Annexures of ESIA of DSPGL PDF

Annexure - 1
Project layout plan

Annexure – 2(a)
HFO Engine Specification
MAN Diesel & Turbo
Nababganj Power Plant - 55MW

Bangladesh
Technical Specification
3 MAN Gensets 18V48/60TS plus mechanical & electrical auxiliaries
Our Reference 5301959-01-B001 Date 2012-02-21

5301959-01-B001 Technical specification Rev000 Page i
MAN Diesel & Turbo
Revision History
Revision Description Date Author

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

5301959-01-B001 Technical specification Rev000 Page ii
MAN Diesel & Turbo
Table of Contents
1 Design data and performance guarantees 1
1.1 Design data 1
1.2 Performance data 4
2 Diesel engine 5
2.1 Engine scope and special engine accessories 6
2.2 Engine System 6
2.3 Detailed Technical Specification of one engine 48/60TS 8
3 Generating set 10
3.1 Connecting elements 11
3.2 Genset 12
4 Mechanical scope 15
4.1 Auxiliary systems, engine related 15
4.2 Auxiliary systems, plant related 18
4.3 Exhaust gas system 21
5 Electrical scope 22
5.1 Control and monitoring system 22
6 Miscellaneous 30
6.1 Plant service and protection systems 30
6.2 Documentation 30
7 Tools, spare and wear parts 31

7.1 Tools and spares 31
8 Services 34
8.1 Quality Management, Quality Assurance 34
8.2 Project engineering 35
8.3 Logistics 37
8.4 Site activities 37
8.5 Project services 40
9 Requirements and limitations 43

9.1 Quality requirements for operating media 43
9.2 Limits of supply 46
10 Operation and maintenance 48

10.1 MAN Diesel & Turbo Service Worldwide 48
11 Standards, Guidelines and Drawings 49

11.1 Applicable standards 49
11.2 General guidelines 49
11.3 Drawings 50
11.4 Division of Works 50
12 General information 51
12.1 List of sub suppliers 51
12.2 References 52
12.3 Leaflets and brochures 57

5301959-01-B001 Technical specification Rev000 Page iii
Section 1 - Design data and performance guarantees
1 Design data and performance guarantees

Our quotation is based on following design data as well as the:
- Drawing of generating set: 11745001770_01_A_Genset Drawing
18V4860TS
1.1 Design data
1.1.1 Site conditions

Site conditions All offered equipment is designed to operate within the following ambient
conditions:
Altitude above sea level 23 m
Wet bulb temperature 29 °C
Minimum ambient air temperature 10 °C
Maximum ambient air temperature 40 °C
Operation outside of these limits without guarantee.
1.1.2 Generating sets

Generating sets Under consideration of your request, this quotation provides for 3 generating
sets based on the MAN 18V48/60TS engine.
Number of generating sets 3
Engine type 18V48/60TS
-1
Engine speed 500 min
Lube oil pump engine driven
HT cooling water pump engine driven
LT cooling water pump engine driven
Electrical The offered equipment is based on the following electrical values:
system Operation mode GRID ONLY
Frequency 50 Hz
Power factor cos phi (lagging) 0.8
Medium voltage 11 kV
Low voltage 400 V

5301959-01-B001 Technical specification Rev000 Page 1 of 58
1.1.3 Other design data

2
Foundation Soil bearing capacity 200 kN/m
Earthquake design according to Peak Ground Acceleration
1
PGA 0.2 g
Lube oil Engine lube oil has to be in accordance to the requirements as stated in
section 9.1
Requirements for viscosity:
Viscosity-class (40°) SAE40
Cooling method Features of the cooling water system:
Type of cooling system RADIATOR
Heavy fuel oil The fuel oil system is designed based on heavy fuel oil in accordance to the
requirements as stated in section 9.1.5.
Alternatively the engines can be operated on diesel fuel oil in accordance to
the requirements as stated in section 9.1.4 for up to 72 hours at a time.
Intake air Ambient air free of dust, salt and sand

Power house Design temperature rise
ventilation inside power house 17 K
The temperature rise to be measured between ventilation outlet und inlet.
The power house ventilation air is blown directly onto the alternator.
The alternator design temperature is 43 °C.
1
Peak ground acceleration with a probability of 10% to be exceeded in 50 years and
a return period of 475 years based on reference ground with a shear wave velocity >
800 m/s

Permissible
frequency limits 105 Continuous power
100
Load [%]
95
90
-6 -4 -2 0 2 4 6
Engine speed / Nominal speed [%]
Table 1: Diagram of permissible frequency and load limits

Table 1 shows that the maximum continuous engine output is ensured at a
mains grid frequency exceeding up to max. +3%, whereas at a frequency drop
to max. -5%, the power output is continuously reduced to 95% MCR. We
permit operation of the engines up to +5% frequency fluctuation for maximum
120 seconds. In any case, the maximum permissible mains grid frequency
deviation is ±5%.
Load When load is suddenly applied to a generating set there will be a transient
application deviation in voltage and frequency. The maximum permissible load increase is
limited to steps of 25% of the nominal power of all generating sets in operation.
Further it depends on the base load before load increase.
The offered generating sets comply with ISO 8528-5 class G2.

1.2 Performance data

The values given here are for information only and without guarantee.
Our stated performance data is based on the design data as per section 1.1
and calculated for the following reference conditions:
Air Inlet temperature (before air inlet filter) 35 °C
Site Reference
conditions Air Inlet pressure (before air inlet filter) 1011 mbar
Charge air temperature before cylinder 54 °C
Exhaust gas back pressure 30 mbar
Intake air pressure loss 20 mbar
In case the site conditions / technical parameters at performance test are
different from the site reference conditions defined above, the performance
guarantees will be adapted in accordance to MAN standard procedure.
Measuring Tolerances in the measuring equipment shall be considered additionally and
tolerances are not included in the guarantee figures stated below. Tests will be done
according to ISO 15550:2002 (ISO 3046-3:1989).
1.2.1 Continuous power of the generating set

Data will follow
1.2.2 Specific fuel oil consumption (SFOC)

Data will follow
1.2.3 Lubricating oil consumption

Data will follow

Section 2 - Diesel engine
2 Diesel engine
General The MAN engine 18V48/60TS is a
description four stroke, medium speed Diesel
engine, two-stage turbocharged and
charge air cooled. The engine is pre-
pared for operation on HEAVY FUEL.
Compared to other medium speed
engines, covering the same power
range, the 18V48/60TS produces high
power from a compact, efficient de-
sign.
Technical data The technical data is summarised in the following table:

Cylinder bore 480 mm
Piston stroke 600 mm
-1
Engine speed 500 min
Piston speed 10.00 m/s
Mean effective pressure 23.21 bar
Power per cylinder 1050 kW/cyl
Power of the engine (at crankshaft) 18900 kW m
Continuous The engine familiy has a well proven service record in marine propulsion,
development marine auxiliary genset and stationary power generation. 48/60TS engines
from MAN have been in service since 1989 and are subject to continuous
development to ensure reliability under the most severe service conditions.
Each 18V48/60TS engine is engineered to optimise its performance to ensure
that your individual requirements are met.
Outline
dimensions
2
Dimensions and weight of the engine 48/60TS:
Height (H) 5355 mm
Length (L) 13148 mm
Width (B) 4700 mm
Weight (dry) 255000 kg
2
The dimensions and weight stated correspond to the engine only. All given masses
are without lube oil and cooling water. Dimensions and weights are given for guid-
ance only and are subject to change without notice.

2.1 Engine scope and special engine accessories
Item Q’ty Description
2.2 Engine System
2.2.1 Engine System
010 3 Engines 18V48/60TS, suitable for operation on heavy fuel oil, as per following
MJA10 AV010 detailed Technical Specification
2.2.2 Turbocharger off engine
010.202 3 Turbocharger off engine
2.2.3 Lubrication system
010.220.010 3 Engine attached lube oil pump(s)

MJV21 AP050
Capacity approx. 504 m³/h including pressure control valve and connecting
pipe between pumps
2.2.4 Cooling water system
010.230.010 3 Engine attached HT cooling water pump

MJG31 AP030
Capacity approx. 220 m³/h
010.230.020 3 Engine attached LT cooling water pump

MJG32 AP030
nominal capacity 280 m³/h. The cooling water flow through the charge air
cooler will be adapted to 280 m³/h by installation of orifices.
2.2.5 Special equipment of the engine
010.250.030 3 Slow-turn facility on the engine.

The engine is automatically turned slowly prior to engine start with being
monitored by the engine control. If the engine does not reach the expected
number of crankshaft revolutions within the specified period of time, an error
message is issued. Slow-turn serves as an indication that there is liquid (oil,
water, fuel) in the combustion chamber.
2.2.6 Engine control and monitoring
010.290.420 3 Sensors / cabling for TC off engine

2.2.7 Factory Acceptance Test (FAT)
010.330.020 1 Factory Acceptance Test of the engine

The test will be done with the MAN Diesel & Turbo testbed equipment and
installations but without other offered equipment.
Pre tests:
Checking of systems and installations
Testing of monitoring and safety equipment
Running-in and adjusting
Running up to 100% load
Adjusting of ignition pressure
Adjusting of governor
Checking of all operation data
Workshop test procedure:
Starting tests approx. 15 min.
Warming up to 100% load approx. 25 min.
Continuous power of 100% load 60 min.
Continuous power of 85% load 30 min.
Governor test approx. 15 min.
For the FAT Diesel fuel and lube oil will be used in line with the MAN Diesel &
Turbo standards. The test will be executed according to the actual conditions
prevailing at our workshop. The operating values to be expected at site can be
calculated by using well-proven methods on basis of the main operating values
as certained on the test bed. The measuring parameters, including relevant
accuracies, are based on ISO 3046.
Extension or changes of our test programme would result in additional cost and
have to be clarified upon request.

2.3 Detailed Technical Specification of one engine 48/60TS

Design features One-part crankcase with safety valves on crankcase covers
Crankshaft made of forged steel with torsional vibration damper at free end
Main bearings and big-end bearings with two-part thin-walled bearing shells
and main bearings cross-braced by tie-rods
Connecting rod (splitted with flange) drop-forged of steel
Three-ring piston with forged steel crown and nodular cast-iron skirt
Cast-iron cylinder liners with fire band ring
Nodular cast-iron cylinder head with armour-plated inlet and exhaust valves,
valve seat rings for the inlet and exhaust valves. Valve rotators on the inlet and
exhaust valves. Indicator valve on each cylinder
Multi-part camshaft for enhanced Miller timing
Pipes on the engine with counter flanges or connecting screws
Fuel injection Injection pump on each cylinder
system Rocking levers between camshaft and pump plungers, on an excentric shaft,
adjustable from outside for optimising the injection timing
Variable injection timing (VIT), with automatic adjustment
Injection pipes, double walled
2 buffer pistons at the fuel admission and return pipes
Speed control Woodward EM300 electronic speed governor with actuator
Electric speed transmitter for engine speed and turbocharger speed
Electro-pneumatic emergency shutdown device on the engine for manual
remote emergency stop and for automatic stop at over speed and other stop
criteria within the safety system
Turbo charging 2 exhaust gas turbocharger, type TCA88 and TCA77 mounted at the FREE
and charge-air END. Lube oil run down tank, decoupled from turbocharger. Washing device
cooling (wet) for the exhaust gas turbine and compressor.
2 Charge-air cooler in fresh water and two-stage design; with counter flanges,
standard design for top removalAir pipe sound insulated between compressor
and charge air cooler (including air intake casing)
Exhaust gas piping on the engine, uncooled, thermally insulated and lagged
Platform Brackets on the engine for attaching the main gallery supports
Operation and Engine safety and control system SaCoS_one
control comprising of:
Control unit, resiliently mounted on engine, consisting of high integrated control
modules, one for safety system and one for alarm handling and control,
including the following functions:
Splash oil temperature monitoring
Main bearing temperature monitoring
Lube oil temperature and pressure monitoring
Cooling water temperature and pressure monitoring
Charge air temperature and pressure monitoring
Exhaust gas temperature monitoring
Speed monitoring and overspeed protection
Engine control

Electronic speed governing

Interface cabinet, as floor-standing cabinet for engine room installation
(standard colour RAL7035), including gateway module for plant communication
via interfaces to
Plant automation system
Power supply
Power management and starters for cylinder lubrication
Power management and starters for valve seat lubrication
HT, LT and CHATCO temperature control
Oil mist detector, make Schaller VN115
Temperature Thermocouples for measuring the exhaust gas temperature after each cylinder,
measuring before and after turbocharger, with terminal box and cabling on the engine.
Start and stop Compressed air starting equipment with main starting valve and with starting
equipment valve on each cylinder of one cylinder bank
Lubricating and Cylinder lubrication oil pump with attached electrical motor (IP 55)
cooling Forced-feed lubrication for all bearing points of running gear, camshaft, timing
gear, governor drive and turbocharger
Pressure control valve for engine lube oil
Cylinders, cylinder heads, fuel injection valves, and charge-air cooler are
water-cooled, pistons are oil cooled
Flywheel and Flywheel with toothing, without protection cover
turning gear Bolts connecting the flywheel with the crankshaft
Turning gear for the running gear, with electric motor (reversible; IP 54)
Push button switching equipment, control cable
Starting interlock when turning gear engaged, with limit switch (not cabled; 24
V DC; IP 65) for display
Engine painting The outer surface of the engine is covered with paint “white aluminium” RAL
9006. Painting consists of one finishing coat, approx. 20 µm.
Acceptance Works acceptance / factory approval.
Calculation Torsional vibration calculation

Section 3 - Generating set
3 Generating set
General Our generating sets are designed for power generation in continuous, durable
description and safe operation. The area of application comprises ranges from supplies of
basic loads in public mains or coverage of peak loads to isolated applications
for industrial consumers.
The engine is rigidly mounted on a steel frame, acting as the lubricating oil
service tank, which is resiliently seated on a simple concrete foundation by
spring isolators. The alternator is connected to the engine by a flexible
coupling, rigidly mounted and grouted onto a separate and elevated concrete
foundation.
This genset design is prerequisite for our simple, small, single-floor power
house concept to get short assembly and commissioning periods at low cost.
Outline
dimensions
3
Dimensions and weight of the generating set:
Height (H) 6530 mm
Length (C) 18558 mm
Width (W) 4700 mm
Weight (dry) 375000 kg
3
The dimensions and weight stated correspond to the complete unit including alter-
nator. The total weight varies depending on the alternator make. All given masses
are without lube oil and cooling water. Dimensions and weights are given for guid-
ance only and are subject to change without notice. The length of the genset unit
depends on the alternator make.

3.1 Connecting elements
3.1.1 Coupling arrangement
020.010.010 3 Flexible coupling

The flexible coupling is mounted between engine flywheel and alternator shaft.
The scope includes a connection hub for the alternator shaft and fixing bolts for
connection to the flywheel.
A standard coupling is used. Size and rubber quality are determined by the
torsional vibration calculation.
020.010.040 3 Cover for flywheel and coupling
3.1.2 Engine seating
020.020.020 3 Engine seating

Set of foundation bolts for ridgid seating of the engine.
3.1.3 Pipe adapters
020.030.025 3 Flexible pipe connections for the engine
020.030.080 3 Rubber expansion joint for intake air duct

to be installed upstream of turbocharger, delivered with counterflange
020.030.090 3 Adapter for exhaust gas duct

to be installed downstream of turbocharger, without counter flange
3.1.4 Low pressure turbo charger ducts
020.035.010 -1 3 Intake air ducting

interconnecting ducts for intake air between low pressure- and high pressure
turbo charger
020.035.020 -1 3 Exhaust gas ducting

interconnecting ducts for exhaust gas between low pressure- and high
pressure turbo charger
020.035.030 -1 3 Miscelleanous piping

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

3.2 Genset
3.2.1 Alternator system
025.020.010 -1 3 Three phase synchronous alternator

MJA10 AG011
Design:
The stator frame is a rigid, welded steel structure construction. The stator core
is built of thin electric sheet steel laminations which are insulated on both sides
with heat-resistant inorganic resin. The radial cooling ducts in the stator core
insure uniform and effective cooling of the stator.
The rotor consists of a forged steel shaft, a hub and sheet steel poles fixed on
the hub. The pole laminations are pressed together with steel bars fixed to the
end plates.
The windings, epoxy resin impregnated, are provided with very strong bracing
which withstands all expected mechanical and electrical shocks and vibrations.
Engine-independent, self lubricated bearing design, to avoid possible lube oil
contamination by the engine.
The alternator is self-ventilated and needs no external forced air flow. The
surrounding air is used for cooling. The cooling air is drawn in through air filters
and blown out to the surrounding environment.
Rated technical data:
Output approx. 22988 kVA
Voltage 11 kV
Current approx. 1207 A
Frequency 50 Hz
Power factor 0,8
Temperature rise stator/rotor F/F
Insulation class F
Mounting design IM1101 or IM7301
Protection class alternator IP23
Protection class terminal box IP54
Cooling method IC0A1 (Air cooled)
Operation S1, continuous
Operation mode Grid parallel
Applicable standard IEC 60034
The alternator is optimized for voltage-stability in case of load variation.
Accessories:
Anti-condensation heater
Pt100 sensors for winding temperature detection
Pt100 element and lubrication oil sight-glass for monitoring, for each
bearing
Main terminal box (terminals U/V/W/N) and auxiliary terminal box (for
accessories) inclusive suitable cable glands for bottom entry
Brushless self-excitation system including rotating diodes and protection

against overvoltage
Droop current transformer installed in main terminal box
Star point current transformers for protection purposes installed in main
terminal box
Painting similar to engine colour
Foundation bolts
Final series test report according to manufacturers standard is included.
025.020.050 3 Automatic voltage regulator (AVR)

Digital excitation control system type Basler DECS 200 is installed on a
mounting plate integrated in the Genset Interface Panel (GIP).
Features:
Voltage regulation within 0.25% from no-load to full-load
Proportional (P), integral (I) and derivative (D) stability control
Underfrequency limiter or V/Hz ratio limiter
Paralleling compensation of two or more generators using reactive droop
Manual and automatic channel
Several protection functions
Diode monitoring function is included
Serial bus coupling for read out of different measuring values
3.2.2 Foundation system
025.030.010 3 Steel foundation frame

The engine is rigidly mounted and bolted on a steel foundation frame which is
resiliently seated on the foundation. The steel foundation frame is used as lube
oil service tank.
025.030.030 3 Grouting material for seating of alternator
025.030.050 3 Foundation frame seating

Spring elements for resilient, vibration-isolated mounting of the steel foundation
frame with engine on the concrete foundation including equipment for lining
(balancing aids) and fixing.
3.2.3 Genset addons
025.035.010 3 Frame auxiliaries and frame assembly

Engine and steel foundation frame are mounted at the MAN Diesel & Turbo
workshop. Attachment of turning gear, terminal boxes, piping and cabling is
included. Additionally an installation drawing is provided.
025.035.060 3 Lube oil tank level monitoring

3.2.4 Genset service platforms
025.040.010 3 Engine service platform

Free standing engine service platform, with floor plates, railing, stair and
fasteners.
025.040.020 2 Interconnecting bridges for engine service platforms, with railing
025.040.050 1 Service platform for turbocharger

Section 4 - Mechanical scope
4 Mechanical scope
4.1 Auxiliary systems, engine related
4.1.1 Lube oil service system
030.020.010 -1 3 Lube oil module

MJG32 AP040
consisting of:
Lube oil heat exchanger
Lube oil automatic filter
Lube oil priming pump with e-motor
lube oil temperature regulating valve
Terminal box
The above equipment is mounted on a frame with corresponding fittings
completely piped and wired.
030.020.150 3 Lube oil replenishing and flow rate measuring device consisting of:
MJV23 CF010 Oval gear meter including pulse trigger
Solenoid valve
030.020.160 3 Lube oil separator module

GBK37 AT020
consisting of:
Separator, self-cleaning, capacity min. 4725 l/h with motor
Switch cabinet, complete with control and power part as well as temperature
control and temperature switch
Steam heated lube oil preheater with safety valve and insulation
Sludge collector and sludge pump
Supply pump, not fitted
030.020.280 3 Oil mist eliminator

MJV28 AN010
The vent gases originate from the following:
Crankcase: Gases from the combustion chamber leak past the piston rings
Turbocharger vent: The bearing housing of the turbocharger is pressurized
to prevent the hot exhaust gases entering the bearing housing. It is
pressurized by letting some of the gases from the compressor side of the
turbocharger into bearing housing. This process can not be controlled
precisely so some of the gases are vented via a pressure regulating value
to the atmosphere.
The oil mist eliminator reduces the air emissions from the vents of the engine
crankcase chamber and the turbocharger.

4.1.2 HT cooling water service system
030.030.035 3 Cooling-down pump, free-standing

MJG31 AP020
capacity 30 m³/h, with e-motor 2.5 kW
030.030.040 3 HT cooling water temperature regulating valve

MJG31 AA010
with electric actuator, to be fitted in the cooling water pipe to radiator and
resistance thermometer Pt 100 to be fitted in HT cooling water pipe
downstream the mixing point.
030.030.050 3 Resistance thermometer for HT cooling water, loose supply
030.030.060 3 Cooling water expansion tank

MJG31 BB010
The tank is designed with two separate compartments for HT and LT circuit,
capacity 1000/500 l, with mechanical level indicator and minimum alarm
contact
4.1.3 Low temperature cooling water system
030.040.050 3 LT cooling water temperature control valve

MJG32 AA025
DN200, with electric actuator and resistance thermometer Pt100 to be installed
in LT cooling water pipe downstream the mixing point
030.040.063 6 Charge air temperature control valve (CHATCO)

MJG32 AA010
030.040.066 6 Resistance thermometer for charge air temperature

MJG32 AA015
4.1.4 Two circuit radiator cooling system
030.050.010 -1 3 Two-circuit radiator cooling system

MJG31 AC020
The engines are cooled with outside mounted, horizontal type radiators with
electrically driven induced draft fans with space heaters.
Scope of supply:
Radiator cooler with separate cooling circuits for high and low temperature
cooling water
Frame material: Hot dipped galvanized steel.
Tube material: copper
Fin material: Aluminum
The radiator coolers are designed for a minimum temperature of 10°C (without
glycol) and a maximum ambient temperature of 40 °C.
Supply without steel supporting structure.
Each engine is cooled by separate radiator units.
Noise power level of the radiators for one engine is 107 dB(A).

4.1.5 Fuel oil service system
030.110.140 3 Fuel oil booster module

designed as single-module, acting engine related, consisting of:
Flow rate measuring device, volumetric type
Mixing tank
Booster pump with motor and safety valve
Stand-by booster pump with motor end safety valve
Fuel oil cooler for Diesel fuel oil
Duplex filter approx. 0.034 mm serving as indicator filter, with manual
change-over and differential pressure contact indicator
Pressure compensation tank
Control cabinet
The above equipment mounted on a frame, complete with pipes, with leakage
oil pan, fittings, valves, insulation and fixing bolts.
4.1.6 Combustion air system
030.120.010 3 Intake air filter unit

MJQ61 AC020
consisting of:
Vertical weather louvre
Pocket filters (dry filters)
Filter house
Difference pressure transmitter
Transition piece with integrated silencer for a noise attenuation of approx.
40 dB(A) and flange(s) to intake air duct
030.120.050 3 Intake air duct upstream of turbocharger

including supports
4.1.7 Engine exhaust gas system
030.130.020 3 Expansion joint for exhaust gas duct

to be installed after adapter, without counter flange
030.130.030 3 Exhaust gas duct inside power house

with bend and supports, without wall sockets, without counterflange
4.1.8 Insulation
030.160.010 3 Insulation material for exhaust gas duct inside powerhouse

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

4.2 Auxiliary systems, plant related
4.2.1 Lube oil supply system
040.010.020 1 Leakage oil module,

EGD51 AP040
This module collects the fuel oil leakage quantities of the engine and of the fuel
oil module.
The leakage oil module is equipped with:
Leakage oil tank, 500 l capacity, with level indicator and level switch
2 Discharge pumps for fuel oil
Terminal box
The above equipment is mounted on a frame completely piped and wired.
040.010.030 1 Lube oil supply pump

MJV23 AA010
capacity 3 m³/h, with e-motor 2 kW. The pump is used to supply lube oil from
the storage tank to the service tank.
040.010.040 1 Lube oil transfer pump

MJV23 AP060
capacity 10 m³/h, with motor 4 kW and attached pressure relief valve. The
transfer pump is used to refill the foundation frame (lube oil service tank) with
the lube oil stored in the maintenance tank.
4.2.2 HT cooling water supply system
040.030.010 -1 1 Preheater set for cooling water

MJG31 AC010
If, after a longer engine shut down, the temperature of the cooling water is
below 20°C, preheating is necessary before the start-up of the engine.
A preheater set delivers the necessary energy. A circulating pipe interconnects
the preheating set with the engine.
Cooling water preheating module, consisting of:
Continuous flow water heater (steam heated)
Temperature regulator
Terminal box
4.2.3 Main water supply and condensate system
040.040.010 1 Cooling water collecting tank

GBK35 BB050
capacity 10000 l with mechanical level indicating.
040.040.020 1 Cooling water replenishing pump

GBK35 AP010
capacity 3 m³/h, with e-motor 2 kW and expansion pot, capacity 200 l.

4.2.4 Fuel injection nozzle cooling system
040.045.010 3 Nozzle cooling water module

MJG32 AP020
consisting of:
Nozzle cooling water circulation pump with motor
Expansion tank
Heat exchanger (connected to LT circuit)
Temperature regulating valve
Safety valve
The above mentioned eqiupment is mounted on a frame with corresponding
fittings, completely piped and wired.
4.2.5 Fuel system, plant related
040.050.070 1 Diesel oil pressure limiting valve

EGD53 AA010
to be mounted in the Diesel oil piping inside engine room.
040.050.080 1 Heavy fuel oil pressure limiting valve for installation in piping for heavy fuel oil
END55 AA040 inside the engine room.
4.2.6 Fuel oil treatment and supply unit
040.060.010 1 Heavy fuel oil separator module

EPN54 AC201
consisting of:
Separator (self-cleaning), effective separator capacity min. 13422 l/h, with
motor
Switch cubicle complete with control and power part, as well as temperature
Steam heated fuel oil pre-heater with safety valve and lagging
Sludge collector and sludge pump
Flexible pipe connections
Supply pump, not fitted, with dirt trap.
040.060.015 1 Heavy fuel oil separator module (stand-by)

consisting of:
Separator (self-cleaning), effective separator capacity min. 13422 l/h, with
motor
Switch cubicle complete with control and power part, as well as temperature
Steam heated fuel oil pre-heater with safety valve and lagging- Sludge
collector and sludge pump
Flexible pipe connections
Supply pump, not fitted, with dirt trap.

040.060.040 1 Set of heavy fuel fuel oil supply pumps

END55 AP030
(1x for service + 1x as stand by)
capacity approx. 20 m³/h each, with motor 15 kW, with dirt trap and safety
valve.
040.060.050 1 Set of Diesel oil supply pumps,

EGD53 AP020
(1 x service + 1 x stand-by), capacity approx. 25 m³/h each, with motor 11 kW,
with dirt trap and safety valve.
040.060.060 1 Heavy fuel oil filter module

EGD53 AT050
consisting of:
Automatic backwash filter for fuel oil approx. 0.025 mm, with attached
differential pressure contact indicator, steam heated
Flushing tank
The above equipment mounted on a frame, complete with pipes.
040.060.080 1 Diesel oil duplex filter

mesh width 0.025 mm with attached differential pressure contact indicator
4.2.7 Starting air system
040.070.010 2 Starting air receiver

SCB71 BB010
capacity 5000 l, working pressure 30 bar, with valve head, fittings, pressure
gauge, supports and retaining bracket. The starting air receivers are connected
in parallel, each one can be isolated from the system by shut-off valves.
The capacity of the starting air receivers is designed for 3 starts of one engine
without refilling. After a longer standstill of the engine a slow turn manoeuvre is
required which needs additional starting air. 1 slow turn manoeuvres are
considered in dimensioning of total capacity of the starting air receivers.
040.070.030 2 Automatic draining equipment for starting air receiver

SCA71 AT020
040.070.040 1 Compressor module

SCA71 AN010
consisting of 2 compressors with eletric motor, 30 bar pressure, capacity 172
m³/h each at 20°C and 1013 mbar barometric pressure, with suction filter, air
cooled, intermediate and final cooler, oil and water traps, electro-magnetic
water drain and switch and control device.
Module complete with three-phase motor 45 kW, flywheel and flexible coupling.
Equipment mounted on a skid for resilient mounting.
040.070.060 2 Pressure reducer for control air

QFA71 AA010
with water trap, dirt trap and safety valve. One in operation plus one in stand-
by.
The pressure reducer is installed in the 30 bar air line, the pressure is reduced
to 7 bar for providing control air to the engine and accessories.

040.070.070 1 Control air drier

QFB72 AT020
Dehumidification of the control air. Complete system with
thermometer for dew point temperature indication
automatic condensate discharge
040.070.080 1 Control air tank for pump house

QFB72 BB010
content 120 l, vertical tank with safety valve, pressure gauge and shut-off
valve.
The control air tank to be installed in the pump house.
040.070.140 -1 3 Start-up air blower
4.3 Exhaust gas system
4.3.1 Exhaust gas silencer
060.005.010 3 Exhaust gas silencer:

MJR65 BS010
Silencer for installation outside of the power house,
Technical features:
Reactive and/or absorptive attenuation principle
Noise attenuation approx. 25 dB(A)
Total pressure loss < 10 mbar
Material of main components S235JR
Absorptive material, if any, within special cushions retained by perforated
plates
Scope of supply for silencer including:
Corrosion protection of non-insulated external surfaces
Support brackets and fixing accessories for installation on roof or in steel
structure
Delivery loose, without counterflange and insulation material
Insulation works by Third Parties according to engineering specification
4.3.2 Insulation material for exhaust gas duct
060.140.020 3 insulation material for silencer

incl. insulation material and sheathing

Section 5 - Electrical scope
5 Electrical scope
5.1 Control and monitoring system
5.1.1 Genset Interface Panel (GIP)
070.010 -1 3 Genset Interface Panel (GIP)

The genset interface panels are arranged for floor mounting with cable insert
from backside into plinth. Design as steel frame construction, totally closed,
front door with rubber gasket. The panels are equipped with fans, thermostat,
air filters and anti-condensation heating. The panels are with panel light and
electrical outlet.
Dimensions of each panel:
Width approx. 800 mm
Height approx. 2,000 mm
Depth approx. 600 mm
Plinth approx. 200 mm
protection class IP 42
structural painted to RAL 7035
plinth painted to RAL 7022
labels: white, with black standard-type letters, design according to DIN EN
60439-1, IEC 60439-1 and ISO 8528, Part 4.
Control equipment:
AC power supply input for panel equipment
AC UPS power supply input for control and generation of DC 24V
1 x AC UPS Voltage / DC 24 V power supply unit for PLC equipment
Emergency stop push button with interlocking relais with positively driven
contacts and external reset terminals. Function: engine shut down and
engine aux. stop
PLC equipment (Siemens ET200)
1 PROFIBUS connection to Interface Cabinet
1 PROFIBUS connection to EAP (Engine Auxiliary Panel)
1 Interface module to EDS-D system
Integrated devices:
AVR with power factor regulation (item 025.020.050)
1 EDS-D system
5.1.2 Genset control panel (GCP)
070.020 -1 3 Genset control panel (GCP)

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


Width: approx. 800 mm
Height: approx. 2000 mm
Depth: approx. 600 mm
with panel fan incl. thermostat and filter for each panel
with panel light, incl. electrical outlet
with heating resistance humidity controlled
protective system IP 42
instruments: frame size: 96 x 96 mm, scale 90°, class 1,5
labels: white, with black standard-type letters, design according to DIN EN
60439-1, IEC 60439-1 and ISO 8528, Part 4.
located in control room, cable insert from bottom
MEASURING:
1 Voltmeter
1 Voltmeter selector switch for generator, 3 positions
3 Ammeters
1 Power factor meter 0,5-1-0,5*

1 MW-meter for connecting on transducer*
1 MWh-meter with pulse output*
1 Measuring transducer for active power*
1 Measuring transducer for reactive power*
1 Measuring transducer for current*
1 Measuring transducer for voltage*
1 Measuring transducer for power factor*
1 Measuring transducer for frequency*
* can be integrated in one device
1 Set of test terminals for performance test

1 Set of measuring and control circuit MCBs
SYNCHRONISING:
1 Automatic synchronizing unit with black busbar possibility door mounted
1 Synchrocheck relais with black busbar possibility
1 Key selector switch "GCP-SCADA"
1 Selector switch for GCP synchronizing "AUTO-OFF-MANUAL"
1 LED synchronoscope with integrated synchronizing check relay
1 Double-voltmeter
1 Double-frequency meter
1 Push button "CB ON"
1 Push button "CB OFF"
1 Switch "frequency lower / 0 / frequency higher"
1 Switch "voltage lower / 0 / voltage higher"


1 Mimic diagram equipped with position indicator for generator circuit
breaker
1 Mimic diagram equipped with position indicator for alternator earthing CB
with push buttons "ON / OFF"
ALTERNATOR PROTECTION:
digital protection relays, with following protection functions:
Stator earth fault (59N)
Directional earth fault (67N), with cable current transformer
Over-current (51)
Short-circuit (50)
Negative sequence (46)
Differential current (87 G)
Loss of excitation (40)
Reverse power (32)
Over-/under-frequency (81)
Under-voltage (27)
Over-voltage (59)
Over-excitation (24) realized in AVR

Loss of excitation (40) realized in AVR as backup
CONTROL:
AC Supply input for panel equipment (fan, socket, anti-condensation
heating).
AC Supply input from UPS for control
Necessary set of mcbs
Necessary set of contactors, relays, transducers, terminals a.s.o.
Fault indication light on roof
Interface to external control with pot. free contacts, digital in/outputs, pot.
free analogue inputs according interface list.
All devices marked on device and mounting plate acc. circuit diagram.
1 Panel inside fixed list of mcbs and related functions.
Emergency stop push button with interlocking relays with connection to the
positively driven contacts and external reset terminals in ECP, function:
engine shut down
Spare terminals 10% of installed
PLC Part:
with Siemens Simatic S7-400
1 Power supply unit
1 CPU
1 Communication processor for industrial Ethernet
*Digital input boards with 32 inputs.
*Digital output boards with 32 outputs.
*Analogue input boards with 16 inputs.

1 PROFIBUS connection to ECP (Engine Control Panel)

1 Siemens Operator Panel
1 MPI connection from CPU to Operator Panel
*Number of boards as required (15 % spare).
Data link to Central Supervisory System / Common Control Panel: Ethernet
SOFTWARE:
consisting of:
Start/stop and monitoring program for genset auxiliaries (automatic /
manual)
Start and stop program for engine
Generator active power monitoring
Generator current monitoring
Generator voltage monitoring
Generator power factor monitoring
Generator frequency monitoring
Generator circuit breaker control / Synchronizing release
Engine load regulation
Engine analogue value monitoring
Storage of analogue values
Overload monitoring (> 100 % load, load reduction)
Alternator winding temperature protection (49)
(alternator equipped with 6 Pt100 sensors)
Alternator bearing temperature protection (39)
(bearing equipped with Pt100 sensor)
In case of trouble, the indication of arisen failures will be indicated in sequence
of incidence with additional indication of time, when it happened.
5.1.3 Common control panel (CCP)
070.030 -1 1 Common control panel (CCP)

arranged for floor mounting, metal enclosed cubicle, steel frame construction,
totally closed with ventilation slots, front door with rubber gasket.
Dimensions:
Width approx. 2000 mm
Height approx. 2000 mm
Depth approx. 600 mm
with panel fan incl. thermostat and filter
with panel light, incl. electrical outlet
with heating resistance thermostat controlled
protective system IP 4x


instruments: frame size: 96 x 96 mm, scale 90°, class 1,5
labels: white, with black standard-type letters,
design according to DIN EN 60439-1, IEC 60439-1 and ISO 8528, Part 4.
Located in control room, cable insert from bottom
MEASURING:
For 1 outgoing to step-up transformer:
Voltmeter
Voltmeter selector switch, 3 positions
3 Ammeter
1 Power factor meter 0,5-1-0,5*
1 MW-meter for connecting on transducer*
1 Measuring transducer for active power*
1 Measuring transducer for reactive power*
1 Measuring transducer for current*
1 Measuring transducer for voltage*
1 Measuring transducer for power factor*
1 Measuring transducer for frequency*
* can be integrated in one device
for 1 MV bus bar:

1 Voltmeter
1 Voltmeter selector switch, 3 positions
1 Measuring transducer for voltage
1 set of test terminals for performance test

1 set of measuring and control circuit MCBs
SYNCHRONISING
1 automatic synchronizing unit for outgoing to grid,
1 automatic synchronizing unit for LV circuit breaker to station transformer
1 Key selector switch "CCP-SCADA"
1 Selector switch for CCP synchronizing: "AUTO-OFF-MANUAL"
1 LED synchronoscope with integrated synchronizing check relay
1 Double-voltmeter
1 Double-frequency meter
1 Mimic diagram equipped with position indicator and push buttons ON/OFF
for each MV circuit breaker (except alternator CBs) and synchronisable LV
CBs
1 Control switch "frequency lower / 0 / frequency higher"
1 Control switch "voltage lower / 0 / voltage higher"
PROTECTION

1 multi function protection relay for station transformer, with:

Short-circuit (50)
Overcurrent (51)
Earth fault (50N/51N)
1 multi function protection relay for outgoing feeder to step-up transformer,
with:
Short-circuit (50)
Overcurrent (51)
Earth fault (50N/51N)
Over/under voltage (59/27)
Over/under frequency (81)
CONTROL:
consisting of:
AC supply input for panel equipment (fan, socket, anti-condensation
heating)
AC UPS input for control
Necessary set of mcbs with short circuit withstands 10kA for values <= 20A
and 15kA for values > 20A
Necessary set of contactors, relays, transducers, terminals a.s.o.
Horn for alarm door mounted, fault indication light on roof
Interface to external control with pot. free contacts, digital in/outputs, pot.
free analogue inputs according interface list
All devices marked on device and mounting plate acc. circuit diagram
1 Panel inside fixed list of mcbs and related functions
1 Set of push buttons: lamps test, horn off, reset etc.
1 Set of control lamps: common aux. fault etc.
1 Control equipment for detection of mains fault
PLC Part:
Hardware with Siemens Simatic S7-400
Consisting of:
1 Power supply unit
1 CPU41_
1 Communication processor for industrial ethernet
*Digital input boards with 32 inputs
*Digital output boards with 32 outputs
*Analogue input boards with 16 inputs
1 Siemens Operator Panel OP 677 19"
1 MPI connection from CPU to OP 677 19"
1 Profibus connection to CAP
1 Profibus connection to CAPP
Data link to Central Supervisory System: Ethernet.
*Number of boards as required (15 % spare)

Software:
consisting of:
Control (switch ON/OFF, interlocking, release) of all motor operated circuit
breakers in MV switch gear and LV main distribution
Control of all plant auxiliaries acc. to power station design "Automatic-
Manual"
Plant power management acc. to remote or local demand
Load sharing program for load balance of the engines, including monitoring
of nominal load and reverse power
Control for start and stop of the gensets depending on load demand.
Island operation features
Load shedding program, in case of overload and underfrequency
Control for earthing resistors with selector switch "Automatic-Manual"
Mimic diagram for earthing CB with control lamp "ON"
Control for interlocking of earthing CBs (only one CB is on)
Mimic diagram for all motor driven CBs
5.1.4 Operation and monitoring system
070.040 -1 1 CENTRAL SUPERVISORY SYSTEM

Automation control system for supervision and control with 2 Server PCs and 3
Operator Station PCs for supervision:
Hardware:
2 Server PC with CPU with appropriate performance and memory capacity,
with state of the art operating system, with hard disk, CD-ROM, interfaces 2
x serial, 1 x parallel, state of the art graphic board, 3 Ethernet connections
standard keyboard (english)
redundant remote control via modem
3 Operator Station PCs with CPU with appropriate performance and
memory capacity, with state of the art operating system, with hard disk, CD-
ROM, interfaces 2 x serial, 1 x parallel, USB, state of the art graphic board,
ethernet connection
standard keyboard (english) and mouse
19" Monitor (TFT)
one color inkjet desk top printer, DIN A4 with cut sheet feeder
one black/white laser desk top printer, DIN A4 with cut sheet feeder
Ethernet switches
Software:
for 3 generating sets installed on each PC, consisting of:
complete overview of the power station
presentation of genset with analog value indication
single line diagram of the power station
overview of the lube oil system
overview of the cooling water system


overview of the fuel system
overview of the intake air system
overview of the exhaust gas system
overview of the steam generation system
presentation of these values in monthly bar diagram
presentation of 32 analog values as a line diagram of the last 24 hours (8
values in one diagram simultaneously)
presentation of 32 stored analog values as a line diagram at days before (8
values in one diagram simultaneously)
documentation of fault indications and operation signals as short term / long
term history.
5.1.5 Plant sensors for piping
070.060.010 -1 1 Plant sensors for piping

Sensors and instrumentation for visualization of operating conditions
transmitted via electrical signals (no local sensors without any wiring)
Scope of supply:
Sensors and instrumentation connected to pipes (connecting pipes between
modules) which are not included neither in the scope of the Diesel engine nor
in any module or component of the plant.

Section 6 - Miscellaneous
6 Miscellaneous
6.1 Plant service and protection systems
6.2 Documentation
170.010.010 -1 3 Engine, turbocharger and plant documentation

in paper edition, consisting of:
Operating instructions and maintenance schedule for engine and turbo-
charger
Working Instructions
Spare parts catalogue
Tools and spare parts list
Workshop test acceptance certificate for engine and turbo-charger
Set of documentation for the plant accessories and
Set of documentation for control and monitoring accessories (after
commissioning)
Additionally the above mentioned documents will be handed over in PDF-
format on CD or DVD. The documentation will be in English language and in
MAN Diesel & Turbo Standard format (duplex printed).

Section 7 - Tools, spare and wear parts
7 Tools, spare and wear parts
7.1 Tools and spares
7.1.1 Engine tools
015.010.010 1 Set of standard and special tools for the engine

required for servicing and inspection of the engine, consisting of:
BASIC TOOLS
Eye bolt, socket wrench insert with adapters, screw driver inserts, torque
spanners
HYDRAULIC TOOLS
Pneumatically driven hydraulic high-pressure pump with hyraulic bolt
tensioning devices
MEASURING TOOLS
Valve seats in the inlet and exhaust valve seat rings
Elongation of the connecting rod bolts
TOOLS FOR INJECTION
Adjusting device for the fuel injection pumps
Hydro pneumatic injection tester and cleaning tool for the fuel injection
valves
TOOLS FOR GOVERNOR
Tools for the speed governor
GENERAL
Piston ring expander
Cleaning device for the injection and starting valve seats in the cylinder
heads
DEVICES
Hydraulic lifting and lowering device for the main bearing caps
Supporting device for the running gear
Mounting and removing devices for:
Valves in the cylinder heads
Inlet and exhaust valve springs
Fuel injection pumps and their drive
Springs of the fuel injection pumps
Sealing rings of the fuel injection pump elements
Pistons including insertion bush
Cylinder liners
Fire ring
Connecting rod bearing caps
Crankshaft and connection rod bearing shells
Connecting rods
Suspension devices for:


Rocker arm casing
Cylinder head
Fuel injection pumps
Connection rod shank
MILLING AND GRINDING TOOLS
Milling device for the fuel injection valve seat in the cylinder heads
015.010.020 1 Crank web deflection measuring device
015.010.080 1 Electric valve cone grinder

for the exhaust valves, make HUNGER
015.010.090 1 Electric valve seat grinder

for the inlet and exhaust valve seats (alternating current 230V)
015.010.110 1 Electronic firing pressure gauge 250 E
015.010.182 1 Assembly and reversing device for the cylinder heads
015.010.370 1 Set of tools for turbocharger

including 1 set of blocking / closing device
7.1.2 Engine spare and wear parts
015.020.010 1 Set of spare parts for turbocharger
015.020.020 3 Set of engine standard spare parts

for engine type 18V48/60TS, consisting of:
Piston:
1 Set of compression and oil scraper rings
Cylinder head:
1 Valve seat insert for inlet valve with round seal ring
1 Valve seat insert for exhaust valve with round seal ring
1 Valve guide with round seal ring
Inlet valve:
1 Inlet valve, complete
Exhaust valve:
1 Exhaust valve, complete
Operation/Monitoring:
1 Three-way solenoid valve
1 Pressure reduction valve
Fuel injection pump with drive:
1 Pump plunger with barrel (pump element)
1 Set of seal rings for fuel injection pump
Fuel injection valve:
1 Fuel injection valve, complete


3 Fuel injection nozzles with needle and guide
3 Sets of round seal rings for injection valve
Fuel injection pipe:
1 Fuel injection pipe with connection parts (without threaded piece)
Seals and round seal rings:
1 Set of seals and seal rings for 1 cylinder
Sealing material:
1 Set of sealing material.
015.020.070 1 Spare parts for operating and monitoring the engine
015.020.140 1 Set of spare parts for SACOS
015.020.170 1 Spares for oil mist detector
7.1.3 Plant tools
015.030.025 1 Tools for nozzle cooling water unit
015.030.090 1 Mobile strainer cleaning unit

for lube oil and heavy fuel oil automatic filter, consisting of:
Tank
High-pressure pump
Pump protecting filter
Microfilter
Cleaning gun with high-pressure hose
Cleaning liquid
7.1.4 Plant spares
015.040.020 -1 1 Set of spare parts for alternator

consiting of:
1 Set of diodes; varistor (for one generator)
1 PC PT100 for bearing

Section 8 - Services
8 Services
8.1 Quality Management, Quality Assurance
8.1.1 man hours Quality Planning
205.010 -1 1 Establishing of a Quality Plan

MAN Diesel & Turbo has implemented a Quality Management System that
conforms to ISO 9001 and ISO 14001 environmental standards. The integrated
quality and environmental management manual is applied to all internal
process steps to assure MAN Diesel & Turbo's grade of quality for our engines
as well as for equipment delivered by subsuppliers.
An individual quality plan will be issued, containing order-specific outlines of the
quality standard related to quality assurance and quality documentation. In
addition, individual processes are scheduled, deliveries are defined and test
plans are assigned to the components to be suppiled. Factory/Site Acceptance
Tests follow the individual items of this plan.
The electronic version of the documentation shall consist of:

Project specific Quality Plan
Inspection and Test Plans
Inspection and Test Records
The above mentioned documents will be handed over in PDF format on

CD/DVD. The documents will be in English language and in MAN Diesel &
Turbo standard format.

8.2 Project engineering
8.2.1 System engineering
210.015.010 -1 1 System engineering

MAN will engineer the standard systems of the power plant and supply the
design data required for specification of the concerned equipment
Design of the lube oil, cooling water, fuel, intake air and exhaust gas
systems
Heat recovery system for auxiliary consumption
Adaption of the engine configuration to site conditions
The results of the system engineering are dimensioning data such as
consumption, pressures, flow rates, temperatures, etc. and technical
requirements at interfaces which will be used for ordering of the equipment.
MAN will execute P&I Diagrams of all mediums required for the operation of the
electrical power generating equipment (i.e. lube oil, cooling water, fuel)
including all relevant pipe sizes.
210.015.020 -2 1 Basic Design criteria - Engineering Tankfarm

Basic dimensioning of tanks
Definition of heating requirements
Recommendation for tanks incl. generic standard drawings for tanks
and heating device
Recommendation for instrumentation of tanks
8.2.2 Mechanical project engineering
210.020 -1 1 Mechanical project engineering

MAN will execute following order drawings:
Power house layout drawing

8.2.3 3D modelling
210.022 -1 1 3D modelling
Based on the engineering services mentioned above MAN Diesel & Turbo will
execute a 3D modelling for Powerhouse.
As an outcome of the finished 3D model following drawings will be provided.
General drawings for mechanical erection of the plant:
Equipment location plan
Support location plan
Main cable tray plans
Guidance drawings for the preparation of plant steel works:
Pipe support drawings
Additional steel support drawings
Drawings for preparation and execution of piping works:
Pipeline installation plans
System isometric drawings
Pipe isometric drawings
8.2.4 Calculation of genset foundation
210.033.010 1 Design of the genset foundation base

Based on the genset foundation drawing mentioned above, MAN will execute
civil design works for the genset foundation.
As an outcome of the civil design works MAN will prepare following
documentation:
General arrangement drawing
Reinforcement drawing
Steel bending and quantity list
Foundation calculation
Short construction manual.
Calculation of the foundation is based on the soil bearing capacity as per
section 1 and does not consider engineering or design for piling.
8.2.5 Engineering of auxiliaries
210.040 -1 1 Engineering of auxiliaries

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

8.2.6 Electrical engineering
210.060 -1 1 Electrical engineering

establishing of the electrical documentation of the plant, consisting of:
Technical specification of electrical equipment
Electrical cabinet drawings
PLC architecture / schematic diagrams
Single-line diagrams for MV and LV system
List of measuring and control devices (plant)
List of Electrical Consumers
8.3 Logistics
8.3.1 Transportation of equipment
220.020.050 -1 1 Sea transport to CIF Mongla, not unloaded
220.020.090 -1 3 Engine lifting device (on loan basis)

MAN Diesel & Turbo will deliver the engine together with an engine lifting
device. This equipment is required for transport and installation purpose only
and shall be returned to MAN Diesel & Turbo once installation of the engines /
generating sets is over.
The customer shall cover the cost for return transport to MAN Diesel & Turbo's
workshop in Augsburg and shall also arrange for temporary import permission
of the device (if necessary).
8.4 Site activities
8.4.1 Supervision of installation
230.030.040 -1 34 man days monitoring of mechanical installation

The MAN Advisor joins the placing of the gensets on the foundation, alignment
as well as installation of the offered auxiliary equipment to implement the MAN
Diesel & Turbo quality standard. After completion, a final check of all systems
will be done.
230.030.060 -1 13 man days of electrical equipment erection

8.4.2 Commissioning
230.110.010 -1 75 man days commissioning of engine by technician

The technician will assist the commissioning engineer in performing all
mechanical pre-tests, signal testing, starting up the genset, collecting of
operational data and adjusting of engine parameters.
230.110.020 -1 75 man days commissioning of engine by engineer

The commissioning engineer will perform all mechanical and electrical pre-tests
and starting up of the individual auxiliary systems. The commissioning engineer
is responsible for running-in the engine according to manufacturers
instructions. He verifies functional tests of the engine and plant control and
safety system. Additionally he will assist the measurement team during the
execution of performance tests.
230.110.040 -1 75 man days commissioning LV/Control (SaCoS)
230.110.200 -1 15 man days commissioning alternator

One commissioning engineer from the manufacturer will commission the
alternator according to the manufacturers instruction. He will check the correct
installation as well as the function of the alternator protection and control
system.
230.110.210 -1 9 man days commissioning lube oil seperators
230.110.210 -2 6 man days commissioning separators

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

8.4.3 Site Acceptance Test (SAT)
230.120.010 -1 3 Performance test

Specialists from MAN Diesel & Turbo will perform measurements to
demonstrate the guaranteed values according to MAN Diesel & Turbo test
procedures. The measurements will be done by our engineers in cooperation
with the customers operating personnel.
Output at site:
Measurements are taken at by using an external high precision power meter
Type Zimmer LMG 450.
Fuel oil consumption:
Measurements and calculations of the fuel oil consumption will be carried
out in line with ISO 3046, ISO 15550 and MAN standard procedures.
Measuring equipment is an external high-precision mass flow meter type
Endress+Hauser Promass 83, which is temporarily installed on the fuel oil
booster module. The duration of the test has to be adapted to the local
availability of constant load. As a guideline, 3 tests of 2 hours each could be
performed. The determination of the lower calorific heat value of the fuel oil
used will be carried out at the MAN laboratory in Augsburg.
Lube oil consumption:
The measurements and calculations of the lube oil consumption will be
carried out in line with ISO 3046, ISO 15550 and MAN standard procedures
(engine running in). Due to the required measuring time being minimum 24
hours, lube oil consumption measurement will continue after the fuel
consumption test.
230.120.040 -1 9 man days exhaust gas emission test

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

8.5 Project services
8.5.1 Factory training (mechanical)
Optional service
240.010 -1 1 Factory training (mechanical)
Basic mechanical training course for up to 6 plant operators at the PrimeServ
Academy. Duration of the training is 5 days, training without traveling
expenses, boarding and lodging. The training language will be English.
Seminar contents:
Welcome and general introduction:
Introduction to the specified engine type
Safety and special tools
Handling of manuals and work cards
Hydraulic tensioning tools
Running gear maintenance
Fuel injection system
Lube oil system
Pneumatic system
Engine starting system
Cooling water system
Operating data of systems on engine
Turbocharger basics
Turbocharger maintenance
Introduction to Engine Control System
Operation of Engine Control System
Operating and maintenance experience
Identifying minor faults and troubleshooting
Execution of maintenance tasks defined byMAN Diesel & Turbo
instructions.
The training is subject to our general terms and conditions published on our
homepage www.mandiesel.com.

8.5.2 Factory training (electrical)
Optional service
240.015 -1 1 Factory training (electrical)
Basic training in electrical operation up to 6 participants. The training consists
of 5 working days, training without traveling expenses, boarding and lodging.
A detailed training schedule for the training program will be elaborated by the
PrimeServ Academy at least fourteen days prior to course implementation. The
training language will be English.
The course includes theoretical training as well as field exercises:
Maintenance procedures on alternators, transformers, switchgears and DC
systems.
Review of single line diagrams, switchgear and relay maintenance and
trouble shooting,
Introduction to the instrumentation and control system, such as e.g. control
fundamentals, sensors, transmitters, instrumentation and control systems.
The course will be held by professional trainers, dedicated to training only,
using multi-media equipment. Each participant will receive a personal copy of
the full course documentation.
The training is subject to our general terms and conditions published on our
homepage www.mandiesel.com.

Additional site activities

The above mentioned site services are based on our experience and cover the
normal supervision duration of a standard power plant. In case this project
requires additional supervision or commissioning services, we are able to offer
further supervision services based on the following conditions.
The costs of the services rendered shall be accounted on the basis of the costs
incurred for each MAN Engineer as follows:
For each working day (8 hours),
without Saturdays, Sundays and Holidays EUR 1,100.00
Daily allowance per calendar day
with free accommodation EUR 85.00
For each overtime hour in excess of the
daily working time of 8 hours,
as well as for each working hour
on Saturdays, Sundays and Holidays EUR 200.00
The costs of the services rendered shall be accounted on the basis of the costs
incurred for each MAN Technician as follows:
For each working day (8 hours),
without Saturdays, Sundays and Holidays EUR 880.00
Daily allowance per calendar day
with free accommodation EUR 85.00
For each overtime hour in excess of the
daily working time of 8 hours,
as well as for each working hour
on Saturdays, Sundays and Holidays EUR 160.00
Should any evaluation costs be made in the workshops, then these will be
added to the invoice.
Travelling time will be charged at above mentioned prices. Travelling and
accommodation costs will be invoiced as incurred.
Value added tax
The above mentioned rates, resp. expenses, are quoted without VAT. The
corresponding VAT (turnover tax) will have to be added to those amount
according to the legal regulations which apply.

Section 9 - Requirements and limitations
9 Requirements and limitations
9.1 Quality requirements for operating media

MAN Diesel engines are designed for continuous operation on the operation
media as listed below. Project specific system layout for the respective
operating media are mentioned in the respective chapters of our offer.
Compliance with environmental regulations (e.g. World-Bank Guidelines for
stack emissions) cannot be stipulated and has to be checked for the operating
media that will be used for the project.
9.1.1 Lube oil

Use of engine lube oils according to the approval list of MAN Diesel & Turbo.
More detailed information on the lube oils approved by MAN Diesel & Turbo is
available in the engine manuals.
Requirements for viscosity:
Viscosity-class (40°) SAE40
Requirements for Base Number (BN):
TBN (Total Base Number),
if sulphur concentration < 1.5% wt. 30 mg KOH/g oil
if Sulphur concentration > 1.5% wt. 40 mg KOH/g oil
Please note that our cooling systems are designed to operate with the above
mentioned lube oil class SAE40 only. Operation of the plant with other lube oils
requires a detailed modification in the cooling systems and additional equipment
cost.
9.1.2 Cooling water

The engine and radiator cooling water must be carefully selected, treated and
controlled. The treatment with an anti-corrosion agent has to be effected before
the first commissioning of the plant. During subsequent operations the
concentration specified by the engine manufacturer must always be ensured.
The MAN operating instructions contain the additive brands that are approved
by the manufacturer.
The characteristics of the water used for engine cooling must be within the
following limits:
Type of water preferably distilled water or freshwater,
free from foreign matter
4
Total hardness < 10°dH
pH-value 6.5 - 8
Chloride ion content max. 50 mg/l
Silicid acid max. 50 mg/l
Not to be used: Sea water, brackish water, brines
industrial waste water and rain water
4 1 °dH (German hardness) = 10 mg CaO in 1litre water

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

9.1.3 Water for separators

The water for separator operation must be carefully selected, treated and
controlled. The characteristics of the water used must be within the following
limits:
Type of water preferably distilled water or freshwater,
free from foreign matter
5
Total hardness < 6°dH
pH-value > 6.5
Chloride ion content < 50 mg/l
TSS < 10 mg/l
Not to be used: Sea water, brackish water, brines
industrial waste water and rain water
9.1.4 Diesel fuel oil
9.1.4.1 Fuel system related characteristic values

Diesel fuel oil (DFO) – based on ISO F- DMB. (ISO 8217-2010)
The usability of the DFO depends on its conformity with the key properties listed
below:
Lower calorific value (LCV) 42,250 kJ/kg
3
Density at 15° C 900 kg/m
2
Kinematic viscosity at 40°C 2.0 … 11 mm /s
Pour Point, winter quality < 0 °C
Pour Point, summer quality < 6 °C
Flash point (Pensky Martens) > 60 °C
Total sediment fraction 0.10 % wt.
Water content < 0.3 % vol.
Sulphur content < 2.0 % wt.
Ash content < 0.01 % wt.
Coke residue (MCR) < 0,3 % wt.
Cetane number or cetane index > 35
Hydrogen sulphide < 2 mg/kg
Total acid number < 0.5 mg KOH/g
3
Oxidation stability < 25 g/m
Lubricity (wear scar diameter) < 520 µm
Copper-strip test <1
If the above mentioned fuel oil specification is not met, it can only be used in
case of fuel treatment.
9.1.4.2 Diesel fuel oil properties related to site conditions

2
Required kinematic viscosity at engine inlet: 2,5 … 14 mm /s
To meet the Diesel oil requirements at engine inlet the Diesel oil provided must
be in a range between minimum viscosity and maximum viscosity as specified
5 1 °dH (German hardness) = 10 mg CaO in 1litre water

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

bellow, considering project-specific ambient conditions (minimum air

temperature Tamb min. / maximum air temperature Tamb max. plus ΔT = 10 K):
2
Min. kinematic viscosity: 2.5 mm /s at 50 °C
2
Max. kinematic viscosity: 14 mm /s at 10 °C
MDT is recommending a fuel management suitable for seasonally occurring
temperatures, i.e. subsequently to the requirements above it might be
necessary to provide two different Diesel oil qualities for summer season and
winter season.
In case the viscosity limits as stated above cannot be met, a special Diesel oil
cooling system respectively a Diesel oil heating system is required and can be
offered upon request.
9.1.5 Heavy fuel oil

The HFO specified in the following chapters is the worst-case fuel that Diesel
engines can operate satisfactorily.
9.1.5.1 Fuel system related characteristic values

The fuel system is designed to operate based on the following fuel oil
specification based on ISO 8217-2010:
Lower calorific value (LCV) 40230 kJ/kg
2
Viscosity (at 50°C) up to 180 mm /s
3
Density (at 15°C) max. 1010 kg/m
Sulphur content up to 3.4%-wt.
Ash content up to 0.15%-wt.
Flash point min. 60 °C
Pour point max. 30 °C
Coke residue (Conradson) max. 20 % wt.
Vanadium max. 450 mg/kg
Water max. 0.5 % vol.
Sediment (potential) max. 0.1 % wt.
Aluminium and silicon (total) max. 60 mg/kg
Total acid number max. 2.5 mg KOH/g
Hydrogen sulphide max. 2 mg/kg
Asphaltene content max. 2/3 of coke residue
% wt (Conradson)
Sodium Sodium < 1/3 vanadium,
Sodium < 100 mg/kg
CCAI number max. 870
Current fuel oil characteristics is not sufficient for estimating the combustion
properties of the fuel oil. This means that service results depend on oil
properties which cannot be known beforehand. This especially applies to the
tendency of the oil to form deposits in the combustion chamber, gas passages
and turbines. It may, therefore, be necessary to rule out some oils that cause
difficulties.
The fuel must be free of admixtures not based on mineral oil, such as coal oil or
vegetable oils, free of tar oil and lubricating oil, free of any chemical waste,
solvents and polymers.

9.1.5.2 Treated heavy fuel oil at engine inlet

Inorganic foreign particles <20 mg/kg
(incl. catalyst residues) (aluminium + silicon content < 15 mg/kg)
particle size: < 5 m
Water < 0.2% vol.
9.1.6 Intake air

The quality and the condition of the intake air (combustion air) exert great
influence on the engine output as well as on the engine's lifetime.
For this reason, effective cleaning of the intake air and regular
maintenance/cleaning of the air filter are required.
The concentrations before the turbocharger inlet must not exceed the following
limiting values:
Dust (sand, cement, CaO, Al2O3 etc.) max. 5 mg/Nm³
Chlorine max.1.5 mg/Nm³
Sulfur dioxide (SO2) max.1.25mg/Nm³
Hydrogen sulphide (H2S) max.15 mg/Nm³
9.2 Limits of supply
9.2.1 General remark

The “Limits of Supply” are to be read in connection with the offered scope of
supply as per the technical specification.
All equipment comes with steel frames or mounting plates and with bolts, studs
and screws to install the equipment on the foundations or elevated platforms /
walkways.
Any steel supporting structures, steel mounting elements, etc. necessary to
install the equipment / modules / auxiliaries are not included in the scope of
supply of MAN Diesel & Turbo.
9.2.2 Generating sets

Mechanical:
Pipe connection terminal on the engine to connect the engine to various
pipes
Electrical:
Terminal box of the alternator
Civil:
Steel foundation frame with frame stoppers and leveling screws; grouting
material (pagel)

9.2.3 Engine and plant related auxiliaries, modules, equipment

and tanks
Mechanical:
Flanges and counter flanges on the modules / auxiliaries / equipment for
connection to the various system pipes (e.g. fuel, lube oil, water, sludge,
steam, condensate, pressurized air)
Electrical:
Terminal boxes on the modules / auxiliaries / sensors for connection to the
power and control cables
9.2.4 Electrical equipment / Engine and plant control system

Connectors on Genset Interface Panel (GIP) and Genset Control Panel
(GCP) for bus cables (Profibus)
Connectors for power supply on GIP and GCP
9.2.5 Engineering
Civil: n/a
E&M: Inside power house
PIDs: For fuel, intake air, exhaust gas, cooling water, lube oil.

Section 10 - Operation and maintenance
10 Operation and maintenance
10.1 MAN Diesel & Turbo Service Worldwide

For all engines delivered by us or built according to our design, MAN Diesel &
Turbo offers high-quality service 24 hours a day and around the world.
Therefore, our customers may rely on assistance through our service team
during the entire life-time of their engine plant.
The scope of services and products covered by the MAN Diesel & Turbo
Service network comprises the following essential features:
All over the globe, along the major shipping routes as well as in the most
thriving economies, the MAN Diesel & Turbo Service team is near you! This
ensure 32 service centres, 49 authorised workshops, 24 spare parts stocks and
70 agencies, which provide the best possible care for your plant.
If necessary, a swift, around-the-clock spare parts supply permits delivery of
parts, usually within one day from the receipt of your order.
Our specialists, located both at our global service bases and in our Augsburg
headquarters, offer free-off-charge counselling by phone. From among them, a
stand-by team of particularly experienced service personnel will render
competent assistance; 24 hours a day and 365 days a year!
Original, high-quality spare and wear parts ensure the safe, reliable and
economic operation of your engine plant; at a reasonable price! This also
applies to our inexpensive reconditioning service.
If you wish to combine utmost operational reliability with certainty regarding the
future working expenses of your plant, you may take advantage of our
maintenance and operation contracts. We provide the required exchange parts
as well as the connected services over the requested contract period at exactly
calculated costs.
Even the best state-of-the-art engines require a qualified service, which we
have been offering for over a century, now.
Make use of our experience!

Section 11 - Standards, Guidelines and Drawings
11 Standards, Guidelines and Drawings
11.1 Applicable standards

All materials, equipment and services mentioned in this quotation comply with
the respective standards and codes of the country of manufacture.
In particular, equipment supplied from EU countries complies, as far as
applicable, with the following standards and codes:
ISO International Standards Organisation
IEC International Electro technical Commission
EN standard - European Institute for Standardisation
Manufacturer’s QA/QC System
Manufacturer's standards
11.2 General guidelines
11.2.1 Heat exchangers for engine cooling

The heat exchangers offered are suitable for non-aggressive raw water (fresh
water). If aggressive raw water is used (e.g. brackish water, industrial waste
water) we are unable to accept any warranty for the heat exchangers, pumps,
pipes and other units in contact with such water.
Water For the first filling of the system, water used in the cooling system has to meet
treatment, the requirements listed in chapter 9. The treatment, kind and amount of added
mains water chemicals are related to the water quality available at site.
supply The water shall be available at the plant premises with a pressure of 4-6 bar.
11.2.2 Painting of the supplied equipment

Auxiliary equipment is delivered in the original colour as supplied by the sub
supplier, if not specified in this document otherwise.
11.2.3 Miscellaneous
Anything not specifically mentioned in the quoted scope is not included.
Minor changes due to technical development, design and output are reserved.
11.2.4 Required information from the customer

In case of order the customer shall supply to MAN Diesel & Turbo the following
documents and information in due time:
Actual site plan and arrangement drawing showing the exact location and
dimension of the area of the power plant and the neighbouring installations
Main wind directions and seismic activities to be considered
Minimum load bearing capacity of power plant subsoil or soil investigation
report
List of electrical consumers to be provided locally by customer
Sample of heavy fuel oil, raw water

Section 11 - Standards, Guidelines and Drawings
11.3 Drawings
11.3.1 Drawing of generating set

Drawing: 11745001770_01_A_Genset Drawing 18V4860TS (Rev. A, Dtd.
06.06.11)
11.4 Division of Works

5301959-01-B001 DOW Rev000

Section 12 - General information
12 General information
12.1 List of sub suppliers

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

Alternator ABB, Hyundai, Indar, WEG GermanyCummins, Jeumont
Flexible coupling VULKAN, Centa
Anti vibration mountings GERB
12.1.2 Lube oil system

Lube oil module Auramarine, MAS, Alfa Laval,
GEA Westfalia Separator
Lube oil flow rate measuring device Endress & Hauser,
Bopp & Reuther
Lube oil separator module GEA Westfalia Separator, Alfa Laval
Lube oil transfer pump Kracht, Rickmeier
12.1.3 Cooling water system

Cooling water pre-heater set ELWA, Midland Combustion
Nozzle cooling water module ELWA
Radiator cooling system Ecodyne, Alfa Laval Vantaa, Thremofin,
Friterm, GEA Ergé-Spirale
12.1.4 Fuel oil system

Diesel fuel oil supply pumps KRAL, Imo Pump, LEISTRITZ
Heavy fuel oil supply pumps KRAL, Imo Pump, LEISTRITZ
Heavy fuel oil filter module Alfa Laval Moatti, BOLL & KIRCH, Filtrex
Diesel oil filter module Alfa Laval Moatti, BOLL & KIRCH, Filtrex
Fuel oil separator module Alfa Laval, GEA Westfalia Separator
Leakage oil module Hydac, MAS
12.1.5 Intake air system

Intake air filter unit AAF International, GEA Delbag, ALS

12.1.6 Compressed air system

Starting air compressor Sauer & Sohn, Neuenheuser, Kaeser
Starting air receiver Römer
Compressor unit for working air Sauer & Sohn, Neuenheuser, Kaeser
12.1.7 Exhaust gas system

Expansion joint for exhaust gas KE-Burgmann, Stenflex, Witzenmann
12.1.8 Electrical equipment

Engine and alternator control system Kuhse, Woodward,
Siemens Pakistan, Natus
12.2 References
MAN Diesel & Turbo can look back on nearly

120 years of experience in the manufacture and
operation of Diesel engines. It was at MAN in
Augsburg that, between 1893 and 1897, Rudolf
Diesel's groundbreaking idea, the Diesel engine,
was developed to the point where it was ready
to go into service.
MAN Diesel built the world’s first large scale Diesel
power station in Kiev in 1904 and supplied engines
for the first ocean-going Diesel engine-powered
vessel in 1912.
To date MAN Diesel &Turbo SE has installed approx.
26,900 medium speed engines with an output of
approx. 56,000 MW all over the world.
References of engines from the current programme:
Engine type No. of engines Total Power

16/24 2,525 1,486 MW
21/31 1,454 2,074 MW
27/38 2,176 5,144 MW
28/32 5,106 8,201 MW
28/33 52 400 MW
32/40 3,006 13,572 MW
32/44CR 44 260 MW
48/60 784 9,411 MW
51/60DF / 51/60G 19 254 MW

58/64 462 4,903 MW

Others 11,231 10,283 MW
Please find below a reference list of selected power plant installations.
Total
Customer Country No. x Engine
Power
VINLEC Extension St. Vincent 2 x 9L32/40 9.0 MW

Guadeloupe France 9 x 18V48/60 170.1 MW
Breitener Gas Conversion Brazil 1 x 18V51/60DF 17.5 MW
Stelco IV Maldives 2 x 18V32/40 18.0 MW
Yanbu Cement Extension Saudi Arabia 6 x 12V48/60 75.6 MW
Komsilga Burkina-Faso 1 x 18V48/60 18.9 MW
Extension Owen Springs Australia 1 x 12V51/60DF 11.7 MW
Karadeniz Power Ship #1 Turkey 6 x 18V51/60DF 149.4 MW
3 x 14V48/60
EDF Extension Martinique 6 x 18V48/60 113.4 MW
AL TAKAMOL Egypt 5 x 18V32/40CD 45.0 MW
PLC MEZHREGIONENERGO Russia 1x 18V32/40PGI 8.1 MW
ENDESA GENERACION Spain 1 x 12V48/60 12.6 MW
HUB POWER Pakistan 11 x 18V48/60 207.9 MW
ELECTRAWINDS Belgium 2 x 18V32/40 18.0 MW
Endesa Spain 1 x 9L21/31 1.9 MW
CENTRAIS ELETRICAS Brazil 2 x 9L32/40 9.0 MW
CENTRAIS ELETRICAS Brazil 38x 18V32/40 342.0 MW
OKINAWA Electric Japan 1 x 18V48/60 18.9 MW
Asian Colour Coated Ispat Ltd. India 2 x 16V28/32S 7.5 MW
Honda Siel Cars India 1 x 8L27/38 2.6 MW
Asian Colour Coated Ispat Ltd. India 1 x 18V28/32S 4.2 MW
Grasim Industries India 1 x 8L27/38 2.6 MW
POWER AND WATER Australia 2 x 12V51/60DF 24.0 MW
Ambatovy Madagascar 3 x 7L27/38 6.7 MW
STX Dalian South Korea 2 x 6L27/38 4.0 MW
STX Dalian South Korea 2 x 8L27/38 5.3 MW
Electric Power Develop. Co Ltd Japan 3 x 18PA 6 15.9 MW
VOESTALPINE Stahl Austria 2 x 12V32/40DF 9.6 MW
National Electricty Corporation Sudan 2 x 18V28/32S 8.5 MW
EDA, Electricidade dos Acores Portugal 1 x 7L32/40 3.5 MW
CARIBBEAN UTILITIES Cayman Is. 1 x 14V48/60 14.7 MW
UNE Cuba Energoimport Cuba 11 x 9L28/32H 20.8 MW

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

BEC Cat Island Bahamas 2 x 9L28/32H 3.8 MW
BEC Hatchet Bay Bahamas 4 x 18V28/32S 16.2 MW
PPC - Grecce Islands Greece 1 x 12V32/40 6.0 MW
Grønlands Energiforsyning Greenland 1 x 18V28/32S 4.2 MW
Grand Bahama Power Bahamas 1 x 18V48/60 18.9 MW
EDF – Port Est, La Reunion France 9x18V48/60 170.1 MW
EDA, Electricidade dos Acores Portugal 2x5L21/31 2.0 MW
EDF – Bellefontaine, Martinique France 6x18V48/60 113.4 MW
Grønlands Energiforsyning Greenland 1x18V28/32S 4.2 MW
Geoterm El Salvador 4 x 18V48/60 75.6 MW
Electrawinds, Brugge Belgium 2 x 18V48/60 37.8 MW
Belco Bahamas 4 x 12V48/60 50.4 MW
Energetica Camacari Muricy Brazil 8 x 18V48/60 151.2 MW
Atlas Power Pakistan 11 x 18V48/60 213.6 MW
BEC Bimini Bahamas 2 x 9L32/40 9.0 MW
BEC Cat Island Bahamas 2 x 9L32/40 9.0 MW
Tortola Brit. Virgin 4 x 18V32/40 36.0 MW
Island
BLM-Suez Panama 10 x 18V32/40 90.0 MW
Barcelona Airport Spain 5 x 18V32/40DF 36.0 MW
IGI Termoindustriale Italy 1 x 18V32/40 9.0 MW
OXON Termoindustriale Italy 1 x 18V32/40 9.0 MW
Isolux Ecuador 2 x 12V32/40 12.0 MW
Milos Greece 2 x 12V32/40 12.0 MW
PAMPA Energia S.A. Argentina 2 x 18V32/40 16.2 MW
ADANAC Ruby Creek USA 4 x 18V32/40 36.0 MW
Ingemas Senegal 4 x 18V32/40 36.0 MW
Surimane Phase 3 Suriname 1 x 18V32/40 9.0 MW
N.V.Energiebedrijven Suriname
Ceuta Spain 3 x 12V48/60 37.8 MW
ENDESA
Mosoblenergogas Russian 2 x 16.0 MW
Federation 18V32/40PGI
Melilla Spain 3 x 12V48/60 37.8 MW
ENDESA

Total
Power
Arabian Cement Co. Ltd. Saudi 3 x 18V48/60 56.7 MW

Arabia
INCA Dominican 2 x 9L32/40 9.0 MW
Santo Domingo Republic
UNE 2 Cuba 7 x 18V48/60 132.2 MW
Energoimport de la Habanna
UNE 3 Cuba 1 x 18V32/40DF 6.9 MW
Energoimport de la Habanna
SONABEL Burkina 1 x 18V48/60 18.9 MW
La Soc. Nat. d’Electricité Faso
Chekka Lebanon 1 x 18V48/60 18.9 MW
Holcim Leban S.A.L.
Sepcol Pakistan 1 x 18V48/60 128 MW
Southern Electric Power Co.Ltd. 5 x 18PC4.2
Ibiza Spain 4 x 18V48/60 75.6 MW
ENDESA for Gas y Electricidad S.A.
Sharourah Saudi 3 x 12V48/60 63.0 MW
Al-Saleem / Saudi Electric Comp. Arabia 2 x 12V48/60
Fortune Electric, Taipei Taiwan 4 x 9L32/40 18.0 MW
Taiwan Power Co.
NATCO Yemen 1 x 16V32/40 20.0 MW
Public Electric Comp. 1 x 12V32/40
Surimane Suriname 2 x 18V32/40 17.2 MW
N.V.Energiebedrijven Suriname
Shuaiba Kuwait 1 x 9L48/60 9.4 MW
ABB / Public Authority for Industry
GECSA Guatemala 2 x 18V32/40 19.0 MW
Genedora Electrica S.A.
White Nil Petroleum Operating Sudan 5 x 18V32/40 54.0 MW
Company
Choloma I–III Honduras 14 x 18V48/60 265 MW
Energia Renovables S.A.
Los Guinchos, Las Palmas Spain 4 x 12V48/60 50.4 MW
ENDESA for UNELCO
Las Salinas, Fuerteventura Spain 3 x 18V48/60 56.7 MW
ENDESA for UNELCO
Punta Grande, Lanzarote Spain 5 x 18V48/60 94.5 MW
ENDESA for UNELCO
Weipa Australia 6 x 9L32/40 27.0 MW
Comalco Aluminium Ltd.
Pico / Belo Jardim Portugal 1 x 7L32/40 58.5 MW
Electricidade dos Acores 2 x 12V48/60
4 x 9L40/54

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

Grand Bahama Power Comp. Bahama
Caracol Knits Honduras 1 x 12V48/60 12.6 MW
Ingemas, Gijon
St. Vincent St. Vincent 2 x 9L32/40 9.0 MW
Vinlec
Pembroke / Bermunda Bermuda 2 x 14V48/60 29.4 MW
Bermuda Electric Light Comp. Ltd.
Benue Cement Company (BCC) Nigeria 5 x 18V32/40 45.0 MW
Comp. des Pétroles Libya 2 x 18V32/40 17.0 MW
Pedregal Power Company Panama 3 x 18V48/60 56.7 MW
Caribbean Utilities Comp. Ltd. Cayman 2 x 14V48/60 38.0 MW
Grand Cayman Islands 1 x 12V48/60
Aqualectra, Curacao Netherlands 4 x 18V32/40 34.5 MW
Antilles
China National Offshore Oil Corp. China PR 5 x 16V32/40 76.8 MW
(CNOOC) 5 x 16V32/40
Poplar Bluff / Mississippi USA 3 x 18V32/40DF 21.0 MW
Consorcio Breitener Brasil 8 x 18V48/60 167 MW
for Forteleza Power Station 2 x 16V32/40
Peng Hu Taiwan 8 x 9L58/64 125 MW
TATUNG Co. 4 x 12RK270
Habas Kasimpasa Turkey 3 x 18V48/60 57.0 MW
Esemboga Turkey 7 x 16V32/40 53.8 MW
Ankara Enerji Uretim A.S.
Mineracao Rio Do Norte S.A. Brasil 5 x 9L48/60 47.0 MW
Dohuk, Erbil, Sulaimaniyah Iraq 3 plants with 92.0 MW
UNDP for Local Electricity Authority, 4 x 16V32/40
Union Fenosa S.A. Dominican 5 x 18V48/60 94.5 MW
Republic
Power Barge Esperanza Guatemala 7 x 18V48/60 132 MW
Puerto Quetzal Power Ltd.
Nouakchott Mauretania 2 x 9L48/60 54.0 MW
SONELEC 4 x 52/55B

12.3 Leaflets and brochures
Following brochures are available on our homepage in electronic format or can

be handed out as hardcopy upon your request.
Stationary Engine
Programme 2011
MAN Diesel & Turbo power plants are located in all
regions of the world – in deserts, on pack-ice, at
low altitude or in high mountain regions. Whether
located in an area with a climate of dry heat,
tropical air humidity, permanent frost or extreme
temperature fluctuations, our power plants always
provide reliable energy.
Our power plants are able to be operated on
various kinds of fuels with highest flexibility and
economy.
Powering the World

Brochure with general information about the
MAN AG Group of companies and specially
MAN Diesel SE, its history, product portfolio and
worldwide services.
MAN Diesel, the "birthplace of the Diesel
engine", is one of the world's leading suppliers of
large-bore Diesel engines for marine application,
energy production, railways and heavy duty
vehicles. In addition, MAN Diesel & Turbo also
build turnkey power stations and complete
propulsion systems for ships.
Power Plants
Energy wherever you need it.
MAN Diesel & Turbo is one of the world’s leading
suppliers of land-based and floating power plants
based on Diesel and gas engines. Over the last
century we have built thousands of Diesel power
plants worldwide. The experience we have gained
and the technology we have developed over that
time enables our specialists to tailor power plants
to the individual needs of customers all over the
world.

18V48/60TS
Two-stage turbocharged diesel engine
Brief description of the MAN Diesel & Turbo engine
type 18V48/60TS with technology information and
technical details as well as engine dimensions.
The first choice when it comes to economy and
ecology. With a power output range of 18,900 kW
to 21,600 kW, this reliable, high-output engine is
the four-stroke heart of medium and large diesel
power plants the world over.
A true “prime mover”.
TCA
The New Turbocharger Generation
MAN Diesel & Turbo has more than 60 years
unprecedented experience of producing
turbochargers with plain bearings and uncooled hot
gas casings.
The new series of TCA turbochargers are available
in 2 stroke and 4 stroke versions for diesel, dual fuel
and gas engines. They have been developed to
provide a robust and reliable platform for engine
applications ranging from 2,500 kW up to
35,400 kW output per turbocharger.
Courses 2011
MAN PrimeServ Academies
Customised training programmes from basic Diesel
engine maintenance to complete power plant
operation.
We offer training modules for your Plant Managers,
Maintenance Personnel, Operators and Control &
Instrumentation staff.
In-factory and at-site courses for increased
productivity and enhanced quality.

Annexure – 2(b)
Co-generation Engine Specification
RUPALI ENGINEERING & TRADERS
LIMITED
TECHNO-COMMERCIAL OFFER
COGENERATION – 2.35MW
28.05.2013
(3X18V48/60TS MAN POWER PLANT)
MAGNUS POWER PRIVATE LIMITED BANGALORE – INDIA

TABLE OF CONTENTS
COGENERATION POWER PLANT
1 GENERAL
2 SCOPE OF SUPPLY
3 TECHNICAL SPECIFICATIONS OF BOILER
4 TECHNICAL SPECIFICATIONS OF TURBINE GENSET
5 PRICE SCHEDULE
6 GENERAL TERMS & CONDITIONS
1- GENERAL
The Cogeneration Power Plant includes a well designed:
 One (3) nos. of ALFA LAVAL (AALBORG)WHRB with all other auxiliaries.
 One (3) nos.of DAMPER, Electrically operated gas diverter damper.
 One(1) no. of TRIVENI Turbine Generator Set with Steam turbine, Condensing System
and AC Generator with all other auxiliaries.
Sl No. Description Parameters
1 Plant Location Bangladesh
2 Details of each engine
a Engine Capacity (MWm) MAN-18V48/60 TS 18.9
b Fuel HFO
c Exhaust Gas Flow (Kg/hr) 122000
d Exhaust Gas Temperature (Deg C) 300
e Exhaust Gas Composition (V/V%)
CO2 5.50
O2 12.10
H2O 7.50
SOX 0.08
NOX 0.12
CO 0.01
N2 75
TECHNICAL SPECIFICATIONS OF COGENERATION POWER PLANT
Sl No. Description Unit Qty
1 Exhaust gas flow in HRU (for one engine) Kg/hr 122000

2 Exhaust gas temperature HRU (for one engine) Deg.C 300
3 GENERAL INPUT DATA
A Number of boilers 3
B HP-evaporator Natural circ
C Number of steam drums 3
D Superheater YES
E HP economizer YES Forced cir. LP evaporator
F LP evaporator/preheater YES with cir. pumps, 2 pcs
G Hot water section NO
H By pass Modulating
I Automatic rake soot blowers 9 PCS
J Exhaust gas pipe diameter DN 1600
4 THERMAL INPUT DATA
A Exhaust gas flow/engine 33.9 kg/s 122 000 kg/h
B Exhaust gas temperature IN 300.0 0C
C Exhaust gas temperature OUT, ECO 204.6 0C
D Exhaust gas temperature OUT, LP 194.9 0C
E Temperature in feed water tank 135 0C NOTE:
F Condensate temperature 80.0 0C F. W. Tank heating
G Condensate return % 97.0 % included
H Make-up water temperature 30 Boiler steam flow data is
Stated after deduction of
I HP evaporating pressure 16.1 bar(a)
Heating steam
J Steam pressure after superheater 16.0 bar (a)
5 OUTPUT DATA (With clean heating surface) per

boiler
A Capacity HP 4048 Kw
B Steam flow per boiler HP 6071 kg/h
C Steam Temperature HP 2800C
D Exhaust gas pressure drop (clean) 1130 Pa
6 PRELIMINARY DIMENSIONS( BOILER)

A Length 5460 mm
B Width 2690 mm
C Total height (incl. drum) 11410 mm
D Total water volume (boiler/drum/pipes) 4.1/3.8/1.m3
E Max weight (full of water) 69299 kg
7 Power Generation Equipment
Turbine –steam turbine- multistage –condensing

A Gross Electric Power Generation kWe 2350
B Power generation Voltage/Frequency kV/Hz 11/50
2 – SCOPEOF SUPPLY
√-IncludedinMPPLScope X-ExcludedfromMPPLScope
Fabrication
Basic Detailed Sup
ItemDescription Supply Site &
Engineering Engineering Com
Erection
VILWORKANDRELATEDACTIVITIES
asteHeatRecoveryBoilers √ √ X X
ilerfeedwaterPumps √ √ X X
cessories&AuxiliariesPackageforWasteHeatRecoveryBoiler √ √ X X
eamTurbinePackage √ √ X X
aterCooledCondenserPackage √ √ X X
ndscaping,Roadandrelatedactivities √ √ X X
ilerWaterTreatmentPlant&ETP √ √ X X
ow downpit,NeutralizationPit,EarthingPit √ √ X X
uck ableroadup tofoundation √ √ X X
ASTEHEATRECOVERYBOILER PACKAGE
ainHeatRecoveryBoiler- 3 No’s √ √ √ X
essurePart √ √ √ X
ilerCasing √ √ √ X
uctureandSupport √ √ √ X
aterCooledCondenserPackage √ √ √ X
undationBolts √ √ √ X
otblowersfortubecleaning √ √ √ X
struments,MountingsandControlsof WHRB √ √ √ X
haustandbypassgasDivertervalveforgasisolation √ √ √ X
rewAirCompressorforInstrumentair √ √ X X
aterTreatment PlantforBoiler feedand cooling towermake-up. √ √ X X
mplecoolers √ √ √ X
owdownsystemforWHRB √ √ √ X
aerationsystemstankandChemicaldosing √ √ √ X
xiliariesandaccessoriesofWHRB √ √ √ X
HAUSTGASDUCTINGAND SUPPORTING STRUCTURE PACKAGE

ctingfromHeatSourcetoDiverterdamper √ √ √ X
ctingfromDampertoWHRBInlet √ √ √ X
ctingfromWHRBOutlettoExistingDuct √ √ √ X
pportingstructureforDucting √ √ √ X
EAMTURBINEANDAUXILIARIES PACKAGE
eamTurbinewithGenerator √ √ √ X
aterCooledCondenserPackage √ √ √ X
olingTowerPackageforMainandAuxiliary √ √ √ X
ushingLubricantsOilandfirstfillofchemical √ √ √ X
ECTRICAL&INSTRUMENTATION PACKAGE
steamandwatercontrolvalveassemblies √ √ √ X
strumentation and control cabling for Wasteheat driven power plant
√ √ √ X
thin battery limit.
rbine and Generator Protection Panels (NGR, Relay metering control &
√ √ √ X
nch panel,Turbine control panel, AVR panel).
ectricalinspectorateclearancesifany √ √ X X
earances/approvalsstatutorybodyfromproposedSEBorPoweranyotherPlant. √ √ X X
cumentation support for the inspection /
√ √ √ X
proval,statutoryapprovalsetc.ofelectricalinspectorate
art-up,GenerationCumPower
acuationsystem:-
kVPowerPlantSwitchgearSystemwithinbattery limit √ √ √ X
Cable
cablewithinbatterylimit. √ √ √ X
VSwitchgearSystemforpowerplantwithinbatterylimit
KVIndoorMVSwitchgearSystem √ √ √ X
Vcableandcabletraywithinbatterylimit √ √ √ X
tterybackupforMVswitch gearchargersystem&EOP(1starter)
√ √ √ X
PINGWITHSUPPORTINGSTRUCTURE PACKAGE
eam&FeedWaterPiping √ √ √ √
ndensatePiping √ √ √ √
strumentair,DrainandVentPiping √ √ √ √
olingWater&CondensatePiping √ √ √ √
pansionLoops/BellowsinabovePiping √ √ √ √
pportingstructureforabovePiping √ √ √ √
SULATIONANDCLADDINGPACKAGE
sulationandCladdingforWHRBPackage
cludingmainWasteheatrecoveryboilers, √ √ √ √
Atank,Blowdowntank,Dampers,Ductotheraccessoriesinboiler package
sulationandCladdingforDuctingPackage √ √ √ √
sulationandCladdingforPipingPackage √ √ √ √
sulationGeneratorandsetPackageCladdingforTurbine& √ √ √ √
SCOPE – EXCLUDED
Sl. No. DESCRIPTION

B
1 Cold start up power
2 Water treatment plant for boiler water and cooling water topping up
3 Required land, landscaping, road and related activities
4 Effluent treatment Plant
5 Statutory approvals
6 Freight & Transit Insurance
7 Street Illumination system and Illumination outside battery limit of Proposed power plant
8 Pollution and Factory approval
9 Any Electrical system analysis and study
10 EPABX System
11 Emergency shutdown system
3 – TECHNICALSPECIFICATIONS OF HEAT RECOVERY BOILER – ALFA LAVAL
1.) EXHAUST GAS BOILER, AV-6N / NATURAL CIRCULATION – 3 No
Construction: AV-6N exhaust gas boiler is a water tube exhaust gas boiler, optimized for
heat recovery from diesel engine exhaust gas. The boiler generates superheated steam for
steam turbine application.
The boiler consists of following heating sections: Super heater, evaporator and economizer.
The exhaust gas inlet is in the upper part and the outlet in the lower part of the boiler, i.e.
exhaust gas flows downwards.
The extended heat transfer surfaces consist of horizontal plain steel tubes equipped with
steel fins. These water tubes are connected to inlet and out manifold pipes. The tubes are
twin tube construction of material P235GH/EN10217-2 or equal and the size of the tube is
φ38mm. The minimum wall thickness is 3mm.
Special attention is paid to the flexible construction of the heating surface where the tubes
can freely expand to minimize thermal stresses.
The heat surface is surrounded with welded steel cover casing, stiffened by steel bars and
connected to upper/lower exhaust gas chambers. Material of steel construction is S235JRG2
or equal.
Soot blowers: The boiler is equipped with three (3) automatic rake soot blowers. The soot
blowers are operated one at a time when the engine is running. Steam soot blowing is used
to prolong the interval of manual water washing.
Water washing: The off-service manual water washing is very important and recommended
to be made as minimum during every major engine shut-down and can be executed through
the service hatches.
The washing water drain connection at boiler bottom is equipped with a camlock system.
The connection is normally closed with a cap. During the water washing, the connection is
locked to a plastic drain hose (common hose included).
System Connections: The individual AV-6N exhaust gas boiler is to be connected to its own
steam drum and to the common feed water tank via feed water piping. The individual AV-
6N exhaust gas boiler is also to be connected to a common steam line.
Operational description (individual boiler): The feed water is pumped with feed water
pumps through the economizer into the steam drum. The water recirculation between the
steam drum and the evaporator is maintained by natural circulation. The evaporated
(saturated) steam is separated in the steam drum and directed through the super heater
into the steam header and further as the combined superheated steam flow to steam
turbine.
Note: Feed water tank heating is included; boiler steam flow data is stated after deduction
of heating steam.
The stated values are valid with clean heating surfaces. Aalborg Industries guarantees the
indicated steam flow at the design point when the boiler is operated and maintained clean
according to the AI instructions and O & M manuals.
When defining the steam capacity the exhaust gas mass flow of the engine is determined by
calculations, meaning and no separate flow-measuring device is included in the scope of
supply.
The exhaust gas boiler is delivered as a complete construction with loose packed insulation
material including the following items;
 Exhaust gas chambers with flanged connections
 Top casing prepared for site-installation of stem drum
 Flanged inlet/outlet connections for water side
 Insulation flat bar supports
 Maintenance/service hatches
 Supporting and lifting lugs
 Water washing cam lock drain with common plastic hose of 20m*)
 Valves and fittings (closing valves, thermometers, pressure gauges pressure
difference gauge) with bolts, nuts, gaskets and counter-flanges*)
 Soot blowers*)
 Prefabricated boiler pipes with site allowance; rises, down comer, economizer outlet
and superheating inlet pipe*)
 Exhaust gas counter flanges (incl. gasket, bolts and nuts*))
 Feed water control as unit*)
2.) STEAM DRUM – 3 No
Individual steam drums to be connected to individual exhaust gas boilers.
Construction: UNEXTM HK is an all-welded steam drum consisting of steel cylinder and dished
ends. Material of steel construction is P265GH/EN10028-2 or equal.
Note: Steam turbine pressure fluctuation range should be checked against the above design
pressure and when presetting the safety valve opening pressure.
The steel construction of HK steam drum is delivered as a complete unit with insulation
including the following items
o Stands for installation
o Fittings with flanged connections
o Man hole for maintenance/service
o Lifting lugs
o Valves and fittings according to the following instrumentation list *)
 Steam outlet closing valve
 Safety valve (with a spare connection)
 level gauge
 automatic FW control with valves and water level alarms
 manual bottom blow down/drain
 manual scum blow out valve
 sample cooler
 venting
 pressure gauge
 pressure switch for high pressure alarm
 pressure transmitter for bypass damper control
3.) STEAM HEADER – 1 No
The steam header is used to collect steam from individual exhaust gas boiler for further
distribution to steam turbine.
 Steam from exhaust gas boilers (1) with closing valves

 Stem from oil fired boiler, with closing valve
 Steam to consumers, with closing valve
 Steam to consumers, with closing valve
 Steam to feed water tank, with closing valve
 Pressure gauge with cock
 Pressure transmitter with cock for bypass damper control
 Condensate/Drain with steam trap and closing valves
The steam header is delivered without insulation. Unused standard connections are
equipped with blind flanges. All valves and instruments are delivered loose.
Manual blow-out valves for the incoming boiler steam lines are included as loose.
4.) AUXILIARY CONTAINER, AIC-20/COMMON SYSTEM – 1 No
The containerized modular includes ready installed components as specified in items (ITEM
3) and necessary fittings including all piping and cabling work inside a 40’ container (not
classified)
Note: Feed water tank is to be site-installed on top of the container on a separate

supporting. The tank foundation supporting and service platform. Connecting pipes
between the feed water tank and container (prefabricated with work allowance) are
supplied loose and will be installed at site by the KPPGL. Chimney (height 10m without
insulation) and foundation anchoring for chimney are included as loose supply.
Hot surfaces inside the container are insulated and covered with aluminum plates. Valves
are insulated or contact protected, if they are close to general walkways or service areas.
The container is equipped with one double door at the other end, one service door at the
side and ventilation hatch with fan.
5.1 FEED WATER PUMPS – 2 Nos
The delivery consists of 2 feed water pumps; both sufficient for pumping feed water for 3
exhaust gas boilers at nominal capacity. The both pumps have 100% of needed capacity.
The other pump is a spare.
The indication of the emergency low level of feed water tank is used to stop the feed water
pumps
Technical data
 Type Vertical centrifugal pump
 Capacity 10.2 m3/h ; 13 bar
 Motor 7kWe
 Shaft sealing Mechanical
5.2) Local PLC control system, Siemens TCP/IP – 1 No
The delivery includes the necessary control system with all required components for
controlling and operating the steam heat recovery system according to Aalborg Industries
standard.
The following alarms are available for remote monitoring

 Common alarm
 Pressure alarm high
 Steam pressure at the common steam header
 Steam temperature at the common steam header
 Bypass damper position
The control system consists of one common control panel with Siemens MP277 &WInAC MP
2007 control logic.
5.4.1) Drum water regulating and control system
The boiler water regulating and control system is based on direct measurement of the water
level by conductivity and capacitance method. The system consists of two electrodes and
electric controllers.
This system controls feed water control valves (open/close) and gives an alarm signal of high
and low water level as well as emergency low water level alarm.
5.4.2) Feed water regulating and control system – 1 Set
The feed water tank’s regulating and control system is based on direct measurement of the
water level. This system control makeup water value (open/close) and gives an alarm signal
of high and low water level as well as emergency low water level alarm. The emergency low
water level of the feed water tank stops also the feed water pumps.
5.4.3) Starter for feed water pump
The starter includes the following components:
 Protection switches
 Contractors
 Main switch
 Operation switches for pumps:
 Indication lamps
- Pump 1 is operating
- Pump 2 is operating
- Pump failure
5.4.4) Capacity control of the exhaust gas boilers
Stem production of the boiler is controlled according to pressure in the system
Normal pressure range of the system is between 13,5 …16 bar(a)
The capacity of the exhaust gas boiler is controlled by PID-controller which gets the pressure
signal from the pressure transmitter installed to the respective steam drum. PID-controller
gives control signal to the modulating by pass damper. Set point of the PIC-controller is 16
bar(a)
6.) Chemical dosing unit – 1 No

This unit is mean for adding chemicals into the feed water system for mild after-treatment
and oxygen removal.
The system includes following:
 Dosing pump
 Suction filter
 Dosing nozzle
 Plastic tank of 100 liters
Note: A steam turbine application sets strict requirement for the water quality and
therefore the combined cycle plants usually are equipped with special treatment plants for
securing high quality water.
7.)BLOWDOWN TANK, BDT-150 – 1 Nos
Blow out procedures must be executed periodically for any type of steam boiler to remove
concentrations of solids, which would otherwise buildup in the boiler water.
The blow down tank is designed to safety handle those hot discharge with a self-acting
temperature control of cooling water.
8.) PRESSURIZED FEED WATER TANK, PSVS-16 – 1 No
The feed water tank is used to secure the feed water reserve for the exhaust gas boiler
system. Water in the tank consists of condensate and fresh make-up water, which are
mixed in tank together with boiler water light-adjustment chemicals
Construction NEX ™ PSVS is an all-welded horizontal feed water tank consisting of

horizontal steel cylinder and dished ends. Material of steel
construction is P265GH/ EN10028-2 or equal
Condensate line is connected to the tank and added make-up water

to the stainless steel deaerator which is installed on the top of feed
water tank.
Temperature control Feed water is kept hot in order to reduce the amount of oxygen in
boiler water.
The temperature in the feed water tank is maintained by an

automatic temperature control value. This is backup system activated
by low set point of feed water tank temperature whilst the exhaust
gas preheating is the primary heating method. As the heat transfer
from the exhaust gas preheater is proportionally to temperature of
the water flow, increasing temperature will automatically be
controlled by respectively reduced heal transfer to feed water tanks
circuit.
Technical data
 Total volume 16 m³
 Operation temperature 134 ºC
 Operation pressure 3 bar (a)
 Design pressure 4 bar(g)
The steel Construction for PSVS-pressurized feed water tank is

delivered as a complete unit with insulation including the following
items.
 Stands for installation

 Fittings with flanged connections
 Man hole or maintenance /service
 Lifting lugs
 Deaerator
 Valves and fittings according to the following instrumentation
list*)
- Feed water outlet closing valve
- Safety valve
- Automatic makeup water regulating and control with
valves and water level alarms(integrated level
indicator)
- Manual bottom blow down/drain
- Manual scum blow out valve
- Sample cooler
- Venting
- Thermometer
- Automatic stem injection control for maintaining the
set temperature.
9.ELECTRICALLY OPERATED GAS DIVERTER DAMPER

 Medium : Exhaust gas
 Flow rate : 129900 Kg/hr
 Temperature : 400⁰C
 Pressure : 300mmWC
 Damper size : 1650 sq.mm
 Blade type : Single type
 Sealing efficiency : 99.5% on C/s area
 Operation : Electrical
 Duty : Modulating
4 – TECHNICALSPECIFICATIONS OF TURBINE GENERATOR SET – (TREVENI)
1.) STEAM TURBINE
Design:
Type : Multistage, impulse, nozzle governed
Condensing
Casing split : Horizontal
Rotor type : Solidly forged & machined rotor with integral
disks.
Shaft seal : Labyrinth
No. of governing valves : Three (Inlet)
One/(Extraction)
Bearing support : Double pedestal
Rated power : 2350 KW
Oil System
- Oil:
Governing oil pressure : 5.5 kg/cm²g
Lube oil pressure : 1.5 KG/Cm²g
Oil type : Servo prime ISO VG-46 /57 /68
Oil quantity for initial fill
And flushing : 5100 L
Oil reservoir capacity : 3200 L (integral)
Retention time : 5 minutes
Material of oil reservoir : Carbon steel
Material of oil piping from
Pumps to filter : Carbon steel
Filters to bearings : SS 304
Bearing to reservoir : Carbon Steel
- Main oil pump:

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

Type : Gear (positive displacement)/screw
Capacity : 350 L / Minute
Drive : AC motor
Material of end Cover : CI
Material of drive gear : EN 36 EN 40
- Emergency oil pump

Type : Gear (Positive displacement)
Capacity : 48 L / minute
Driver : DC motor
Material of end cover : CI
Material of drive gear : EN36 /EN40
- Oil cooler:
Design code : HEI/TEMA
Type : Plate Hear Exchanger
Oil inlet temperature : 60 ºC
Oil outlet temperature : 46 ºC
Plate material : SA 240 Gr.316
Oil flow capacity : 550 Liters /minute
Mounting : Saddle support
- Lube oil Filter

Element type : Micro –felt
Oil flow Capacity : 350 liter/minute
Oil filtration Capacity : 10-15 microns
Mounting : Foot
- Oil Vapor Extractor

Type : Centrifugal
Capacity : 400m³/Hr
Driver : AC Motor
Mounting : Flange
Bearings:
- Journal bearings :
Type : Tilting pad
Material : White metal with steel Babbitt
- Thrust Bearings
Type : Tilting Pad
Material : White metal with steel Babbitt
Governing system
- Governor:
Type : Electronic (Wood ward)
Inputs (critical) : 2 Speeds from MPU -1 & 2
Control range : 80 to 110% of rated speed
Control accuracy : As per NEMA class D
Speed droop : 3 to 6% (Programmable)
Power supply : 110 V DC
Accessories : 2 Magnetic speed pick-ups(MPU)
1 electro-hydraulic actuator
- Hydraulic Accumulator
Type : Bladder
Working fluid : Pre-charged Nitrogen
Capacity : 20 liters
- Governing oil filter

Element type : Micro-felt
Oil flow capacity : 35 Liters /minute
Oil filtration Capacity : 10-15 microns
GEARBOX
Design:
Type : Double helical, single reduction
S.F. : 1.3
Accessory : Air breather
COUPLINGS:
- High Speed Coupling
Type : Flexible element
- Low Speed Coupling
Type : Flexible element with Shear pins
ACCESSORIES
- Barring gear:
Type : Auto disengage
Driver : AC Motor
- Gland vent condenser

Type : Shell and tube
Tube material : Admiralty brass
Shell & end cover material Carbon Steel
Tube sheet material : IS-2002
Accessory : Motor driven centrifugal air blower
Driver for air blower : AC Motor
Noise level : 90 dB(A)
2.) CONDENSING SYSTEM

STEAM SURFACE CONDENSER
Type : Shell and tube
Capacity : To suit exhaust flow
Construction : Divided water box
Cleanliness factor : 0.85
Hot well retention time : 2 minutes
Tube fixing : Expanded joints
Tube material : SS 304 FRW(22 Bwg)
Tube sheet material : IS-2062 Gr.B
Water box & Shell material IS-2062 Gr.B
STEAM JET AIR EJECTORS

Suction medium : Air / Vapour
System elements : Twin Stage, 2 x100% main ejectors
Single stage, 1x 100% start-up ejector
1x100% inter/after condenser
Accessory : Integral steam strainers
Time to reach 60% vacuum
With start-up ejector : 20 minutes
Material of nozzle : AISI-304
Material of shell & diffuser CS
Material of tubes : SS-304 ERW
Material of tube sheet : IS-2026
Material of silencer : CS
CONDENSATE EXTRACTION PUMPS

Type : Centrifugal
Mounting : Horizontal
Suction pressure : Same as condenser pressure
Discharge pressure : 80 MWC
Operating speed : 2900 RPM
Driver : AC motor(415 V, 3 Phase)
Type of bearings : Anti – friction
Type of seal : Mechanical
Type of coupling : Flexible
Type of lubrication : Oil
Material of casing : CI
Material of impeller : CF8M
Material of shaft : C45
Material of shaft sleeve : AISI 316
EXPANSION BELLOW
Type : Rectangular with flow liner
Design code : Universal type rectangular expansion joints
Material of bellows element SS-304
Material of liner : SS-304
Material of flanges : Is-2062
3.) ELECTRICAL
AC GENERATOR
Design:
Rated output : 2350 kW
Rated voltage : 11KV +/- 10%
Rated frequency : 50Hz +/- 5%
Combined variation of
Voltage & frequency : +/- 10%
Rated p.f : 0.8 (lag)
No. of phases : 3 phase,
No. of terminals : 3 for phase & 3 for neutral
Connection : Star
Rated speed /No. of pole : 1500 rpm / 4 pole
Short circuit ratio : More than 0.5
Ambient temperature : 45 Deg.C
Excitation : Brush less
Rotor : cylindrical
Cooling method : CACW
Mounting : Horizontal
Insulation : class F (both rotor and stator)
Temperature rise : Class B limits(both rotor and stator)
Enclosure : IP-54(Stator) & IP-54 (Exciter)
Duty : Continuous and suitable for parallel operation
Rotation : To suit driver output
Noise level : 90 dB(A)
Terminal box : To suit HT cables
Reference standard : Is -4722
Harmonic loading : As per IEEE 519
Bearings:
Type : Sleeve
Accessory : Temperature gauge
Lube oil system:

Type Forced feed
Source : Turbine lube oil system
Air coolers:
Cooling method : CACW
Capacity : 2 x 60%
Cooler tube material : Admiralty brass
Mounting : Top
Anti Condensation heaters
Type : Resistance heating
Power supply : 230 V, single phase
Water leakage detector

Location : Bottom of cooler
Quantity : 1No. per cooler
AVR CUM EXCITATION PANEL
Design:
Control type : Analog
Control modes : 1 auto +1 manual
Voltage adj. Range : +/- 10%
Regulation : +/- 0.5%
Dead time : Less than 30 mS
Features:
- Compounding
- Auto PF controller
- Remote voltage control
- Auto- Manual follow-up
- Under frequency protection
- Field flashing provision
AVR cum excitation panel shall be complete with generator voltmeter, field voltmeter, field
ammeter, PF meter, Auto/Manual selector switch, AC supply & DC supply on /off control
switches, indicating lamps and space heater with thermostat.
TURBINE CONTROL PANEL

Turbine control panel shall house the following:
- Electronic governor with keyed-in operating program
- Condenser hot well level indicator cum controller
- Relay based hard wired turbine safety interlocks and trip logic
- Remote controls comprising of selector switches, ammeters, push buttons &
Indicating lamps for:
 AOP motor
 EOP motor
 CEP-1,2 motor
 Barring gear motor
 Air blower motor
 Vapour extractor motor
- Push buttons for turbine speed raise and lower
- Turbine remote trip/reset push buttons
- Temperature scanner for Monitoring turbine and gearbox bearing temperature
- Alarm annunciator for Turbine fault monitoring.
The Panel shall be complete with AC supply & DC supply on / off control switches, indicating
lamps and space heater.
TURBINE GAUGE PANEL
Turbine gauge panel shall house the following gauges:

- Pressure gauges for:
Inlet steam
HP Wheel case
Bleed steam
Exhaust steam
Lube oil
Control oil
- temperature gauges for:
Inlet steam
Bleed steam
5 - PRICE SCHEDULE- THREE BOILER SYSTEM
Sl No. DESCRIPTION EURO’S
A BOILER
1] 3nos Exhaust Gas Boiler, AV-6N/Natural circulation
2]3nos Modulating Bypass Damper, DN 1600
3] Steam Drum
4] Steam Header
5] Auxiliary Container, AIC-20/ Common System
6] Blow down Tank, BDT-150
7] Pressurized Feed Water Tank, PSVS-16
8] Condensate Tank C-6
9] Standard Spare parts for Commissioning
10] General Input Data
11] Thermal Input Data
12] Output Data [with clean heating surface]
13]cooling tower
B TURBINES
1] Steam Turbine: Multistage, impulse, nozzle Euro 2,975,000.00
governed condensing 2350 KW.
2] Steam surface Condenser (TWO MILLION NINE
3] AC Generator 2350kW
4] AVR Cum Excitation Panel SEVENTY FIVE
5] Generator Relay Panel THOUSAND EUROS
6] Generator Control (Metering Cum Synchronizing) ONLY)
Panel
7] Neutral Grounding Resistor Panel
8] Turbine Control Panel
9] 11KV panel
Auxiliaries
1.Exhaust Duct and supports/expansion joints
2. Steam & water Pipeline and fittings
C 3. Cabling
4. Insulation.& cladding
5. support structural frame
Erection & commissioning:

Erection & Commissioning- supervision - AALBORG
D Engineers
Erection & Commissioning supervision - Triveni
Engineers
Euro 160,000.00
[ONE HUNDRED SIXTY
E FRIGHT AND INSURANCE - CHITTGONG PORT (CIF) THOUSAND EUROS
ONLY]
6 - TERMS AND CONDITIONS OF SALE
Scope of Supply
The scope of supply is limited to the equipment as listed in our specification
1.0 Scope of Work
The scope of work shall comprise of Works to be performed in accordance with The Scope of
supply provided.
2.0 Contract Price
The Contract Price shall be payable at the time and in the manner provided in PRICE
SCHEDULE.
3.0 Effective Date of the Contract-(EDOC)
The Contract commencement date (CCD) shall be the date of signing of this Contract.
The Effective Date of this Contract (EDOC) shall occur on the fulfillment of each of the
following:
a) Signing of the Contract.

b) Advance Payment and Letter of Credit establishment
c) Approval to proceed with placement of Orders for major equipments.
In case any of these above conditions are not fulfilled within 120 (One hundred and
twenty) days from the date of signing of the Contract, the Parties to this Contract shall
meet and discuss the further course of action.
4.0 Project Execution
This quotation is based on the following assumptions regarding the project execution time
table:
 Delivery of equipment : 8 month
 Commissioning of the installed equipment : 12 month
5.0 Payment Terms
We have calculated our prices on the assumption that payment will be effected out of an
irrevocable documentary credit, free of charge to us, opened through a Local National bank
confirmed by a German National bank acceptable to us.
 The price is payable as follows:

 20% down payment with placement of the order.
 80% against irrevocable first class bank letter of credit.
6.0 Warranty
The warranty will be valid for 12 months from the date of commissioning or 18 months from
the date of shipment or 8000 working hours for the Power Plant whichever is earlier.
We agree to repair or replace at our option any defective part in the equipment of our own
manufacture, where defects develop under use and arise solely from faulty material or
workmanship, and provided that the equipment is used as per our recommended operating
and maintenance procedures.
In the case of goods not of our manufacture, you are entitled to the benefits of the warranty
given to us in respect thereof, and our liability in respect of such goods is limited to the
warranty given by the respective manufacturer.
The defective parts replaced by us shall become our property. The replacements, if any will
be delivered on the same basis as the main equipment. W shall not be liable for any
consequential damage or loss incurred during warranty claims.
The provisions contained in this clause are not applicable
a. In case of normal wear and tear

b. In case of damage due to negligence or improper handling or repairs/alterations carried out
without our approval or due to damage by any cause beyond our control.
c. If the purchaser has not notified us in writing within a week from the occurrence of any
defect.
d. If the DG set is run after raising a warranty claim but without awaiting our prior
permission/clearance to restart.
7.0 Validity
Unless withdrawn the offer will remain valid till 30.06.2013
8.0 Cancellations
MPPL is entitled for full compensation of all raised material, manufacturing, engineering,
and administration costs in the event that the project or any parts of it is cancelled or
considerably postponed or the Contract is terminated. All such costs will be paid by REATL.
MPPL also entitled for full compensation of bank charges on PERFORMANCE SECURITY
GUARANTEE (PSG), if the project or any part of it has been cancelled or considerably
postponed or the Contract is terminated. The Performance security Guarantee should be
returned immediately to MPPL
9.0 The General Terms and Conditions of Sale:
Attached
10.0 Confidentiality
Please note that the contents of this letter and the documents included in our offer are to be
treated as strictly confidential and none of the information to be disclosed to any third
party.
We trust that our offer will meet your requirements and should you have any questions, or
require any additional information, please do not hesitate to contact us.
For Magnus Power Pvt. Ltd.,
________________________
Rajakumar
Director
Annexure – 2(c)
Engine Catalogue
18V48/60TS
Two-stage turbocharged diesel engine
MAN Diesel & Turbo
The responsible way in leading technology
MAN Diesel & Turbo is the world’s leading designer and manufacturer of low and
medium speed engines. Our involvement with electrical power generators goes
back to 1904 when we supplied the first ever diesel generator sets to the Kiev Tram
System.
Since those early days, MAN Diesel & Turbo has never lost its technological pre-
eminence in the large engine field. Likewise, our engines have never relinquished
their status as the most efficient combustion engines available.
More than ever before, MAN Diesel & Turbo’s development focus is on the environ
mental performance of our engines. Using our unrivalled grasp of large engine
technology, we aim to make our engines progressively cleaner, more powerful and
more efficient.
With our firm commitment to reducing emissions while increasing fuel efficiency
and power density, and with our active partnership with environmental institutions
and development banks, we intend to be part of the global emissions solution.
18V48/60TS – Four-stroke diesel engine 3

The Best in its Class A New Dimension
18V48/60TS
Two turbochargers in sequence provide a new dimension in engine performance The diesel engine 18V48/60TS
The 48/60 type diesel engine is a perfect example of For the two-stage turbocharged 18V48/60TS, only a
and operational flexibility. A wide load range from 1,050 to 1,200 kW/cyl., a specific proven technology and robust design. Over 800 units few modifications were made to the standard engine:
fuel oil consumption of 171 g/kWh at 1.050 kW/cyl. and reduced NOx emissions set have been sold since the product was launched in
1988. They are now operating in a range of applica- n Adapted fuel injection nozzles
a new benchmark for four stroke diesel engines. tions in power generation and marine propulsion. n Three-ring piston with higher compression ratio
Thanks to its high efficiency, the 18 cylinder engine is n Modified camshaft for enhanced Miller timing
the 48/60 engine family’s best-selling configuration. n Additional exhaust gas bypass valve to avoid
Turbochargers from MAN Diesel & Turbo smoke during engine start-up
Turbochargers are the core of this innovative new a limited pressure ratio. A specially designed com-
concept – and MAN Diesel & Turbo is the only engine pressor, as in the TCA88/RCF23, can increase the TC Efficiency
manufacturer that also designs and builds turbo- pressure ratio – but also has the effect of decreasing
2-Stage operation
chargers. This unique expertise translates into ex- efficiency. The only solution to this dilemma is two- 0,78
ceptional efficiency and reliability. stage turbocharging, also known as sequential tur- 0,76
bocharging (STC). 0,74

TCA88 +TCA77
Two-stage turbocharging 0,72 TCA88
The idea is simple: just place two of MAN’s most The 18V48/60TS deploys MAN Diesel & Turbo’s tried 0,70
TCA88/RCF23
TC efficiency tot-tot
efficient turbochargers upstream from the engine, and tested TCA88 and TCA77 standard turbocharg- 0,68
one after the other. The result: the engine gets twice ers in sequence. The TCA88 is located upstream and 0,66
the charge air pressure, while turbocharger efficien- provides the low pressure turbocharger, while the 0,64
cy is increased significantly. TCA77 forms the high pressure turbocharger, next to 0,62
the engine. In this configuration, both turbochargers 0,60

1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5 6,0
A single turbocharger, such as MAN Diesel & Turbo’s can achieve pressure ratios over 6 bars and efficien-
p_out / p_in compressor
well known TCA88, is highly efficient; however, it has cies of more than 76 per cent.
4 18V48/60TS – Four-stroke diesel engine 18V48/60TS – Four-stroke diesel engine 5

Standard Components, Proven Design
Low pressure Turbocharger
High pressure Turbocharger
Standard components, proven design Lowest fuel oil consumption or NOx emissions Effects of Two-Stage Turbocharging
The overall design of the two-stage turbocharged The excess combustion air from the turbochargers Two-stage turbocharging is a modular system: its 1200
Power output kW/Cyl.

1200
18V48/60TS has been kept as simple as possible. provides greater operational flexibility. The high design enables most MAN Diesel & Turbo power 1150
1150
Apart from the modifications described above, the charge air pressure can be used for enhanced Miller plants to be retrofitted with this solution. 1100
1100
engine is standard, with the high pressure turbo- Cycling, delivering significant fuel savings and further 1050
1050
charger directly mounted to it. reducing NOx emissions. Flexibility in fuels, flexibility in operations
1000
The low pressure turbocharger is located upstream As a result, the 18V48/60TS diesel engine’s extrem- Like the 48/60 series standard engines the two-stage Op. mode 1 2 3 4
from the engine, on its own steel frame. The combus- ely low specific fuel oil consumption of 171 g/kWh turbocharged 18V48/60TS can be operated with a
1850
tion air and exhaust gas piping between both turbo- makes it the most cost-effective in its class. wide range of different fuels: 1850
1800
chargers is fitted with compensators, ensuring com-
1750
Alternatively, the excess combustion air can be n Heavy fuel oils with a viscosity up to 700 cst
NOx mg/Nm3 @15%O2

plete insulation from vibrations. 1740
1700
leveraged to significantly increase the engine’s n Marine diesel and gas oil
1650
An air blower is situated below the steel frame of the power output, up to 1200 kW/cylinder. Although this
1600
low pressure turbocharger. Active during engine does not save as much fuel, it does allow for a great- Due to the unique features of two-stage turbocharg- 1580
1550
start-up and low part-load operation (up to 25 per er reduction of NOx emissions within a wide opera- ing, the 18V48/60TS can be operated continuously
1500
cent load), it avoids smoke emissions caused by the tion range. NOx emissions of 1480 mg/Nm³ make the at shaft power outputs from 18,900 up to 21,600 kW. 1480
lack of combustion air from the turbochargers in this 18V48/60TS the cleanest diesel engine in its power For example, this allows power producers to operate Op. mode 1 2 3 4
operation range. range. the engines at a normal load of 18,900 kW – taking 177
Fuel consumption
177
advantage of the extremely low fuel oil consumption
175 174
and giving them the possibility of a spinning reserve
173 172
g/kW/h
up to 21,600 kW. 171
171

18V48/60TS Technical Data
Overview
A B
C W
18V48/60TS engine Engine type: 18V48/60TS General definition of diesel engine ratings
according to ISO 3046-1: 2002
Operation mode Engine cycle: four-stroke
Performance data Unit 1 2 3 4 Turbocharging system: 2-stage, constant pressure ISO Reference conditions:
n Low pressure TC type: MAN TCA88
Power per cylinder kW 1050 1100 1150 1200 n High pressure TC type: MAN TCA77 n Air temperature: +25°C (77F)
Tot. engine power kW 18,900 19,800 20,700 21,600 n Air pressure: 1000 mbar
Tot. el. genset power kW 18,428 19,305 20,183 21,060 Number of cylinders: 18 n Cooling water temperature upstream
Spec. fuel oil consumption Bore: 480 mm of charge air cooler: +25°C (77F)
acc. to ISO 3046, without pumps, g/kWh 171 172 174 177 Stroke: 600 mm n Relative air humidity: 30%
mech. Power output, +5% tolerance Swept volume per cyl.: 108.6 dm³
Heat Rate Engine speed 50/60Hz: 500/514 rpm Figures are given with a tolerance of 5%, except for
acc. to ISO 3046, without pumps, kJ/kWh 7,305 7,350 7,430 7,560 Mean piston speed: 10.0/10.3 m/s the lubrication oil consumption, which is given with a
mech. Power output, +5% tolerance tolerance of 20%.
NOx emissions (dry at 15% O2) mg/Nm3 1850 1740 1580 1480 Nom. generator efficiency: 97.5%
Mean effective pressure bar 23.2/22.6 24.3/23.7 25.4/24.7 26.5/25.8
Spec. lube oil consumption g/kWh 0,60 0,60 0,60 0,60 Cooling: Abbreviations:
Cylinder cooling: HT cooling water
A B C H W LP-TC charge air cooler: 2-stage HT and LT cooling water TC Turbocharger
HP-TC charge air cooler: 2-stage HT and LT cooling water HP High pressure
Dimensions (mm) 9625 5410 24510 9023 4694 LP Low pressure
Starting method: compressed air with HT High temperature
blower for low part load LT Low temperature
Dry mass (t) 407 407 407 407 407 operation up to 25% load

World Class Service
Expert advice and assistance
PrimeServ – peace of mind for life PowerManagement by MAN Diesel & Turbo

With more than 150 PrimeServ service stations and Complementing the PrimeServ after-sales offering is
service partners worldwide and our growing network the MAN PowerManagement concept.
of PrimeServ Academies, MAN Diesel & Turbo is
committed to maintaining the most efficient, acces- MAN PowerManagement packages provide integrated
sible after-sales organisation in the business. support solutions for all aspects of running a power or
co-generation plant. Individually negotiated agreements
PrimeServ’s aim is to provide: can cover assistance with – or delegation of – the man
n Prompt, OEM-standard service for the complete life agement of all mechanical, electrical and thermal equip
cycle of an installation ment. This gives the power plant operator comprehensive
n Training and qualification of service personnel at access to the technology, experience, best practices
our PrimeServ Academies to maximise the plant’s and professional resources of MAN Diesel & Turbo.
availability and viability
n Rapid, global availability of genuine, quality-as- In short: PowerManagement by MAN Diesel & Turbo
sured MAN Diesel & Turbo spare parts via local allows you to benefit from our specialist expertise in
outlets or our 24 hour hotline. running a power plant while you concentrate on your
core business.
10 18V48/60TS – Four-stroke diesel engine

All data provided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depending on the subsequent specific
individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of
each individual project, especially specific site and operational conditions · Copyright © MAN Diesel & Turbo · D2366483EN Printed in Germany GMC-AUG-06110.3
powerplant-aug@mandieselturbo.com
86224 Augsburg, Germany
www.mandieselturbo.com
Fax +49 821 322-3382
Phone +49 821 322-3897
MAN Diesel & Turbo
Annexure - 3
Fuel Specification
Fuel system related characteristic values:
The fuel system is designed to operate based on the following fuel oil
specification based on ISO 8217-2010:
Lower calorific value (LCV) 40230 kJ/kg

Viscosity (at 50°C) up to 180 mm2/s
Density (at 15°C) max. 1010 kg/m3
Sulphur content up to 3.4%-wt.
Ash content up to 0.15%-wt.
Flash point min. 60 °C
Pour point max. 30 °C
Coke residue (Conradson) max. 20 % wt.
Vanadium max. 450 mg/kg
Water max. 0.5 % vol.
Sediment (potential) max. 0.1 % wt.
Aluminium and silicon (total) max. 60 mg/kg
Total acid number max. 2.5 mg KOH/g
Hydrogen sulphide max. 2 mg/kg
Asphaltene content max. 2/3 of coke residue % wt (Conradson)
Sodium Sodium < 1/3 vanadium, Sodium < 100 mg/kg
CCAI number max. 870
Current fuel oil characteristics are not sufficient for estimating the combustion
properties of the fuel oil. This means that service results depend on oil
properties which cannot be known beforehand. This especially applies to the
tendency of the oil to form deposits in the combustion chamber, gas passages
and turbines. It may, therefore, be necessary to rule out some oils that cause
difficulties.
The fuel must be free of admixtures not based on mineral oil, such as coal oil
or vegetable oils, free of tar oil and lubricating oil, free of any chemical waste,
solvents and polymers.
Annexure - 4
The Greenery layout
Annexure - 5
Land Use Map
Annexure - 6
Land Development Map
Annexure - 7
Drainage Layout
Annexure - 8
Oily Water Separation System
EcoStream
Technical information for bilge water treatment

Inside view
The EcoStream bilge water treatment system from Alfa Laval is a reliable
fully automated, single-stage centrifugal separation system to clean oily
wastewater on board vessels at sea and at land-based power plants.
3 Summary
4 The EcoStream bilge water treatment system

Overview
System requirements
System benefits
6 Towards cleaner oceans

What is bilge water?
Bilge water treatment
Bilge water legislation
8 Stable emulsions in bilge water

What are emulsions and suspensions?
Chemical usage aids stabilization
Effect on separation performance
Mechanisms for emulsion breakdown
10 Equipment
Operating principle
Key components
13 Optional components
14 Flow diagram
16 Retrofitting
16 Documentation
16 Classification
16 Spare parts, service and support

Alfa Laval EcoStream
2 Alfa Laval Marine & Diesel Equipment

Summary
Bilge water must be treated to reduce the oil content to levels that meet
international regulations for release into the environment. This is critical
to keeping the world’s oceans and their vast marine ecosystems healthy
and productive.
The Alfa Laval EcoStream bilge water treatment system Benefits for owners and operators
is a centrifugal separation system for bilge water treatment • Reduced operating costs thanks to low maintenance,
that has been approved by the International Maritime automated control, no waste disposal and an absence
Organization. of filter elements that require replacement.
This system generally cleans bilge water to less than five • Reliable, always-available system. Operates continuously,
parts per million (ppm) oil in water. It operates at flow rates of regardless of variations in feed, oil shocks and rough
up to 2,000 liters per hour to meet even the toughest bilge weather conditions.
water treatment applications.
• Easy to operate. Automated control and monitoring system
As a major equipment and technology supplier to the integrates with existing Alfa Laval systems, providing a
marine industry, Alfa Laval understands the requirements single user-friendly interface.
of all treatment systems on board vessels.
• Safe operation. A key lock switch can be set in manual
We use equipment and technology know-how to build or locked position to ensure that only the individual
solutions of all kinds for cost-effective and efficient operation responsible for environmental compliance may authorize
of vessels – from engine room applications including oil treat- overboard discharge.
ment and fuel conditioning to waste disposal applications,
including bilge water treatment.
Benefits for designers of ships and power plants
Our aim is to work continuously to improve customer • Compact, modular, easy-to-install system saves time,
processes – time and time again. space and money.
This document provides technical information about • Continuous, single-stage operation requires less holding
the Alfa Laval EcoStream bilge water treatment system. tank volume and provides more space for payload.
It includes information about the bilge water separation
process, advances in system design, system benefits • Easy integration with existing communications systems
and a description of equipment. on board.
The Queen Mary 2 is equipped with two EcoStream bilge water treatment systems.
Alfa Laval Marine & Diesel Equipment 3

The Alfa Laval EcoStream

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

Treatment methods must meet individual ship requirements Conditioning Module and Separation Unit controllers,
and demands for safety, reliability, compactness, automation, facilitating ease of operation.
low maintenance and the ability to withstand rough weather
conditions. In addition, performance of the treatment system Easy to access and maintain
can vary depending on the oil content and the size of the Built-in service areas facilitate inspection and maintenance.
droplets or particles present in the water and on various A central pillar houses all motor starters and the advanced
operating conditions. process controller, making the EcoStream unit easier to
service and easier to operate than other units available.
Centrifugal separation has proven to be a reliable, efficient
and flexible method for continuous removal of oil and other More uptime, less maintenance
contaminants suspended in the bilge water on board ships Maintenance-free components, automation and remote con-
and at land-based power plants. trol increase operating time and decrease service disruptions.
Durable components contribute to longer service intervals
between inspections.
Overview
The EcoStream bilge water treatment system from Alfa Laval Lower installation and operating costs
is a centrifugal separation system for treatment of large bilge Thanks to pre-testing, installation requires less time and
water volumes at sea. EcoStream operates at flow rates of money than installation of separate components. Automation
between 1,500 and 2,000 liters per hour and usually cleans and remote control reduce operating costs.
bilge water to less than 5 ppm.
Technical support
EcoStream is easy to install for any new or existing All spares, service and sales engineers are available through
installation. It does not require large bilge water holding the Alfa Laval International Service Network.
tanks. This increases payload capacity. Compared to con-
ventional bilge water systems, EcoStream significantly
reduces operating costs, thanks to automation and remote
control. In addition, there is no expensive filter element
replacement required.
EcoStream enables cleaning of bilge water under a wide Dimensions

range of real operating conditions. It complies with the
Marine Environment Protection Committee Resolution,
MEPC 107(49), of the International Maritime Organization
(IMO), MED 96/98/EC. EcoStream is not only certified by
these organizations, but has proven its high level of per-
formance under real operating conditions, normally below
5 ppm – even when subjected to oil shock or rough weather.
1768 mm
System benefits
Compact, modular and flexible design
This provides great flexibility to install the unit in a convenient
location. A wide range of options for functionality, remote
control and other features adds more flexibility.
635 mm
Easy to install
This simple, plug-and-play installation of this factory-tested
1450 mm
module makes it easy to install. Pipe connections located

underneath the unit make EcoStream easy to install.
Faster, more secure commissioning

Pre-tested, pre-installed and pre-approved components for all
system functions make commissioning quick, easy and much
less expensive than buying separate components and 750 mm
designing a bilge water treatment system. Access area
1070 mm
Easy to operate 1810 mm

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

Towards cleaner oceans

Bilge water generated on board ships is a major environmental
concern for the shipping industry.
Regardless of its source, bilge water must be treated to Alfa Laval’s bilge water treatment solution is superior to many
reduce the oil content to levels that meet international regula- competing technologies with respect to the volumes of waste
tions for release into the environment. This is critical to generated.
keeping the world’s oceans and their vast marine ecosystems
healthy and productive.
What is bilge water?
Efficient bilge water treatment minimizes the impact of ship Bilge water collects in a ship’s bilge wells, which are located
propulsion on the marine environment as well as the heavy in the lowermost part of the vessel just above the hull. The
fines that ship operators can face for pumping oily bilge water wells receive water and mechanical fluids from operational
overboard. sources, such as technical rooms, propulsion systems and
different machinery.
Efficient treatment also reduces the need for and cost of
waste disposal ashore. Over the years, waste disposal costs Bilge water also contains fluids from machinery spaces,
have continued to climb as local authorities enforce stricter internal drainage systems, sludge tanks and various other
laws for the land-based companies that process this waste. sources.
Bilge water contains

a mixture of water Cleaning and Water from purifier
and fluids from maintenance sludge tanks
various sources on
board that is treated
Drains Water from waste
for clean water and leaks oil tank
discharge overboard.
Tank Condensate
overflows from air coolers
Incidents
Clean water
overboard
Bilge
pump
Bilge water tanks Bilge water

treatment
Bilge well Bilge well

Bilge water
composition.
Fresh water
Water
Seawater
Heavy fuel oil Emulsions,

suspensions
Oil Lube oil
Hydraulic oil
Organic
Particles
Inorganic
Emulsifying, corrosive
Chemicals
Other
The definition of bilge water is thus much wider in scope Bilge water legislation
than merely the contents of a ship’s bilge, the enclosed area Bilge water treatment is an environmental application that
between the frames where the sides of the vessel curve in to must meet stringent requirements of international legislation.
form the bottom. Disposal of untreated bilge water into our oceans is strictly
prohibited by international law and subject to heavy fines,
In simple terms, bilge water contains two types of sub- especially in sensitive waters.
streams: (1) flows that are reasonably continuous and pre-
dictable, and (2) flows that are intermittent in nature and diffi- Current MARPOL legislation stipulates that separated bilge
cult to foresee. The first category includes water from the water containing 15 ppm or below oil in water can be dis-
separator sludge tank and water from cleaning activities in posed into international waters. Some national, regional and
the ship’s engine room. The second category may include local authorities, especially those governing sensitive waters,
soot water, leakage and incident spills from tanks and have more stringent regulations. In the United States and in
machinery spaces. the Baltic and North Seas, for instance, disposal of separated
bilge water is only permitted at least 12 nautical miles from
Bilge water is thus composed of a mixture of water, deter- shore.
gents and other chemicals, fuel oil, lubricating oil, hydraulic
oil, cat fines, oil additives, soot and dirt. This mixture is col- The International Maritime Organization (IMO) resolution
lected in the bilge water holding tank, which generally is MEPC 107(49) specifies how to type approve equipment
maintained at an elevated temperature. This high temperature used on board ships. The resolution complies with the
facilitates primary gravity separation, preferably of the two- or European Marine Equipment Directive, MED 96/98/EC.
three-stage type, in the bilge water tank. Here, oil rises to the
top and particles settle on the tank bottom, generally dividing Many manufacturers have succeeded in meeting the speci-
bilge water into three distinct layers in the tank: fied requirements for equipment certification, but much of
this equipment falls short of delivering the high separation
• Top layer efficiency required under real operating conditions for bilge
This contains most of the oil and organic solvents and con- water discharge.
stitutes a small portion of the total tank volume. Skimming
this top layer for separate treatment is recommended.
• Middle, or main, layer

This aqueous phase contains water polluted by oil, chemi-
cals and particles in emulsified form. This is fed to the bilge
water treatment system.
• Bottom layer
This contains solids and heavy sludge, which should also
be removed for separate treatment.

Stable emulsions in bilge water

Separation of oil and particles from bilge water is becoming increasingly
challenging, due to the presence of stable emulsions and suspensions.
Emulsion and suspension formation and stability are of major concern in
the context of bilge water treatment.
What are emulsions and suspensions? What used to be lubricating and hydraulic oils of relatively
By definition, an emulsion is a mixture of two immiscible elemental composition, based on simple mineral oils, are now
liquids. An oil-in-water emulsion consists of small oil droplets complex formulations, sometimes based on synthetic oils and
dispersed in a continuous water phase. A suspension is a incorporating a variety of additives.
mixture in which solid particles are dispersed in the con-
tinuous water phase. Modern lubricating and hydraulic oils have a greater ability to
take up water due to the action of detergents. Likewise,
Emulsions, or small droplets of one liquid (the dispersed cleaning chemicals have a great ability for oil and dirt uptake.
phase), can form in the other liquid (the continuous phase)
under agitation, such as during pumping or throttling in Stabilizers may also occur naturally in the oil. These stabilizers
valves. Droplets of oil dispersed in water generally coalesce, concentrate at the oil-water interface and lower the interfacial
or combine, into larger droplets because oil is not soluble tension, thus stabilizing the liquid mixture.
in water.
Some chemical residuals generally end up in a vessel’s waste
Increasing the droplet size helps facilitate separation. treatment system or holding tank. The bilge water treatment
The presence of surfactants, such as detergents, soaps system, in particular, processes a heavy load of chemical
and other surface-active compounds, however, may residuals.
contribute to stabilization of small oil droplets. This
makes separation very challenging. High centrifugal force Chemical usage in the engine room inevitably causes the for-
is then required to separate the small droplets that do mation of stable emulsions and suspensions as well as some
not spontaneously separate when subjected to gravita- form of environmental impact. Most chemical manufacturers
tional force. claim that their products do not stabilize emulsions in bilge
water. But the use of surface-active chemicals make many
Emulsion stabilizers may consist of: products contribute to the formation of stable emulsions.
• Low molecular weight surface-active compounds, or Usage of chemicals always causes some type of compromise
surfactants, that reduce the surface tension of the oil-water between cleaning efficiency and separation efficiency on the
interface and thereby create small droplets that contribute one hand and environmental friendliness on the other.
to emulsification.
Alfa Laval strongly recommends the use of quick-separating,
• Polymers and other macromolecules form a film around environmentally friendly and non-toxic detergents. Choosing
the emulsion droplet to establish a physical barrier to chemicals that are compatible, non-toxic, biodegradable and
coalescence and thereby stabilize emulsions further. non-emulsifying, helps prevent problems downstream.
• Fine particles can accumulate and adsorb at the oil-water

interface to form a physical barrier around the emulsion Effect on separation performance
droplets. The formation of stable emulsions and suspensions affects
separation efficiency. Many conventional technologies fail to
split stable emulsions and remove suspended colloidal parti-
Chemicals usage aids stabilization cles from the water phase. This often results in equipment
Emulsion stabilizers may originate from a variety of sources in malfunction because separation of oil below 15 ppm is not
the engine room – from the use of cleaning detergents, from achieved or because of clogging from excessive solids.
lube oil additives and so on. Clearly, the use of chemical sub-
stances on board is excessive. Understanding the factors that contribute to the formation
and breakdown of stable emulsions is essential to under-
Chemicals on board are used for: cleaning and maintenance, standing why centrifugal bilge water treatment systems can
treatment of water, improving fuel quality, and improving the efficiently separate bilge water, despite a high concentration
quality of lubricating oil. of stable emulsions.

High centrifugal force in

the separator contributes
Oil
to coalescence and
flocculation, which aid
emulsion breakdown.
Water
Solids
Feed
Flocculation of particles Coalescence of droplets
Mechanisms for emulsion breakdown • Flocculation is a process by which two or more particles
There are different mechanisms for emulsion destabilization aggregate without losing their individual identities.
and breakdown, including coalescence and flocculation.
– A high centrifugal force induced in a centrifugal separator
• Coalescence is a process where two or more droplets greatly contributes to the flocculation of small particles.
collide, resulting in the formation of one larger droplet.
– A high alkaline pH value promotes flocculation. The pH
– A high centrifugal force induced in a centrifugal separator value provides a measure on a scale from 0 to 14 of the
greatly contributes to the coalescence of small droplets. acidity or alkalinity of a solution.
– Elevated temperature accelerates the rate of coalescence – Chemical flocculants decrease or cancel the repulsive
by increasing the probability of the droplets to collide and electrostatic forces between particles in a suspension,
by decreasing the viscosity of the continuous phase. thus promoting flocculation.
– Chemical demulsifiers decrease or cancel the repulsive

electrostatic forces between droplets in an emulsion,
causing droplet coalescence.
What parameters affect separation efficiency? The expression states that the greater the difference in density,
Centrifugal separation relies on the difference in density among the greater the efficiency. However, the density difference is not
the various components present in emulsions or suspensions. the most important parameter affecting the separation efficiency.
Stokes’ Law (below) describes the settling velocity (vg ) of a The sedimentation velocity increases exponentially with the
particle or droplet when subjected to gravitational force, such as droplet, or particle, size. This means that the smaller the droplet
static settling in a tank, which in turn determines the separation or particle, the more challenging the separation task.
efficiency. The general formula is:
For separation of small droplets and particles, which are found
in the stable emulsions and suspensions in bilge water, gravity
d 2 (ρd – ρc) alone is not sufficient. In a centrifuge, the term (g) in the expres-
νg = g sion is replaced by (w2r), the centrifugal force, which is several
18 µc
thousand times greater than the acceleration due to gravity.
Therefore, even droplets and particles that are only a few
νg the sedimentation velocity due to gravity micrometers in size can be efficiently separated.
d the diameter of the dispersed droplet/particle
ρd the density of the dispersed phase Another important factor that has a positive effect on separation
efficiency is low viscosity. The viscosity of the continuous phase
ρc the density of the continuous phase
affects sedimentation velocity, which increases in inverse propor-
µc the viscosity of the continuous phase tion to the viscosity. Therefore, any medium with low viscosity,
g the gravitational acceleration such as a continuous water phase, facilitates separation.

Equipment
Environmental protection requires reliability. This is how Alfa Laval
has met the bilge water treatment challenge.
Operating principle water holding tank in order to avoid re-contamination. This

A positive displacement feed pump with variable frequency helps make bilge water handling more efficient.
drive control directs oily water from the bilge water settling
tank or equivalent to the system. The pump provides a feed
range of between 1,500 and 2,000 liters per hour. The Key components
process liquid should always maintain a pH value above five. EcoStream makes the best use of available space and
An optional chemical dosing unit can be connected after the provides flexibility and easy access for operation and main-
pumping stage although chemicals usually are not required tenance. These key EcoStream components are more fully
to accomplish efficient bilge water treatment. detailed later in this section:
Bilge water then passes through a dual basket strainer which Forwarding pump
traps large particles from the fluid before entering a heat An eccentric screw pump with variable frequency drive
exchanger, which raises the fluid temperature to required control.
levels, generally between 60° and 95°C, for optimum separa-
tion efficiency. Strainer
A dual basket strainer of mesh size 1.5 mm.
A three-way changeover valve then directs the fluid to the
separation stage if all process conditions, such as feed Heat exchanger
temperature, feed pressure and separator speed, fall within A shell-and-tube heat exchanger using steam as its heating
preset process values. If any process condition is not met, medium.
the valve re-circulates the fluid back to the bilge water
settling tank. Three-way changeover valves
Two three-way changeover valves handle bilge water at
A high-speed centrifugal separator continuously processes critical junctions.
large volumes of bilge water. The oil outlet continuously dis-
charges out-separated oil and emulsions. Solids that collect Constant pressure valve
at the separator bowl periphery are discharged intermittently A fast-acting, high-precision constant pressure modulating
to a cyclone, which reduces the velocity and energy of the valve handles the required backpressure with accuracy.
discharged volume. Discharge occurs at preset intervals,
which is generally set at 20 minutes, depending on the Transmitters
installation. Solids are then directed to a sludge, or waste Electronic transmitters monitor temperature and pressure.
oil, collecting tank.
Separator
A built-in water pump, or paring disc, continuously dis- The BWPX 307 high-speed centrifuge uses the most modern
charges separated bilge water through the water outlet. fluid dynamics technology for high separation efficiency.
The destination of the separated bilge water depends upon
its oil content, which is continuously monitored at an iso- Control cabinet
kinetic sampling point by an oil-in-water monitor. Two separate compartments houses the process controller
and the electric power functions.
If oil content is less than or equal to 15 ppm, the separated
bilge water can be pumped either directly overboard or to a Process controller
‘clean’ bilge water holding tank for discharge overboard later. The EPC 50 process controller facilitates monitoring and
If oil content exceeds 15 ppm, the effluent is re-circulated, control of all EcoStream functions, which are displayed in
preferably to the cleanest part of, the bilge water settling tank clear text and on a mimic display.
for re-processing.
Oil-in-water monitor
As an alternative, separated bilge water with an oil content Certified according to IMO resolution MEPC 107(49), this
just above 15 ppm can be directed to an ‘almost’ clean bilge in-line unit accurately measures the content of oil in water.

Components in the system
Pump unit
The pump unit consists of a stand-alone compact pump
module, which is designed for ease of installation and ease
of accessibility for maintenance.
Thanks to its variable speed control, this screw pump easily

handles changing fluid capacities and enables adjustment of
the feed rate setting during operation. The feed rate ranges
between 1,500 and 2,000 liters per hour.
To protect the pump from dry running, the unit is equipped

with a water-priming device, which is automatically activated Oil-in-water monitor according to IMO resolution MEPC 107(49).
upon startup. This water-priming device may also be acti-
vated manually, whenever necessary. The pump has a pres-
sure relief valve, pressure gauges and a non-return valve on Oil-in-water monitor
the discharge side. This in-line unit monitors the oil content of separated bilge
water in compliance with IMO Resolution MEPC 107(49).
Strainer It is capable of monitoring oil content from zero to 30 ppm
To trap large foreign particles suspended in the bilge water at sample temperatures of up to 65°C.
that may cause unnecessary operational disturbances, a dual
basket strainer with a mesh size of 1.5 mm is installed as a To minimize response time, the iso-kinetic sampling point of
safety measure. the monitor is located as close as possible to the separation
stage. Before processing occurs through the monitor, the
Heat exchanger sample passes through a cooler, which is used when separa-
This shell-and-tube heat exchanger uses steam as the tion temperature exceeds 65°C, to prevent damage to the
heating medium. All heater parts that come into contact with monitor from excessive heat.
the bilge water are made of cupronickel, a corrosion-resistant
alloy. A proportional integral (PI) temperature controller accu- Two independent alarm circuits come with a factory setting of
rately maintains the temperature set point within ± 2°C, even 15 ppm, but may be set independently to indicate oil content
under variable bilge water feed conditions. This is especially in water ranging from two to 15 ppm. An alarm setting above
important to achieve high separation efficiency. Installation in 15 ppm is impossible.
a horizontal position reduces the risk for build up of conden-
sate and provides easy access for maintenance. Three-way changeover valves
Two pneumatically activated three-way changeover valves
Separation unit regulate bilge water at critical junctions. The first directs bilge
The BWPX 307 high-speed centrifuge utilizes the latest water to the separation stage for treatment, and then re-
achievements in modern fluid dynamics technology. Designed circulates bilge water that does not meet pre-set conditions
for continuous, high-efficiency separation of large bilge water back to the bilge water settling tank. The second routes
volumes, the centrifuge handles throughput capacities of separated bilge water with oil content that is less than or
1,500 to 2,000 liters per hour. Its unique design provides equal to 15 ppm to a holding tank for discharge overboard
reliable operations, even when subject to oil shocks and later or pumps the water directly overboard.
rough weather conditions.
During an alarm situation when any preset condition is not
The patented Alfa Laval disc inlet, Optiflow, gently accelerates met, loss of operating air pressure or power failure, the three-
bilge water into the separator bowl with a minimum of way changeover valves automatically shift to re-circulation
shearing and foaming. This greatly improves separation effi- mode, thus preventing overboard discharge of any bilge
ciency by preventing the splitting of drops and the formation water with oil content exceeding 15 ppm.
of further emulsions.
Constant pressure valve
The new disc-stack design provides the maximum surface This fast-acting, high-precision constant pressure modulating
area possible for separation. Specially designed concentrator valve prevents the formation of air bubbles during the separa-
distribution holes and caulk configuration further optimize tion stage and thereby helps insure the accuracy of the oil-in-
separation efficiency. water monitor. It is installed after the separator.
A speed sensor and an optional unbalance sensor monitor Whenever solids or sludge are discharged from the separator
the mechanical status of the separator. A cyclone, installed bowl, additional air pressure is applied to the valve to prevent
in the sludge outlet, provides ventilation and reduces the any untreated bilge water from penetrating and polluting the
velocity and energy of the discharge volume. system downstream.

Transmitters
Electronic transmitters provide accurate readings for pressure
and temperature and improve control to achieve high separa-
tion efficiency.
Sampling cocks
Situated before the separation stage and after the three-way
changeover valves, these sampling cocks enable analysis
of bilge water samples and provide an alternative way to
measure the accuracy of the oil-in-water monitor.
Control cabinet
Centrally located to monitor all EcoStream functions, the
control cabinet has two separate compartments. The lower
compartment contains all electric power functions, such as a
multi-transformer, for power supplies in the range of 230 to
690 V, all motor starters, pump unit speed control, power
supply for the optional chemical dosing unit and all pneumatic
control devices. The upper compartment contains the
Alfa Laval EPC 50 computer-based process controller and
operator panels.
Process controller
The EPC 50 is the latest generation of the Alfa Laval com-
puter-based process controller. Easy to operate, the unit pro-
vides fully automated advanced monitoring and control of all EPC 50 process controller.
EcoStream functions. To assist with trouble tracing, an alarm
log registers the last 31 alarms. It also records time when the
alarm appeared, time until the alarm was reset and the
sludge discharge time interval. More process data are easily accessible by simply pressing
a button. These include feed temperature, feed pressure,
The process controller has several built-in self-cure functions water outlet pressure, oil content in cleaned water, separator
that automatically activate to ensure continued operation bowl speed and total operating hours. All critical process
should a system problem occur. A proportional integral (PI) parameters and operation mode, including start-up, standby,
temperature controller accurately maintains the temperature pre-production, production and stop, are displayed in
set point for separation within ± 2°C, even under variable clear text.
bilge water feed conditions.
A key lock switch that controls discharge of separated water
Standard hardwired input and output signals include: is also located on the panel. Bypass, or locked, position re-
• Emergency stop button, circulates separated bilge water, regardless of its oil in water
• Emergency shut down (ESD), content. Inserting the key enables selection of automatic
• Process shut down (PSD), position, which directs bilge water with oil content of 15 ppm
• Common alarm indication, and, for discharge overboard.
• Process status indication.
It is also possible to set the limit for overboard discharge
The EPC 50 process controller is based on the same hard- lower than 15 ppm – at five ppm, for instance. This enables
ware used in other Alfa Laval units, making it easy to use for safe discharge in environmentally sensitive waters, where
operators who are already familiar with this equipment. lower oil in water content is required by regulatory bodies.
Operator panels Located next to the LED panel, the operator panel controls
A push button and light-emitting diode station displays the the feed rate of the variable frequency drive feed pump.
status of cleaned bilge water for discharge overboard and for
re-circulation, the pumping stage, the electric motors,
optional chemical dosing units and optional automatic
cleaning unit for the oil-in-water monitor.
A mimic display continuously indicates the operation mode of:

• Feed to the separation unit or re-circulation,
• Cleaned water for discharge overboard or re-circulation,
• Pressure and temperature transmitters.

Optional equipment
The EcoStream system offers these equipment options to provide
greater flexibility.
• Chemical dosing unit The CIP unit reduces downtime and maintenance man-
Under extreme conditions, centrifugal force alone may not hours and saves money. It also minimizes the potential risk
be sufficient to deliver high separation efficiency for satis- for mechanical damage of vital bowl parts.
factory treatment of the bilge water. This is usually the case
when large quantities of suspended solids, such as soot or • Automatic cleaning device for the oil-in-water monitor
detergents, are present in bilge water. An automatic pneumatic cleaning device for the oil-in-water
monitor is available as an alternative to manual cleaning of
For these conditions, an optional chemical dosing unit effi- the measuring cell in the oil monitor.
ciently handles strongly emulsified oil as well as suspended
colloids. The cleaning device activates at every sludge discharge,
ensuring accurate monitoring of oil content by continuously
Chemicals should only be added when a combination cleaning the measuring cell in the oil monitor.
of high separation temperature (95°C) and low flow rate
(1,500 liters per hour) is insufficient to separate bilge water • Serial bus connection
to contain 15 ppm or less oil in water. Fully remote operation of the EcoStream is possible by
connecting the process controller via serial bus to an
Alfa Laval recommends the use of safe and environmentally external computer or communications system.
friendly Alpacon chemicals, MP 300/302. The combination
of these water-based additives promotes demulsification This provides complete coordination with a Central Control
and flocculation to achieve clean water with less than System (CCS) or a plant’s Integrated Administration and
15 ppm for more difficult feed compositions. Control System (IACS). Proprietary field bus interface
boards, according to Profibus DP or Modbus RTU stan-
• Automatic self-cleaning filter dards, are installed in the process controller. This enables
If the feed water is expected to have a high solids or fiber communication to external automation systems. Most local
content, installation of an automatic, self-cleaning filter is functions can be replicated with the use of the field bus in-
recommended. This may be necessary, for instance, if the terface boards.
risk of overflow from black and grey water tanks into the
bilge wells exists. Please contact Alfa Laval if other protocol boards,
such as CANopen, DeviceNet or InterBus, are required.
Removing fibers and other coarse solids helps prevent Customers assume responsibility for coordination of pro-
clogging of passages, such as the distribution holes in the gramming on the remote side through their automation
separator disc stack. This prolongs service and maintenance providers. Alfa Laval provides documentation describing
intervals, which may otherwise be unacceptably short. the protocol for the system developers.
• Sludge removal kit (SRK)

When installation of EcoStream on top of a sludge-
collecting tank is impossible, an optional sludge removal kit
(SRK) is available.
As part of the oily water pre-treatment stage, this small,

intermediate sludge tank comes equipped with a pneu-
matically driven sludge removal pump, level controller and
level switch.
• Cleaning-in-place unit
An optional cleaning-in-place (CIP) unit is available to
enable cleaning of separator bowl parts without dis-
mantling the separator.

Flow diagram
Two-stage bilge water Automatic self-cleaning filter Steam pre-heater
settling tank (optional) Raises temperature of the liquid
Pre-heats the bilge water. Removes coarse solids and fibers. to the required treatment tem-
perature.
Chemical dosing units (optional) Pressure transmitters
Enhances separation efficiency if Measures the pressure in the water Temperature transmitters
stable emulsions are present. inlet and outlet and signals this in- Measures the temperature of the
formation to the process controller, liquid from the pre-heater and
Feed pump with which monitors pressure to ensure signals the process controller.
variable speed control remains within acceptable limits.
Transfers liquid to the steam Temperature controller
pre-heater. Dual basket strainer Alerts operator when the tempera-
Traps large particles from the fluid ture exceeds, or falls below, a pre-
before entering the heater. set limit and acts as a backup to
provide temperature control should
the temperature transmitter fail.
From From drains

bilge wells and leaks Recycling to tank
Feed recycling

Alpacon Alpacon
MP 300 MP 302
VFD
PT
Feed inlet


Three-way changeover valves BWPX 307 high speed Constant pressure

Directs bilge water from the tank centrifugal separator modulating valve
to the separation stage and from Continuously separates large Prevents the formation of air bub-
the separation stage either to volumes of bilge water. bles during the separation stage
pump for discharge overboard if and thereby helps insure the accu-
it contains less than 15 ppm oil Oil-in-water monitor racy of the oil-in-water monitor.
in water or back to the bilge water Continuously measures oil content
settling tank if these conditions of cleaned bilge water and com-
Intermediate sludge tank with
are not met. pares these measurements to a sludge pump (optional)
pre-set value. Temporarily stores sludge for waste
Cyclone processing on shore.
Reduces the velocity and energy of
the discharged volume of solids
before reaching the sludge outlet.

PT Clean water

outlet
Ventilation QT

QC

TC

TT TT
Sludge outlet

Retrofitting Documentation
EcoStream is ideal for replacing older bilge water Alfa Laval supplies each EcoStream bilge water treat-
treatment systems. Its compact size easily fits into ment system with full documentation either as paper
any available space. copies or as PDF (Portable Document Format) files on
a CD-ROM. The instruction manual, which can also
To facilitate transport through small passageways, be made available in most major languages, covers:
EcoStream can also be divided into four parts:
• Safety
• A separator with a frame, • System description
• Valve and piping rack, • Operating instruction
• Feed pump, and, • Parameter list
• Control cabinet. • Alarms and fault finding
• System reference/installation instructions
• Separator manual
• Spare parts catalogue
• Component descriptions
Classification Spare parts,

society approval service and
Alfa Laval ensures that the EcoStream fulfils the
requirements of all major classification societies.
support
Upon request, Alfa Laval delivers the EcoStream with
an individual test certificate. This includes approval by Alfa Laval provides spare parts kits for all service and
the society of the main components as well as work- maintenance needs. Global technical service, training
shop testing of the complete module. Several key and support are available throughout the lifetime of
components are also type approved by the leading the EcoStream.
classification societies.

Alfa Laval reserves the right to make changes at any time without prior notice.
Any comments regarding possible errors and omissions or suggestions for improvement
of this publication would be gratefully appreciated.
Copies of this publication can be ordered from your local Alfa Laval company.
Published by: Alfa Laval Tumba AB

Marine & Diesel Equipment
SE-147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB 2004.

Alfa Laval in brief
Alfa Laval is a leading global provider
of specialized products and engi-
neering solutions.
Our equipment, systems and services

are dedicated to helping customers
to optimize the performance of their
processes. Time and time again.
We help our customers to heat, cool,
separate and transport products
such as oil, water, chemicals, bever-
ages, foodstuff, starch and pharma-
ceuticals.
Our worldwide organization works

closely with customers in almost 100
countries to help them stay ahead.
How to contact Alfa Laval

Contact details for all countries are
continually updated on our web site.
Please visit www.alfalaval.com to
access the information.
www.fotoskrift.se
EMD00050EN 0412
Annexure – 9(a)
Elevation & Layout of FGD Plant
Annexure – 9(b)
Technical Description of FGD Plant
Specification for FGD System
Scope of Supply and Services
Dhaka Southern Power Generations Ltd.
55 MW HFO Power Plant
Nababgonj,Dhaka.
November 2013
3
1 Project Profile
Your company has 3 fuel boiler, dust removal equipment, but you have no
desulfurization equipment. Therefore SO2 is out of gauge and need to revise. After our
careful consideration, we decided to adopt to add a set of desulfurization dust removal
equipment to back of the fan. In principle, this project adopts the single (sodium) process,
equipment adopts desulfurization tower desulfurization system, so as to meet the local
environmental allowed emissions and ensure the desulfurization effect. Below we will quote
according to the single boiler design.
The technology is mature, with high absorption, high efficiency of utilization, low
operation maintenance cost etc. It provided advanced equipment and materials, ensure to meet
the latest industrial standard requirements of the quality , services and the equipment.
2 Design Basis and Indicators
2.1 Flue Gas Parameters
Flue Gas（for one furnace）80000-90000 m3/h
Furnace flue gas outlet temperature＜350OC （Guide equipment import of flue gas
temperature）
So2 content≤2500-3700mg/m3。
2.2 Desulfurization Agent Quality
Main Desulfurization Agent：90％caustic soda flakes；
2.3Codes and Standards
《The Integrated Emission Standard of Air Pollutants》（GB16297-96）
《Industrial furnaces standards for the discharge of atmospheric pollutants》

（GB9078-1996）
《Industrial boiler and furnace wet flue gas desulfurization engineering technical
specifications》（HJ462 -2009）
《Standard of noise at boundary of industrial enterprises》（GB12348-90）

《GBZl》
（GBZ1-2002）
《Concrete structure design code》（GBJ10-89）
《Welds technical specification for concrete structures》（JGJ/T114-97）
《Industrial metal pipeline design specifications》（GB80316-2000）
《 Industrial equipment and pipeline insulation engineering design specifications 》
（GB50264-97）
《Pipe rack first part: technical specifications》（GB/T17116.1-1997）
《Pipe rack second part: pipe connection parts》（GB/T17116.2-1997）
《pipe supports and hangers third part：Intermediate fittings and architectural structure
fittings》（GB/T17116.3-1997）
《Water supply and drainage pipeline engineering construction and acceptance specification》
（GB50268-97）
《Water structure construction and acceptance specification》（GBJ141-90）
《Stationary steel straight ladder》（GB4053.1-93）
《Stationary bevel steel ladder》（GB4053.2-93）
《Stationary industrial protective barrier》（GB4053.3-93）
《Fixed steel industrial platform》（GB4053.4-93）
《Industrial enterprise lighting design specifications》（GB50034-92）
《Low voltage distribution design specifications》（GB 50054-95）
《General electric equipment distribution design specifications》（GB 50055-93）
《Building structure load standard》（GBJ9-87）
《Building ground design specifications》（GB50037-1996）

《Architectural lighting design standards》（GB50033-2001）
《Building lightning protection design specifications》（GB 50057-94）
《Earthquake Resistant Design Code》（GB50011-2001）
《Structure seismic design code》（GB50191-93）
《Industrial equipment pipeline anticorrosion engineering construction
and acceptance specification》（HGJ229-91 ）
《Fluid delivery with stainless steel seamless steel pipe》（GB/T14976-94）
《Fluid delivery with seamless steel tube》（GB/T8163-1999）
《Stainless steel seamless steel pipe》

（GB2270-80）
《Steel welding atmospheric vessel》（JB/T4735-1997）
《Stell Buildings and Bridges》（GBJ17-91）
《Equipment and flue of the general principles of the thermal insulation technology》
（GB4272-92）
《Code for design of building》（GBJ7-89）
《Steel structure construction and acceptance specification》（GB 50205-95）
2.4 Design Objective
According to the national 《 Industrial stoves standards for the discharge of
atmospheric pollutants》（GB9078-1996）, Considering the total quantity control and the
improvement of environmental protection standard，The desulfurization process designs
desulfurization efficiency≥90％，the emission concentration of SO 2≤100 mg/Nm 3 ，
ringelman emittance＜1level.
2.5 Scope of Supply
The flue gas furnace production line (desulfurization) complete set of equipment
management，that is：the original equipment modification installed internals, increase a new
efficient desulfurization tower, the new equipment export increase pipeline and fan
connection. After the transformation, all things keep the same, just change the flue gas system,
desulfurization tower system, desulfurizer preparation system and other systems’ carry
information, design, construction, manufacture, installation, debugging and training. Reform
its internal structure, etc.
3 Technical Principle：
3.1 Desulfurization adopts TFGD
Single (sodium) process is to use soluble alkaline clear liquid（main：NaOH or
Na2 CO3）as an absorbent to absorb SO 2 .Because in the process of absorption liquid, it
use the same type of alkali, so called single process.
3.2 Desulfurization principle
Single process uses NaOH or Na2CO3 alkali liquor to absorb SO2, produce HSO32-、SO32-and
SO42-，reaction equation as below:
desulfurizing process
Single alkaline process desulfurization serves caustic soda flakes seriflux as the main
desulfurization agent, soda is continuously recycling. Because of this, the system will not
appear scaling blocking phenomenon, so the operation is safe and reliable.
Due to the quick rate of sodium alkali absorption and SO2 reaction, comparing with
calcium base, it can achieve a very high SO2 removal rate in smaller liquid gas ratio
condition.
3.3 Dust Removal Principle and Original Equipment Modification
After high atomization nozzle, doctor solution will blow into small droplets, and
will have full contact with SO2. the dust in the flue gas was set down, SO2 is
piecewise desulfurization neutralization, so as to achieve the effect of
desulfurization
Remark； The production does not suitable for TFGD desulfurization,because

TFGD exists the risk of Blocked.
3.4 Technics Characteristic
a 、 Advanced technology, complete set of equipment, set sulfur removal
integration
This technology fully ensure the new and old equipment is mixture with flue gas
and doctor solution. After absorption, adsorption and chemical reaction, it can
completely remove the flue gas dust and sulfur dioxide emissions, to meet environmental
protection requirements. The equipment was awarded the national patent in 2010.
b、Low operating cost
The design using sodium as the circulation desulfurization agent and efficient
absorption tower,has low liquid gasrate, low circulation，and the desulfurization agent
and electric water consumption is low.
c、System stable operation
Using sodium as the circulation desulfurization agent in the circulation process is

without scale and blocking phenomenon to water pump, piping, equipment, and the
system can be stable operation.
d、High Desulfurization efficiency
For the absorption efficiency of sodium alkali desulfurization agent is much higher
than albany grease, at the same time, using the high absorption tower design, its
desulfurization efficiency is 90 ~ 97%.
4. Process design
The project adopts advanced technology, stable operation of sodium - alkali TFGD,
taking the new and high efficiency desulfurization dust removal technology. Below is the
overall design principle:
1) To meet the environmental emissions standards and design index and client's
requirements；
2) To use a set of composite desulfurization tower and a set of utility system

configuration;
3) In the premise of guarantee system reliability, rational distribution, and as far as
possible to use of the existing flue, reducing investment cost and floor space;
4) Saving energy and reducing consumption, under the precondition of meeting the
indicators and sulfur removal system to ensure the best absorption liquid gas ratio and other
control parameters, in order to decrease the desulfurization agent consumption, energy and
water consumption.
5) Not set up the bypass flue;
6) This system is fully considered the change of SO2(that is, the range change of
1500～2300mg/m3），and combined with the gas flow parameters 50～100％ to design.
4.1 Process design parameters (sulphur content 5-2%)
Content Unit
Data Remark
Inlet flue gas temperature C ≤350 Fan outlet temperature
80000-90000 Provided by the

Gas flow m3 /h
manufacturer
SO2 concentration mg/ m3 2500-3600mg/m3
3.5×14m XGP-20
thionizer specification
m 2.5X14m Twin Composite efficient
(Diameter x height)
Towers desulfurization tower
Tower gas rising velocity m/s 2.5
liquid-gas ratio L/m3 4
Export so2 concentration mg/Nm3 ≤100～250
The amount of caustic soda

kg/h 12-15
consumption
Export flue gas to carry water
mg/m3 ≤75
content
Spray tower
Desulfurization system
Pa ＜900 desulfurization
pressure drop
resistance
System added water Kg/h 6
Absorption tower design

annual ＞15
service life
observation every week
Production staff person/ class
and clearing channel
System installed power kW 30
service power of the

power consumption kWh 15
system
desulfurization efficiency % ＞90
4.2 Process overview
Exhaust gas of dust removal, desulfurization equipment is from the original equipment
out into efficient desulfurization case for flue gas treatment. Flue gas is through the high
efficiency desulfurization tower efficient filter layer. And this filter layer with special design,
flue gas going through the filter layer, enhance the efficiency of absorption. And after
desulfurization tower top three layers of atomized spray absorption area, desulfurization agent
atomized into tiny droplets collision adsorption, absorption of SO2, complete gas
desulfurization dust absorption, and then into the efficient desulfurization tower at the back of
the mist device. The flue gas of the droplet capture down, mist eliminator is equipped with
flushing device, timing to wash. Flue gas is through the mist eliminator (vice tower) to
remove the liquid gas after the reconstruction in a period of pipeline to gas pipeline
Single (sodium) process mainly includes：1 Flue gas piping system、2 clarification
system（thionizer、pool）、3 Desulfurization agent preparation system、4 Circulating water
tank system、5、other system.
4.3 Formulate
4.3.1 Flue gas system
Dust gas by the transformation of the original equipment out enter the sulfur
removal system. Exhaust gas is through efficient desulfurization tower, dehydrator (vice
towe) equipment，finishing the flue gas desulfurization dust cleaningand then through the
fan and chimney to high emission

Desulfurization main equipment’s side is not setting bypass flue. Pipeline are all
made of steel structure，among import and export pipeline desulfurization take the
preservative treatment. The increasing pipeline internal all take the preservative
treatment.
（1）Pipeline
According to the possibility of the worst operating conditions（e.g.：temperature,
pressure, flow rate and the content of pollutants）to design the pipe.
Pipeline design can bear below load：self weight of pipeline、wind load、snow load、
seismic load、dust accumulation、the weight of the lining and so on。Some places add line
support.
Pipe is a gas tightness of welding structure，and all non flange connection interface are
continuous welding，complying with the above rules.
Piping layout can ensure condensate emissions，won't have water or condensate
fluid accumulation.So pipeline can provide the measures accumulation of low point
drainage and prevention condensate. In any case expansion joint and damper are not
arranged in low point。

Pipe external will fully reinforcement and support, in order to prevent the chatter and
vibration, and to meet stable operation in all sorts of flue gas temperature and pressure
(including stratification and uneven).
All the way of anti-corrosion protection should only use external reinforcement, do
not use internal stiffeners or support
Pipe external reinforcement uniform spacing arrangement.Use reinforced uniform
size or try to reduce the size of reinforcement。And add the beauty of outer appearance.
When arranging the reinforcement,we need to consider preventing water

All piping in the appropriate position is equipped with a sufficient number and size of
manhole door and soot cleaning hole, so that the pipeline (including expansion joint and
damper) can be maintenance and check and remove soot formation. The design of the pipeline
will minimize piping system pressure drop, and its layout,sharp and internal parts（Such as
turning guide plate）have optimization design.
4.3.2 Flue gas desulfurization dust removal system
1）、design consideration
See above：codes and standards
2）、design objective
1、desulfurization efficiency≥90%。Ringelmann shade scale≤1 Dust emissions＜
100mg/m³
Sulfur emissions＜100～250mg/m³
2、Equipment service life≥15years.
3）、design parameter（Provided by manufacturer）
1、Furnace shape：oil burning boiler
2、Treatment medium： SO2 produced from the furnace.
3、Day of working time 24 hours
4、Equipment flue gas inlet temperature：≤350℃
3
5、Gas flow：managing gas flow：80000-90000m /h（working condition）
6、 Sulfur inlet concentration＜2500mg/m³-3600mg/m³
7、Sulfur out concentration＜100-250mg/m³
4）、Design Philosophy
1、Adhere to the advanced ,reliable economic principle, so as to meet the domestic
advanced level
2、Environmental protection standard is stricter than state specified standard.
3、All equipment are based on domestic processing production, important parts
(shower nozzle, effuser, etc.) are made of strong corrosion resistant material.
4、The dust removal system installation, operation does not affect the original
production facility structure and process.
5、The sulfur removal technology is advanced：taking the integration of sulfur
removal which was produced by our company:“A new efficient desulfurization
tower”.The project has been granted the national patent，PATENT NO：
ZL200920119623.5
System configuration is reasonable and complete，complying with the relevant state
safety norms.
Safe and reliable operation，convenient maintenance，low operating cost，the
reasonable and reliable connection，and can quickly input and switching.
6、 The main part of the dust removal system (dust desulfurization equipment) is
transformed in the original equipment, increasing the length of 400 mm 6 branches filter layer
and open the roof.
7、Steel structure joint parts adopt standard joint.
5）、Dust removal system design and limit of works area

1、Equipment pipeline door system design
2、Desulfurization dust removal equipment design：including pipeline（remark：
equipment connected air duct），a new efficient desulfurization tower，a mist eliminator，
and to rebuild original dust removal equipment.
3、The range of construction scheme is

for fuel boiler flue gas purification and removal sulfur project design, equipment
production, transportation, guide installation and debugging, training and comprehensive
work
4、The scheme does not include pool, supplement water and so on.
6）、Desulfurization system design and Equipment Selection

1、Desulfurization system process
According to our company’s experience, in order to achieve relatively satisfied result.

Below is the technological process:
Original dust removal equipment→draught fan→Efficient desulfurization dust
removal equipment dehydrator→chimney net gas emission
Determination of the pipeline system：According to the economic flow velocity
13～15m/s and through the pipe flow calculation，the diameter of the pipe system
isφ1500mm.
2、Desulfurization system design features

According to client's requirement，combining with our successful examples and
experience，according to the principle of seeking truth from facts, learning from others's
strong points to offset one's weakness and optimal design，Below is the technical design
for flue gas desulfurization system：
2.1 Desulfurization system is running in a negative state，maximum manage So2 in
the production process,in order to ensure not affect furnace work.
2.2 Sulfur removal system design、equipment selection emphasize low resistance、
big flow theory，reducing operation cost，to ensure the normal work of the furnace.
2.3 de-dusting、desulfurization equipment filter material is temperature resistance
350，filter material prevention corrosion.
2.4 To ensure the normal operation of desulphurization system，achieving
environmental protection standard.

2.5 Desulfurization system is running low resistance,and equipment floor space is
little.
2.6 The main equipment selection
3. System air flow：Flue gas inlet temperature≤350℃ and local atmospheric pressure
conditions，desulfurization system pipeline chose no air leakage rate, airflow is

3
80000-90000 m /h.
3、1 Desulfurization equipment choice

According to the original parameters and the characteristics of the furnace，and after
the management it should achieve all aspects of requirements of the environmental protection
departments，that,is, sulfur dioxide emissions and Ringelmann coefficient. According to the
requirement and our work experience and other examples,we decide to take the technology of
TFGD,to manage SO2, and the purpose is to effectively remove a large amount of SO2. The
specific equipment include new efficient desulfurization equipment（dehydration unit in the
back）.
3、2 Water Pump：here，we will take engineering plastics submerged pump
feedwater（strong corrosion resistance），with two sets.
7）、Desulfurization dust removal equipment principle of work
New composite efficient desulfurization equipment
Composite high efficiency low resistance desulfurization dust removal equipment is in

the original granite water film dust removal and monomer desulfurization tower and turbulent
ball tower, on the basis of three kinds of equipment to improve.It will be recombination with
these three simple equipment, so as to make up the big resistance defect for the granite water
film spiral wind and spray tower and turbulent ball tower.
Inside of the equipment added garden shape desulfurization layeran and the filter layer
devices which produced by ourselves. This filter layer is made by several small circular
support arm, and according to the characteristics of the fixed Angle, when the gas go through
the circular support arm, because of the wind movement characteristics, turn round, so the
contact surface will become bigger. And the circular surface is a lye, so gas and lye contact
surface will increase, contact time lengthen, and flue gas of sulfur of molecules and molecules
of the alkali lye can be fully in close, it is in the equipment structure to ensure the
desulfurization effect
So that the old water film is only by a cyclone principle into relying on a variety of
principle of comprehensive dust desulfurization and dehydration of new equipment, greatly
improving the sulfur removal effect, and now the new high efficiency desulfurization
equipment on modelling is not granite form, but external for steel plate, internal for corrosion
resistant material.
External is steel plate for 316 L stainless steel internal corrosion resistant materials
(divided into two layers: a layer for steel structure, the steel plate thickness, a layer of 8 mm a
layer of stainless steel 316 L, thickness of 2 mm) of several single formation, after a series of
desulfurization flue gas temperature dropped to 80-120 range.
In the installation，the equipment manufacturer firstly make every good single day，
and then to the scene to organic every single according to the need for flange
connection.After combination, enter pipe installation and duct connection work. So in
equipment installation, process, it greatly reduces the time; in equipment manufacturing,
it also reduces a lot of joint.When designing, I design the tower have each two filter
layer, three distributor, each layer of distributor layer has valve, a dehydrator (vice
tower). After water separation, the clean gas go through chimney into the atmosphere.
In the above equipment structure, it divides spillway hole and cleaning eye, air inlet,
spray layer, the filter layer, water pipe, ladder stand and platform eight parts. Leave clean
window in part of the window to clean up, there are clear when open, need not when closed.
The characteristics of the equipment：reliable operation, no maintenance, easy to use,
clean simple, low operating cost.It is the best equipment,also is the most commonly used
among all kinds of boiler and furnace and smelting furnace.
Remark：Pool diagram will be supplied by our company within10days after
establishment of contract.
8）、Operating expense
This set of equipment does not exist maintenance，observing two to three times
every week,mainly observing the bottom water situation. Water is recycled，if below the
water level,moisturizing. Temperature is not high, flue gas with water is few, so water is
on a case-by-case basis. The main cost is adding alkaline，that is desulfurization cost.
This fee should according to the factory actual situation.
9) Project Implementation Plan

Since the project contract effective date，including equipment design, manufacture,
installation, the plan period is 55 days.
5. Other system
Other system includes process water 、 accident slurry system 、 drainage 、 fire
protection and so on.
5.1 Process water system
Due to the desulfurization system circulating fluid containing ash and particles, the
installation structure is reasonable, and we design to residue precipitation in pipe, and also use
the water flow in channel to add alkali content, like this: it can achieve dosing mixing effect.
It is also available to clean up powder sediment in the channel (very simple). So the water in
pool is very clean, no cleaning.
5.2 Drainage、Fire extinguishing system
a. Drainage：Rainwater of desulfurization island area collected by drainage ditch,
gutter inlet, inspection well and then flow to our existing drainage system.
b. Fire protection：using chemical fire extinguisher method.

5.3 Electric System
All equipment of this system does not contain the electrical system.
5.4 Equipment heat preservation paint
①Heat preservation and paint
Heat preservation range ： Pipeline is no need for heat preservation,but for
Anti-corrosion design.
The surface of all piping and box tank should besmear brushes anti-corrosive primer. To
not heat preservation and medium temperature less than 130℃ heat preservation of equipment
pipelines and accessories, support post, escalator platform to besmear brushes anticorrosive
paint, paint color should be coordination with the main project.
②Corrosion Prevention
Corrosion Prevention Range ： All desulfurization serous or sodium alkali contact
equipment, pipeline and cell body may contact with low temperature saturated and flue gas
condensate, pipes have to take anticorrosion measures as follows:
6. After-sales service
For this project, our company promised the following items e：Product technical
service and after-sales service and measures：
（一） Equipment installation commissioning training：

1、 Our company will undertake 1 complete set of equipment installation and
debugging and the whole process of production. All equipment will be inspection and
acceptance according to relevant standards. After the acceptance, the equipment will be with
manufacturer's certificate. After reach the standard of equipment installation debugging,we
will delivery user management to use.
2、 Before installation，our company will provide the user the equipment installation
diagramand drawings. You can send technical person to the site for installation, serious
investigation, accurate to installation termination.
3、 The company is responsible for equipment operation personnel training,
maintenance， according to the specified time, place, we will seriously to the scene for user
training operation and management personnel， And prepare relevant training maintenance
operation data, puts forward fault hair color’s causes and treatment methods, combining
theory and practical operation for equipment operation training
4、 To master relevant equipment structure principle，the most basic operation
to attempt.
5、 First， company will have training technical operation and maintenance
personnel for user, completes the training plan, schedule, method and time.
6、 The user operation and maintenance worker training general arrange in the
period of equipment installation and operation, the time is about 5 to 7 days. It is for
management personnel to can fully understand the performance of the equipment,
maintenance and knowledge.To ensure that equipment in the commissioning period and
the future operation process, each user should master all the operation function and the
equipment failure causes and simple maintenance methods.
7、Installation and construction according to the relevant state of industry standards
and reference. After the operation to the delivery of the buyer's use. To ensure achieve
GB8978-1996 <integrated emission standard> of the second kind of pollutants emission
concentration and standard.
（二） Equipment in auxiliary for general acceptance

1. The whole system equipment in the installation is completed for debugging and
acceptance， cooperating with users and local departments in the equipment 。 And
according to the design requirements, the company worked out the project schedule,
debugging program, debugging main point and safety measures, etc.
2. According to the whole system equipment for installation check, equipment structure
layout and pipeline rout, node seal degree sealing, equipment operation has abnormal noise,
electric machine instrument performance is reasonable.If you find any unreasonable points,
pur company will be responsible for correcting until the user feel satisfied.
（三）、 After-sale service：

1、First of all， to ensure that the user’s supply of spare parts and to provide relevant
auxiliary material production of customers list, in order to remove the worry of user in
equipment maintenance, to ensure that the supplied goods operates continuous normal, free to
provide relevant technical data.
2、All the equipment are implement three guarantees. Guarantee period is for one year,
and during the warranty period, the company will provide free repair for the product quality.
For not belong to a responsibility or the warranty equipment repair, we only take cost of
production. And we only accept costs when the time is more than warranty period
maintenance.
3、For users that put forward relevant technical consulting requirements,we will reply
within 24 hours. In the domestic, we will catch the field to solve, service item will be within
24 hours to make a decision, and 48-72 hours to the county to solve the problem.
4 、 The normal operation of equipment in every three months for technical
communication, taking a product quality tracking service, in order to improve the economic
benefit of the normal operation of production.
For above terms, welcome the user to supervise the implementation, and put forward
your valuable opinions and suggestions, so we can improve the product quality and after-sales
service.
Annexure - 10
Air Modeling Report
STACK EMISSION DISPERSION
MODELING OF
DHAKA SOUTHERN POWER
GENERATIONS LTD.
At
Nawabganj, Dhaka.
Prepared By:
Adroit Environment Consultants Ltd (AECL)

10/17, Iqbal Road, Mohammadpur, Dhaka-1207, Bangladesh
Tel: 8126082, 8152113, Fax: 880-2-8155542
E-Mail: aecl@dhaka.net, Web: www.aecl-bd.org
November, 2013
TABLE OF CONTENTS
1. INTRODUCTION 2
2. METHODOLOGY 2
2.1 About AERMOD View 2
2.2 Meteorological Condition 3
3. STANDARDS AND GUIDELINES 6
4. SOURCE PARAMETERS 6
5. BACKGROUND POLLUTANT LEVELS 6
6. MODELING RESULTS 7
7. CONCLUSION 8
8. REFERENCES 32
AECL/AEDM/DSPGL/2013 Page 1 of 33
1. INTRODUCTION
Air Emission Dispersion modelling uses mathematical formulations to characterize the

atmospheric processes that disperse a pollutant emitted by a source. Based on emissions
and meteorological inputs, a dispersion model can be used to predict concentrations at
selected downwind receptor locations. These air quality models are used to determine
compliance with National and international Ambient Air Quality Standards.
It orders to estimate the pollutant concentration from a point source emission, USEPA
AERMOD view 8.0.5 model have been used. AERMOD view is a Gaussian plume model
that incorporates source-related factors, meteorological factors, receptors, terrain and
building downwash factors to estimate pollutant concentration from continuous point source
emission. The following report describes the prediction of emission of NO₂ from the gas fired
engine generated power plant and it’s impact on ambient air quality within 5 Km radius.
2.0 METHODOLOGY
2.1 About AERMOD View

AERMOD View is a complete and powerful air dispersion modelling package that seamlessly
incorporates the popular U.S. EPA models, AERMOD, ISCST3, and ISC-PRIME into one
interface without any modifications to the model. These models are used extensively to as-
sess pollution concentration and deposition from a wide variety of sources.
Features
Create impressive presentations of the model results with the easy and intuitive graphical
interface of AERMOD View. We can customize the project using display options such as
transparent contour shading, annotation tools, various font options, and specify compass
directions.
 Specify model objects such as sources, receptors and buildings graphically.
 Automatically eliminate receptors within the facility property line.
 Import base maps in a variety of formats for easy visualization and source
identification.
 Use the major digital elevation terrain formats - USGS DEM, NED, GTOPO30 DEM,
UK DTM, UK NTF, XYZ Files, CDED 1-degree, AutoCAD DXF.
 Interpret the effects of topography by displaying the model results with 3D terrain us-
ing the powerful 3D visualization built right into the interface.
 Complete building downwash analysis effectively and quickly using the necessary
tools that AERMOD View provides.
 Prepare meteorological data quickly and accurately using AERMET view by the step-
by-step meteorological pre-processing interface.
 Take advantage of AERMOD View's integrated post-processing with automatic con-
touring of results, automatic gridding, blanking, shaded contour plotting and posting
of results.
The dispersion modelling was conducted to appraise environmental impact assessment

(EIA) for the proposed HFO fired reciprocating engine power plant. In the study, the SO 2 &
NO₂ emissions for the HFO fired engine discharged through stack was modelled to obtain
maximum possible concentration. This model was also tested in case of area source and
showed good correlation with the measured data under Bangladesh condition.
Information required for the model includes:
a) Pollutant emission rate

b) Stack exhaust exist temperature
c) Stack exhaust exist velocity flow
d) Stack diameter
e) Meteorological data
All the required information was obtained from manufacturer specification. Discharge
concentration was estimated at 500m increments from the plant up to 5 km radius.
2.2 Meteorological Condition
The Nawabganj, Dhaka area where the power plant is located has a sub-tropical climate and
is under the influence of the strong southwest or summer monsoon and weak northeast or
winter monsoon. It has been understood from last few years of air quality monitoring, the air
quality level of the area greatly influenced by the Asian monsoon. The air quality
characteristic over the area and it’s surrounding shows distinct seasonal variations, with high
pollution episode observed during winter, while summer has relatively cleaner ambient air.
During dry winter and part of the post-monsoon season, the strength of north, northwest
wind coming from India, Nepal and Southeast China to the Bay of Bengal through
Bangladesh may transport the air pollutants to the city. Moreover, during dry season the
wind speed is so low that the pollutants emitted from the local sources cannot travel away
from the city.
The use of site-specific meteorological data has been collected from the World Meteorologi-
cal Organization (WMO) who has provided 1 Year of MM5-Preprocessed site specific Mete-
orological data for the period of Jan 01, 2011 to Dec 31, 2011 at Latitude: 22°14'17.94"N,
Longitude: 91°48'47.76"E , Time Zone: UTC +6. These data contain hourly value of wind
speed & direction, wind velocity, surface roughness, bowen ratio, albedo, temperature & ref-
erence height, precipitation rate, relative humidity, surface pressure and cloud cover over the
period mentioned above. The data then have been analysed and processed through MET
processing model AERMET View which uses Samson format to process the data and create
surface met data file & profile met data file computable to the USEPA AERMOD view disper-
sion model. These surface met data file & profile met data file were then used in AERMOD
view as Met input data for calculation.
The wind rose plots were drawn from the AERMET view met processor model and shows
distinct four wind directional patterns representing four seasons in a year as per air blowing
to and from (Figure 2.1 & 2.2). The mixing height in the boundary layer is one of the
important factors to assess the influence of meteorology on the dispersion of pollutants.
Figure 2.1: Seasonal wind direction (Pre-monsoon, Monsoon, Post-monsoon and winter
respectively) blowing to the project location based on Samson data processing obtained
from AERMET view.
Figure 2.2: Seasonal wind direction (Pre-monsoon, Monsoon, Post-monsoon and winter
respectively) blowing from the project location based on Samson data processing obtained
from AERMET view.
3.0 STANDARDS AND GUIDELINES
Since HFO will be used for the proposed engine power plant, the principal air pollutant of
concern is nitrogen dioxides (NO₂) and Sulphur Di-oxide (SO2). The guideline value for NO₂
& SO2 in case of ambient air is shown in Table 3.1.
Table 3.1: Ambient air quality guideline for SO2 & NO₂.
Pollutants Average period Standard in µg/m3

BNAAQS*** WHO/IFC 2007* US EPA
NO2 1 hr 200** 188
Annual 100 40** 200
SO2 24 hr 365 20
Annual 80
PM10 24 hr 150 20
Annual 50 50
* IFC Environmental Health & Safety Guidelines 2007

** Ambient air quality standard for small combustion facility
***Bangladesh National Ambient Air Quality Standard
4.0 SOURCE PARAMETERS
The exhaust specifications and stack parameters for the proposed HFO generator is used as
input to USEPA AERMOD view model. The model calculates the values of 3 HFO
generators as point source of PM10, SO 2 & NO2 emissions. The parameters and
corresponding values are summarized in Table 4.1.
Table 4.1: The exhaust specifications and stack parameters (for each stack)
Parameters Values
Stack height (m) 32
Stack inside diameter (m) 4.5
Stack exit velocity (m/s)
Exhaust temperature (K) (195+273) = 468
Exhaust flow rate (m3/sec) 14.22
NOx emission rate as NO2 (gm/sec) 10.01
SO2 emission rate (gm/sec) 49.33
PM emission rate (gm/sec) 7.64
Ambient temperature (K) 273
5.0 BACKGROUND POLLUTANT LEVELS
This information was needed for the purpose of estimating the worst-case combined impact
of the proposed power plant and existing pollutant sources, which can then be compared to
the air quality objectives. There was no long-term data available for the area of concern. A
limited monitoring was conducted by AECL (sampling & analysis has been done by AECL
Lab team on 03/11/2013 to 05/11/2013) for obtaining 24-hour average of pollutant
concentrations at different distances from the project site. The data are given in Table 5.1.
Table 5.1: The average concentrations at different distances
Ambient Air Pollution Concentration in micro gram/cubic meter.

SN Description
PM2.5 PM10 SPM SO2 NOX CO
Jacob and
Method of analysis Gravimetric Gravimetric Gravimetric West-Geake Indicator Tube
Hochheiser
Test Duration (Hours) 24 24 24 24 24 24
Bangladesh (DoE) Standard for ambient Air 65 150 200 365 100 10000
WHO /World Bank Standard 25 50 NF 20 NF
Test result (Concentration present) in Project
1 West-North corner near boundary area. 27 67 143 12 21 170
(Date :03/11/2013)
(Date :04/11/2013)
(Date :05/11/2013)
Remarks Pollution source from normal activities
Note: 1. Fine Particulate Matter (PM2.5).

2. Respirable Dust Content (PM10).
3. Suspended Particulate Matter (SPM).
4. Oxides of Nitrogen (NOX).
5. Sulphur Di-Oxide (SO2).
6. Carbone Mono-Oxide (CO).
The weather was sunny and the wind direction was from the north-west to south-east corner.
6.0 MODELING RESULTS
The modelling was conducted for the 3 individual engines releasing gaseous
emission as point source with simple terrain using USEPA AERMOD view version
8.0.5 model. The model assumes the stack tip downwash with receptors on flat
terrain and no flagpole receptor heights. The PM10, NO2 & SO2 concentration
contour have been analysed with 500 m interval with a radius of 5000m from the
point source.
NO2 concentration:
The NO2 concentration contour of 24 hour and annual average of have been
analysed. The maximum of 24 hour concentration of NO 2 (30-50 µg/m3) has been
predicted at a radius of 200mnorth & south and 1000m north & south to the project.
The concentrations are found below 10-30 µg/m3 within 1000m north & south and
around up to 5000 to the other sides. The maximum annual concentration of NO2
has been detected as 3-5 µg/m3 at 500m around the project side and the
concentrations are within 0.5-3 µg/m3 on the either sides up to 5000m from the
project.
SO2 concentration:
The SO2 concentration contour of 24 hour and annual average of have been
analysed. The maximum of 24 hour concentration of SO2 (100-300 µg/m3 ) has been
predicted at a radius of 500m north & south and 2000m northwest & northeast to the
project, whereas the concentrations are within 50-100 µg/m3 at a radius of 500-
1000m north & south and up to 5000m to the other sides. The maximum annual
concentration of SO2 has been detected as 20-50 µg/m3 at 500m around the project
site, whereas the concentrations are within 5-20 µg/m3 on the either sides at around
1000 m north & south and up to 5000m at the other sides to the project.
PM10 concentration:
The PM10 concentration contour of 24 hour and annual average of have been
analyzed. The maximum of 24 hour concentration of PM10 (10-40 µg/m3) has been
predicted at a radius of 200-500m north & south and up to 5000m east & west to the
project site. The concentrations are found below 10 µg/m3 at the other sides of the
project site beyond 500m. The maximum annual concentration of PM10 has been
detected as 3-8 µg/m3 at 500m around the project side and the concentrations are
below 3 µg/m3 at all the sides which is coming down to 0.3 µg/m3 from 500m 5000m
surrounding the project.
7.0 CONCLUSION
NO2 Concentration:
There is no IFC/WHO and Bangladesh standard set for 24 hour concentration for
NOx. The maximum yearly concentration of NOx have been detected (max 5 µg/m3)
well below the IFC/WHO and Bangladesh standard at all sides at any radius around
the project.
SO2 Concentration:
There is no IFC/WHO annual standard set for SO 2 for ambient air quality, the 24
hour concentration of SO2 have been found (100-300 µg/m3 ) above the IFC/WHO
standard (20 µg/m3) but below the Bangladesh standard (24 hour average 365 µg/m3
and annual average 80 µg/m3) at all sides of the proposed project. The plant would
have a FGD, in which the emission level for SO2 will further be reduced by 90% and
thus will come down to 10-30 µg/m3 (24 hour average) and 0.20-0.50 µg/m3 (annual
average) which all will comply the both the IFC/WB standard and Bangladesh
NAAQS standard.
PM10 Concentration
The IFC/WHO and Bangladesh standards for 24 hour PM10 concentrations are (50
µg/m3 and 150 µg/m3 respectively) and annual concentrations (max 20 µg/m3 and 50
µg/m3 respectively). The 24 hour and annual PM10 concentrations have been found
below Bangladesh and IFC/WB standard at all the sides of the project. Further, on
installing FGD, it will also substantially reduce PM emission (>50%) as it uses a wet
scrubbing process.
Figure 6.1: Emission contour map showing the NOx concentration (24 hour average) at 5000m surrounding the project location
Figure 6.2: Emission contour map showing the NOx concentration (Annual average) at 5000m surrounding the project location
Figure 6.3: Emission contour map showing the SO2 concentration (24 hour average) at 5000m surrounding the project location
Figure 6.4: Emission contour map showing the SO2 concentration (Annual average) at 5000m surrounding the project location
Figure 6.5: Emission contour map showing the PM10 concentration (24 hour average) at 5000m surrounding the project location
Figure 6.6: Emission contour map showing the PM10 concentration (Annual average) at 5000m surrounding the project location
The following are the emission concentration plots in different directions of the power project at 24 hour and annual average of NO2
concentration:
Figure 6.7a: NO2 Emission concentration plots (24 hour average) at 5000m east to the project location
Figure 6.7b: NO2 Emission concentration plots (24 hour average) at 5000m north to the project location
Figure 6.7c: NO2 Emission concentration plots (24 hour average) at 5000m south to the project location
Figure 6.7d: NO2 Emission concentration plots (24 hour average) at 5000m west to the project location
Figure 6.8a: NO2 Emission concentration plots (Annual average) at 5000m east to the project location
Figure 6.8b: NO2 Emission concentration plots (annual average) at 5000m north to the project location
Figure 6.8c: NO2 Emission concentration plots (Annual average) at 5000m south to the project location
Figure 6.8d: NO2 Emission concentration plots (Annual average) at 5000m west to the project location
Figure 6.9a: SO2 Emission concentration plots (24 hour average) at 5000m east to the project location
Figure 6.9b: SO2 Emission concentration plots (24 hour average) at 5000m north to the project location
Figure 6.9c: SO2 Emission concentration plots (24 hour average) at 5000m south to the project location
Figure 6.9d: SO2 Emission concentration plots (24 hour average) at 5000m west to the project location
Figure 6.10a: SO2 Emission concentration plots (annual average) at 5000m east to the project location
Figure 6.10b: SO2 Emission concentration plots (annual average) at 5000m north to the project location
Figure 6.10c: SO2 Emission concentration plots (annual average) at 5000m south to the project location
Figure 6.10d: SO2 Emission concentration plots (annual average) at 5000m west to the project location
8. REFERENCES
1. Screening Procedures for Estimating the Air Quality Impact of Stationary Sources,
Revised, EPA-450 R-92-019.
2. Bilkis A. Begum, Naima A. Khan, M. Khabir Uddin and Swapan K. Biswas,
.Characteristics and short-range transport of particulate matter from Dhaka-Aricha highway..
J.of Bangladesh Chemical Society, 22(1), 2009, 18-34.
3.Bilkis A. Begum, Swapan K. Biswas, Andreas Markwitz and Philip K Hopke, .Identification
of sources of fine and coarse particulate matter in Dhaka Bangladesh.. Aerosol and Air
Quality Research, 10, 2010, 345-353.
4. IFC Environmental Health and Safety Guidelines. 2007
5. Air/Superfund National Technical Guidance Study Series, Volume 4: Guidance for Ambi-
ent Air Monitoring at Superfund Sites, Revised EPA Number: 451R93007, NTIS number
PB93-199214
6. Jindal, M., Heinold, D., 1991, "Development of Particulate Scavenging Coefficients to
Model Wet Deposition from Industrial Combustion Sources". Paper 91-59.7, 84th Annual
Meeting – Exhibition of AWMA, Vancouver, BC, June 16-21.
7. Ontario Ministry of the Environment, July 2005. Air Dispersion Modelling Guideline for On-
tario, Version 1.0. PIBS#5165e. Ontario Ministry of the Environment, Toronto, Ontario.
8. U.S. Environmental Protection Agency, 1985. Guideline for Determination of Good Engi-
neering Practice Stack Height (Technical Support Document for the Stack Height Regula-
tions). Revised EPA-450/4-80-023R. U.S. Environmental Protection Agency, Research Tri-
angle Park, North Carolina 27711.
9. U.S. Environmental Protection Agency, 1986. User’s Guide to the Building Profile Input
Program. Revised EPA-454/R-93-038. U. S. Environmental Protection Agency, Research
Triangle Park, NC.
10. U. S. Environmental Protection Agency, 1987. Guidelines on Air Quality Models (Re-
vised) and Supplement A. EPA-450/2-78-027R. U. S. Environmental Protection Agency, Re-
search Triangle Park, NC.
Annexure - 11
Noise Modeling Report
Noise modeling of 55 MW Power Project of
Dhaka Southern Power Generations Ltd.
Table of Contents
1. Noise Pollution
2. Impact on Noise Quality
3. Noise Modeling input data
4. Noise Modeling
5. Noise Modeling Result
6. Resultant noise emission
AECL/NM/DSPGL/2013 Page 1 of 6
1.0 Noise pollution
The word "noise" comes from the Latin word "nausea" meaning Sea sickness. Noise
is among the most pervasive pollutants today. Noise pollution can be caused by
many sources including highways, vehicles, factories, engines, machine, aircraft,
helicopters, industrial development and construction work. Noise negatively affects
human health and well-being. Problems related to noise include stress, sleep loss,
distraction, and a general reduction in the quality of life. Noise pollution can be also
harmful to animals. High enough levels of noise pollution may interfere with the
natural cycles of animals. Noises are irregular and disordered vibrations including all
possible frequencies. The intensity of a sound I can be expressed in decibels with
the standard equation:
L=10 log(I/I0)
where I0 is the quietest sound most people can hear, the threshold of hearing 10-
12Wm-2. When the ratio is between two field strength (so that the power being
transmitted is proportional to the square of the pressure, the formula is:
LdB=10 log[p2/(p0)2]
The decibel unit is often used in acoustics to quantify sound levels relative to some 0
dB reference. The reference may be defined as a sound pressure level (SPL),
commonly 20 micropascals. The reference sound pressure (corresponding to a
sound pressure level of 0 dB) can also be defined as the sound pressure at the
threshold of human hearing, which is conventionally taken to be 20 micropascals. It
can therefore be seen that a ratio expressed in decibels. A-weighted decibels are
abbreviated dB(A) . When acoustic measurements are being referred to, then the
units used will be dB SPL (sound pressure level) referenced to 20 micropascals = 0
dB SPL.
The frequency range of sound audible to humans is approximately between 20 and

20,000 Hz. The amplitude range of sound for humans has a lower limit of 0dB, called
the threshold of hearing. Sound is technically at its upper limit at 194.09 dB. Sounds
begin to do damage to ears at 85 dB and sounds above approximately 130 dB.
The intensity of two sounds L1 and L2 can be added in decibels with the standard
equation:
LdB=10 log[(p1/p0)2+[(p2/p0)2]
and then,
LdB=10 log[10L1/10+ 10L2/10]
In this way, decibels from two different sources can be added. CUSTIC Software will
consider this method of calculation.
2.0 Impact on Noise Quality
The main sources of noise during operations of the power plant will be from the 3
exhaust stack of the HFO engine generator. The generators will be fitted with a
silencer prior to disperse the emission through stack. The power house building will
adopt modern building design and the use of sound absorbing materials to minimize
noise and vibration from the powerhouse.
A. Engine room noise:
The generator room will have internal noise level of around 107 dBA at 1m distance
from each reciprocating engine and the noise level at the steam turbine unit is 90
dBA, the combined noise effect from the 3 engines and turbines can be found by
applying the formula of (∑L = 10. Log10 (10L1/10 + 10L2/10) dBA, in which the
equivalent noise will be 112 dBA from all engines & turbines, which will be minimized
by sophisticated acoustic power house building design so as to minimize the noise
emission up to standard. The generators and turbines are enclosed in buildings
acoustically designed, providing Styrofoam filler of 100 mm width in between 150
mm thick brick walls both side (sandwich type).
The Styrofoam filter and brick wall will absorb noise as following:
Material Thickness, Approximated noise

mm absorption capacity, dBA
Styrofoam (Acrylic -Poly- 100 90
Methyl-Meta-
Acrylate (PMMA)
Brick with or without plaster 150 40
Total Equivalent noise 90
It is estimated that the noise abatement measures of the power house building will
be capable to absorb around 90 dBA noise from the engine room, but the maximum
engine room noise is around 112 dBA near the generators & steam turbine, the
further noise emission simulation from the power house building will be determined
by the modelling calculation.
B. External noise emission:
The individual reciprocating engine stack will emit a noise level of 65 dBA after
providing the silencer (25 dBA abatement from the steam turbine exhaust). Further
noise emission simulation from the stack will be determined by the modelling
calculation.
3. Noise Modeling input Data:
The following input data has been used for the modeling:
A. Internal point source
Equivalent Noise Power: 112 dBA (from 3 engines and turbines)

Total External surface area: 1640 sq.m
Noise insulation : 90 dBA
Engine room noise: 107 dBA
Turbine Noise : 90 dBA
B. External point source
Noise Power: 65 dBA (Single stack point)

Total stack: 3 Numbers
Stack height : 32m
Terrain: Flat Terrain without sound attenuation
Height of noise calculation: Surface height
4. Noise Modeling
Noise Modeling Software: CUSTIC 3.2
Canarina CUSTIC 3.2 software for noise pollution modelling is used for the
assessment of the noise propagation of this power project. The CUSTIC Software
allows us to create robust and useful numeric simulations that fully make use of the
graphical user interface, with a certain security that the software CUSTIC 3.2 is one
of the best tool, to carry out numeric simulations of noise pollution.
The cumulative impact from the stationary noise sources at proposed project site has
been predicted using the above model. It was found that the ambient noise is higher
than predicted levels therefore, due to the masking effect, an increase is not
expected.
5. Noise Modeling Results
A. Internal Noise Modelling result
At 112 dBA equivalent noise output from the 3 engines and turbines and equivalent
noise absorption of 90 dBA by the Styrofoam and brick wall, the resultant noise
emission simulation has been done by the model and the predicted noise output is
as below:
Radius, m 30 50 100 200 300 400

Output Sound power level 25.03 20.85 16.89 12.52 8.34 4.17
in dBA
Fig 1: Plot of output noise power level in dBA vs Radius in meter (Internal Engine room noise)
B. External Noise Modelling result
At 65 dB noise output from the each stack after silencer, the resultant noise emission
simulation has been done by the model and the predicted noise output is as below:
Radius, m 30 50 100 200 300 400

Output Sound power level 27.70 23.09 18.48 13.86 9.24 4.62
in dBA
Fig 2: Plot of output noise power level in dB vs Radius in meter (external stack noise)
6. Resultant noise emission from External and Internal Sources
The resultant noise emission from the internal and external sources of the power
plant has been calculated by the equivalent noise summation formula and the
resultant noise has been given below:
Radius, m 30 50 100 200 300 400

Output Sound power level in 25.03 20.85 16.89 12.52 8.34 4.17
dBA (Internal noise)
Output Sound power level in 27.70 23.09 18.48 13.86 9.24 4.62
dBA (External noise)
Equivalent Noise emission 29.58 25.12 20.77 16.25 11.82 7.41
(internal & external)
Annexure - 12
NOx & SO2 Calculation
Exhaust flow rate calculation:
Exhaust Flow rate: 127 Tons/hour at 573 OK

The density of air at 300 OK is 1.3 kg/cu.m
The density of air at 598 OK is 2.48 kg/cu.m (Using V1/T1 = V2/T2)
So, the Exhaust flow rate is 51209 m 3/hr at 573 OK = 14.22 m3/sec
NOx emission rate calculation:
1. Nox emission concentration: 1480 mg/Nm3

2. Exhaust flow rate: 51209 m3/hr
3. Stack temperature: 300 0C = 300+273 = 573 OK
Using V1/T1 = V2/T2

Where V1 = 51209 m3/hr, T1 = 573 OK, V2 =? & T2 = 273 OK
Using the formula: V2 = 24398 Nm3/hr = 6.77 Nm3/sec
Now the NOx emission rate is 1480 x 6.77 = 10019.6 mg/sec = 10.01 gm/sec
SO2 emission rate calculation:
Fuel Consumption = 68800 tons/year

Sulphur content in the fuel = 3.4%
Total Sulphur content per year = 68800 x 3.4/100 = 2339 tons/year
Total SO2 emission rate per year = 4678 tons/year = 148 gm/sec
Total SO2 emission rate per year through one stack = 148/3 = 49.33 gm/sec
Annexure - 13
Land lease Agreement
Annexure - 14
Ambient Noise Quality Test Report
Annexure - 15
Ambient Air Quality Test Report
Annexure - 16
Site Clearance Certificate
Annexure - 17
Electrical Interconnection for power
Evacuation
Annexure - 18
Elevation Survey Report of the Site
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Annexure - 19
Fuel Transmission Line
Annexure - 20
General Arrangement of Pontoon
Annexure - 21
Contour Map of River & Road Site

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Annexure - 1

Project layout plan

Nababganj Power Plant - 55MW

Our Reference 5301959-01-B001 Date 2012-02-21

Revision Description Date Author

Our Reference 5301959-01-B001 Date 2012-02-21

7 Tools, spare and wear parts 31

9 Requirements and limitations 43

10 Operation and maintenance 48

11 Standards, Guidelines and Drawings 49

Our Reference 5301959-01-B001 Date 2012-02-21

1 Design data and performance guarantees

1.1 Design data

1.1.1 Site conditions

1.1.2 Generating sets

Our Reference 5301959-01-B001 Date 2012-02-21

1.1.3 Other design data

Intake air Ambient air free of dust, salt and sand

Our Reference 5301959-01-B001 Date 2012-02-21

Table 1: Diagram of permissible frequency and load limits

Our Reference 5301959-01-B001 Date 2012-02-21

1.2 Performance data

1.2.1 Continuous power of the generating set

1.2.2 Specific fuel oil consumption (SFOC)

1.2.3 Lubricating oil consumption

Our Reference 5301959-01-B001 Date 2012-02-21

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

Our Reference 5301959-01-B001 Date 2012-02-21

2.1 Engine scope and special engine accessories

Item Q’ty Description

2.2 Engine System

2.2.1 Engine System

2.2.2 Turbocharger off engine

010.202 3 Turbocharger off engine

2.2.3 Lubrication system

010.220.010 3 Engine attached lube oil pump(s)

2.2.4 Cooling water system

010.230.010 3 Engine attached HT cooling water pump

010.230.020 3 Engine attached LT cooling water pump

2.2.5 Special equipment of the engine

010.250.030 3 Slow-turn facility on the engine.

2.2.6 Engine control and monitoring

010.290.420 3 Sensors / cabling for TC off engine

Our Reference 5301959-01-B001 Date 2012-02-21

Item Q’ty Description

2.2.7 Factory Acceptance Test (FAT)

010.330.020 1 Factory Acceptance Test of the engine

Our Reference 5301959-01-B001 Date 2012-02-21

2.3 Detailed Technical Specification of one engine 48/60TS

Our Reference 5301959-01-B001 Date 2012-02-21

Electronic speed governing

Our Reference 5301959-01-B001 Date 2012-02-21

Our Reference 5301959-01-B001 Date 2012-02-21

Item Q’ty Description

3.1 Connecting elements

3.1.1 Coupling arrangement

020.010.010 3 Flexible coupling

020.010.040 3 Cover for flywheel and coupling

3.1.2 Engine seating

020.020.020 3 Engine seating

3.1.3 Pipe adapters

020.030.025 3 Flexible pipe connections for the engine

020.030.080 3 Rubber expansion joint for intake air duct