Power Plants Layout Gas Engines
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Power plants layout with Gas Engines (Planning and Installation Notes) 06-2016 Caterpillar Energy Solutions GmbH Carl-Benz-Straße 1 D-68167 Mannheim Phone: +49(0)621 384-Fax: +49(0)621 384-8612 This handbook including all illustrations is protected by copyright. All rights for it are reserved, including rights to the extracts. Any use outside of the limits prescribed by copyright law without written consent is prohibited and punishable. This particularly applies to reproduction, translation, microfilming and storage and processing in electronic systems. © Caterpillar Energy Solutions GmbH Mannheim 2016 The reproduction of trademarks, utility names, trade names, descriptions of goods, etc. in this document, even where not specifically marked, does not justify the assumption that such names may be considered to be free within the meaning of the laws governing the protection of trademarks and brand names and may therefore be used by anyone. Should any reference be made, directly or indirectly, in this document to or quotations cited from any laws, regulations or directives (e.g. DIN,VDI, VDE…) neither the authors nor Caterpillar Energy Solutions GmbH can accept any guarantee with regard to correctness, completeness or currency. It is recommended, should your own work require it, that you read the complete regulations or directives in the currently applicable version. Figures, drawings, diagrams and circuit diagrams within the handbook represent general information for the project planning. The relevant order documentation is binding for orders. There is no revision service for the drawings of the installation guidelines. They will only be updated with the next edition of the installation guidelines. Masthead Caterpillar Energy Solutions GmbH VI-T1S Carl-Benz-Str. 1 68167 Mannheim Germany Tel.: +49 (0) 6 21 3 84-0 Fax: +49 (0) 6 21 3 84-86 12 © 2016 All rights reserved Chapter_00 - Contents.docx Page 2 / 4 VI-T1S 2016-06 EN 02999408 FOREWORD The guidelines of this handbook are not operating instructions for the final machine user. They apply to all designers and manufacturers of products who use one of our gensets. Thus the guidelines are not user information as defined by standard DIN EN 82079-1 (IEC 82079-1), but fulfil a similar purpose, because their observance ensures the engine functioning and thus protects the product user from danger which could result from genset use. Operating safety and a long service life can only be expected from perfectly installed systems. This also allows maintenance work to be carried out simply and quickly. These guidelines provide information for mounting and give information about limit values to be observed. The safety provisions, which are a component of the gensets and/or system documentation, must be complied with during layout, maintenance and operation of the systems. The wide range of installation options does not allow for generally applicable and strict rules. Experience and special knowledge are necessary in order to ensure optimum installation. The standards, directives and regulations listed have no claim to completeness. Therefore the local requirements must be investigated and duly taken into account in each individual case. Therefore we recommend an installation consultation with Caterpillar Energy Solutions GmbH or an authorized sales partner during the planning stage. Caterpillar Energy Solutions GmbH does not accept warranty claims and is not responsible for damage or loss occurring from failure to comply with the information and instructions given in this handbook. Your suggestions on how to enhance or supplement these guidelines are always highly appreciated. Caterpillar Energy Solutions GmbH, VI-T1S, 06-2016 Chapter_00 - Contents.docx Page 3 / 4 VI-T1S 2016-06 EN 02999408 Contents Chapter Title 1 Layout of gas engine-powered gensets 2 Genset output 3 CHP genset 4 Requirements for genset installation 5 Engine room ventilation 6 Engine cooling systems 7 Fuel system 8 Lubricating oil system 9 Combustion air system 10 Exhaust system 11 Compressed air system 12 Measuring, monitoring and limiting devices 13 Network connection requirements 14 Electrical switchgear systems 15 Isolated operation mode with gas engines 16 Load switching capability 17 Cabling 18 Transport and positioning of gensets 19 Genset installation and alignment instructions 20 Laying pipes 21 Health and safety at work, accident prevention, environmental protection Chapter_00 - Contents.docx Page 4 / 4 VI-T1S 2016-06 EN 02999408 Power plants layout Chapter 1 Layout of gas engine-powered gensets for combined power and heat generation at power plants (CHP's) 06-2016 Caterpillar Energy Solutions GmbH Carl-Benz-Straße 1 D-68167 Mannheim Phone: +49(0)621 384-0 Fax: +49(0)621 384-8612 1 Contents 1. Layout of gas engine-powered installations for combined power and heat generation at power plants (CHPs) ................................................................................................................... 3 1.1 Types of use .................................................................................................................................. 3 1.1.1 Heat-led operation ......................................................................................................................... 3 1.1.2 Electricity-led operation ................................................................................................................. 4 1.1.2.1 Mains parallel operation ................................................................................................................ 4 1.1.2.2 Isolated operation mode ................................................................................................................ 4 1.1.2.2.1 Back-up power operation .............................................................................................................. 4 1.1.2.2.2 Black start ...................................................................................................................................... 5 1.1.3 Operation dependent on the availability of combustion gas ......................................................... 5 1.1.4 Dual gas operation ........................................................................................................................ 5 Chapter_01 - Layout of gas engine-powered gensets.docx Page 2 / 8 VI-T1S 2016-06 EN 02999408 1. Layout of gas engine-powered installations for combined power and heat generation at power plants (CHPs) A gas engine-powered genset comprises a combustion engine, generator, coupling, base frame and mounting arrangement. The engine and generator are rigidly mounted on the base frame. This unit is described as a CHP genset and is used to generate electricity and heat. A CHP set comprises a CHP genset and the following components: • Cooling water heat exchanger • Exhaust heat exchanger • Exhaust silencers • Exhaust gas cleaning system • Fuel tank or gas supply • Lube oil supply • Monitoring system A CHP plant may comprise one or more CHP sets: the electrical switchgear with control system, the air supply system and the exhaust air system. The basic principles, requirements, components, implementation and maintenance of electricity generating sets are described in DIN 6280, Part 14 (see Fig. 1.1). Attention ! It is not allowed to change any parts in the gensets, components and control cabinets which are delivered by the manufacturer. To avoid EMC problems, the parts on the system side, e.g. frequency converters, must be connected with shielded lines in accordance with the manufacturer's specifications. See also Chapter 14 and 17. 1.1 Types of use Depending on its use, the system may be primarily used to generate either electricity or heat. 1.1.1 Heat-led operation In the case of heat-led operation, the demand for heat is the lead factor which determines the output of the CHP plant. To cover the demand for heat during peaks, the CHP plant may be supported by other heating systems. Chapter_01 - Layout of gas engine-powered gensets.docx Page 3 / 8 VI-T1S 2016-06 EN 02999408 1.1.2 Electricity-led operation In the case of electricity-led operation, the demand for electricity is the lead factor which determines output of the CHP plant. 1.1.2.1 Mains parallel operation In system-parallel operation, the CHP plant supplies consumers e.g. until the maximum electrical output is reached according to the nominal power of the engine. Any further additional demand is covered from the mains power supply. During high-tariff periods, the gensets can be used to offset peak loads. In the event of a mains fault, the CHP plant can be operated in isolated mode. 1.1.2.2 Isolated operation mode When operating in isolated mode, the CHP plant supplies the power demand of the consumers by itself. The gensets are required to supply the power for all connected consumers at any time of operation. This applies both to load switching and load shedding. The switching system's load management has to ensure that the gensets are never overloaded. Load surges should not exceed the maximum permissible load steps as specifically determined for each engine type under any circumstances (refer to Chapter "Load steps"). This applies both to load switching and load shedding. The required switching power of the respective consumers is of particular consideration here, not the nominal power (See also Chapter 15 "Isolated operation mode" and Chapter 16 "Load steps"). 1.1.2.2.1 Back-up power operation Taking due account of the appropriate additional measures