants with gas engines as prime mover, allow high efficiency by combining electrical and thermal energy generation (called CHP - Combined Heat and Power - or cogeneration). Right now, our engines are converting up to 38% of the energy introduced into electricity. Using thermal sources, the overall efficiency can exceed 85 %. The design of a heat recovery system is tied to the analysis of the customer thermal needs, and an elaborate study is necessary to optimize the installation in order to achieve the best efficiency.
Key drivers and competitive advantages

Electricity is the most valuable form of energy generated in our business. Comparing the electrical to the thermal energy, the purchase price ratio is 5 to 1 at least in the combined heat and power market. Nevertheless, the higher the overall efficiency, the higher is the value of electricity. So waste heat is costing a lot. Total efficiency and output purchase prices are the key drivers. Compared to gas turbines, lean burn gas engines benefit as they have a very high electrical efficiency, which is maitained at part loads and over long period of time under severe operating conditions. The gas turbine is heavily derated by ambient temperature, altitude and back pressure, and typically suffers from a reduced electrical efficiency running hours accumalate. Varying load and frequent starts and stops also cause increasing wear and reduced efficency. The gas engines offer better overall economy since it is not as sensitive to variations in the operating conditions. Customer needs compliance Heat can be recovered to produce hot water, steam and even cold water by using an absorption machine. Provided the electricity purchase price is high enough, a steam turbine can be driven with the high pressure steam produced with the exhaust gas.
Basic knowledge
To achieve a thermal change, the fluid which is used to the process, must be colder than the one to be cooled.
QSV 81-91G
25 Partnership
To achieve a correctly installed, reliable, and economic power plant a partnership between the customer and Cummins is of great benefit. It allows the exchange of upto date information and detail, together with advice based on operational experience from other installations. The partnership may then continue throughout the life of the equipment, with routine maintenance and breakdown problems being resolved quickly and efficiently, to the satisfaction of all involved.
U.K. offices.
Maintenance
Cummins is well represented world wide and can therefore commit itself to a long lasting relationship with its clients. The Cummins service organization will not only participate in the start up of plant, but can also help perform the operation and maintenance of the plant during commercial operation. The degree of Cummins involvment will be negotiated at the sales discussion, or during the lifetime of the plant. Preventive maintenance In order to maintain a sustainable operation it is of importance that the maintenance of the power plant is performed continuously. Such a maintenance program is established in the Preventive Maintenance Guidelines included in contractual documentation, which is a comprehensive instruction describing when certain activities will take place. Some of them can easily be performed by the plant operation personnel but certain activities need external assistance from Cummins network personnel.
Engineering
Engineering of gas Power Plants is performed by a Cummins project team, supported by local representatives. Some information given in this handbook may be used for pre-configuration studies. At any time, up-to-date information is available from Cummins representatives, in Cummins Power Generation at Manston U.K. offices, for a final design. Commissioning Commissioning of the equipment delivered by Cummins is normally included in the main contract, and needs to be carried out by trained personnel. This reduces warrantee issues, as the recommended procedures are followed. Documentation The contents of the final documentation depends on the extent of delivery. In principle, the following documents are included in each delivery from Cummins : - Installation drawings and diagrams, for equipment supplied by Cummins. - Installation handbook, for equipment supplied by Cummins. - Operators manual, - Operation and maintenance manuals for components, supplied by Cummins. - Parts list, for equipment supplied by Cummins. All the above are in English as standard.
Operation of the power plant

Cummins can, when appropriate, enter into operational agreements which implies that when a customers so requires, Cummins can, on his behalf, operate the plant. All consumables such as filters, and lube oil can be arranged by Cummins. Cummins also has the facilities to offer a full operation and maintenance agreement, where the customers plant is operated and maintained by Cummins, including all consumables. The details on specific arrangements may be obtained from Cummins Power Generation at Manston U.K. offices. In this sort of the plant will be interconnected to the service main office where all operational parameters can be studied and measures recommended for adjustment of the plant.
A basic operator training session at the factory or on site is available on request. This training may be oriented to engines, or to power plant and electrical systems. Further training may be carried out if required, details may be obtained from Cummins Power Generation at Manston
QSV 81-91G
26 Units,Formulae
Current equivalents Power imperial measurements
1 British horsepower = 745.7 W 1 British horsepower = 0.7457 kW 1 British horsepower = 33,000 ft.lbF/min 1 British horsepower = 550 ft lbF/s 1 British horsepower = 2,544 Btu/h 1 British horsepower = 42.41 Btu/min 1Btu/min = 17.58 W 1Btu/min = 0.01758 kW 1Btu/min = 0.02358 Bhp 1 Btu/h = 0.2931 W 1 kW = 1000 W 1 kW = 1.341 BHP 1 kW = 44,250 ft.lbF/min 1 kW = 737.6 ft.lbF/s 1 kW = 3,412 Btu/h
Energy measurements
1 Btu = 9338 in.lbF 1 Btu = 778.2 ft.lbF 1 Btu = 0.000293 kWh 1 Btu = 1.055 kJ 1 ft.lbF = 1.356 N.m 1 ft.lbF/s = 0.001356 kW 1 ft.lbF/s = 0.001818 Bhp 1 therm (U.S)= 99,98Btu
1 ft.lbF = 0.001285 Btu 1 kWh = 3412 Btu
Refrigeration
288,000 Btu = 1 Ton.day 1ton= 12,000 Btu/h
QSV 81-91G
Conversion factors
From Unit_1Multiply by To Unit_2 Unit_1 > Unit_2 To convert from Unit_1 to Unit_2, use the two conversion lines Unit_1 to Ref_Unit and Unit_2 to Ref_Unit as described hereafter:
Unit_1 Unit_2
Factor_1 Factor_2
Factor _ 1 Factor _ 2
Ref_Unit Ref_Unit
Unit_1
Unit_2
Scientific notation
3.7 E+5 = 3.7 x 105 = 370 000 3.7 E-5 = 3.7 x 10-5 = 0.000 037 Prefix Giga Mega Kilo Hecto Deca Deci Centi Milli Micro Length Inch in 2.540 E-2 ft m Meter m Meter Meter G M k h da d c m 1.000 E+9 1.000 E+6 1.000 E+3 1.000 E+2 1.000 E+1 1.000 E-1 1.000 E-2 1.000 E-3 1.000 E-6 Unit Unit Unit Unit Unit Unit Unit Unit Unit
Foot = 12 inches Yard = 3 feet yd
3.048 E-1 m
9.144 E-1
QSV 81-91G Area

Square inch Square foot Square yard Acre acre in2 ft
2
6.452 E-4 9.290 E-2 8.361 E-1 m

2
m2 m
2
Square meter Square meter Square meter
yd2
m2
4.047 E+3 in3 ft3 yd3 gal
Square meter m3 m3 m3 m3 m3 m
3
Volume
Cubic inch Cubic foot Cubic yard US gallon Acre.inch Acre.foot 1.639 E-5 2.832 E-2 7.646 E-1 3.785 E-3 Cubic meter Cubic meter Cubic meter Cubic meter Cubic meter Cubic meter
273.15 T ( C ) + 273.15 m
3
acre.in1.028 E+2 acre.ft 1.233 E+3
Gas normal cubic meter:
P ( barG ) + Plocal ( barA ) 1.013
( at T and P )
Mass
Grain gr 6.480 E-5 2.835 E-2 4.536 E-1 kg kg kg Kilogram Kilogram Kilogram Newton N Newton Newton 1.000 E+2 Pa, N/m2 Pascal Pascal Pascal Ounce oz Pound lb
Force
Kilogram.forcekgf Ounce.force Pound.force ozf lbf 9.807 N 2.780 E-1 4.448 N
Pressure, stress
Hectopascal, millibar hPa, mbar Kilopascal, Pieze Bar bar Newton per square centimeter 1.000 E+5 Megapascal Pz, kPa, kN/m2 Pa, N/m2 1.000 E+3 Pascal Pa, N/m2 Pascal Pascal Pa, N/m2
2
Pa, N/m2 Pa, N/m2
N/cm2 1.000 E+4
MPa, N/mm2 1.000 E+6
Meter of water mW, mH20, mCE Kilogramforce per square mm Atmosphere (technical) Atmosphere (standard) Centimeter of mercury Foot of water ftH2O, ftW atm
9.807 E+3 kgf/mm2

2
Pa, N/m2 9.807 E+6 Pa, N/m2 Pa, N/m2 Pascal Pascal
Pascal
kgf/cm , At 9.807 E+4 1.013 E+5
Pa, N/m
Pascal Pascal
Pascal Pa, N/m2 Pascal
Millimeter of mercury, Torricelli
mmHg, Torr 1.333 E+2 Pa, N/m2 Pa, N/m2
cmHg 1.333 E+3 2.989 E+3
Inch of water inH2O, inW 2.491 E+2

Pressure, stress (continuation) Inch of mercury Foot of mercury inHg 3.386 E+3 ftHg 4.064 E+4 Pa, N/m2 Pa, N/m2 6.895 E+3 Pascal Pascal Pa, N/m2
2
QSV 81-91G
Pound.force per square inch psi, lbf/in2

2
Pascal
Pound.force per square foot lbf/ft 4.788 E+1
Pa, N/m
Pascal
Suffixes : suffix G = relative pressure; suffix A= absolute pressure Absolute pressure (A) = relative pressure (G) + local pressure. G means gauge
Temperature
Kelvin K K - 273.15 F C Degree Celsius Degree Celsius Degree Farenheit F Degree Farenheit Degree CelsiusC (F - 32)/1.8 C
(1.8 x C) + 32
Ounce per cubic inch oz/in3 1.730 E+3 Ounce per cubic yard oz/yd3 3.708 E-2 Ounce per US gallon oz/USgal Pound per cubic inch lb/in3 2.768 E+4 Pound per cubic foot lb/ft3 1.602 E+1 Pound per cubic yard lb/yd3 5.933 E-1 Pound per US gallon lb/USgal
kg/m3 Kg / cubic meter kg/m3 Kg / cubic meter kg/m3 Kg / cubic meter kg/m3 Kg / cubic meter kg/m3 Kg / cubic meter kg/m3 Kg / cubic meter Watt Watt
Ounce per cubic foot oz/ft3 1.001 kg/m3 Kg / cubic meter 7.489 kg/m3 Kg / cubic meter
1.198 E+2 W W Joule J
Power
Horsepower Metric HP Horsepower British Bhp 7.355 E+2 7.457 E+2 J
Energy
Watthour Calorie cal Wh 3.600 E+3 Joule 1.055 E+3 J Joule 3.600 E+6 7.937 E+6 J/kg J/kg J/kg Joule per kg Joule per kg J/kg Joule per kg Joule J Joule 1.899 E+3 Btu 4.187 J
British thermal unit Therm th
Centigrade heat unit Pcu, CHU 4.187 E+6
Specific energy (mass)

Kilowatthour per kilogram kWh/kg Kilowatthour per pound Kilocalorie per kilogram kWh/lb
CHU/lb, kcal/kg
4.187 E+3 Joule per kg J/kg
Kilocalorie per poundkcal/lb9.230 E+3 British thermal unit per pound
Btu/lb 2.326 E+3
Joule per kg
QSV 81-91G
Specific energy (volume)

Watthour per cubic meter Watthour per cubic inch Watthour per cubic foot Wh/m3 3.600 E+3 Wh/in35.900 E-2 Wh/ft3 1.020 E+2
3
J/m3 J/m3 J/m3
J per cubic meter J per cubic meter J per cubic meter J/m3 J/m3 J per cubic meter J per cubic meter
Kilocalorie per cubic meter kcal/m Kilocalorie per cubic inch Kilocalorie per cubic foot Btu per cubic foot Btu per US Gallon CHU per cubic foot
4.187 E+3 6.862 E-2 J/m

3
kcal/in3
3
kcalft 1.186 E+2 J/m3
J per cubic meter
Btu/ft3 3.726 E+4 Btu/USgal
J per cubic meter J/m3 J per cubic meter J/m3 J per cubic meter
2.787 E+5
Pcu/ft3, CHU/ft3
6.707 E+4
Therm per US Gallon Therm/USgal 2.787 E+10 J/m3
J per cubic meter J/(kgK) J/(kgK) J/(kgK) Joule per kg.K Joule per kg.K Joule per kg.K
Specific heat capacity (mass)

Kilowatthour per (kilogramKelvin) kWh/(kgK) 3.600 E+6 Kilocalorie per (kilogramKelvin) kcal/(kgK) 4.187 E+3 4.187 E+3
Btu per (pounddegree Fahrenheit) Btu/(lbF)
Specific heat capacity (volume)

Kilowatthour/(cubic meterKelvin) kWh/(m3K) 3.600 E+6 Kilocalorie per (cubic meterKelvin) kcal/(m3K) Btu per (cubic inchdegree Fahr.) Btu per (cubic footdegree Fahr.) 4.187 E+3 J/(m3K) J/(m3K) J/(m3K) J/(m3K) Joule / m3.K Joule / m3.K Joule / m3.K Joule / m3.K
Btu/(in3F) 1.159 E+8 Btu/(ft3F) ppm(wt) ppm(wt) ppm(wt) 6.707 E+4
Water hardness
German degree dH French degree Fr Clark degree Ck 1.790 E+1 1.000 E+1 1.425 E+1 Parts / million CaO3 Parts / million CaO3 Parts / million CaO3 Parts / million CaO3 ppm(wt) Parts / million CaO3
Millival per liter
mval/l 5.000 E+1
ppm(wt)
Grain of CaO3 per US Gallon of water
GPG 1.712 E+1
Miscellaneous
Per cent % Per thousand 1.000 E-2 1 Unit 1 Unit 1 Unit 2.778 E-4 1 1 / unit 1.000 E-3 ppm
Parts per million
1.000 E-6
Efficiency: kilojoule per kilowatt.hour
kJ/kW.h
Gas Power Plant Project Guide Formulae

Brake M ean Effective Pressure ( BM EP )
1.528 x kW (mechanical output) (rated rpm) x (stroke in m) x (bore in m ) x (nb of cylinders )
2
QSV 81-91G
BMEP (bar) =
( for 4 - cycle engine )
Temperature
Temp. ( C ) = ( F - 32 ) 1.8 F = ( C x 1.8 ) + 32
Power Factor and kVA

cos phi = kW kVA kVA = kW cos phi
Current, Power, Reactive- and Complex- Power

To obtain kW e = Single phas e A C V x A x cos phi 1000 V x A x cos phi 1000 X gen. eff. VxA 1000 kVA x (1-cos2phi) kW x 1000 V x cos phi kVA x 1000 V Three phas e AC kVA x cos phi kVA x cos phi gen. Eff V x A x 30.5 1000 kVA x (1-cos2phi)0.5 kW x 1000 V x phi x 30.5 kVA x 1000 V x 30.5 kW x 1000 V Direct current DC VxA 1000
engine meca kW =
kVA = kVAr = A (base kW ) =
A (base kVA ) =
Generator Frequency
Hz = No. of poles x rpm 120
QSV 81-91G
27 Mechanical data
QSV 81-91G gas regulating unit
Largest dimensions for the lowest gas input pressure
Engine type QSV 81G QSV 91G
L 2700 + 400 2700 + 400
H 820 820
W 310 310
A gas regulating unit is delivered with each engine. Operating conditions The role of the outboard gas regulating unit is to purify the gas by filtration, to regulate its pressure to a constant preset level and vent any overpressure downstream of the pressure regulator to atmosphere. The gas train is adaptable for upstream pressures in three models: 1.25 bar, 1.8 bar, 3.0bar. If the upstream pressure is above 3.0 bar then separate provision must be made to reduce the gas pressure. Manufacturing description Main shut off valve A manual ball valve allows the operator to cut-off the supply for maintenance.
ensures the downstream gas pressure limit is not exceeded, should any operation trouble such as sudden closing of engine valves, delay in pressure reducing valve operation, occur.
Safety shutoff solenoid valve

A double safety shutoff solenoid valve, under engine control, ensures the gas supply is cutoff should the pressure be detected out of operating range. The valve closes by deenergizing the solenoid coils.
Vent valve
A solenoid operated valve vents the space between the two shut off valves above to atmosphere.
Optional gas flow meter.

A gas flow meter may be installed on line to monitor the consumed gas amount.
Gas filter
The filter is equipped with an easily interchangeable cartridge filter unit with a pore size of 50m
Optional gas train without pressure reducer

If clients gas distribution fulfils the pressure variation requirements, the gas train may be delivered without a pressure reducer. Precautions for installation It is very important: for safety reasons, that each gas venting line shall be routed separately to the building exterior, keeping at least 50cm away from any heat source which has a temperature exceeding 120C, and at least 50cm away from conductors which have a voltage exceeding 500V. Venting lines are mandatorily metallic, with aging resistant sealings (Teflon, copper). Local regulations for gas installations should be followed.
Pressure reducer ( standard)

The pressure reducer has been designed to keep the outlet pressure of the gas stable, even if the upstream pressure is unstable, within limits, and is independent of distribution influences, like delivery pressure, and/or flow rate changes. A mechanically controlled safety shut off valve, (slam shut), prevents overpressure downstream of the pressure reducer. The control element of this valve, installed upstream of the pressure reducer shuts off the gas if the downstream pressure rises above the preset limits. The safety shut off valve must be reset by hand after the pressure reducing valve has been checked. The safety relief valve, membrane controlled,
Gas Power Plant Project Guide Compressed Air Production Unit

An air production unit is an assembly of a compressor, three receivers and, if necessary, an additional air storage skid. An air production skid is the assembly of a compressor set, accessories, and three receivers, on a skid. An air storage skid is an assembly of three receivers and associated drain on a skid. Manufacturing description Air production skids are made up of an electric driven compressor and three 200 litres vertical receivers. 1200l capacity is obtained with an additional air storage skid. Service pressure is 30 to 40 barg. The compressor is a flat twin, two-stages type, with intermediary air cooling, designed for 40 bar maximum operating pressure. Start and stop is controlled by a pressure switch. Compressor outlet separator and receivers are automatically drained by a cycle operated solenoid valve A connection manifold is provided to feed other air receivers, or to interconnect multiple air production skids. An asynchronous motor drives the compressor through an elastic coupling. A universal motor is suitable for both 50 and 60 Hz utilities. Speed and output are increased when operating in 60Hz (refilling times are indicated for 50Hz). Receivers are made of welded carbon steel internally epoxy painted. Design pressure is 40 bar, hydraulic test pressure is 50 bar, with french certification (for other countries on request). Each receiver starting head includes a relief valve, a dial pressure indicator and an output hand valve for isolation purposes.. The condensate returns to a separator through a filling line. Starting line is connectable at each end of the manifold. A pressure switch low-low is installed on the manifold for alarm purposes. The table below defines air production units for one engine with air storage capacity for 3 start attempts as a minimum.
Engine type Receiver capacity Elec. Power absorbed @ 50 Hz Elec. Power Air flow Air flow absorbed @ @ 50 Hz @ 60 Hz 60 Hz Dimensions Air outlet Height mm 2700 2700 O.D. 1" 1"
QSV 81-91G
Weight
Length litres QSV 81G QSV 91G All All 3 x 200 3 x 200 kW 4.8 4.8 kW 5.8 5.8 Nm /h 16.5 16.5 Nm /h 19.5 19.5 mm 1100 1100
Width mm 700 700
kg 540 540
Emergency spare parts air production unit International Lloyds or Veritas certification for air receivers
QSV 81-91G Air Storage Unit

An air storage unit is an assembly of one or more air storage skids. An air storage skid is the assembly of three receivers and associated drain, on a skid. Manufacturing description Air storage skids are made up of an assembly of three 200 litres vertical receivers. Service pressure is 40 barg. They are identical to the ones installed in air production skids, and a timed solenoid drain valve is installed on the supply line (cycle operated). Installation In a power plant, when multiple gensets are installed, air storage capacity is obtained by combination of air compressor skids and storage skids, as determined in the tables below. If all receivers are connected together with no isolating valves, or the interconnecting valves normally left open, then a leak may reduce the content of all receivers at the same time, or force compressors to operate continuously. Valves should be installed to isolate compressor and storage sub-assemblies, and they should only be opened on failure in part of the system.
Storage capacity liters 2 x 200 4 x 200 All
Dimensions Air Weight outlet Length Width Height mm mm mm O.D. kg 1 000 700 2 700 1" 460 2 x 1000 700 2 700 1" 2 x 460 International Lloyds or Veritas certification for air receivers
800l unit capacity is obtained with two 400l skids
Number of gen sets Number of air production skids Number of additional air storage skids Refilling time in minutes (*)
1 1 0 10
2 2 0 10
3 2 0 15
4 2 0 20
5 2 0 25
6 2 1 29
7 2 1 34
8 2 1 39
9 2 2 44
10 3 1 33
(*) Time to fill the receivers after 3 starting attempts of 5 seconds for each genset
QSV 81-91G
The Project Guide will be extended as information is checked and approved for issue.

173-Gas Substations Project Guide

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QSV 81-91G

Gas Power Plant Project Guide

Gas Power Plant Project Guide

Contents Foreword 1. General 1 6

2. Generating sets Gas engine

3 Combustion 4 Gas Definition

Gas Power Plant Project Guide

5 Engine Lubricant & Coolant Definition

Coolant Treatment ........................................... 19

6 Boiler Water Treatment 7 Alternator

8 Genset Control Panel (GCP)

Generator Set Connections ........................................... 35

Gas Power Plant Project Guide

23 Cogeneration systems 24 Partnership 25 Units,Formulae

Gas Power Plant Project Guide

Gas Power Plant Project Guide

Gas Power Plant Project Guide

World electricity supplies

Frequency (Hz) Supply Voltage Levels in Common Use (V)

Gas Power Plant Project Guide

Frequency (Hz) Supply Voltage Levels in Common Use (V)

Gas Power Plant Project Guide

Frequency (Hz) Supply Voltage Levels in Common Use (V)

Gas Power Plant Project Guide

Gas Power Plant Project Guide

Gas Power Plant Project Guide Cylinder liner

Main bearings and conrod big end bearing

Camshaft and valve mechanism

Gas Power Plant Project Guide

Free end cover

Gas Power Plant Project Guide

l= (m air/ m gas) actual

(m air/ m gas) stoichiometric

QSV 81-91G design: open chamber

Gas Power Plant Project Guide

Exhaust Gas composition

Diagram of combustion limits

Gas Power Plant Project Guide

N = normal, and is at an ambient temperature of 0C, at a pressure of 101.3 kPa gauge.

Current Methane Numbers (MN)

Gas Power Plant Project Guide

Generic composition of natural gas Gas quality requirements

criteria 30-40 0,7-0,9 >70 >75% <10% <0.01% 50

kg/Nm MN CH C2H6 H2S C

Gas Power Plant Project Guide

5 Engine Lubricant & Coolant Definition

Lube Oil Quality

Pegasus 805 Pegasus 705 Nateria MH 40 Mysella LA Estor SHPC

SAE 40 SAE 40 SAE 40 SAE 40 SAE 40

6.2 5.3 5.2 5.0 5.1

0.50 0.46 0.45 0.45 0.48

Lube Oil Grade (weight)

Gas Power Plant Project Guide

Gas Power Plant Project Guide

Water or Coolant & Inhibitors Preparation

A total hardness up to 250 ppm as CaCO3 may be toleratedin the circuit,

Gas Power Plant Project Guide

Product category working conditions

Recommended brands Producer ROHM & HAAS Tradename Type of product

HIGH-GRADE COOLANT ANTIFREEZE

ROHM & HAAS

Glycol Shell type D

Gas Power Plant Project Guide