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Technical description
Notice: technical data and specification marked with an asterisk (*) are for preliminary information only and not binding and will be specifically determined upon order placement.
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Ignition Microprocessor-controlled high-voltage ignition system with low-voltage distribution; respectively one ignition coil per cylinder; without moving parts; wear-free; triggered via tooth rim of the flywheel and a pick-up sensor at the camshaft; variable ignition times; ignition energy and distribution via calculator at primary side of the ignition coils; high-performance industrial engine or special sparkplugs and integrated ignition cable; buffered voltage supply by 24 V battery. Antiknock control Knock sensor monitoring for each cylinder; ignition control for the individual cylinders, gas-air mixture and engine power adjustment; knock-free operation at maximum power with best degrees of efficiency while complying with emission thresholds. Fuel mixture generation Air intake via dry air filters (with optical maintenance indicator) into the multigas mixer; gas supply from safety gas control train; dosing of the gas-air quantity ratio in the multigas mixer. Fuel mixture charging Two exhaust gas turbochargers take air and gas out of the gas mixer at atmospheric pressure; subsequent compression of the gas mixture and re-cooling in the two-stage mixture coolers (lowtemperature stage in the separate cooling circuit); rotary slide valve throttle unit for each cylinder row downstream of mixture cooler for power control. Gas mixture control and monitoring Electronic control and monitoring of the air-gas mixture at the mixer actuator via combustion chamber temperature (1 temperature sensor per cylinder) and the power/speed, combined in the MWM TEM system. Starter Compressed-air starter turbine with integrated gear and 24 V magnetic valve; pressure reduction station with ball valve and filter, as well as connection option for compressed-air supply of the engine flywheel turning device and the electro-pneumatic valves of the gas control train; flanged on crankcase. Lubricating oil system Forced-feed circulatory lubrication by toothed wheel pump, lubricating oil cooling in the separate cooling circuit; oil filter in the main stream; additional fine filter in the auxiliary stream; automatic lubricating oil refilling into the oil pan through controlled inflow; automatic pre-lubrication by electric pump; oil discharge by the same pump at the unit; lubricating oil pre-heating by means of separate circulating pump and plate heat exchanger (heat transfer from cooling water pre-heating). Cooling water connections Rubber compensators with counter-flange for connection to the cooling water lines. Exhaust gas connection 2 pieces stainless steel compensators to be attached with clamps, with the respective welding flanges for connection to the exhaust gas line.
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Sensors/actuating elements and cabling Sensors for cooling water temperatures, intake air temperatures, mixture temperatures, oil temperature, oil level, oil pressure, speed, combustion chamber temperatures, exhaust gas temperatures, exhaust gas turbocharger speeds, crank chamber pressure, starter air pressure, gas mixer position recording, knock sensors, actuator throttle element, gas mixer actuators, cooling water pre-heating control, ignition coils completely cabled to two central connecting elements (respectively 1 connecting element per cylinder row) by means of detachable connections. Engine test run A test run of the engines is performed at the manufacturer's factory. The test runs are performed on gauged test facilities. The test reports are included in the documents. Procedure and content of the test: Test - general Engine assembly and cabling according to assembly plan Engine installation on test stand with cold functional test Engine run-in according to run-in programme Set engine, leak test and recording of measured values Engine acceptance 60 min 20 min Controller test 100% power at rated speed 50% power 100% at zero load 2 measurements 1 measurement
Recording of measured values Speed, brake force or electrical output, consumption (degree of efficiency), controller position, exhaust gas temperatures, intake temperature, lubricating oil pressure, lubricating oil temperature, cooling water pressures high-temperature (HT) and low-temperature circuit (NT), cooling water temperatures NT and HT, mixture pressure, mixture temperatures downstream of compressor and downstream of mixture cooler, turbocharger speed, exhaust gas emissions (% O2 dry, mg/m i.N. NOx). Preservation Standard preservation of the engine to protect against corrosion during transport and possible subsequent storage at the place of destination. Maximum protection period of 6 months after delivery, for storage in a closed dry room.
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Stator The stator casing has a welded design. The stator pack is manufactured from hydraulically pressed, low-loss dynamo sheet and is compressed with the stator by pressure plates into a compact unit. A rigid design adapted to the special operating conditions prevailing in diesel units is thus achieved. The stator coil corresponds to insulation class F according to VDE 0530/IEC 34. The coil heads and switching connections are supported by suitable attachment elements and attached to each other by fixed mechanic connection and thus protected against dynamic stresses caused by electrodynamic forces. Rotor The rotor comprises the shaft and the main pulse wheel. The main pulse wheel in salient pole design consists of hydraulically pressed sheets or steel plates. By standard, a copper dampening cage is installed that is electrically connected in the pole shoes and between the poles. The coils of the main rotor are made of flat copper and are protected by suitable components against centrifugal forces. The rotor coil corresponds to insulation class F according to VDE 0530/IEC 34. By standard, the rotor is balanced with half feather key according to VDE 0530/IEC 34, Part 34. Bearing shields The bearing shields are welded or made of cast iron. According to the design, the generator feet are attached underneath the bearings. Storage Antifriction bearings are designed as loose bearings on the drive side and as fixed bearings on the counter-drive side. Specifications, norms Design specifications: VDE 0530, IEC 34 (EN 60034), ISO 8528-3
Components/subassemblies/standard design Terminal box generously dimensioned for installation of current transformers. Terminal boxes with cable inlet connections and cable strain relief Electronic control Basic module MEC 100 D, including failure monitoring: highly constant voltage regulation reactive-current dependent static Underspeed protection by U/F function Function blocks Cos-phi regulator: Cos-phi balancer o The power factor of the controlled generator is the same as that of the entire current or of the current of the other generators (depending on the current transformer connection) o Suitable for parallel operation with generators without linear voltage static o Generators protected by adjustable over- and under-excitation limits o Target value setting by potentiometer or by current signal 4 20 mA
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Voltage balancer: Automatic synchronisation balancer o Automatic adaptation of the generator idle voltage to the mains voltage prior to synchronising o No separate voltage adjustment by additional devices in the switchgear required Exciter and diode monitoring: Exciter system monitoring direct current relay; delivery loose for installation in the control/switch panel o Recording of over- and under-excitation states o Recording of faults of the rotating diodes by means of unevenness of the direct current of the exciter Static transformer: for parallel operation with the mains and with each other, installed in the generator Auxiliary heating: installed in the generator Temperature monitoring o 6 PT 100 sensor for coil o 1 PT 100 sensor for each bearing
Electrical data and properties Voltage operating range Voltage adjustment range Voltage accuracy, static Uninterrupted short-circuit current Overload capability or Overspeed Between 90 ... 110 % of the rated voltage +10 % / -10 % rated voltage for continuous operation 0.5 ... 1 % For 3-pole terminal short-circuit at least 3 x rated current for 3 s 10 % for 1 h, within 6 h according to IEC 34/VDE 0530, i.e. 50 % for 30 s. according to VDE 0530 for 1.2 the rated speed for 2 min
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Additional parts of the plant The components listed in the following are delivered "loose" and are not mounted to the plant. The assembly must be carried out on site by the customer. 1 set of maintenance-free steel feather elements with height adjustment for easy adjustment of the unit on the foundation at the customer's. A vibration insulation of approx. 88 94 % can be achieved with these bearing elements. Structure-borne noise is reduced by a rubber fibre plate on the bottom side of the bearing. 2 pieces magnetic valves with connecting parts for lubricating oil flow 1 piece fan for ventilating the crankcase with integrated filtering of the oil mist vapours for discharging the exhaust air 1 piece differential pressure monitor for monitoring the crank chamber ventilation fan 1 can touch-up paint RAL 5010
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The gas control train is designed for a gas flow pressure of 300 mbar with a permissible variation of 10%, variation frequency < 1/6 min. The equipment of the gas control train might vary, depending on the type of gas or operation. The separate parts list as listed upon placement of the order is binding.
Setup
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The TEM-EVO system comprises 3 components: Power unit control cabinet ("AGS") Complete with connected cables to the unit; contains the unit control and the TV certified safety chain. I/O controller For installation in the control cabinet of the auxiliary power unit. Workstation The system can flexibly be adjusted to the local conditions. Susceptibility to failure and cabling expenditure for the plant is minimised. The unit control cabinet is installed in direct vicinity to the unit. The engine cables are tested at the factory and the cables are tested and fully connected to the unit control cabinet to ensure trouble free commissioning and high operational reliability. The signals that are relevant to the power stack are exchanged directly with the TEM-EVO system via the I/O controller in the auxiliary power unit control cabinet. Data are transmitted to the unit control via a highly fault free CAN bus connection. The workstation can be placed anywhere on the plant, at the unit or in the switch room, at the customer's choice.
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Basic functions Automatic program sequence for start and stop for the gas engine plant Reliable control of the exhaust gas emissions to low values Integrated digital speed and power control TV certified safety chain Connection of actuators and sensors at the I/O controller in the auxiliary power unit control cabinet and data transmission via CAN bus to the TEM-EVO unit cabinet Monitoring of all sensors at the unit Monitoring of the engine cooling water Control and monitoring of the lubricating oil circuit inclusive oil pre- and after-lubrication as well as oil change Test mode for checking the connected actuators, sensors and auxiliary power units Electronic line recorder for measured values for control and diagnostic purposes over periods of 40h/6min as well as synchronous with work cycle Electronic operation diary for recording any warning, malfunction and operational messages with date and time for detailed monitoring of the operation Electronic operating hours counter with breakdown in 5 load ranges Connection option for one workstation [MK] Engine cooling water control: The cooling water circuit control ensures an optimal cooling water temperature by piloting a three-way valve. The cooling water inflow temperature is increased for partial load [GK] Intercooling circuit: Control of the intercooling water inflow temperature by piloting a control valve in the intercooling water circuit; monitoring of the receiver temperature [IOC] I/O controller: The I/O controller controls the auxiliary power units, pumps, valves, etc. and records the respective measured values The I/O controller is delivered loose for installation in the auxiliary power unit control cabinet [16M] 16 configurable messages: Digital inputs with comprehensive configuration options in order to be able to connect plant-specific malfunctions, warnings or messages directly to the TEM-EVO system. Monitoring a plant is thus considerably easier and clearer by the protocol function in the operation diary. For such purpose, the configurable messages are arranged as potential-free contacts (openers) in the TEM auxiliary power unit control cabinet at the I/O controller [SER] Serial coupling for data exchange: Exchange of data, such as e.g. target values, measured values, messages, warnings and malfunctions, with super ordinate control via serial coupling using protocol 3964R with RK512 via TTY or CS 20 mA. [AKRK] Antiknock control: Highly dynamic individual antiknock control for each cylinder to ensure safe operation of the engine also at a low methane number. Maximum possible power with best degrees of efficiency while complying with emission thresholds [GL] Monitoring of the generator bearing temperatures: Display (screen, history, serial coupling) and monitoring of the two generator bearing temperatures. A malfunction or warning is triggered if a configurable limit value is exceeded
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[GLT] To protect the engine, the basic bearing temperature (main engine bearing temperature) is recorded and monitored in the TEM-EVO. Exceeding the limit value will trigger a warning and then a malfunction, depending on by how much it was exceeded [SATL2] Measurement and restriction of the exhaust gas turbocharger speeds: Display (screen, history, serial coupling) and restriction of the exhaust gas turbocharger speeds [NATL2] Variable monitoring of the exhaust gas temperature after exhaust gas turbochargers A and B: Display (screen, history, serial coupling) and variable monitoring of the exhaust gas temperature after the exhaust gas turbocharger. A malfunction will be triggered if a configurable limit value is exceeded [BSX], [BSXK] Preliminary setup for eService system [BSX] with cable loom [BSXK]: Preliminary setup for remote operation of the TEM EVO (BSX): required for each TEM EVO that is to be connected to an eService modem system, a mechanical change-over switch or an intelligent selection unit (IAE) [AVW] The TEM-EVO controls the intake air pre-heating by piloting the control valve. Where preheating is requested, the intake air temperature is regulated according to the configurable target value. The controller actuates the control valve of the heat exchanger unit [VAWT/VSWT]Measurement of the heating water temperature upstream of the exhaust gas heat exchanger and before lubricating oil heat exchanger [SPC] Connection for service PC: Rugged service connector at the TEM-EVO unit control cabinet. When the service PC is connected, a control unit will interrupt the connection to the workstation or any modem that might be connected. The TEM-EVO system can then be operated from the service PC [2xNKAT] To protect the catalytic converter, the TEM-EVO measures the exhaust gas temperature after the catalytic converter and monitors it in dependence on the operating point. A malfunction will be triggered if the configurable limit value is exceeded
Operation An intelligent workstation provides access to all functions ensuring easy operation of the TEM EVO system The workstation is equipped with a 15" TFT touch monitor. The touch function of the workstation ensures easy and intuitive operation of the unit. Using the navigation bar, the user can operate the unit by quick and direct changing between screens. Each workstation screen provides the user with information on the state of the connected unit. All regulation, service, control and monitoring functions can conveniently be operated without the need for long training. Communication with the user can be in one of many available national languages of the TEM EVO system. The language can quickly be changed at any time by pressing a button. In the event of a service, a different language than the one used by the plant staff may temporarily be set. All information that is important for normal operation and operating options are clearly summarised on the "Operation" screen (Fig. 1) (the figure below also contains options).
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Operation diary With its recording function, the electronic operation diary (Fig. 2) of the TEM-EVO system makes the operation of the gas engine plant and its peripheral devices transparent. All operation messages and switching actions that are important for the operation as well as any changes to the configuration are recorded with the exact time stamp (date/time). In total, the TEM-EVO system can monitor and distinguish more than 600 different incidents. This allows for quick and detailed analysis of the operation of the unit incl. the auxiliary functions controlled by the TEM EVO.
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The curves can be followed with the cursor; the respective measured value is depicted as numeric value with exact time stamp. In the event of a failure, the recording will stop automatically after 40s to facilitate failure diagnosis. The "Real-time scope" function allows for continuous monitoring of measured values and control function. These measured values can optionally be saved for further analysis and re-read at a later time.
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1.9 Tools
Set standard tools 1 Comprising: Tool set o Toolbox o Double open ended wrench o Double open ended wrench o Double open ended wrench o Double open ended wrench o Double open ended wrench o Double open ended wrench o Double open ended wrench o Double ended ring spanner o Double ended ring spanner o Double ended ring spanner o Feeler gauge set o Socket wrench insert o Hinged handle o Socket wrench insert o Socket wrench insert
DIN 003110- 810 DIN 003110-1214 DIN 003110-1415 DIN 003110-1317 DIN 003110-1922 DIN 003110-24x27 DIN 003110- 3032 DIN 000838-1317 DIN 000838-1922 DIN 000838-24x27 DIN 002275-D DIN 003124- 1012.5 DIN 003124-1312.5 DIN 003124- 1412.5
Sparkplug wrench for mounting and dismounting sparkplugs Comprising: Socket wrench Grooved nut key Compressed-air operated drive for turning the engine flywheel during maintenance and repair Comprising: Compressed air motor Operating device
2. System components
The following components are included in the delivery scope and are delivered as a "loose" item.
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Floating air valve in hot-pressed brass design with red brass effect, with caulked shut-off device and corresponding shut-off valve. Maximum temperature Maximum pressure Connection size 120 10 1/2 C bar G
Water level limiter with glass floater as glandless device with magnetic transmission of the floater movement to a micro switch. Protection type Micro switch Max. operating overpressure Max. operating temperature Installed position 65 Single-pole change-over contact 10 120 Main axle vertical bar C IP
Membrane safety valve with upstream seat gasket separate from the membrane, liftable by rotary handle. Casing made of hot-pressed brass/red brass, spring cap made of GD Zn/hot-pressed brass/MS cast, inner parts made of Ms 58, membrane and gasket made of high-temperature resistant non-ageing rubber elastic plastic, spring made of corrosion-resistant spring steel wire Response overpressure Operating temperature Three-way valve (GK) Three-way valve with actuator, designed as pressurising valve. Control valve maintenance-free soft-sealing heating control valve, casing made of GG-25, 3-way valve shape, spindle made of 1.4571, tight-closing. Connections* 80 / 16 DN / PN 3 max. 140 bar C
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Actuating drive electric actuator drive, 5 kN, permissible ambient temperature -20C to +70C, protection type IP 65, mechanical stroke indicator, manual override. Motor voltage/frequency Capacity 230 / 50 / 60 26 1" 80 / 16 Differential pressure monitor for flow control (GK) {PDSA- 309} Differential pressure measuring and switching unit with robust movement and attenuator valve, measuring elements made of surface-treated steel 1.4310, with micro switch (single-pole change-over contact). Measurement range Max. static operating pressure Permissible ambient temperature Permissible medium temperature Protection type Pressure connection (olive type fitting) Differential pressure switch value (preset) 0 to 0.6 10 -10 to 70 70 54 12 80 bar bar C C IP mm mbar V/Hz VA R DN / PN
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Cooling water monitoring group (MK) Premounted monitoring group in a stable painted steel casing with flange connection (delivery scope does not include counter flanges and gaskets) for direct installation in the pipework of the plant, comprising: Casing Connection flanges Paint 100 / 10 3000 DN/PN RAL
Floating air valve in hot-pressed brass design with red brass effect, with caulked shut-off device and corresponding shut-off valve. Maximum temperature Maximum pressure Connection size 120 10 C bar G
Water level limiter with glass floater as glandless device with magnetic transmission of the floater movement to a micro switch. Protection type Micro switch Max. operating overpressure Max. operating temperature Installed position 65 Single-pole change-over contact 10 120 Main axle vertical bar C IP
Membrane safety valve with upstream seat gasket separate from the membrane, liftable by rotary handle, casing made of hot-pressed brass/red brass, membrane and gasket made of high-temperature resistant non-ageing rubber elastic plastic. Response overpressure Operating temperature Three-way control valve (MK) Three-way valve with actuator, designed as pressurising valve. Control valve maintenance-free soft-sealing heating control valve, casing made of GG-25, 3-way valve shape, spindle made of 1.4571, tight-closing. Connections* Actuating drive electric actuator drive, 5 kN, permissible ambient temperature -20C to +70C, protection type IP 65, mechanical stroke indicator, manual override. Motor voltage/frequency Capacity 230 / 50 / 60 53 1" V/Hz VA R 125 / 16 DN / PN 3 max. 140 bar C
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Differential pressure monitor for flow control (MK) {PDSA- 126} Differential pressure measuring and switching unit with robust movement and attenuator valve, aluminium pressure chamber, measuring elements made of surface-treated steel 1.4310, with micro switch (single-pole change-over contact). Measurement range Max. static operating pressure Permissible ambient temperature Permissible medium temperature Protection type Pressure connection (olive type fitting) Differential pressure switch value (preset) 0 to 0.6 10 -10 to 70 70 54 12 80 bar bar C C IP mm mbar
3. Services
3.1 Packing Standard foil packing for truck land transport.
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