BC Global Projects

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Global Proects MARCH 2011


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Broadcrown is a leading independent

manufacturer of complete power

generation systems. We are trusted

around the world to deliver an

extensive range of standard and

bespoke systems from small standby

diesel generators to large-scale turnkey

power projects.

Broadcrown was one of the rst power

generation companies to be approved

to ISO 9001 standards and quality

drives every aspect of our business.

Our designs use superior components

throughout; not just in the generatorsets but also the associated

equipment, such as skid bases, fuel

handling, ventilation units, air start

modules and control systems.

Our standard product range of high-

speed single units extends from 5We

to 2.6MWe. In addition, our medium

speed engines and gas turbine single

units complement the range from

1.0MWe to 11.2MWe. All units can

be combined to meet the requirements

of larger projects for a broad range of

applications delivering standby, prime

or continuous power.

We will work with you to implementany product modications that you

need specically for your project.

Our generator set range includes:

• Prime & standb bac up power

• Base load generation• Oil & gas industr applications

• Marine power generation

• Critical power including UPS

sstems

• Gas and co-generation (CHP)

applications

• Rental applications

Broadcrown offers ou full-designed and proectmanaged turne power solutions from the

foundations up.


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contents

Introduction 3

Scope of supply 4 – 5

Typical power station layout 6 – 7Case studies: 1. Madagascar 8

2. Netherlands 9

3. Qatar 10

4. England 11

5. Botswana 12

Prime mover selection guide 14

Generator set designations & denition of ratings 15

Selected high speed generator sets 16 – 17

Selected medium speed generator sets 18 – 19

Selected gas and co-generation sets 20

Gas turbine generator sets 21

Fuel exibility 22Control systems 23

Service and support 24


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Broadcrown Global Proects:

designing and delivering complete power generation

projects, worldwide.

Global Proects division is the

contracting group within Broadcrownresponsible for delivering an

etensive range of power generation

solutions including bespoe turne

or etended scope, across the

world. Since 1993, the division has

established an unrivalled reputation

for high qualit design, best-t

procurement and a successful

‘on time–on budget’ approach to

construction management.

Our project managers have engaged

in projects in over 50 countries

installing in excess of 750MWe of

essential power; requiring the division

to demonstrate its vast experience,

breadth of knowledge and application

skills across the entire power

generation spectrum.

Our UK-based design team canincorporate the Broadcrown standard

or bespoke generator set product

into a complete system for you. They

will engineer the project, select and

procure the equipment and carry out

the construction from the ground up.

In addition, our service group will

listen to your operational needs and

guide you through the benets of a

long-term supply agreement providing

you with complete peace of mind

during the operation of your power

system.

We have engaged in many different

projects, worldwide, including—

• Black start for large turbine power

plants

• Base load thermal power plants for

utility companies and industrial

facilities

• Back up standby generation when

power is a critical component• Combined heat and power systems

providing both electricity and heat

• Peak shaving schemes generating on

local power to avoid high electricity

tariffs

More details about specic projects are

included in the Case Studies later in

this brochure.

BROADCROWN USA

BROADCROWN GROUP HEADQUARTERS

BROADCROWN WEST AFRICA

BROADCROWN SOUTH AFRICA

BROADCROWN CHINA

BROADCROWN INDIA

BROADCROWN SINGAPORE

BROADCROWN AUSTRALIA(2011)


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Broadcrown Global Proects’ exibility in our scope of

supply means we deliver a project optimised to meet your

exacting requirements every time.

Global Proects will wor with ou

to establish the optimum scope ofsuppl required for our specic

proect. We are eible and can

provide a minimal scope right

through to a complete turne

sstem.

To ensure that every project is

executed competitively but to a

high quality, we use local cost

effective resources wherever possible

while maintaining rigorously high

Broadcrown standards. By actively

encouraging in territory collaborative

partnerships with our clients, we

ensure both the lowest installed

costs per kWe and the maximum use

of local resources.

The ve levels of scope detailed on

these two pages illustrate the wide

range of power generation solutions

we can provide.

level 1.

ESSENTIAL

ESSENTIAL scope consists of agenerator set:

• Engine and coupling

• Alternator

• Baseframe

• Anti vibration mountings

• Generator set/engine control panel

• Lube oil circulation tank or engine wet

sump

• Combustion air ltration.

and the following etras:

• Factory testing

• Operation & maintenance manuals

• Parts for commissioning

level 2.

ESSENTIAL PLUS

ESSENTIAL PLUS includes all theESSENTIAL scope items plus the

following:

• Baseframe-mounted and remote cooling

water radiators

• Heat exchangers

• Fuel treatment and fuel pumping skids

• Exhaust silencers

• Air-starting compressors and reservoirs

• Local daily fuel tanks

• Remote generator control systems for

control room location

• Commissioning services

• Project management & site supervision


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level 3.

ESSENTIAL COMPLETE

ESSENTIAL COMPLETE includes all theESSENTIAL PLUS items with the addition

of the following equipment:

• Plant room ventilation systems

• Chimney stacks

• Medium voltage switchgear

• Neutral earthing panels with contactors

and resistor

• Low voltage distribution boards

• Low voltage motorised control centres

• Step up and step down transformers

• Powerplant SCADA systems

• Generator set diagnostic equipment.

ESSENTIAL COMPLETE also includes:

• Fuel and oil bulk storage tanks

• Gas supply control, metering and

pressure monitoring

• Clean & dirty lubrication oil storage

• Heat recovery systems

• Engine hall inlet and outlet ventilation

systems

• Acoustic treatment including attenuators

• Air conditioning for control rooms and

temperature sensitive areas

• Oily water separation, sludge tanks andincinerators

• SCADA system for total powerplant

control and monitoring

• DC battery based back up power supplies.

and the following services:

• Site performance testing

• Freight and delivery of goods to site

• Ofoading onto prepared foundations

• Product training at works and on site

supervision

level 4.

TURNkEy

TURNkEy includes all the ESSENTIALCOMPLETE items with the addition of

all site wors, mechanical and electrical

installation, civils and buildings.

Buildings include:

• Main powerhouse building

• Fuel handling buildings

• Electrical switchgear rooms

• Substations

• Administration building

• Workshop and storage

Site wors include:

• Site demolition and clearing

• Soil stabilisation, concrete foundations

and slabs

• Plant boundary fencing

• Fuel and oil unloading area

• Roads and parking in plant

• Above & below ground site pipework

• Above and below ground power and

control cabling

• Steel structures such as pipe bridges and

mezzanine oors

• Building and chimney stack lightening

and aviation protection• Overhead cranes for maintenance

• Access ladders and service platforms

Installation wors include:

• Installation of all equipment

• Fire ghting systems including re pump

modules, re detection and bulk water

storage

• Potable water treatment, raw and treated

water storage

• Fuel tank farm containment

• Floor drain systems with sump pumps• Power station internal and external

lighting and small power

• Fit out and furnishing of control rooms

and rest spaces

• Temporary power during construction

level 5.

TURNkEy PLUS

TURNkEy PLUS includes all the TURNkEyitems plus operation and maintenance:

• Flexible maintenance contracts and long

term supply agreements

• Operational services

• Spare parts supply

• Fit out of tooling workshops


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Tpical power station laout1. Substation

2. Worshop

3. Powerhouse with integral switch and control room

4. Remote coolers

5. Fuel pump house6. Fire water storage

7. Fuel farm

8. Fuel unloading station

9. Securit and administration

1

2

3


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4

5

6

7

8

9


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C A S E

S T U D I E S

Broadcrown was chosen to supply,

install and commission an additional

generator set and associated

equipment with an electrical output

of 4MWe at Mahajanga power station

in Madagascar. The power station is

operated by Jirama, the Madagascarelectric utility, and will provide

essential baseload electricity to local

communities.

Broadcrown engineers selected the

Rolls-Royce B32:40L9 engine which

provided the optimum prime mover

for this application. The nine-

cylinder engine operates on heavy

fuel oil (HFO). Broadcrown’s scope of

works included the balance of plant

equipment, fuel ltration, controls and

ventilation systems and partnered with

a local civils contractor to carry out

site works as required.

Signicant advantages from a high

qualit medium speed generator set

Broadcrown is an independent power

generation company and a supplier of

both high speed and medium speed

generator sets putting us in a strongposition to advise clients impartially

on the optimum selection for their

projects.

At Mahajanga, the client uses HFO as

the primary fuel source, which reduces

operational costs when compared to

traditional distillate fuels. Broadcrown

offered a medium speed unit capable

of successful operation on the less

rened HFO as high speed engines

are limited to operation on distillate

fuels only. The capital expenditure

required is signicantly higher for

a medium speed product compared

with an equivalent power high speed

installation but this is more than

offset by the lower fuel costs and

higher availability of a medium speed

generator set.

1. Madagascar

Supplying baseload power efciently

required a medium speed generator

set running on heavy fuel oil

optimising fuel costs.

MAHAjANGA POWER STATION

Broadcrown proect management and integration

Rolls-Roce Bergen engine

Civil wors in partnership with local sub contractor

Operating on heav fuel oil (HFO)

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C A S E

S T U D I E S

AMSTERDAM DATA CENTRE


Generating at 10,000V

Wartsila diesel engines

Plant room installation

Air starting sstem

Broadcrown were employed to supply

and install six 3.76MWe generator

sets at a key European bre optic

connection hub in Amsterdam. This

data centre provides high reliability

and security of data storage to its

international customers.

The generator sets produced their

power at 10,000V 3 phases 50Hz and

were located in a plant room with

remote radiators. The sets, when

synchronised, provide a total of

22.8MWe of critical back up power.

Wartsila 18 clinder engines

selected b Broadcrown

For this project the Broadcrown

engineers selected the Wartsila 18V200

prime movers. These 136 litre V18

engines have the feature of rapidstarting via single air turbine starter

motors. All sets are designed to

synchronise to each other on to the

10,000V busbar of the high voltage

switchboard. The engines are set up

to operate on diesel fuel fed from

bunded bulk storage fuel tanks located

adjacent to the plant room.

2. Netherlands

Critical power for a key European

data centre using 18 cylinder

Wartsila engines with rapid starting

air turbine motors.

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C A S E

S T U D I E S

Broadcrown provided four specially

designed 2000kWe generator sets to

the Doha North Sewage Treatment

works which is the largest waste water

and sludge treatment project in the

Middle East. The treatment works,

operating at peak capacity, can treatup to 439,000 cubic metres of waste

water per day and serves a population

of over 900,000.

A back up power supply in the event

of a mains failure is a critical aspect of

the overall system, as failure of power

supply to the process would make it

impossible to deal with the incoming

waste. This would lead to a major

incident at the works.

Full power even at ver high ambient

temperatures

Broadcrown’s four specially designed

2000kWe generator sets had to be

capable of operating in ambient

temperatures up to 50°C. To achievethis we located remote cooling systems

capable of dealing with very high

temperatures outdoors on a prepared

12m2 concrete plinth.

Broadcrown engineers paid particular

attention to the design of the

coolers ensuring they were sized to

accommodate maximum ambient

temperatures whilst maintaining the

required maximum coolant return

temperatures to the engines.

Generating at 3300V 3 phase 50Hz, the

sets are designed to rapidly start and

synchronise to each other within 60

seconds from the initial start signal.

Broadcrown also developed and

supplied the control suite including all

synchronising equipment. Built as a

six section panel the suite was shipped

with the generator sets for installation

in the nearby building control room.A neutral earthing panel was also

included containing four contactors

and one common resistor section.

3. Qatar

Critical back up power capable of

rapid start and synchronisation in

ambient temperatures up to 50°C.

DOHA NORTH SEWAGE TREATMENT



50°C operation capabilit with no reduction in power

Rapid starting and snchronising

Plant room installation

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C A S E

S T U D I E S

LONDON CRITICAL POWER



Strict 65dBA noise limits

Parallel redundant PLC control sstems

Floating concrete oor design

Broadcrown’s design team designed

and installed three Broadcrown

1600kWe 11,000V 3ph 50Hz generator

sets into a very tightly spaced plant

room in London’s nancial district.

The generator sets were located in a

high-rise corporate building, housinglarge nancial trading oors. Even

a short interruption of power to

the trading oor, shutting down its

operation, could have resulted in many

millions of pounds of lost revenue.

Back up power was critical.

At the same time, the design had to

comply with a stringent maximum

noise level of only 65dBA from outside

the building. The natural vibration

from the running equipment had also

to be isolated from the building’s main

structure, eliminating risk of structure-

borne noise travelling through the

oors of the building.

30 ears of Broadcrown eperience

helped meet stringent noise

requirements.

Broadcrown designers adopted a ‘room

within room’ approach by installing

an acoustic panelling system to allinternal walls and ceiling. To ensure

that noise was not transmitted

through the building structure, the

sets were mounted on a specialist

concrete ‘oating’ oor supported by

rubber isolation mountings.

Due to the critical nature of the

supply, the client stipulated that no

part of the overall system should have

a potential single point of failure.

Therefore all auxiliary balance of plant

systems were designed with parallel

redundant back up capability.

4. England

Critical back up power for nancial

trading oors with stringent noise

control.

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C A S E

S T U D I E S

Broadcrown provided nine specially

designed containerised generator sets

each rated at 2000kWe generating

at 6,600V/3ph/50Hz to Botswana.

Botswana’s energy capacity is

provided by thermal sources, mainly

coal-red, with some small dieselgenerators in rural areas. The bulk of

domestic electricity is generated by

the Morupule 600 MW coal-red steam

turbine power station.

The sets were housed in Broadcrown’s

CSC-plated enclosures ensuring that

they are treated as a standard ISO

container, for shipping purposes,

enjoying the benet of minimal

shipping costs. Broadcrown also

provided the neutral earthing, and

synchronising control and monitoring

systems.

Special design for high start up

loads

Often, in the case of black start

applications, the initial start load of

the power plant’s process equipment is

signicantly higher than the runningload. This is mainly due to the large

induction motors used to accelerate

the turbine rotors to ring speed.

Invariably these motors are energised

direct on line without any assisted

starting devices. Therefore it is

necessary to ensure the generator sets

selected are optimised for ‘best in

class’ step load capability.

As an independent company,

Broadcrown has the benet of

selecting the best engine and AC

generator congurations available

for the application from the many

manufacturers who supply us. The

better the generator set’s performance

in this area, the fewer the number of

generator sets needed on site and the

lower the installed cost for the client.

5. Botswana

Black start power shipped as

containerised generator sets.

MORUPULE POWER STATION


Oversized alternators for improved motor starting


CSC plated containers

Neutral earthing sstem

Full ‘set to set’ and ‘set to mains’ snchronising

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All generator model designations

begin with the prex BC indicating aBroadcrown generator set.

The following letter(s) are used to

indicate the manufacturer of the

engine on which the generator is

based. For example—

MAN: BCMN

Rolls-Royce: BCR

General Electric: BCG

Rolls-Royce Turbine: BCRT

Cummins: BCC

Mitsubishi: BCM

MTU: BCMU

Waukesha: BCWA

Guascor: BCGU

Perkins: BCP

The next part of the designation is

a number that represents the poweroutput of the generator set—

Liquid fuel products

50Hz applications: rating is in kVA

60Hz applications: rating is in kWe

Natural gas products



The fourth section of the designation

represents the Power Rating Denition

as identied in ISO8528-1:2005:

C: is Continuous Operating Power

(COP)

P: is Prime Power (PRP)

S: is Emergency Standby Power (ESP)

or Limited Time Power (LTP)

The fth section indicates the

frequency (Hz) of the generator set—50: is a 50Hz machine

60: is a 60Hz machine

The nal part of the designation

applicable to medium speed engine

and gas turbine generator sets denes

the number of poles in the

AC generator—

4: is a 4 pole machine

(1500 and 1800 r/min)


(1000 r/min)

8: is an 8 pole machine

(900 r/min and 750 r/min)


(720 r/min)

For gas generator sets the nal

designation indicates the fuel type—

NG: Natural gas

Generator set designations and denition of ratings

- / POWER OUTPUT

6110BCSTANDARD

PREFIx

Summar

C

RATING

MN

ENGINE

MANUFACTURER

8

NO. OF

POLES

OR FUEL

TyPE

50FREQUENCy


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Reciprocating engines can provide

cost effective and efcient powergeneration solutions and may be

divided into two different types,

high speed and medium speed.

For applications with low operating

hours and at outputs below 3.2MW,high speed engines are chosen for

their low installation cost, small

footprint and short installation and

manufacturing times.

On these two pages are extracts from

Broadcrown’s high speed engine setproduct offering. Please refer to our

50Hz and 60Hz generator set brochures

for details of the entire standard

product range.

Efcient and cost-effective reciprocating engine

generator sets: high speed sets

for design and technical ecellence

A selection of 1875 to 3350VA 50Hz 1500 r/min generator setsLight fuel, high speed reciprocating engines

GensetModel

PRP or ESP(See note 1)

Manufacturer Engine VA We No ofclinders

Conguration CubicCapacit(litres)

Length(mm)

Width(mm)

Height(mm)

WetWeight

(kg)

BCC 1875P-50 PRP Cummins QSK 60 G3 1875 1500 16 Vee 60.2 5540 1875 2720 13800

BCM 1900P-50 PRP Mitsubishi S16R-PTA2 1900 1520 16 Vee 65.4 5300 2320 2570 13480

BCM 1900S-50 ESP Mitsubishi S16R-PTA 1900 1520 16 Vee 65.4 5300 2320 2570 13100

BCM 2000P-50 PRP Mitsubishi S16R-F1PTAW2 2000 1600 16 Vee 65.4 5300 2320 2570 13785

BCC 2000S-50 ESP Cummins QSK 60 G3 2000 1600 16 Vee 60.2 5540 1875 2720 13800

BCMU 2000S-50 ESP MTU 12V 4000 G63 2000 1600 12 Vee 57.2 5260 2310 3220 14300


BCM 2090S-50 ESP Mitsubishi S16R-PTA2 2090 1672 16 Vee 65.4 5300 2320 2570 13480

BCMU 2100P-50 PRP MTU 16V 4000 G23 2100 1680 16 Vee 76.3 6080 2310 3220 17380




BCM 2200S-50 ESP Mitsubishi S16R-F1PTAW2 2200 1760 16 Vee 65.4 5300 2320 2570 13785





BCC 2500P-50 PRP Cummins QSK 78 G6 2500 2000 18 Vee 78.0 7000 2325 2900 17000BCMU 2500P-50 PRP MTU 20V 4000 G23 2500 2000 20 Vee 95.4 6920 2360 3200 20480






BCMU 3050P-50 PRP MTU 20V 4000 G63L 3050 2440 20 Vee 95.4 6650 2600 3300 21900



BCMU 3350S-50 ESP MTU 20V 4000 G63L 3350 2680 20 Vee 95.4 6650 2360 3300 21900


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NOTES

1. Generator set power is generally in accordance withISO8528–1:2005 Prime Power (PRP) or Emergency

Standby Power (ESP). Please refer to Broadcrown

for any variances. Standard reference conditions as

specied in ISO3046-1:2002 and ISO15550:2002

apply. Derate may be required for any other site

conditions. Please contact Broadcrown.

2. The generator sets shown are designed to operate ondistillate fuels only. For fuel consumption, heat rate

and exhaust emissions information please contact

Broadcrown.

3. Emissions compliant machines are also available.

Please contact Broadcrown.

4. Other engine manufacturers are available. For furtherdetails please contact Broadcrown.

5. All data given is indicative only and based on low

voltage AC generators. For other voltages and for

guaranteed gures, please contact Broadcrown.

6. The electrical power outputs assume a power factor of

0.8.

A selection of 1500 to 3200We 60Hz 1800 r/min generator setsLight fuel, high speed reciprocating engines

GensetModel

PRP or ESP(See note 1)

Manufacturer Engine VA We No ofclinders


Length(mm)

Width(mm)

Height(mm)

WetWeight

(kg)

BCC 1500S-60 ESP Cummins KTA 50 G9 1875 1500 16 Vee 50.3 5639 2057 2362.2 11010BCMU 1600P-60 PRP MTU 12V 4000 G83 2000 1600 12 Vee 57.2 5260 2310 3220 13968

BCM 1600S-60 ESP Mitsubishi S16R-PTA 2000 1600 16 Vee 65.4 5309 2337 2590.8 13100

BCMU 1600S-60 ESP MTU 12V 4000 G43 2000 1600 12 Vee 35.8 5207 2286 3200.4 13469

BCM 1650P-60 PRP Mitsubishi S16R-PTA2 2063 1650 16 Vee 65.4 5309 2337 2590.8 13470


BCM 1800S-60 ESP Mitsubishi S16R-PTA2 2250 1800 16 Vee 65.4 5309 2337 2590.8 13470

BCC 1825P-60 PRP Cummins QSK 60 G6 2281 1825 16 Vee 60.2 6020 2337 2895.6 13550

BCMU 1900P-60 PRP MTU 16V 4000 G43 2375 1900 16 Vee 57.2 6020 2286 3200.4 14268

BCC 2000S-60 ESP Cummins QSK 60 G6 2500 2000 16 Vee 60.2 6020 2337 2895.6 13550


BCMU 2050P-60 PRP MTU 16V 4000 G83 2563 2050 16 Vee 57.2 6020 2286 3200.4 14268





BCMU 2800P-60 PRP MTU 20V 4000 G83L 3500 2800 20 Vee 95.4 6604 2565 3300 21850

BCMU 2800S-60 ESP MTU 20V 4000 G83 3500 2800 20 Vee 76.3 6858 2337 3175 20434BCMU 3200S-60 ESP MTU 20V 4000 G83L 4000 3200 20 Vee 95.4 6604 2565 3300 21850

powering applications worldwide for over 30 ears


20/2818 sets can be modied to meet our needs

Durable and fuel efcient reciprocating engine

generator sets: medium speed sets

1300 to 4900VA 50Hz 1000 r/min generator setsHeav fuel and light fuel medium speed reciprocating engines

Genset Model Manufacturer Engine VA We No ofclinders


Length(mm)

Width(mm)

Height(mm)

Weight(kg)

BCMN 1305C-50/6 MAN 5L21/31 1305 1045 5 Inline 54 5829 1750 3183 21500


BCMN 1830C-50/6 MAN 7L21/31 1830 1463 7 Inline 75 6639 1750 3183 25900BCR 1950C-50/6 Rolls-Royce C25:33L6 1950 1560 6 Inline 97 7485 1910 3060 28600

BCG 2000C-50/6 GE 6L250 2000 1598 6 Inline 94 8544 2194 2827 27010



BCR 2595C-50/6 Rolls-Royce C25:33L8 2595 2075 8 Inline 130 8040 1950 3180 36100

BCG 2665C-50/6 GE 8L250 2665 2130 8 Inline 126 9229 2234 2947 34490


BCG 3635C-50/6 GE 12V250 3635 2906 12 Vee 188 7682 2492 2756 39200

BCG 4845C-50/6 GE 16V250 4845 3876 16 Vee 251 8351 2174 2661 43100

1625 to 13,500VA 50Hz 750 r/min generator setsHeav fuel and light fuel medium speed reciprocating engines

Genset Model Manufacturer Engine VA We No of

clinders

Conguration Cubic

Capacit(litres)

Length

(mm)

Width

(mm)

Height

(mm)

Weight

(kg)








BCR 3245C-50/8 Rolls-Royce B32:40L6 3245 2595 6 Inline 193 8230 2150 3830 48000


BCMN 4075C-50/8 MAN 6L32/44CR 4075 3259 6 Inline 212 10378 2490 4768 71000


BCMN 4510C-50/8 MAN 16V28/32S 4510 3610 16 Vee 315 9938 2470 3449 62200



BCMN 5075C-50/8 MAN 18V28/32S 5075 4061 18 Vee 355 10707 2470 3449 70800




BCR 6550C-50/8 Rolls-Royce B32:40V12 6550 5240 12 Vee 386 10550 2650 4220 91000


BCMN 7275C-50/8 MAN 12V32/40 7275 5820 12 Vee 386 10690 3370 4795 98000

BCMN 8150C-50/8 MAN 12V32/44CR 8150 6518 12 Vee 425 11431 4200 5000 117000

BCMN 8490C-50/8 MAN 14V32/40 8490 6790 14 Vee 450 11320 3370 4795 112000


BCMN 9505C-50/8 MAN 14V32/44CR 9505 7605 14 Vee 495 12061 4200 5200 131000

BCMN 9700C-50/8 MAN 16V32/40 9700 7760 16 Vee 515 12120 3500 5240 131000

BCMN 10865C-50/8 MAN 16V32/44CR 10865 8691 16 Vee 566 12691 4260 5200 144000

BCMN 10915C-50/8 MAN 18V32/40 10915 8730 18 Vee 579 12750 3500 5240 139000

BCMN 12225C-50/8 MAN 18V32/44CR 12225 9778 18 Vee 637 13321 4260 5200 159000

BCMN 13580C-50/8 MAN 20V32/44CR 13580 10864 20 Vee 708 13951 4260 5200 172000

A medium speed engine is the

best choice of prime mover if your

requirement is to generate power for

longer periods amounting to severalthousand hours per annum.

Medium speed engines offer improved

fuel consumption, higher durability

and lower maintenance costs when

compared with high speed engines,

despite their comparatively largersize, higher cost and heavier weight.

Medium speed engines also have the

advantage of being able to operate on

cheaper, less rened fuels.

Broadcrown offers medium speed

generator sets incorporating reputableengines from manufacturers such as

MAN, GE and Rolls Royce.


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1045 to 3490We 60Hz 900 r/min generator setsHeav fuel and light fuel medium speed reciprocating engines

Genset Model Manufacturer Engine VA We No ofclinders


Length(mm)

Width(mm)

Height(mm)

Weight(kg)



BCG 1440C-60/8 GE 6L250 1798 1438 6 Inline 94 8544 2194 2827 27010BCMN 1465C-60/8 MAN 7L21/31 1829 1463 7 Inline 75 6639 1750 3183 25900




BCG 1920C-60/8 GE 8L250 2398 1918 8 Inline 126 9229 2234 2947 34490



BCG 2615C-60/8 GE 12V250 3271 2617 12 Vee 188 7682 2492 2756 39200

BCG 3485C-60/8 GE 16V250 4359 3487 16 Vee 251 8351 2174 2661 43100

1245 to 10,865We 60Hz 720 r/min generator setsHeav fuel and light fuel medium speed reciprocating engines

Genset Model Manufacturer Engine VA We No of

clinders

Conguration Cubic

Capacit(litres)

Length

(mm)

Width

(mm)

Height

(mm)

Weight

(kg)












BCMN 3455C-60/10 MAN 16V28/32S 4320 3456 16 Vee 315 9938 2470 3449 62200



BCMN 3890C-60/10 MAN 18V28/32S 4860 3888 18 Vee 355 10707 2470 3449 70800






BCMN 5820C-60/10 MAN 12V32/40 7275 5820 12 Vee 386 10690 3370 4795 98000

BCMN 6520C-60/10 MAN 12V32/44CR 8148 6518 12 Vee 425 11431 4200 5000 117000


BCMN 6790C-60/10 MAN 14V32/40 8488 6790 14 Vee 450 11320 3370 4795 112000

BCMN 7605C-60/10 MAN 14V32/44CR 9506 7605 14 Vee 495 12061 4200 5200 131000

BCMN 7760C-60/10 MAN 16V32/40 9700 7760 16 Vee 515 12120 3500 5240 131000

BCMN 8690C-60/10 MAN 16V32/44CR 10864 8691 16 Vee 566 12691 4260 5200 144000

BCMN 8730C-60/10 MAN 18V32/40 10913 8730 18 Vee 579 12750 3500 5240 139000

BCMN 9780C-60/10 MAN 18V32/44CR 12223 9778 18 Vee 637 13321 4260 5200 159000

BCMN 10865C-60/10 MAN 20V32/44CR 13580 10864 20 Vee 708 13951 4260 5200 172000

NOTES

1. Generator set power is in accordance with ISO8528-

1:2005 Continuous Operating Power (COP). Standard

reference conditions as specied in ISO3046-1:2002

and ISO15550:2002 apply. Derate may be required forany other site conditions. Please contact Broadcrown.

2. The generator sets are designed to operate on

distillate and heavy fuels with a viscosity up to 700

cSt at 500C except for GE engined generator sets that

operate on distillate fuels only. For fuel consumption,

heat rate and exhaust emissions information using

standard or other heavy and light fuels please contact

Broadcrown.

3. Medium speed generator sets operating on DualFuel, Natural Gas and Renewable fuels may also

be available. For further details and ratings please

contact Broadcrown.

4. Other engine manufacturers, such as Wartsila, are able

to offer alternative engine models to meet with

your project requirements. For further details please

contact Broadcrown.

5. All data given is indicative only. For guaranteed

gures, please contact Broadcrown.6. The electrical power outputs assume a power factor

of 0.8.

7. Please note that territory restrictions may apply.

Contact Broadcrown for further details.

independent epertise and advice


22/28


23/2821

Turbine generator sets up to 5MWe with co-generation:

gas turbine generator sets

50Hz 1500 r/min gas turbine generator setsNatural gas, light fuel, erosene and dual fuel gas turbines

Genset Model Manufacturer Engine Fuel kVA We Engine Speed

(r/min)

Conguration Length

(mm)

Width

(mm)

Height

(mm)

Weight

(kg)

BCRT 4935C-50/4Centrax CX501-KB5 Liquid 4815 3852 14571 Aeroderivative 9000 2700 3100 39000

Centrax CX501-KB5 Gas 4934 3947 14571 Aeroderivative 9000 2700 3100 39000



60Hz 1800 r/min gas turbine generator setsNatural gas, light fuel, erosene and dual fuel gas turbines

Genset Model Manufacturer Engine Fuel kVA We Engine Speed(r/min)

Conguration Length(mm)

Width(mm)

Height(mm)

Weight(kg)





Our gas turbine generator set range

is available in a reliable and efcient

standard package that can be

specically congured to meet yourparticular project requirements. Gas

turbine generators are best suited to

continuous running applications and,

with the addition of heat recovery

equipment, work as highly efcient

co-generation packages.

Gas turbines are considerably lighter

with a much smaller footprint than

equivalent output reciprocating

medium speed engines. Typicalusers include the oil & gas, mining,

manufacturing and processing

industries together with district

heating schemes.

Gas turbine generator sets generally

have a lower efciency, as pure

electrical generators in simple cycle

operation, compared with reciprocating

engines although their low weight

may be benecial. However, whenoperating in conjunction with heat

recovery systems the overall efciency

is signicantly increased. There is a

high proportion of turbine generators

in service that operate in a combined

cycle mode.

GAS TURBINE NOTES

1. Performance will vary depending on site

conditions, please contact Broadcrown with specic

requirements.

2. The generator sets are designed to operate on

natural gas, kerosene and distillate fuels. For fuel

consumption, heat rate and exhaust emissions

information using these fuel types please contact

Broadcrown.

3. All data given is indicative only. For guaranteed

gures, please contact Broadcrown.

4. Dimensions are based on the gas turbine generator

set container package only and does not include the

external air ltration or exhaust system

5. The electrical power outputs assume a power factor

of 0.8.

6. Gas turbine generator sets with heat recovery systems

are available. Please contact Broadcrown for further

details

7. Please note that territory restrictions may apply.

Contact Broadcrown for further details.

responsive, professional service


24/2822

Fuel eibilit

Generator sets can be matched to

your exact fuel requirements from

our comprehensive range of gas and

liquid fuel prime movers.

Fossil fuel oils are comprised of

mitures of petroleum distillate

hdrocarbons, obtained b distilling

crude oil and removing the different

fractions through the crude oil

rening process.

Depending upon where in the

fractionating process the oil is

obtained, the lighter and higher

liquid fractions include Petroleum

and kerosene with lighter oils (gas

oil, distillates) lower down the

fraction and residual oils (heav fuel

oil and residual oils) closer to the

bottom.

Two major categories of fossil fuel oil

are burned in compression ignition

engines — distillate oils and residual

oils. In addition crude oil may also be

burned if suitably treated and within

the parameters required by the engine

manufacturer. Fuels can be further

broken down into individual grades

and mixtures and are given product

denitions that may be different in

industrial and marine applications.

kerosene is a parafn type fraction

and used extensively in the aviation

industry. Kerosene may be burned in

gas turbine engines but may only be

used in compression ignition engines

as a mix with distillates. Kerosene’s

low lubricity content does not suit thedesign of fuel systems of compression

ignition engines.

Distillate Fuel Oils, or Light Fuel Oils

(LFO), comprise gas oil, which is a

very high quality distillate often used

in smaller high speed engines and

other distillate fuel variants, burned in

the majority of compression ignition

engine types and gas turbines. Various

other terms may be used for distillates

such as MDO (marine diesel oil), Diesel

Oil or LFO (Light fuel oil, not liquid

fuel oil).

Residual Fuel Oils include Heavy

Fuel Oil (HFO) that may be burned

in certain medium speed engines

depending upon design, as can crude

oil. The heavier the oil, the greater

is its viscosity. Viscosity is a measure

of the uids ability to ow or be

pumped. Kinematic Viscosity is the

most popular measure and is expressed

in centistokes (cSt). The majority

of engine manufacturers limit the

heavy fuel to a Kinematic Viscosity

of 700 cSt @ 50°C. Prior to burning

in the engine the oil requires further

treatment and heating which lowers

the Kinematic viscosity to a level

suitable for use by the on engine fuel

systems. Crude oil, the least rened

of residual fuels may also be burnedin medium speed engines if suitably

treated. Crude is a more volatile fuel

hence increased health and safety

awareness must be considered.


25/2823

Control sstems

A wide spectrum of reliable, safe and

intelligent systems are available to

deliver the precise level of control

required.

It is critical that operators have

access to a reliable, safe and

intelligent control sstem at all

times. It must be straightforward,

user-friendl and sufcientl

comprehensive to give the valuable

data required to eep the power

sstem operating efcientl and in

good health.

At Broadcrown we provide a wide

spectrum of control equipment — from

an entry level simple generator set

control panel through to complete

site wide Supervision Control and Data

Acquisition (SCADA) systems.

Local Generator Control Panel

(LGCP)

Mounted alongside the generator set,

the LGCP provides for the control,

monitoring and protection of the

engine, alternator and all associated

systems. The LGCP can be congured

to control the generator set in two

different conditions —

• Base load grid connected: The

LGCP controls the engine governor

and alternator Automatic Voltage

Regulator (AVR) maintaining a

constant output frequency and

voltage from the alternator. This

is used for applications where

the generator set is continually

connected to an innite gridnetwork.

• Island Operation: In this case

the LGCP controls the engine and

alternator AVR in a different manner,

sharing the site load with other

power sources. An example of such

an application would be a site with

multiple generator sets all connected

to a small local grid network.

Remote Generator Control Panel

(RGCP)

The GCP can be provided with a

repeater panel known as an RGCP for

location outside the powerhouse in the

quieter environment of a plant control

room. A GCP alone does not provide

sufcient control and monitoring of

the entire site network of installed

equipment utilised at a powerplant.

For this it is necessary to incorporate a

SCADA system.

SCADA

Located at the main control room

on site the SCADA system provides

centralised full monitoring and

coordination of all systems including

generator set(s), switchgear, fuelservices and all other associated

services at the plant.

NEUTRALEARTHING

GENERATORCIRCUITBREAkER

ENGINE ALTERNATORCOOLINGCIRCUITS

VENTILATIONUNITS

LUBE OIL& FUEL

TREATMENT

FUELFARM

MAINSWITCHGEAR

GENERATOR SETCONTROL PANEL

SUBSTATIONOTHER

ANCILLARIES

SCADA

OFF-SITEMONITORING


26/2824

Service and support

Every package is supplied with a

comprehensive warranty and comes

with fast 24 hour support from your

local Broadcrown partner in territory.

With our global networ of local

ofces and partners, service and

support from Broadcrown is alwas

close at hand to minimise downtime

and eep our equipment in service

ensuring high availabilit of our

plant.

Our dedicated service engineering

team offers a full package to help you

manage your ‘through lifecycle’ costs,

including:

• Single point of contact

• Full aftersales and technical support

• Remote operation & monitoring 24

hours per day 365 days a year

• Complete service packages with

extended warranties tailored to suityour needs

• Package rehabilitation and rebuild

service

• Fluid and oil sampling

• Onsite and offsite load testing,

inspection & site surveys

• Fully qualied and experienced

factory trained engineers

Broadcrown’s full operation and

maintenance contracts can be

congured for periods of up to 20

years. These can be particularly helpful

when operating on base load power for

planning ‘through lifecycle’ costs.

Our UK production facility has a

specic area dedicated to rebuild and

maintenance of customer equipment.

Once the work has been carried out,

the package is transferred to our

purpose-built test house which has

three test bays capable of handling

packages up to 4MW each with

resistive and reactive load facility.

Spare parts

Spare parts can be supplied from our

fully-stocked UK warehouse or can be

ordered and shipped within 24 hours.

Parts can be provided on a per order

basis or as part of a frame agreement

which spans the life of the equipment.

Broadcrown is brand independent.That means we not only offer

our service and parts supply for

Broadcrown packaged equipment but

are happy to extend our service to any

other prime mover equipment at site,

offering a total site service contract

for equipment at competitive rates.

We also offer tailored training

modules, at site or at our UK Group

Headquarters, covering all elements

of the package. Our trainers have

in depth knowledge of all aspects

from the mechanical driver through

to the full electrical system and

switchgear including PLC and software

conguration.


27/28

Broadcrown is independently owned

and managed. When you contact

us you are talking to professionals

who will work with you to meet your

specic needs.

We are trusted around the world to

deliver an extensive range of standard

and bespoke systems from small

standby diesel generators to large-

scale turnkey power projects.

When you contact us you are talking to

professional people who will work with

you to meet your needs.

Our generator set range includes:

• Prime & standb bac up power

• Base load generation

• Oil & gas industr applications

• Marine power generation

• Critical power including UPS

sstems

• Gas and co-generation (CHP)

applications• Rental applications

Production Facilities

All Broadcrown products are designed

and manufactured in our purpose-built

factories at our corporate headquarters

in Hixon, England and in Newtown,

Wales.

For full details on all our products,

services and international ofces

please visit www.broadcrown.com

Broadcrown, broadcrown, their respective logos, the “crown” logo, as well as corporate and product identity used herein are trademarks

of Broadcrown and may not be used without permission. BROADCROWN is a registered trademark of Broadcrown Holdings Plc.


28/28

GROUP HEADQUARTERS

Broadcrown Ltd

Aireld Industrial Estate

Hion, Stafford

Staffs ST18 0PF

England

tel: +44 (0) 1889 272200

fa: +44 (0) 1889 272220

email: [email protected]

www.broadcrown.com

INTERNATIONAL NETWORK

Our growing international network of

distributors backed by the Broadcrown

Regional Support Centres of Miami,

Singapore, Nigeria, South Africa, India

and China, provides worldwide product

availability and after sales support

including training.

Broadcrown (China) LtdRoom 1503, Tower B, SOHO Newtown, 88 Jianguo Avenue, Chaoyang Dist., Beijing, China 100022

tel: +86 (0) 10 8589 3698 fax: +86 (0) 10 8589 5771

email: [email protected] www.broadcrownchina.com

Broadcrown Singapore Pte Ltd3791 Jalan Bukit Merah, #05-08, E-Centre @ Redhill, Singapore 159471

tel: +65 6235 3630 fax: +65 6732 4355

email: [email protected] www.broadcrownsingapore.com

Broadcrown (West Africa) Ltd4/6 Kudirat Abiola Way, Alausa, Ikeja, Lagos, Nigeria

tel: +234 1 761 7107 email: [email protected]

www.broadcrownwestafrica.com

Broadcrown SA (Pt) LimitedOfce Address: Unit 1 Atom Park, Neutron Street, Stikland 7530, South Africa

Postal Address: PO Box 1065, Durbanville 7551, South Africa

tel: +27 21 946 3463 fax: +27 21 946 3953

email: [email protected] www.broadcrownsouthafrica.com

Broadcrown Inc.9705 NW 108th Avenue, Suite 10, Miami, Florida 33178, USA

tel: +1 305 888 1414 fax: +1 305 888 1801

email: [email protected] www.broadcrownusa.com

Broadcrown India (PVT) LtdR-06 A, 3rd Floor, MGF Plaza, Mehrauli-Gurgaon Road, Gurgaon – 122002, Haryana, India

email: [email protected] www.broadcrownindia.com

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