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1、QSV91 1250 kW Gas Generator Sets Design Specification:CPG Basic Containerised Generator SetThis Preliminary Design Specification is of a general nature only. Where submitted against a specific project in the event of any conflict between this document and the Scope of Supply document then the projec
2、t specific Scope of Supply will take precedence.ContentsGAS GENERATOR SET SPECIFICATION3Mechanical Specification41.1General41.2Engine41.3Alternator71.4Cooling System71.5Lubricating Oil System81.6Exhaust System81.7Tests9Electrical Specification102.1Generator Control System102.2CENSE Module (Cummins E
3、ngine Sensor Equipment)102.3GQMA GQNA Genset Control Panel Incorporating PCSTM122.4Switchgear242.5Electrical Ancillary Equipment242.6Cabling25Acoustic Container263.1General263.2Construction263.3Ventilation and Attenuation263.4Power and Lighting263.5Fire and Gas Detection273.6Ancillary Items273.7Cabl
4、e and Gas Access273.8Finish27Project Services284.1Documentation284.2Engineering284.3Packing & Transport284.4Erection284.5First Fills284.6Commissioning284.7Tools & Spare Parts284.8Training28Gas Generator Set SpecificationEquipment proposed:a) 1250GQNA, COP rated at 1250kW, 1562kVA at 0.8 power factor
5、 lag, 480 volts, 60 Hz, 1200 rpm. This is the nominal output at maximum ambient conditions of 40C aspiration air temperature, 1000 metres above sea level, using natural gas continuously having an LHV of 980 Btu/scf or greater and a Methane Number of 60 or greater and with the generator set operating
6、 in parallel with the utility.Mechanical Specification 1.1 General1.1.1 DescriptionThe generator sets proposed are designed for continuous (COP) operation as defined in ISO 8528. Design parameters prior to any derating are as follows:Maximum aspiration air inlet temperature95FMaximum altitude, asl32
7、80 feetMaximum cooling water inlet temperature122FMinimum gas pressure3.6 psi(G)Minimum LHV980 Btu/scfMinimum Methane Index 601.2Engine1.2.1DescriptionThe engine is an 18V configuration. Cylinder bore is 180mm, stroke 200mm, giving a displacement of 91 litres. The standard engine includes a pre-lubr
8、ication engine oil pump, oil filtration, and air inlet filters suitable for normal operating conditions. 1.2.2BaseframeThe coupled engine and alternator assembly are mounted on a welded, structural steel baseframe. This provides the assembly with a stable and torsion resistant platform.1.2.3Flexible
9、 CouplingThe engine torque is transmitted to the alternator by a flexible coupling, which reduces vibration and provides torque damping characteristics.1.2.4Anti Vibration Mounts (AVMs)The generator set is supplied with spring type anti vibration mounts (AVMs). These are factory installed between th
10、e bedframe and the container floor. The AVM base plate has a friction pad that interfaces with the container floor. Additionally the AVMs are bolted down.1.2.5Engine ProtectionThe engine is continuously monitored by means of the Cummins Engine Sensors Equipment (CENSE) module which is an environment
11、ally hardened digital controller mounted on the generator set. It is connected to dedicated engine sensors and senders via engine looms. CENSE is as fully detailed later in this specification.1.2.6 Engine StarterThe generator set is supplied with a single 24 Volt Electric starter motor as standard.
12、This engages onto the engine flywheel starter ring when the starter solenoid receives a start signal from the Generator Control Panel. Starting Power is supplied by four 210Ah batteries suitable for one complete starting cycle. A 30A battery charger is standard to top up batteries ready for next sta
13、rt cycle. The system is fully installed but will require battery acid to be added before system can be commissioned.1.2.7Gas TrainThe Gas Train is an inline gas inlet manifold which incorporates a hand valve, a solenoid emergency shutdown valve, dust filter pressure regulator. The flange sizes of th
14、e inlet and outlet flanges are 80mm NB BS54504 PN16. Adaptor flanges are available for Ansi Flange types.Two gas train modules are available the correct selection being made in accordance with the inlet supply pressures. Standard state inlet pressures are as follows:- inlet pressure up to 26 psi(G)-
15、 inlet pressure up to 43.5 psi(G)The Gas Train, the components of which are supplied loose, has to be mounted and installed external to the container. Pipework is supplied to connect to the internal gas pipeline. Ihe internal pipeline consists of the engine mounted gas inlet solenoid valve and a 0.5
16、m flexible pipe, which has 80mm NB BS54504 PN16 flanges.It is assumed that assembly of all pipework, etc. between the gas train components and the container gas connection point will be to the care of others. Supply, installation and testing of all pipework before the gas train is also considered to
17、 be responsibility of other1.2.8 FiltrationThe engine is fitted as standard with the following filtration:- duplex type, replaceable element, lubricating oil filters.- centrifugal oil filter- gas filter (supplied loose for incorporation in the gas train)- replaceable aspiration air filters1.2.9 Lubr
18、icating Oil Sump Automatic Filling / Level Switch This system allows the generator set to have continuous availability. The system keeps the optimum engine oil level by means of a float mechanism and a flexible connection (1.6 ft of inlet hose which has a 1” BSP straight female hose adapter fitting)
19、 which is connected to an engine lubricating oil make up tank. A site glass is included on the gauge for the operator to visually check. Electrical switch contacts are provided which will initiate a low level warning indication displayed on the GCP. The engine lubricating oil make up tank has a volu
20、me of 450 litres.1.2.10Engine Pre-heatingWhilst stationary the engine temperature is maintained at a constant 104F for instant start and load acceptance. This is achieved by the provision of thermostatically controlled water heaters (2 heaters of 6 kW each) integrated as a module in to the engine bl
21、ock. In addition to the heating elements a water circulation pump (.3 kW) is included to circulate the cooling water through the block. This allows for an even heat transfer through the engine block. The heating elements and pumps are controlled from the GCP.1.2.11Flexible ConnectionsAll connections
22、 to the engine that are required are supplied with flexible connections. These connections are: coolant water circuits, crankcase breather filter drains, lubricating oil sump drain, gas inlet, cooling system venting, etc. Fittings are as per the following table: ConnectionFittingsCoolant Water Circu
23、its (Dual Circuit)SAE 3” Weldable Flange Flexible Cooling System Venting” BSP Female Swivel Flexible Gas Fuel Inlet80mm NB BS54504 PN16 FlangeGas Fuel Inlet Solenoid Vent Line3/4” Gas Flexible Air Emergency Stop1”BSPFlexible Crankcase Breather filter drains (to spill tank)” BSPAll fittings internal
24、to the container have been completed at time of assembly. However, all connections at the transition plates to the external components will require final assembly on sites. All materials are supplied with the container to complete these services. However, it is considered the responsibility of the c
25、ustomer or his agent to provide suitably competent labour to complete these services.1.2.12Crankcase BreatherA crankcase breather filter is mounted on the engine. The crankcase breather vent is piped to this filter. The outlet of the filter must be routed to discharge to atmosphere external to the C
26、ontainer housing. This was completed at time of assembly and integrity will be verified at time of commissioning.1.2.13Exhaust BellowsThe exhaust bellows provide a flexible connection to the exhaust system which allows for some generator set movement / vibration. The exhaust bellows terminate with a
27、 250mm NB BS4504 Table 6/3 flange in the termination plate in the container roof and are installed within the container as a part of the exhaust system. Blanking flanges are fitted to the outlets for shipping purposes which must be removed prior to fitting the Y Piece and silencer connections on the
28、 roof of the container at site.1.2.14FinishThe generator set is finished to our standard colour, Munsell Jade Green, in high gloss. The plant will be complete with safety and warning labels, in English.1.3Alternator1.3.1DescriptionThe six pole, two bearing alternators are of the brushless, rotating
29、field design. Insulation and temperature rise is class H. The Newage alternators use a permanent magnetic generator (PMG) excitation system which provides power excitation for the exciter field via the automatic voltage regulator (AVR). The automatic voltage regulator (AVR) and power factor control
30、(PFC) are controlled through the Power Command SupervisorTM based GCP. 1.3.2Alternator ProtectionThe alternator has an IP22 enclosure and includes:- bearing resistive temperature devices (RTDs), one per bearing- winding resistive temperature devices (RTDs), two per phase- anti-condensation heater, t
31、hermostatically controlledThe GCP also houses AmpSentryTM which guards the electrical integrity of the alternator and the power system from the effects of overcurrent, short circuit, over / under voltage, under frequency and overload. Current is regulated to 300 % for both single phase and 3 phase f
32、aults when a short circuit condition is sensed.1.4Cooling System1.4.1GeneralThe engine cooling system comprises low temperature and high temperature circuits each requiring an external cooling system.1.4.2RadiatorThe cooling water system external to the container will consist of the units as follows
33、: a twin circuit horizontal flatbed radiator, including cooling fans, designed for a noise level of 85dB(A) at 1 metre. a single, combined expansion tank for the HT and LT circuits.A dry air liquid cooler system will be provided as a “stand alone” unit complete with copper tubes and aluminium fins.
34、The body will be mild steel with Plastisol covering and will be mounted on a galvanised mild steel frame.The electrically driven cooling fans (6 fans at .55 kW each) will draw sufficient cooling air through the horizontal, free-standing module to cool the engine at ambient temperatures of up to 104F
35、. All necessary fan starters are located in generator set auxiliaries control panel which is housed within the electrical compartment of the container. An isolator for each of the six fans will be located on the radiatorThe radiator and associated expansion tank are designed to be located on the con
36、tainer roof. The expansion tank should be mounted at the highest point of the cooling system and will be provided with top-up port, overflow pipe and vent. The volume of the expansion tank is at least 15% of the total volume of the cooling circuit.An electric pump is provided for cooling system fill
37、 and topping-up purposes. This pump is located in the generator compartment of the container.All pipework, valves and other components necessary to complete the cooling water system will be included within our scope of supply. Adequate valves will be fitted to facilitate maintenance and flexible bel
38、lows will be fitted to accommodate expansion. Pipework, etc. within the container will be factory installed. That which is external to the container will, along with the radiator and expansion tank, be shipped loose for installation locally on arrival at site. Labour to fit these pipes etc. will be
39、the responsibility of the customer or his agent. 1.5Lubricating Oil System1.5.1 GeneralThe engine is fitted with an automatic lubricating oil make-up valve as detailed above.1.5.2 Lubricating Oil Make-up TankInstalled within the generator compartment of the container will be a lubricating oil make-u
40、p tank. The tank will have a 120 gallon capacity and will supply the engine by gravity via the generator set mounted automatic filling device.All pipework, isolating valves and other components necessary to complete the lubricating oil system will be included within our supply. These items will be f
41、actory installed within the container.1.6 Exhaust System1.6.1GeneralThe exhaust gas system is designed to minimise flow restrictions in the system, maximum allowable exhaust gas back pressure being 20 in WG.The exhaust gas system will be designed to achieve a noise level of 85dB(A) at 1 m under free
42、-field, non-reverberant conditions. This will be achieved by the use of an exhaust gas silencer mounted on the container roof. The exhaust silencer will be finished in a heat resistant silver paint.All other components necessary to complete the exhaust system will be included within our supply. Thos
43、e items within the container will be factory installed. Those external to the container will, along with the exhaust gas silencer, be shipped loose for installation locally on arrival at site.Internal pipework is lagged and clad to reduce heat input into the cooling air stream.1.7 TestsThe generatin
44、g sets will be fully tested at our works prior to being installed within the container. Our standard tests in accordance with our Quality Procedures will be undertaken. Tests are of approximately four hours duration and will include:- 0 100% load testing- controls / engine protection / safety testin
45、gAll tests will be conducted at unity power factor. Copies of our works test certificates will be provided.Electrical Specification2.1Generator Control System 2.1.1General DescriptionThe generator control system consists of three main components:- the generator control panel (GCP)- an a.c. auxiliary
46、 enclosure- generator set interconnection enclosure. 2.1.2 Generator Control PanelThis is a free-standing control panel and is as fully detailed later in this specification.2.1.3 AC Auxiliary EnclosureThis is a separate enclosure mounted on the generator set baseframe. It interfaces with the GCP and
47、 houses the equipment which controls / monitors and protects the generator set a.c. systems which are not located in the GCP.2.1.4 Generator Set Interconnection EnclosureThis enclosure is mounted on the generator set baseframe. It interfaces with the GCP and is the termination box for all engine con
48、trols, etc. which are not located in the a.c. auxiliary enclosure.2.2CENSE Module (Cummins Engine Sensor Equipment) 2.2.1GeneralThe Cummins Engine Sensor Equipment (CENSE) Module is an environmentally hardened digital controller which is mounted directly on the generator set. CENSE continuously moni
