Mechanical sides of this power plant:

Fuel Supply System:

In fuel supply system there are one storage tank, where oil in stored. This oil then pump to dry tank,
by means of transfer pump. During transferring from main tank to smaller dry tank, the oil passes
through strainer to remove solid impurities. From dry tank to main tank, there is another pipe
connection. This is over flow pipe. This pipe connection is used to return the oil from dry tank to
main tank in the event of over flowing. From dry tank the oil is injected in the diesel engine by
means of fuel injection pump.
In this power plant , there are two types of storage tank:
1. Day Tank
2. Storage Tank
The from the storage tank transfer to the Day tank for the daily use of fuel. The sediment and the
heavy materials of the fuel is separated by the pump about the 9000 rpm speed and the lightly
portion of the fuel is transferred to the day tank.

Air Intake System:

This system supplies necessary air to the engine for fuel combustion. It consists of a pipe for
supplying of fresh air to the engine. Filters are provided to remove dust particles from air. The air is
compressed about 20 to 25 bar for the engine. Air is used for the supply of oxygen.So the air
compressor is used for this purpose. For six engine , we need six air compressor in this plant.

Exhaust System:
The exhaust gas is removed from engine, to the atmosphere by means of an exhaust system. A
silencer is normally used in this system to reduce noise level of the engine.
In this power plant , there are about six(6) chimney for the exhaust of the engine.

Cooling System:
The heat produced due to internal combustion, drives the engine. But some parts of this heat raise
the temperature of different parts of the engine. High temperature may cause permanent damage to
the machine. Hence, it is essential to maintain the overall temperature of the engine to a tolerable
level. Cooling system of diesel power station does exactly so. The cooling system requires a water
source, water source, water pump and cooling towers. The pump circulates water through cylinder
and head jacket. The water takes away heat from the engine and it becomes hot. The hot water is
cooled by cooling towers and is re-circulated for cooling.

Lubricating System:
This system minimises the water of rubbing surface of the engine. Here lubricating oil is stored in
main lubricating oil tank. This lubricating oil is drawn from the tank by means of oil pump. Then
the oil is passed through the oil filter for removing impurities. From the filtering point, this clean
lubricating oil is delivered to the different points of the machine where lubrication is required the oil
cooler is provided in the system to keep the temperature of the lubricating oil as low as possible.

Starting System:
For starting a diesel engine, initial rotation of the engine shaft is required. Until the firing start and
the unit runs with its own power. For small DG set, the initial rotation of the shaft is provided by
handles but for large diesel power station. Compressed air is made for starting.

Boiler:
Here , the boiler is used for the purpose of heating the HFO( heavy furnace oil) to reduce the density
of the furnace oil. The steam is produced and pass through the pipe to heat the fuel/furnace oil.

Steam Generation Section:

A steam generator is a closed vessel made of steel. Its function is to transfer the heat produced by
the combustion of fuel to water, and ultimately to generate steam. In a HFO power plant heat
generated by combustion of diesel oil or by exhaust gas from engines. A burner is used to burn the
diesel oil. In a HFO power plant steam is used to preheat heavy fuel oil to reduce its density and
viscosity.
Types of steam generators: There are two types of steam generator. They are:
Auxiliary boiler
Exhaust gas boiler

Auxiliary boiler:
This is a forced circulated, stationary, horizontal, internally fired, multi tubular, fire tube boiler. A
booster pump in water treatment unit supplies water to the feed tank from water day tank. If pH and
conductivity of the water cannot meet the requirement then the chemical dosing unit supplies
necessary chemical to the feed tank to gain required pH and conductivity. Then feed pump force
water to circulate in boiler shell. A water level controller controls the water level in the boiler shell
automatically. A burner is used to burn fuel in furnace. Products produced in furnace change its
direction for first time in reversal chamber and goes through the smoke tubes. When flue gas
reaches to front reversal chamber then it changes its direction for second time and goes through
another set of smoke tube. Then flue gas passes through smoke tube aggregates at flue gas chamber.
Water surrounds these tubes become heated to generate steam by taking heat from smoke tubes
produced by flue gas. This steam comes out through steam outlet and is send to steam header.
Exhaust gas from flue gas chamber comes out through exhaust gas outlet. Steam generation of this
boiler is 1500kg/h at feed water temperature 90C.

Auxiliary boiler configuration:

Maximum water volume of boiler : 3610L
Working pressure of boiler : 7bar
Safety device set pressure of boiler : 10bar
Test pressure of boiler : 15.7bar

Maximum temperature : 194C

Working temperature : 170C

 Exhaust gas boiler:
Exhaust gas boiler is also fire tube boiler but in this boiler any combustion doesnt take place.
Temperature of exhaust gas of engine is used to boil water. As this boiler recovers heat from
exhaust gas, this is also known as heat recovery system of engine. Smoke of exhaust gas is
circulated through the smoke tube of the boiler and heat is exchanged from the exhaust gas to the
water outside of the smoke tube. Generated steam supplied to the steam header from where steam is
supplied to the required places. Steam generation rate of this boiler is 2550kg/h at feed water
temperature 90C.

Operation procedure:
Start operation:
At first feed pump should be started after opening the feed valve. Then needs to be run at stage-
1.After that vent valve needs to be open till the pressure gauge shows the reading of pressure at
2bar. When pressure gauge shows 2bar then vent valve needs to be closed and burner should be set
at stage-2. When steam pressure reached to 7 bar steam valve needs to be open slowly. Blow out
should be run in every 1 week for 2 second. When boiler works container fan must be run for all
time.
Stop operation:
At first burner should be stop by selecting burner switch from stage 2 to stage and then
from stage 1 to stage 0. Now feed pump needs to be stopped and then feed valve should be
closed. Then steam valve needs to be closed and container fan should be switched off.

Use of steam:
From boilers steam is sent to steam header. Then steam header distributes this steam to different
pipes. All fuel pipes are surrounded by copper pipe. Steam is circulated through copper pipe. Fuel
get heat from this copper pipe and its density reduced. As a result fuels can flow smoothly through
pipes.
Steam distribution process:
Steam produced in boiler is send to the steam header. From steam header steam is send to the steam
distributor system, Oil treatment unit, Storage tank unit, day tank unit. Condensed steam from each
unit comes back to the steam condensate through another pipe. Steam distributor system sends
steam to the powerhouse where steam is distributed to the compact booster unit, lube oil separator
unit and engine auxiliary module. From there condensed steam is send to the steam distributor
system from where steam is send to the steam condensate system. From steam condensate system
steam is send to the feed water tank.

Oil Treatment Section

Engine has a fixed requirement for oil quality. It is very important to fulfill these
requirements for longer durability of engines. To improve the quality of HFO, oil treatment unit
treats this HFO before feeding it to the engine. Objectives of oil treatment unit to improve quality of
HFO are to separate HFO from any other impurities by HFO separator, to send separated HFO to
day tank and to feed separated HFO to engine from day tank via feeder unit.
To fulfill these objectives oil treatment unit consists of two different units.
HFO separator unit
Feeder unit

HFO Separator unit:

This unit consists of two HFO separators. HFO separator is a mechanical device which is used to
separate unwanted liquid and solid particle from HFO. HFO separator works on the basis of
centrifugal force. This centrifugal force generated by the rotation of the bowl (rotor). This rotation
generates hundred or thousand times of earths gravity. When liquid or particles of different specific
gravity enters to the bowl, the different centrifugal force acts on them. Liquid or particle having
higher specific gravity faces higher centrifugal force and moves away from the Centre. So heavier
liquid and particles move toward the periphery of the bowl and collected into sludge space. This
heavier liquid and particles are known as sludge which is discharged from the bowl by opening
sludge port.

Different components of HFO separator

Feed pipe
Discharge pipe
Disk stacks
Hydro hermetic feed system
Cooling, hood
Solids ejection ports
Annular valve
Discharge nozzle
Cooling, solid catcher
Pre-filling chamber
Nozzle
Operating water discharge
Sealing liquid discharge
Slide-ring packing
Leakage outlet
Sealing liquid feed
Sliding piston
Closing chamber
Feed, solids catcher cooling
Discharge, solid catcher cooling
Feed, cooling
Centripetal pump
Importance of heavy fuel oil separation:
Engines have a fixed requirement for density and viscosity of heavy fuel oil. HFO separation is
necessary because density and viscosity of heavy fuel oil must be allowable for engines.
Unseparated oil is harmful for engines. The efficiency of engines will decrease if separated HFO is
not used. Proper combustion cannot be done by engine if unseparated HFO is used. Consequently
electricity production will decrease. Beside this, as the viscosity and density of unseparated HFO is
excessive so the flow rate of it is low. This can hinder the proper circulation of HFO inside
pipelines.
Feeder unit:
Feeder unit consists of three centrifugal pump(a duplex and a simplex). Duplex centrifugal
pump is used to supply HFO to the engine booster unit and simplex pump is used to supply LFO.
Automatic filter is integrated here to remove remaining impurities from separated HFO. Pressure of
HFO is increased before sending it to the engine booster unit by pressure valve. Its temperature is
also increased by a heater.

Generator:
The generator is designed to operate together with reciprocating engines.The electrical generator
converts mechanical energy to electrical energy, generally using electromagnetic induction. A
generator forces electric charges to move through an external electrical circuit, but it does not create
electricity or charge, which is already present in the wire of its windings. It is somewhat analogous
to a water pump, which creates a flow of water but does not create the water inside. The source of
mechanical energy is prime mover.

Flexible coupling:
A flexible coupling between the engine flywheel and the generator transmits the torque from the
engine to the generator. By using a flexible coupling the crankshaft is not loaded by any external
bending forces. The elements in the coupling are made of rubber. Six flexible coupling is used for
six generator set.

Operation Procedure:
Start procedure:
Before starting the engine it was checked that:
The lubricating oil level is correct.
The fuel system is in running order (correct preheating, correct pressure, sufficient pre
circulation to heat the fuel injection pumps)
Both cooling water system circuits, the LT and HT water circuits, are in running order
(correct pressures, circulating water preheated and pre- circulated sufficiently to heat
the engine)
oil level in the governor is correct.
The starting air pressure exceeds 15bar.
The starting air system is drained of condensate.
The drain pipe of the air cooler casing is open, no leakage.
Stop lever is in work position.
Pre lubricating oil pump is running and pressure is over 0.3bar
Turning device is disengaged
Indicator valves are closed. The automation system indicates ready for start.
Then following steps are done:
The pre lubricating oil pump is started to obtain a lubricating oil pressure over 0.3bar.
The valve in the starting air supply system is opened and condensate is drained via the blow-
off valve. Then the blow-off valve is closed when there is no more condensate.
The engine is run on starting air for some revolutions by pressing the button on the solenoid
valve and keeping the stop lever in stop position (red ball knob) and the indicator valves
open. In doing so the risk of water locks is eliminated. After blowing, the indicator valves are
closed.
The turning gear from the flywheel (yellow ball knob) is disengaged.
Start blocking on the LDU is checked. Then blocking was removed and is returned to the
main page.
It is checked that the automation system indicates ready for start.
It is checked that the stop lever is in work position.
It is checked that the local/remote switch is in local position.
The start button is pushed.
Finally it is checked that the automation system indicates that the engine is running and that
the running parameters are normal.

Stop procedure:
Following steps are done to stop the generator:
Engine is idled before stopping.
The engine is stopped by moving the stop lever into stop.
Pre-lubricating oil pump is kept in operation for 90 minutes after stop.

Diesel Engine:
A diesel engine power plant is the combination of the diesel engine with an electric generator to
generate electrical energy. Katakhali 50 MW peaking power plant is a diesel engine power plant.
Actually the diesel engine performs as the prime mover thats drives the alternator.
The turning gear is also located here.
The engine is designed by Turbocharger and supply connections are located on the left side
of the engine.
On the right side of the engine the coupling end of the crankshaft is shown.
or operation with heavy fuel oil as fuel, however it may be alternatively operated with diesel
oil up to 72 hours.
Surrounding air from engine house is used as inlet air.

Auxiliary systems:
Charge-air cooling (LT)
Control and monitoring
Heavy fuel oil supply
Heavy fuel oil main system
 Engine cooling (HT)
Exhaust gas System
Charge air system
Lubrication oil cleaning
Lubrication oil main system
Lubrication oil supply
Starting and control air
Water supply

The following components are attached to each engine:

Turbocharger
Lubricating oil pump
Lube oil filter
HT cooling water pump (engine cooling)
LT cooling water pump
Turning gear

Man 18V 32/40 General Data:

The rating Capacity of generator: 9.7 MW
Nominal speed: 750 r/min
The lowest stable speed: 250 r/min
Mean effective pressure: Pm= 24.87 bar
Compression ratio rp: 14.51 (* rp=(Full cylinder volume/clearance Volume)
Maximum burning pressure: 190 bar
Max Compression pressure :160 bar
Firing order: A1-B1-A3-B3-A5-B5-A7-B7-A9-B9-A8-B8-A6-B6-A4-B4-A2-B2
(Cylinder order: A Bank is on left see from coupling side,cylinder number start from
coupling side)
Pm= (Work done/displacement Volume)=Const. Pressure acting on the Piston during the
working stroke)

Lubrication System:
Brand of lubrication oil : SAE 40 (145 mm2 /s at 40)
The volume of attached lubrication oil pump: 226 m3/h (when the outlet pressure is 8.0 bar)
Speed of the pump: 1800 r/min
Nominal Outlet pressure: 4.55.5 bar
Flow of the lubrication oil: 180 m3/h (when the pressure before the engine is 4.0 bar)
Pressure after filter (before crankcase): 4.04.5 bar
Oil pressure at the turbocharger inlet:1.50.2 bar
Cooling system:
Volume of attached high and low temperature water pump: 140 m3/h (When the outlet
pressure is 4.5 bar)
Flow of high temperature water system: 108 m3/h
Flow of low temperature water system: 108 m3/h
Pressure of low temperature water at engine inlet: 2.54.5 bar
Temperature of LT water at engine inlet: 3040
Pressure of HT water at engine inlet: 2.04.0 bar
Temperature of HT water at engine outlet: 7585
Flow of fuel injector cooling pump: 3.2 m3/h (When the outlet pressure is 3.0 bar)
Inlet temperature of fuel injector cooling water :60
Expansion tank of HT,LT water: minimum volume is 0.5m3the height from the bottom of
the tank to the center of the crankshaft is 6-9m
Preheating of HT water heating power: min 108 kW(heating the water to 60from 10
within 4h)
Flow of electric preheating water pump: min 22 m3/h
With Electric temperature control device for HT, LT water

Air system:
Type of turbocharger: NR34/S (with air charging silencer)
Maximum speed of turbocharger: 26300 r/min
Weight of turbocharger: 1450 kg
With water cleaning device for compressor wheel and turbine of the turbocharger
Way of chargeConstant pressure system
Air flow: 17kg/s
Scavenging pressure: 4.0 bar (absolute pressure)
The type of intercooler: 2 stage fresh water cooling, with condensation water collecting
device
Pressure drop of intercooler : max 80 mbar
Charged air temperature after inter cooling : 4555
Exhaust gas temperature of the cylinder : 380420
Exhaust gas temperature difference between cylinders: average exhaust gas temperature is
50
Maximum burning pressure: 190 bar
Maximum burning pressure difference between cylinders: average burning pressure is 5 bar
Starting pressure of the safety valve: 247 bar
Exhaust gas temperature before turbine: 520530
Exhaust gas temperature after turbine: 320370
Exhaust gas flow of turbine: 17.5kg/s
Air suction vacuum of turbocharger 25 mbar
Height of stack: 32m
 Exhaust back pressure of turbocharger:30m
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