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Rev.

Technical Description "ts18087-0"

Genset

JGS 320 GS-B.L

static Grid Code


grid parallel operation

Electrical output 1063 kW el.

Emission values
NOx < 250 mg/Nm³ (5% O2)

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0.01 Technical Data (at genset) __________________________________________ 4 
Main dimensions and weights (at genset) 5 
Connections 5 
Output / fuel consumption 5 
0.02 Technical data of engine ___________________________________________ 6 
Thermal energy balance 6 
Exhaust gas data 6 
Combustion air data 6 
Sound pressure level 7 
Sound power level 7 
0.03 Technical data of generator_________________________________________ 8 
Reactance and time constants (saturated) 8 
connection variant 1K _________________________________________________ 9 
0.05 Cooling water circuit _____________________________________________ 10 
Oil - heat (Engine jacket water cooling circuit) 10 
Engine jacket water - heat (Engine jacket water cooling circuit) 10 
Mixture Intercooler (1st stage) (Engine jacket water cooling circuit) 10 
Mixture Intercooler (2nd stage) (Low temperature circuit) 10 
0.10 Technical parameters_____________________________________________ 11 
1.00 Scope of supply - Genset _________________________________________ 12 
1.01 Spark ignited gas engine __________________________________________ 13 
1.01.01 Engine design ________________________________________________ 13 
1.01.02 Additional equipment for the engine (spares for commissioning) ______ 14 
1.01.03 Standard tools (per installation)__________________________________ 14 
1.02 Generator - low voltage ___________________________________________ 15 
1.03 Module accessories ______________________________________________ 17 
1.03.01 Engine jacket water system _____________________________________ 18 
1.03.02 Automatic lube oil replenishing system incl. extension tank __________ 19 
1.05.01 (Bio) Gas train ________________________________________________ 19 
1.07 Painting ________________________________________________________ 20 
1.11 Engine generator control panel – DIA.NE XT __________________________ 20 
1.11.02 Remote information by MODBUS-RTU ____________________________ 25 
1.11.03 Remote Data-Transfer with DIA.NE XT - HERMES ___________________ 25 
1.20.01 Starting system _______________________________________________ 27 
1.20.03 Electric jacket water preheating __________________________________ 28 
1.20.04 Flexible connections ___________________________________________ 28 
1.20.48 (Bio) Gas Blower ______________________________________________ 29 

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2.00 Electrical equipment _____________________________________________ 29 
2.02 Grid monitoring device ___________________________________________ 29 
2.03.04 Power control for bio gas applications ____________________________ 31 
2.04 Generator switchgear, low voltage __________________________________ 32 
3.01 Lube oil system (1/plant) __________________________________________ 33 
3.03.01 Exhaust gas silencer ___________________________________________ 33 
3.10 Cooling system – Intercooler ______________________________________ 34 
3.11 Cooling system – Emergency Cooler ________________________________ 34 
4.00 Delivery, installation and commissioning ____________________________ 34 
4.01 Carriage 34 
4.02 Unloading 34 
4.03 Assembly and installation 34 
4.04 Storage 35 
4.05 Start-up and commissioning 35 
5.01 Limits of delivery - Genset_________________________________________ 35 
5.02 Factory tests and inspections ______________________________________ 36 
5.02.01 Engine tests 36 
5.02.02 Generator tests 36 
5.02.03 Module tests 36 
5.03 Documentation __________________________________________________ 37 

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0.01 Technical Data (at genset)
Data at: Full Part Load
load
Fuel gas LHV kWh/Nm³ 4,5 4,5 4,5
100% 75% 50%

Energy input kW [2] 2.677 2.063 1.448


Gas volume Nm³/h *) 595 458 322
Mechanical output kW [1] 1.095 821 548
Electrical output kW el. [4] 1.063 796 529

Heat to be dissipated [5]


~ Intercooler 1st stage (Engine jacket water cooling circuit) kW 194
~ Intercooler 2nd stage (Low temperature circuit) kW 85
~ Lube oil (Engine jacket water cooling circuit) kW 131
~ Jacket water kW 335
~ Surface heat ca. kW [7] 99

Spec. fuel consumption of engine kWh/kWh [2] 2,45 2,51 2,64


Lube oil consumption ca. kg/h [3] 0,33 ~ ~
Electrical efficiency % 39,7% 38,6% 36,5%
*) approximate value for pipework dimensioning
[_] Explanations: see 0.10 - Technical parameters

All heat data is based on standard conditions according to attachment 0.10. Deviations from the standard conditions can result in a
change of values within the heat balance, and must be taken into consideration in the layout of the cooling circuit/equipment
(intercooler; emergency cooling; ...). In the specifications in addition to the general tolerance of +/- 8% on the thermal output a
further reserve of 10% is recommended for the dimensioning of the cooling requirements.

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Main dimensions and weights (at genset)
Length mm ~ 5.700
Width mm ~ 1.700
Height mm ~ 2.300
Weight empty kg ~ 13.600
Weight filled kg ~ 14.100

Connections
Jacket water inlet and outlet DN/PN 80/10
Exhaust gas outlet DN/PN 250/10
Fuel gas (at gas train) DN/PN 100/16
Fuel Gas (at genset) DN/PN 100/10
Water drain ISO 228 G ½''
Condensate drain mm 18
Safety valve - jacket water ISO 228 DN/PN 2x1½''/2,5
Lube oil replenishing (pipe) mm 28
Lube oil drain (pipe) mm 28
Jacket water - filling (flex pipe) mm 13
Intercooler water-Inlet/Outlet 1st stage DN/PN 80/10
Intercooler water-Inlet/Outlet 2nd stage DN/PN 65/10

Output / fuel consumption


ISO standard fuel stop power ICFN kW 1.095
Mean effe. press. at stand. power and nom. speed bar 18,00
Fuel gas type Biogas
Based on methane number|Min. methane number MZ d) 135|100
Compression ratio Epsilon 12,50

Min./Max. fuel gas pressure at inlet to gas train mbar 80 - 200 c)


Allowed Fluctuation of fuel gas pressure % ± 10
Max. rate of gas pressure fluctuation mbar/sec 10
Maximum Intercooler 2nd stage inlet water temperature °C 50
Spec. fuel consumption of engine kWh/kWh 2,45
Specific lube oil consumption g/kWh 0,30
Max. Oil temperature °C 90
Jacket-water temperature max. °C 95
Filling capacity lube oil (refill) lit ~ 342
c) Lower gas pressures upon inquiry
d) based on methane number calculation software AVL 3.1

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0.02 Technical data of engine
Manufacturer GE Jenbacher
Engine type J 320 GS-C26
Working principle 4-Stroke
Configuration V 70°
No. of cylinders 20
Bore mm 135
Stroke mm 170
Piston displacement lit 48,67
Nominal speed rpm 1.500
Mean piston speed m/s 8,50
Length mm 3.320
Width mm 1.358
Height mm 2.065
Weight dry kg 5.200
Weight filled kg 5.700
Moment of inertia kgm² 8,61
Direction of rotation (from flywheel view) left
Radio interference level to VDE 0875 N
Starter motor output kW 7
Starter motor voltage V 24
Thermal energy balance
Energy input kW 2.677
Intercooler kW 279
Lube oil kW 131
Jacket water kW 335
Exhaust gas cooled to 180 °C kW 481
Exhaust gas cooled to 100 °C kW 624
Surface heat kW 56
Exhaust gas data
Exhaust gas temperature at full load °C [8] 439
Exhaust gas temperature at bmep= 13,5 [bar] °C ~ 469
Exhaust gas temperature at bmep= 9 [bar] °C ~ 502
Exhaust gas mass flow rate, wet kg/h 5.929
Exhaust gas mass flow rate, dry kg/h 5.497
Exhaust gas volume, wet Nm³/h 4.610
Exhaust gas volume, dry Nm³/h 4.091
Max.admissible exhaust back pressure after engine mbar 60
Combustion air data
Combustion air mass flow rate kg/h 5.451
Combustion air volume Nm³/h 4.217
Max. admissible pressure drop at air-intake filter mbar 10

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Sound pressure level
Aggregate b) dB(A) re 20µPa 96
31,5 Hz dB 78
63 Hz dB 90
125 Hz dB 92
250 Hz dB 89
500 Hz dB 92
1000 Hz dB 90
2000 Hz dB 89
4000 Hz dB 87
8000 Hz dB 90
Exhaust gas a) dB(A) re 20µPa 122
31,5 Hz dB 97
63 Hz dB 108
125 Hz dB 118
250 Hz dB 110
500 Hz dB 113
1000 Hz dB 114
2000 Hz dB 117
4000 Hz dB 115
8000 Hz dB 114
Sound power level
Aggregate dB(A) re 1pW 117
Measurement surface m² 109
Exhaust gas dB(A) re 1pW 130
Measurement surface m² 6,28
a) average sound pressure level on measurement surface in a distance of 1m according to DIN 45635, precision class 2.
b) average sound pressure level on measurement surface in a distance of 1m (converted to free field) according to DIN 45635,
precision class 3.
The spectra are valid for aggregates up to bmep=18 bar. (for higher bmep add safety margin of 1dB to all values per increase of 1
bar pressure).
For operation with 1200 rpm see above values, for operation with 1800 rpm add 3 dB to the above values.
Engine tolerance ± 3 dB

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0.03 Technical data of generator
Manufacturer Leroy-Somer e)
Type LSAC 50.2 VL10 e)
Type rating kVA 1.475
Driving power kW 1.095
Ratings at p.f. = 1,0 kW 1.063
Ratings at p.f. = 0,8 kW 1.052
Rated output at p.f. = 0,8 kVA 1.315
Rated reactive power at p.f. = 0,8 kVar 789
Rated current at p.f. = 0,8 A 1.899
Frequency Hz 50
Voltage V 400
Speed rpm 1.500
Permissible overspeed rpm 2.250
Power factor (lagging - leading) 0,8 - 0,95
Efficiency at p.f. = 1,0 % 97,1%
Efficiency at p.f. = 0,8 % 96,1%
Moment of inertia kgm² 25,67
Mass kg 3.300
Radio interference level to VDE 0875 N
Construction IMB 24
Protection Class IP 23
Insulation class H
Temperature (rise at driving power) F
Maximum ambient temperature °C 40

Reactance and time constants (saturated)


xd direct axis synchronous reactance p.u. 2,42
xd' direct axis transient reactance p.u. 0,13
xd'' direct axis sub transient reactance p.u. 0,11
x2 negative sequence reactance p.u. 0,11
Td'' sub transient reactance time constant ms 18
Ta Time constant direct-current ms 27
Tdo' open circuit field time constant s 4,06
e) GE Jenbacher reserves the right to change the generator supplier and the generator type. The contractual data of the
generator may thereby change slightly. The contractual produced electrical power will not change.

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connection variant 1K
0.05 Cooling water circuit
Oil - heat (Engine jacket water cooling circuit)
Nominal output kW 131
Max. Oil temperature °C 90
Loss of nominal pressure of engine jacket water bar 0,20
Safety valve - max press. set point bar 2,50

Engine jacket water - heat (Engine jacket water cooling circuit)


Nominal output kW 335
Max. engine jacket water temperature (outlet engine) °C 90
Engine jacket water flow rate m³/h 31,8
Safety valve - max press. set point bar 2,50

Mixture Intercooler (1st stage) (Engine jacket water cooling circuit)


Nominal output kW 194
Max. inlet cooling water temp. (intercooler) °C 74,0
Nominal pressure of cooling water / (max. operating pressure) PN 10
Loss of nominal pressure of engine jacket water bar 0,40
Safety valve - max press. set point bar 2,50

Mixture Intercooler (2nd stage) (Low temperature circuit)


Nominal output kW 85
Max. inlet cooling water temp. (intercooler) °C 50
Aftercooler water flow rate m³/h 25,0
Nominal pressure of cooling water / (max. operating pressure) PN 10
Intercooler water pressure drop bar 0,20
Safety valve - max press. set point bar 2,50

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0.10 Technical parameters
All data in the technical specification are based on engine full load (unless stated otherwise) at specified
temperatures and the methane number and subject to technical development and modifications.

All pressure indications are to be measured and read with pressure gauges (psi.g.).

(1) At nominal speed and standard reference conditions ICFN according to DIN-ISO 3046 and DIN 6271,
respectively
(2) According to DIN-ISO 3046 and DIN 6271, respectively, with a tolerance of + 5 %.
Efficiency performance is based on a new unit (immediately upon commissioning). Effects of
degradation during normal operation can be mitigated through regular service and maintenance work;
reference value --> 65%CH4
(3) Average value between oil change intervals according to maintenance schedule, without oil change
amount
(4) At p. f. = 1.0 according to VDE 0530 REM / IEC 34.1 with relative tolerances
(5) Total output with a tolerance of +/- 8 %
(6) According to above parameters (1) through (5)
(7) Only valid for engine and generator; module and peripheral equipment not considered (at p. f. = 0,8)
(8) Exhaust temperature with a tolerance of +/- 8 %

Radio interference level


The ignition system of the gas engines complies the radio interference levels of CISPR 12 and EN 55011
class B, (30-75 MHz, 75-400 MHz, 400-1000 MHz) and (30-230 MHz, 230-1000 MHz), respectively.

Definition of output
 ISO-ICFN continuous rated power:
Net break power that the engine manufacturer declares an engine is capable of delivering continuously,
at stated speed, between the normal maintenance intervals and overhauls as required by the
manufacturer. Power determined under the operating conditions of the manufacturer’s test bench and
adjusted to the standard reference conditions.
 Standard reference conditions:
Barometric pressure: 1000 mbar (14.5 psi) or 100 m (328 ft) above sea level
Air temperature: 25°C (77°F) or 298 K
Relative humidity: 30 %

 Volume values at standard conditions (fuel gas, combustion air, exhaust gas)
Pressure: 1013 mbar (14.7 psi)
Temperature: 0°C (32°F) or 273 K

Output adjustment for turbo charged engines


Standard rating of the engines is for an installation at an altitude ≤ 500 m and an air intake temperature
≤ 30 °C (T1)
Maximum room temperature: 50°C (T2) -> engine stop

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If the actual methane number is lower than the specified, the knock control responds. First the ignition
timing is changed at full rated power. Secondly the rated power is reduced. These functions are carried
out by the engine management system.
Exceedance of the voltage and frequency limits for generators according to IEC 60034-1 Zone A will lead
to a derate in output.

Parameters for the operation of GE Jenbacher gas engines


The genset fulfills the limits for mechanical vibrations according to ISO 8528-9.
The following "Technical Instruction of GE JENBACHER" forms an integral part of a contract and must be
strictly observed: TI 1100-0110, TI 1100-0111 and TI 1100-0112.
If possible, railway trucks must not be used for transport (TI 1000-0046).

Parameters for the operation of control unit and the electrical equipment
Relative humidity 50% by maximum temperature of 40°C; Altitude up to 2000m above the sea level

Parameters for using a gas compressor


The gas quantity indicated under the technical data refers to standard conditions with the given calorific
value. The actual volume flow (under operating conditions) has to be considered for dimensioning the gas
compressor and each gas feeding component – it will be affected by:
 Actual gas temperature (limiting temperature according to TI 1000-0300)
 Gas humidity (limiting value according to TI 1000-0300)
 Gas Pressure
 Calorific value variations (can be equated with methane (CH4) variations in the case of biogas)
 The gas compressor is designed for a max. relative under pressure of 15 mbar(g) (0.22 psi) and a inlet
temperature of 40°C (104°F) , if within scope of supply GE Jenbacher

1.00 Scope of supply - Genset


Design:
The genset is built as a compact package. Engine and generator are connected through a coupling and
are mounted to the base frame. To provide the best possible isolation from the transmission of vibrations
the engine is mounted to the frame by means of anti-vibrational mounts. The remaining vibrations are
eliminated by mounting the module on isolating pads (e.g. Sylomer). This, in principle, allows the genset
to be placed directly on any floor capable of carrying the static load. No special foundation is required.
Prevention of sound conducted through solids has to be provided locally.

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1.01 Spark ignited gas engine
Four-stroke, air/gas mixture turbocharged, aftercooled, with high performance ignition system and
electronically controlled air/gas mixture system.
The engine is equipped with the most advanced

LEANOX® LEAN-BURN COMBUSTION SYSTEM

developed by GE JENBACHER.

1.01.01 Engine design


Engine block
Single-piece crankcase and cylinder block made of special casting; crank case covers for engine
inspection, welded steel oil pan.

Crankshaft and main bearings


Drop-forged, precision ground, surface hardened, statically and dynamically balanced; main bearings
(upper bearing shell: 3-material bearing / lower bearing shell: sputter bearing) arranged between crank
pins, drilled oil passages for forced-feed lubrication of connecting rods.

Vibration damper
Maintenance free viscous damper

Flywheel
With ring gear for starter motor

Pistons
Single-piece made of light metal alloy, with piston ring carrier and oil passages for cooling; piston rings
made of high quality material, main combustion chamber specially designed for lean burn operation.

Connecting rods
Drop-forged, heat-treated, big end diagonally split and toothed. Big end bearings (upper bearing shell:
sputter bearing / lower bearing shell: grooved bearing) and connecting rod bushing for piston pin.

Cylinder liner
Chromium alloy gray cast iron, wet, individually replaceable.

Cylinder head
Specially designed and developed for GE JENBACHER-lean burn engines with optimized fuel
consumption and emissions; water cooled, made of special casting, individually replaceable; Valve seats,
valve guides and spark plug sleeves individually replaceable; exhaust and inlet valves made of high
quality material.

Crankcase breather
Connected to combustion air intake system

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Valve train
Camshaft, with replaceable bushings, driven by crankshaft through intermediate gears, valve lubrication
by splash oil through rocker arms.

Combustion air/fuel gas system


Motorized carburetor for automatic adjustment according to fuel gas characteristic. Exhaust driven
turbocharger, mixture manifold with bellows, water-cooled intercooler, throttle valve and distribution
manifolds to cylinders.

Ignition system
Most advanced, fully electronic high performance ignition system, external ignition control.

Lubricating system
Gear-type lube oil pump to supply all moving parts with filtered lube oil, pressure control valve, pressure
relief valve and full-flow filter cartridges. Cooling of the lube oil is arranged by a heat exchanger.

Engine cooling system


Jacket water pump complete with distribution pipework and manifolds.

Exhaust system
Turbocharger and exhaust manifold

Exhaust gas temperature measuring


Thermocouple for each cylinder

Electric actuator
For electronic speed and output control

Electronic speed monitoring for speed and output control


By magnetic inductive pick up over ring gear on flywheel

Starter motor
Engine mounted electric starter motor

1.01.02 Additional equipment for the engine (spares for


commissioning)
The initial set of equipment with the essential spare parts for operation after commissioning is included in
the scope of supply.

1.01.03 Standard tools (per installation)


The tools required for carrying out the most important maintenance work are included in the scope of
supply and delivered in a toolbox. This item includes an oscilloscope, high voltage cable and clamp.

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1.02 Generator - low voltage
The 2 bearing generator consists of the main generator (built as rotating field machine), the exciter
machine (built as rotating armature machine) and the digital excitation system.
The digital regulator is powered by an auxiliary winding at the main stator or a PMG system

Main components
 Enclosure of welded steel construction
 Stator core consist of thin insulated electrical sheet metal with integrated cooling channels.
 Stator winding with 2/3 Pitch
 Rotor consists of shaft with shrunken laminated poles, Exciter rotor, PMG (depending on Type) and fan.
 Damper cage
 Excitation unit with rotating rectifier diodes and overvoltage protection
 Dynamically balanced as per ISO 1940, Balance quality G2,5
 Drive end bracket with re greaseable antifriction bearing
 Non-drive end bracket with re grease antifriction bearing
 Cooling IC01 - open ventilated, air entry at non-drive end , air outlet at the drive end side
 Main terminal box includes main terminals for power cables
 Regulator terminal box with auxiliary terminals for thermistor connection and regulator.
 Anti-condensation heater
 3 PT100 for winding temperature monitoring+3 PT100 Spare
 2 PT100 for bearing temperature monitoring

Option:
Current transformer for protection and measuring in the star point
xx/1A, 10P10 15VA , xx/1A, 1FS5, 15VA

Electrical data and features


 Standards: IEC 60034, EN 60034, VDE 0530, ISO 8528-3, ISO 8528-9
 Voltage adjustment range: +/- 10 % of rated voltage (continuous)
 Frequency: -6/+4% of rated frequency
 Overload capacity: 10% for one hour within 6 hours, 50% for 30 seconds
 Asymmetric load: max. 8% I2 continuous, in case of fault I2 x t=20
 Altitude: < 1000m
 Max permitted generator intake air temperature: 5°C - 40°C
 Max. relative air humidity: 90%
 Voltage curve THD Ph-Ph: <3,5% at idle operation and <5% at full load operation
with linear symmetrical load
 Generator suitable for parallel operating with the grid and other generators
 Sustained short circuit current at 3-pole terminal short circuit: minimum 3 times rated current for 5
seconds.
 Over speed test with 1.2 times of rated speed for 2 minutes according to IEC 60034

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Digital Excitation system ABB Unitrol 1010 mounted within the AVR Terminal box with following
features:

 Compact and robust Digital Excitation system for Continuous output current up to 10 A (20A Overload
current 10s)
 Fast AVR response combined with high excitation voltage improves the transient stability during LVRT
events.
 The system has free configurable measurement and analog or digital I/Os. The configuration is done via
the local human machine interface or CMT1000
 Power Terminals
3 phase excitation power input from PMG or auxiliary windings
Auxiliary power input 24VDC
 Excitation output
 Measurement terminals: 3 phase machine voltage, 1 phase network voltage, 1 phase machine current
 Analog I/Os: 2 outputs / 3 inputs (configurable), +10 V / -10 V
 Digital I/O: 4 inputs only (configurable), 8 inputs / outputs (configurable)
 Serial fieldbus: RS485 for Modbus RTU or VDC (Reactive power load sharing for up to 31 GEJ engines
in island operation), CAN-Bus for dual channel communication
 Regulator Control modes: Bump less transfer between all modes
Automatic Voltage Regulator (AVR) accuracy 0,1% at 25°C ambient temperature
Field Current Regulator (FCR)
Power Factor Regulator (PF)
Reactive Power Regulator (VAR)
 Limiters: Keeping synchronous machines in a safe and stable operation area
Excitation current limiter (UEL min / OEL max)
PQ minimum limiter
Machine current limiter
V / Hz limiter
Machine voltage limiter
 Voltage matching during synchronization
 Rotating diode monitoring
 Dual channel / monitoring: Enables the dual channel operation based on self diagnostics and setpoint
follow up over CAN communication. (as option available)
 Power System Stabilizer (PSS) is available as option. Compliant with the standard IEEE 421.5-2005
2A / 2B, the PSS improves the stability of the generator over the highest possible operation range.
 Computer representation for power system stability studies: ABB 3BHS354059 E01
 Certifications: CE, cUL certification according UL 508c (compliant with CSA), DNV Class B,

Commissioning and maintenance tool CMT1000 (for trained commissioning/ maintenance personal)
 With this tool the technician can setup all parameters and tune the PID to guarantee stable operation.
The CMT1000 software allows an extensive supervision of the system, which helps the user to identify
and locate problems during commissioning on site. The CMT1000 is connected to the target over USB
or Ethernet port, where Ethernet connection allows remote access over 100 m.
 Main window
 Indication of access mode and device information.
 Change of parameter is only possible in CONTROL access mode.
 LED symbol indicates that all parameter are stored on none volatile memory.
 Setpoint adjust window
 Overview of all control modes, generator status, active limiters status and alarms.
 Adjust set point and apply steps for tuning of the PID.
 Oscilloscope

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 4 signals can be selected out of 20 recorded channels. The time resolution is 50ms. Save files to your
PC for further investigation.
 Measurement
 All measurements on one screen.

Routine Test
Following routine tests will be carried out by the generator manufacturer
 Measuring of the DC-resistance of stator and rotor windings
 Check of the function of the fitted components (e.g. RTDs, space heater etc.)
 Insulation resistance of the following components
Stator winding, rotor winding
Stator winding RTDs
Bearing RTDs
Space heater
Bearings
 Polarisation index
 No Load saturation characteristic (remanent voltage)
 Stator voltage unbalance
 Direction of rotation, phase sequence
 No-Load Vibration Test per IEC 34-14 --- Rigid Mounting at min. medium and max. speed
 Excitation Test
 Setting of AVR System Parameters
 High voltage test of the stator windings (2 x Unom. + 1000 V) and the rotor windings (min. 1500 V)

1.03 Module accessories


Base frame
Welded structural steel to accommodate engine, generator and heat exchangers.

Flexible coupling
With torque limiter to couple engine with generator. The coupling isolates the major subharmonics of
engine firing impulses from the generator.

Bell housing
To connect engine with generator housing. With two ventilation and control windows.

Anti-vibration mounts
Arranged between engine/generator assembly and base frame. Isolating pads (SYLOMER) for placement
between base frame and foundation, delivered loose.

Exhaust gas connection


Connection of exhaust gas turbocharger; including flexible connection to compensate for expansions and
vibrations.

Combustion air filter


Dry type air filter with replaceable filter cartridges, including flexible connection to carburetor and service
indicator.

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Interface panel
Totally enclosed sheet steel cubicle with front door, wired to terminals, ready to operate; Cable entry at
bottom

Painting: RAL 7035

Protection: IP 54 external, IP 20 internal (protection against direct contact with live parts)

Design according to IEC 439-1 (EN 60 439-1/1990) and DIN VDE 0660 part 500, respectively.
Ambient temperature: 5 - 40 °C (41 - 104 °F), Relative humidity: 70 %

Dimensions:
 Height: 1000 mm (39 in)
 Width: 800 mm (32 in)
 Depth: 300 mm (12 in)

Power supply from the starter battery charger

Power distribution to the engine mounted auxiliaries (power input from the supplier of the auxiliaries
power supply):
3 x 400/231 V, 50 Hz, 16 A

Essential components installed in interface panel:


 Terminal strip
 Decentralised input and output cards, connected by a data bus interface to the central engine control of
the module control panel.
 Speed monitoring
 Relays, contacts, fuses, engine contact switch to control valves and auxiliaries
 Measuring transducer for excitation voltage
 Air conditioning system (option)

1.03.01 Engine jacket water system


Engine cooling jacket system
Closed cooling circuit, consisting of:
 Expansion tank
 Filling device (check and pressure reducing valves, pressure gauge)
 Safety valve(s)
 Thermostatic valve
 Required pipework on module
 Vents and drains
 Jacket water pump, including check valve
 Jacket water preheat device

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1.03.02 Automatic lube oil replenishing system incl. extension tank
Automatic lube oil replenishing system:
Includes float valve in lube oil feed line, including inspection glass. Electric monitoring system will be
provided for engine shut-down at lube oil levels "MINIMUM" and "MAXIMUM". Solenoid valve in oil feed
line is only activated during engine operation. Manual override of the solenoid valve, for filling procedure
during oil changes is included.

Oil drain
By set mounted cock

Oil sump extension tank 300 l


To increase the time between oil changes

Aftercooling oil pump:


Mounted on the module base frame; it is used for the aftercooling of the turbocharger; period of operation
of the pump is 15 minutes from engine stop.
Consisting of:
 Oil pump 250 W, 400/231 V
 Oil filter
 Necessary pipework

1.05.01 (Bio) Gas train


Pre-assembled, delivered loose, for installation into gas pipework to the module.

Consisting of:
 Shut off valve
 Gas filter, filter fineness <3 µm
 Gas admission pressure regulator
 Pressure gauge with push button valve
 Solenoid valves
 Leakage detector
 Gas pressure switch (min.)
 Gas pressure regulator
 Gas flow meter (option)
 p/t compensation (option)

The gas train complies with DIN - DVGW regulations.


Maximum distance from gas train outlet to gas entry on engine, including flexible connections, is 2 m (78
in).

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1.07 Painting
 Quality: Oil resistant prime layer
Synthetic resin varnish finishing coat

 Colour: Engine: RAL 6018 (green)


Base frame: RAL 6018 (green)
Generator: RAL 6018 (green)
Module interface
panel: RAL 7035 (light grey)
Control panel: RAL 7035 (light grey)

1.11 Engine generator control panel – DIA.NE XT


Dimensions:
 Height: 2200 mm (87 in) [including 200 mm (8 in) pedestal]
 Width: 1000 mm (40 in)
 Depth: 600 mm (24 in)

Control supply voltage from starter and control panel batteries: 24V DC

Supply of power for auxiliaries from auxiliary power panel:


3 x 400/231 V, 50 Hz, xx A

Consisting of:
DIA.NE XT 3 (Dialog Network new generation) motor management system

System elements visualisation with central engine and module control

1) Visualisation:
Industrial control with 10,4“ QVGA TFT colour graphics display and 8 function keys.
10-key numeric keyboard for parameter input.
Keys for START, STOP, Generator circuit breaker OPEN, Generator circuit breaker
CLOSED/SELECTED, display selection keys and special functions.
Interfaces:
 Ethernet (twisted pair) for connection to DIA.NE WIN server
 CAN-Bus: bus connection to the intelligent sensors and actuators
 Data bus connection to the control in- and outputs
Interfacing with the customer’s plant management MODBUS-RTU as slave
Protection class: IP 65 (front)
Dimensions: W x H x D = approx. 212 x 255 x 95 mm (8,4 x 10 x 3,75 in)

A clear and functional graphic compilation of measured values is displayed on the screen. User prompts
are by means of direct-acting display selection keys and function keys.

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Main displays:
 Electrical schematic
 Oil and hydraulic schematic
 Gas data
 Engine controllers
 Cylinder data
 Exhaust gas data
 Auxilliaries controllers
 Spare screen for customer specific purposes
 System display screens
 Parameter manager
 User setting
 Alarm management

Recipe handling:
Setting, display and storage of all module parameters

Alarm management:
Efficient diagnostic instrumentation listing all active fault messages both tabular and chronologically, with
the recorded time.

2) Central engine and module control:


A real-time, modular industrial control system which handles all jobs for module and engine-side
sequencing control (start preparation, start, stop, synchronizing, after-cooling, control of auxiliaries), as
well as all control functions.

Control functions:
 Speed control in no-load and isolated operation
 Power output control in parallel operation system; job-specific with respect to internal and external set
point values.
 LEANOX control system for control of boost pressure; dependent upon the generator terminal power
and the mixture temperature via the engine-driven air-gas mixer
 Knocking control: adjustment of the ignition point, power output and (insofar as is locally possible) the
mixture temperature in the event of detection of knocking.
 Load sharing between several modules in isolated operation
 Linear reduction of power output in the event of excessive mixture temperature and ignition failures

 Interface relays as per the interface list


 Multi-transducer, to record the following electrically measured variables of the generator:
 Phase current (with slave pointer)
 Neutral conductor current
 Voltages Ph/Ph and Ph/N
 Active power (with slave pointer)
 Reactive power
 Apparent power
 Power factor
 Frequency
An additional 0 - 20 mA output is produced for active power, as well as a pulse output for active power
demand.

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The following alternator supervisions are integrated with the multi-transducer (max. 8 functions
simultaneous):
 Overload/short-circuit [51], [50]
 Over voltage [59]
 Undervoltage [27]
 Asymmetric voltage [64], [59N]
 Unbalance current [46]
 Failure Exitation [40]
 Overfrequency [81>]
 Underfrequency [81<]
 Lockable operation mode selector switch positions:
 "OFF"
No operation is possible, running set will shut down;
 "MANUAL"
Manual operation using (start, stop) is possible, unit is not available for fully automatic operation.
 "AUTOMATIC"
Fully automatic operation, according to remote demand signal:
 Automatic start
Fully automatic operation at full load
 Stop with cooling down run for 1 minute
Continuous operation of auxiliaries for 5 minutes after engine shutdown
 Demand switch with the positions:
 Demand OFF
 Demand ON
 Remote demand
 Supply disconnecting device for auxiliaries with lockable circuit breaker

Shut-down functions with display:


 Low lube oil pressure
 Low lube oil level
 High lube oil level
 High lube oil temperature
 Low jacket water pressure
 High jacket water pressure
 High jacket water temperature
 Overspeed
 Emergency stop/safety loop
 Gas train failure
 Start failure
 Stop failure
 Engine start blocked
 Engine operation blocked
 Misfiring
 High mixture temperature
 Measuring signal failure
 Overload/output signal failure
 Generator overload/short circuit
 Generator over/undervoltage
 Generator over/underfrequency
 Generator asymmetric voltage

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 Generator unbalanced load
 Generator reverse power
 High generator winding temperature
 Synchronising failure
 Knocking failure

Warning functions with display:


 Low jacket water temperature
 CPU battery failure

Operational functions with display:


 Ready to start
 Operation (engine running)
 Generator circuit breaker "CLOSED"

Remote signals:
(volt free contacts)

1NO = 1 normally open


1NC = 1 normally closed
1 COC = 1 change over contact

 Ready for automatic start (to Master control) 1NO


 Operation (engine runs) 1NO
 Collective signal "shut down" 1NC
 Collective signal "warning" 1NC

External (by others) provided command/status signals:


 Engine demand (from Master control) 1NO

Single synchronizing Automatic


With voltage balance

For automatic synchronizing of the module with the generator circuit breaker to the grid by PLC-
technology, integrated within the module control panel.

Consisting of:
 Lockable synchronizing mode selector switch, with positions "MANUAL - OFF - AUTOMATIC"
 AUTOMATIC:
Automatic module synchronization, after synchronizing release from the control panel
 MANUAL:
Manual initiation of synchronizing by push button. Speed adjustment and closing of the circuit breaker
is automatically controlled via microprocessor
 OFF:
Synchronization is disabled
 Additional PLC hardware for the fully automatic synchronizing of each module, and monitoring of the
"CIRCUIT BREAKER CLOSED" signal.
Logic for monitoring of:
 Non-logic breaker positions
 Switch ”ON” trouble

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 Switch ”OFF” trouble
 Automatic synchronizing device to control the electronic speed governor adjustment, double voltmeter,
double frequency meter and synchronoscope
 Automatic voltage balancing
 Luminous push button “GENERATOR CIRCUIT BREAKER OPEN / SELECT”
 To indicate synchronizing mode
 To indicate “Generator circuit breaker closed”
 For manual synchronizing selection with the synchronizing mode selector switch in the MANUAL
position
 For manual closing of the generator circuit breaker to the voltage free bus bar (first connection) with
synchronizing mode selector switch in the MANUAL position
 Luminous push button “GENERATOR CIRCUIT BREAKER OPEN”
 To indicate “Generator circuit breaker open”
 To manually open the generator circuit breaker
 Control switch
 Required relays for control and monitoring
 Voltage relay for monitoring of bussbar voltage (only for island operation)

Operational indications for:


 Generator circuit breaker CLOSED
 Generator circuit breaker OPEN

Fault indications for:


 Generator circuit breaker return signal fault
 Generator circuit breaker closing fault
 Generator circuit breaker opening fault

Remote signals
(Volt free contacts)

 Generator circuit breaker CLOSED 1 NO

The following reference and status signals must be provided by the switchgear supplier:
Generator circuit breaker CLOSED 1 NO
Generator circuit breaker OPEN 1 NO
Generator circuit breaker READY TO CLOSE 1 NO
Mains circuit breaker CLOSED 1 NO
Mains circuit breaker OPEN 1 NO

 Mains voltage 3 x 400/231V or 3x 110V/v3 – other measurement voltages available on request


 Bus bar voltage 3 x 400/231V or 3x 110V/v3 – other measurement voltages available on request
 Generator voltage 3 x 400 or 3x 110V/v3 – other measurement voltages available on request

Voltage transformers in star point with minimum 50VA, Class 1

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The following volt free interface-signals will be provided by GE Jenbacher to be incorporated in
switchgear:
 CLOSING/OPENING command for generator circuit breaker
(permanent contact) 1 NO + 1 NC
 Signal for circuit breaker undervoltage trip 1 NO

1.11.02 Remote information by MODBUS-RTU


Data transfer from GE JENBACHER-module control to customer's plant management system by
MODBUS-RTU-network (RS 485).
The Jenbacher module control panel works as a SLAVE.
The data transmission by the customer's MASTER shall be cyclical.

Transmitted data:
Individual failure information, plant operating information, measuring values for generator power, oil
pressure, oil temperature, jacket water pressure, jacket water temperature, cylinder and average exhaust
gas temperatures.

GE Jenbacher limit of delivery:


Interface connector at the PLC in the module control panel.

1.11.03 Remote Data-Transfer with DIA.NE XT - HERMES


General
HERMES is the remote data transfer solution for DIA.NE XT. HERMES is available via three connection
methods and two applications.

Connections methods

1.) Internet (OPTION)


Site – Customer connection via secure Internet access
See comments under Technical instruction TI 2300 - 0006

Scope of Supply
 DIA.NE WIN – Server (Industrial PC without display, keyboard or mouse, built into the control panel,
including operating system)
 Ethernet–Network card (10/100 BASE T)
 Firewall–Appliance with connection feasibility to a customer network with a maximum of 10 Hosts
(Installation and service by GE Jenbacher; during warranty period included, afterwards as a service
package with costs) (built into the control panel)
 Feature – service package (access monitoring, clock synchronization for server)

Customer Requirements
 Broad band Internet access with at least two official IP addresses.
Connection feasibility for the Firewall–Appliance to the Internet–Router via Ethernet
(RJ45 Connector, Network Address Translation (NAT) is not permitted)

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2.) Mobile internet (OPTION)
Site – Customer connection via secure Internet access
See comments under Technical instruction TI 2300 - 0006

Scope of Supply
 Mobile internet router (incl. antenna)
 DIA.NE WIN – Server (Industrial PC without display, keyboard or mouse, built into the control panel,
including operating system)
 Ethernet–Network card (10/100 BASE T)
 Firewall–Appliance with connection feasibility to a customer network with a maximum of 10 Hosts
(Installation and service by GE Jenbacher; during warranty period included, afterwards as a service
package with costs) (built into the control panel)
 Feature – service package (access monitoring, clock synchronization for server)

Customer Requirements
 SIM card for 3G
 Broad band Internet access with at least two official IP addresses.
Connection feasibility for the Firewall–Appliance to the Internet–Router via Ethernet
(RJ45 Connector, Network Address Translation (NAT) is not permitted)

Applications

1.) DIA.NE WIN


DIA.NE WIN is the Windows based „man-machine interface“ for GE Jenbacher gas engines. The system
offers extensive facilities for commissioning, monitoring, servicing and analysis of the site. The system
DIA.NE WIN extends the visualization of DIA.NE XT with respect to user friendliness, historical analysis
and remote use. Several service stations can be independently operated in parallel. The system consists
of a central PC (DIA.NE WIN – Server) which is built in to the control panel and one or more service
stations (DIA.NE WIN – Clients). The system runs on a Microsoft Internet Explorer platform.

Function
Service and monitoring, trend analysis, alarm management, parameter management, long-term data
analysis, multi-user system, remote control, OPC (OLE for process control), print and export functions,
operating data protocols, available in several languages.

Scope of supply
 Software package DIA.NE WIN on the DIA.NE WIN – Server
 DIA.NE WIN – Client License (Right to access of the user to the server on site)

Customer requirements
 Standard PC with keyboard, mouse and monitor (min. resolution 1024*768)
 231 V supply for the customers’ PC
 Operating system Windows 98, Windows NT, Windows 2000 or Windows XP
 Microsoft Internet Explorer (min. Version 6.0) including Java support

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2.) DIA.NE RMC
DIA.NE RMC (Remote Message Control) is the automatic alarm system for DIA.NE XT. DIA.NE RMC can
fully automatically transmit essential operational information from the DIA.NE XT Alarm Management to a
remote station. The messages can be forwarded to an e-mail address, fax machine or mobile phone
(SMS). Furthermore the stored messages can be visualized at the remote station. The system consists of
a central PC (DIA.NE WIN – Server) which is built into the control panel and one or more customer
remote stations.

Function
Automatically transfer of messages to the customer via email, fax or SMS. Display and printing of the
messages (also distributed via LAN). Automatically and manually transfer of messages, trend data and
operating data protocols.

Scope of supply
 Software package DIA.NE message on the DIA.NE WIN – Server
 Software package DIA.NE control and DIA.NE report on the remote station
Only for connection method “Internet”:
 Firewall–Appliance for customer computer with connection feasibility to a customer network with a
maximum of 10 Hosts (Installation and service by GE Jenbacher; during warranty period included,
afterwards as a service package with costs)

Customer requirements
 Standard PC with keyboard, mouse and monitor (min. resolution 1024*768)
 231 V supply for the customers’ computer.
 Operating system Windows 2000 (Professional and Server), Windows XP Professional or
Windows Server 2003.
 Internet connection (provider account) for the case that messages from the RMC should be forwarded
to an email receiver (incl. SMS for mobiles and pagers). (Mobiles and pagers to be provided by the
customer).
 Customer fax software for message forwarding via fax
Only for connection method “Internet”:
 Broad band Internet access with at least two official IP addresses.
Connection feasibility for the Firewall–Appliance to the Internet–Router via Ethernet
(RJ45 Connector, Network Address Translation (NAT) is not permitted)

1.20.01 Starting system


Starter battery:
2 piece 12 V Pb battery, 200 Ah (according to DIN 72311), complete with cover plate, terminals and acid
tester.

Battery voltage monitoring:


Monitoring by an under voltage relay.

Battery charging equipment:


Capable for charging the starter battery with I/U characteristic and for the supply of all connected D.C.
consumers.
Charging device is mounted inside of the module interface panel or module control panel.

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 General data:
 Power supply 3 x 320 - 550 V, 47 - 63 Hz
 Max. power consumption 1060W
 Nominal D.C. voltage 24V (+/-1%)
 Voltage setting range 24V to 28,8V ( adjustable)
 Nominal current (max.) 40 A
 Dimensions 240 x 125 x 125 mm
 Degree of protection IP20 to IEC 529
 Operating temperature 0 °C - 60 °C
 Protection class 1
 Humidity class 3K3, no condensation.
 Natural air convection
 Standards EN60950,EN50178
UL/cUL (UL508/CSA 22.2)

Signalling:
Green Led: Output voltage > 20,5V
Yellow Led: Overload, Output Voltage < 20,5V
Red Led: shutdown

Control accumulator:
 Pb battery 24 VDC/18 Ah

1.20.03 Electric jacket water preheating


Installed in the jacket water cooling circuit, consisting of:
 Heating elements
 Water circulating pump

The jacket water temperature of a stopped engine is maintained between 56°C (133 °F) and 60°C
(140°F), to allow for immediate loading after engine start.

1.20.04 Flexible connections


Following flexible connections per module are included in the GE Jenbacher -scope of supply:

No. Connection Unit Dimension Material

2 Warm water in-/outlet DN/PN 80/10 Stainless steel


1 Exhaust gas outlet DN/PN 250/10 Stainless steel
1 Fuel gas inlet DN/PN 100/16 Stainless steel
2 Intercooler in-/outlet DN/PN 65/10 Stainless steel
2 Lube oil connection mm 28 Hose

Sealings and flanges for all flexible connections are included.

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1.20.48 (Bio) Gas Blower
The installation of the gas compressor guarantees, that the gas pressure at the gas train inlet is above
the minimum requirement.

Following components are delivered loose:


 Gas compressor
Gas flow ~650 Nm3/h (acc. to site specific data)
Inlet pressure 0-75 mbar
Outlet pressure 125-200 mbar
Inlet temperature ~20 °C
Electric motor: 400/231 V, 50 Hz
 1 Flow regulating valve
 1 Pressure gauget at in- and outlet
 1 Thermometer at in- and outlet
 Electric resistance thermometer at outlet (1 item)
 Pressure sensor at outlet (1 item)

2.00 Electrical equipment


Totally enclosed floor mounted sheet steel cubicle with front door wired to terminals. Ready to operate
with cable entry at bottom; Naturally ventilated

Protection: IP 42 external
IP 20 internal (protection against direct contact with live parts)

Design according to EN 60439-1 / IEC 60439-1 and ISO 8528-4.


Ambient temperature: 5 - 40 °C (41 - 104 °F), 70 % Relative humidity

Standard painting: Panel: RAL 7035


Pedestal: RAL 7020

2.02 Grid monitoring device


Standard with static Grid Code - 50Hz alternator

Function:
For immediate disconnection of the generator from the grid in case of grid failures

Consisting of:
 High/low voltage monitoring
 High/low frequency monitoring
 Specially adjustable independent time for voltage and frequency monitoring
 Vector jump monitoring or df/dt monitoring for immediate disconnection of the generator from the grid
for example at short interruptions
 Indication of all reference dimensions for normal operation and at the case of disturbance over LCD and
LED

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 Adjusting authority through password protection against adjusting of strangers

Scope of supply:
Digital grid protection relay with storage of defect data, indication of reference dimensions as well as
monitoring by itself.

Grid protection values:

Parameter Parameter limit max time delay[s] Comments

49-51HZ Do work normal

f<[ANSI 81U] 47,5Hz 0,1 Load reduction with 10% / Hz below 49Hz

f>[ANSI 81O] 51,5Hz 0,1 Load reduction with 30% / Hz above 51Hz

U<[ANSI 27] 80% 1 Load reduction with 1%P / %U below 95%

U<<[ANSI 27] 75% 0,2 Load reduction with 1%P / %U below 95%

U>[ANSI 59] 108% 60 Load reduction with 1%P / %U above 105%

U>>[ANSI 59] 115% 0,1 Load reduction with 1%P / %U above 105%

Df/dt [ANSI 81R] 2Hz/s, 5 Periods Cos phi range:

Or Or 0,8ind (overexcited) - 0,95cap (underexcited)

Vector shift 8° - 3pol

[ANSI 78]

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2.03.04 Power control for bio gas applications
Power adjustment:
Starting and stopping of the module is carried out depending on the on site module demand.

The modules output is controlled via on site signals.


The power adjustment of the module is possible between 50 – 100% of the rated power.

Automatic power reduction in relation to landfill/bio/mines gas applications


 Motor control
For all biogas, landfill gas, and mines gas sites, the optimal start position is calculated by means of the
calorific value of the gas and via interpolation of the gas types in the motor control system (only Dia.ne,
gas type 1-2). The calculation is enabled via a customer provided CH4 signal. If a CH4 signal is not
available, the motor will be started at a preset gas mixer start position.
Advantage: The motor can start without problems even in the case of large variations in the calorific
value of the gas.
Attention: The CH4 signal must represent the true gas quality that the motor receives (normally only
possible in conjunction with a sample line)

Blocking or release of the gas motor is controlled via the gas supply plant.

 Possible methods of output reduction:


Limiting the output via the gas pressure at the limit of GE Jenbacher’s scope of supply
(customers’ 4 - 20mA signal, voltage free)
Function: with this set-up, the motor output can be reduced (between 50 and 100%) depending on the
supplied site gas pressure.
Advantage: Using this approach, an over-suction of the gas system can be prevented. Furthermore
this also prevents or delays the possibility of the gas pressure failing and the resulting motor trip.

Output reduction based on a CH4 signal


(customers’ 4 - 20mA signal, voltage free)
Function: with this set-up, the motor output can be reduced (between 50 and 100%) depending on the
CH4 signal.
Advantage: Using this approach, an over-suction of the gas system can be prevented. Furthermore
this also prevents or delays a motor trip due low gas quality.
Recommended application if the motor is the only user of the gas supply!

Output reduction based on suction pressure before the gas compressor


(customers’ 4 - 20mA signal, voltage free)
Function: with this set-up, the motor output can be reduced (between 50 and 100%) depending on the
suction pressure of the compressor.
Advantage: Using this approach, an over-suction of the gas system can be prevented. Furthermore
this also prevents or delays the possibility of the gas pressure failing and the resulting motor trip.
Recommended application if the motor is the only user of the gas supply!
The switching on/off of this function must be activated via an external signal.

Monitoring of the O2 content


(customers’ 4 - 20mA signal, voltage free + definition of the limiting values by the customer)

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Function: this control function allows the GE Jenbacher scope of supply to switch out when a certain
limiting value is reached. This prevents the formation of additional ignition sources in the case of an
explosive gas mixture.

Further signals for display/reading


 Gas temperature
 Gas flow rate

Please see also the checklist for motor control for landfill/bio/mines gas.

2.04 Generator switchgear, low voltage


Dimensions:
 Height: 2200 mm (87 in) (including 200 mm [8 in] pedestal)
 Width: 600 mm (32 in)
 Depth: 600 mm (32 in)

Essential components installed in power cubicle:


 Power part
 1 motorised 3-phase circuit breaker with integrated electronic overload and short circuit relays,
containing:
Adjustable overload protection
Adjustable short circuit protection with short time delay
Breaking capacity: 100 kA
Peaking capacity: 220 kA
 Undervoltage trip coil 24 V DC
 3 x 1 FS 5 current transformers, for measuring (xxx A)
 1 x 5-wire copper bussbar system (L1, L2, L3, PE, N and Cu-Bridge), with connection facilities for
incoming
 Control and auxiliary relays, terminal block for control cables, Plexiglas protection for live parts, spare
space for additional relays
 Panel ventilator

Remote signals (potential free contacts):


 Overload / short circuit generator circuit breaker 1 NC
 Generator circuit breaker ON 1 NO
 Generator circuit breaker OFF 1 NC
 Generator transformer current 3 x 5 A, 1 FS 5, 15 VA
 Generator voltage (measuring voltage) / V, 4 A
 Voltage for auxiliaries / V, xx A
 Generator voltage for synchronizing system / V, 4 A
 Voltage of busbar for synchronizing system / V, 4 A

Terminals are provided at the synchronizing device for the incoming signal "GENERATOR-CIRCUIT
BREAKER ON"

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3.01 Lube oil system (1/plant)
Consisting of:
 Electric driven fresh oil pump
 Electric waste oil pump
 Level switches
 Shut-off devices

Through simple switch over of the pumps following functions are given:
 Filling the fresh oil tank (fresh oil pump)
 Emptying of the oil pan into the waste oil tank (waste oil pump)
 Emptying of the waste oil tank (waste oil pump)
 Filling of the oil pan from the fresh oil tank

3.03.01 Exhaust gas silencer


Residual sound pressure level:
Designed for a residual sound pressure level of 65 dB(A) in 10 m (32 ft) (as measuring area level
according to DIN 45635 or ISO 3744) measured at the chimney escape.

Material:
Carbon steel, based upon exhaust gas temperature of ~500°C

Consisting of:
 Exhaust gas silencer
 Flanges, seals

Insulation:
The insulation for reducing surface irradiations of the exhaust gas silencer is not included in our scope of
supply and must be provided locally.

Insulation thickness for outdoor installation:


 For 50 dB(A) in 10 m (32ft) 100 mm (4 inch) rock wool covered with 1 mm (0,04 inch)
galvanized steel sheet
 From 55 dB(A) in 10 m (32ft) 100 mm (4 inch) rock wool covered with 0,75 mm (0,03 inch)
galvanized steel sheet
 For < 50 dB(A) in 10 m (32ft) insulation thickness is determined for each project

Insulation thickness for indoor installation:


 Insulation has to be dimensioned upon heat radiation

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3.10 Cooling system – Intercooler
The heat produced by the engine intercooler 2nd stage is dumped through a radiator, installed outside.

Sound pressure level _ dB(A) at 10 m (32 ft) (as measuring area level according to ISO 3744 / EN
13487)

Consisting of:
 Radiator
 Pump
 Electrical control
 Expansion tank

The radiator is designed for an ambient temperature of 35°C (95°F). Special versions for higher ambient
temperatures are available upon request.

3.11 Cooling system – Emergency Cooler


The heat produced by the engine (jacket water, lube oil, 1st stage intercooler) is dumped through a
radiator, installed outside.

Sound pressure level 65 dB(A) at 10 m (32 ft)


(as measuring area level according to ISO 3744 / EN 13487)

Consisting of (delivered loose):


 Plate heat exchanger (emergency circuit / warm water circuit)
 Radiator
 Pump
 Short-circuit thermostat
 Safety valve
 Expansion tank

The radiator is designed for an ambient temperature of 35°C (95°F).

4.00 Delivery, installation and commissioning


4.01 Carriage
"Free Carrier / FCA", Gebrüder Weis GmbH Warehouse of GE Jenbacher GmbH & Co OG,
Feldstrasse 9, 6020 Innsbruck, Austria, according to INCOTERMS 2010

4.02 Unloading
Unloading, moving of equipment to point of installation, mounting and adjustment of delivered equipment
on intended foundations is not included in GE Jenbacher scope of supply.

4.03 Assembly and installation


Assembly and installation of all GE Jenbacher -components is not included in GE Jenbacher scope of
supply.

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4.04 Storage
The customer is responsible for secure and appropriate storage of all delivered equipment.

4.05 Start-up and commissioning


Start-up and commissioning with the GE Jenbacher start-up and commissioning checklist is not included
in GE Jenbacher scope of supply.

5.01 Limits of delivery - Genset


Electrical:
 Genset:
 At terminals of genset interface panel
 At terminals of generator terminal box
(screwed glands to be provided locally)
 Genset control panel:
At terminal strips
 Auxiliaries:
At terminals of equipment which is supplied separately

Cooling water
At inlet and outlet flanges on genset

Exhaust gas
At outlet flange of the genset

Combustion air
The air filters are set mounted

Fuel gas
At inlet and outlet flange of gas train
At inlet flange of gas pipework on genset

Lube oil
At lube oil connections on genset

Draining connections and pressure relief


At genset

Insulation
Insulation of heat exchangers and pipework is not included in our scope of supply and must be provided
locally.

First filling
The first filling of genset, (lube oil, engine jacket water, anti freeze-, anti corrosive agent, battery acid) is
not included in our scope of supply.

The composition and quality of the used consumables are to be strictly monitored in accordance with the
"Technical Instructions" of GE JENBACHER.

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Suitable bellows and flexible connections must be provided locally for all connections.
Cables from the genset must be flexible.

5.02 Factory tests and inspections


The individual module components shall undergo the following tests and inspections:

5.02.01 Engine tests


Carried out as combined Engine- and Module test according to DIN ISO 3046 at GE Jenbacher test
bench. The following tests are made at 100%, 75% and 50% load, and the results are reported in a test
certificate:
 Engine output
 Fuel consumption
 Jacket water temperatures
 Lube oil pressure
 Lube oil temperatures
 Boost pressure
 Exhaust gas temperatures for each cylinder

5.02.02 Generator tests


Carried out on test bench of the generator supplier

5.02.03 Module tests


The engine will be tested with natural gas (methane number 94). The performance data achieved at the
test bench may therefore vary from the data as defined in the technical specification due to differences in
fuel gas quality.
Carried out as combined Engine- and Module test commonly with module control panel at GE Jenbacher
test bench, according to ISO 8528, DIN 6280. The following tests are made and the results are reported
in a test certificate:
Visual inspection of scope of supply per specifications.
 Functional tests per technical specification of control system.
 Starting in manual and automatic mode of operation
 Power control in manual and automatic mode of operation
 Function of all safety systems on module
 Measurements at 100%, 75% and 50% load:
 Frequency
 Voltage
 Current
 Generator output
 Power factor
 Fuel consumption
 Lube oil pressure
 Jacket water temperature
 Boost pressure
 Mixture temperature
 Exhaust emission (NOx)

The module test will be carried out with the original generator, except it is not possible because of the
delivery date. Then a test generator will be used for the module test.

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To prove characteristics of the above components, which are not tested on the test bench by GE
JENBACHER, the manufacturers’ certificate will be provided.

5.03 Documentation
Preliminary documentation 60 days after receipt of a technically and commercially clarified order:
 Module drawing 1)
 Technical diagram 1)
 Drawing of control panel 3)
 List of electrical interfaces 2)
 Technical specification of control system 2)
 Technical drawing auxiliaries (if included in GE Jenbacher-limit of delivery) 1)

At delivery:
 Wiring diagrams 3)
 Cable list 3)

At start-up and commissioning (or on clients request):


 Operating and maintenance manual 4)
 Spare parts manual 4)
 Operation report log 4)

Available Languages
1) DEU, GBR
2) DEU, GBR, FRA, ITA, ESP
3) DEU, GBR, FRA, ITA, ESP, NLD, HUN, RUS, POL, TUR, CZE
4) DEU, GBR, FRA, ITA, ESP, NLD, HUN, RUS, POL, TUR, CZE, SLOWEN, SLOWAK, SERB,
SCHWED, ROM, PRT, NORWEG, LITAU, LETT, BULGAR, CHINA, DNK, ESTN, FIN, GRC, KROAT

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