DIESEL ENGINES II for ship propulsion and power plants FROM 0 TO 100,000 kW
Year: 2008 Language: english Author: Kees Kuiken Publisher: Target Global Energy Training ISBN: 978-90-79104-02-4 Format: PDF Quality: Scanned pages Number of pages: 424 Description: DIESEL ENGINES for ship propulsion and power plants FROM OTO 100,000 kW The author has paid scrupulous attention to the compilation of this book and it may be used by anyone desiring to do so, but Target Global Energy Training shall not be held responsible or liable in any way for the accuracy of information provided. The task of completing this book could not have been accomplished without many substantial contributions by a considerable number of companies both in The Netherlands and abroad. These companies each in their own manner have contributed to the realisation of this edition by allowing interviews and providing photo-material and technical information. It is impossible to single out any specific company. However, special reference is made of MAN Diesel AG and Wiirtsila, for their generous contributions. Introduction Diesel engines play an important role in today’s society: we are quite dependent on them. Over 100 years after Rudolf Diesel developed a working diesel engine, there is still no real alternative for ship propulsion and electric generators in tropical and/or remote areas. The diesel engine is indispensable for road haulage, inland shipping, aquatics, electric power emergency systems, agriculture, and passenger transport by road or rail, oil and gas industry and various other industries. We have chosen to make use of many pictures accompanied by a written explanation. Much highly in-depth technical theory has been omitted as these topics are covered by specialist books available on the market; these topics include thermodynamics, vibrations, materials, and electronics. We, at Target Global Energy Training have opted for a more practical approach. This includes ample information with respect to the construction of engines, use of materials, various engine categories, maintenance, repairs, and the use of engines. Much attention has been paid to the choice of proper graphic material. This, in our opinion, is helpful for the reader to gain insight in the various subjects. This publication is indispensable for every person who has dealings with the diesel engine industry, from the smallest engine to ‘The Cathedrals of the Oceans’. Kees Kuiken, Onnen, The Netherlands, July 2008.
Diesel Power Plants
Diesel Power Plants 18 Diesel Power Plants 19 Ship propulsion 20 Transmission gears, flexible couplings, shafts, propeller shafts and generators 21 Diesel engine manufacturers 22 Engine emissions 23 Calculating fuel and lubricating-oil consumption 24 Auxiliary systems: Fuel and lubricating-oil 25 Operational management and automation 26 Reconditioning engines and their parts 27 Maintenance and repairs vibration dampers, shafting and 28 Casting of engine parts shaft generator drives 29 New fuel developments 30 Bedplates and engine alignments, gearboxes, 31 Propellers 32 Regulations for propulsion engines, classification separators repair and damage 396 Electricity is generated by diesel power plants in most parts of the world. This includes mobile floating power plants. Shown here; discharging a floating power plant with MAN-B&W engines from a semi-submersible ‘Dockwise’ vessel.
CONTENTS
Introduction 18 Diesel Power Plants 18.1 Introduction 18.2 Classification of diesel power plants 25 Operational management and automation 208 26 Reconditioning engines and their parts 218 27 Maintenance and repairs 284 vibration dampers, shafting and 28 Casting of engine parts 312 shaft generator drives 76 29 New fuel developments 338 30 Bedplates and engine alignments, gearboxes, 22 Engine emissions 14218.3 Applications for diesel power plants 18.4 Types of diesel power plants 18.5 Special applications of diesel power plants 18.6 An example of a large diesel power plant for the generation of electricity 18.7 Auxiliary engines 18.8 Outside the engine hall 18.9 Fuel quality 18.10 A few particulars 18.11 Examples of power plants 19 Ship propulsion 19.1 Introduction 19.2 Ship types and hull resistances 19.3 Load-lines of a ship 19.4 Ship dimensions and their values 19.5 Hull forms 19.6 Ship’s resistance 19.7 Screw propulsion 19.8 Propeller types 19.9 Flow conditions around the propeller 19.10 Propeller dimensions 19.11 Operating conditions of a propeller 19.12 Increasing ship speeds 19.13 Parameters causing heavy-running conditions 19.14 Manoeuvring speed 19.15 Direction of propeller rotation - lateral forces 19.16 Engine layouts and load diagrams 19.17 Electronic governors with load limitation 19.18 Use of charts 19.19 Summarising the effects of the various types of resistance on engine operation 19.20 Some comments 20 Transmission gears, flexible couplings, vibration dampers, shafting and shaft generator drives 20.1 Introduction 20.2 Diesel-engine arrangements 20.3 Gear transmission 20.4 Various constructions and designs of gear transmissions 20.5 Position of the input and output shaft 20.6 Types of teeth 20.7 Gear transmission for shaft generators 20.8 Couplings 20.9 Torsional vibration dampers 20.10 Engine shafts 20.11 Examples of complete systems with diesel engines, reduction gearing, shafting, couplings and vibration dampers 20.12 Vibration dampers below the engine frame 20.13 Examples of engine arrangements with flexible vibration dampers 20.14 Flexible connections to the diesel engine 21 Diesel engine manufacturers 21.1 Introduction 21.2 Engine categories 22 Engine emissions 22.1 Introduction to ‘the fossil fuel’ society 22.2 Exhaust gas composition 22.3 Units of contamination 22.4 Methods for the reduction of exhaust-gas emissions 22.5 Secondary methods 22.6 Reduction of sulphur oxides in 22.7 Removal of fine particles from exhaust gases 22.8 Examples of techniques engine manufacturers apply to reduce emissions 22.9 Measurements on board large modern sea going vessels 22.10 New techniques: the Miller process 22.11 New developments: the Hercules project 23 Calculating fuel and lubricating-oil consumption 23.1 Introduction 23.2 Diesel-engine efficiency 23.3 Shaft power in kW or MW 23.4 Specific fuel consumption 23.5 Fuel consumption 23.6 Fuel consumption for engines in diesel-power plants 23.7 Fuel consumption for propulsion diesel engines 23.8 Lubricating-oil consumption and specific lubricating-oil consumption 23.9 Measuring fuel consumption 23.10 Fuel consumption measured in trials 23.11 The oil-price development 24 Auxiliary systems: Fuel and lubricating-oil separators 24.1 Introduction 24.2 Fuels 24.3 The principle of centrifugal separators 24.4 Separation in a settling tank 24.5 Separation with a centrifugal separator 24.6 Types of separators 24.7 New separators by Alfa Laval 24.8 Effects of separators 24.9 Examples of cleaning systems for lubricating oil, fuel, sludge and bilge water 25 Operational management and automation 25.1 Introduction 25.2 Automation of diesel engines 25.3 Examples of automation systems 25.4 Operational management 25.5 Complete systems for diesel engines, some examples 26 Reconditioning engines and their parts 26.1 Introduction 26.2 Four-stroke engines 26.3 Two-stroke engines 27 Maintenance and repairs 27.1 Introduction 27.2 Types of maintenance 27.3 Instruction manuals/ Maintenance manuals 27.4 Engine maintenance 27.5 Maintenance for small engines - category I 27.6 Examples of maintenance for engines category III 27.7 Some examples of maintenance of large two-stroke crosshead engines 28 Casting of engine parts 28.1 Introduction 28.2 Cast-iron parts of diesel engines 28.3 Advantages of cast engine parts 28.4 Foundries 28.5 Casting process 28.6 Casting location 28.7 Moulds 28.8 Filling the casting moulds 28.9 Mould assembly 28.10 Cleaning the castings 28.11 Casting stresses 28.12 Checking air inclusions and damage 28.13 Control of the dimensions 28.14 Operations in the machining factory 28.15 Manufacturing crankshafts 29 New fuel developments 29.1 Introduction 29.2 Use of combination fuels 30 Bedplates and engine alignments, gearboxes, shafts, propeller shafts and generators 30.1 Introduction 30.2 Ship propulsion 30.3 Construction of the bedplate - Engine category IV 30.4 Examples of rigid mounting - Engine category III 30.5 Resilient mounting of propulsion engines - Engine categories I, II and III 30.6 Alignment of engines 30.7 Flexible arrangement of diesel engines, piping, cables and other fittings connected to the engine 30.8 Mounting methods for propulsion engines and other components with a critical alignment 31 Propellers 31.1 Introduction 31.2 Fixed-pitch propellers 31.3 Use of controllable-pitch propellers of the engine categories 31.4 Fixed-pitch propellers, construction 31.5 Controllable-pitch propellers, the construction 31.6 Propeller shaft and coupling flange 31.7 Stern tube 31.8 Stern tube seals 31.9 Hydraulic bolts 31.10 Material used for controllable-pitch propellers 31.11 Propeller design 387 31.12 Cavitation 388 31.13 Calculating the propeller-blade model 390 31.14 Examples of other propulsion systems with controllable-pitch propellers 391 32 Regulations for propulsion engines, classification, repair and damage 396 32.1 Introduction 398 32.2 The IMO: International Maritime Organization 398 32.3 Classification societies 400 32.4 Periodic inspections of the diesel engine and its parts 401 32.5 Examples: Germanischer Lloyd 404 32.6 Materials for diesel engines 408 32.7 Tests and trials 409 32.8 The tests of mass-produced engines 412 32.9 Shipboard trials 412 32.10 Some important points 413 32.11 Regulations for propulsion engines 415 32.12 Engine alignment 424 32.14 Procedure for reconditioning parts 426 32.15 New parts 427 32.16 Special cases of wear and damage to engine parts 427 32.17 Damages to the engine or engine parts 429 32.18 Damages 429 32.19 Examples of certificates 431
DIESEL ENGINES > PART II
DIESEL ENGINES > PART II A large diesel power-station contains fourteen eighteen-cylinder V-engines running on H.F.O. for driving the electric generators. On the left; the gensets and on the right the turboblowers with the exhaust-gas pipes on the engines. Bottom left: Manufacture of a floating-diesel power plant. Make: Wartsila. Bottom right: A floating diesel-power plant or power barge travelling to its final destination. Make: MAN-B&W. At the front; the electric distribution section with the transformer, switches and pylons for connection to the high-voltage feeder on shore. Left of the engine room the air-inlet filters, with right the exhaust-gas lines and sound dampers. 18.1 Introduction For over fifty years diesel power plants have been used to generate electricity all over the world. They are located mainly on islands, in remote areas and often in regions with poor or nonexistent infrastructures, for instance in the tropics or in developing countries. Four-stroke high-speed diesel engines operating on .Vl.D.O. - generating up to ± 5 MW power output per set. Four-stroke medium-speed diesel engines operating on H.F.O. - generating up to ± 20 MW power output per set. Two-stroke low'-speed crosshead engines operating on H.F.O. - generating up to ± 50 MW power output per set. Floating diesel power plants with four-stroke trunk piston- or two-stroke crosshead diesel engines operating on H.F.O. - Delivering from ± 5 MW up to ± 20 MW power output per set. Mobile gensets installed in a container with four-stroke high-speed diesel engines, operating on M.D.O. - generating to ± 5 MW power output per set. 18.3 Applications for diesel power plants Electricity is generated in various parts of the world by diesel engines for the following reasons: 1 The required electric power is not large enough to justify building large-scale power stations with gas- and steam turbines. The return on capital expenditure is only acceptable when operating at full load. 2 The electric power is required for a short time-span. This occurs in projects for large infrastructures, special events or following major natural disasters. In these situations large emergency generators are used. These comprise diesel gensets placed in containers. This is also applied on a smaller scale with a single genset providing electricity. A transformer station fed by diesel gensets. Many countries with diesel-power plants, such those found in developing countries, only have an electricity grid in densely populated areas or areas with a high electricity demand. Here the transformers are fed by the diesel gensets increasing the voltage from 13,800 to 110,000 volt. The investment per kilowatt hour is much lower than that of traditional power generators such as steam- and gas turbines. At partial load with an installation comprising several engines, a certain number of engines are switched off, so that the remainder operate at full load. Thus the total efficiency for the generation of electric power remains high. The efficiency for the generation of electric power using steam- and gas turbines at partial loads is extremely low. Operating and maintaining gas- and steam turbines requires highly skilled personnel. This is to a lesser extent applicable for the maintenance of diesel engines. Maintaining diesel engines is relatively inexpensive. Stand-by diesel gensets: The stand-by genset is automatically started with a power failure of the mains. This system is often found in public buildings such as hospitals, institutions and large office blocks, but also as ‘black start’ in power plants, in industry and other vital processes. These diesel gensets can be started within several seconds and immediately operate at full load. 3 The local high-voltage electricity network is not capable to transport large amounts of electric power. 4 The electricity requirement per area is relatively small, for instance only a few dozen megawatts. The efficiency of this power output is much higher (± 40%) than the efficiency when using a gas and/or steam turbine. A diesel power plant of 100 MW is large. Some disadvantages of diesel power plants - Relatively high exhaust-gas emissions. - Limited power output per engine: - four-stroke: maximum 40 MW; - two-stroke crosshead engine: maximum 100MW; - gas turbine: maximum 400 MW; - steam turbine: maximum 1500 MW; - Relatively heavy. - Relatively high maintenance costs. A total efficiency graph for the various engines and engine combinations up to 50 megawatt shaft power. DIESEL ENGINES > PART II Location - Often in scarcely populated areas (with modest power requirements). - Especially in the tropics (poor infra-structure). - Often in third-world countries (low investment levels). - On islands and other isolated areas. - In remote areas with large industrial activities, such as in mining, gas- and oil drilling industries. 18.4 Types of diesel power plants 18.4.1 Utilizing four-stroke high-speed diesel engines operating on M.D.O. Engine category II Here the power output per diesel genset is limited to 1 to 5 i\1W due to comparatively expansive diesel oil. They are used to generate electricity locally for various purposes: - lighting; - infra-structure; - production processes in manufacturing plants such as breweries and water treatment. The number of revolutions per minute is usually 1500 and 1800, depending on the frequency (50 or 60 Hz). For the slightly larger engines the number of revolutions is lower. However, at approximately 1200 revolutions or less, there is the use of heavy fuel oil is possible. This is cheaper than diesel oil. The engine types used often fall in category II. A In diesel-power plants, four-stroke medium-speed diesel engines are often used. Shown, an eighteen-cylinder V-engine. Considering weight, size and capital cost this is the best choice as two in-line nine-cylinder engines have a similar maximum output, but are heavier, take up more space and capital cost is higher. An artist’s impression of a modularly built diesel-power plant only for electric power. 1 high-speed four-stroke diesel engine 2 electric generator 3 main switch board 4 engine-room ventilation 5 space for distribution station and transformers 6 air coolers for discharging the heat from the fresh water, lubricating-oil and combustion air-cooling systems. 14 Familiar makes are: Caterpillar, Cummins, MTU/DDC, GM. With the use of light diesel oils (M.D.O.), the fuel cleaning process is simple and the exhaust-gas emissions in comparison to those of heavy fuel oil (H.F.O.) are less. The high-speed high-load diesel engines used for gensets are usually arranged in V-shape. They arc compact and relatively light and are mounted either in a fixed or flexible manner on a steel frame and can immediately be positioned on the factory floor. In the gas- and oil industry, many high-speed diesel gensets are set up on locations that lack (natural) gas for operating gas-engine gensets. The total power output varies from several megawatts to over ten megawatts. A high-speed four-stroke diesel genset with its own generator cooling. In the foreground the electric generator with its own air-cooling system. Offshore, for instance gas and oil platforms, complete sets are often substituted during major maintenance, so as little work as possible needs to be done on location. This is cost effective. 18.4.2 Utilizing four-stroke medium-speed diesel engines operating on H.F.O. Engine category III Most of the world’s larger diesel power plants are in this category. These plants have a total capacity of up to 150 - 250 MW. To reach these capacities, several dozen of sixteen or eighteen cylinder V-engines with large cylinder bores are installed. A fuel treatment and supply system is an integral part of the installation. The large amounts of fuel are delivered by pipeline, ship or fuel tankers and stored temporarily in the storage tanks, enough supply for several days of consumption. A The entrance to a large diesel power-plant in the tropics. Here near Mombassa, Kenya. Left the plant and right the electric distribution to the high-voltage grid. A high-speed four-stroke genset running on diesel oil for electricity generation. The frame can be easily positioned on the shop floor.
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DIESEL ENGINES II for ship propulsion and power plants FROM 0 TO 100,000 kW
Year: 2008
Language: english
Author: Kees Kuiken
Publisher: Target Global Energy Training
ISBN: 978-90-79104-02-4
Format: PDF
Quality: Scanned pages
Number of pages: 424
Description:
DIESEL ENGINES for ship propulsion and power plants FROM OTO 100,000 kW
The author has paid scrupulous attention to the compilation of this book and it may be used by anyone desiring to do so, but Target Global Energy Training shall not be held responsible or liable in any way for the accuracy of information provided.
The task of completing this book could not have been accomplished without many substantial contributions by a considerable number of companies both in The Netherlands and abroad. These companies each in their own manner have contributed to the realisation of this edition by allowing interviews and providing photo-material and technical information.
It is impossible to single out any specific company. However, special reference is made of MAN Diesel AG and Wiirtsila, for their generous contributions.
Introduction
Diesel engines play an important role in today’s society: we are quite dependent on them.
Over 100 years after Rudolf Diesel developed a working diesel engine, there is still no real alternative for ship propulsion and electric generators in tropical and/or remote areas.
The diesel engine is indispensable for road haulage, inland shipping, aquatics, electric power emergency systems, agriculture, and passenger transport by road or rail, oil and gas industry and various other industries. We have chosen to make use of many pictures accompanied by a written explanation.
Much highly in-depth technical theory has been omitted as these topics are covered by specialist books available on the market; these topics include thermodynamics, vibrations, materials, and electronics.
We, at Target Global Energy Training have opted for a more practical approach. This includes ample information with respect to the construction of engines, use of materials, various engine categories, maintenance, repairs, and the use of engines.
Much attention has been paid to the choice of proper graphic material. This, in our opinion, is helpful for the reader to gain insight in the various subjects. This publication is indispensable for every person who has dealings with the diesel engine industry, from the smallest engine to ‘The Cathedrals of the Oceans’.
Kees Kuiken, Onnen, The Netherlands, July 2008.
Diesel Power Plants
Diesel Power Plants18 Diesel Power Plants
19 Ship propulsion
20 Transmission gears, flexible couplings, shafts, propeller shafts and generators
21 Diesel engine manufacturers
22 Engine emissions
23 Calculating fuel and lubricating-oil consumption
24 Auxiliary systems: Fuel and lubricating-oil
25 Operational management and automation
26 Reconditioning engines and their parts
27 Maintenance and repairs vibration dampers, shafting and
28 Casting of engine parts shaft generator drives
29 New fuel developments
30 Bedplates and engine alignments, gearboxes,
31 Propellers
32 Regulations for propulsion engines, classification separators repair and damage 396
Electricity is generated by diesel power plants in most parts of the world. This includes mobile floating power plants.
Shown here; discharging a floating power plant with MAN-B&W engines from a semi-submersible ‘Dockwise’ vessel.
CONTENTS
Introduction18 Diesel Power Plants
18.1 Introduction
18.2 Classification of diesel power plants
25 Operational management and automation 208
26 Reconditioning engines and their parts 218
27 Maintenance and repairs 284 vibration dampers, shafting and
28 Casting of engine parts 312 shaft generator drives 76
29 New fuel developments 338
30 Bedplates and engine alignments, gearboxes,
22 Engine emissions 14218.3 Applications for diesel power plants
18.4 Types of diesel power plants
18.5 Special applications of diesel power plants
18.6 An example of a large diesel power plant for the generation of electricity
18.7 Auxiliary engines
18.8 Outside the engine hall
18.9 Fuel quality
18.10 A few particulars
18.11 Examples of power plants
19 Ship propulsion
19.1 Introduction
19.2 Ship types and hull resistances
19.3 Load-lines of a ship
19.4 Ship dimensions and their values
19.5 Hull forms
19.6 Ship’s resistance
19.7 Screw propulsion
19.8 Propeller types
19.9 Flow conditions around the propeller
19.10 Propeller dimensions
19.11 Operating conditions of a propeller
19.12 Increasing ship speeds
19.13 Parameters causing heavy-running conditions
19.14 Manoeuvring speed
19.15 Direction of propeller rotation - lateral forces
19.16 Engine layouts and load diagrams
19.17 Electronic governors with load limitation
19.18 Use of charts
19.19 Summarising the effects of the various types of resistance on engine operation
19.20 Some comments
20 Transmission gears, flexible couplings, vibration dampers, shafting and shaft generator drives
20.1 Introduction
20.2 Diesel-engine arrangements
20.3 Gear transmission
20.4 Various constructions and designs of gear transmissions
20.5 Position of the input and output shaft
20.6 Types of teeth
20.7 Gear transmission for shaft generators
20.8 Couplings
20.9 Torsional vibration dampers
20.10 Engine shafts
20.11 Examples of complete systems with diesel engines, reduction gearing, shafting, couplings and vibration dampers
20.12 Vibration dampers below the engine frame
20.13 Examples of engine arrangements with flexible vibration dampers
20.14 Flexible connections to the diesel engine
21 Diesel engine manufacturers
21.1 Introduction
21.2 Engine categories
22 Engine emissions
22.1 Introduction to ‘the fossil fuel’ society
22.2 Exhaust gas composition
22.3 Units of contamination
22.4 Methods for the reduction of exhaust-gas emissions
22.5 Secondary methods
22.6 Reduction of sulphur oxides in
22.7 Removal of fine particles from exhaust gases
22.8 Examples of techniques engine manufacturers apply to reduce emissions
22.9 Measurements on board large modern sea going vessels
22.10 New techniques: the Miller process
22.11 New developments: the Hercules project
23 Calculating fuel and lubricating-oil consumption
23.1 Introduction
23.2 Diesel-engine efficiency
23.3 Shaft power in kW or MW
23.4 Specific fuel consumption
23.5 Fuel consumption
23.6 Fuel consumption for engines in diesel-power plants
23.7 Fuel consumption for propulsion diesel engines
23.8 Lubricating-oil consumption and specific lubricating-oil consumption
23.9 Measuring fuel consumption
23.10 Fuel consumption measured in trials
23.11 The oil-price development
24 Auxiliary systems: Fuel and lubricating-oil separators
24.1 Introduction
24.2 Fuels
24.3 The principle of centrifugal separators
24.4 Separation in a settling tank
24.5 Separation with a centrifugal separator
24.6 Types of separators
24.7 New separators by Alfa Laval
24.8 Effects of separators
24.9 Examples of cleaning systems for lubricating oil, fuel, sludge and bilge water
25 Operational management and automation
25.1 Introduction
25.2 Automation of diesel engines
25.3 Examples of automation systems
25.4 Operational management
25.5 Complete systems for diesel engines, some examples
26 Reconditioning engines and their parts
26.1 Introduction
26.2 Four-stroke engines
26.3 Two-stroke engines
27 Maintenance and repairs
27.1 Introduction
27.2 Types of maintenance
27.3 Instruction manuals/ Maintenance manuals
27.4 Engine maintenance
27.5 Maintenance for small engines - category I
27.6 Examples of maintenance for engines category III
27.7 Some examples of maintenance of large two-stroke crosshead engines
28 Casting of engine parts
28.1 Introduction
28.2 Cast-iron parts of diesel engines
28.3 Advantages of cast engine parts
28.4 Foundries
28.5 Casting process
28.6 Casting location
28.7 Moulds
28.8 Filling the casting moulds
28.9 Mould assembly
28.10 Cleaning the castings
28.11 Casting stresses
28.12 Checking air inclusions and damage
28.13 Control of the dimensions
28.14 Operations in the machining factory
28.15 Manufacturing crankshafts
29 New fuel developments
29.1 Introduction
29.2 Use of combination fuels
30 Bedplates and engine alignments, gearboxes, shafts, propeller shafts and generators
30.1 Introduction
30.2 Ship propulsion
30.3 Construction of the bedplate - Engine category IV
30.4 Examples of rigid mounting - Engine category III
30.5 Resilient mounting of propulsion engines - Engine categories I, II and III
30.6 Alignment of engines
30.7 Flexible arrangement of diesel engines, piping, cables and other fittings connected to the engine
30.8 Mounting methods for propulsion engines and other components with a critical alignment
31 Propellers
31.1 Introduction
31.2 Fixed-pitch propellers
31.3 Use of controllable-pitch propellers of the engine categories
31.4 Fixed-pitch propellers, construction
31.5 Controllable-pitch propellers, the construction
31.6 Propeller shaft and coupling flange
31.7 Stern tube
31.8 Stern tube seals
31.9 Hydraulic bolts
31.10 Material used for controllable-pitch propellers
31.11 Propeller design 387
31.12 Cavitation 388
31.13 Calculating the propeller-blade model 390
31.14 Examples of other propulsion systems with controllable-pitch propellers 391
32 Regulations for propulsion engines, classification, repair and damage 396
32.1 Introduction 398
32.2 The IMO: International Maritime Organization 398
32.3 Classification societies 400
32.4 Periodic inspections of the diesel engine and its parts 401
32.5 Examples: Germanischer Lloyd 404
32.6 Materials for diesel engines 408
32.7 Tests and trials 409
32.8 The tests of mass-produced engines 412
32.9 Shipboard trials 412
32.10 Some important points 413
32.11 Regulations for propulsion engines 415
32.12 Engine alignment 424
32.14 Procedure for reconditioning parts 426
32.15 New parts 427
32.16 Special cases of wear and damage to engine parts 427
32.17 Damages to the engine or engine parts 429
32.18 Damages 429
32.19 Examples of certificates 431
DIESEL ENGINES > PART II
DIESEL ENGINES > PART IIA large diesel power-station contains fourteen eighteen-cylinder V-engines running on H.F.O. for driving the electric generators.
On the left; the gensets and on the right the turboblowers with the exhaust-gas pipes on the engines.
Bottom left: Manufacture of a floating-diesel power plant. Make: Wartsila.
Bottom right: A floating diesel-power plant or power barge travelling to its final destination.
Make: MAN-B&W.
At the front; the electric distribution section with the transformer, switches and pylons for connection to the high-voltage feeder on shore. Left of the engine room the air-inlet filters, with right the exhaust-gas lines and sound dampers.
18.1 Introduction
For over fifty years diesel power plants have been used to generate electricity all over the world. They are located mainly on islands, in remote areas and often in regions with poor or nonexistent infrastructures, for instance in the tropics or in developing countries.
Four-stroke high-speed diesel engines operating on .Vl.D.O. - generating up to ± 5 MW power output per set.
Four-stroke medium-speed diesel engines operating on H.F.O. - generating up to ± 20 MW power output per set.
Two-stroke low'-speed crosshead engines operating on H.F.O. - generating up to ± 50 MW power output per set.
Floating diesel power plants with four-stroke trunk piston- or two-stroke crosshead diesel engines operating on H.F.O. - Delivering
from ± 5 MW up to ± 20 MW power output per set.
Mobile gensets installed in a container with four-stroke high-speed diesel engines, operating on M.D.O. - generating to ± 5 MW power output per set.
18.3 Applications for diesel power plants
Electricity is generated in various parts of the
world by diesel engines for the following reasons:
1 The required electric power is not large enough to justify building large-scale power stations with gas- and steam turbines. The return on capital expenditure is only acceptable when operating at full load.
2 The electric power is required for a short time-span. This occurs in projects for large infrastructures, special events or following major natural disasters. In these situations large emergency generators are used. These comprise diesel gensets placed in containers. This is also applied on a smaller scale with a single genset providing electricity.
A transformer station fed by diesel gensets.
Many countries with diesel-power plants, such those found in developing countries, only have an electricity grid in densely populated areas or areas with a high electricity demand. Here the transformers are fed by the diesel gensets increasing the voltage from 13,800 to 110,000 volt.
The investment per kilowatt hour is much lower than that of traditional power generators such as steam- and gas turbines.
At partial load with an installation comprising several engines, a certain number of engines are switched off, so that the remainder operate at full load. Thus the total efficiency for the generation of electric power remains high. The efficiency for the generation of electric power using steam- and gas turbines at partial loads is extremely low.
Operating and maintaining gas- and steam turbines requires highly skilled personnel.
This is to a lesser extent applicable for the maintenance of diesel engines.
Maintaining diesel engines is relatively inexpensive.
Stand-by diesel gensets: The stand-by genset is automatically started with a power failure of the mains. This system is often found in public buildings such as hospitals, institutions and large office blocks, but also as ‘black start’ in power plants, in industry and other vital processes. These diesel gensets can be started within several seconds and immediately operate at full load.
3 The local high-voltage electricity network
is not capable to transport large amounts of electric power.
4 The electricity requirement per area is relatively small, for instance only a few dozen
megawatts. The efficiency of this power output is much higher (± 40%) than the efficiency when using a gas and/or steam turbine. A diesel power plant of 100 MW is large.
Some disadvantages of diesel power plants
- Relatively high exhaust-gas emissions.
- Limited power output per engine:
- four-stroke: maximum 40 MW;
- two-stroke crosshead engine: maximum 100MW;
- gas turbine: maximum 400 MW;
- steam turbine: maximum 1500 MW;
- Relatively heavy.
- Relatively high maintenance costs.
A total efficiency graph for the various engines and engine combinations up to 50 megawatt shaft power.
DIESEL ENGINES > PART II
Location
- Often in scarcely populated areas (with modest power requirements).
- Especially in the tropics (poor infra-structure).
- Often in third-world countries (low investment levels).
- On islands and other isolated areas.
- In remote areas with large industrial activities, such as in mining, gas- and oil drilling industries.
18.4 Types of diesel power plants
18.4.1 Utilizing four-stroke high-speed diesel engines operating on M.D.O. Engine category II
Here the power output per diesel genset is limited to 1 to 5 i\1W due to comparatively expansive diesel oil.
They are used to generate electricity locally for various purposes:
- lighting;
- infra-structure;
- production processes in manufacturing plants such as breweries and water treatment.
The number of revolutions per minute is usually 1500 and 1800, depending on the frequency (50 or 60 Hz). For the slightly larger engines the number of revolutions is lower. However, at approximately 1200 revolutions or less, there is the use of heavy fuel oil is possible. This is cheaper than diesel oil. The engine types used often fall in category II.
A
In diesel-power plants, four-stroke medium-speed diesel engines are often used.
Shown, an eighteen-cylinder V-engine. Considering weight, size and capital cost this is the best choice as two in-line nine-cylinder engines have a similar maximum output, but are heavier, take up more space and capital cost is higher.
An artist’s impression of a modularly built diesel-power plant only for electric power.
1 high-speed four-stroke diesel engine
2 electric generator
3 main switch board
4 engine-room ventilation
5 space for distribution station and transformers
6 air coolers for discharging the heat from the fresh water, lubricating-oil and combustion air-cooling systems.
14
Familiar makes are: Caterpillar, Cummins, MTU/DDC, GM.
With the use of light diesel oils (M.D.O.), the fuel cleaning process is simple and the exhaust-gas emissions in comparison to those of heavy fuel oil (H.F.O.) are less.
The high-speed high-load diesel engines used for gensets are usually arranged in V-shape. They arc compact and relatively light and are mounted either in a fixed or flexible manner on a steel frame and can immediately be positioned on the factory floor.
In the gas- and oil industry, many high-speed diesel gensets are set up on locations that lack (natural) gas for operating gas-engine gensets. The total power output varies from several megawatts to over ten megawatts.
A high-speed four-stroke diesel genset with its own generator cooling.
In the foreground the electric generator with its own air-cooling system. Offshore, for instance gas and oil platforms, complete sets are often substituted during major maintenance, so as little work as possible needs to be done on location. This is cost effective.
18.4.2 Utilizing four-stroke medium-speed diesel engines operating on H.F.O. Engine category III
Most of the world’s larger diesel power plants are in this category. These plants have a total capacity of up to 150 - 250 MW. To reach these capacities, several dozen of sixteen or eighteen cylinder V-engines with large cylinder bores are installed.
A fuel treatment and supply system is an integral part of the installation. The large amounts of fuel are delivered by pipeline, ship or fuel tankers and stored temporarily in the storage tanks, enough supply for several days of consumption.
A
The entrance to a large diesel power-plant in the tropics. Here near Mombassa, Kenya.
Left the plant and right the electric distribution to the high-voltage grid.
A high-speed four-stroke genset running on diesel oil for electricity generation.
The frame can be easily positioned on the shop floor.
Примечание от: Arcan [перевести]
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