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Caterpillar, CG260-16, Natural Gas Engine Generator Set, 4500 kWel, 10.5 kV, 50 Hz, 1000 rpm

Caterpillar, CG260-16, Natural Gas Engine Generator Set, 4500 kWel, 10.5 kV, 50 Hz, 1000 rpm

Description

  1. Overview
    1. Caterpillar CG260-16 natural gas engine generator sets (reciprocating, V16).
    2. Quantity: 6 sets available.
    3. Rated electrical output: 4500 kWel (4.5 MW) at 10500 V, 50 Hz, 1000 rpm.
    4. Rated electrical efficiency: 43.9% (ISO 3046/1).
    5. Engine and generator set: Caterpillar, Germany; package ECIM, China.
  2. Scope Of Supply, Each Set
    1. 4 MW class gas generator set: CG260-16 engine, TD145 generator 10.5 kV 50 Hz 4500 kWe / 5625 kVA.
    2. Electric pre-lubrication system.
    3. Gas valve train: DN 125, 15 kPa.
    4. Control system: TEM-EVO.
    5. Compressed air starter motor: 20 to 30 bar.
    6. Three-way valves, sensors, water pumps, pressure switches and similar components.
    7. Intake air preheating system.
    8. Auxiliary equipment.
    9. Factory standard testing, with electronic files, to CES specifications.
    10. Documentation: unit user manual, drawings, and operation and maintenance manual.
    11. Commissioning accessories.
    12. On-site service: installation and commissioning.
    13. On-site service after commissioning: 1 electrical and 1 mechanical engineer per year.
  3. Engine
    1. Engine / configuration code: CG260-16 / R.
    2. Arrangement: V16.
    3. Bore / stroke / displacement: 260 mm / 320 mm / 272 dm3.
    4. Speed / mean piston speed: 1000 rpm / 10.7 m/s.
    5. Compression ratio: 12; brake mean effective pressure: 20.3 bar.
    6. Lube oil consumption, average at full load: 0.2 g/kWh.
    7. Lube oil capacity, engine: 1850 dm3.
    8. Net weight, engine / generator set: 24890 kg / 54300 kg.
    9. Generator set voltage / voltage range / power factor: 10500 V / 10% / 1.00; speed / frequency: 1000 rpm / 50 Hz.
  4. Design Conditions And Gas Data
    1. Intake air temperature / relative humidity: 25 °C / 80%; altitude: 1000 m; exhaust cooled to 120 °C.
    2. Genset raw NOx emission (tolerance -8%): 500 mg/Nm3 at 5% O2.
    3. Fuel gas: methane number 87, lower heating value 10.09 kWh/Nm3, density 0.76 kg/Nm3; CH4 94.58%, C2H6 2.34%, N2 2.00%, C3H8 0.63%, CO2 0.20%, C4H10 0.19%, C5H12 0.02%, CxHy 0.01% by volume.
  5. Energy Balance At 100% / 75% / 50% Load
    1. Electrical power (ISO 8528-1, COP): 4500 / 3375 / 2250 kW.
    2. Jacket water heat: 1925 / 1422 / 947 kW (±8%).
    3. Intercooler water heat: 238 / 156 / 90 kW (±8%).
    4. Lube oil heat: 696 / 623 / 526 kW (±8%).
    5. Exhaust heat, cooled to 120 °C: 1913 / 1600 / 1250 kW (±8%).
    6. Exhaust temperature: 378 / 406 / 446 °C (±25 °C).
    7. Exhaust mass flow, wet / dry: 24552 / 22471, 18436 / 16837, 12577 / 11456 kg/h.
    8. Combustion air: 23782 / 17841 / 12157 kg/h.
    9. Engine / generator radiant heat: 198 / 101, 154 / 83, 109 / 72 kW (±8%).
    10. Fuel consumption: 10249 / 7922 / 5592 kW (+5%).
    11. Electrical / thermal efficiency: 43.9 / 44.2%, 42.6 / 46.0%, 40.2 / 48.7%.
    12. Total efficiency: 88.1 / 88.6 / 88.9%.
  6. System Conditions
    1. Intake air flow at 15 K temperature rise (including combustion air): 118100 kg/h.
    2. Intake air temperature minimum / design: 5 / 25 °C.
    3. Exhaust back pressure minimum / maximum: 30 / 50 mbar.
    4. Exhaust volume flow, wet / dry: 19090 / 17053 Nm3/h.
    5. Maximum pressure drop before the air filter: 5 mbar.
    6. Gas zero-pressure regulating train, pressure range: 20 to 200 mbar; gas pre-pressure-reducing train: 0.5 to 10 bar.
    7. Compressed air receiver: 2000 dm3 / 30 bar; starter motor: 800 dm3/s / 16 bar.
  7. Cooling System
    1. Antifreeze content, jacket water / intercooler water: 50 / 50% by volume.
    2. Circulating water volume: 570 / 51 dm3; KVS / Cv value: 88 / 62 m3/h.
    3. Jacket water temperature in / out: 78 / 92 °C; intercooler water in / out: 44 / 48 °C.
    4. Jacket water flow minimum / maximum: 110 / 137 m3/h.
    5. Circulating water flow, jacket / intercooler: 134 / 65 m3/h; pressure drop: 2.4 / 1.2 bar.
    6. Engine coolant outlet pressure minimum / maximum: 3.1 / 3.4 bar (gauge).
    7. Engine inlet lube oil maximum temperature / lube oil flow: 80 °C / 125 m3/h.
  8. Noise
    1. Air intake noise: sound power level 132.4 dB(A) ±4 dB (DIN EN ISO 3746).
    2. Exhaust noise: sound power level 137.2 dB(A) ±3 dB, measured in the exhaust pipe (DIN 45635-11 Annex A).
  9. Generator (TD145)
    1. Make: TD Power Systems; model TD145; stationary, continuous duty, IEC 60034-1.
    2. Rating: 4500 kWe / 5625 kVA; 10500 V ±10%; 309 A; 50 Hz ±5%; 1000 rpm; power factor 0.8 to 0.95.
    3. Mounting: IM1101 (IM B20); winding pitch 5/6; star connection (3/1).
    4. Insulation class F, temperature rise class B; enclosure IP23, terminal box IP54; cooling IC01.
    5. Cylindrical rotor; sleeve bearings with forced lubrication; shaft center height 365 mm.
    6. Brushless excitation through PMG; AVR DEIF DVC 550, voltage regulation ±0.25%, response under 20 ms.
    7. Efficiency at 100% load: 96.60% (0.8 pf lagging) to 97.80% (1.0 pf).
    8. Short-circuit ratio 0.65; overload 110% for 1 hour in every 12 hours.
    9. Accessories: 6 winding RTDs, 2 bearing RTDs, 4 x 150 W space heaters (1-phase, 240 V), 3 CTs and 3 PTs.
    10. Suitable for parallel operation with other generator sets and island mode.
    11. Generator weight: 19000 kg.
    12. The alternator make and type may be substituted by the engine plant during the order stage; the power output does not change.
  10. Controls And Electrical
    1. Multiple genset control architecture: TEM engine management per set, HAS auxiliary panel (MCC), ZAS common control panel (main control cabinet), GLF generator circuit breaker cabinets, main circuit breaker, customer control system interface, outgoing feeders and utility grid connection.
    2. Auxiliary electrical load per set, stationary power module: HAS 84 kW / 152 A, FUS 94 kW / 159 A (stationary CHP: HAS 107 kW / 192 A, FUS 94 kW / 159 A).
    3. Auxiliaries include pre-lubrication oil pump 15 kW, electrical pre-heater 21 kW, jacket water pump 22 kW, after-cooling water pump 11 kW, heating circuit water pump 18.5 kW, air compressor 7.5 kW, radiator fans (10 x 2.45 kW and 14 x 1.8 kW) and inlet air ventilation fans (4 x 7.5 kW) on frequency converters.