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Cooper Superior, 2406, 4.74 MW Natural Gas Power Plant, 6x 790 kW, 50 Hz, with 883 kW Mitsubishi Diesel Backup

Description

  1. Overview
    1. Inventory number: E-1815
    2. Six Cooper Superior model 2406 natural gas powered generators
    3. 790 kW each at 50 Hertz, continuous duty
    4. Total 4.74 MW
    5. Includes one 883 kW Mitsubishi diesel prime power emergency back-up generator
    6. Complete 5.4 MW islanded generating system
    7. Fully black start capable, with island or grid-parallel operating modes
    8. Modular construction with six modules each containing one natural gas engine, radiator, and auxiliaries
    9. Seventh module contains the 1.0 MW diesel emergency generator, plant switchgear, oil, and compressed air utilities
    10. Modules can be removed and transported as individual units
    11. Single ply membrane applied on top of modules for continuous leak-proof roof over engine sections
  2. Electrical Connections
    1. Buss duct used for all gas generator output power connections to main switch
    2. Cable tray for all connecting control wiring
    3. Diesel generator connected via conventional wire and wireway
  3. Cooling System
    1. Jacket water and auxiliary (oil and turbocharger intercooler) radiators are roof mounted horizontally above an air plenum room
    2. Plenum room pressurized by four 5 HP electric motor-driven cast propeller fan assemblies
    3. Fans for each module individually controlled based on return jacket water temperature by house controller to minimize parasitic fan energy losses
    4. Auxiliary radiator and jacket water radiator are in series in the airflow, with air passing through auxiliary radiator first, then jacket water radiator
  4. Block Heating
    1. Each group of three gas engines thermally coupled by a three pass welded plate heat exchanger
    2. Allows a single running engine to maintain 160 degF jacket water temperatures in its two companion gensets
    3. Three engines’ jacket water systems are completely isolated from one another by the plate heat exchanger
    4. Diesel engine has a conventional thermostatically controlled electric block heater
  5. Utilities
    1. Makeup oil supplied from central location via hard piping and permanent pump to each engine’s makeup oil tank and directly to oil sump fill point ahead of oil level regulator
    2. Spent oil from each engine’s sump and oil cooler evacuated via permanent pump and hard piping to outdoor waste oil tank capable of storing one complete set of oil changes for all six gas engines
    3. Compressed air supplied via a 10 HP Ingersoll Rand industrial air compressor with vertical tank
    4. Compressed air available for operating pneumatic engine controls and pneumatic service tools
    5. Engine pneumatics can also be operated using high pressure natural gas fuel supply, provided fuel gas supply pressures are maintained above 50 psig to achieve full generating system output
  6. Sound Attenuation
    1. Generation modules fully noise attenuated with engineered acoustical materials
    2. Exhaust noise muffled with critical grade silencers
    3. System currently emits sound resulting in noise levels below 65 dBA at property line approximately 100 feet away
    4. Noise drops to almost 55 dBA when radiator fans are not operating
    5. Use of variable speed drive to slow fan rotational speed could lower overall sound levels to below 58 dBA at all times under all load conditions
  7. Cogeneration Equipment
    1. Each gas generator equipped with a welded plate jacket water heat exchanger sized for complete recovery of jacket water heat
    2. Secondary side of these heat exchangers is not currently connected to any plant thermal load
  8. Ratings – Cooper Superior Model 2406G
    1. Continuous: 1,200 rpm – 1,200 bhp, 895 kWm, 850 kWe; 1,000 rpm – 1,060 bhp, 790 kWm, 750 kWe; 900 rpm – 950 bhp, 708 kWm, 675 kWe
    2. Prime: 1,200 rpm – 1,320 bhp, 984 kWm, 935 kWe; 1,000 rpm – 1,110 bhp, 825 kWm, 785 kWe; 900 rpm – 990 bhp, 738 kWm, 700 kWe
    3. Intermittent: 1,200 rpm – 1,385 bhp, 1,033 kWm, 980 kWe; 1,000 rpm – 1,155 bhp, 861 kWm, 820 kWe; 900 rpm – 1,045 bhp, 779 kWm, 740 kWe
  9. Equipment List – Cooper Superior System
    1. Engines: Cooper Superior model 2406G, 6 units (5 new, 1 used with 7,000 hours)
    2. Alternators: Newage Stamford model HC736F, 6 units, 97% efficiency at 1.0 PF
    3. Prime power genset assemblies: Simpower model SP0900N3Q:2406G, 6 units, 925 kW at 0.80 PF, 935 kW at 1.00 PF
    4. Backup diesel genset assembly: Mitsubishi, 1 unit, 1,000 kW
    5. Genset enclosures: PCX, 6 units, noise attenuated to 65 dBA at 50 feet
    6. Jacket water heat exchangers: WTT, 3 units
  10. Additional Equipment – Cummins Diesel Generators
    1. Sixteen Cummins diesel generator sets, model DQKC, QSK60 series engine
    2. Continuous rating 1,200 kW each at 50 Hz
    3. Total 19.2 MW at 50 Hz
    4. Total run hours: 20 to 230 hours, average 60 hours
    5. Complete power generating station with 16 Cummins 2,000 kW diesel generator sets and accessories
    6. Units are new, operated only for commissioning and testing
    7. Each DGS in its own weather-tight, noise attenuating housing (removable for shipping)
    8. Fifteen thousand gallon double-wall fuel tanks for each DGS (16 total)
    9. Utility building with urea supply tanks (5), one potable water tank, breakers, control room, and storage
    10. Substation with ABB reclosers to connect to power grid
    11. Units have selected catalytic reduction (SCR) for reduction of NOx by 90% and CO by 85%
    12. Generating set ratings: 1,750 kW to 2,000 kW at 60 Hz; 1,500 kW to 1,650 kW at 50 Hz
    13. Warranty provided to original owner, transferable to buyer