1200 kW Baudouin Natural Gas Engine (CHP) CNG CHP Gas Generator

1.1 Basic Requirements of Project

1.1.1 Output voltage: 400kV

Frequency: 50Hz

Power Factor: 0.9 and above.

1.1.2 Operation Mode: Isolated and synchronized. Generators are started by 24V power black startup, no outside power supply is required.

1.1.3. Other Requirements: The generators shall be in canopy with horizontal cooling system and electrical fans. Gas leakage warning devices are needed.

1.2 Gas Composition & Heat Value

Daily natural gas supply is 60000 cubic meters per day. However, gas pressure is not clear. The generator sets need natural gas pressure around 20-50kPa.G Natural gas composition as following:

Table 1-1 Natural Gas Composition

The natural gas heat value is around 40.6MJ/Nm³. Gas generator can, according to variant of gas composition, automatically adjust natural gas concentration and timing of ignition to ensure reliable and efficient operation of the generator itself.

2. Gas Generators

Weichai 16M33D1280NG gas engines and mecc alte ECO46 alternators are selected. In one canopy, one 1.2MW gas generator, one horizontal cooling system and one control system are integrated. The canopy is sand and catkin proof. The temperature zone control design enables the generator be normally operated at temperature range -30℃ to 50℃.

Total power plant capacity is 12MW and all generators are combined. Any of the generators can be backup set which enables urgent shift of any other generator. An isolate switch is installed for each of the generator which will isolate any gas generator when necessary.

Generator Model: EW-1200NGB-1/4A.

1.2MW Gas Generator Design

3.1 Canopy

The 30-feet long canopy is exclusively designed for the 1.2MW generator. The surface is coated by polyurethane which is shining and wear-resisting. In the canopy, there are control cabinet, generator cabin, air inlet/outlet filtering system. On the top of the canopy, there is horizontal cooling system. Gas supply is set at one end and power cable is connected from another end. This layout makes site gas pipe and cable arrangement easy and convenient.

3.2 Gas Engine

Baudouin 16M33D1289NG gas engine is selected. The gas engine is deeply developed in fuel control systems to improve its electric efficiency, reliability and fuel adaptivity for certain working conditions. The development also give consideration for dynamic responsiveness, fuel economy, reliability and safety.

Proven gas engine is controlled by imported gas close-loop lean-burn control system which includes latest Woodward control system, Hoerbiger intelligent ignition system, ABB high efficient turbocharger, single cylinder in-dependant compactive ignition, electrical speed regulating system, fuel close-loop control system, environment self-adaptation system and self diagnose and protection system. All these systems will ensure accurate and reliable control of gas engine and ensure its economic, dynamic and environmental performances. The systems are also optimized by our company to achieve high reliability and efficiency.

3.3 Cooling System

High-low temperature horizontal cooling system, high efficient, low power electrical fans, inter-cooler and jacket water cooling capacity close-cycle control are equipped to enable the generator being used in different ambient temperature.

Table 3-1:1.2MW Cooling System Parameters

3.4 Alternator

Mecc Alte ECO46 brushless synchronous alternating-current generator with strengthen moving components is selected to improve the alternators resistance to load impact and interference and to ensure its long term reliable and stable operation.

3.5 Generator Set Control System

Generator control system is DEIF intelligent generator control system which realizes automatic start, speed up, switching on, parallel, load allocation, brake separation, cooling and halt. Remote control and monitoring system is also available.

3.6 Gas Generator Technical Parameters

Table 3-2 Technical Parameters for 1.2MW/400V Gas Generator

• Gas Generator Functions
• Startup Model

The gas generators are started by 24V DC battery. No other diesel generator or grid power supply needed.

• Emergent Stop

There are manual emergent stop and automatic failure emergency stop in the cases of natural gas leakage, overcurrent etc.

• Gas Generator Control

One-button control, air-fuel ratio auto adjustment, power factor auto control, automatic load increase and decrease can be realized on the generator.

Generator Control System: The control cabinet has one displayer. In the cabinet, there are controllers, relays, fuses, meters, adjusting buttons, indicators and emergent stop button to monitor and control the generator’s working process.

• Generator Protection in case of Failure

The control system has protection functions and sound/light alarmings for over load, over current, short circuit, reverse power, underfrequency, overfrequency, undervoltage, overvoltage, over speed etc.

For slight failures like high temperature of cooling water, low pressure of lubricant, over load, fail startup, there will be light and sound alarming and auto or manual stop is allowed.

For severe failure like high temperature of engine, low lubricant pressure, over speed etc, it will stop automatically and alarming will be sent out.

• Conditions for Generator Operation
  • Natural Gas Requirement
    • At rated power natural gas pressure at inlet flange shall be within 20kPa≥P≥50kPa.
    • At rated power natural gas inlet pipe ID shall be DN80 or above.
    • At normal operation gas heat value is 40.6MJ/Nm³, considering all other circumstances, natural gas supply rate shall be 2500Nm³/h or above (calculated at 10MW load).

Table 5-1: Required Compositions for Natural Gas

Note: There will be effect to the engine if natural gas is not as required.

• Coolant

Each engine shall be filled with 560L of coolant. Coolant shall be rust, scale and freezing resistant and shall contain glycol. Exact requirement as following table.

Table 5-2 Coolant Requirement

5.3 Lubricant

Each engine shall be filled with 190 liters of lubricant for the first time and each replace volume shall be 170 liters. Gas (CNG/LNG) engine exclusive lubricant shall be added.

Lubricant Model vs Ambient Temperature as following table

Table 5-3:Lubricant Code and Corresponding Temperature

5.4 Ambient Temperature & Humidity

The generator sets are for ambient temperature -30℃～50℃; If ambient temperature is above 40℃, rated power of generator will decrease. Ambient temperature increase each 5℃, rated power of generator set will decrease 5%.

Maximum allowed humidity is 95%. When humidity is above 30%, it will have effect on generator.

5.5 Altitude

Generator set allowed altitude is no more than 3000m; if altitude is above 1000m, rated power will decrease by 3% for each 500 m altitude increase.

• Quality Guarantee

Guarantee period will be 12 months from EXW date or 3000 hours of operation, whichever comes first. Manufacturer will provide gas generator user manual and train buyer’s engineers. Any damages caused by misoperation or improper operation shall be responsibility of buyer.