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Operation of Diesel Power Plant

Article February 2012

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Priyanka M M
Visvesvaraya Technological University
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Operation of Diesel Power Plant

Priyanka Mankale1 Student Member IEEE , Sunita Tambakad2 Member IEEE and Jangamshetti S.H3 Senior Member IEEE

Abstract: The diesel power plant is designed for base load

operation for stationary application and is intended for
electricity production in parallel operation with a public
supply as well as island mode operation. This paper
presents the case study of Tata diesel power plant. The
capacity of the plant is 81.3MW. The power plant is equipped
with five generating sets consisting of a WATSILA 18V46 as
prime mover driving a three phase brushless, self cooled,
synchronous, ABBAMG 1600SS12DSEB generator. The
capacity of each DG is 16.26MW. The plant is designed for
operating on heavy fuel oil (HFO) with light fuel oil (LFO)
as standby fuel. The fuel is being received by road tankers
from the nearest oil terminal of Indian Oil Corporation Ltd
(IOCL). Annual consumption of HFO for the plant would
be around 0.110 million tones. The power plant in the field
of power generation and distribution maintaining eco
friendly environment by adopting green belt design as per
the guideline of Karnataka State Pollution Control Board
(KSPCB). By following generally recognized diesel
maintenance procedures and specific manufacturer
recommendations will assure that standby power system will
start and run when it need the most.
Index Terms - Heavy fuel oil, Light fuel oil, Wartsila
operator interface system.

I. INTRODUCTION
Tata Power conceptualized & installed diesel plant between
1999 & 2001. The plant went into commercial operation in
March 2001.Five units, each consisting of Wartsila make,
model 18V46 diesel engine coupled to a generator produce
16.26 MW. The plant also has a fuel oil receiving (by road
tankers) & fuel oil purification facility. The power generated
is evacuated at 110 kV through two transmission lines, Tata
Line 1 and Tata Line 2 both connected to 220 kV sub-station
at Indal. The islanding scheme, which provided power from
Plant to the city of Belgaum during grid disturbances, ceases
to exist with the Line 2 modification carried out by KPTCL. In
case of a black out the plant can start on its own without the
necessity for startup power. Power generated at Alternator
terminal is at 11 kV & is fed to the grid at 110 kV using step
up transformer. The heavy fuel oil & lube oil are purified by
separators using centrifuging technology. The entire plant heat
requirement is met from the steam generated by waste heat
recovery boilers installed DG exhaust. The Engine & its

auxiliaries are monitored & controlled by a PLC system

located in the Control Room.The heavy fuel oil received
through tankers are unloaded through a pumping station &
stored in two 7000m3 capacity storage tanks. Similarly the
fresh lube oil received from tankers is also stored in New Lube
oil tank of 50 m3 capacity. Hidkal dam located 50 kM from the
plant is the chief source of water. The water received from
Hidkal dam is stored in an open reservoir of 10000 m3
capacity. The entire Plant is protected from fire by a protection
system & fire hydrant pipelines are systematically laid to
cover all important locations & equipment. The engine room
is equipped with Ultra Violet / Infrared fire detection
equipments which sends signal to the Control room. The
Control room is equipped with Hot Line facility to interact
with the Citys Fire tenders in case of eventualities. This paper
gives detailed description of the Tata diesel power plant. It
explains essential elements of diesel power plant like diesel
engine(DG) set, fuel system, lubrication system, cooling
system, compressed and exhaust system. The processing of
each system and technical features of electrical equipments are
also included in the paper. The responsibilities and authorities
of operational department is clearly explained.

II. DETAILED DESCRIPTION OF DIESEL POWER

PLANT
A. Fuel Supply System
It consists of storage tank, strainers, fuel transfer pump and all
day fuel tank. The fuel oil is supplied at the plant site by rail or
road. The oil is stored in the storage tank. From the storage
tank, oil is pumped to smaller all day tank at daily or short
intervals. From this tank, fuel oil is passed through strainers to
remove suspended impurities. The clean oil is injected into the
engine by fuel injection pump.
Operating principle
The fuel oil system is normally operated in a fully automatic
mode. HFO (Heavy fuel oil) buffer tanks are automatically
filled by the fuel oil transfer pump system. The HFO is treated
in the separator system before being transferred into the HFO
fuel oil day tanks. From the day tanks the HFO is fed to the
booster unit and from this to each fuel oil unit which supplies
the engine with the fuel at the correct pressure. The LFO is
stored only in main storage tank, also acting as a day tank.
LFO may be supplied via the booster unit, but can also be fed

directly from the feeder unit to the fuel oil unit supplying the
engine.
Operating conditions:
The HFO & LFO day tanks must be filled with fuel oil of the
correct quality.
B. Air Intake System
This system supplies necessary air to the engine for fuel
combustion. It consists of pipes for the supply of fresh air to
the engine manifold. Filters are provided to remove dust
particles from air which may act as abrasive in the engine
cylinder. Diesel engine requires close tolerances to achieve its
compression ratio, and because most diesel engines are
turbocharged, the air entering the engine must be clean, free of
debris, and as cool as possible. Also, to improve a
turbocharged engines efficiency, the compressed air must be
cooled after being compressed. The air intake system is
designed to perform these tasks. Air intake systems are usually
one of two types, wet or dry. In this plant system used is, a dry
filter system. In dry filter system paper, cloth, or a metal
screen material is used to catch and trap dirt before it enters
the engine. In addition to cleaning the air, the intake system is
usually designed to intake fresh air from as far away from the
engine as practicable, usually just outside of the engines
building or enclosure. This provides the engine with a supply
of air that has not been heated by the engines own waste heat.
The reason for ensuring that an engine's air supply is as cool
as possible is that cool air is denser than hot air. This means
that, per unit volume, cool air has more oxygen than hot air.
Thus, cool air provides more oxygen per cylinder charge than
less dense, hot air. More oxygen means a more efficient fuel
burn and more power. After being filtered, the air is routed by
the intake system into the engine's intake manifold or air box..
The intake system also serves to reduce the air flow noise.
C. Cooling System
The heat released by the burning of fuel in the engine cylinder
is partially converted into work. The remainder part of the heat
passes through the cylinder wall, piston, rings etc. and may
cause damage to system. In order to keep the temperature of
the engine parts within the safe operating limits, cooling is
provided. The cooling system consists of a water source, pump
and cooling towers. The pump circulates water through
cylinder and head jacket. The water takes away heat from the
engine and it becomes hot. The hot water is cooled by cooling
towers and re circulated for cooling.
Operating conditions:
The engine jacket water system must be filled with treated
coolant of the correct quality. The expansion tanks must be
filled and in operating condition.

D. Lubricating System
The system minimizes the wear of rubbing surfaces of the
engine. It comprises of lubricating oil tank, pump, filter and
oil cooler. The lubrication oil is drawn from the lubricating oil
tank by the pump and is passed through filter to remove
impurities .The clean lubrication oil is delivered to the points
which require lubrication. The oil coolers incorporated in the
system keep the temperature of the oil low.
Operating condition:
a) The engine crankcase, turbo chargers and governor must
be filled with lube oil of the correct quality.
b) The lube oil cooler must be assembled.
E. Compressed Air System
Operating principles:
The compressed air system is normally in continuous
operation. The air is taken from surrounding and compressed
into the air receiver. The heat generated is removed in the
radiators installed on the compressor unit.
Operating conditions:
The air compressor unit must be assembled in operating
condition. The air receiver must be assembled, tested and
ready to receive compressed air. The heat generated must be
removed in the radiators installed on the compressed air.
F. Charge Air System.
Operating principles:
The charge air system is normally in continuous operation
when the engine is running. The engine charge air is drawn
through the external filtration unit and the silencer by the
engine driven turbo charger. The compressed combustion air
is then transferred into the engine cylinder after heat generated
by the compression removed in the charge air cooler and
transferred to the engine jacket water system.
Operating conditions:
a) The external filtration unit must be in operation.
b) The intake silencer must be assembled and in operation.
G. Exhaust System
This system leads the engine exhaust gas outside the building
and discharges it into atmosphere. A silencer is usually
incorporated in the system to reduce the noise level. The
exhaust system of a diesel engine performs three functions.
First, the exhaust system routes the spent combustion gasses
away from the engine, where they are diluted by the
atmosphere. This keeps the area around the engine habitable.
Second, the exhaust system confines and routes the gases to

the turbocharger, if used. Third, the exhaust system allows

mufflers to be used to reduce the engine noise.
Operating condition:
The exhaust gas silencer and any other components installed
in the external gas system must be assembled and in operation.
H. Diesel Engine
Diesel engine is the prime mover, which drives an alternator to
produce electrical energy. In the diesel engine, air is drawn
into the cylinder and is compressed, during this compression.
A metered quantity of diesel fuel is then injected into the
cylinder, which ignites spontaneously because of the high
temperature.

When the engine start has been selected and confirmed on the
WOLS screen, the PLC system will start the engine and then
as engine starts running for approximately ten secs, in auto
mode the PLC system will give a synchronization order to the
synchronization device.
2) Stop sequence.
Normally the engine will be stopped from the operators
Wartsila operator interface system monitor (WOIS). When
engine stop has been selected confirmed on the WOIS screen,
the PLC system will stop the engine according to the preset
stop sequence. The generator is first unloaded close to no load
valve and then breaker open command is given and the engine
is automatically shut down after a 30 sec run without load.
The major technical features of generator

Operating principal:
The generator set is normally operated in a fully automatic
mode and will start and take up load fully automatically. The
start signal normally given from the Wartsila operator
interface system (WOIS) monitor in the central control room.
Operating conditions:
1) The fuel oil system is activated
2) Correct pre heating.
3) Correct pressure.
4) Sufficient pre circulation to heat the fuel injection
pumps.
5) The lube oil system is activated
6) The lube oil system is in operation.
7) The pre lube pump has been in operation for at least
15 mins.
8) The engine air system is activated..
9) The cooling water air system is activated
10) The pre-heating unit is in operation
11) The temperature in the cooling system is correct.
12) The charge air system and exhaust gas system are
activated.
1) Start sequence.
Normally the engine will be started from the operators WOIS
(Wartsila operator interface system) monitor. Start is possible
only if all start conditions are valid and no start blocking is
activated. The conditions are as follows.
a)
Emergency stops are inactive.
b)
Engine control alarm is inactive.
c)
Generator breaker trip alarm is inactive.
d)
Main breaker trip is in service position.
e)
Protection relay fault is inactive.
f)
Stop order and starting failure alarm is inactive.
g)
Auto stop is inactive and electrical pneumatic stop
valve is closed.

TABLE I

TECHNICAL FEATURES OF WARTSILA DG SET

Machine type
Output
Voltage
Current
Engine speed
Cylinder Bore
Stroke
Power factor
Frequency
Weight
Insulation class

AMG 16005512 DSEB

19300 kVA
11000 V
1013A
500 rpm
460mm
580mm
0.85
50 Hz
55000 kg
F

There are two types of transformers namely 58 MVA Power

Transformers and 2 MVA Aux Transformer. The major
technical features transformers given below.
TABLE II
58 MVA POWER TRANSFORMERS
Manufacturer
Serial No
Year of Manufacture
Elec Specification No
Diagram Drawing no
Cooling
Rating
Insulation Level HV
Insulation Level LV
No load voltage HV
No load voltage LV
Line Current HV
Line Current LV
Wt of Oil
Total Wt
Oil Quantity

Bharat Heavy Electrical

Limited
2013455, 56
2000
625789
14561950445
ONAF
58 MVA
450 KVP
75 KVP
116 KV
11 KV
288.675 A
3044.210 A
18200 KG
92700 KG
20500 Liters

TABLE III
AUX TRANSFORMER 2 MVA
Manufacturer
Serial No
Year of Manufacture
Cooling
Rating
HV rated voltage
LV rated voltage
Line Current HV
Line Current LV
Wt of Oil
Total Wt
Untanking mass
Oil Quantity

EMCO ltd Jalgon

979,980
2000
ONAN
2 MVA
11000 V
433 V
105 A
2666.74 A
1020 KG
5400 KG
2370 KG
1200 Liters

The plant requires about 2989 m3/day water for its operations.
The water requirements will be met from Hidkal reservoir,
Belgaum. In order to minimise the water consumtion, the
engine will be equipped with partial air cooling and water
cooling for injection systems.The treated water meeting the
stipulated standards used for Greenbelt development within
plant premises. Excess treated waste water discharged to the
adjacent INDAL industry growth centre for green belt
development.
D. Green belt development
An area of about 5 acres is developed under greenbelt. The
green belt design made as per the guideline of Karnataka State
Pollution Control Board (KSPCB).

IV OPERATION DEPARTMENT
III. ENVIRONMENTAL MANAGEMENT PLAN
A.

Organization chart for operation department

A. Air pollution
Emission from the plant are mainly due to the burning of
heavy fuel oil having sulphur content of 2.0% maximum. As
the ash content in the fuel is less than 0.1%, there will be
negligible emission of particulate
matter. The major
pollutants generated from the power plant are sulphur dioxide
and oxides of nitrogen.The generated pollutents are routed to
atmosphere through a single stack of 100m height comprising
of five flues each of 100 m height connected to five DG sets.
The exhaust gases of the diesel engines has high heat energy.
In order to utilise this heat energy in generation of steam for
fuel heating requirements, heat recovery system using waste
heat recovery boilers is considered.
Low NOx combution- Wartsila diesel has developed a low
NOx combustion process which reduces the NOx level
without comprising on thermal efficiency. The low NOx
combution is based on the following.
a) A higher combustion air temperature at injection start
drastically reduces the ignition delay.
b) A retarded injection start and shorter injection period
means that combustion takes place at the optimal point
with respect to efficiency.
B. Noise environment
Proper encasement of noise generating sources done to control
the noise level below 75dB at plant boundary.
C. Water environment

HOD

Shift in charge

Shift engineer

Operators
Fig.1 Organization chart

B. Responsibilities and Authorities

1) Head of Department
Responsibilities:
1) To ensure systematic and effective operation of the
plant.
2) To address customer complaints on timely basis and
lay guidelines for operational activities.
3) To optimize resource for competitiveness.
4) Plan for necessary inventory to take care of materials
requirements for plant operation.
5) To comply with all required safety practices.

6)
7)
8)

9)

To initiate and issue indent from the department for

necessary work order / purchase.
Request to purchase department for order
amendment. To co-ordinate with other sections.
To take corrective actions for major critical or
recurring non-conformities and maintain record for
the same.
Generate and maintain EMS related document for
department.

Authority:
Approval of group receipt note (GRN).
Authorized to release equipments for maintenance.
Authorized to issue material from stores.

1)
2)
3)

2) Shift in charge
Responsibilities:
1) To handle all the responsibilities related to start and
stop of the plant.
2) To communicate with KPTCL Bangalore for
regulating power evacuation to the grid.
3) To co-ordinate with local 220kv /110 kv substations
for load monitoring.
4) Monitoring of plant parameters and take corrective
action.
5) Ensure data logging and operational schedules.
6) To prepare daily generation report and forward to
KPTCL.
7) Assist the HOD in maintaining the all relevant
documents.
Authority:
1) To send energy export details to KPTCL.
2) To raise defect notification through SAP-PM
module.
3) Shift engineer
Responsibility:
a) To assist shift incharge activities related to start and
stop of plant and prepare various reports.
b) To attend various schedules related to operational
requirement.
c) Data logging for various parameters.
d) To attend electrical jobs and comply with all required
safety practices.
e) To carryout jobs as per operation schedule.
4) Field Operator
Responsibility:

1)
2)
3)
4)
5)

To start and stop the equipments as per the

instruction of control room.
To take round in the area periodically for monitoring
of parameters and observe leakages.
To carryout scheduled operational/ maintenance
activities as per the instruction.
To log the parameters periodically.
To comply with all required safety practices.

Authority:
Authorized to stop the equipment during
conditions.

abnormal

V. CONCLUSION
Preventive maintenance for diesel engine generators plays a
critical role in maximizing reliability, minimizing repairs and
reducing long term costs. By following generally recognized
diesel maintenance procedures and specific manufacturer
recommendations will assure that standby power system will
start and run when it need the most. In order to minimize the
water consumption, the engine will be equipped with partial
air cooling and water cooling for injection systems. As all
engines are V type, model the balancing is easy, resulting in
minimum generation of noise and vibration.

REFERENCES
[1] Plant
operational
manual
TEC
Belgaum,
WARTSILA NSD, Corporation.
[2] Plant maintenance manual TEC Belgaum, WARTSILA
NSD Corporation.
[3] Rapid Environmental Impact Assessment report by TATA
Consulting Engineers (TCE).
[4] Power system engineering by M.L.Soni, P.V.Gupta,
U.S.Bhatnagar, A. Chakrabarti.

BIOGRAPHY
Priyanka Mankale, was born in Karnataka, India on 06 April 1987.
She obtained B.E (Electrical and Electronics) from Vishveswaraya
Technological University, Belgaum, Karnataka, India. She is
currently persuing M.Tech Degree in Power and Energy Systems in
Electrical and Electronics Engineering, Basaveshwar Engineering
College, Bagalkot, India. Her areas of interest include Power
Systems, Power Electronics and Drives.
Sunita S. Tambakad, was born in Bijapur, Karnataka, India on 3
August 1982. She obtained B.E (Electrical and Electronics) from
Visveswaraih Technological University, Belgaum, Karnataka India in
2005 and M.Tech (Power and Energy System) from Basaveshwar
Engineering College, Bagalkot, Karnataka, India in 2009.

Presently she is working as faculty in the Department of Electrical &

Electronics Engineering at Basaveshwar Engineering College,
Bagalkot, India.
Dr. Suresh. H. Jangamshetti: (S'88, M'90, SM'97) was born in
Bijapur, Karnataka, India on May 28, 1963. He obtained his B.E
(Electrical) degree from Karnataka University Dharwad in 1985 and
M.Tech. (Power Systems) & Ph.D (Wind Energy Systems) from IIT
Kharagpur in 1989 & 2000 respectively.
His areas of interest include Wind-Solar Energy Systems, Energy
Conservation, Computer Applications to Power System and FACTS
He won the "Outstanding IEEE Student Branch Counsellor" award
for the year 1996(R10) and 2010 (IEEE Bangalore Section) at
Basaveshwar Engineering College, Bagalkot, Karnataka, India. He
was Fulbright-Nehru Visiting Lecture Fellow at Michigan
Technological University, Houghton MI USA during Fall 2011. He is
working as Professor in the department of E&E at Basaveshwar
Engineering College, Bagalkot.