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Operation of Diesel Power Plant
Article (PDF Available) · February 2012 with 48,428 Reads
Cite this publication
Priyanka M M
2.17 · Visvesvaraya Technological University
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.
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Operation of Diesel Power Plant
Priyanka Mankale1 Student Member IEEE , Sunita Tambakad2
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 8 1.3MW. The power plant is equipped
with five generating sets consi sting of a WATSILA 18V46 as
prime mover driving a three phase brushless, self cooled,
synchronous, ABBAMG 16 00SS12DSEB genera tor. The
capacity of each DG is 16.26MW. The plant is designed for
operating on heavy fuel oil (HFO) with light fuel oi l (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 m illion tones. The power plant in the f ield
of power generation an d d istribution 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 manufa cturer
recommendations will assure that s tandby power system will
start and run when it need the m ost.
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 2 001.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-st ation
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 mo dification carried out by KPTCL. In
case of a black out the plant can start on its own without the
necessity for st artup power. Power generated at Alternator
terminal is at 11 kV & is fed t o the grid at 110 kV using step
up transformer. The h eavy 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
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 s ystem supplies necessary air to the engine for fuel
combustion. It consists of pipes for the supply of fresh air to
the engine mani fold. Filters are provided to remove dust
particles from air which may act as abrasive in the engine
cylinder. Di esel engine requires close tolerances to achieve it s
compression ratio, an d because most diesel engines are
turbocharged, the ai r entering the engine must be clean, fr ee of
debris, and as cool as possible. Also, to impro ve a
turbocharged engine’s efficiency, the co mpressed 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, w et or dry. In this plant system u sed is, a dry
filter system. In d ry filter system paper, cloth, o r a metal
screen material is used to catch and trap dirt before it enters
the engine. In addition t o cleaning the air, the intake system is
usually desi gned to i ntake fresh air from as far awa y from the
engine as practicable, usual ly just out side of the engine’s
building or enclos ure. This provides the engine with a supply
of air that h as not been heated by the engine’s 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 o xygen than hot air.
Thus, cool air provides more oxygen per cylinder ch arge than
less dense, hot air. More o xygen 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 t he engine cylinder
is partially converted into work. Th e 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 con sists of a water source, pump
and cooling towers. The pu mp circulates water thro ugh
cylinder and head jacket. The water takes away heat from the
engine and it becomes hot. The hot wate r is cooled b y cooling
towers and re circulated for cooli ng.
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 .
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, wh ich 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 spont aneously because of the high
temperature.
Operating principal:
The generator set is normally operated in a fully automatic
mode and will start and take up load full y 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 acti vated
6) The lube oil system is in ope ration.
7) The pre lube pump has been in operation for at least
15 min’s.
8) The engine air system is activat ed..
9) The cooling water air s ystem is activated
10) The pre-heating unit is in operation
11) The temperature in the cooling system is c orrect.
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 i nterface system) monitor. Start is possible
only if all start conditions are valid and no start blocking is
activated. The conditions are as foll ows.
a) Emergency stops are inactive.
b) Engine control alarm is inactive.
c) Generator breaker trip alarm is in active.
d) Main breaker trip is in service positi on.
e) Protection relay fault is inactive.
f) Stop order and starting failure alarm is inactive.
g) Auto stop is i nactive and electrical pneumatic stop
valve is closed.
TABLE III
AUX TRANSFORMER 2 MVA
Manufacturer EMCO ltd Jalgon
Serial No 979,980
Year of Manufacture 2000
Cooling ONAN
Rating 2 MVA
HV rated voltage 1100 0 V
LV rated voltage 433 V
Line Current HV 105 A
Line Current LV 2666.74 A
Wt of Oil 1020 KG
Total Wt 5400 KG
Untanking mass 2370 KG
Oil Quantity 1200 Liters
III. ENVIRONMENTAL MANAGEMENT PLAN
A.
A. Air pollution
Emission from the plant are mainly due to the burning of
heavy fuel oil having sulphur content o f 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 o xides of nitrogen.The generat ed pollutents are routed to
atmosphere through a single stack of 100m height com prising
of five flues each o f 100 m height connected to five DG set s.
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 considere d.
Low NOx combution- Wartsila diesel has developed a low
NOx co mbustion pr ocess which reduces the NOx l evel
without comprising on thermal efficiency. The low NOx
combution is based on the followi ng.
a) A higher combustion air temperature at injection start
drastically reduces the ignition del ay.
b) A retarded injection start and shorter injection p eriod
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 pl ant boundary.
C. Water environment
6) To initiate and issue indent from the department for
necessary work order / purchase.
7) Request to purchase department for order
amendment. To co-ordinate with othe r sections.
8) To t ake corrective actions fo r major critical or
recurring non-conformities and maintain record for
the same.
9) Generate and maintain EMS related document for
department.
Authority:
1) Approval of group receipt note (GRN).
2) Authorized to release equipments for maintenance.
3) Authorized to issue material from stores .
2) Shift in charge
Responsibilities:
1) To han dle all th e responsibilities related to start and
stop of the plant.
2) To co mmunicate with KPTCL B angalore for
regulating power evacuation to the grid.
3) To co-ordin ate with local 220kv /110 kv substations
for load monitoring.
4) Monitoring of plant parameters and take corrective
action.
5) Ensure data logging and operatio nal 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 rais e 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 vario us parameters.
d) To attend electrical jobs and comply wit h all required
safety practices.
e) To carryout jobs as p er operation schedule.
4) Field Operator
Responsibility:
Presently she i s 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) d egree from Karnataka University Dharwad in 1985 and
M.Tech. (Pow er Systems) & Ph.D (Wind Energy S ystems) from IIT
Kharagpur in 1989 & 2000 respectively.
His areas of interest incl ude Wind-Solar E nergy Systems, Energy
Conservation, Computer Applications to Power System and FACTS
He won the "Out standing IEEE Student Branch Counsellor" award
for the year 1996(R10) and 2010 (IEEE Bangalore Section) at
Basaveshwar Engineering College, Bagalkot, Karnataka, India. He
was Fulbr ight-Nehru Visiting Lecture Fellow at Michigan
Technological University, Houghton MI USA during Fall 2 011. He is
working as Professor in the department of E&E at Basaveshwar
Engineering College, Bagalkot.
Citations (0) References (1)
She obtained B.E (Electrical and Electronics) from Vishveswaraya Technological University She is currently persuing
M.Tech Degree in Power and Energy Systems in Electrical and Electronics Engineering
May 1987
Priyanka Mankale · Karnataka
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.
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Member IEEE and Jangamshetti S.H3 Senior Member IEEE
auxiliaries are monitored & controll ed 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
3
oil tank of 50 m capacity. Hidkal dam located 50 kM f rom 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 prot ected from fire by a protection
system & fire hydrant pipelines are systematically laid to
cover all important locations & equipment. The engine room
is equipped with U ltra Viol et / I nfrared fire detection
equipments which sends signal to the Control room. The
Control room is equipped with Hot Line facility to interact
with the City’s 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, coolin g
system, compressed and exhaust system. The processing of
each system and technical fe atures of electrical equipments are
also inclu ded in the paper. The responsibilities and authorities
of operational department is clearl y explained.
II. DETAILED DESCRIPTION OF DIESEL POWER
PLANT
A. Fuel Supply System
It consists of storage tank, strain ers, fuel transfer pump and all
day fuel tank. The fuel oil is suppli ed 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 i mpurities. The clean oil is injected into the
engine by fuel injection pump.
Operating principle
The fuel oil system is normally operated in a f ully automatic
mode. HFO (Heavy fuel oil) buffer tanks are automatically
filled by the f uel oil transfer pump s ystem. The HFO is treated
in t he separator system b efore being transferred into the HFO
fuel oil day tanks. From the da y tanks the HFO is fed to the
booster uni t and f rom this to each fuel oil u nit 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
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 rem ove
impurities .The cl ean lubrication oil is deli vered 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 qualit y.
b) The lube oil cooler must be assembled.
E. Compressed Air System
Operating principles:
The co mpressed air system is normally in continuous
operation. The air i s taken from surrounding and compressed
into the air receiver. The heat generated is removed in the
radiators installed on the compresso r 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 t he 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 comp ressed combustion air
is then transferred i nto the engine cylinder after heat generated
by the com pression removed in the charge air cooler and
transferred to the engine jacket water system.
Operating conditions:
a) The external filtration unit must be in o peration.
b) The intake silencer must be assembl ed and in operation.
G. Exhaust System
This system leads the engin e exhaust gas outside the building
and discharges it into atmosphere. A silencer is usuall y
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 dil uted by th e
atmosphere. This keeps the area arou nd the engine habitable.
Second, the exhaust system confines and routes the gases to
When the engine start has been selected and confirmed on the
WOLS screen, t he PLC system will start th e engine and then
as engine starts running for approximately ten sec’s, 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 st op has b een selected confi rmed on t he 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 t hen breaker open command is given and t he engine
is automatically shut down after a 3 0 sec run without load.
The major technical features of generator
TABLEI
TECHNICAL FEATURES OF WARTSILA DG SET
Machine type AMG 16005512 DSEB
Output 19300 kVA
Voltage 11000 V
Current 1013A
Engine speed 500 rpm
Cylinder Bore 460mm
Stroke 580mm
Power factor 0.85
Frequency 50 Hz
Weight 55000 kg
Insulation class F
There are two types of transformers namely 58 MVA Power
Transformers and 2 MVA Aux Transformer. The major
technical features transformers given b elow.
TABLE II
58 MVA POWER T RANSFORMERS
Manufacturer Bharat Heavy Electrical
Limited
Serial No 2013455, 56
Year of Manufacture 2000
Elec Specification No 625789
Diagram Drawing no 14561950445
Cooling ONAF
Rating 58 MVA
Insulation Level HV 450 KVP
Insulation Level LV 75 KVP
No load voltage HV 116 KV
No load voltage LV 11 KV
Line Current HV 288.675 A
Line Current LV 3044.210 A
Wt of Oil 18200 KG
Total Wt 92700 KG
Oil Quantity 20500 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 minimis e 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 in dustry 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 gu ideline of Karnataka State
Pollution Control Board (KSPCB).
IV OPERATION DEPARTMENT
Organization chart for operation department
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 timel y basis and
lay guidelines for operational activities .
3) To optimize resource for competitiveness.
4) Plan for necessary inventory t o take care of materials
requirements for plant operation.
5) To comply with all required safet y practices.
1) To start and stop the equipments as per the
instruction of control room.
2) To take round in the area periodically for monitoring
of parameters and observe leakages.
3) To carryout scheduled operational/ maintenance
activities as per the instruction.
4) To log the parameters periodically.
5) To comply with all required safet y practices.
Authority:
Authorized to stop the equipment during abnormal
conditions.
V. CONCLUSION
Preventive maintenance for diesel engine generators plays a
critical role in maximizin g reliability, minimizing repairs and
reducing long term costs. By following generally recognized
diesel maintenance procedures and specifi c 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, resul ting in
minimum generation of noise and vibr ation.
REFERENCES
[1] Plant operational manual TEC Belgaum,
WARTSILA NSD, Corporation.
[2] Plant maintenance manual TEC Belgaum, WARTSILA
NSD Corporation.
[3] Rapid Environmental Impact Assess ment report by TATA
Consulting Engineers (TCE).
[4] Power system engi neering b y 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, K arnataka, India. Sh e 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 in clude Power
Systems, Power Electronics and Drives.
Sunita S. Ta mbakad, 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.
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