24 MW MAN POWER PLANT (Containerized), 50 Hz, 11kV

Consisting of Six (6) units of MAN 18V28/32S, 4 MW each

Benefits to Modular Design

y 24 MW containerized HFO Power Plant.
y Uses straight forward foundations for Generator sets.
y Balance of the plant has been desig ned and inst alled into standard shipping containers for easy
transport.
y The modular design minimizes set up time and cost on site.
y Can be put into operation 4 months from arrival to site.
Basic Description
y MAN Diesel (HFO) 18V28/32 Containerized Generator Sets
y Siemens Control and Instrumentation
y Alfa Laval fuel processing equipment
y Chubb fire protection

Introduction to MAN 18V28/32S

The MAN 18V28/32S Generator Set is a well-proven m edium-speed unit providing over 4 M W at
ISO conditions. It is conservatively rated and offers exceptional reliability and operating economics.
(see the attached)
The prime mover for the Generating Sets is a MAN 28 cm bore Medium -Speed Diesel Engine with
18 cylinders in VEE configuration. The Engine
is turbochar ged and intercooled and is
conservatively rated; both in terms of its piston speed and its operational pressures and temperatures.
The Engine runs at 750 rev/m in, and is suitable for continuous base load operation on HFO (Heavy
Fuel Oil) with viscosity up to 700 centistokes (cSt) at 50 deg C and with a sulfur content up to 3.5%.
Engine Jacket and Fuel Oil Hea ting Systems enable the Engines to operate without delay on HFO,
reducing the consumption of expensive Light Diesel Fuel to an absolute minimum.
Integral Fuel Injector C ooling Systems are provi ded, preventing the build up of fuel deposits and
cold corrosion on the injector nozzle tips.
This solution is constructed so that groups of three (3) G enerator Sets share fueling and other
auxiliary systems to reduce both set up costs and installation time.
These M3 Plants can be linked together to create Power Plants from 12 to 72 MW.

Acoustic Enclosures
Each Gener ating Set is insta lled w ithin a pu rpose designe d and built enclosur e th at achieves a
reduction in Plant noise levels by up to 50 db(A).
The Enclosures are of sufficient size to enable al l Plant servicing and m ajor overhauls to be carried
out within the protected environment of the Enclosure.
The Enclosure is designed to be transportable
within ISO 40 ft c ontainers and then easily
constructed at the generation site piece by piece.

Electrical Module
The primary function of this Module is to s ynchronize the outputs from the individual Generating
Sets. To provide the Plant output to a Power Transformer or to Switchgear.
To provide auxiliary supplies throughout the Plant and to provide a Black-Start capability.

Switchgear

HFO Fuel Tank

Based upon a standard ISO 40-foot c ontainer, this Module provides suf ficient fuel to operate each
group of three MAN Generating Sets at maximum continuous output for approximately 24 hours.
A number of Tanks could be grouped together and stacked to increase fuel storage capacity.
Constructed with an integral bund wall to contain spills, and with integral h eating coils, an HFO
Buffer Tank is located adjacent to each group of Generating Sets.
A Local Pumping Chamber with duty/standby units
transfers the f uel oil dir ectly to th e HFO
Treatment Module.

Water Pumping System

The Engines have clos ed-circuit air -blast Radiat ors and water consum ption is f or initial f ill and
occasional make-up only.
The HFO and Lube Oil centrifuges use a sm all amount of water to maintain a gravity seal in the
centrifuge bowls, but this water can be treated and re-used if required.
Fire Pumps complying with current NFPA standards, and a Reverse Osmosis unit providing process
and drinking quality water for the plant and domestic facilities are Contained in Module 7.

Multi-function Skids
The m ulti-function skid installed be tween th e E ngine and the end wall of the a coustic Enclosu re
contains the Engine starting air supplies, Air
Compressors, Fuel Changeover System , Injector
Cooling Module, Dosing System for Engine coo
ling water , Lube Oil Centrifuges, and the
Emergency Fuel Shut-Off System.
Modular Radiators
The Engine Cooling Radiators are a closed circuit, fan cooled design, with zero evaporation losses.
They are suitable for continuous operation in high ambient and high humidity conditions.
Fan operation is controlled therm ostatically to optim ize operational efficiency, and pipe work and
control cabling are already fitted into the Modules.
The vulnerable soft alloys necessary for ef ficient cooling are encased in a robust space-fram e for
transport.
The frame then becomes the Radiator support stand when the unit is mounted adjacent to the Engine
Enclosure

HFO Module
Based upon a standard ISO 40-foot container , th is Module will continuously treat HFO with
viscosities ranging up to 380 cen tistokes at 50 deg C, and supply it to each group of three MAN
Generating Sets.
The Module Equipm ent com prises the latest fuel treatm ent technology , including Alfa Laval
duty/standby centrifuge filters and fuel forwarding units.
Conservatively rated transfer a nd circulating Pumps, pre and pos t centrifuge Treatment Tanks, and
Fuel Oil Heating Units are an integral part of this Module.
The Module design is adequate for the treatment of HFO at ambient temperatures down to 10 deg C
using either electric heaters or high temperature hot water produced by Exhaust Gas Economizers.
Individually pumped ring mains supply the treated HFO to the MAN Generating Sets.
An individual Generating Set can be taken out
of service for scheduled m aintenance without
impacting upon the security or reliability of the remaining running units.

Alfa Laval Centrifuges

Fuel conditioning module

Module HFO Pump

ISO 40 ft Container

Radiators

Standard Pipe work and Connections

The pipe Modules link the different items of Plant to enable them to run as a fully-integrated Power
Station.
The size of the individual Modules and thei
r connection system s ha ve been designed and
manufactured to minimize site work and to achieve the fastest possible installation times.
These Modules carry the Fuel Oil, b oth Light and Heavy, from the bulk s torage facility to the Fuel
Treatment and forwarding Plant and on to the Engines.
They also carry the Engine Cooling Water to the Radiators and the site support services:-Fire Main,
Domestic (Potable) Water and Compressed Air.

Air Filters
Oil-bath Air Filte rs pre vent abra sive dusts and particles f rom entering the sensitive com bustion
spaces within the Engines.
Easy to clean and m aintain, these Air Filters enab le the Generating Sets to be used in dif ficult
environmental conditions.

Exhaust System
Exhaust gas from the Engines is routed through an economizer to achieve high operating efficiency.
The Silencer achieves approximately 45 bB(A) reduction in noise levels and the height of the S tack
can be adjusted to meet gas dispersion requirements.

Control Centre
Based upon an ISO 40-foot Contain er, this Module provides the air-conditioned heart of the Power
Plant.
All generating operations are controlled from t his point, including ener gy dispatch to the power
purchaser, data logging and trend analysis of all key operating functions, communications with local
and national control centers, and starting and stopping of the individual Generating Sets.

Electrical Module Diagram

Other Technical Information

The offered Six (6) units of MAN 18V28/32S are brand new and manufactured in year 2009. All units
were never used for any commercial operation and are with full OEM warranty.
Type and make of Control and Instrumentation.
Control system was designed by Regulateurs Europa and set of Siemens make SCADA control
equipment.
Type and make of the components of the switchgear and circuit breakers
Siemens Simoprime 11KV Switchgear and Circuit Breakers.
Output Voltage of the plant
Generator voltage is 11KV
Step-up transformers voltage is 11/33KV.
Transformers and output power
Two 11/33KV step-up Transformers.
Each Transformer rating is 16MVA
Make of Step-up Transformers is Winder Electricals.

OneContainerized33KVSwitchgearwithtwoincomingfeeders(each1250A)fromtwo11/33KV
Transformersand6outgoingfeedersof1250Aeach.
All6circuitbreakerswillhaveCopperbus.Besidesthatitwillalsoinclude2TransformerProtection
Panels,GridProtectionPanel,SynchronizingPanel,InstrumentationandHTCabling(Copper).
Wehaveconsidered10meterslengtheachbetweenTransformersand33KVSwitchgear.
Scope of Supply plus engineering and supervision.
The plant to be supplied is complete and containerized.
It will be supplied with the complete design and engineering together with the execution drawings for
installation.

Alocalcontractorwilltakecareofthecivilwork,installationandcommissioning,asperthedesign
andengineeringprovided.

Warranty
Allsixunitsareunderfullwarranty(1year)fromMAN.

YearofManufacture
Theyearofmanufactureof6MANenginesandBalanceofPlantis2008/2009.

FuelConsumptionatfullload
Pleaseseefuelconsumptionatvaryingambienttemperaturesandcorrespondingloadsincludingfull
loadpertrain(3units,12MWISO).Wehaveassumed100m elevation and a calorific value of fuel at
42,700 kJ/kg:

Temp (C)
20 C
25 C
30 C
35 C
40 C
45 C
50 C

Plant net output capacity (MW) at 11kV

taking into account the site parasitic
losses.
11.60 MW
11.60 MW
11.60 MW
11.60 MW
11.26 MW
10.82 MW
10.41 MW

Plant net fuel efficiency/consumption

(g/kWh) at 11kV taking into account
the site parasitic losses.
216.4 g/kWh
217.8 g/kWh
219.2 g/kWh
220.6 g/kWh
222.3 g/kWh
224.2 g/kWh
226.1 g/kWh

Fuel Tanks

TheHFOtankper3unittrainisincludedasperthescopesentearlier.ThecapacityofeachHFO
tank/containerwillcaterHFOfuelfor3enginesfor24hoursoperation.

Dimensions:
The plant consists of two 12 MW blocks (3 x 4 MW). They can be used together and independently.
Each 12MW self-contained block (3 units) requires a site with dimensions 55m x 35m.
The layout/position of each component is fixed within the design and cannot be altered being
containerized.
The position of the two 12MW blocks with respect to each other is flexible.
Within the generic layout drawing the 24MW power plant occupies a site with approx. 18,000 meters
square (dimensions: 140m x 130m).
This includes a bulk HFO storage tank and HT electrical switch yard (in your case 33KV) as well as a
generous access/perimeter road and perimeter fence buffer.

ERECTION & COMMISSIONING

Technical Description of Erection
All items and systems indicated below including piping, cabling and accessories (containerized) will be
erected and prepared for commissioning.

6 units of MAN 18V28/32S HFO based Containerized Gensets

Siemens Controls and Instrumentation
Alfa Laval Fuel processing equipment
Chubb Fire protection
Tank Farm house including HFP and Diesel Tanks
Water Pumping Station
Modular Radiators
HFO Modules
Pipe work and connections
Control center
Control panels
Step-up Transformers (11/33 kV)
33kV HT Switchyard
Cables, wiring, etc.
If required, Flushing of oil, water, fuel lines
Workers of erection team will take all safety precautions during their work (safety belts, glass,
handgloves, barret, etc.)
Engineering team will support engineering work for any change or modifications.

Technical Description of Commissioning

All commissioning work will be done by erection team and their qualified engineers.

Checking of all power plant equipment, piping, cabling

Checking of main engines, generators, etc.
Valve clearance adjustments
Alignment check
Adjustment of speed governors, voltage regulators, transformers, synchronizing, load shedding,
etc.
Short running of electrical motors, pumps for correct running
Simulation of all alarm points
Simulation of all shut-down points
Re-adjustment or re-calibration of sensing elements
Inspection of HFO, Lube oil, compressed air, water, etc. lines
Flushing of pipes, if required
Turbochargers inspection
Getting into operation of all auxiliaries
Running-in process for engines
Booster module viscosity/temperature/pressure adjustment
Getting into operation separators, filters, pumps, preheating modules, compressors, etc.
Getting into operation of complete power plant and delivery to owner
Civil work (whatever required), ground leveling, etc. will be carried out by erection team

Responsibilities of Owner for Erection and Commissioning

Supply of compressed air

Supply of power and lighting

Supply of HFO, Diesel, Lube oil
Supply of oxygen/acetilen for welding
Supply of available crane facility during all erection time
Accommodation and food for all erection and commissioning workers/engineers at site
Supply of security, in case of any danger providing fastest and safest way to leave the site
Preheater for engine oil by steam or electricity
Treated water supply for engine cooling water, separators
Cleaning of equipments and engines, engine components, etc.
All statutory clearances, permits, licenses, etc.