CW 170 - CW 200 Diesel Power Plant Project Guide

Foreword
This project guide includes the electric power description and auxiliaries data sheets may
generation applications of CW170 and CW200 be reproduced and given to client.
diesel engine series. The content of this handbook is based on the
The project guide is intented for use in most current information at the time of
presales activities, and also as support for publication, and is subject to change without
final design of power plants from 1 to 20MW. notice. Please contact your sale support before
closing contracts.
It does not contain confidential information,
but distribution should be limited to sales We hope this handbook will help your daily
organization and engineering partners. Parts job, don’t hesitate to give us your comments,
of this document, such as equipment complementary information or needs for next
revision.

CUMMINS WÄRTSILÄ,
1 RUE DE LA FONDERIE,

BOÎTE POSTALE 1210

68054 MULHOUSE CEDEX
FRANCE issue 1.3. apr 99
Enhanced range of alternators.
issue 1.3.1 june 99
genset data sheets deleted ( discrepancies with other
issue 1.2. fev 99 publication ways)
New lube oil recommendations, reference sheets added ( paper print only)
New range of alternators, Print 6 June 1999
list of indicators and protections for CW 170, issue 1.3.2 coolant treatment updating.
Change in genset scope of supply. print 7 august 99

issue 1.3 Apr. 99 page 1

Diesel Power Plant Project Guide CW 170 - CW 200

Contents

FOREWORD........................................1 2.3.4 CW200 genset control panel....... 28

CONTENTS.........................................2 2.4 GENERATOR SET .........................28

2.4.1 Generator set construction.......30
1.GENERAL.......................................4
2.4.2 Generator set performances.............31
1.1 introduction.....................................4
2.4.3 Generator set arrangement..........32
1.2 Quality assurance............................4
2.4.4 Generator set connections..........34
1.3 World electricity supplies.................5
2.4.5 Generator set handling................36
1.4 Standards.........................................8
3. TURNKEY POWER PLANTS................36
2. GENERATING SETS.............................9
3.0 GENERAL...................................36
2.1 REFERENCE CONDITIONS...................9
3.1 POWER PLANT BUILDINGS..............40
2.2 DIESEL ENGINE.............................10
3.1.0 General.......................................40
2.2.1 Engine design...............................10
3.1.1 Building layout..............................40
2.2.2 Engine technical data..................13
3.1.2 Fire detection systems.................41
2.2.3 Standard generator set technical data......14
3.1.3 Noise level....................................41
2.2.4 Fuel oil definition..........................15
3.1.4 Generator set foundation............42
2.2.5 Engine lubricant & coolant definition...............16
3.1.5 Maintenance facilities..................42
2.2.5.1Lubricant definition...................16
3.1.6 Power plant arrangements............43
2.2.5.2 Ccoolant definition...................17
Basic power plant.................................43
2.3 ALTERNATOR...............................18 Technic power plant.............................44
Arctic power plant...................................46
2.3.0 General.......................................18
2.3.1 Salient poles PMG alternator ....................18
2.3.2 salient poles alternator,
shunt -booster excitation.....................20
2.3.3 Non-Salient poles alternator ,
PMG excitation.....................................................22
2.3.3 CW 180 genset control panel.... 24

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CW 170 - CW 200 Diesel Power Plant Project Guide

3.2 CONTAINERIZED POWER PLANTS......48 3.4.2 Fuel-oil system...........................73

3.4.3 Lubricating oil system.................75
3.2.0 General.......................................48
3.4.4 Cooling systems.........................76
3.2.1 Installation requirements............48
Radiator system.....................................77
3.2.2 Mechanical container description.................49 Tower system.........................................78
3.2.3 Containers installation.................50 Raw watersystem...................................80
3.2.4 Containers handling....................53 3.4.5 Charge air system......................81
3.2.5 Electrical container description..............................54 3.4.6 Exhaust gases system................82
3.2.6 Container single line diagrams................55 3.4.7 Ventilation and noise control.........83
3.3 ELECTRICAL SYSTEMS....................56 4.PARTNERSHIP.................................84
3.3.0 General........................................56 4.1 Engineering...................................84
3.3.1 Power generation.......................56 4.2 Maintenance..................................84
3.3.2 Power plant single line diagrams..................57 4.3 Operation of the power plant........................84
3.3.3 Power distribution equipment.................60
5. UNITS, FORMULAE........................... 85
3.3.4 Power plant control...............................62
5.1 Current equivalents.......................85
3.3.5 Plant Control panels ..................63
5.2 Conversion factors.........................86
3.3.6 Auxiliaries control panels..................................65
5.3 Formulae........................................90
3.3.7 Plant monitoring & control system.................67
3.3.8 Power plant earthing system.......70 6.DATA SHEETS
6.1GENSET DATA SHEETS
3.4 MECHANICAL SYSTEMS...................71
see detailed content on front page
3.4.0 General.......................................71
6.2MECHANICAL DATA SHEETS
3.4.1 Starting air system......................72
see detailed content on front page
6.3 ELECTRICAL DATA SHEETS
see detailed content on front page
7. APPENDED DRAWINGS
see detailed content on front page

issue 1.3 Apr. 99 page 3

Diesel Power Plant Project Guide CW 170 - CW 200

1. General

1.1 INTRODUCTION 1.2 QUALITY ASSURANCE

The Cummins Wärtsilä company is the leading designer The quality of the products is ensured by a quality
and manufacturer of baseload and Power managing assurance program, as described in Quality Assurance
plants in the range of 0.5 to 4 MW per generating set. Manual and Quality Instructions.
The Cummins Wärtsilä CW 170 and CW 200 diesel en- These meet the requirements of the ISO 9001 Interna-
gines, built in United Kingdom and France are used as tional Quality Standard and each production section
prime movers for Light Fuel Oil ( L.F.O.) power plants, within the Cummins Wärtsilä company has acquired
and are designed for driving : such a certificate. All activities in their operations are
evaluated and revised continuously through their in-
√ Emergency diesel generators ternal and external quality reviews.
√ Peak-lopping plants The Quality Assurance System ensures that the deliv-
√ Load management plants ered products are of high quality and reliability, pro-
viding good overall economy for the customers.
√ Baseload plants for IPP’s (independant power
Cummins Wärtsilä develops and maintains a worldwide,
producers) or industrial manufacturers high quality service network which ensures continu-
ous operation of delivered products under all circum-
The Cummins Wärtsilä turnkey Plants are designed to
stances, by means of preventive and corrective ser-
give low-cost investment and be built to short time
vice, spare part supply, training of operation staff, tech-
scales.
nical support and information.
When designing a power plant, some general design
criteria are required. It is of utmost importance that
all relevant auxiliary systems are considered in the early
stages of project design work.
The environmental conditions (noise level,
emissions, pollution, wind) should also be considered
at an early stage.
Prior to the final engineering stage, contractual docu-
mentation for the project must be available.

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CW 170 - CW 200 Diesel Power Plant Project Guide

1.3 WORLD ELECTRICITY SUPPLIES

Country Frequency (Hz) Supply Voltage Levels in Common Use (V)
Abu Dhabi (United Arab Emirates) 50 11 kV;415/250
Afghanistan 50; 60 380/220; 220
Algeria 50 10 kV; 5.5 kV; 380/220; 220/127
Angola 50 380/220; 220
Antigua 60 400/230; 230
Argentina 50 13.2 kV; 6.88 kV; 390/225; 339/220: 220
Australia 50 22 kV; 11 kV; 6.6 kV; 440/250; 415/240; 240
Austria 50 20 kV; 10 kV; 5 kV; 380/220; 220
Bahamas 60 415/240; 240/120; 208/120; 120
Bahrain 50; 60 11 kV; 400/230; 380/220; 230; 220/110
Bangladesh 50 11 kV; 400/230; 230
Barbados 50 11 kV; 3.3 kV; 230/115; 200/115
Belgium 50 15 kV; 6 kV; 380/220; 2201127, 220
Belize 60 440/220; 220/110
Benin (Dahomey) 50 15 kV; 380/220; 220
Bermuda 60 4.16/2.4 kV; 240/120; 208/120
Bolivia 50; 60 230/115; 400/230/220/110
Botswana 50 380/220;220
Brazil 50; 60 13.8 kV; 11.2 kV; 380/220,220/127
Brunei 50 415/230
Bulgaria 50 20 kV; 15 kV; 380/220; 220
Burkina-Faso (Upper-Volta) 50 380/220; 220
Burma 50 11 kV; 6.6 kV; 400/230; 230
Burundi
Cambodia (Khmer Republic) 50 380/220; 208/120; 120
Cameroon 50 15 kV; 320/220; 220
Canada 60 12.5/7.2 kV;4,16 kV 600/347; 240/120; 208/120; 600; 480; 240
Canary Islands 50 380/220; 230
Cape Verde Islands 50 380/220; 127/220
Cayman Islands 60 480/240; 480/227; 240/120; 208/120
Central African Republic 50 380/220
Chad 50 380/220; 220
Chile 50 7.2 kV;380/220; 220
Christmas Islands
Colombia 60 13.2 kV; 240/120; 120
Congo-democratic Republic of (Zaire) 50 380/220; 220
Congo-Republic of 50 380/220; 220
Costa Rica 60 240/120; 120
Cuba 60 440/220; 220/110
Cyprus 50 11 kV; 415/240; 240
Czechoslovakia 50 22 kV; 15 kV; 6 kV; 3 kV; 380/220; 220
Denmark 50 30 kV; 10 kV; 380/220; 220
Dominica (Windward Islands) 50 400/230
Dominican Republic 60 220/110; 110
Dubai (United Arab Emirates) 50 6.6 kV; 330/220; 220
Ecuador 60 240/120; 208/120; 220/127; 220/110
Egypt (United Arab Republic) 50 11 kV; 6.6 kV; 380/220; 220
Eire (Republic of Ireland) 50 10 kV; 380/220; 220
El Salvador 60 14.4 kV; 2.4 kV; 240/120
Ethiopia 50 380/220; 220
Faeroe Islands (Denmark) 50 380/220
Falkland Islands (UK) 50 415/230; 230
Fiji 50 11 kV; 415/240; 240
Finland 50 660/380; 500; 380/220; 220
France 50 20 kV; 15 kV; 400/230; 380/220; 380; 220;
French Guiana 50 380/220
French Polynesia 60 220; 100
Gabon 50 380/220
Gambia 50 400/230; 230
Germany (BRD) 50 20 kV;10.5 kV; 10 kV; 6 kV; 400/230; 380/220; 220
Germany (DDR) 50 10 kV; 6 kV; 660/380; 380/220; 220/127; 220; 127

issue 1.3 Apr. 99 page 5

Diesel Power Plant Project Guide CW 170 - CW 200

Country Frequency (Hz) Supply Voltage Levels in Common Use (V)

Ghana 50 440/250; 250
Gibraltar 50 415/240
Greece 50 22 kV; 20 kV; 15 kV; 6.6 kV; 380/220
Greenland 50 380/220
Grenada (Windward Islands) 50 400/230; 230
Guadeloupe 50; 60 20 kV; 380/220; 220
Guam (Mariana Islands) 60 13.8 kV; 4 kV; 480/277; 480: 240/120; 207/120
Guatemala 60 13.8 kV; 240/120
Guyana 50 220/110
Haiti 60 380/220; 230/115; 230; 220; 115
Honduras 60 220/110; 110
Hong Kong (and Kowloon) 50 11 kV; 346/200; 200
Hungary 50 20 kV; 10 kV; 380/220; 220
Iceland 50 380/220; 220
India 50; 25 22 kV; 11 kV; 440/250; 400/230; 460/230; 230
Indonesia 50 380/220; 2201127
Iran 50 20 kV; 11 kV; 400/231; 380/220; 220
Iraq 50 11 kV; 380/220; 220
Israel 50 22 kV; 12.6 kV; 6.3 kV; 400/230; 230
Italy 50 20 kV; 15 kV; 10 kV; 400/230; 380/220; 220/127; 220
Ivory Coast 50 380/220; 220
Jamaica 50 4/2.3 kV; 220/110
Japan 50; 60 6.6 kV; 200/100; 22 kV; 6.6 kV; 210/105; 200/100; 100
Jordan 50 380/220; 220
Kenya 50 415/240; 240
Korea Republic (South) 60 200/100; 100
Kuwait 50 415/240; 240
Laos 50 380/220
Lebanon 50 380/220; 190/110; 220;110
Lesotho 50 380/220; 220
Liberia 60 12.5/7.2 kV; 416/240; 240/120; 208/120
Libyan Arab Republic 50 400/230; 220/127; 230;127
Luxembourg 50 20 kV; 15 kV; 380/220; 220
Macao 50 380/220; 220/110
Malagassy Republic (Madagascar) 50 5 kV; 380/220; 220/127
Malawi 50 400/230; 230
Malaysia (West) 50 415/240; 240
Mali 50 15kV; 380/220; 220/127; 220; 127
Malta 50 415/240
Manila 60 20 kV; 6.24 kV; 3.6 kV; 240/120
Martinique 50 220/127; 127
Mauritania
Mauritius 50 400/230; 230
Mexico 60 13.8 kV; 13.2 kV; 480/277; 220/127; 220/120
Monaco 50 380/220; 220/127; 220; 127
Montserrat 60 400/230; 230
Morocco 50 380/220; 220/127
Mozambique 50 380/220
Muscat and Oman 50 415/240; 240
Naura 50 415/240
Nepal 50 11 kV; 400/220; 220
Netherlands 50 10 kV; 3 kV; 380/220; 220
Netherlands Antilles 50; 60 380/220; 230/115; 220/127; 208/120
New Caledonia 50 220
New Zealand 50 11 kV; 415/240; 400/230; 440; 240; 230
Nicaragua 60 13.2 kV; 7.6 kV; 240/120
Niger 50 380/220; 220
Nigeria 50 15 kV; 11 kV; 400/230; 380/220; 230; 220
Norway 50 20 kV; 10 kV; 5 kV; 380/220; 230

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CW 170 - CW 200 Diesel Power Plant Project Guide

Country Frequency (Hz) Supply Voltage Levels in Common Use (V)

Pakistan 50 400/230; 230
Panama 60 12 kV; 480/227; 240/120; 208/120
Papua New Guinea 50 22 kV; 11 kV; 415/240; 240
Paraguay 50 440/220; 380/220; 220
Peru 60 10 kV; 6 kV; 225
Philippines 60 13.8 kV; 4.16 kV; 2.4 kV; 220/110
Poland 50 15 kV; 6 kV; 380/220; 220
Portugal 50 15 kV; 5 kV; 380/220; 220
Portuguese Guinea 50 380/220
Puerto Rico 60 8.32 kV; 4.16 kV; 480; 240/120
Qatar 50 415/240; 240
Reunion 50 110/220
Romania 50 20 kV; 10 kV; 6 kV; 380/220; 220
Rwanda 50 15 kV; 6.6 kV; 380/220; 220
Sabah 50 415/240; 240
Sarawak (East Malaysia) 50 4151240; 240
Saudi Arabia 60 13,8 kV; 380/220; 220/127; 127
Senegal 50 220/127; 127
Seychelles 50 415/240
Sierra Leone 50 11 kV; 400/230; 230
Singapore 50 22 kV; 6.6 kV; 400/230; 230
Somali Republic 50 440/220; 220/110; 230: 220; 110
South Africa 50; 25 11 kV; 6.6 kV; 3.3 kV; 433/250; 400/230; 380/220; 500; 220
Spain 50 15 kV; 11 kV; 380/220; 220/127; 220; 127
Spanish Sahara 50 380/220; 110; 127
Sri Lanka (Ceylon) 50 11 kV; 400/230; 230
St. Helena 50 11 kV; 415/240
St. Kitts Nevis Anguilla 50 400/230; 230
St. Lucia 50 11 kV; 415/240; 240
Saint Vincent 50 3.3 kV; 400/230; 230
Sudan 50 415/240; 240
Surinam 50; 60 230/115; 220/127; 220/110; 127; 115
Swaziland 50 11 kV; 400/230; 230
Sweden 50 20 kV; 10 kV; 6 kV; 380/220; 220
Switzerland 50 16 kV; 11 kV; 6 kV; 380/220; 220
Syrian Arab Republic 50 380/220; 200/115; 220; 115
Taiwan (Republic of China) 60 22.8 kV; 11.4 kV; 4.16 kV; 380/220; 220/110
Tanzania (Union Republic of) 50 11 kV; 400/230
Thailand 50 380/220; 220
Togo 50 20 kV; 5.5 kV; 380/220; 220
Tonga 50 11 kV; 6.6 kV; 415/240; 240; 210
Trinidad and Tobago 60 12 kV; 400/230; 230/115
Tunisia 50 15 kV; 10 kV; 380/220; 220
Turkey 50 15 kV; 6.3 kV; 380/220; 220
Uganda 50 11 kV; 415/240; 240
United Kingdom 50 22 kV; 11 kV; 6.6 kV; 3.3 kV; 400/230; 380/220; 240; 230; 220
Uruguay 50 15 kV; 6 kV; 220
USA 60 480/277; 208/120; 240/120
USSR (former republics of) 50 380/230; 220/127 and higher voltages
Venezuela 60 13.8 kV; 12.47 kV; 4.8 kV; 4.16 kV; 2.4 kV; 240/120; 208/120
Vietnam (Republic of) 50 15 kV; 380/220; 208/120; 220; 120
Virgin Islands (UK) 60 208; 120
Virgin Islands (US) 60 110/220
Western Samoa 50 415/240
Yemen-Northern (Sana'a) 50 440/250; 250
Yemen-Southern (Aden) 50 400/230
Yugoslavia 50 10 kV; 6.6 kV; 380/220; 220
Zambia 50 400/230; 230
Zimbabwe 50 11 kV; 390/225; 225

issue 1.3 Apr. 99 page 7

Diesel Power Plant Project Guide CW 170 - CW 200

1.4 STANDARDS
The following standards are used for our machines con-
struction (if applicable) and advised for power plants
design.
Prime movers Electrical Equipment
ISO 3046 (BS 5514 ) - Specification for reciprocating
IEC 4391(BS EN 60439)(EN 604392) Specification for
internal combustion engines, parts 1 to 6.
low-voltage switchgear and control gear assemblies.
ISO 8528 Reciprocating internal combustion engine driven
IEC 9471(BS EN 60947)(EN 609472) Specification for
alternating current generating sets, parts 1 to 10.
low voltage switchgear and control gear.
EEC Directive 84/536/EEC - Noise from construction
IEC 3641(BS 7671) Requirements for electrical instal-
equipment - power generators.
lations. IEE Wiring Regulations (sixteenth edition).
BS 2869 1970 - Fuel Oils for Oil Engines and Burners
EC 439(BS 5486) Factory Built assemblies of Low Volt-
for non- marine use.
age Switchgear and Control Gear.
ASTM D 975 Standard specification for diesel fuel oils
EC 479 Effects of Current Passing through the Human Body.
and associated testing ASTM standards.
BS3950 Electrical Protective Systems for A.C Plant.
The engine and its auxiliaries are manufactured and/
or controlled under a registered quality control sys- BS 159 1957 Busbars and Busbar Connections.
tem approved to ISO 9001. BS 162 1661 Electrical Power Switchgear and Associ-
Generators ated Apparatus.
IEC 34-1 Rotating electrical machines BS 2757 Insulation.
BS2615 The Electrical Performance of Rotating Electri- BS 5424 Part 1 1977 - Contactors.
cal Machinery.
BS 4999(IEC 341) General requirements for rotating
electrical machines.
BS 5000(IEC 341)Rotating electrical machines of par-
ticular types or for particular applications.
NEMA MG 1 Motors and generators.
EN 50081(BS EN 500812)Electromagnetic compatibil-
ity. Generic emission standard.
EN 50082(BS EN 500822)Electromagnetic compatibil-
ity. Generic immunity standard.
The generator set and its control system are manufac-
tured under a registered quality control system ap-
proved to ISO 9001.

page 8 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

2. Generating sets
2.1 REFERENCE CONDITIONS
Service is defined from ISO 8528/1 :
COP, for “continuous power”, applies to baseload combustion of fuel-oil. Also, global combustion tem-
plants, or industrial plants operated continuously. No perature increase leads to abnormal heating of cylin-
overload is allowed. der heads and pistons, which might result in engine
problems.
PRP, for “prime power” applies to generating sets
used under variable load, without time limitation, PRP To determine true ambient conditions, be aware of true
rating being the maximal available power. application indications. Altitude indication is easy to
verify, but temperature range is mostly dependant on
LTP for “Limited time running output”, applies to
local weather, and true temperatures may cause power
standby diesel generators, operated less than 500 hours
loss, operating problems, or damage to engines. If an
per year with a maximum of 300 hours of continuous
engine is taking combustion air in the generator set
operation. No overload is allowed on indicated power.
room, don’t forget to include in the calculation the
This LTP service is mainly dedicated to Standby ap- temperature rise caused by alternator and engine. It
plications. is not necessary to apply a specific derating factor for
alternator cooling, because diesel derating is higher.
In these operating figures, there is no time limitation
between the stated maintenance intervals. The performance of the generator set will be effective
Reference conditions are from ISO if exhaust backpressure is in the specified range, if
cooling water return temperature is lower than indi-
3046/1
cated limit, and if fuel feeding temperature is below
Reference conditions are not strictly the same for CW the indicated limit.To fulfill these conditions, auxilia-
170 and CW 200 engines. Alternative temperature and ries choice, implementation and piping shall be per-
altitude combinations are proposed for hot climates, formed following the enclosed information.
near sea level, and at higher altitudes.
Exhaust gases emissions
If intake temperature is lower than reference, engine The exhaust gas contains hazardous compounds which
output increase can not be authorised. are detrimental to the environment and therefore
For applications where ambient temperature condi- comprehensive legislation has been introduced. Un-
tions or altitude of the installation are above the ref- fortunately a legal harmonization of levels and how to
erence conditions defined in data sheets, the genera- estimate these emissions have not been achieved. For
tor set output has to be derated following these the 50 Hz market in Europe the German TA-Luft rules
data sheets. have become a guide line while the 60 Hz market is
guided by the US legislation.The standard NOx emis-
Derating factors versus site ambient
sion rates are indicated in generating set data sheets.
conditions Lower NOx adjustment is available on request.Values
Derating purpose : Derating of the diesel engine ver- are expressed in metric units. (TA-luft methods with
sus the altitude and the temperature is mandatory, 5% dry O2, applicable for internal combustion engines).
because altitude increase and air temperature increase To convert NOx rate in g/kWh, in g/bhph, please ap-
results in reduction of oxygen mass entering the ply 0.746 factor.
cylinders. Diesel engine power is reduced, and smoke
increases due to lack of air, necessary for complete

Please refer to technical data sheet of generator set for pending values

issue 1.3 Apr. 99 page 9

Diesel Power Plant Project Guide CW 170 - CW 200

2.2 DIESEL ENGINE

2.2.1 ENGINE DESIGN There is one camshaft for each of the two cylinder
banks bearing both valve cams and injection cams. The
bearing housings are fully integrated into the engine
The CW 170 and 200 series engines are four stroke
block and located on the outside of the cylinders. There
high speed diesel engines. Banks are disposed in V
are large crankcase openings as well as openings
formation. Direct high pressure injection increases per-
for the camshafts on both sides of the engine block.
formance and reduces emissions. All main auxiliaries
and ducts are integrated, allowing easy maintenance Cylinder head
by large inspection doors. Vibration level is lowered to The cylinder head is made of special cast iron. The
permit simple resting of generator sets on the floor, thermally loaded flame plate is efficiently water cooled.
without sealing features. The intermediate deck improves the cylinder head cool-
CW 170 is a 170 mm bore high speed engine, ing as well as absorbing the mechanical loads on the
cylinder head. The high and stiff design of the cylin-
CW 200 is a 200 mm bore high speed engine. der head allows it to be fixed by only four hydrauli-
Engine block cally tightened studs.
The engine block is cast in one piece in modular cast The cylinder head features two inlet and two exhaust
iron. It has a stiff and durable design to absorb inter- valves per cylinder. The exhaust valve seat is water
nal forces and to enable resilient mounting. cooled. The valves have stellite-coated seat faces and
The engine has an underslung crankshaft held in place chromium-plated stems.
by main bearing caps. The main bearing caps are nodular Crankshaft
cast iron and guided laterally by the engine block and The crankshaft is forged in one piece in a high tensile
axially by a locating pin. They are fixed by two hy- steel. All the crankshaft surface is nitrided. Journals
draulically tightened studs and secured by lateral and crankpins ends on recessed fillets.
screws.
The crankshaft fulfills all classification societie’s re-
The supercharge air duct is integrated between the quirements. The two counterweights per crankthrow
cylinder banks disposed in a V angle of 60°. The jacket are each bolted on by three screws. They are posi-
cooling water supply to the cylinder heads and the tioned by locating pins which prevent any fretting-
return are integrated in the engine block. corrosion.
The lubricating oil supply to the bearings and the pis-
ton cooling occurs through a drilled channel in the
middle of the engine block.

CW200 cylinder block and crankshaft

page 10 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

The main drive crankshaft pinion is shrunk on the fly- Piston

wheel end, to drive camshafts. Correct toothing allows Direct-injection engine uses a composite piston, made
operation without axial efforts on thrust bearings. The of a steel open combustion chamber, screwed on alu-
gear wheel for coolant, lube oil pumps drive and torsional minium skirt. The piston cooling is from oil nozzles
vibration damper are bolted at the free end. fed by the main oil duct of the cylinder block. The
Connecting rod piston ring grooves are hardened.
The connecting rod is forged in one piece. The CW200 Piston rings
big end has an angular split with serrated mating sur- The piston ring set includes two chromium plated com-
faces , and the CW170 has a right split, with stepped pression rings and one spring loaded oil scraper ring.
mating surfaces. The CW 200 connecting rod passes All piston rings are situated in the steel crown.
through the liner for maintenance. Both the caps are
tightened by two studs, hydraulically tensioned. The Camshaft and valve mechanism
cap is installed and tightened from the side where the The camshafts are made of flanged together sections.
cylinder is situated, opening one inspection door. The The cams and bearing surfaces are case hardened. The
oil supply for the small end bush lubrication passes camshaft turns in bushings force-fitted in the engine
through a drilling in the connecting rod. block. The valve tappets are of piston and roller type
Main bearings and conrod big end bearing and located in the “multi housing”, integrated
housing for the injection pump.The
The main bearing con- camshaft drive is fully in-
sists of two thin tegrated in the engine
prefinished bearing CW170
block, flywheel side. camshaft section
shells. Both shells are
peripherically slightly Flywheel housing
longer than the housing The flywheel housing has
thus providing the shell several functions. It supports the flange mounted al-
fastening and seating. ternator as well as starter, barring devices, some gov-
CW 170 erning accessories and ducts.
conrod The main bearing located
closest to the flywheel is Free end cover
p rov i de d w i t h fo u r The torsional vibration damper is fully enclosed in the
thrust washers for the axial guidance of the crank- free end cover. All engine driven pumps are installed
shaft. The flywheel is bolted on crankshaft end. on the free end cover. There are as standard the twin
Cylinder liner cooling water pump and the pump unit including en-
gine driven main lubricating oil pump, electric pre-
The cylinder liner is made of centrifugally cast iron,
lubricating pump as well as engine driven fuel-oil pump.
finished by lapping. The jacket water is sealed off by
two O-rings in the lower part and metal on metal bear-
ing under mating
flange. An anti-
polishing ring is
inserted at liner
top, allowing
heavy duty opera-
tion with mini-
mized wear.
CW 170
liner

issue 1.3 Apr. 99 page 11

Diesel Power Plant Project Guide CW 170 - CW 200

Starting system
The gear-drive air starter, delivered as standard, is Each cooling circuit is controlled by thermostatic valve
motorized by a turbine, operating under low pressure elements with wax sensors.
of 10 bar. Manual and remote electrical starts may be
The thermostatic valves for both circuits are in the
performed .
same casing, cooling water control unit, assembled on
Engine fuel-oil system the rear side of the free end cover.
The fuel-oil system is based on one cylinder (individual) The CW 200 engine has basically only one inlet and outlet
injection pumps with built-in tappets in the to the external cooler and an internal heat sharing cir-
“multihousing” (common casted piece for injection cuit. The CW 170 engines have basically two inlets/out-
pump and valve tappets). The fuel feeding line is fully lets for the separate HT and LT circuits.
integrated in the injection pump bodies, and surround-
ing ducts. An aluminium cover encloses the system to Optional electrical pre-heating is built-in engine, in-
safeguard against fire hazards. cluding an electrically driven circulating pump.

The multi-hole injector is centrally located in the cyl-

Exhaust gas and turbocharging system
inder head, and sprays directly in the open combus- The exhaust gases are led from the cylinder head
tion chamber formed by the piston head. through the multiduct toward the turbocharger. The
multiduct is water cooled, and carries the charge air
The engine is equipped in standard with a gear driven
and coolant from heads. The exhaust manifold, which
fuel-oil feed pump, an electrically driven fuel-oil re-
design is adapted to reloading performance, is enclosed
turn pump installed on separated module and a du-
in an insulation box in order to ensure low surface
plex full flow fuel-oil filter, exchangeable while the
temperature.
engine is running.
Engine Lubricating system
Engine cooling system
The lubricating oil system includes the wet oil sump,
The internal cooling water system consists of two
the pump unit, the lubricating oil module and the by-
separate cooling circuits : the low temperature (LT)
pass centrifugal filter.
and the high temperature (HT) circuit.
The pump unit, including engine driven lubricating
The low temperature circuit water cools both the charge
oil pump, electrically driven pre-lubricating pump and
air (second pass ) and the lubricating oil coolers in
direct driven fuel-oil pump, is externally mounted di-
parallel.
rectly on the free end cover.
The high temperature cooling water cools the charge
The lubricating oil module includes the temperature
air (first pass), cylinders jacket, cylinder heads and
control, the cooling and the filtration of the lubricat-
the cylinder head exiting duct of the exhaust system.
ing oil. The full flow filters are of paper cartridge type
Both cooling water circuits are circulated by the twin and horizontally assembled in the module.
pump. The twin pump is a one shaft centrifugal pump
Additionally the lubricating oil system includes a by-
with a double sided impeller, one side for the low tem-
pass centrifugal filter which can be cleaned while the
perature circuit and the other side for the high tem-
engine is running.
perature circuit.

page 12 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

2.2.2 ENGINE TECHNICAL DATA

The CW 170 engine is a four stroke turbocharged and
intercooled engine.

· Cylinder bore : 170 mm

· Stroke : 200 mm
· Displacement per cylinder : 4.47 litres
· Number of valves per Head : 4
· Cylinder configurations : 16 V / 18 V
· Compression ratio : 16 : 1
· Rotation : CCW
· Rated Speed : 1500 /1800 rpm
· Mean piston speed : 10 / 12 m/s
· Mean effective pressure : 19.3 to 23.2 bar

The CW 200 phase 1C engine is a four stroke turbo-

charged and intercooled engine.

· Cylinder bore : 200 mm

· Stroke : 240 mm
· Displacement per cylinder : 7.54 litres
· Number of valves : 4
· Cylinder configurations : 12 V /16 V / 18 V
· Compression ratio : 14,5 : 1
· Rotation : CCW
· Speed : 1200 /1500 rpm
· Mean piston speed : 9.6 / 12 m/s
· Mean effective pressure : 21.3 to 25.5 bar

issue 1.3 Apr. 99 page 13

Diesel Power Plant Project Guide CW 170 - CW 200

Engine instrumentation 2.2.3 STANDARD GENERATOR SET

The instrumentation system consists of a local super-
TECHNICAL DATA
vision unit operating from engine fitted analog sen-
sors data. Supervision unit is placed outboard, on a
Technical data sheets are enclosed in this handbook
panel. Regrouped alarm is connected to generator set
for information only. Please refer to up-to date sheets,
Control Panel. User can scan the fault appearance his-
available through sales support organisation, for en-
tory directly. Each cylinder temperature is measured
gineering activities.
as standard.

Below are listed parameters which are sensed using

specific analog sensors installed on the engine. Pa-
rameter values are displayed in digits on front face,
and integrated alarms are triggered if threshold is
passed. Exhaust temperature faults are reported to-
ward Generating set Control Panel (GCP)

Monitored parameter Set for Set for Alarm

CW 170 CW 200
Fuel pressure inlet low low
Lube oil pressure low low
Starting air pressure low low
HT water pressure before engine low low
LT water pressure before engine low low
Charge air pressure after charge air cooler off high local display
Fuel-oil temperature before engine high high alarm
Lubricating oil temperature after cooler high high
HT water temperature after engine high high
LT water temperature before charge air cooler high high
Charge air temp. after charge air cooler high high
Scanner internal temperature high high
Exhaust gas temperature at each cylinder high high 1st remote
Exhaust gas temperature average bank A high high grouped
Exhaust gas temperature average bank B high high alarm
nd
Regrouped faults(engine&scanner) on on 2 remote
alarm

page 14 issue 1.3 Apr. 99

 CW 170 - CW 200 Diesel Power Plant Project Guide

2.2.4 FUEL OIL DEFINITION

Fuels available on the market:
The CW 170 & CW 200 engines are designed to run - “Regular” fuel-oil, (ISO F-DX, F-DMX) with sulfur con-
using light fuel-oil with characteristics inside the fol- tent between 0.2 and 1%, currently available as “do-
lowing limits : mestic” use, suitable for use with most of the indus-
trial lubricants available on market.
ASTM test ISO test - Fuel-oil with very high sulfur content over
CRITERIA LIMIT VALUE
method method 1%, (ISO F DMA-DMB) is mainly a light ma-
Density @ 15°C D 4052 3675
rine fuel, containing residuate fuel, which
800 to 900 kg/m3
necessitates high TBN (over 15) lubricants,
Kinématic viscosity @ 40°C 2.0 to 11 cSt D 445 3104 basically formulated for marine engines.
Flash point °C 38......120°C D 93 or D56 2719 - Low sulfur content fuels below 0.05%,
have been recently formulated for on-road
6°C under lower storage D2500
cloud point °C 3015 use. They necessitate a low TBN lube oil, of
temperature or D 3117
new generation (lower than 11).The low-
Cetane number mini 35 D 613 5165 sulfur content fuel trends to be used in sta-
Sulfur content maxi 2% weight D 129 - tionary diesel engines, in USA and Europe.

Water content max 0.3% volume - 3733 Sulfur in fuel ensures the fuel lubricity in
regard with injection equipment. Fuel pro-
Ash content maxi 0.01 weight D 482 6245 ducer mix some additives in low sulfur fu-
Sediment by extraction maxi 0.1% weight D 2276 3735 els to protect injection equipment against
seizing. We advise the purchaser to get a
Water and sediment maxi 0.05 % volume D1796 - fuel lubricity test result, to prevent injec-
Carbon residue, ramsbottom 4262 section tion equipment damage.
maxi 0.35 % D 524
% on 10% residue 3.3
It is mandatory to respect at all times the
Copper corrosion up to 3 index D130 - fuel-oil/lube oil adequacy to prevent pis-
ton rings and bearings damages. See fol-
lowing chapter for lubricants definition.
The table above gives most current test methods. Italic Fuels conforming to the specifications below can be
printed testing methods may be used as alternative. used without prior restriction. If fuel specification is
Lower Heating Value (LHV) of fuel is defined in diesel not included in this list, please compare its analysis
generator data sheets.Copper strip corrosion is not im- results with limits in table above.
portant, because our circuits are made of steel and - U.S. standard ASTM D975-1994 N°1-D and N°2-D.
cast iron
- ISO fuel-oil F-DX, ISO 8217 marine fuel-oil F-DMX,
When output power guarantees are required, we require F-DMA and F-DMB.
a complete analysis of fuel-oil from the forecasted fuel
seller. If analized fuel has some characteristics out of - British standard BS 2 869 A1, A2 and B1.
above specifications, please ask Cummins Wärtsilä for - French syndical specs.CSR.09 and CSR.10 Q,
further information. Some characteristics may be en- FOD N°1 and FOD N°2.
hanced with special features: excessive water content
can be removed using a water trap or a centrifugal sepa- Be aware of the fact that, generally, the quality of
rator, as well as sediment. Excessive sediment and ash fuel-oils continues to decrease due to changing refin-
content reduces fuel filter exchange interval. ery techniques.
Fuel-oil/lube-oil adequacy
Lube oil quality is defined by used fuel-oil properties and
lube-oil grade is defined by service & ambient temperature.

issue 1.3 Apr. 99 page 15

Diesel Power Plant Project Guide CW 170 - CW 200

2.2.5 ENGINE LUBRICANT & COOLANT DEFINITION

2.2.5.1 LUBRICANT DEFINITION
Carefully tested high-quality lubricants should be used - For black-start diesel generators, for which service is
for the lubrication of Cummins Wärtsilä engines. Prod- for short duration, and cold starting time require-
ucts from well-known companies who can assure a con- ments are severe, the use of a multigrade SAE 15W40
sistent supply of quality oils, and who can also pro- or synthetic base SAE 5W50 lubricants is suitable.
vide oil analysis from engines in operation, is preferred.
Lubricants listed below are homologated for use in CW
The selected oil must have enough heat resistance to 170 and CW 200 engines, without restriction, and man-
prevent from hard carbon and ash deposits at the tem- datorily during waranty period.
perature to which it is exposed. It must also maintain
Before using a lubricant not listed, the lubricant shall
a satisfactory oil film between the moving components
be tested by user, under Cummins Wärtsilä survey, ac-
on all temperature range.
cording to CW procedures available on request. Test
Moreover, the oil must contain adequate detergent and cannot be conducted during waranty period.
dispersent additives to prevent soot from being depos-
ited on internal engine parts. The final selection of
specific oil should be governed by the operating con- Brand name & characteristics
ditions and the type of fuel-oil to be used. Producer
for continuous
for standby
Lube oil quality duty
(weight) TBN
(weight)
To define lube oil quality, it is necessary to take fuel
Engines operated with fuel which sulfur content is
sulfur content as main definition input.
between 0.2 and 1%
If fuel is low sulfur content (under 0.05%), use of an Mobilgard HSD
15W40
API-CG4 lube oil is mandatory. TBN is between 8 and MOBIL (for low sulfur 10
11, adapted to the low sulfur content. content fuel only)

If fuel sulfur content is high (0.2 to 1%) use of API- Gadinia SL0391
SHELL ( SAE 40) 12
CDII, and API CE, or MIL-L 2104E class are adequate.
TBN should be between 10 and 15. LO with TBN over CASTROL TLX 154 15
15 may be used to increase oil change intervals.
EXXMAR CM
If fuel sulfur content is very high (1 to 2%) use of EXXON super 40 15
API-CDII, CE, and MIL L 2104 E, with very high TBN ( SAE 40)

over 15, is adequate. TBN over 20 is preferred. Engines operated with fuel which sulfur content is
between 1 and 2%
As basic principle, TBN value should be as a minimum15
Sirius X 40
Myrina X
times the sulfur content in percent.If they are not, oil SHELL ( SAE 40)
15W40 17
change intervals shall be reduced. (former Myrina)

Rubia FP 40
Lube oil grade (weight) TOTAL (SAE 40) 17
Lube oil grade is defined by the cold starting requirement.
CASTROL TLX 204 20
Use of SAE 30 or lower weight lubricant is forbidden
- For continuous duty or power management diesel ELF
Aurelia 4020
20
( SAE 40)
generators, SAE 40 grade is always recommended.
220 MXD
- For emergency diesel a monograde SAE40 is recom- CASTROL ( SAE 40) 22
mended if preheating is effective before the starting
is performed.

page 16 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

2.2.5.2COOLANT TREATMENT
General Rules of the art :
The purpose of water treatment is to prevent: - Use of distillated water or rain-water without treat-
- Furring of heat exchange surfaces due to mineral ment is strictly forbidden, even for short duration tests.
content of water, - Life-time of antifreezed coolant of grade 1 is about
- Corrosion of metals due to dissolved oxygen and 3 years in air-tight circuits.
carbon dioxide, - An analysis of coolant quality is recommended ev-
- Cavitation due to boiling points, pump impeller ery three months, whatever its nature. Quick-check
vacuum effect or vibrations, sets are proposed by the chemicals manufacturers.

- Freezing if coolant is exposed to frost. - If new products are installed in existant circuitry, it
is advised to clean the former product layer and/or
We have defined for our diesel engines, a set of water treatment remove bottom deposits, and rinse carefully.
products, having given satisfactory results in use. They are depicted
in table right. It is mandatory to use one of these selected products Particularities
during warranty period.
LT water and HT water in engine shall be protected
Water for coolant & inhibitors preparation using the same chemical. These circuits are in contact
inside the engine.
If concentrated products are used, you have to use
demineralized water for coolant preparation or good Use of other products
quality drinking water.
During warranty period, use of recommended products
The minimum quality requirements allowing our anti- is mandatory. After warranty period, other products
corrosion products efficiency are : may be tested following Cummins Wärtsilä procedures.
Consult our service department.
- Water totally clean and limpid.
- Total Hardness < 5.6 °dH(1) (100 ppm as CaCo3) . Particular recommendations for ecology
- Acidity 6.5 < pH < 7.5. Water treatments are chemicals which may cause pol-
lutions ,or which are containing non-degradable sub-
- Chlorides contents < 60 mg/liter of NaCl. stances, such as monoethylene glycol based formulas.
- Sulphates contents < 40 mg / liter of SO4Ca The antifreezes shall be recycled, and never drained
in a sewage. The producer may take it back for recy-
Above these figures, use softened or demineralized cling process.In any cases, handling shall be performed
water, or ready-to use coolants. Another solution is to with usual protective wear, even if product is not toxic.
demineralize water using chemicals which causes pre-
cipitates of calcium carbonates and silicates. After Producer Tradenam e Type of product
chemical demineralizing, water can be used after fil-
tering to remove deposits Coolef W ith antifreeze, m inus
supra 25°C ,ready to use
Coolant preparation E LF
Glacelf W ith antifreeze, u p to
For antifreeze based coolant preparation a maintenance supra m inus 50°C, to be d iluted

tank where water and treatment chemicals are mixed W ith antifreeze, u p to
Diagel-6N
together is proposed. A pump and a set of flexible m inus 50°C, to be d iluted
hose is included, to connect pump, tank, with circuit ROHM & W ith antifreeze , m inu s
filling orifice and antifreeze drum. This tank is trans- Diamigel-6N
H AAS 35°C, ready to use
portable using a fork lift truck.
W ith antifreeze , m inu s
Triagel-6N
20°C, ready to use
(1)
corresponding to 10°f (french degrees ). A total Glycol Shell W ith antifreeze rea dy to
S HELL
hardness up to 250 ppm as CaCO3 may be tolerated, but type D use, m inu s 25°C

top-up with this kind of water, to compensate evapora- ROHM & Anticorrosion without
H AAS
RD 25 antifreeze, to be dilute d
tion in service, would cause deposits or saturate the
furring inhibitors.

issue 1.3 Apr. 99 page 17

Diesel Power Plant Project Guide CW 170 - CW 200

2.3 ALTERNATOR

2.3.0 GENERAL tively. The actual values are indicated in generator

data sheet.
The alternator is an IC 01air-cooled synchronous ma- Radio Interference
chine in the medium voltage range with a brushless
excitation system. For generator sets up to 3 MVA, a The absence of brushgear and the high quality AVR
low-voltage alternator is available. ensure low levels of interference with radio transmis-
sions. Additional RFI suppression may be supplied if
Construction form is IM 2001, i.e., built with two feet
required.
and one flange for fixing on engine end. Shaft end is
cylindrical and keyed. Telephone Interference
THF (as defined by B54999 Part 40) is better than 2%.
The alternator number of poles is 4 for 50hz alternators
TIF (as defined by ASA C50.12) is better than 50.
operated at 1500 r.p.m., 4 for 60 Hz alternators oper-
ated at 1800 r.p.m., and 6 for 60 Hz alternators oper- Waveform Distortion
ated at 1200 r.p.m.
Total harmonic distortion (THD) of the open circuit
Two technologies of alternator are used for CW genera- voltage waveform is in the order of 1.5%. Under 3 phase
tor sets design: balanced, linear, load conditions the THD is in the or-
- Salient poles PMG excitation, standard for CW 170 low der of 3.5%.
and medium voltage and CW 200 low voltage alterna- Generator design
tors.
Enclosure IP23 (NEMA1) is standard for all industrial
- Salient poles, shunt-booster excitation, standard for
alternators. The frame is made of welded steel, opti-
CW 200 medium and high voltage alternators,
mizing strength and power to weight ratio.
- Non-salient poles PMG excitation, optional for CW 200
medium and high voltage alternators. Stator laminations are made of high quality Silicon
Standard ones are described below. Diesel generator as- electrical steel. Salient poles rotor is designed to re-
sociated controls are depicted in following chapters. sist of 150% of rated overspeed.
Two bearing constructions ( IM 20001) are available
2.3.1 SALIENT POLES PMG ALTERNATOR with SAE 00 adaptors. Alternators incorporate long
life regreasable bearings.
The alternator is equipped with two regreasable roller
bearings. The standard features are defined in genera- The cooling fan is cast aluminium.End brackets are
tor set data sheet. made of welded plates with cast iron bearing hous-
ings, seals, and exciter stator support parts. On D.E. a
Winding and Electrical Performance
cast voluted housing is used.
The stator winding in conjunction with carefully se-
lected pole and tooth designs ensures optimum perfor-
mance and low waveform distortion. A fully intercon-
nected damper winding stabilises the rotor during load
changes.
Generators will sustain a maximum short circuit of
around 250% (50HZ), 300% (60HZ),rated current under
a three phase L-L-L short circuit condition.The AVR will
support this condition for some eight seconds, at which
point the AVR protection system will de-excite the ma-
chine.
Current levels under 2 Phase L-L or 1 Phase L-N short
circuit conditions are much higher than the above L-L-L
levels, and must be removed from the generator by break-
ers within typically 5 seconds and 2 seconds respec-

page 18 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

Terminal Boxes
Instrument and control connections are in segregated
compartments, with external access for safety.
Vibration Limits
All alternator rotors are dynamically balanced to bet-
ter than BS6861: Part 1 Grade 2.5 for minimum vibra-
tion in operation. Two bearing alternators are balanced
with a half key.

Insulation/Impregnation of windings
Standard insulation classes for the alternators are
class H for low voltage (400 - 480V), and F for medium
& high voltage (4.160 - 13.800 V) .Please refer to data
sheet for actual specifications. (built-in version)
The 3 phase RMS voltage sensing AVR provides very
All wound components are impregnated with materi-
accurate vc!tage regulation, from no load to full load
als and processes designed specifically to provide pro-
including cold to hot variations for any power factor
tection against the harsh environments encountered
between 0.8 lagging and unity allowing for 4% en-
in generator applications. Resins are selected and de-
gine speed variations. It is particularly suitable for
veloped to provide the high build required for static
non linear load applications.
windings and the high mechanical strength required
for rotating components. Three Phase Sensing
An Hybrid System using the best features of Global Three phase sensing centres any voltage imbalance,
VPI, and Resin Rich Technology is used, to give a su- caused by load imbalance, around the nominal volt-
perior product, optimising insulation life in the slot age, and helps to ensure trouble-free operation under
section, with the advantages of VPI epoxy in the the most demanding loads.
outhangs for strength, electrical properties and opti- Parallel Operation
mum protection. 5kV machines and above, have Co- All alternators are well-suited for parallel operation
rona Protection tapes applied. (optional droop kit fitted) with the mains utility or
PMG excitation with other generators. A fully interconnected damper
Permanent Magnet Generator (PMG) excitation system, (amortisseur) winding reduces oscillations around the
performing in regard with reliability, response and sta- synchronisation point during paralleling.
bility, is delivered as standard feature. The PMG pro- Advanced regulation features
vides power via the AVR to the main exciter, giving a PMG alternators may be operated directly with the
source of constant excitiation power independent of PowerCommand™ system, including its own voltage
generator output. The exciter output is then fed to regulator. See enclosed PowerCommand™ description
the main rotor, through a full wave bridge rectifier, for more information.
protected by a surge suppressor. The AVR has in-built
protection against sustained over-excitation, caused
by internal or external faults. This de-excites the al-
ternator after a preset period.
Over voltage protection is built-in and short circuit
current level adjustment is an optional facility.
Voltage Regulator

issue 1.3 Apr. 99 page 19

Diesel Power Plant Project Guide CW 170 - CW 200

2.3.2 SALIENT POLES ALTERNATOR,

SHUNT-BOOSTER EXCITATION Take the alternator air inlet temperature for calcula-
tion, and not the outdoor temperature, which is any
The alternator is equipped with two roller bearings. case lower. Add altitude derating, as defined above.
The following is normally included as standard.
Current transformers for protection and measurement
· Automatic voltage regulator (AVR) three functions,
are installed on neutral connection bars.
· Current transformers in terminal box,
· Temperature sensors for winding and bearings, Standards and Classifications
· Anti-condensation heater, The alternators meet the requirements of the follow-
· Terminal boxes for main and control cable connec- ing standards and classification authorities Land ap-
tion, plications : IEC, VDE, BS.
. Medium and high voltage measurement transform Stator
ers for regulation gives 100V image for rated. The frames are made of welded steel and are heavily
Waveform ribbed to prevent deformations. The upper part sup-
Low voltage alternators for stationary applications, ports the main terminal box. The magnetic circuit con-
have a 2/3 pitch winding as standard, designed in or- sists of low-loss silicon magnetic laminations, securely
der that the voltage waveform between phase and neu- wedged to the frame’s ribs.
tral at no load has no third harmonics.
Rotor
Radio Interference
This consists of a shaft, main rotating exciter wind-
Radio interference (RFI) is guaranteed to be within ing, a fan, a balancing disc, an exciter armature and a
the limits defined in the international standard CISPR.
rotating rectifier bridge. The shaft is made of carbon
Overload Capacity steel, forged or laminated according to its size. The
The generator can withstand overloads if it is designed
for emergency generator set applications (LTP).
The stator winding withstands even higher overloads
for short durations, e.g. the continuous shortcircuit
current can be over 3 times the rated current for
approx. 10 seconds. The stator winding supports, also
withstand the stresses caused by the maximum asym-
metrical short-circuit current.
Unbalanced Load
The AC generators can operate on an asymmetric net-
work. None of the phase currents exceed the rated
current with an unbalanced current of 30 %.
Power derating factor due to altitude rotor is of salient pole design manufactured with low
When an air cooled machine, using ambient air as pri- magnetic loss laminations. The exciter coils are main-
mary cooling fluid, is to be used at an altitude above tained in position by full length heat shrink wedges
1000 m A.S.L. and a specified ambient temperature, which serve for thermal diffusion as well as opposing
we consider that the cooling loss due to high altitude centrifugal forces. The fan and the balancing flywheel
is equivalent to an increase of the ambient tempera-
are keyed on the shaft. Dynamic balancing of the com-
ture (in °C) of 1 % for every 100 m above 1000 m.
plete rotor and shaft is carried out on all alternators.
Once the equivalent ambient temperature has been
established using the above guideline, you should re- Bearings
fer to following paragraph. Roller bearings are rigidly fixed to the stator end plate.
Power derating factor due to temperature Lubrication is performed by means of grease, with a
The reference temperature is 40°C. Apply a derating used grease escape valve. New grease is inserted dur-
of 7 % for 10 K of cooling air temperature increase. ing operation causing the old grease to be evacuated.

page 20 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

Fan Cooling Rotor winding

The air inlet is located at the rear of the alternator and The Rotor is built with rectangular copper enameled
the air outlet at the driving end ; air escapes through bars or insulated with two fiberglass layers and to-
the gap by means of the fan keyed on the shaft. tally impregnated with solventless polyester resin
Stator winding under vacuum and pressure.

Low voltage coils are wound with round enameled Terminal box - Connection
wires. Impregnation is done with polyester based var- A large-sized and easily accessible terminal box is lo-
nish impregnated under vacuum. Medium voltage coils cated at the alternator top. Inside, the six windings
are built with fiberglass-lapped flattened enameled ends are wired to connecting bars (for low voltage)
wires, the sections are isolated using mica products. or to insulators (for medium and high voltage), thus
allowing easy connection.
Thermal protection
PT 100 thermal sensors (100 ohms at 0°C) are enclosed
in the stator winding and implanted in the bearings.
Output is used either for temperature measurement
or alarm and tripping.
Brushless excitation
Field flashing is ensured by residual magnetism, de-
livering minimal field to enable voltage regulator
operation. Excitation alternating current is drawn off
an inverted alternator keyed on rotor shaft. Inverted
means that armature is rotating, and field poles are
fixed. The excitation current is rectified through Graetz
bridge of silicon diodes properly sized and protected
by resistors connected in parallel on the alternator ro-
tor windings. Rectifier is fixed on alternator rotor, and
so named “rotating rectifier”. If out of control, exciting
system trends to minimal voltage output.
Shunt regulator
Special precautions are taken to ensure perfect The regulator (6) is supplied by the generator output
wedging of the sections and connections using insu- (1) and controls the excitation in the exciter field (5).
lating rings and inserts. The excitation current from the exciter armature (4)
Global impregnation with solventless polyester resin is rectified by the rectifier bridge (3) and supplies the
under vacuum and pressure provides the unit with a alternator pole wheel (2). A three phase current
remarkable mechanical strength, a very high degree booster is supplied, and a current transformer (dot-
of insulation impervious to humidity, oil, fuel-oil, die- ted line on diagram) is allowed for parallel operation
sel fumes and industrial chemicals. reactive power control.
Standard insulation classes for the alternators are A potentiometer allows adjustment of the nominal
class H for low voltage (400 - 480 V), and F for me- voltage over a ± 5 % range.
dium & high voltage (4.160 - 13.800 V).

issue 1.3 Apr. 99 page 21

Diesel Power Plant Project Guide CW 170 - CW 200

Voltage regulator functions Short-circuit current

The function of the basic AVR is to keep the terminal Compounding is designed so as to sustain a three-phase
voltage of the alternator constant at set point under or single-phase current equal to 2 to 5 time rated cur-
rent for a few seconds in the event of short-cir-
cuit, enabling proper operation of protections and
ensuring selectivity in distribution systems.
Generator protection
Generator protections for isolated and paralleled
operation are provided. Optional protections are
to be defined according to bus specificities or lo-
cal regulation. Power distribution system protec-
tions are defined by others, but they shall be com-
municated to project staff to check the effective
various load conditions, when operating on isolated selectivity in whole system.
bus. AVR controls also the paralleled operation with
other units in a power generation system, and with an 2.3.3 NON SALIENT POLES ALTERNATOR,
infinite grid. To make paralleling possible, the AVR is PMG EXCITATION (OPTIONAL)
equipped with a voltage droop circuit, which is en-
abled as soon as DG is paralleled on live bus. When The alternator is equipped with two roller bearings. The
increasing reactive load, the terminal voltage decreases instruments are as defined for standard featuring.
according to a predetermined characteristic. This re-
Waveform
active load sharing is important to prevent an imbal-
ance and circulating currents in the system. Low voltage alternators for stationary applications, have
a 5/6 pitch for medium voltage, designed in order that
Basic function : the regulator allows operation of a single the voltage waveform between phase and neutral at no
AC generator by itself or parallel-coupled to AC genera- load has no harmless harmonics.
tors of comparable power. A current transformer al- Overload Capacity
lows appropriate sharing of the reactive power.
The alternator can withstand specified overload 1 hour
2nd function : the second function also allows parallel every 12 hours. The stator winding withstands even
operation with a much more powerful network with higher overloads for short durations, e.g. the continu-
regulation of the AC generator power factor. ous short-circuit current can be around 3 times the rated
current for approx. 10 seconds. The stator winding sup-
3rd function : the third function also offers voltage ports, also withstand the stresses caused by the maxi-
pre-equalization between the AC generator and the mum asymmetrical short-circuit current.
network before coupling.
Unbalanced Load
The rotor poles include a damper winding to assist in The AC generators can operate on an asymmetric net-
parallel operation. work. None of the phase currents exceed the rated cur-
Regulation basic performances rent with an unbalanced current of 30 %.
Following performances are typical and cannot con- Standards and Classifications
stitute a contractual guarantee. The alternators meet the requirements of the IEC 34 stan-
dard, fulfilling generally the local substandard.
Under steady conditions, the voltage is kept constant
within ±1% between 0 and 4/4 load, P.F 0.6 to 1 induc- Stator magnetic circuit
tive, in cold or hot state, at rated speed within ±5%. The stator stacking is used as the main structure. Two
end covers, made of thick iron sheet are fixed on stator
Output voltage is remotely adjustable by +/-5%.
to constitute the frame. Feet are part of these end pieces.
Under transient conditions, the alternator is able to The magnetic circuit is made of low-loss silicon mag-
return to nominal voltage under 0.5s. Please contact netic laminations, pressed between two tick end plates.
sales support for calculation of performance in regard Pressure is maintained using longitudinal welded beams.
with step reloading nature.

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CW 170 - CW 200 Diesel Power Plant Project Guide

Rotor arrangement Brushless excitation

Poles are made of insulated magnetic laminations. As- Main power of excitation is drawn off PMG( Perma-
sembled sheets are shrank on shaft. Excitation genera- nent magnet generator); regulation additive current
tor, keyed on shaft, delivers voltage to rotating recti- is drawn off an inverted alternator keyed on rotor shaft,
fier. controlled by voltage regulator. The regulator (7) is
Bearings, fan supplied by the PMG (8) and controls the excitation
in the exciter field (6). The excitation alternating
Deep groove type ball bearings are installed both sides. current from the exciter armature (5) is rectified by
Drive end bearing is blocked, free end bearing is pre- the rectifier bridge (3) and protected by varistor (4)
stressed to enable dilatation. They are grease lubri- and supplies the alternator pole windings (2). A cur-
cated, excess grease is rejected in a removable con- rent transformer (9) is allowed for parallel operation
tainer. NDE bearing is insulated to prevent from shaft reactive power control. Measurement circuits are pro-
currents. Fan is keyed on shaft.
Stator winding
Low voltage coils are wound with round enameled
wires. Impregnation is done with polyester based var-
nish impregnated under vacuum. Medium voltage coils
are built with fiberglass-lapped flattened enameled
wires, the sections are isolated using mica products.
Special precautions are taken to ensure perfect
wedging of the sections and connections using insu-
lating rings and inserts. Global impregnation with sol-
ventless polyester resin under vacuum and pressure
provides the unit a high life duration. The insulation
classes and temperature rise for the alternator are
specified in the data sheet .
Rotor winding tected by fuses(11). A potentiometer (10) allows ad-
The Rotor is built with flat copper enameled bars held justment of the nominal voltage over a specified range.
in place in the slots using thick glass mat wedges and
Voltage regulator functions
totally impregnated with solventless polyester resin
under vacuum and pressure. AVR is provided in”three functions” tobe operated ei-
ther on isolated bus or paralleled with infinite grid.
AVR control is numeric, owner can set quicly the op-
erating set points.

issue 1.3 Apr. 99 page 23

Diesel Power Plant Project Guide CW 170 - CW 200

2.3.3 CW 170 GENSET CONTROL PANEL

Control components
The generator control system consists of three main on the last 20 alarms or shutdown complete with an
components: The generator control panel (GCP), an AC amber light indicating a Warning or a red light indi-
auxiliary enclosure and a Genset interconnection box. cating a Shutdown.
The system can be used in single or multi-set isolated Emergency stop buttton.
bus or single set base load utility paralleling applica-
The HMI is a micro-processor based graphic interface
tions.
(touchscreen) which allows an operator to monitor the
It provides both isolated bus paralleling control (set Genset. (see detail below)
to set synchronising, isochronous KW and KVAR load The PLC performs and controls:
sharing) and base load KW control, VAR / PF control.
Engine heaters, Alternator heaters, Coolant circulation
The system has compatibility with master controllers
pump, Clean fuel pump, Oil priming pump, Alarm /
for multi-set utility paralleling applications requiring
data handling.
supervisory system control.
Data communications:
Data control and monitoring is available via an op-
tional (Modbus) communicatons interface. Engine protection system, CENSE -> PLC
The GCP is built as a free standing steel enclosure PCCTM <-> PLC.
sealed to IP54, arranged for bottom cable entry only.
HMI <-> PLC.
TM
The GCP comprises of a Power Command Control (PCC), PLC <-> External device via Modbus
a Human Machine Interface (HMI), a Programmable logic
Controller (PLC), and the control panel batteries with The customer will need to provide volt free contacts
battery charger. for e.g. radiator fan tripped, louvres closed alarm, util-
ity parallel enable, circuit breaker position etc.
The front panel (door) mounted equipment have sealed
front faces to minimise the effects of dust and mois- The AC auxiliary enclosure is Genset mounted and
ture. houses the equipment which control / monitor and
protect engine AC auxiliary systems.
The internal components of the GCP use a power sup-
ply of 24V DC. The Plant interconnection box is Genset mounted
and acts as the main connection interface between the
The power supply to the GCP requires a permanent Genset and the GCP.
single phase AC supply (determined by the site appli-
cation) via the fused supply from the AC Genset Site Location
mounted auxilliary enclosure or the customers power The GCP can be located locally near the Genset or re-
distribution board. motely up to a distance of 100 metres*, ie in a con-
The PCCTM is a microprocessor-based Genset monitor- trol room environment. If the GCP is location exceeds
ing, metering and control system which has the fol- 18 metres from the Genset, then the battery charger
lowing features: and batteries will be supllied as loose items.
Genset monitoring and display of all critical engine GENSET CONTROL PANEL SPECIFICATION
and alternator functions (except engine auxiliary sys-
tems see PLC). The CumminsWärtsilä G.C.P. is a micro-processor based
system designed to directly interface with the CW170
Digital governing and voltage regulation.
diesel genset control and monitoring components. The
Digital alarm and status message display. AmpSentryTM control panel provides extensive integrated system
gives alternator overcurrent and short circuit protec- monitoring and control functions using the highly re-
tion. liable Power Command Controller™. It further utilises
Analogue meters and digital displays. a PLC to generate a range of communication protocols
for both internal and external usage.
Alarm and status message display with historical data

page 24 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

Genset Control Panel Cense Data & Fault Codes

PC Based
HMI 3-Phase AC Supply
by Customer Alternator Engine
PLC
RS-485 Supply to prelube, wtr circ, CENSE
AC sensors Woodward
RS-422
I/O Terminal clean fuel spill pumps, (Level 1) Actuator
Box eng & alt heaters
RS-232
DC sensors sensors
Power Command Control
Terminal
Box

Cust. Full Governor Control by PCC

Supplied
Interconnect
Wiring
VAR/PF control). It provides compatibility with mas-
ter controllers for multi set utility paralleling applica-
tions requiring supervisory system control, ie, load
Control Batteries demand, multi level load shed/add etc, whilst enabling
& Charger
data control and monitoring via an optional (Modbus)
communications interface.
Genset CB
CONTROL PANEL ENVIRONMENTAL HARDENING
The control system touchscreen, PCC and other optional
door mounted equipment are provided with sealed front
faces to minimise the effects of dust and moisture on
GCP SYSTEM CONFIGURATION.
the equipment.
The Genset Control Panel is designed to be specifically
The control system is housed in a rigid, free standing,
integrated onto the 170 range of CW engines. It can be
metal enclosure designed to require front access only.
located either locally at the genset or remotely, up to
Terminals for field connection are provided with re-
a distance of 100 metres, ie; in a control room envi-
movable plugs for ease of installation.
ronment.
Standard components used to provide the system con- PC BASED H.M.I. (TOUCHSCREEN).
trol comprise : The “HMI” is the Human Machine Interface. A micro-
Control batteries and charger , processor based graphic interface (touchscreen) pack-
age is provided to allow operator monitoring and con-
PC based HMI (touchscreen) , trol. Data from the genset is displayed to the operator
PLC based auxiliary control , in layered menus so that it is easy to understand and
allows operators to easily learn the functionality and
PLC based CENSE interface , diagnostic facilities of the unit The touchscreen pro-
Power Command ControllerTM , vides data and graphics on an EL monochrome display.
The microprocessor is 80486SXLC2-50 technology and
Aux AC enclosure (genset mounted) ,
includes a DOS based operating system and ‘InteractTM’
Engine interface enclosure (genset mounted) . application software. It is complete with a real time
clock, (month/day/year/hour/min/sec) with separate
The system is intended for use in single or multi-set
battery backup and holds an extensive 5MB of FlashDisk
isolated bus or single set base load utility paralleling
memory.
applications whilst providing both isolated bus paral-
leling control (set to set synchronising, isochronous The screen is mounted on a console on the front of the
kW and kVAR load sharing) and base load utility paral- GCP with gaskets between the touchscreen and the
leling (synchronising to utility, base load kW control, enclosure Nema 4 for environmental protection. The

issue 1.3 Apr. 99 page 25

Diesel Power Plant Project Guide CW 170 - CW 200

H.M.I. is interconnected to the PLC via serial comms

via a Modbus protocol. External Optional Connectivity
: VGA monitor, disk drive, mouse interface, IBM AT
keyboard port.

MAIN SCREEN :
The main screen is designed to enable the operator to
determine the current genset status. It further allows
access to the data embedded in the layered screens.Data
Includes voltage per phase, Current per phase, kW, MW/
hr, Frequency, Power factor, Oil pressure, Speed and
Engine hours.
Touchscreen activities allow the following access:
· Engine Data,
· Alternator Data, · Low oil pressure (shutdown)
· AC Auxiliaries mimic, · High coolant temperature (shutdown)
· Alarm Activities, · Fail to crank (shutdown, indicates failure of en
· GCP Configuration, gine to rotate on start command)
· Related Plant Data · Overcrank (shutdown, indicates cranking time
The main screen is designed to include an alarm capa- exceeds 75 seconds or failed to start after all cycle
bility so that the operator is immediately advised of cranking attempts)
all alarm and shutdown conditions. · Magnetic pick up failure (shutdown)
The digital display provides status of the following criti- · Overspeed (shutdown, engine speed >= 115% of nominal)
cal engine functions : · Emergency stop (shutdown)
· Oil temperature (oF or oC) The control has provisions for four programmable fault
· Coolant temperature (oF or oC) conditions. These may be either warning or shutdown
· Oil pressure (PSI or kPA) conditions. Labels for customer faults can be pro-
· Battery voltage grammed into the control.
· Engine operating hours
Historical data
· Number of engine starts
· Speed The control maintains an historical data log of the lat-
est alarm and status conditions on the genset. On an
ENGINE WARNING AND SHUTDOWN MESSAGES. alarm or shutdown condition the control logs the na-
On sensing a warning or shutdown condition the con- ture of the fault and the engine operating time that
trol displays the warning or shutdown message, and a the fault occurred. The control displays the last 20
code to be cross-referenced using the genset manual. alarm and/or shutdown messages.
Functions provided include:
· Low oil pressure (warning)
· Low coolant temperature (warning)
· High coolant temperature (warning)
· Low coolant level (programmable warning or shutdown)
· Low fuel day-tank (warning, external input signal)
· Oil pressure sender (warning, indicates a sender or
wiring failure in the oil pressure monitoring system)
· Engine temperature sender (warning, indicates a
sender or wiring failure in the engine temperature
monitoring equipment)

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CW 170 - CW 200 Diesel Power Plant Project Guide

POWERCOMMAND™ SUPERVISOR
PowerCommand Control
This unit is a microprocessor based genset monitoring,
metering and control system. It is integrated into the
GCP and incorporates the following key features;
• Voltage Regulator
• Synchronizer (Freq, Phase & Volts)
• Iso-Bus kW and kVAR load sharing
• Utility Paralleling kW Load Control
• Utility Paralleling pF Control
• AmpSentryTM Alternator Protection
• Overload,
• Overcurrent [51],
• Short circuit [50],
• High AC Volts [59],
• Low AC Volts [27], OPERATOR’S CONTROLS
• Underfrequency [81u], Operator may choice the operating display screens:
• Sync Check, Fail to Sync, Generator set monitoring, engine warning and shut-
• CB Fail to Close, down messages, the fault occurence historic, and can
• Reverse Power [32], reset faults from front face controls. Some parameters
• Loss of Excitation [40], or set points may be adjusted under access code pro-
• Phase Rotation tection, from front face controls.
• Alternator Metering
Upper face of PowerCommand™ bears the indicators
ENCLOSURE ENVIRONMENTAL HARDENING. for AC output metering: kW meter, Frequency meter,
AC voltmeter and Ammeter switchable on each of the
The front face is impervious to water spray, dust and
Three phases.
oil/exhaust residue. Switches for control are incorpo-
rated into the door which is gasketted with a dual Digital metering of alternator is available on screen
moisture and RFI/EMI gasket to protect internal com- for accurate indication and energy counting
ponents from airborne contaminants. AC GENERATOR VOLTAGE REGULATOR , SYN-
CONTROLS AND ADJUSTMENT SWITCHES. CHRONIZING AND LOAD SHARING FEATURES

An oil tight, three position switch starts and stops the PMG Generator digital voltage regulator is built-in PCC.
generator set locally or enables start/stop control from It controls the isolated generator set voltage, ensures
a remote position. matching of voltage and frequency for synchronizing,
and controls the load and reactive power when paral-
It provides the following functions:
leled. Genset breaker is controlled abnd secured for
. The ‘OFF’ position de-energises all primary DC cir- closure and opening on dead or live bus.
cuits. When the switch is in this position, the non-
automatic indicator will flash continuously. SMART STARTING CONTROL SYSTEM

. The ‘RUN’ position energises the control and initiates Starting parameters are controlled to minimize over-
the genset starting operation. shoots, take in account temperature, avoid alternator
overexcitation. Start attempts are automatically con-
Note : the non-automatic indicator will flash when the trolled, and cranking sequence may be programmed.
switch is in the ‘run’ position. Starting battery is checked during starting sequence.
. The ‘AUTO’ position enables the control to receive a
start signal from a remote location. AMPSENTRY PROTECTION

Emergency Stop Switch. AmpSentry protection is a comprehensive power moni-

toring and control system integral to the PCC that guards
A two position safety ‘mushroom’ head switch provides the electrical integrity of the alternator and power sys-
an easy and obvious means to immediately shut down tem from the effects of overcurrent, short circuit, over/
the genset in the event of an emergency condition. under voltage, underfrequency and overload. Current
is regulated to 300% for both single phase and 3 phase
faults when a short circuit condition is sensed.

issue 1.3 Apr. 99 page 27

Diesel Power Plant Project Guide CW 170 - CW 200

2.3.4 CW 200 GENSET CONTROL PANEL

SPEED GOVERNING SYSTEM
The speed governing system ensures the active power GCP means “GENSET CONTROL PANEL”. You need one GCP per
output of generator set, while voltage regulator man- installed generator set. In all cases, GCP contains equip-
ages the reactive power. The type of installation, the ment for synchronizing, paralleleing and load control
accuracy of frequency required, affect the choice of for paralleled operation.
speed governing mode. Two different operation modes
To choose your power plant panels and your auxilia-
are of interest, isochronous and speed droop modes.
ries panels, please refer to section 3 “power plants”
Isochronous mode maintains a fixed frequency regard-
less of load, while droop mode gives a decrease in speed
GENSET CONTROL PANEL SCOPE OF SUPPLY
or frequency proportional to load. Our governing sys- Panel contains all controls needed for a genset opera-
tems are basically operated in isochronous mode. Op- tion, and supports the interface for remote controls.
erating in isochronous mode involves that the gover- Start, stop, diesel governing, overspeed, alternator pro-
nor receives a signal when paralleled operation is pend- tective features and genset auxiliaries controls are in-
ing. If this signal cannot be delivered, the system shall cluded. Logic control of genset and auxiliaries is from
be operated in speed droop mode. For both these oper- programmable controller, genset actuator is controlled
ating modes, a load feedback signal is issued from gen- by speed electronic governor, with power feedback and
erator output measurement and treated in digital con- speed setting correction inputs. Generator operation
troller. is watched by multifunction programmable protection
relay. Some basic protections are preset, optional ones
PARALLELING REQUISITES may be programmed and enabled following customer
Our generator sets may be paralleled with other of same demand. HMI ( Human-machine interface) is through
or different type, if any one of the DG’s in the system annonciator, needle&digital indicators, buttons, and
has a proportional load control system. selector switches.
Paralleling of one generator set on an live bus, or par- Faults are grouped in two families: the minor faults
alleling a group of DG’s operating in parallel on a bus which requires operator corrective action; and the im-
with an infinite grid necessitates the receipt of a par- portant faults, which trips diesel generator.
alleling logic signal, as soon as paralleling breaker is
Integrated governing system is operable in isochro-
closed. This signal is mandatory to change the mode
nous mode or in speed droop mode, following installa-
of operation of voltage regulator and of prime mover
tion requirements. Change of mode is set through soft-
electronic governing system.
ware mean.
PANELS SELECTION Front face of panel bears the monitoring indicators for
Control panels are available as manufacturer standard, genset itself, as listedin table right.
and are finished according to user’s requirements.
Flowchart in chapter 3.3.4 precises shows implanta-
tion of GCP in a power plant control.

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CW 170 - CW 200 Diesel Power Plant Project Guide

PARALLELING DEVICES
Synchronizing equipment is implanted for operating - A synchronizing indicator allows the operator to check
genset in parallel. phases rotation.
- An automatic synchronizer ensures speed and volt- Functions listed in table below are available in stan-
age matching for synchronizing. It changes speed set dard control panels. Some additional alarms may be
point of electronic governor and changes voltage set added if needed or replaced by others (for example,
point of alternator through logic signals from control- radiator fans alarm replaced by raw water pump flow
ler or operator. detection).
- A live busbar phasing detector enables or disables the INDICATORS AND PROTECTIONS
synchronizer action on paralleling breaker,
see table below

Digital tachometer Single alarms

Running hours counter Cranking bar missing
Starting attempts counter
Control panel fault
Engine shutdowns
24Vcc fault
Lub oil pressure low (for idle and for rated speed)
Lub oil temperature high
Failure to start
turbocharger oil level low Fuel oil filter clogged
Prelubrication sequence failure (start inhibition) Lube oil filter clogged
Expansion tank level low-low Fuel daytank level low
Coolant temperature high Fuel daytank leakage
Coolant pressure low Dirty fuel oil level high
Control air pressure low
Expansion tank level low
Exhaust gas temperature high
Radiator fan fault (regrouped)
Overspeed
Starting air pressure low
Tachometry fault
Alternator data Water temperature low (inhibits rated speed)
3 x current Engine monitor regrouped alarm
3 x voltage Battery low voltage
Frequency Synchronizing failure (in GCP2 only)
Active power Fresh lube oil tank level low+high (if any)
Reactive power Used lube oil tank level high (if any)
Power factor
Controls and selectors
Energy totalizer
Operating mode selector switch (stop,
Battery voltmeter
manual, auto, test)
Alternator protections ANSI Code
Start/stop pushbuttons
Overcurrent / short circuit 50/51
Output breaker control pushbutton
Reverse power 32
Undervoltage / overvoltage 27 / 59 Manual control selector switch, (idle, rated,
Underfrequency / overfrenquency 81 / 81 synchro, loading)
Stator earth fault 51 N Emergency stop pushbutton
Phase balance fault 46
Load/speed control pushbutton
Loss of excitation 40
Fault reset pushbutton
Ground fault 59 U0 (optional)
Paralleling devices
Bearing overtemperature high+tripping 38
Winding over temperature high+tripping 49 Synchronizer
Differential protection 87 G (optional) Phase offset and bus voltage relay
Circuit breaker fault Phase indicator

issue 1.3 Apr. 99 page 29

Diesel Power Plant Project Guide CW 170 - CW 200

2.4 GENERATOR SET

2.4.1 GENERATOR SET CONSTRUCTION

Engines Resilient Mounts
The CW 170 and CW 200 oil engines are the prime mov- To prevent from structural born noise and vibration,
ers of the Cummins Wärtsilä Diesel Power Plants. The the generating set is mounted on rubber resilient el-
alternator is flanged on flywheel end of engine and ements (Anti-Vibration Mounts) , which are currently
generating sets are fitted on baseframe. The engine resting on the floor without sealing. Floor fixed ele-
crankshaft drives the alternator shaft through a flex- ments are provided on request.
ible coupling. Connections
Generator One set of flexible hoses for water, fuel-oil, air
The alternator is currently supplied with two roller starting and exhaust gases is supplied.
bearings. Stator frame rests on feets rigidly fixed on Wiring
baseframe
All electrical devices are connected to a terminal box,
Flywheel housing installed on the floor of the plant.
A flywheel housing is mounted between the engine
and the alternator. The flywheel housing secures a rigid
mechanical assembly without any special adjustment.

Two bearings
AC generator

Coupling housing

Resilient mounts Rigid bedframe

page 30 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

2.4.2.GENERATOR SET PERFORMANCES

Loading performance prime

t1 t2 Px t4 n1 t3
mover
Generator sets are built for high reloading performance.
16V170 10s 5.6s 60% 3.6% 4s
The stated values for loading performance are guid-
ance values, the generator power, capacity, excitation- 18V170 10s 5.6s 60% 3.6% 4s
regulation system influences values, as well as nature
of the load : resistive, capacitive, or inductive. These 12V200 12.5s(*) 5s 55% 6s 3% 2s
performances are for one generating set, on resistive
18V200 13.5s(*) 6.2s 60% 7s 6% 2.5s
load. Percentage value may be applied for multiple AC
generator sets working in parallel.

Values indicated for CW 170 are typical

Step reloading
t1 = minimum time for start and rated frequency & Px = Largest single load (active power value) which
voltage build-up. can be instantly applied, causing a speed drop of
10% or less. Load is percentage of nominal out
(*)For emergency generating set, the value could be
put COP.
reduced to 10 s with special booster equipment.
Sudden unloading
t2 = time elapsing before the speed has recovered
steady state (settling time). t3 = time for speed to recover steady state.
t4 = minimum delay between two load steps. n1 = overshoot at sudden unloading.

Starting of asynchronous motors

Note that if asynchronous motors of large size are to

be started by generator set, it is mandatory to consult
sales support to verify if alternator and excitation sys-
tem are able to comply. Generator type is mainly based
on this requirement.

issue 1.3 Apr. 99 page 31

Diesel Power Plant Project Guide CW 170 - CW 200

2.4.3 GENERATOR SET ARRANGEMENT

Following figures shows generator set general arrange-
ments. More details are enclosed in appended genset
drawings

CW 170 series

Low voltage genset with 16 V 170 engine

Low voltage genset with 18 V 170 engine

page 32 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

CW 200 series

Genset with 12 V 200 phase 1C engine

High voltage genset with 18 V 200 phase 1C engine

issue 1.3 Apr. 99 page 33

Diesel Power Plant Project Guide CW 170 - CW 200

2.4.4 GENERATOR SET CONNECTIONS

The CW 170 & CW 200 generating sets are delivered tion of each engine connection, flexible hose not
as standard with flexible hoses and exhaust compen- included.
sators
Please refer to job contractual documentation for fle-
The attached table gives the dimension and the posi- xible dimensions and conditions of installation.

16V170 18V170
connection dimension X Y Z X Y Z
408 HT water inlet 3" - 197.50 - 140 + 680 - 197.50 - 140 + 680
402 HT water outlet 3" - 48.50 - 191 + 680 - 48.50 - 191 + 680
451 LT water inlet 3" - 48.50 - 400 + 680 - 48.50 - 400 + 680
456 LT water outlet 3" - 197.50 - 423 + 680 - 197.50 - 423 + 680
101 fuel inlet 1" - 540 - 195 - 490 - 610 - 195 - 490
102 fuel outlet 1" - 540 - 350 - 490 - 610 - 350 - 490
105 fuel prim ing pump NA - 560 + 460 - 630 - 560 + 460 - 630
215 oil filling dia 60 - 200 + 240 - 580 - 200 + 240 - 580
216 oil drainage 1" + 140 - 605 - 60 + 140 - 605 - 60
301 starting air inlet 1" +1120 -790 -380 +1370 -790 -380
404 HT water perm anent venting 3/4" -625 -430 +1575 -625 -430 +1575
454 LT water permanent venting 3/4" -625 +450 +1575 -625 +450 +1575
+ 279 + 279
501 exhaust gas outlet ND 250 + 1050 + 1375 + 1194 + 1375
- 279 - 279
blind
according to alternator model
TB01 generator term inal box glandplate

page 34 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

* Framed gensets, delivered actually have the same connecting arrangement. Refer to enclosed genset drawings or
contractual drawing for crankshaft altitude from floor.

12V200 18V200
Connection Dimension X Y Z X Y Z
Units mm mm mm mm mm mm
701 Crankcase breathing Ø 4" 1945 - 520 1020 2845 - 520 1020
501-1 Exhaust gas outlet ND 250 - 200 520 1600 - 200 520 1600
501-2 Exhaust gas outlet ND 250 - 200 -520 1600 - 200 -520 1600
451 Cooling water inlet Ø 5" - 210 770 - 10 - 210 770 - 90
402 Cooling water outlet Ø 5" - 210 770 - 395 - 210 770 - 395
480 Cooling water prim. pump Ø 2" connected on inlet pipe, plant side
404 Cooling water outgasing Ø 1/2" - 110 465 1580 - 110 465 1580
301 Starting air inlet Ø 1" 2125 - 700 - 100 3025 - 700 - 100
215-1 Lub oil manual filling (std) Ø 61 - 255 750 335 - 255 750 335
215-2 Lub oil automatic filling (opt) Ø 1/2" - 445 - 655 - 465 - 445 - 655 - 465
216-1 Lub oil sump draining Ø 1" 0 - 180 - 650 0 - 180 - 650
101 Fuel oil inlet Ø 1" - 820 - 470 - 250 - 820 - 470 - 250
102 Fuel oil outlet Ø 1" - 820 - 600 - 250 - 820 - 600 - 250
103 Clean fuel oil leakage Ø 1" 1935 - 680 - 610 2835 - 680 - 610
104-1 Dirty fuel oil leakage Ø 1" 1935 -650 - 610 2835 -650 - 610
104-2 Dirty fuel oil leakage Ø 1" 1935 650 - 610 2835 650 - 610
blind
according to alternator model
TB01 Alternator terminal box glandplate
TB02 Display unit connector
TB03 Engine terminal box connector

TB 02 and Tb 03 boxes are on delivered on a support to fix on floor.

issue 1.3 Apr. 99 page 35

Diesel Power Plant Project Guide CW 170 - CW 200

2.4.5 GENERATOR SET HANDLING

Generator set handling (CW 170 and CW200)
Generator set is delivered packed in crates, which can Distancers shall mandatorily be disposed to main-
be handled using standard equipment. Handling points, tain air gap between slings and engine/alternator.
weight indication and adapted protections against me-
If two cranes are used for lifting, we recommend to
tallic slings are disposed at right place.
keep a level difference less than 3 cm per meter.
When unpacked, generator set shall be handled using
In any case, slings arrangement shall limit to a maxi-
lifting eyes disposed on baseframe. Two distancers,
mal 60° angle in all directions. Recommended lengths
available through Cummins Wärtsilä shall be disposed
of slings are indicated in table right.
as shown on figures below.
Lifting points on frame are disposed to ensure load
balancing.

Slings B

Distancers

Shacles A

Slings A

Shacles B

Shacles A

page 36 issue 1.3 Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

Generator sets to CW 16V and 18V 170&180 series( 16 to 21.5 tons)

CW 18V 200 & 220 series (32 tons)
be handled CW12V 200 & 220 series (23.5tons)

Handling system
16 to 30 tons 30 to 40 tons
weight capacity

Characteristics Number Type Length Force Number Type Length Force

Shacle A 10 or 12 regular NA 15 tons 10 or 12 regular NA 20tons

2 (for CW
Shacle B narrow NA 15 tons 2 narrow NA 20 tons
200&220 only)

textile textile 2.5 to 3.2

Sling A 4 2.5 to 3.2 m 15 tons 4 20 tons
preferred preferred m

metal or metal or
Sling B 4 2.5 to 5 m 15 tons 4 2.5 to 5 m 20 tons
textile textile

CW SMO CW SMO
Distancer 2 2 meters 20 tons 2 2 meters 20 tons
188 200 188 200

All weights in metric tons, tolerance +15% depending on optional features

Holes in CW 170/180 frames: 50 mm Holes in CW 200/220 frame: 80 mm Holes in CW distancer: 52 mm

Sling B

Distancer

Shacles A

Sling A

Shacle B

Shacle A

issue 1.3 Apr. 99 page 37

Diesel Power Plant Project Guide CW 170 - CW 200

3. Turnkey Power Plants

3.0 GENERAL
Cummins Wärtsilä proposes a large range of turnkey This performance is named “Energy Optimizer”. It is
power plants, including containerized power plants, based on our service know-how, return of experience
basic buildings for cost effective solutions and long- from numerous plants, getting constant improvement
life plants for heavy duty service. We can perform op- of predictive maintenance and monitoring techniques.
eration & maintenance, under a pluriannual contract.

Containerized power
plants are particu-
larily suitable for min-
ing power stations,
which have to be
moved with working
plant. (Minera Esc-
ondida, Chile)

Peak lopping power plants may be

built in residential areas, and oper-
ated with adequate soundproofing
equipment. ( Yorkshire Electric
Wakefield, England)

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CW 170 - CW 200 Diesel Power Plant Project Guide

Tecnic power plants

are built from our
standard components,
which , assembled,
constitute a tailor-
made solution. Envi-
ronmental constraints
such as high tempera-
ture and sand are cov-
ered by catalog item
equipment. ( Aden
Free Zone, Yemen)

We can install the CW 170 and CW 200

gensets in existing buildings .When they
are replacing medium or low speed gen-
erator sets, power generation capacity may
be increased without building extension.
Our technical office performs complete im-
plantation study, according to most ad-
vanced engineering rules, complying with
local regulations. ( Supreme Petrochem
and Arishta spinning Mills, India)

issue 1.3 / Apr. 99 page 39

Diesel Power Plant Project Guide CW 170 - CW 200

3.1 POWER PLANT BUILDINGS

3.1.0 GENERAL
Building regulations
This section describes the design principles of the Die- Planning and building legislation varies throughout
sel plants buildings. Typical layouts are shown in the the world. However the principles behind such legis-
appendices for various configurations. Due to local lation are almost always the same and have therefore
regulations and clients’ requirements this information been given due consideration. These principles are :
is a guideline only when establishing diesel Power
- Location suitability and environmental friendli-
Plants.
ness
3.1.1 BUILDING LAYOUT The “zoning plan” for a particular area dictates the
function and general appearance (size and height
The building is largely a reflection of the processes etc....) of buildings in the area.
that exists inside it. Not simply mechanical and elec-
trical processes but also processes involving movement - Structural stability
of people and maintenance activities.
The buildings structure must naturally withstand the
The main process movements can be summarized as pressures placed upon it by local conditions. Build-
follows : ing regulations decides the loadings that the build-
Process movements such as fuel, coolant, lubricating ing must be designed with. Other factors include
oil, electricity between the different components in- local weather conditions, inundation possibility, hur-
side and outside the building. ricane, risk for insect attack and, in the event of
People movements and in particular the relationships fire, the buildings ability to remain structurally stable
that exists between periodicity of movement and dis- long enough to allow emergency evacuation.
tance. Codes throughout the world differ in respect to re-
Equipment movements. How, when, where, what and quirements on structural stability and therefore the
why equipment shall be moved into and around the final structural arrangement of the building will dif-
building. This includes giving consideration to required fer. Extreme circumstances, such as risk for earth-
space during installation. quake, storm, require special consideration.
Piping, Ducting, and Cabling Fire Protection
In conjunction with process movements, consid-
The following questions are those most commonly
eration should also given to the media in which the
posed by fire authorities and have been taken into
movement takes place, i.e. piping and cabling. The
closer components are to each other the smaller the account when designing the building :
amounts of piping and cabling will be required and the I. What is the risk that the building will catch fire
cheaper the installations will be. Priority is given to ?
more expensive mediums such as exhaust gas piping
and power cabling. 2. What are the consequences of the building catch-
ing fire in terms of risk to persons ?
Processes are much more effective if pipes, ducts, and
cable runs are as straight as possible. Back pressure 3. How can the outbreak of fire be avoided ?
will be minimized in piping systems and disturbance
will be minimized in cable systems. 4. How can the spread of fire from one area of the
plant to others be avoided ?
When process arrangements are finalized and piping
and cable runs are decided upon an even distribution 5. Do persons inside the building have adequate time
of piping and cabling exists throughout the process to escape from the building before it collapses af-
related parts of the power plant. ter they have detected a fire ?

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CW 170 - CW 200 Diesel Power Plant Project Guide

6. Does the building design ensure the safety of fire may be called by automatic system (optionally). Gen-
fighting personnel ? erator set and auxiliaries of power plant are
immediatly stopped by an emergency shutdown or-
7. Should the building collapse, will surrounding build-
der, equivalent to local emergency pushbutton. We
ings and/or installations be damaged?
recommend to provide a dump line for the fuel and
oil service tanks, if it is possible(earthed storage
3.1.2 FIRE DETECTION SYSTEMS tanks), this draining is controlled by a remote puller,
placed outside. To limit oxygen entering air louvres(if
Fire detection systems are strongly advised to ensure motorized) shall be automatically closed.
personnel and equipment protection. Diesel generator
fire hazards are at the higher level, due to fuel and 3.1.3 NOISE LEVEL
high temperature presence. A good fire detection sys-
tem allows rapid fire fighting, by automatic or human
Local authorities are placing higher requirements on
means.
industries and thereby industrial processes we live
The core of fire detection systems is constituted by a in. The future promises further increases in require-
control unit, which receives fire information from sen- ments for environmental pollution control.
sors placed in critical locations. If a sensor is tripped, a
One form of environmental pollution is noise. The
fire alarm is given locally (and remotely on option), to
“technic” plant has been specifically designed to meet
ensure personnel evacuation and fire fighting action.
the residual noise level of today.
Fume sensors are to be placed away from fresh air inlet
A study of noise level requirements in European coun-
ways, to prevent fumes dilution. Air exhaust places are
tries showed that there are substantial differences
suitable. Temperature sensors are to be placed at high
between east and west and even differences between
locations, taking care that settings will not cause trip
regions within countries.
during hot seasons, or directly near the parts to be
protected, particularily in enclosures where fire takes “Technic” power plant has been designed with a double
place out of operator view. Emergency pushbuttons shall enclosure system. Sound is first attenuated by genset
be accessible any time, from all directions. They shall enclosure, and then by soundproofed building. Ven-
be positioned at a suitable height to allow operators to tilation, intake and exhaust systems are soundproofed.
localize them in seconds.
The detection center is to be supplied with a non-inter-
ruptible power supply. Internal batteries must operate
it for one month without reloading in the case of power
supply failure.
The fire alarm is given by a land audible alarm. Firemen

flame sound alarm

and fume
sensors
Equipment shutdown

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Diesel Power Plant Project Guide CW 170 - CW 200

3.1.4 GENERATOR SET FOUNDATION On the table below, the dimensions “A” and “B” of the
foundation are indicated for vell resting of generator
on top surface. They can be increased if block weight
The Cummins Wärtsilä generating sets are mounted on
is to be augmented, resulting in undergroung pressure
resilient elements and do not need special anchorage. The
reduction. Depth “C” is to be determined by civil engi-
standard rubber elements have a vibration filtration
neer according to concrete specific weight, including
efficiency of 95 %. For higher efficiency or special
re-bars. As indicative value, ferro-concrete regular den-
applications, other types of mounts can also be used.
sity is 2,4 t/m3 (150 lb/cu ft), taken in reference for
The foundation slab should be able to support the static calculation of “C” in table below. Basement shape is to
weight of the generating set. Usually, the weight of be designed according to soil resistance to maintain
the foundation should be at a minimum the weight of any time rated pressure.Building contractor shall pre-
the generating set. If, for any reason, elastic mounts pare ground to prevent foundation tilting.
are not used, block weight should be 125% of genset
If plant is built on a floating slab, it should have a
weight. Dynamic forces can be disregarded for iloted
400 mm thickness as a minimum and bear on a well
and paralleled operation(start, step loading, sudden
compacted soil, permanently drained and out of freez-
unloading) using our standard control equipment,
ing depth.
which prevents out of phase coupling .
3.1.5 MAINTENANCE FACILITIES
To prevent further operation costs, a power plant shall
be designed to allow maintenance tasks to be performed
with sufficient space to avoid use of special lifting
equipment, stopping and removal of adjacent units, or
partial building demolition. Each cylinder bank of die-
sel engine shall be provided with an overhead crane,
to ensure fast and easy maintenance.
The surrounding of a building shall allow cranes to
safety support the loads. When turning the crane, at-
tention is drawn to the fact that it can reach the ex-
haust stack; arrangement of handling area shall avoid
that. Trenches shall be stepped to allow a generator
set to be passed over, installing H profile irons for pas-
sage with skates or rolling bars. Pipes shall not pre-
vent bridge installation.
Trenches shall be well drained, and metallic mesh fit-
ted to prevent rodent intrusion.
Storehouses shall be protected from
large temperature variation, be free
Engine Weight of the Dimensions of the foundation(mm) of dust, humidity and ultraviolet
type genset (kg) (concrete spec. weight = 2,4) rays penetration ( windows are blue
in operation A B C painted and lighting is with incan-
16V170 20,500 6,500 1,900 700 descent bulbs).
18V170 22,000 6,500 2,000 700
12V200 28,000 7,000 2,000 830
18V200 37,500 8,000 2,400 810

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3.1.6 POWER PLANT ARRANGEMENTS

“BASIC” POWER PLANT

Main features
This power plant is designed for cost ef-
fective installation, allowing short time
commissioning and simplified servicing.
The whole building is erected on elevated
slab to prevent flooding. Structure of
building is made of steel, wall filling may
be corrugated steel or masonry. Blowers
are disposed on façades of building and
push air toward engine, transformer and
generator. Room ventilation is by natu-
ral convection effect, through large inlet
and outlet duct, when machines are
stopped.
The mechanical auxiliaries are positioned
near free end of engine to reduce piping
length.
The oil bath filter, placed outdoor takes
air at middle altitude to prevent dust
and exhaust hot air aspiration. Radia-
tors are grouped together to prevent hot
air recirculating. It is recommended to
place them 10 metres (30 ft) from the power sta-
tion.
genset number
Electrical room should be built in masonry to pre- with W P E H of
engine gensets
vent temperature changes and effects of condensa-
MV-HV
tion. It is placed in middle of the building to shorten 16V170
15.0 m 6.5m
18V170 2 to 8
power and control lines. Power cables may be routed 12V200
49 ft
5.0m
21 ft
5.5m
in trenches or on cable trays, overhead. 16' 5"
LV
18 ft
16.5 m 7.0 m
18V200 2 to 10
This arrangement includes an optional workshop 54 ft 23 ft

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Diesel Power Plant Project Guide CW 170 - CW 200

“TECHNIC” POWER PLANT

Main features, with sound proofing Power cables may be routed in trenches or on cable
This power plant is designed for temperate climate or trays, overhead.
hot climate countries, enhanced for sound attenua- Main features, without sound proofing
tion capacity and auxiliary equipment quality.The re- Generator set cells are to be removed,and a single
sidual noise level is 50 dB A @ 50 metres. exhaust silencer is suitable. We can design any kind
The basic principle is to build closed generator set cells, of power plant, adapting civil engineering to surround-
providing a first step of sound attenuation, and place ings and client requests.
them in a sound proofed building to obtain forecasted
sound attenuation. Generator sets can be operated
without necessity for an operator to enter the engine
rooms. Maintenance areas are reserved around
the generator set cells, providing the ability to
repair each generator set individually without
noise increase out of building.
The external structure of building may be made
of steel with insulating material or of concrete,
generator set enclosure is made of steel and
insulating material. Maintenance doors are pro-
vided for the generator set removal from the
building.
Combustion air is taken from the generator set
room. This fresh air is obtained from outside
by a fan through a sound trap. Air outlet is
also soundproofed. The exhaust line is equipped
with two high efficiency silencers.

Example of “Technic” building

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CW 170 - CW 200 Diesel Power Plant Project Guide

Floor level plan view

genset A B C D

16V170

18V170 10.0m (33') 5.7m(18.7') 3.4m (11') 14.5m (47.6')

12V200

18V200 11.0m (36') 5.9m (19.4') 3.6 (11.8') 15.5m (60')

issue 1.3 / Apr. 99 page 45

Diesel Power Plant Project Guide CW 170 - CW 200

“ARCTIC” POWER PLANT

Main features
This power plant is designed for cold climate coun- through a sound trap. For winter, inlet air can be pre-
tries, with sound attenuation and equipped with air heated. Air outlet is also soundproofed. Exhaust line
preheaters. is equipped with two high efficiency silencers.
The basic principle is to build closed generator set cells, Power cables may be routed in trenches or on cable
providing a first step of sound attenuation, and place trays, overhead.
them in a sound proofed building to obtain forecasted
sound attenuation. Gensets can be operated
without necessity for operator to enter the
engine rooms. Maintenance areas are reserved
around the cells, providing ability to repair
individually each generator set without out-
door noise increase.
The external structure of building may be
made of steel with insulating material or of
concrete, generator set enclosure is made of
steel and insulating material.
the roof is made of corrugated steel, with a
slope for snow melting water easy flowing
down
Facade removable panels are provided for genera-
tor set exit from building, following a right way.
Combustion air is routed in a separated duct,
and cell is fed with fresh air by fans operated

Example of arctic building

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Floor level plan view

genset A B C D

16V170

18V170 10.0m (33') 5.7m(18.7') 3.4m (11') 14.5m (47.6')

12V200
18V200 11.0m (36') 5.9m (19.4') 3.6 (11.8') 15.5m (60')

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Diesel Power Plant Project Guide CW 170 - CW 200

3.2 Containerized Power plants

3.2.0 GENERAL
Containerized power plants are designed to be EASILY Operating power supply needs (25 to 50 kW per gen-
AND QUICKLY DELIVERED ALL OVER THE WORLD, AND INSTALLED IN A VERY erator set) for preheating and starting, and fresh wa-
SHORT TIME. Size of containers is the same for all the ter delivery for cooling circuit top-up.
prime movers of the Diesel Power Plants range. The LOW
Black-start containerized power plant can be provided
SOUND LEVEL of soundproofed container is 85dbA at one
on request.
metre distance around the container.
Installation of radiators
Modularity
Radiators should be installed at ten metres distance
Power plant functions are enclosed in two kinds of
from mechanical containers, to prevent recirculating
containers, one 40ft for all kind of diesel generator,
of exhaust gases through the radiator. If multiple ra-
and 20ft or 40ft container(s), air conditioned, for elec-
diators are installed, it is recommended they are
trical equipments. Radiators are delivered separately
grouped, ensuring the lateral air inlet section is equal
for installing near the mechanical container. Step-
or more than the top surface of bundle. This arrange-
up power transformers are situated outside. Prepared
ment ensures fresh air can reach the central blowers.
cables are available for interconnecting mechanical
If these rules are followed, recirculating of hot air ex-
and electrical containers. External cooling piping ma-
iting radiator is minimized.
terial is delivered raw. All the external equipment (si-
lencers, radiators, ventilation) is delivered in a sepa- Exhaust stack
rate container. If exhaust lines are grouped in a common stack, each
A workshop container, with air conditioning may be engine exhaust shall be routed separately.
ordered as an option. Civil works
Free areas should be provided between containers, with
3.2.1 INSTALLATION REQUIREMENTS separated trenches for pipes and power cables. Control
and instrumentation cables may be eventually installed
Containerized plant is intented to allow quick instal- over the pipes, but never be routed with power cables.
lation on a paved area. Cable and pipe trenches can be Trenches shall be well drained, by a large section free
provided for multiple generator sets interconnection. running pipe.
Slab flatness fault should be lower than 30 mm on the
whole resting area of generator set container. Hori- The slab shall be layed on a compacted and well drained
zontal tolerance is 10 mm per metre. Slab resistance area. Slab around containers shall be able to support
shall be sufficient to support indicated weights only. the weight of the generator sets when removing from
There are no significant dynamic forces during opera- container, and surrounding shall provide free and solid
tion. base for operating the loading cranes.

There is no need to seal the containers, only the radia- A paved or gravelled area shall be layed under radia-
tor and electricals container are to be fixed by bolts tors, to prevent dust clogging.
against the effects of storm.
Local scope of supply is mainly the storage tank for
the power plant, the fuel oil piping between storage
and container, the electrical distribution system and/
or switchboard.

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CW 170 - CW 200 Diesel Power Plant Project Guide

3.2.2 MECHANICAL CONTAINER DESCRIPTION

Fire detection
The mechanical container is designed to support the Fuel and lube oil storages are situated in a separated
heaviest generator set of CW170 and CW200 genset section of the container, to minimize fire risk.
range (CW 18V200-35tons). It is composed of a struc-
A fire detection system is provided, including flame
ture with eight welded ISO corners, on which is as-
and fumes (or CO2) detection, and with fire fighting
sembled the sound proofing means. This soundproof-
alarm, shutdown of generator set and fuel supply cut-
ing is ensured by the side panels & doors, and the
off. On request, an extinguishing system can be pro-
ventilation sound traps. The side panels are inter-
vided; its nature depending on local regulations, wa-
changeable with the doors; they can both be easily
ter availability, and fire fighting arrival delay.
removed by two operators. The daily maintenance on
the engine (access to the cylinder head...) is facilitated Maintenance facilities
by two large doors of 3.6 m on each side of the engine. Two 500 kg overhead cranes slide over each cylinder
These two doors are composed of four panels, and are head row. They can also be used to remove the turbo-
completed by a canopy for protection against the sun charger. Additional cables and piping can be fixed over-
or the rain. head on rails inserted in the roof. In case of heavy
Integrated auxiliaries maintenance, all the façades can be removed in order
to access the whole generator set or to put it out of
All mechanical auxiliaries are installed inside the con-
the container, axially or transversally.
tainer, ensuring standby, starting and operative servi-
tudes. A 1000 liters fuel service tank and 500 liters The manufactured genset is sent ready to connect and
lube oil combinated reservoir is provided. Ventilation to start. All the external equipment (sound baffles, ex-
is directed first on to generator and then passes along haust silencer, ...) are shipped in own container, and
the engine before exiting container. The air intake of mounted on site.
the engine can be fitted inside or outside of the con-
tainer, if an oil bath filter is needed. Standard connec-
tions are identical for all containers : four flanges 5”,
PN16 (cooling circuit) and four 1”1/2 male unions
(fuel oil, lube oil).

Example of containerized power station, soundproofed, for a 18V200 genset

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Diesel Power Plant Project Guide CW 170 - CW 200

3.2.3 CONTAINERS INSTALLATION

Containers are delivered on site with ventilation, in- rately. Please follow indications of chapter 3.2.4 for
take and exhaust silencer removedand packed sepa- handling.
container sectional view

container overview

Containers dimensions in millimeters and (feet)

(elec container of 20' length, type ISO 1CC, not represented)

L1 L2 W1 W2 H1 H H2
(meca) (elec) (meca) (elec) (meca) (meca) (elec)

12,192 6,058 2,438 2,438 3,700 7,150 2,591

(40') (20') ( 8') ( 8') (12'5") (23' 5") (8' 6")

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CW 170 - CW 200 Diesel Power Plant Project Guide

“Container mono” power plant

The figure below shows the installation of a container ing an external oil bath filter. Care must be taken to
based power plant with a single diesel generator. Slab place it at distance from the container to prevent the
dimension of this example is adapted for equipment hot air exiting ventilation to be reaspirated.
placing. Square arrangement reduces the operator’s
The fuel oil storage tank may be grounded or be in-
walking during production and cables/pipes lengths
stalled near the slab. If step-up transformeris provided,
are shortened. The advised thickness of slab is 25 to 30
it should be placed near electrical container, with ad-
cm of concrete, on stabilized soil.
equate fences.
If cables are routed on external trays, an electrical
Every time, area facing the compressor end of con-
container is to be installed on an elevated foundation
tainer shall be maintained free to allow the genset to
(out of our scope of supply) to allow bending radius of
be handled out of the container for maintenance pur-
power cables entering down the cubicles. If cables are
poses. Free area shall be reserved for cranes and load-
routed in trenches, or in ducts, the electrical container
ing truck to operate at short distance.
is rested directly on the floor. Installation shown be-
low is for hot climate and dusty atmosphere, requir-

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Diesel Power Plant Project Guide CW 170 - CW 200

“Container multi” power plant

The figure below shows the installation of a container low is for hot climate and dusty atmosphere, requir-
based power plant with a single diesel generator. Paved ing an external oil bath filter. Care must be taken to
area dimension of this example allows more space than place it at distance from the container to prevent the
in a mono container power plant, because equipments hot air exiting ventilation to be reaspirated.
removal needs an elevator or a crane to operate be-
The fuel oil storage tank may be grounded or be in-
tween containers. Square arrangement reduces the
stalled near the slab. If step-up transformeris provided,
operator’s walking during production and cables/ pipes
it should be placed near electrical container, with ad-
lengths are shortened. Required thickness of slabs under
equate fences.
mechanical containers is 25 to 30 cm of concrete, on
stabilized soil. Other areas ( passages between con- Every time, area facing the compressor end of con-
tainers) may be bituminizeded, allowing resistance for tainer shall be maintained free to allow the genset to
trucks, elevators and cranes implementation. Paving be handled out of the container for maintenance pur-
shall be completed before equipment delivery on site. poses. Free area shall be reserved for cranes and load-
ing truck to operate at short distance.
If cables are routed on external trays, the electrical
container is to be installed on an elevated foundation
(out of our scope of supply) to allow bending radius of
power cables entering down the cubicles. If cables are
routed in trenches, or in ducts, the electrical container
is rested directly on the floor. Installation shown be-

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CW 170 - CW 200 Diesel Power Plant Project Guide

3.2.4 CONTAINERS HANDLING

Single generator set is installed (container mono) The containers are of ISO type, but the genset con-
The power plant will be composed of a 40 ft mechani- tainer requires handling special care, using the beams
cal container including the generator set & associated and attachements if they are delivered with the con-
mechanical auxiliaries and an electrical container in- tainer. Maximal angle of slings shall be 30°, as shown
cluding generator set control, power measurement below. Generator set container shall be stored on a paved
equipment and output switchgear. (CW12V170 and 16V or compacted area to prevent structure deformation.
170 generator set containers includes all these items).
Flatness fault should be less than 5 cm on total length
of container. The electrical container and auxiliary
equipment container may be handled without particu-
Single set arrangement lar precaution.
Mechanical Electrical crane 1
type of engine Auxiliaries
container container crane2
customer slings
CW 16V170
CW 18V170 radiators, fuel
One 40 ft One 20 ft storage, combustion
CW 12V200 air filter, eventual beams and attachemen
container container ts
CW 16V200 step-up transformer
CW 18V200

Two or more generator sets are in-

stalled : (container multi)
The power plant will be composed of some mechanical handling of 40”genset container
containers each including one generator set, its auxil-
iaries, and one electrical container where are located
Genset Control Panel GCP, switchgear and measurement
cubicles, Power Station Control Panel PSCP and Auxil-
iaries Control Panel ACP, common for all generator
sets. This electrical container may be adapted to the
wish of the client, on option.

handling of other containers

Multiple set arrangement Genset with engine: Weight (metric tons)

Diesel generator Electrical
"Loose" auxiliaries
40"containers container CW 16V170 40.5
One 40 ft CW 18V170 43.0
2 to 3 containers
container
Radiators, fuel CW 12V200 48.0
two 40 ft storage tanks,
4 to 6 containers
containers heavy duty intake
air filters, eventual
CW 18V200 57.0
Three 40 ft step-up
7 to 9 containers
containers transformers. electrical container 20" 6.0
10 to 12 four 40 ft
containers containers
electrical container 40" 12.0

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3.2.5 ELECTRICAL CONTAINER DESCRIPTION 3.2.6 CONTAINER SINGLE LINE DIAGRAMS

The electrical container encloses the generator set con- Single line diagram for one generator set
trol, output measurements, auxiliaries supply, and black The diagram below shows a low or medium voltage con-
start batteries. Electrical container is designed to be tainer with step-up transformer, installed outside, sup-
the operator’s working location, and for this purpose plying a local bus.
is air conditioned. Electrical equipment remains under
controlled ambient conditions and is protected against Genset delivers power through a circuit breaker and an
engine fire hazards. It contains : isolator switch to allow safe maintenance when bus is
live. Genset output is manually groundable when iso-
- GCP Genset Control Panel; lator and breaker are open. A measurement voltage
transformer (2) is provided for generator set. It is pro-
- Power equipment as shown on following single line
tected by fuses, on primary and secondary windings.
diagrams; Current transformers (1) are built-in generator set out-
- PSCP Power Station Control Panel, if multiple con- put cell or in generator terminal box.
tainers are to be paralleled in load sharing mode with The primary of auxiliary tapping transformer is pro-
offsite power. tected by fuses and isolated by switch isolator, even-
tually motorized. The secondary of transformer out-
Power plant switchgear is made, using standard equip-
puts three phases and neutral supply. Fuse(s) melting
ment. Particularities of network or client interfaces
opens isolator. A double earthing system allows the
are adapted on request.
change of fuses having cancelled any cable capacitor
residual voltage.
A bus measurement voltage trans-
former is provided, for synchroniz-
ing purposes of diesel generator. Pri-
mary is protected by an isolator and
by a fuse.
Output to local bus delivers power
through an isolator. Plant output
bus is manually groundable when
isolator is open.
Interlocking system is defined ac-
cording to local network modes of
operation.

T11 step-up transformer

T 12 step-down transformer

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CW 170 - CW 200 Diesel Power Plant Project Guide

Single line diagram for multiple generator sets

The diagram below shows a low or medium voltage pro- Primary of auxiliary tapping transformer is protected
duction power plant, supplying an offsite network or by fuses and isolable by isolator, eventually motor-
a local bus through step-up transformers. ized. Secondary of transformer outputs three phases
and neutral supply. Fuse melt opens isolator. A double
Each generator set delivers power through a circuit
earthing system allows the change of fuses having can-
breaker and an isolator to allow safe maintenance when
celled any cable capacitor residual voltage. Step down
bus is live. Genset output is manually groundable when
transformer is protected by fuses on primary.
isolator and breaker are open. Current and voltage trans-
formers are built in power output cell. This equipment Plant bus delivers power through an isolator switch
is installed in electrical container, as well as Genset and a circuit breaker to allow safe power plant mainte-
Control Panel (GCP2). nance when utility is live. Voltage measurement on
utility is provided in circuit breaker cell, and may be
The step-up transformer is installed outside for better provided in separated cubicle if utility voltage cannot
cooling. It is a sealed transformer, with DGPT2 protec- be switched off breaker output side. Plant output bus
tion. is manually groundable when isolator and breaker are
A measurement voltage transformer is provided for bus open.
synchronizing purposes. Primary is protected by an Optionally, two tapping tansformers may be provided.
isolator and fuses. Multiple output breakers may also be provided on re-
quest.

T11 step-up transformer

T 12 step-down transformer

issue 1.3 / Apr. 99 page 55

Diesel Power Plant Project Guide CW 170 - CW 200

3.3 Electrical systems

3.3.0 GENERAL 3.3.1 POWER GENERATION
The following pages describe the Power generation sys- Electrical power generation is ranged from low volt-
tems, up to power plant bus end. Distribution systems age 400V to medium (high) voltage 13.8KV. Depend-
are not covered here. Standard equipment allows mul- ing on the purpose of Diesel Power Plant, diesel gen-
tiple functions regarding the generator set(s) modes erators may be operated in various configurations:
of operation. Basically, our power plants are operated
- single generator set supplying an isolated bus,
in an isochronous speed mode, or in droop mode on
request. They may be paralleled with an utility, and - multiple generator sets paralleled supplying an iso-
power managing is realized through digital controls. lated bus,
Described functions are applicable for all available gen- - multiple generator sets paralleled with infinite power
erator sets from CW 170 or CW 200 engines. network.
Versatile solutions are available to manage power, us-
ing a modular arrangement of standardized compo-
nents.

TO BUS OR GRID

ACP PSCP GCP measures output draw-off Genset1 Genset n

auxiliaries
transformer

Plant auxiliaries
Optional

Step-up transformer
If voltage > 13.8 kV

page 56 issue 1.3 / Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

3.3.2 POWER PLANT SINGLE LINE DIAGRAMS

Single line diagram for isolated system,
Medium voltage generators
The diagram below shows a medium voltage produc- motorized. Secondary of transformer outputs three phases
tion power plant, supplying an isolated grid. At the and neutral supply. Fuse melting opens switch isolator. A
top of the cell, an item number indicates standard cu- dual earthing system allows the change of fuses having
bicle. The width of cell is indicated just below for stan- cancelled any cable capacitor residual voltage.
dard items. If other cells are used, arrangement and
width may be different, but single line diagram re- Output toward local bus delivers power through an iso-
mains the same. lator and a circuit breaker to allow safe power plant
maintenance when bus is live. Plant output bus is manu-
Each generator set delivers power through a circuit ally groundable when isolator and breaker are open.
breaker and an isolator to allow safe maintenance when
bus is live. Genset output is manually groundable when A measurement voltage transformer incorporated in
isolator and breaker are open. breaker cell is provided for bus (not needed for dead
bus). Primary is isolated by a isolator and protected
A measurement voltage transformer is provided for each by a fuse, secondary is closed by interruptor and pro-
generator set. It is protected by fuses, on primary and tected by a fuse.
secondary windings. Current transformers are in gen-
erator terminal box or in the circuit breaker cell. Two neutral grounding solutions are shown here: Op-
tion A is a low impedance grounding, and optionB is
Primary of auxiliary tapping transformer is protected an artificial neutral point for multiple generators with
by fuses and isolated by switch isolator, eventually fault current limiting resistor on secondary of trans-
former.

Neutral
grounding
option B
32851 32826 32826 32851 32826 item

1000 1000 1000 width

To local bus

Neutral
grounding
option A

issue 1.3 / Apr. 99 page 57

Diesel Power Plant Project Guide CW 170 - CW 200

Single line diagram for baseload

The diagram below shows a low voltage production tral supply. Fuse melting opens isolator. A dual switch
power plant, supplying an offsite network through step- earthing system allows the change of fuses having
up transformers. At the top of cell, an item number cancelled any residual voltage.
indicates standard model. The width of the standard
Output toward local bus delivers power through an iso-
cell is indicated just below. If other cells are used, lator and a circuit breaker to allow safe power plant
arrangement and width can be different, but single maintenance when bus is live. Plant output bus is manu-
line diagram remains the same. ally groundable when isolator and breaker are open.
Each generator set delivers power through a circuit A measurement voltage transformer is provided for
breaker and a isolator to allow safe maintenance when grid, incorporated in output btraker cell. Separated
bus is live. Genset output is manually groundable when voltage measurement cell is optional. A phasing trans-
isolator and circuit breaker are open. Current and volt- former is provided on secondary to allow proper syn-
age transformers are built-in to generator. chronizing.
The auxiliary tapping transformer is protected by fuses Neutral grounding is to perform according to the one
and isolated by switch isolator, eventually motorized. chosen for the grid operation.
Secondary of transformer outputs three phases and neu-

item 32811 32811 32851 32826

width 1000

To grid

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CW 170 - CW 200 Diesel Power Plant Project Guide

Single line diagram for power

management
The diagram below shows a low or medium voltage pro- by fuses and isolated by switch isolator, eventually
duction power plant, supplying an offsite network and motorized. Secondary of transformer outputs three
local consumers through step-up transformers. At the phases and neutral supply. Fuse melting opens isola-
top of the cell, an item number indicates standard tor. A double earthing system allows the change of
model. The width of the standard cell is indicated just fuses having cancelled any residual voltage.
below. If other cells are used, arrangement and width Output toward offsite grid delivers power through an
are different, but single line diagram remains the same. isolator and a circuit breaker to allow safe power plant
Each generator set delivers power through a circuit maintenance when bus is live. Plant output bus is manu-
breaker and a isolator to allow safe maintenance when ally groundable when isolator and breaker are open.
bus is live. Genset output is manually groundable when A measurement voltage transformer is provided for
isolator and breaker are open.Genset current and volt- grid, incorporated in output btraker cell. Separated
age transformers are built-in generator. voltage measurement cell is optional. A phasing trans-
Output toward local bus(es) passes through a hand- former is provided on secondary to allow proper syn-
controlled switch isolator, which may be motorized. chronizing.
Bus is groundable when isolator is open. Neutral grounding is to perform according to the one
Primary of auxiliary tapping transformer is protected chosen for the grid operation.

item 32811 32811 32846 32846 32851 32826

width 1000

To grid

issue 1.3 / Apr. 99 page 59

Diesel Power Plant Project Guide CW 170 - CW 200

3.3.3 POWER DISTRIBUTION EQUIPMENT

Medium Voltage Switchgear
Medium voltage switchgear contains breakers for genera- tropical climates, and in acid industrial atmosphere.
tor sets outputting, measurement transformers for com- Use of tinned copper ends is recommended for all these
mon part of governing systems, and tapping power switch- situations.
ing.
The CW generator set range allows to use, in most of
Location of the MV switchgear the cases, the following series in MVV cubicles:
The switchgear is normally located in the main control • Rated current 630A ( busbar and breakers)
building. It is important to install the equipment in
such way that operation, maintenance and supervi- • Rated short circuit current 12.5 kA
sion can be performed safely and easily. See our in-
stallation documents for further information.
• Voltage range 3.3 to 20 kV
Breaker Types Step-up transformer
The SF6 breaker is the most commonly used type in the Some generator sets are installed with transformer in-
medium voltage range. Standard breaker is of truck-type stalled close to generator, with a direct busbar or cable
(can be withdrawn), making it easy to interchange and connected between generator and transformer. These
maintain. It has a high current breaking capacity. The transformers are self-cooled, and fully enclosed type.
isolating gas is SF6 (Sulphurhexafluoride). A “DGPT2” oil pressure, temperature, and level
combinated protection is delivered as standard. We
The load breaker is used for switching load currents . The advise care, when installing transformers, to allow
LB (Load Breaker) is completed with fuses for breaking proper ventilation to prevent overheating.
short-circuit current. An arrangement is provided for
tripping the breaker if one of the three fuses blows. The
Station auxiliary transformer
load breaker is normally used for protection of trans- For the power plant auxiliaries a tapping transformer,
formers or DG output. connected from the MV switchgear to a main LV distri-
bution board, is used. This provides the power supply
Optional breakers may be defined “tailor-made” regard- for the power plant various auxiliaries, such as heat-
ing the network requirements, the client preferences, ers, pumps, radiator fans, compressors....
the voltage and the operation requisites (ambient, pos-
sible overloads, maximum opening delay required for con- The transformer is of sealed oil cooling type, to be
sumers protection, number of openings at full load per installed indoor or outdoor. A “DGPT2 “ protection does
day....) not need an oil retention system.
Busbar System Location of the transformers
The units in a MV switchgear are interconnected by Transformers are “self cooled”. When they are located
busbar system. The required area and rated current in a switchgear room or in a separate area, it is impor-
for the busbars, depends on the voltage, number of tant to provide the transformer with sufficient cooling
power generation units, connected short-circuit cur- air. The temperature rise of the air should not exceed
rent, protection class of the switchgear and spare ca- 10°C to provide an acceptable cooling capacity. Gener-
pacity required for future extension. Our advice is to ally, an air flow of 5m3 per minute and kW loss is re-
prohibit aluminium busbars in humid, maritime, and garded as an acceptable ventilation rate.

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CW 170 - CW 200 Diesel Power Plant Project Guide

Neutral Grounding System

There are numerous methods for local neutral grounding impedance grounding resistor that limits the earth fault
of the generator. This depends on past practices, ground- current to about 5 to 15 Amps . This system is simple to
ing philosophy and local electricity board regulations. realize ( if existing bus or grid allows to make it) and
ensures proper protections selectivity in most of the cases.
Our recommendation is to ground neutral through a low

Common LV solution Preferred HV solution

N.E.T. N.G.R.
.

Ie>100A

e < 100A

Floating Direct Impedance Resistance Resistance

(low ohm ic) (high ohmic)

NEUTRAL GROUNDING PHASES INSULATION PROTECTION HUMAN BODY DAMAGE RESULTING OF

OPERATING PRINCIPLE
PRINCIPLE NEEDS SELECTIVITY PROTECTION FAULT

very good
lowers the fault very important due
neutral directly low level is selectivity, dangerous while
overvoltage to high fault
grounded. needed. 1st step trips fault is pending.
occurences. current.
generator.

phase/ground safe if first step equipment not

isolated neutral or determination and
allows to continue insulation shall be detection is well damaged due to nil
neutral grounded setting of first step
operation with 1st equal or higher set. Fault searching or limited current.
through high is not easy, 2nd step
step fault pending. than phase/phase shall be immediatly (fault current lower
impedance. trips generator.
insulation. performed. than 3 amps)

equipment is not
simple protections
permanent fault heavely damaged,
neutral grounded may be used with
current is limited, regular insulation good protection by power is dissipated
through low good selectivity. 1st
and internal surge system is suitable. voltage limitation. in impedance. (fault
impedance. step trips
is limited. current is betwen 3
generator.
and 50 amps)

Fault current is
limited as soon as selectivity is large voltage surge
neutral grounded
it appears. (suitable regular insulation ensured if IL>>Ic may be caused equipment may be
through a
for extended system is suitable. network. 1st step when fault is damaged by surge.
reactance system
distribution trips generator. eliminated.
networks)

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Diesel Power Plant Project Guide CW 170 - CW 200

3.3.4 POWER PLANT CONTROL

Synchronizing features Soft loading and unloading
Automatic synchronizing feature is included in our The load can be gradually increased to a preset level to
genset control panels, for each generator set, against get a smooth load transfer when paralleling a genera-
offsite power. This feature is measuring live bus phas- tor set onto a live bus. When generator set is going to
ing and frequency, and changes the speed of generator be stopped, the load is gradually decreased to preset
set to match them for synchronizing. The bus voltage level (gapload) before the generator set is separated
is measured and a correction signal is sent to the volt- from the parallel system. Automatic orders are gener-
age regulator to equalize voltages. As soon as these ated by power plant digital control built in PSCP pan-
parameters are matched in preset tolerance, instant els, and loading/unloading ramps are controlled by
order is sent to the paralleling breaker for closure. Angle generator set GCP panels, or by PowerCommand™ su-
and voltage errors are preset 50 % under acceptable pervisor.
limits by generator. We recommend to start and syn- Multiple generator set management
chronize gas fueled generators one by one with offsite
This feature provides for automatic start and stop of
power.
generator sets depending on the actual load level and
Load control modes the loading set point. The paralleled generator sets
Load control of a single generator set on an isolated may be controlled in load sharing or in baseload mode.
bus, is achieved by the actual load caused by consum- When the load increases to a preset level, an auto-
ers. Governing system controls only the speed for rated matic start order will be given to the next selected
any time. generator set. After synchronizing, the unit will share
the load with the other units in the parallel system or
Load control of paralleled generator sets may be com-
deliver its baseload rating.
pleted by two ways :
The system will switch off generator sets when the
- The load is preset in generator set control panel, and
load setting decreases, but only after carrying out a
is maintained as long as generator set is operated in
control, confirming that the remaining generator sets
parallel : this mode is called Baseload. Load of gen-
will not be overloaded. These functions are supported
erator set does not change, output of power plant is
by PSCP3 panels.
multiple of operating generator sets.The common
panel PSCP sets the load step and starts automati- Plant Power Management
cally the generator sets to fulfill load step. Power management is applicable for situations where a
- The load is proportionnally controlled in power plant power plant is operated in parallel with an offsite power
common panel, and all the paralleled generator sets network, with or without a local load of consumers. The
are sharing proportionally the load : this mode is called global power of plant is managed under operator con-
load sharing. Load of generator set changes accord- trol, and the generator sets are operated in load sharing
ing to the power plant global output and/or accord- mode. Multiple generator set management feature is en-
ing to the number of generator sets operating on the abled as described above.These functions are supported
bus. Gross output of power plant is set by operator, by PSCP panels, or by PowerCommand™ system .
through PSCP panel .

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CW 170 - CW 200 Diesel Power Plant Project Guide

3.3.5 PLANT CONTROL PANELS

PSCP choice
PSCP means “Power station control panel”. Choose PSCP2 if generator sets are operated together
paralleled with an infinite power network, and you
You need one PSCP for the power plant, as soon as 2
will operate them as baseload power plant (load is con-
or more generator sets are installed. All PSCP panels
trolled at set point for each generator set).
contains control for starting generator sets following
power demand. This control is programmed accord- Choose PSCP3 if generator sets are operated together
ing to site requisites. on local consumers & paralleled with an infinite power
network, and you will operate them with power im-
Note:
port-export control towards offsite power (load is shared
PSCP1, PSCP2, PSCP3, panels are suitable both for between generator sets to fulfill power setting by im-
diesel and gas plants, without cogeneration. port-export control in PSCP3).
Choose PSCP1 if generator sets are operated together follow below flowchart to determine suitable panel,
on an isolated bus, without paralleling with infinite then, look in data sheets for further information
power network. Load is equally shared between gen- PSCP panels description
erator sets.
The panel contains all controls needed for a power plant
operation, and supports the interface for logic remote
controls. Power plant Start/stop controls are included.

START

GCP

NO YES
n > 1 Genset

PSCP not required

ACPx required

NO Synchronizing with YES

grid Power management Global cogen plant
Base load operation import-export power
Isolated plant import-export load shedding management
load shedding auto resynchro

PSCP1 PSCP2 PSCP3 PSCP4

+ ACPx + ACPx + ACPx + ACPx

(1) (1) (1)

issue 1.3 / Apr. 99 page 63

Diesel Power Plant Project Guide CW 170 - CW 200

OPERATOR’S CONTROLS GOVERNING EQUIPMENT

Control from operator is local on front panel, or remote, Governing of each genset is ensured by a standard elec-
by logic signals. Main controls and monitors are: tronic governor, with a power control entry. PSCP digi-
tal controller sets the power input signal in genset
Operating mode selector swich: manual, auto.
governor, when DG is operated in parallel. Progressive
Start-stopDG’s, plant output breaker control PB’s. loading, load shedding, progressive unloading are con-
Voltage, current, frequency, active and reactive power, trolled by PSCP digital controller.
power totalizing indicators are disposed on panel front SYNCHRONIZING HARDWARE
face.
PSCP2 and PSCP3 panels includes a solid state syn-
DIGITAL CONTROLLER chronizing equipment, to synchronize whole power
plant , unloaded (PSCP2) or supplying local consum-
Core of system is a programmable controller, which
ers, (PSCP3) with utility, before paralleling it.
controls the gensets starting, stopping, automatically
according to power demand. Global power of plant is - An automatic synchronizer ensures speed matching
also set by the controller, from preset threshold or by for synchronizing with offsite network. It changes speed
operator control. set point of all governors of gensets operated on the
bus;
Controller delivers orders to start gensets, when power
demand or power control leads to increase plant out- - A live busbar phasing detector enables or disables
put. Generator set synchronizing orders are issued the synchronizer action on main paralleling breaker,
from the PSCP controller, but synchronizing sequence
- A synchronizing indicator allows the operator to check
of each genset is performed and controlled in GCP2
phases rotation.
panels. As soon as a genset is paralleled, PSCP control-
ler ensures progressive reloading of this genset, up to: Paralleling may be performed manually using
synchronoscope.
- proportional sharing of power demand,for PSCP1panels
- Genset individual preset baseload for PSCP2 panels, PANELS CONSTRUCTION
- equal sharing of actual load, set by import-export PSCP panel may be operated in ambient temperature
system, for PSCP3 panels. between +15 and +50°C,90% RH without condensa-
tion. A heater-blower ensures the inner parts of panel
to be kept some degrees over ambient, to prevent con-
densation.

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CW 170 - CW 200 Diesel Power Plant Project Guide

3.3.6 AUXILIARIES CONTROL PANELS

All the previous panels (GCPs and PSCPs) have to be numberous or powerful radiator fans if any. Contactors
supplied with a three phase LV line. This power supply of genset auxiliaries are included in Genset Control
is coming from the existing installation and/or from Panel (GCP)
the auxiliary transformer. The role of the ACPs is to
Following flowchart guides choice of ACP for your
distribute LV triphase power to all the panels and the
project.
plant auxiliaries. The ACP control panels principle dia-
grams are pre-elaborated, but panels are built accord- ACP0 is an extension for GCP or PSCP panels
ing specific needs of each project. Size, enclosure na- ACP1 is common auxiliaries panel containing bus, fuses,
ture and power diagrams are nearly the same for each contactors and protections.
project.
ACP2 is ACP1with counting OR low voltage source
ACP are available as manufacturer standard, and are switch normal/backup, for black start purposes.
adapted to used auxiliaries . ACP means “AUXILIARIES
CONTROL PANEL”. This control panel, currently known un- ACP3 is ACP1with counting AND low voltage source
der “motor control center” name, contains low voltage switch normal/backup, for black start purposes.
bus, contactors for common auxiliaries, and for ACP4 is an extension which contains auxiliaries
contactors only, for a plant with more than 6 gensets.
START On request, ACP front panel may bear a motor power
displaying unit.

NO YES
n > 2 Genset

ACP0 to be added
to:
PSCPx or GCPx

CACP (1)

NO YES
n > 6 Gensets

Select
Select ACP1 + ACP4 or
ACP1, ACP2 or ACP3 ACP2 + ACP4 or
ACP3 + ACP4
CACP (1)
CACP (1)

(1) CACP: to be installed in case of containerized power plant

issue 1.3 / Apr. 99 page 65

Diesel Power Plant Project Guide CW 170 - CW 200

Low voltage supplies

Auxiliaries are operated as shown in table below. Step low the starting, prelubrication and preheating auxil-
-down transformer is connected to bus, allowing aux- iaries operation. When main generator set is operated,
iliaries to be energized even if generator set is shut- auxiliaries are reconnected to auxiliary transformer,
down. causing a short-time cutoff. It is recommended to de-
If diesel generator is operated as black-start situation, lay the re-connecting of auxiliaries on bus after comple-
an auxiliary diesel generator shall be provided to al- tion of main part of reloading sequence.

AUXILIARIES SEQUENCES
Stand-by Starting Operation Shut down
Control system UNINTERRUPTED 24V SOURCE
Fuel-oil transfer pump X X
Water pre-heat. pump + pre-heater
Pre-lubricating pump
Fan coolers / Water cooling pump X X
Room fan X X
Air electro-compressor
Battery loaders
Lubricating oil transfer pump X X
Clean fuel-oil draining pump X X X
Generator space heater X

LEGEND : Essential X If possible

Auxiliaries consumptions
Installed power of auxiliaries are indicated here as in- ing. Please note true power of auxiliaries for final defi-
formation base for transformer and ACP pre-dimension- nition, particularily for fan radiators.

AUXILIARIES power consumption (kW)

CW16V170 CW18V170 CW12V200 CW18V200
Pre-lubricating oil pump 1.3 1.3 3.5 3.5
Water preheater 2x6 2x6 3 x 10 4 x 7,5
Pre-heating water pump 0.3 0.3 0.3 0.3
Generator heater 0.5 0.5 0.5 0.5
Air electro-compressor 4.0 4.0 4.0 4.0
Lubricating oil transfer pump 0.75 0.75 0.75 0.75
Maintenance water pump 1.5 1.5 1.5 1.5
Radiator fans without noise requirement @ 40° C 21-26 21-32 35-53 63-74
or radiator fans with noise requirement @ 40° C 15 15-18 27-31 42-45
or cooling water tower 15-18 15-18 15-18 15-18
Ventilation for hot climate delta 10° C 18-24 37-46
Lighting 2 2 2 2
Battery charger 0.3 0.3 0.3 0.3
Control panel heaters 0.075 0.075 0.075 0.075

Electric motors power for 50 HZ - 400 V for 60 HZ - 440 V, please add 15 %; for resistors add 10 %

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CW 170 - CW 200 Diesel Power Plant Project Guide

3.3.7 PLANT MONITORING

& CONTROL SYSTEM
The optional power plant control and monitoring sys- trippings are displayed as soon as they occur, and a
tem running with PANORAMA software offers an unique journal is printed in real time, including event, date,
Human Machine Interface, convivial and performant. and concerned genset.
Operator works from a control desk with computer,
The operating parameters and faults are stored on hard
screen and printer, nervous centre of the Supervisory
disk, it is possible to print them in table or list form.
Control and Data Acquisition system (SCADA).
An automatic phone call is tripped (optional) if main
Operator can start, set the load, and stop any genset
alarm occurs, and operator may check remotly the event
of power plant from its desktop. He receives on screen
history, using a remote software on a delocalized com-
the operative data of engines and generators. Detailed
puter (optional).
description and typical screens are depicted below.
Logic data is routed from/to GCP Programmable Logic
The monitoring software allows display of all engines(s)
Controller, and PSCP Programmable Logic Controller on
operating parameters, in real time.The alarms and
a common bus. Analog data is from scanners built-in
Genset Control Panels. Additional Power data may be
acquired on multiple bus outputs (as shown below)

Example of SCADA arrangement for an eight CW200 power plant, with eight local bus outputs

issue 1.3 / Apr. 99 page 67

Diesel Power Plant Project Guide CW 170 - CW 200

Software main screens

The power plant con-

trol screen, arranged
as single line diagram,
allows the operator to
start and stop any
generating set of the
plant. Pertinent infor-
mation concerning the
whole power plant has
been regrouped on
this entry screen. Fur-
ther information is
contained in genset
monitoring screens.

The engine control

board shows all infor-
mation concerning the
engine operating pa-
rameters, and the ex-
haust temperatures.
Alarms board is di-
rectly accessible from
any one of the display
screens.

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CW 170 - CW 200 Diesel Power Plant Project Guide

Software main screens (continuation)

This Fuel oil control

panel displays the
level switches states,
level in service tank,
and any other infor-
mation from optional
sensors. All system
screens are made on
the same principle,
including all installed
sensors data for the
whole power plant

This trending screen

may be configurated
in various arrange-
ments by buttons. The
historical trending
may be choosen by
operator to obtain an
instant wiew, an
hourly history or a
monthly report. Data
is stored in worksta-
tion hard drive for
long term logs.
Also, these logs are
available in table or
list form, as well as
alarms with date of
tripping. Long term
storage is performable
on standard supports.

issue 1.3 / Apr. 99 page 69

Diesel Power Plant Project Guide CW 170 - CW 200

3.3.8 POWER PLANT EARTHING SYSTEM

Grounding circuits purpose
Grounding circuits are essential for power plant safety. Details for neutral grounding of a substation or of a
They are essential if an electrical incident occurs, as generator supplying a three phases+neutral grid are
for an extinguisher in case of fire. enclosed in IEEE 80 “ IEEE guide for safety in AC sub-
station grounding”.
There are three main functions in power plant ground-
ing circuits : Requirements and neutral systems are described above
in “Power distribution equipment”.
- Personal and equipment protection against phase in-
sulation fault, associated with detection relays or Grounding impedance
differential breakers. Impedance of grounding loop shall be as low as pos-
sible. Impedance value changes with the earth humi-
- Radio interference protection, to prevent perturba- dity ; for this reason, we recommend to ground in hu-
tion of electronic sensitive equipment. mid areas, at sufficient depth to ensure moisture dur-
ing dry season and/or freeze in winter.
- Generator protection by impedance neutral ground-
ing (impedance limits the neutral fault current when Grounding impedance objective value is to determine
generator is operated in abnormal condition). following local regulations, determining maximum pro-
spective touch voltage between ground and conduc-
A lightning arrester should be connected to an indi- tive parts connected to earthing system.
vidual earthing circuit to prevent any flashing of elec-
tronic components and / or personal injury, loss of Be aware that an inadequate local soil may lead to
life. Some local regulations require to interconnect install the electrodes at long distance from power plant,
ground bus and lightning grounding circuit resulting in extra-costs and efficiency diminution.

Neutral grounding Lightning protection

Neutral grounding systems shall ensure the efficient The lightning protection requires a separate earth elec-
protection of equipment and personnel. If neutral is trode, installed independently of the general earthing
directly grounded, grounding electrode and wiring shall network. The shape of this electrode must take the
be able to sustain the full default current, which may high frequency currents of the lightning system to
be equal to one phase current. consideration. The earthing impedance shall be mea-
sured after installation is completed.

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CW 170 - CW 200 Diesel Power Plant Project Guide

3.4 MECHANICAL SYSTEMS

3.4.0 GENERAL
The diesel engine installation depends on the auxi- 4) Circuit filling point must be indicated at the low
liary system in order to operate properly. The environ- points, and the high parts must be fitted with manual
mental conditions must be considered at an early stage, or automatic degasing systems.
and it is of utmost importance that all auxiliary sys- 5) If required by the raw water quality, circuits
tems are considered and optimized for their intended should be made of rust-proofed material : PVC or bronze.
purposes at the project design stage.
6) The connections between the installation and the
Piping complies with the following rules : generator set are flexible, so as to absorb the vibra-
1) All tubes must be installed with a slope of tions and misalignments resulting from relative mo-
1 cm/m in order to facilitate fluid-emptying or strai- tions or expansion.
ning. 7) The inside of lubricating oil pipes and fuel-oil
2) Low points are fitted with valves or drainplugs, pipes must be pickled when situated downstream of
both on fluid circuits and gas circuits. the filters.
3) Tubular exchangers are also inclined by 1 cm/m. Indications to be followed when perfoming installa-
In case of frost, the bundle can be emptied by blo- tion are enclosed in our Power Plant installation hand-
wing through a hole. book.

issue 1.3 / Apr. 99 page 71

Diesel Power Plant Project Guide CW 170 - CW 200

3.4.1 STARTING AIR SYSTEM

The CW 200 engines are started by a pneumatic turbine To take advantage of whole plant air capacity, all air
acting on a gear crown on the flywheel. The starting receivers may be connected together, and compressors
air system supplies the starter motor with compressed are outputting on a common feeding line. Genset de-
air and, via a pressure reducer, the air for overspeed livery lines, connected on engine port 301, can be iso-
protection actuators. All these elements are built in lated separately for maintenance.
the engine.The service pressure of system is 30 bar
(400 psi).Plant feeding line shall be drained with an If generators are used for safeguard function, we rec-
automatic drain, near the engine. ommend to use one complete and independant system
for each generator. Interconnecting lines are opened
Air production unit only in case of compressor failure or repair.
The air productionunit is an eassembly of a compres-
Installed compressors are able to refill all receivers in
sor, two air receivers, and associated draining system.
less than one hour. Data sheet table indicates the num-
It must be installed in a dust, freezing and water free
ber of air production skids and air storage skids to
area. The compressor is a two-stage type, with inter-
ensure this performance.
mediary air cooling. Start and stop are controlled by
pressure switch. Air storage unit
There is one kind of air production unit and one kind Additional air storage units are installed to increase
of air storage unit. Each one has a storage capacity of air storage capacity.
2times 200l. To make a compressor and storage unit of The standard storage unit is designed with two 200l
800l capacity, one air production unit is delivered with receivers. Air storage unit may be installed at distance
one air storage unit. Please refer to technical sheet for from the compressor, but both the delivery pipes to-
determination versus the engine type. ward engine should be as short as possible, to ensure
starting performance.
The air storage capacity is defined for the the whole
power plant to perform three successive start attempts CW 170 electric starting ( optional)
of each engine without compensation requirement. Electric starting system may be provided on request.
24Vdc starter is is supplied by acid starting batteries.
When PowerCommand™ is installed, a battery check is
performed during each starting.

Air sto
rage u
nit

Air pro
ductio
n unit

Air prod
uction u
nit
filling in
tercon
nectio
n

page 72 issue 1.3 / Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

3.4.2 FUEL-OIL SYSTEM

Fuel feeding Storage capacity
Fuel oil feeding and injection systems are built-in to The storage capacity should be adapted to the specific
the engine. Priming of the circuit is performable use of the installation:
through a handpump, linked in parallel with engine
-For an emergency generating set, the storage tank
driven fuel feeding pump. A prefilter is situated up-
capacity must be sufficient to allow the set to go
stream from the pumps, and a full-flow, switchable
through the entire equipment safeguarding sequence.
during operation filter, downstream. Fuel overfed to
injection pumps is released at port 102, to be cooled -For a production generating set, the storage tank ca-
in external heat exchanger, before re-entering feeding pacity must be sufficient to allow continuous opera-
line in port 101. Cooling is necessary, because overfed tion, without interruption during the intervals between
fuel has taken heat in injection pumps, operating at deliveries.
very high pressure. For production plants, we recommend the installation
Fuel spillage is divided in two channels, one for clean of two storage tanks, to use alternatively. One is in
fuel (port 103) and one for dirty spillage (ports 104). service, the other in decantation phase, after truck
Both spillages are routed toward spillage tank ( also delivery. When the first is empty, the second is put
named“leakage module”), divided in two compartments. into service and the first refilled for fuel decantation,
As soon as clean spillage compartment is full, fuel is and so on.
recycled in service tank. Level switch trips alarm when Transfer piping design
dirty spillage compartment needs to be emptied.
All priming faults will be avoided if the day tank lower
Storage tank level is between 1 and 8 m above floor level.
Fuel for the power plant is stored in a storage tank, The transfer pump must be primed without difficulty.
generally locally manufactured. Storage tank should Place a strainer foot valve on storage tank suction.
be installed lower than power plant floor. If tank may
be immersed, it shall be fixed on a loading block, to If transfer pumps are not the ones integrated in our
prevent floating . standard service tank, please follow below recommen-
dations:
If vertical tank is installed outdoor, aluminium re-
flecting paint is advised to limit fuel heating, and bac- -The output of the transfer pump must be at least two
teria proliferation. A recirculating system, with strainer times higher than the engine consumption at full load.
is recommended when tank height is over 5 metres. A -If the delivery column is common to the two pumps,
water draining pot is mandatory. An antisiphon valve it must be able to clear the flow delivered by both
is required when fuel suction is from the top. pumps at the same time (first filling or emergency fill-
ing). Same recommendation is applicable for overflow
(return) pipe, with free running.
When the day tank is located lower than the storage
tank, the use of a transfer solenoid valve is necessary.
A double solenoid valve is recommended.

issue 1.3 / Apr. 99 page 73

Diesel Power Plant Project Guide CW 170 - CW 200

Fuel system particularities

Be aware that fuel inlet is traditionally from service ing circuit. The heat exchanger is operated in full flow
tank, but that the clean fuel spillage line shall be es- of the engine cooling circuit .
tablished without goose neck, sloping toward spillage
Fuel released from feeding circuit crosses heat ex-
module. In any case, fuel return shall be effected with-
changer in cooling media opposite sense. The heat ex-
out pressure. Overflow of spillage module shall be
changer shall be placed on line where the water is at
drained toward hydrocarbon gutter, or hydrocarbons
the coldest possible temperature. The heat exchanger
waste tank by free running.
shall be out of freezing zone.
Operation of fuel cooler
When a cooling tower is used, a special rustproof wa-
The injectors are cooled by the released fuel which ter/fuel heat exchanger may be incorporated in the
may be heated to a temperature of 80°C, and has to be tower open loop. The water must be clean enough to
recooled to less than 50°C before recirculating in feed- prevent rapid clogging and corrosion of the exchanger.

Water/fuel
heat exchange
r
fuel s
er vic
e tan
k

Fue
ls
tank torage
(bul
k
tank
fuel )
s
tank pillage

page 74 issue 1.3 / Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

3.4.3 LUBRICATING OIL SYSTEM

Lubrication of the CW 170 and CW 200 engines is The waste L.O.tank is intended to recover the used
performed from a single lube oil circuit, used both for lube oil, before sending it to recycling. To transfer used
lubricating parts in movement and cooling of the pis- lube oil, an oil transfer caddy is available (optional).
tons. An integrated lub-oil module ensures first the Suction of the mobile pump is to connect on the sump
temperature regulation through a heat exchanger and draining port (216), delivery may be disposed in waste
a thermostatic valve operated in mixing mode. Then, tank or drums.
full-flow filtering through paper cartidges is performed External piping design rules
just before entering engine. The parallel centrifugal
All the fresh lube oil pipes shall be mandatorily pick-
filter can be cleaned during engine operation.
led inside, or made of cold drawn pickled pipes.
The external lubricating oil system involves the fol-
In case of automatic filling, the lubricating oil day
lowings :
tank has to be located between 1 and 4 m above floor
· a fresh lube oil storage tank (optional) level. Install the distribution line with a continuous
slope down to the engine.
· a lubricating oil day tank,
The transfer pump between storage and service tank
· a waste lubricating oil tank (optional).
must be primed without difficulty. Place a strainer foot
and the piping made on site by owner or installer. valve on storage tank suction.
The lube oil storage tank should be installed inside the When the lubricating oil day tank is located lower than
power plant, in a cool area, free of excessive humidity. the storage tank, the use of a solenoid valve is necessary.
The lube oil day tank installed near the engine sup- If a L.O. storage tank is not installed, the size of the
plies the sump by gravity through a manual filling lubricating oil day tank depends on the forecasted
opening (215-1) or optionally trough an automatic longer operating time without tank refilling. For other
filling device fitted on the oil sump (port 215-2). cases, use size recommended in our data sheets.

Lube
oil
servic
e
tank
Lube Opt
stora oil i
was onal
ge ta te lu
nk
oil ta be
nk

issue 1.3 / Apr. 99 page 75

Diesel Power Plant Project Guide CW 170 - CW 200

3.4.4 COOLING SYSTEMS

engine system External system
The internal cooling water system consists of two Heat removed from the engine shall be dissipated
separate cooling circuits : the low temperature (LT) through a final cooler. The nature of this cooler de-
and the high temperature (HT) circuit. pends on environmental conditions. The basic choice
is guided from air ambient temperature, and noise level
The low temperature circuit water cools the charge air
requirements.
( second pass in cooler) and the lubricating oil heat
exchanger. Radiator (Fan cooler) is the most simple and suitable
solution. It takes a part of the generator set output
The high temperature cooling water cools the charge power for fan operation.
air ( first pass), the cylinders (jacket water), cylinder
heads and the uninsulated part of the exhaust system. When ambient temperature is higher than 40- 45°C, a
cooling tower is necessary to obtain a cooled water
Both cooling water circuits are circulated by the twin temperature below ambient, a good solution if suit-
pump. The twin pump is a centrifugal pump with a able water is available to compensate evaporation.
double sided impeller, one side for the low tempera-
A heat exchanger cooled by raw water or sea water is
ture circuit and the other side for the high tempera-
another solution, but needs a large amount of cool
ture circuit.
water. Take care of water nature, because polluted or
Each cooling circuit is controlled by thermostatic valve turbid water may reduce drastically the efficiency in a
elements with wax sensors. poorly defined exchanger.
The thermostatic valves for both circuits are in the Raw water appears to be the cheaper cooling means,
same casing, cooling water control unit, assembled on because it allows the coolest return to engine, heat ex-
the rear side of the free end cover . changer and pump are smaller and quieter final cooling
components. Temperature changes of rivers are lower than
The CW 200 engine has basically only one inlet and air temperature changes through the seasons.
outlet to the external cooler and an internal heat
sharing circuit. In any cases, cooling circuits are loaded using each one
an expansion tank, generally placed at higher altitude
The CW 170 engine has basically two inlets/outlets for of circuit. In some cases, membrane-gas loaded expan-
separated HT and LT circuits. sion tanks may be used. CW170 jacket water (HT) cir-
Electrical pre-heating is built-in to the engine, includ- cuit shall be sealed and maintained under static pres-
ing electrically driven circulating pump. sure between 1.1 and 1.5 bar.

Expansion tank volume calculation

Litres per pipe metres Water expansion with maximum T°C and glycol part (0, 30, 50) Tank volume calculation
DN Ø l/m tank 1 2
0,08 50 %
30 %
25 1" 0,7 0,06
engine litres
0%
40 1"½ 1,5 piping litres
50 2" 2,3 0,04 miscellaneous litres
65 2" ½ 3,9 radiator litres
0,02
80 3" 5,4 total volume litres
100 4" 9,0 0 % expansion %
125 5" 14 0°C 20°C 40°C 60°C 80°C 100°C
150 6" 20 litres

The above table is intended to determine the expansion and antifreeze concentration. Expansion tank capacity
rate versus the temperature, the circuit internal volume should be three times the expansion volume.

page 76 issue 1.3 / Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

RADIATOR SYSTEM
Cooling systems using radiators are operated sealed. engine through a pressure resistant heat exchanger. This
Radiators are built in complete modules, ready to in- principle is known under “remote radiator”name.
stall on anchors, over paved or stoned areas. Fans are Expansion tank
used to suck air through a finned tube bundle.
The expansion tank is delivered mounted on the radia-
The radiator module is of copper tube/aluminium fins tor and equipped with a low level switch and a valve,
type as standard. In maritime climate, acid polluted which limits circuit internal pressure and allows air
areas, and coal power plants, it is necessary to use entry if necessary ( as for automotive radiators). The
copper or heavy protected aluminium fins. If cotton expansion tank has to be placed above the higher part
fibres are present in radiator area, it is preferable to of the circuit, usually between 5 and 10 metres above
replace it by a cooling tower with special air filtering generator set floor. When the radiators are placed re-
system. mote from power plant, install it in generator set room.
Radiator installation When the radiators are installed on the roof, expan-
sion tank remains on the radiator. The priming pipe
Radiators should be installed at a five ( 170 series) to must be connected close to the engine pump inlet,
ten (200 series) metres distance of power plant, to port 451. It must have a sufficient diameter to avoid
prevent exhaust gases recirculating through radiator cavitation effects (DN 50). To limit recirculating, the
bundles. Radiators should be installed at a ten metres degasing connections must be throttled to ID 6 max.
distance of mechanical containers, to prevent exhaust If higher part(s) of the circuit can’t be connected to
gases recirculating through the radiator bundles. If mul- the expansion tank, they must be equipped with a
tiple radiators are installed, it is recommended to group degasing handvalve.
them, ensuring that the lateral air inlet section is equal
or more than the top surface of the bundle This ar- It is mandatory to provide a permanent degasing of the
rangement ensures that hot air recirculating through engine, connecting a ascendant sloping pipe between
the radiator is minimized. Degasing points are equipped port 404 and expansion tank.
with venting cocks. Draining points shall be provided Maintenance water tank
on lower section of lines.
The maintenance water tank is used to store treated
If a radiator is placed on the roof of a high building, or water for the engine cooling systems. It is made of a
skyscraper, total static head shall be limited to 20 metres kit including a polyethylene tank, a portable electric
(2 bar - 29 psi). If this criteria is overpassed, the radia- pump and a set of flexible hoses. Clean water and chemi-
tor circuit shall be separated and interfaced with the cals can be added and mixed in the 1000 liters tank
(by circulating the tank content). The unit can also
retrieve and save the water when the engine needs to
Expansion tank be emptied during maintenance or repair work. Addi-
tional tanks are available on request.
g
asin
deg

g
in
im
pr

Radiator

Main
te
Wate nance
r tan
k

issue 1.2 / feb. 99 page 77

Diesel Power Plant Project Guide CW 170 - CW 200

TOWER SYSTEM
The system makes it possible to use treated water in tower water. The evaporation losses must be compen-
the engine circuit while using fresh water in the cool- sated for by adding new water. To prevent the accumu-
ing tower circuit. The engine cooling loop is running lation of salts and minerals in the cooling media, a per-
in an exchanger as final cooler, and an expansion tank centage of the evaporation losses must be drained off.
is installed on this circuit.
Particular attention shall be paid to the raw water added
Cooling tower in tower circuit. If it contains earth, oxydes in sus-
The cooling water delivered by the circulating pump pension, installing a plates exchanger, engine side is
passes through exchanger, takes heat, and then is the wrong choice, because of rapid clogging of the tower
sprayed into the tower’s internal cooling plates. Water water side. A tubular exchanger is more suitable be-
is collected in a basin at the bottom of the cooling cause it is easily cleaned.
tower, where a pump recirculates it. A fan provides a Raw water used in the tower should be filtered and
forced draft through the cooling tower, which, in con- treated to prevent algal formation, calcareous depos-
junction with the forced evaporation of the water, cools its and excessive salinity. A dosing pump shall be in-
the liquid and the internal plates. stalled on top-up water circuit, for treatment product
An advantage with using the cooling tower is that the addition. If chlorides are used as biocid, circuits and
coolant can reach a temperature lower than the ambi- exchanger must be of stainless manufacture.The tower
ent temperature due to a forced evaporation of the may be painted with strong water resistant paint.

From this table, you can determine the temperature of Some worldwide temperatures are given here for weath-
“wet bulb”of thermometer, from both the ambient tem- ering evaluation, according to country. Be aware that
perature and the relative humidity. Practical tempera- some days in the year, this temperature may be ex-
ture of water exiting tower will be 10°C over the wet ceeded. (don’t accept stringent contractual guarantees
bulb temperature.You can see,that the drier is the air, of result).
the more the evaporation is intense, and the cooling tower
efficiency increases. For a tropical climate, where humid-
ity is any time near 100%, a cooling tower will not be
efficient: choose oversized radiator or raw water if avail- Country Max dry Associat.
(station) bulb wet bulb
Units °C °C
Relative
Associated wet bulb temp. °C Algeria (Alger) 35 25
humid. Australia (Alice Springs) 40 25
(%) Air temperature °C Brazil (Rio Janeiro) 34 27
30 35 40 45 50 China (Shangaï) 34 27
Congo (Brazaville) 34 27
10 13.0 15.5 18.5 21.0 23.0
Egypt (Cairo) 39 24
20 15.5 18.5 22.0 25.0 28.0
France (Paris) 32 21
30 17.9 21.5 25.0 28.5 32.0 Hong Kong (Hong Kong) 33 27
40 19.9 24.0 27.5 31.5 India (Calcutta) 37 28
50 21.9 26.0 30.0 Indonesia (Djakarta) 32 27
60 23.8 28.0 32.5 Pakistan (Karachi) 38 28
70 25.5 30.0 Saudi Arabia (Dharhan) 44 30
80 27.2 32.0 Singapore (Singapore) 33 28
90 28.8 Russia (Moscow) 30 21
100 30.0 Vietnam (Da Nang) 36 30

page 78 issue 1.2 / Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

OPTIONAL DOUBLE PUMP UNIT

Engine cooling loop
The double pump unit transfers the water from the The engine cooling loop is similar to the one with ra-
cooling tower basin to the heat exchanger and then, diator, but the radiator is replaced by a heat exchanger.
the cooling tower. One pump is operated to fulfill the Coolant in this loop shall be treated according to our
cooling system required flow. If this pump fails, a flow general recommendations, with an anti-corrosion, anti-
detector placed on the delivery line allows the genera- cavitation chemical to prevent engine damage.
tor set control system to start the other pump as
backup. Integrated check valves in the double pump The expansion tank is traditionally located near the
body prevents back circulation through the stopped engine and equipped with a low level switch.
pump. The heat exchanger is installed near the engine and a
Automatic change of pump, every week, may be pro- maintenance area shall be reserved for its cleaning.
grammed. Install tubular exchangers with a slight slope in fluid
passage direction, to facilitate the draining of water
and deposits.
A maintenance tank is required for engine cooling loop,
see radiator chapter.

Expa
nsion
tank
coolin
g towe
r
ng
Degasi

top-u
p
ing treatm water
im ent
Pr
Plate
s hea Deco
t exch n
ange
r valve centrati
o n

r
ilte
shf
Me
Main
te
wate nance
r tan
k

t
uni
mp
Pu

issue 1.2 / feb. 99 page 79

Diesel Power Plant Project Guide CW 170 - CW 200

RAW WATER SYSTEM

The raw water cooling system is normally the most bottom, over a sand retaining capacity. Water inlet, at
cost effective solution when raw water is available in low speed is disposed near strainer surface, cleaning
sufficient quantity and quality. If raw water does not its surface continuously. Suction is at a distance avoid-
fulfill the required quality, the choice of a radiator or ing the sand to be aspirated. A foot valve ensures pump
a tower will be more appropriate. priming.
The raw water system makes it possible to use treated Emergency diesel generators operated in the centre of
coolant in the engine circuit while using raw water in towns (or in deserts) may use raw water drawn off one
the final heat exchanger. The engine cooling loop is well, and rejected in another. Distance between wells
running in the exchanger as final cooler, and an ex- shall ensure the recirculating water will come back
pansion tank is installed in this circuit. The engine cooled. For evaluation, 100 metres of distance is suit-
coolant shall be treated following CumminsWärtsilä rec- able for 0.3 to 1 MW generator set, 200 metres is ad-
ommendations. equate for 1-3MW generator set.
Raw water open loop Raw water pump
Raw water shall be pumped to flow with sufficient speed The raw water pump transfers the water from the pond
in a compact heat exchanger. The raw water is taken to the heat exchanger and then, the rejection line. Pump
from a pond freely filled by lake, river or sea water. delivery fulfills the required flow for the cooling system
Whatever the water nature, a stainless bundle shall be operated in the higher load of engine, exchanger foul-
used in the exchanger. ing included.
A coarse screen has to be used to stop large matter The pump is specially designed to be raw water resistant,
from the raw water entering the system. The feeding even if charged with sand, abrasive particles or algal.
channel shall be concreted, and water speed should be Engine cooling loop
limited to 0.3m/s (1ft/s). A sand trap (pond) is nor-
The engine cooling loop is similar to the one with ra-
mally constructed on site and consists of a concrete or
diator, but the radiator is replaced by an easily clean-
metallic chamber with a strainer plate disposed at the
able heat exchanger.

Expansion ta
nk

sing
Dega

From th
e river

ing
im
Pr
Sand
sepa
rator

Main
te
ate
r wate nance
r tan
ww k
Ra p
pum

To the
river

page 80 issue 1.2 / Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

3.4.5 CHARGE AIR SYSTEM

The engine is turbocharged and the charge air tem- in continuous duty. These filters are installed outside
perature is reduced by an air cooler, traversed by con- the engine room, close to the fresh ventilation air in-
trolled temperature cooling circuit(s). let, or outside.
Intake air filtration Intake air duct
The intake shall be equipped with necessary filters to When fresh air intake is necessary, an intake duct is to
remove particles that may cause deposit formations in be locally manufactured, following these elementary
the system or damage the engine. Basically, the en- rules:
gine is equipped with a dry type air filter, fixed di-
- intake ducts shall be manufactured individually for
rectly on the turbocharger inlet.
each engine, a common duct may be made for two
The highest possible dust concentration at turbocharger turbos of an engine, but a square tee connection should
inlet is 3 mg/m3 and largest permissible particle size be avoided, preferring a low angle branch.
at turbocharger inlet is 5µm.
- Internal parts of duct shall be rustproof or painted.
When environmental conditions are extremely dusty
- Duct shall be supported.
(cement factories, etc), the highest allowed particle
concentration at dry filter inlet are evaluated as fol- - A flexible connection must be used to connect the
lows: 10 mg/m3 of cement dust; 5 mg/m3 of calcium duct to the engine turbocharger, to prevent any stress
hydroxide; 1,5 mg/m3 of chlorines; 20 mg/m3 of sul- on the inlet nozzle.
phur oxides. The maximum allowed pressure drop through the in-
Oil bath air filter take air system, including clogged air filter, is indi-
If the air quality does not conform to these condi- cated in generator set data sheets. It is recommended
tions, an increased efficiency filter has to be installed. to design the system to reach half of the limit when
We propose oil bath filters, with sliding media. operated at full load.

The oil bath type filter is particularily suitable for sites

with an abrasive atmosphere, or for engines operated

oil bath air filter

issue 1.2 / feb. 99 page 81

Diesel Power Plant Project Guide CW 170 - CW 200

3.4.6 EXHAUST GASES SYSTEM

Exhaust gases from the turbocharger are discharged ducts, enclosed in a chimney. Sizing of stack should
toward atmosphere through a silencer. These should result in a gases nozzle speed over 25m/s.
be vented as high as possible, and must be prevented
Suitable material is carbon steel sheet, and recom-
from re-entering the engine via the charge air intake,
mended calculation temperature is 450°C. Sliding sup-
or polluting the radiator fins.
ports shall be provided to allow duct dilatation, and
It is important to note that the turbocharger nozzles fixed points should be situated in an opposite posi-
must be always free of loads. A textile or stainless tion to the compensators.
steel exhaust compensator(s) is delivered with gen-
Rain &condensate permanent draining shall be pro-
erator set.
vided to prevent water entering the silencer (if hori-
Exhaust duct zontal) and the engine.
It is of utmost importance that the entire exhaust line Exhaust silencer
is designed properly to minimize flow restrictions, sud-
The exhaust silencer is made of a carbon steel receiver
den direction change, or lines blowing in opposite di-
containing sound attenuator and wave de-phasing sys-
rections. Maximum allowable pressure drop through the
tem made of perforated steel sheet and heavy rockwool.
system is indicated in generator set data sheets. But it
It is asbestos-free.
is recommended to design the system to reach half of
the limit when operated at full load. The exhaust silencer is delivered in two configurations
with an industrial attenuation of about 20 dBA and a
The duct shall be gastight, to protect operators against
residential attenuation of about 35 dBA.
toxic emissions in the generator set room (CO, CO2).
The use of asbestos free materials is mandatory. If two turbochargers are installed on the engine, it is
mandatory to fix the delivered exhaust bellow directly
The duct shall be entirely heat-insulated to protect
on turbocharger output, and make branch connection
the surrounding from fire or excessive heating.
after bellow to prevent the stresses on turbocharger
Uninsulated exhaust lines situated outside shall not
casing.
be routed near engine air intake or power plant venti-
lation entries, to prevent temperature rise, which re-
sults in performance reduction.
Exhaust lines of different engines shall not be mixed in
a common stack, but routed separately in individual

page 82 issue 1.2 / Apr. 99

CW 170 - CW 200 Diesel Power Plant Project Guide

3.4.7 VENTILATION AND NOISE CONTROL

General principles Sizing
The purpose of ventilation is: The engine radiations are given in the generator set
data sheet.
·to remove the heat radiated by the engine and pro-
duced by the generator cooling; To determine generator heat losses, calculate differ-
ence between Electrical Power and mechanical output
·to keep the room pressurized if the surrounding air is
in the “heat balance”
polluted (in this case, a filtering system shall be in-
stalled). The exhaust line also causes thermal loss which may
be determined from insulating system manufacturer
The ventilation can be designed to create overpressure
indications. Coolant pipes thermal loss is negligible.
or air depression in the room. The characteristics of
each type of ventilation are as follows: The inlet/outlet temperature increase to take as a ref-
erence is :
underpressure:
- Hot air suction, requiring a bigger fan for the venti-
15°C FOR TEMPERATE CLIMATE
lation. 10°C FOR HOT CLIMATE
- Dust in the power plant (air sucked through all the
leaks of the building).
Prefiltering
The room air should be pre-filtered if the site
- Leaks on the engine.
is polluted. Limit pollution levels are detailed in charge
- Less pressure in the air inlet of the engine. air system. Prefiltering panels should be dimensioned
to allow ventilation operation with clogged media.
- Difficulties in giving a direction to the air stream.
Noise control
overpressure :
If a noise attenuation requirement is pending, venti-
- Cold air blowed, requiring a smaller fan for the same
lation inlet and outlet apertures shall be equipped with
ventilation flow.
sound traps. They shall be determined according to
- The ventilation air can easily be filtered. attenuation rate, and noise source position.
- The air stream can be directed. If noise attenuators are installed on the ventilation
system, intake line shall be mandatorily installed with
- More pressure in the air inlet of the engine.
a silencer.
Overpressure has to be prefered when both cases are
Doors should be stuffed and windows should be
considered.
equipped with rubber gaskets to prevent vibration and
Pressurized ventilation noise passage.
We recommend for diesel Power Plants pressurized ven-
Note: mufflers and baffles shall be disposed inside the
tilation, where air flow is easier to control: the fan is
building to insonorize; if not, noise exits soundproofed
operated at lower temperature and ensures a higher
volumes through non-insulated duct sections.
quantity in mass to pass through generator set room.
The hot air outlet is installed at a high level, gener-
ally at roof top. This ensures easy hot air evacuation,
even if blowers are shutdown.
The air is aspirated or evacuated through air inlet/
outlet louvres and sound attenuation baffles, if neces-
sary to reduce global noise level of the power plant.

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Diesel Power Plant Project Guide CW 170 - CW 200

4.Partnership
4.1 ENGINEERING 4.2 MAINTENANCE
Engineering of LFO Power Plants is performed by The Group is well represented world wide and can there-
Cummins Wärtsilä project team supported by local rep- fore commit itself to long lasting relations with its
resentatives. Some information given in this handbook clients. The Cummins Wärtsilä service organization will
may be used for pre-configuration studies. At any time, not only participate in start up of plant but also en-
up-to-date information is available for Cummins gages itself to help the user for the operation and
Wärtsilä representatives, in Cummins Wärtsilä offices, maintenance of the plant during commercial op-
for a final design. eration.
Commissioning Preventive maintenance
Commissioning of the equipment delivered by Cummins In order to maintain a sustainable operation it is of
Wärtsilä is normally included in the main contract. importance that the maintenance of the power plant
Documentation is performed continuously.

The contents of the final documentation depends on Such a maintenance program is established in the Pre-
the extent of delivery. In principle, the following docu- ventive Maintenance Guidelines included in contrac-
ments are included in each delivery from Cummins tual documentation, which is a comprehensive instruc-
Wärtsilä : tion describing when certain activities will take place.
Some of them can easily be performed by the plant
- Installation drawings and diagrams, operation personnel but certain activities need exter-
- Installation handbook, nal assistance from Cummins Wärtsilä network person-
nel.
- Operator’s manual,
- Operation and maintenance manuals for components,
4.3 OPERATION OF THE POWER PLANT
- Parts list. Cummins Wärtsilä can when appropriate enter into
operational agreements which implies that when a cus-
A basic operator training session at the factory or on
tomers so requires Cummins Wärtsilä can on his behalf
site is available on request. This training may be ori-
operate the plant. All consumables such as filter, and
ented to mechanical and diesel engines, or to power
lube oil can be arranged by Cummins-Wärtsilä.
plant and electrical systems.
The plant will be interconnected to the service main
office where all operational parameters can be studied
and measures recommended for adjustment of the plant.

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CW 170 - CW 200 Diesel Power Plant Project Guide

5. Units,Formulae
5.1 CURRENT EQUIVALENTS
Power imperial measurements

1 British horsepower = 745.7 W 1 kW = 1 000 W

1 British horsepower = 0.7457 kW 1 kW = 1.341 Bhp
1 British horsepower = 33,000 ft.lbF/min 1 kW = 44,250 ft.lbF/min

1 British horsepower = 550 ft lbF/s 1 kW = 737.6 ft.lbF/s

1 British horsepower = 2,544 Btu/h 1 kW = 3,412 Btu/h
1 British horsepower = 42.41 Btu/min
1 Btu/min = 17.58 W
1 Btu/min = 0.01758 kW
1 Btu/min = 0.02358 Bhp
1 Btu/h = 0.2931 W

Energy measurements

1 Btu = 9338 in.lbF

1 Btu = 778.2 ft.lbF 1 ft.lbF = 0.001285 Btu
1 Btu = 0.000293 kWh 1 kWh = 3412 Btu
1 Btu = 1.055 kJ

1 ft.lbF = 1.356 N.m

1 ft.lbF/s = 0.001356 kW
1 ft.lbF/s = 0.001818 Bhp
1 therm (U.S)= 99,98Btu

Air conditioning

288,000 Btu = 1 Ton.day 1ton= 12,000 Btu/h

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Diesel Power Plant Project Guide CW 170 - CW 200

5.2 CONVERSION FACTORS

From Unit_1 ..................................................... Multiply by ................ To Unit_2

From

Unit_1 —> Unit_2

To convert from Unit_1 to Unit_2, use the two conversion lines Unit_1 to Ref_Unit and
Unit_2 to Ref_Unit as described hereafter:

Unit_1 ............................................................................... Factor_1 ........................... Ref_Unit

Unit_2 ............................................................................... Factor_2 ........................... Ref_Unit

Factor _ 1
Unit_1 .............................................................................. ......................... Unit_2
Factor _ 2

Scientific notation

3.7 E+5 = 3.7 x 105 = 370 000

3.7 E-5 = 3.7 x 10-5 = 0.000 037

Prefix

Giga ......................................................... G .................... 1.000 E+9 ......................... Unit

Mega ....................................................... M .................... 1.000 E+6 ......................... Unit
Kilo .......................................................... k ..................... 1.000 E+3 ......................... Unit
Hecto ....................................................... h ..................... 1.000 E+2 ......................... Unit
Deca ........................................................ da ................... 1.000 E+1 ......................... Unit
Deci ......................................................... d ..................... 1.000 E-1 .......................... Unit
Centi ........................................................ c ..................... 1.000 E-2 .......................... Unit
Milli .......................................................... m .................... 1.000 E-3 .......................... Unit
Micro ....................................................... µ ..................... 1.000 E-6 .......................... Unit

Length

Inch ......................................................... in..................... 2.540 E-2 ......... m ............. Meter

Foot = 12 inches ...................................... ft ..................... 3.048 E-1 ......... m ............. Meter
Yard = 3 feet ............................................ yd ................... 9.144 E-1 ......... m ............. Meter

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CW 170 - CW 200 Diesel Power Plant Project Guide

Area

Square inch ............................................. in2 ........................ 6.452 E-4 ......... m2 ............... Square meter
Square foot .............................................. ft2 ......................... 9.290 E-2 ......... m2 ............... Square meter
Square yard ............................................. yd2 ....................... 8.361 E-1 ......... m2 ............... Square meter
Acre ......................................................... acre ................ 4.047 E+3 ........ m2 ............... Square meter

Volume

Cubic inch ................................................ in3 ........................ 1.639 E-5 ......... m3 ............... Cubic meter
Cubic foot ................................................ ft3 ......................... 2.832 E-2 ......... m3 ............... Cubic meter
Cubic yard ............................................... yd3 ....................... 7.646 E-1 ......... m3 ............... Cubic meter
US gallon ................................................. gal ................... 3.785 E-3 ......... m3 ............... Cubic meter
Acre.inch ................................................. acre.in ............. 1.028 E+2 ........ m3 ............... Cubic meter
Acre.foot .................................................. acre.ft ............. 1.233 E+3 ........ m3 ............... Cubic meter

P( barG ) + Plocal ( barA ) 27315

. 3
Gas normal cubic meter: ⋅ ⋅ m (at T° and P )
1.013 T(° C) + 27315
.

Mass

Grain ....................................................... gr .................... 6.480 E-5 ......... kg ............ Kilogram

Ounce ...................................................... oz ................... 2.835 E-2 ......... kg ............ Kilogram
Pound ...................................................... lb ..................... 4.536 E-1 ......... kg ............ Kilogram

Force
Force

Kilogram.force ......................................... kgf .................. 9.807 ............... N ............. Newton

Ounce.force ............................................. ozf .................. 2.780 E-1 ......... N ............. Newton
Pound.force ............................................. lbf .................... 4.448 ............... N ............. Newton

Pressure
Pressure,, stress

Hectopascal, millibar ............................... hPa, mbar ....... 1.000 E+2 ........ Pa, N/m2 ...... Pascal
Kilopascal, Pieze ..................................... Pz, kPa, kN/m2 . 1.000 E+3 ........ Pa, N/m2 ...... Pascal
Newton per square centimeter ................. N/cm2 ................. 1.000 E+4 ........ Pa, N/m2 ...... Pascal
Bar ........................................................... bar .................. 1.000 E+5 ........ Pa, N/m2 ...... Pascal
Megapascal ............................................. MPa, N/mm2 .... 1.000 E+6 ........ Pa, N/m2 ...... Pascal
Meter of water ......................................... mW mW, mH20, mCE . 9.807 E+3 ........ Pa, N/m2 ...... Pascal
Kilogramforce per square mm .................. kgf/mm2 ............. 9.807 E+6 ........ Pa, N/m2 ...... Pascal
Atmosphere (technical) ............................ kgf/cm2, At ..... 9.807 E+4 ........ Pa, N/m2 ...... Pascal
Atmosphere (standard) ............................ atm ................. 1.013 E+5 ........ Pa, N/m2 ...... Pascal

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Diesel Power Plant Project Guide CW 170 - CW 200

pressure
pressure,, stress (contin uation)
(continuation)

Millimeter of mercury, Torricelli ................. mmHg, Torr ..... 1.333 E+2 ........ Pa, N/m2 ...... Pascal
Centimeter of mercury ............................. cmHg .............. 1.333 E+3 ........ Pa, N/m2 ...... Pascal
Inch of water ............................................ inH2O, inW ...... 2.491 E+2 ........ Pa, N/m2 ...... Pascal
Foot of water............................................ ftH2O, ftW ....... 2.989 E+3 ........ Pa, N/m2 ...... Pascal
Inch of mercury ....................................... inHg ................ 3.386 E+3 ........ Pa, N/m2 ...... Pascal
Foot of mercury ....................................... ftHg ................. 4.064 E+4 ........ Pa, N/m2 ...... Pascal
Pound.force per square inch .................... psi psi, lbf/in2 ......... 6.895 E+3 ........ Pa, N/m2 ...... Pascal
Pound.force per square foot ..................... lbf/ft2 ................... 4.788 E+1 ........ Pa, N/m2 ...... Pascal

Suffixes : suffix G = relative pressure; suffix A= absolute pressure

Suffixes
Absolute pressure (A) = relative pressure (G) + local pressure. “G” means “gauge”

Temperature

Kelvin ....................................................... K ..................... K - 273.15 ........ °C .............. Degree Celsius

Degree Farenheit ..................................... °F .................... (°F - 32)/1.8 ..... °C .............. Degree Celsius
Degree Celsius ........................................ °C ................... (1.8 x °C) + 32 .. °F ............ Degree Farenheit
Ounce per cubic inch ............................... oz/in3 .................. 1.730 E+3 ........ kg/m3 ......... Kg / cubic meter
Ounce per cubic foot ............................... oz/ft3 ................... 1.001 ............... kg/m3 ......... Kg / cubic meter
Ounce per cubic yard .............................. oz/yd3 ................. 3.708 E-2 ......... kg/m3 ......... Kg / cubic meter
Ounce per US gallon ............................... oz/USgal ......... 7.489 ............... kg/m3 ......... Kg / cubic meter
Pound per cubic inch ............................... lb/in3 .................... 2.768 E+4 ........ kg/m3 ......... Kg / cubic meter
Pound per cubic foot ................................ lb/ft3 ..................... 1.602 E+1 ........ kg/m3 ......... Kg / cubic meter
Pound per cubic yard ............................... lb/yd3 .................. 5.933 E-1 ......... kg/m3 ......... Kg / cubic meter
Pound per US gallon ................................ lb/USgal .......... 1.198 E+2 ........ kg/m3 ......... Kg / cubic meter

Power

Horsepower Metric ................................ HP .................. 7.355 E+2 ........ W ............ Watt

Horsepower British ................................ Bhp ................. 7.457 E+2 ........ W ............ Watt

Energy
Energy

Watt·hour ................................................. Wh .................. 3.600 E+3 ........ J .............. Joule

Calorie ..................................................... cal ................... 4.187 ............... J .............. Joule
British thermal unit ................................... Btu .................. 1.055 E+3 ........ J .............. Joule
Centigrade heat unit ................................ Pcu, CHU ....... 1.899 E+3 ........ J .............. Joule
Therm ...................................................... th .................... 4.187 E+6 ........ J .............. Joule

Specific massic energy

energy

Kilowatt·hour per kilogram ....................... kWh/kg ........... 3.600 E+6 ........ J/kg ......... Joule per kg
Kilowatt·hour per pound ........................... kWh/lb ............ 7.937 E+6 ........ J/kg ......... Joule per kg
Kilocalorie per kilogram ........................... CHU/lb, kcal/kg .. 4.187 E+3 ........ J/kg ......... Joule per kg
Kilocalorie per pound ............................... kcal/lb ............. 9.230 E+3 ........ J/kg ......... Joule per kg
British thermal unit per pound .................. Btu/lb .............. 2.326 E+3 ........ J/kg ......... Joule per kg

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CW 170 - CW 200 Diesel Power Plant Project Guide

Specific volumic ener

volumic gy
energy

Watt·hour per cubic meter ....................... Wh/m3 ................ 3.600 E+3 ........ J/m3 ........... J per cubic meter
Watt·hour per cubic inch .......................... Wh/in3 ................ 5.900 E-2 ......... J/m3 ........... J per cubic meter
Watt·hour per cubic foot ........................... Wh/ft3 ................. 1.020 E+2 ........ J/m3 ........... J per cubic meter
Kilocalorie per cubic meter ...................... kcal/m3 ............... 4.187 E+3 ........ J/m3 ........... J per cubic meter
Kilocalorie per cubic inch ......................... kcal/in3 ............... 6.862 E-2 ......... J/m3 ........... J per cubic meter
Kilocalorie per cubic foot .......................... kcalft3 ................. 1.186 E+2 ........ J/m3 ........... J per cubic meter
Btu per cubic foot ..................................... Btu/ft 3 ................. 3.726 E+4 ........ J/m3 ........... J per cubic meter
Btu per US Gallon .................................... Btu/USgal ....... 2.787 E+5 ........ J/m3 ........... J per cubic meter
CHU per cubic foot .................................. Pcu/ft3, CHU/ft3 . 6.707 E+4 ........ J/m3 ........... J per cubic meter
Therm per US Gallon .............................. Therm/USgal .. 2.787 E+10 ...... J/m3 ........... J per cubic meter

Specific massic heat capacity

Kilowatt·hour per (kilogram·Kelvin) .......... kWh/(kg·K) ...... 3.600 E+6 ........ J/(kg·K) ... Joule per kg.K
Kilocalorie per (kilogram·Kelvin) .............. kcal/(kg·K) ...... 4.187 E+3 ........ J/(kg·K) ... Joule per kg.K
Btu per (pound·degree Fahrenheit) .......... Btu/(lb·°F) ....... 4.187 E+3 ........ J/(kg·K) ... Joule per kg.K

specific volumic heat capacity

volumic

Kilowatt·hour/(cubic meter·Kelvin) ............ kWh/(m3·K) ..... 3.600 E+6 ........ J/(m3·K) ... Joule / m3.K
Kilocalorie per (cubic meter·Kelvin) ......... kcal/(m3·K) ...... 4.187 E+3 ........ J/(m3·K) ... Joule / m3.K
Btu per (cubic inch·degree Fahr.) ............. Btu/(in3·°F) ...... 1.159 E+8 ........ J/(m3·K) ... Joule / m3.K
Btu per (cubic foot·degree Fahr.) ............. Btu/(ft3·°F) ...... 6.707 E+4 ........ J/(m3·K) ... Joule / m3.K

Water hardness
hardness

German degree ....................................... °dH ................. 1.790 E+1 ... ppm(wt) ... Parts / million CaO3
French degree ......................................... °Fr ................... 1.000 E+1 ... ppm(wt) ... Parts / million CaO3
Clark degree ............................................ °Ck ................. 1.425 E+1 ... ppm(wt) ... Parts / million CaO3
Millival per liter ......................................... mval/l .............. 5.000 E+1 ... ppm(wt) ... Parts / million CaO3
Grain of CaO3 per US Gallon of water ..... GPG ............... 1.712 E+1 ... ppm(wt) ... Parts / million CaO3

Miscellaneous

Per cent ................................................... % .................... 1.000 E-2 ......... 1 .............. Unit

Per thousand ........................................... ‰ .................... 1.000 E-3 ......... 1 .............. Unit
Parts per million ....................................... ppm ................ 1.000 E-6 ......... 1 .............. Unit
Efficienc
Efficiencyy: kilojoule per kilowatt.hour ...... kJ/kW.h ........... 2.778 E-4 ......... 1 .............. 1 / unit

issue 1.2 / feb. 99 page 89

Diesel Power Plant Project Guide CW 170 - CW 200

5.3 FORMULAE

Brake Mean Effective Pressure (BMEP)

kW mechanical output
BMEP (bar) = 1.528 x —————————————————————————— (for 4-cycle engine)
(rated r.p.m.) x (stroke in m)x (bore in m)2 x (nb of cylinders)

Temperature
(oF - 32)
o o
Temp. ( C) = ———————— F = (oC x 1.8) + 32
1.8

Power Factor & kVA

kW kW
PF = ——— kVA = ——
kVA PF

Formulae for obtaining kW, kVA, reactive kVA, and Amperes

To Obtain: Single Phase AC Three Phase AC Direct Current

V x A x PF kVA x PF VxA
kWe = ————— ———
1000 1000

V x A x PF kVA x PF
engine meca. kW = —————— ——————
1000 x gen. eff. gen. eff.

VxA V x A x 1.732
kVA = ——— ———————
1000 1000

Reactive kVA = kVA x 1 - PF2 kVA x 1 - PF2

kW x 1000 kW x 1000 kW x 1000

A (when kW) = ————— ——————— —————
is know) V x PF V x PF x 1.732 V

kVA x 1000 kVA x 1000

A (when KVA = —————— ——————
is known) V V x 1.732

generator frequency

No. of poles x r.p.m.

Hz = —————————-
120

page 90 issue 1.2 / Apr. 99