W34SG Global ProductGuide

Wrtsil 34SG Power Pl ant Product Guide
Wrtsil Finland Oy Subject to change without notice.

Power Plants Please read disclaimer inside front cover.
Issue I: 17.01.2008
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Wrtsil 34SG Power Pl ant Product Guide TABLE OF CONTENTS
Wrtsil Finland Oy Power Plants
Page 1
Subject to change without notice. Please read disclaimer inside front cover.
TABLE OF CONTENTS
PREFACE ........................................................... 4
1. GENERAL ................................................. 5
1.1 Introducti on .................................................... 5
1.2 Appl i cati ons.................................................... 6
1.3 Pl ant performance .......................................... 6
1.3.1 Plant output...................................................... 6
1.3.2 Engine de-rating............................................... 7
1.3.3 Start and stop performance............................... 8
1.3.4 Loading performance........................................ 9
1.4 Envi ronmental impacts................................... 9
1.4.1 Exhaust gas emissions...................................... 9
1.4.2 Noise emissions.............................................. 10
1.4.3 Water consumption and site effluents.............. 12
1.4.4 Miscellaneous................................................. 12
1.5 Operati on and maintenance......................... 12
1.5.1 Plant operation............................................... 12
1.5.2 Output control................................................. 13
1.5.3 Routine maintenance...................................... 14
1.5.4 Overhaul intervals........................................... 15
1.5.5 Tools and spare parts ..................................... 15
1.5.6 Safety aspects................................................ 15
2. ENGINE GENERATOR SET.................... 16
2.1 Engi ne generator set .................................... 16
2.1.1 Overview........................................................ 16
2.1.2 Flexible coupling............................................. 16
2.1.3 Common base frame....................................... 16
2.1.4 Flexible mounting............................................ 16
2.2 Engi ne........................................................... 17
2.2.1 General .......................................................... 17
2.2.2 Main components ........................................... 17
2.2.3 Gas injection and ignition................................ 18
2.2.4 Engine mounted equipment............................. 19
2.2.5 Internal and engine mounted auxiliary systems 19
2.2.6 Engine control system..................................... 21
2.3 Generator ...................................................... 23
2.3.1 General .......................................................... 23
2.3.2 Generator type and size.................................. 23
2.3.3 Excitation system............................................ 23
2.3.4 Main terminal box........................................... 24
2.3.5 Instrumentation............................................... 24
2.3.6 Protection....................................................... 24
3. ENGINE AUXILIARY SYSTEMS.............. 25
3.1 Overvi ew....................................................... 25
3.2 Standard modul es......................................... 26
3.2.1 Engine auxiliary module (EAM)........................ 26
3.2.2 Exhaust gas module....................................... 27
3.3 Fuel gas system............................................ 28
3.3.1 System description.......................................... 28
3.3.2 Gas regulating unit (GRU)............................... 29
3.3.3 Main shut-off valve(s)...................................... 30
3.3.4 Vent valve...................................................... 31
3.3.5 Pressure reduction station............................... 31
3.3.6 Gas filtration unit............................................. 31
3.3.7 Flow metering unit........................................... 32
3.4 Lube oi l system............................................. 32
3.4.1 System description.......................................... 32
3.4.2 Lube oil storage tanks..................................... 33
3.4.3 Lube oil pump units.........................................34
3.5 Compressed air systems ..............................34
3.5.1 System description..........................................34
3.5.2 Starting air unit................................................36
3.5.3 Control and instrument air unit.........................36
3.5.4 Compressed air tanks......................................36
3.6 Cool i ng water system ...................................37
3.6.2 Radiators........................................................38
3.6.3 Central coolers................................................39
3.6.4 Maintenance water tank...................................40
3.7 Intake ai r system...........................................40
3.7.2 Intake air filters................................................42
3.8 Exhaust gas system......................................43
3.8.2 Exhaust gas silencers......................................44
3.8.3 Rupture disks..................................................44
3.9 Emi ssi on control systems............................45
3.9.1 General...........................................................45
3.9.2 Oxidation catalyst............................................45
3.9.3 Selective catalytic reduction (SCR) ..................45
3.9.4 Integration in exhaust gas system....................47
3.9.5 Emission testing..............................................47
4. HEAT RECOVERY SYSTEM...................49
4.1 General ..........................................................49
4.2 Heat recovery from exhaust gases ...............49
4.2.2 Heat recovery boiler........................................50
4.2.3 Arrangements to decrease boiler fouling..........50
4.2.4 Safety arrangements.......................................50
4.3 Heat recovery from cooli ng water and lube oil
.......................................................................50
4.3.1 General...........................................................50
4.3.2 Standard modules for hot water production......51
5. PIPING SYSTEMS...................................53
5.1 Desi gn pri ncipl es ..........................................53
5.1.1 General principles ...........................................53
5.1.2 Pressure and temperature ratings....................53
5.1.3 Pipe materials.................................................53
5.1.4 Pipe dimensions..............................................55
5.1.5 Flexible pipes and pipe supports.....................55
5.1.6 Trace heating..................................................55
5.1.7 Insulation........................................................56
5.1.8 Pipe instrumentation........................................56
5.1.9 Fuel gas pipes.................................................56
5.1.10 Lube oil pipes..................................................57
5.1.11 Compressed air pipes......................................58
5.1.12 Cooling water pipes.........................................58
5.1.13 Intake air ducts................................................59
5.1.14 Exhaust gas ducts...........................................59
5.1.15 Miscellaneous.................................................60
6. ELECTRICAL SYSTEM...........................61
6.1 General ..........................................................61
6.1.1 System overview.............................................61
6.1.2 Basic system design........................................62
6.1.3 Protection relays .............................................62
Page 2
6.1.4 Protection classes of electrical equipment........ 63
6.1.5 Internal power consumption............................ 63
6.2 Generator system ......................................... 64
6.2.1 Measurement and protection........................... 64
6.2.2 Neutral grounding........................................... 64
6.3 Medi um vol tage swi tchgear .......................... 64
6.3.1 General .......................................................... 64
6.3.2 General design principles................................ 64
6.3.3 Medium voltage busbars ................................. 65
6.3.4 Incoming feeder cubicles................................. 65
6.3.5 Main outgoing feeder cubicles......................... 65
6.3.6 Station transformer feeder cubicles................. 66
6.3.7 Busbar voltage measurement.......................... 66
6.4 Transformers ................................................ 66
6.4.1 General .......................................................... 66
6.4.2 Power (step-up) transformer............................ 66
6.4.3 Station transformer ......................................... 66
6.5 Low voltage switchgear ................................ 67
6.5.1 Overview........................................................ 67
6.5.2 Design principles ............................................ 67
6.5.3 Busbars and conductors.................................. 68
6.5.4 Incoming feeders ............................................ 68
6.5.5 Outgoing feeders ............................................ 68
6.5.6 Busbar voltage measurement.......................... 68
6.5.7 Emergency generator...................................... 68
6.5.8 Emergency busbar.......................................... 69
6.6 DC system..................................................... 69
6.6.1 DC power consumers...................................... 69
6.6.2 DC system design........................................... 69
6.7 Groundi ng..................................................... 70
6.7.1 General .......................................................... 70
6.7.2 Grounding grid................................................ 71
6.7.3 Main grounding bar......................................... 72
6.7.4 Neutral point grounding................................... 72
6.7.5 Lightning protection......................................... 72
6.8 Cabl i ng.......................................................... 72
6.8.1 General .......................................................... 72
6.8.2 Medium voltage cables.................................... 73
6.8.3 Low voltage cables ......................................... 73
6.8.4 DC cables....................................................... 73
6.8.5 Grounding conductors..................................... 73
7. PLANT CONTROL SYSTEM................... 74
7.1 Overvi ew....................................................... 74
7.2 Generator set control cabi net ....................... 75
7.2.1 Overview........................................................ 75
7.2.2 Generator set PLC.......................................... 76
7.2.3 Manual control unit.......................................... 76
7.2.4 Automatic voltage regulator (AVR)................... 76
7.2.5 Protection relays............................................. 76
7.3 Common control cabi net ............................. 77
7.3.1 Overview........................................................ 77
7.3.2 Common PLC................................................. 77
7.3.3 Synchronization units...................................... 78
7.4 Workstati ons................................................. 78
7.4.1 General .......................................................... 78
7.4.2 Operator station WOIS.................................... 78
7.4.3 Reporting station WISE................................... 80
7.4.4 Remote monitoring.......................................... 80
7.4.5 Data sharing with external systems.................. 81
7.4.6 Condition based maintenance......................... 81
7.5 Si gnal and data communi cati on................... 81
7.5.1 General .......................................................... 81
7.5.2 Signal types.................................................... 81
7.5.3 Communication buses.....................................81
7.5.4 Hard-wired signals...........................................82
7.5.5 Control cables.................................................82
7.6 Functi onal descri pti on ..................................83
7.6.1 Start and stop processes.................................83
7.6.2 Output control .................................................83
7.6.3 Control of auxiliary systems.............................84
7.6.4 Safety functions ..............................................84
8. PLANT LAYOUT......................................86
8.1 Si te layout .....................................................86
8.1.1 Site Layout principles ......................................86
8.1.2 Site layout notes..............................................86
8.1.3 Site layout examples .......................................87
8.2 Engi ne hall l ayout..........................................90
8.2.1 Engine bays....................................................90
8.2.2 Other space requirements ...............................90
8.2.3 Layout notes ...................................................90
8.2.4 Layout example...............................................90
8.3 Servi ce rooms or bui l di ngs..........................92
8.3.1 General...........................................................92
8.3.2 Electrical rooms ..............................................92
8.4 Tank yard and unl oadi ng stati on .................93
8.4.1 Tank yard........................................................93
8.4.2 Unloading pump station...................................93
8.5 Pi pes and cables ...........................................93
8.5.1 Pipe layout......................................................93
8.5.2 Cabling...........................................................93
8.6 Hazardous areas ...........................................93
8.6.1 General...........................................................93
8.6.2 Classification of hazardous areas....................94
8.6.3 Protection methods in hazardous areas ...........95
9. SITE, CIVIL WORKS AND STRUCTURES.96
9.1 Si te consi derati ons .......................................96
9.1.1 Site selection criteria.......................................96
9.1.2 Geotechnical investigation...............................96
9.2 Earthworks and site works............................97
9.2.1 General...........................................................97
9.2.2 Site drainage...................................................97
9.2.3 Underground utilities .......................................97
9.3 Engi ne hall foundati on..................................97
9.3.1 General...........................................................97
9.3.2 Engine generator set foundation......................97
9.3.3 Material and strength.......................................99
9.3.4 Floor tolerances ..............................................99
9.3.5 Floor drains...................................................100
9.3.6 Surface treatment..........................................100
9.4 Other foundati ons ....................................... 100
9.4.1 Tank yard and pump station..........................100
9.4.2 Stacks, radiators and transformers.................100
9.5 Frames, outer wall s and roofs .................... 101
9.5.1 General.........................................................101
9.5.2 Engine hall....................................................101
9.5.3 Auxiliary structures........................................102
9.6 Interi or structures ....................................... 102
9.6.1 Inner walls, floors, and ceilings ......................102
9.6.2 Lifting and transportation arrangements.........102
9.6.3 Support structures.........................................102
9.7 Heati ng, ventil ati on and air conditi oni ng.... 103
9.7.1 Process ventilation........................................103
9.7.2 Comfort ventilation and air conditioning.........104
9.7.3 Air filtering and silencers................................104
9.8 Fi re protecti on............................................. 105
Page 3
9.8.1 General ........................................................ 105
9.8.2 Fire areas..................................................... 105
9.8.3 Fire alarm system......................................... 105
9.8.4 Gas detection system.................................... 105
9.8.5 Fire extinguishing systems............................ 106
9.9 Water suppl y system.................................. 107
9.9.1 General ........................................................ 107
9.9.2 Water consumption....................................... 107
9.9.3 Water treatment unit ..................................... 108
9.9.4 Water booster unit......................................... 108
9.9.5 Water storage tanks...................................... 108
9.10 Waste water systems.................................. 108
9.10.1 Sewage system............................................ 108
9.10.2 Oily water system......................................... 108
9.11 Li ghti ng....................................................... 109
10. INSTALLATION AND COMMISSIONING111
10.1 Del i very and storage................................... 111
10.1.1 Engine generator set..................................... 111
10.1.2 Engine auxiliary equipment and pipes............ 111
10.1.3 Electrical and control system equipment........ 111
10.2 Install ati on .................................................. 112
10.2.1 General ........................................................ 112
10.2.2 Installation of engine generator set................ 112
10.2.3 Installation of auxiliary equipment.................. 112
10.2.4 Installation of piping systems......................... 113
10.2.5 Installation of electrical and control systems... 113
10.3 Commi ssi oni ng........................................... 114
10.3.1 General ........................................................ 114
10.3.2 Pre-commissioning....................................... 114
10.3.3 Running in and fine tuning............................. 115
10.3.4 Performance tests......................................... 115
11. TECHNICAL DATA ............................... 116
11.1 Engi ne generator set .................................. 116
11.2 Engi ne Techni cal data ................................ 117
11.3 Engi ne heat bal ances.................................. 118
11.4 Generator data (typi cal ) .............................. 121
12. FLUID REQUIREMENTS....................... 122
12.1 Fuel gas requi rements ................................ 122
12.2 Lubri cati ng oil s ........................................... 123
12.2.1 General requirements ................................... 123
12.2.2 Additives....................................................... 123
12.2.3 Approved lubricating oils ............................... 123
12.3 Water quali ty requirements ........................ 124
13. DIMENSIONS AND WEIGHTS .............. 125
13.1 Engi ne generator set .................................. 125
13.2 Standard auxil i ary equipment..................... 126
13.2.1 Gas regulating unit........................................ 126
13.2.2 Engine auxiliary module (EAM)...................... 127
13.2.3 Exhaust gas module..................................... 127
13.2.4 Standard auxiliary units................................. 128
APP A. STANDARDS AND CODES................ 131
APP B. UNIT CONVERSIONS......................... 133
Wrt sil 34SG Product Guide PREFACE
Page 4
PREFACE
This product guide provides general guidelines and
technical information for planning land-based power
plants using the Wrtsil 34SG lean-burn gas engines.
The guide is directed to customers and customer rep-
resentatives, designers and sales personnel with the
aim to serve as a plant design overview and support
during the early project phase.
This guide does not provide detailed engineering in-
formation.
The content of this document is based on the most
current information available at the time of publica-
tion and is subject to change without notice.
Data given in this guide in texts, tables,
graphs, and figures are to be regarded as typi-
cal values or sample values and must not be used
as design data. Actual values may deviate signifi-
cantly from the typical values.
All power plant design must be in accordance with
locally applicable rules and regulations. Should any
advice, recommendation or requirement given in this
guide differ from the ones given in local, national or
international regulations, the strictest requirements
are valid.
Wrtsil assumes no responsibility for customer or
contractor designed plants, even in cases where they
are designed in accordance with this guide.
Wrt sil 34SG Product Guide 1. GENERAL
Page 5
1. GENERAL
1.1 Introduction
A Wrtsil 34SG power plant typically comprises one
or several engine generator sets. The main compo-
nents of the plant are the gas fired reciprocating en-
gines, the medium voltage generators, the engine aux-
iliary systems, the electrical system and the control
system.
The engine generator sets are delivered as factory
assembled and tested units. The generators have been
sized to match the actual engine power output at site
conditions. Before delivery, the engines can be opti-
mized for the available fuel gas quality and the emis-
sion requirements at site.
The engine auxiliary systems include fuel gas, lubri-
cating oil, compressed air, cooling water, intake air,
and exhaust gas systems. Heat recovery and emission
control systems can be installed depending on the
project specific requirements. To a large extent, the
auxiliary systems are implemented as prefabricated
and tested, skid mounted standard modules and units,
which minimizes the space requirement and simpli-
fies the installation at site.
Each engine generator set has its own fuel gas supply,
lubrication system, cooling circuits, intake air and
exhaust gas systems, and control system. It can there-
fore be started, stopped and operated independently
of the other generator sets in the plant. This modular
structure is also an advantage at a possible future ex-
tension of the plant.
Normally, the buildings are newly built and specifi-
cally designed for power plant operation. In special
cases, existing buildings can be used. A low building
height gives the plant the appearance of a light indus-
trial facility.
Wrtsil delivers well over 100 power plants a year, all
around the world, based on a standard product de-
sign developed from long experience. If needed, the
plants can be adapted to local codes and standards.
Also customer-specific requirements can be included.
Figure 1. Cross section of a typical Wrtsil 20V34SG power plant
Wrtsil 34SG Power Pl ant Product Guide 1. GENERAL
Page 6
1.2 Applications
A Wrtsil 34SG power plant is suitable for base
load, intermediate load, and peak-load power genera-
tion. The plant can be used for feeding a large grid
(parallel operation) or a limited grid, for instance a
manufacturing plant (island operation). It is also pos-
sible to switch between island and parallel operation.
The plant can be specified for either 50 or 60 Hz.
The generator voltage is typically 6 to 15kV (50Hz) or
4.16 to 13.8kV (60 Hz). Frequency and generator
voltage can be selected to best suit the project re-
quirement.
High efficiency at full and part load, fast start-up time
and quick load response makes the Wrtsil 34SG
power plants suitable for base load, load following
and reserve capacity applications.
In a multi-engine plant the engine generator sets can
be started, stopped and controlled individually, part
of the plant can be running at the required load point,
while part of it is kept as reserve capacity.
The power generation can be controlled from the
plants own control room, and with proper configu-
ration from an external control system, for instance,
an ISO dispatch centre. As options, the control sys-
tem supports power management functions, such as
automatic load sharing, load shedding, automatic start
and stop, and load following.
Wrtsil 34SG power plants are also suited for com-
bined heat and power generation (cogeneration).
Heat can be recovered from the exhaust gases, engine
cooling water, and lubricating oil. Heat recovered
from the cooling water and lubricating oil is suitable
for hot water distribution systems. Heat from the
exhaust gases delivered as steam or hot water can
be used in applications demanding higher tempera-
ture heat, such as industrial processes.
The Wrtsil 34SG engine performs well at high alti-
tudes and in hot ambient conditions. Due to low ex-
haust gas emissions, which can be further reduced
with emission control systems, they can be located in
areas with strict emission limits.
1.3 Plant performance
1.3.1 Plant output
General
The plant output and efficiency depends on the site
conditions, fuel gas quality, generator efficiency, and
power factor. It also depends on the plant design and
the level of the internal power consumption. Maxi-
mum total plant efficiency is obtained in plants utiliz-
ing the waste heat.
On request, Wrtsil can provide calculated plant-
specific performance data.
Engine efficiency and optimization
Although the Wrtsil 34SG engines have their opti-
mal efficiency at full load, they also have a high part-
load efficiency, which can be seen in the engine heat
balances found in chapter Technical Data.
Thanks to the totally electronic engine control-
system, and that several compression ratios are avail-
able, the engine can be tuned for optimal perform-
ance at different ambient conditions, with different
fuel gas qualities and different emission requirements.
Reference conditions
Rated power, specific fuel consumption, and emis-
sions stated in this document are based on the stan-
dard reference conditions according to ISO 3046-1;
except for charge air coolant temperature which is 35
C (see the table below). For other conditions, reduc-
tion of the engine output may be necessary. See sec-
tion Engine De-rating
Condition Value
Total barometric pressure 100 kPa
Air temperature 25C
Relative humidity 30%
Charge air coolant tem-
perature
25C
Table 1. Standard reference conditions according
to ISO 3046-1
Generator power
The generator power is determined by the generator
efficiency and the power factor according to the for-
mula:
Page 7
S = P- q / cos
where:
S = generator power in kVA (apparent power)
P = engine shaft power in kW
q = generator efficiency
cos = cosine (power factor)
I nternal power consumption
The plants internal power consumption depends on
the size and configuration of the plant, the ambient
conditions, and the condition of the equipment.
Typically, the internal power consumption is below
3% of the generator power.
1.3.2 Engine de-rating
General
De-rating means a temporary or permanent reduction
of maximum power output to protect the engine
from overloading. De-rating may be necessary due to
environmental or operational conditions.
Temperature definitions
The figure explains the temperatures given in the
derating descriptions below.
Table 2. Explanation of temperatures
1= Suction air temperature (temperature
at turbo charger inlet)
2 = Receiver air temperature (tempera-
ture in charge air receiver)
3 = Charge air cooling water tempera-
ture
The receiver air temperature is defined as the tem-
perature in the air receiver after the charge air cool-
ers. The following formulas can be used for estimat-
ing the receiver air temperature, Treceiver, based on the
charge air coolant temperature to the engine, TLT:
Treceiver[
o
C] TLT [
o
C] + 5
o
C
De-rating factors
Engine de-rating is determined by the following de-
rating factors:
KTC
De-rating due to high altitude and/ or high suc-
tion air temperature, see Figure 2. This de-rating
factor is a function of suction air temperature (the
temperature at the turbocharger suction flange) and
the required compression ratio of the turbocharger
compressor. The compression ratio, in turn, is a func-
tion of the altitude, the NOx setting and the com-
pression ratio of the engine. Higher suction air tem-
perature and higher altitude mean increased de-rating.
Low NOx optimized engines (with higher receiver
temperature) require more de-rating, while engines
with higher compression ratio require less de-rating.
KGAS
De-rating due to low fuel gas feed pressure
and/ or low LHV, see Figure 3. Required fuel gas
flow to the engine depends on the fuel gas feed pres-
sure before the engine (the pressure at the gas pipe
flange on the engine, after the gas regulating unit
(GRU)), the lower heating value (LHV) of the fuel
gas, and the air pressure in the air receiver. The main
fuel gas valve on the engine is designed to handle a
specific fuel gas quality. The engine has to be de-rated
if the fuel gas flow does not correspond to the engine
demand. Lower LHV or lower fuel gas pressure im-
plies more de-rating. Low NOx optimized engines
(with higher receiver pressure) require more de-
rating.
KKNOCK
De-rating due to low fuel gas methane number
(MN) and/ or high combustion air temperature
in air receiver, see Figure 4. Knocking (self igni-
tion) in the cylinder occurs if the fuel-air mixture is
subject to temperatures and pressures that are above
its self ignition point. The tendency for knocking is
affected by the MN value of the fuel gas, the receiver
air temperature, and the compression ratio of the
engine. A lower MN value of the fuel gas or a higher
receiver air temperature implies increased de-rating.
Lower compression ratio of the engine, on the other
hand, means less de-rating.
The graphs below show the values of the de-rating
factors. Value 1 means no de-rating.
Page 8
Note! The de-rating diagrams are made for
high Methane number optimised engine and
NOx setting of 500 mg/ Nm at 5% O2. They
shall be used guidance purposes only. Project
specific de-rating must be verified by Wrtsil.
Figure 2. De-rating factor KTC
Figure 3. De-rating factor KGAS
Figure 4. De-rating factor KKNOCK
Other factors affecting engine de-rating:
- Relative humidity. High relative humidity requires
raised LT cooling water temperature (and with
that raised receiver air temperature) to avoid con-
densation in the charge air cooler. This may lead
to de-rating.
- The glycol content in the cooling water may lead
to engine de-rating.
Calculating service power
The actual service power can be calculated as:
Px = Pr x Kmin
where Px is the brake power under the ambient con-
ditions at site, Pr is rated power, and Kmin is the low-
est de-rating factor:
Kmin = MIN(KTC, KGAS, KKNOCK)
Other performance corrections
The engine brake efficiency has to be adjusted for
ambient air pressure even in cases when the service
output is rated output. The rule is that the brake effi-
ciency drops 0.5% per 10 kPa lower ambient pres-
sure, starting from 85 kPa a (or 0.5% per 1000 m
higher altitude starting from 1500 m).
No adjustment of engine efficiency is needed for en-
gine output de-rated for KKNOCK and KGAS.
1.3.3 Start and stop performance
The following graphs indicate the start and stop per-
formances. The stated time intervals are guidance
values only. The time required for starting a cold en-
gine depends on the actual cooling water tempera-
ture. Engines are normally kept preheated.
Figure 5. Engine start-up time (preheated engine)
Page 9
Figure 6. Engine stop time
1.3.4 Loading performance
The following graph indicates the loading time after
starting a preheated engine. Immediately after syn-
chronization, a 25% load is applied. The stated time
intervals are guidance values only.
Figure 7. Loading time after starting a preheated
engine
The maximum ramp up rate for an engine which has
achieved normal operating conditions is 25 % per
minute. The ramp down rate is 25 % per minute.
The following graph shows maximum instant load
increase when running in isolated mode. Maximum
first load step is 31%. Optimal loading is 0 31 57
77 92 100%. To keep the frequency band 5%,
there must be a 15 seconds delay between subsequent
load steps.
Figure 8. Maximum instant load increase at dif-
ferent actual loads when running in iso-
lated mode (island mode)
1.4 Environmental impacts
1.4.1 Exhaust gas emissions
General
Due to the low peak combustion temperature in the
Wrtsil 34SG engines, the emission of nitrogen ox-
ides (NOx) is low. Running on clean natural gas, the
engines have inherently low emissions of particulate
matter (PM) and sulphur dioxide (SO2).
Natural gas fired Wrtsil 34SG engines typically gen-
erate lower carbon dioxide (CO2) emissions com-
pared to oil and coal plants due lower carbon content
per fuel energy input and high efficiency of the en-
gine. By using co-generation the total efficiency can
be improved and hence relative CO2 emissions per
produced energy unit further reduced.
Wrtsil 34SG engines can be tuned for reduced
NOx emission levels, which may have a minor impact
on plant efficiency. The plant can also be equipped
with secondary emission control systems.
On project specific basis, the engines can be opti-
mized to achieve best economical and environmental
performance.
Emission levels
The following table shows typical emission values for
the Wrtsil 34SG engines at stable operating condi-
tions. The table shows the emissions from an effi-
ciency optimized engine and an engine optimized for
low NOx emission.
Page 10
VOC (Volatile Organic Compounds) is herein de-
fined as total hydrocarbon excluding methane and
ethane. The organic compounds consist of unburned
fuel gas and components generated in the combus-
tion process, such as formaldehyde. The VOC emis-
sions depend significantly on the composition of the
fuel gas.
Efficiency
optimized
engine
Low NOx
optimized
engine
ppmvol,
dry, 15% O2
90 45 NOx
(nitrogen oxides)
Typical set
point
g/ kWh 1.3 0.6
ppmvol,
dry, 15% O2
265 455 CO
(carbon monox-
ide)
g/ kWh 2.2 3.9
CH2O
(formaldehyde)
ppmvol,
dry, 15% O2
24 42
Typical O2
concentration
vol %, dry 11.5 12.1
ppmvol,
dry, 15% O2
80 - 170 140 - 300 VOC as CH4
(volatile organic
compounds)
g/ kWh 0.4 - 0.8 0.7 - 1.5
PM (dry) mg/ m
3
, 15
% O2, dry,
(0C & 1 atm)
< 10 < 10
Table 3 Emission levels at steady 100% load,
constant speed 720RPM or 750RPM, CR
= 12, VOC based on fuel gas with C3
and higher representing less than 3
mole-% of the total hydrocarbons.
Notes:
During start, stop and transient load variations,
the exhaust gas emissions may temporarily devi-
ate from the steady state conditions.
Due to performance and emission optimization
the project-specific values might differ from the
ones given above.
Secondary emission control systems
The following methods are available for reducing the
emissions in the exhaust gas system:
- Catalytic oxidization for reducing CO, CH2O, and
volatile organic compounds
- Selective Catalytic Reduction (SCR) for reducing
the NOx emission.
1.4.2 Noise emissions
Suitable solutions for different environments
Power plants should be designed to meet set mini-
mum criteria. The requirements set for noise vary
depending on the location of the plant. The noise
limit in or near a residential area, for instance, are
much stricter than in an industrial area.
Designing power plants to be located on industrial
areas to the acoustical standards required in residen-
tial areas is not feasible. The background noise level is
often relatively high and thus the noise generated by
the plant would not have significant impact on the
ambient noise level. This applies also for plants con-
structed in areas that do not contain sites detrimen-
tally affected by noise.
Varied design criteria
Primary design target is to meet local legislation and
regulations on environmental noise. In absence of
local norms, international criteria on environmental
noise such as World Bank Environmental, Health
and Safety (EHS) guidelines can be applied.
The responsibility for environmental noise impact
depends on the scope of the delivery.. The noise im-
mission of a power plant can be specified at a certain
distance from the site or at specified receptor posi-
tions. Alternatively, the sound power level (noise
emission) of plant equipment can be specified.
In a limited equipment delivery project, only the
noise emission of the delivered equipment can be
guaranteed. The immission levels at receptor posi-
tions depend on the auxiliary equipment and plant
structures.
Power plant acoustics integrated in the per-
mitting process
Power plant noise impact is estimated during the en-
vironmental impact assessment process. Starting
point is the evaluation of background noise on the
area surrounding the power plant. The potential dis-
turbance to facilities in the plant proximity such as
residences, schools and hospitals can be assessed by
environmental noise modelling. The purpose of this
acoustical modelling, including structural investiga-
tions, is to optimize the methods used to reduce the
plant noise impact. The modelling process is iterative
by nature:
- the estimated plant noise impact is con-
trasted with the ambient or target noise level
Page 11
- component selection, process design optimi-
sation and structural modifications are ap-
plied if needed to reach the set target
- the effect of modifications is simulated and
cross-checked with the ambient or target
noise level until the set target is reached.
The following aspects are addressed in the acoustical
design of power plant:
- Optimising the plant layout, selection and lo-
cation of noise-critical components.
- Attenuation of the charge air intake and ex-
haust outlet
- Engine cooling system: type and location of
the radiator or other cooling equipment
- Plant ventilation system: ventilation air in-
take, fan-generated noise, outlet noise emis-
sion
- Power plant building design: optimal wall
structures
It is apparent that the plant noise emission is as much
due to auxiliary components as the actual generating
set. One important aspect of power plant acoustics is
the design of better and silent auxiliary components.
W34SG engine sound power levels
Engine sound power levels have been measured ac-
cording to ISO9614-2 as applicable. Measurement
uncertainty is 2dB
Engine Sound Power Level
0
20
40
60
80
100
120
140
63 125 250 500 1000 2000 4000 8000 Lwtot
Frequency [Hz]
L
w
[
d
B
(A
)
]
W9L34SG
W12V34SG
W20V34SG
Figure 9 Engine sound power levels
W34SG exhaust gas sound power levels
In Figure 10 can be seen free field sound power spec-
trum after turbo charger. Measurement in exhaust
duct, actual engine operating conditions. Measure-
ment uncertainty is 3dB.
Exhaust Gas Sound Power Level
0
20
40
60
80
100
120
140
31,5 63 125 250 500 1000 2000 4000 Lwtot
Frequency [Hz]
L
w

[
d
B
(
A
)
]
W9L34SG
W12V34SG
W20V34SG
Figure 10 Engine exhaust gas sound power levels
Typically 35 dB(A) exhaust gas silencers are used in
power plants. Figure 11 shows typical transmission
loss spectrum for a silencer
Exhaust Gas Silencer Attenuation
0
5
10
15
20
25
30
35
40
45
50
31,5 63 125 250 500 1000 2000 4000 8000
Frequency [Hz]
T
L

[
d
B
] W9L34SG
W12V34SG
W20V34SG
Figure 11Exhaust gas silencer typical transmission
loss
W34SG charge air sound power levels
In Figure 12 can be seen free field sound power spec-
trum after turbo charger. Measurement uncertainty is
3dB.
Charge Air Sound Power Level
0
20
40
60
80
100
120
140
31,5 63 125 250 500 1000 2000 4000 8000 Lw tot
Frequency [Hz]
L
w

[
d
B
(
A
)
]
W34SG
Figure 12 Charge air sound power levels
Page 12
Typically 35 dB(A) charge air silencers are used in
power plants. Figure 13 shows typical transmission
loss spectrum for a silencer
Charge Air Silencer Attenuation
0
10
20
30
40
50
60
31,5 63 125 250 500 1000 2000 4000 8000
Frequency [Hz]
T
L

[
d
B
] W9L34SG
W12V34SG
W20V34SG
Figure 13 Charge air silencer typical transmission loss
Sound power is a measure of acoustical energy radi-
ated by the sound source. Perceived sound pressure
depends on the sound power rating, the distance
from the source, and the environmental conditions.
Figure 14 indicates typical noise levels at different
distances from a plant with ten Wrtsil 20V34 en-
gine generator sets and standard attenuation equip-
ment.
Radiators
Engine hall
Exhaust gas pipes and stacks
0ft 100ft
Figure 14. Typical noise levels at different dis-
tances from a plant with ten engines
1.4.3 Water consumption and site
effluents
With radiator cooling, which is the most common
cooling method, the cooling water is circulated in a
closed circuit. No waste water results from the proc-
ess. Any contaminated water, for instance, water used
for cleaning the equipment, is collected in a tank.
The process water consumption when using radiator
cooling is negligible (less than 4 litres per produced
MWhe). No de-mineralized water is needed.
Water consumption for heat recovery systems should
be investigated case-by-case.
1.4.4 Miscellaneous
At low exhaust gas temperatures, mainly during start-
up, the exhaust gases may form visible smoke.
Oil mist emerging with the crankcase ventilation
gases is reduced with an oil mist separator and is neg-
ligible.
The flexible mounting of the engine generator sets
along with elastic material between the floor slabs
dampen the vibrations from the engines so that prac-
tically no vibration is transmitted to the environment.
The power generating process produces negligible
amounts of solid waste.
1.5 Operation and
maintenance
1.5.1 Plant operation
General
The operator supervises and controls the plant mainly
from one or more PC workstations, the WOIS work-
stations, in the plant control room. Most actions
needed for normal operation, such as start and stop
of the engines, synchronization, circuit breaker con-
trol, and change of set points can be done at the
workstations.
Also manual controls and a mimic diagram are pro-
vided.
Page 13
Figure 15. Typical control room
Normally, the plant is operated in automatic mode,
where the control system takes care of the start and
stop processes, synchronization and output control.
In manual mode, the operator controls the output
with switches.
With remote monitoring services, the plants person-
nel can monitor the plant from a remote location via
a secure internet connection. Provided that the data
security requirements are fulfilled, remote control can
be implemented.
Start and stop
The operator starts and stops the engines from the
WOIS workstations. The auxiliary units are generally
kept in an automatic mode, where they are started
and stopped automatically.
For emergency stop, engine-specific emergency stop
buttons and buttons for stopping the entire plant are
located in the control room. In the engine hall, each
engine has an emergency stop button, and plant
emergency stop buttons can be installed
Supervision and control
Most temperature and pressure measurements can be
monitored in the control room. The control system
also records and stores the readings in the WISE
workstation (WISE = Wrtsil Information System
Environment).
Abnormal conditions requiring prompt operator ef-
forts are noted by alarms, which are indicated by
sound and light signals in the control room. Engine
alarms may also be indicated by status and alarm an-
nunciator lights in the engine hall. Alarms and events
are recorded by the control system.
The operator should also make regular tours around
the plant to check local meters, drain points, vibra-
tions, etc.
Personnel requirements
When the plant is in operation, personnel should be
present at site, or, if the plant is remotely controlled,
personnel on duty should be stationed close enough
to reach the plant at short notice when needed.
1.5.2 Output control
General
When feeding a small isolated grid (island operation),
the power generation follows the system load. The
control system controls the frequency (engine speed)
by regulating the fuel supply to the engine and the
voltage by regulating the excitation current of the
generator. When connected to a strong grid (parallel
operation), the grid determines the frequency and
voltage. The control system controls the active power
by regulating the fuel supply, and the reactive power
by regulating the excitation current.
Engine speed and load control
The following engine control modes are available:
- kW control. In this mode, which can only be used
in parallel operation, the control system keeps the
engine load (active power) constant at a set value.
The operator can change the set point manually if
needed, based on changes in the demand. Power
management functions, which change the set va-
lue automatically, are available as options.
- Speed droop control. In this mode, the engine is
controlled against a speed set point. At an in-
creased load, the speed drops, the maximum
speed reduction (droop) generally being 4% from
zero to full load. The load is shared equally be-
tween parallel engines with the same set point.
Automatic fine tuning to keep the speed constant
is available as an option. Speed droop is the typi-
cal engine control mode in island operation, and
when providing spinning reserve Ancillary Ser-
vices. It can also be used as a manual back-up
control method in parallel operation.
Page 14
- Isochronous control. In this mode a generator
set will operate at the same frequency regardless
of the load it is supplying, up to the full load ca-
pability of the generator. This mode can be used
on one generator set running alone in an isolated
system. The isochronous mode can also be used
for multiple generator sets running in parallel and
supplying an isolated system (island operation) for
this application load sharing lines (CAN bus) are
required between the speed controllers, the active
load is shared equally between the parallel units
and the frequency is kept at 100%
Generator output control
The following control modes are available:
- Power factor control. In this mode, which is
available only in parallel operation, the control
system strives to keep the power factor (relation
between active and reactive power, cosine phi)
constant at a set value.
- Voltage droop control. In this mode, the voltage
is controlled against a set point. At an increased
reactive load, the voltage drops, the maximum
voltage drop being 1 10% (adjustable) from zero
to full load. A function that adjusts the voltage set
point automatically to keep the voltage constant is
available as an option. Voltage droop is the typical
control mode for small grids and island operation.
It can also be used as a manual back-up control
method in parallel operation.
- Voltage droop compensation. In this mode,
which is available only in island operation and re-
quires data communication between parallel units,
the reactive load is shared equally between the
parallel units and the voltage is kept at 100%.
Synchronization
Before connecting a generator set to a live busbar, it
must be synchronized. Synchronization is automatic
with manual backup.
Loading and unloading
In automatic mode, the load is gradually increased
after connecting a generator set to the grid, and
gradually decreased before disconnecting it.
1.5.3 Routine maintenance
General
Most routine maintenance can be done by the ordi-
nary operating personnel while the engine is in opera-
tion. Extended maintenance measures may require
that the gas is shut-off and the system vented.
Maintenance schedule
The following schedule gives an indication of re-
quired routine maintenance and typical time intervals.
Time in-
terval
Maintenance measure
Check cooling water level, pressure
drops over filters, level in the oil sump.
50 running
hours
Clean the compressor side of the turbo-
charger.
Clean the centrifugal lube oil filters.
Take lube oil samples for analyzing.
500 - 1000
running
hours
Check the water quality.
Clean the turbocharger air filter. 1000 run-
ning hours
Change spark plugs.
Change the lube oil in the turning device.
Inspect safety equipment.
Inspect and clean starting air vessels.
Clean cooling water circuits.
Clean the pre-chamber.
Replace the main gas valve filter insert.
2000 run-
ning hours
Clean the lube oil cooler.
Inspect the lube oil automatic filter.
Clean or replace gas filters.
Overhaul the compressed air systems.
Yearly
Inspect tanks, clean if needed.
Replace the filter candles in the auto-
matic lube oil filter.
Every sec-
ond year
Check the cooling water pumps.
Table 4. Maintenance schedule (example)
The oil change interval depends on the lube oil qual-
ity, operating conditions and engine condition.
The need for cooler and filter cleaning is evaluated by
measuring the pressure drop over the devices.
Page 15
Maintenance of stand-by plants
Stand-by plants which are to be kept ready for start-
up at short notice must be regularly operated. The
engines should be test run once a week.
1.5.4 Overhaul intervals
The following table lists engine overhaul intervals and
average lifetimes for engines. The figures are to be
regarded as guiding values only. The actual service
conditions will have an impact on the overhaul inter-
vals and component lifetimes.
Part Time between
overhauls (h)
Average life-
time (h)
Piston 16 000 24 000 60 000 100 000
Piston rings 16 000 24 000 16 000 24 000
Cylinder liner 16 000 24 000 60 000 100 000
Cylinder head 16 000 24 000 60 000 100 000
Inlet valve 16 000 24 000 32 000
Exhaust valve 16 000 24 000 16 000 24 000
Main bearing 16 000 32 000
Big end bearing 16 000 24 000 16 000 24 000
Main gas ad-
mission valve
8 000 16 000
Prechamber
control valve
4 000 16 000
Prechamber 16 000 24 000 32 000 48 000
Prechamber
non-return
valve
1 000 8 000 12 000
Ignition coil on
plug
16 000 24 000 16 000 24 000
Spark plug 1 000 1 000
Table 5. Time between overhauls and expected
lifetime of components
1.5.5 Tools and spare parts
Normal maintenance and repair can be done using
conventional tools and tools supplied with the en-
gine. If required, special tools are available from the
Wrtsil service stations. Spare parts are available
from Wrtsil.
1.5.6 Safety aspects
The safety risks in a Wrtsil 34SG power plant are
posed by heavy machines with rotating parts, high
temperatures and pressures, high voltages, and poten-
tially explosive fuel gas mixtures.
A gas explosion may occur if an ignition source arises
(spark or hot surface) in a space with a gas - air mix-
ture of an ignitable ratio. In a power plant, the most
serious danger situations are caused by gas leaking
into the engine hall or unburned gas escaping into the
exhaust gas system.
In a Wrtsil 34SG power plant, all reasonable safety
measures should be employed, for instance:
- The plant should be equipped with gas detection
and alarm systems.
- The exhaust gas system should be designed so as
to avoid gas pockets, and ventilated after each en-
gine stop. Rupture disks should be installed to
minimize the pressure build up in case of a defla-
gration.
- During engine start-up, a number of automatic
safety checks and actions take place. The gas sup-
ply is kept shut off during the first engine revolu-
tions to purge any gas in the engine cylinders and
exhaust gas pipes.
- Running time in unloaded condition, where com-
bustion efficiency is low, is limited.
- In an emergency situation, the gas supply is shut
off and the combustion is disabled immediately.
It is not recommended to stay in the engine room or
in a possible exhaust gas boiler room or silencer
room during engine start and no-load operation.
All personnel with access to the plant should be given
safety training.
Wrtsil 34SG Power Pl ant Product Guide 2. ENGINE GENERATOR SET
Page 16
2. ENGI NE GENERATOR SET
2.1 Engine generator set
2.1.1 Overview
The engine and the generator are factory assembled
and aligned, and rigidly fastened to a common base
frame of welded steel. At installation, the base
frame is flexibly mounted to the concrete founda-
tion.
Figure 16. Engine generator set
The engine crankshaft is connected to the generator
shaft via a flexible coupling, protected by a flywheel
cover.
2.1.2 Flexible coupling
The engine torque is transmitted to the generator
with the flexible coupling located between the en-
gine flywheel and the generator shaft. The coupling
reduces vibration and provides torque damping
characteristics.
Possible torque due to an inadvertent out-of-phase
coupling or a 3-phase short circuit would deform or
break the elastic elements, which can be easily re-
placed, but the machine structural parts would not
be damaged.
Since the coupling is flexible, it prevents engine fir-
ing irregularities from being transmitted to the gen-
erator.
2.1.3 Common base frame
The base frame is a welded structural steel assembly
engineered and reinforced to provide the engine
and generator with a stable and torsion resistant
platform. A clearance between the generator feet
and the frame resting pads allows for accurate shaft
line alignment by shimming.
Lifting eyes are provided on the frame for lifting the
whole generator set. Lateral handling plates allow
for jacking.
2.1.4 Flexible mounting
To prevent structural born noise and vibration, the
generator set is mounted on steel springs, which are
normally resting directly on the foundation. The
steel springs are mounted under the base frame dur-
ing installation.
Wrtsil 34SG Power Plant Product Guide 2. ENGINE GENERATOR SET

Page 17
2.2 Engine
2.2.1 General
The Wrtsil 34SG engine is a reciprocating four-
stroke spark ignited gas engine, which works ac-
cording to the Otto process and the lean burn prin-
ciple. The engine is turbocharged and intercooled. It
is started with compressed air.
Cylinder head
covers
Turbochargers
Wastegate
Cooling water pumps
Lube oil pump
Charge air coolers
Gas manifold

Figure 17. Wrtsil 20V34SG engine
The Wrtsil 34SG engine has the following main
characteristics:
Cylinder configuration In-line and V-form
Number of cylinders 9L, 16V and 20V
Cylinder bore 340 mm
Stroke 400 mm
Number of valves per
cylinder
2 inlet valves
2 exhaust valves
Rotational direction Clockwise
Rated speed 720/750 rpm
Mean piston speed 9.6/10 m/s
Mechanical efficiency 0.9
Compression ratio 11:1 or 12:1 (dependent
on engine optimization)
Table 6. Engine main characteristics
The following picture illustrates the engine termi-
nology.
D
r
i
v
i
n
g
e
n
d
F
r
e
e
e
n
d
A
b
a
n
k
R
e
a
r
s
id
e
O
p
e
r
a
t
in
g
s
id
e
B
b
a
n
k
C
o
u
n
t
e
r
-
c
l
o
c
k
w
i
s
e
C
l
o
c
k
w
i
s
e

Figure 18. Engine terminology
2.2.2 Main components
Engine block
The engine block is made of nodular cast iron and
cast in one piece. It incorporates the jacket water
manifold, the camshaft bearing housings, and the
charge air receiver. The crankshaft is mounted in
the engine block in an under slung way. The oil
sump, a light welded design, is mounted to the en-
gine block from below.
The engine block has large crankcase doors allowing
easy maintenance.
Crankshaft
The crankshaft is forged in one piece and counter-
balanced by weights on all crank webs.
Main bearings and big end bearings
The main bearings and the big end bearings are of
trimetal design with steel back, lead-bronze lining,
and a soft running layer.
Connecting rods
The connecting rods are of forged alloy steel and
fully machined with a round cross section. The
connecting rod is a three-piece design, which gives a
minimum dismantling height and enables the piston
be dismounted without opening the big end bear-
ing.


Page 18
Pistons and piston rings
The pistons are of composite type with steel crown
and aluminium skirt. The piston tops are oil cooled
by means of shaker effect. The piston ring
grooves are hardened.
The piston ring set consists of two chrome-plated
compression rings and one spring-loaded oil scraper
ring with chrome-plated edges
Air receiver
Fuel gas system
Cylinder head
Camshaft
Crankshaft
Spark plug
Prechamber
Cylinder liner
Hot box
Exhaust gas manifold
Oil sump
Piston
Connecting rod

Figure 19. Engine cross section
Cylinder liners
The cylinder liners are centrifugally cast of a special
alloyed cast iron. The top collar is provided with
bore cooling for efficient control of the liner tem-
perature. The liner is provided with an anti polish-
ing ring.
Cylinder heads
Each cylinder head contains a centrally located pre-
chamber with a fuel gas valve. A multi-duct casting
fitted to the cylinder head contains a charge air inlet
from the air receiver, an exhaust gas outlet, cooling
water outlet to return pipe, and a gas inlet from gas
manifold. Exhaust gas and inlet valves are equipped
with valve rotators.
The cylinder heads are made of vermicular cast iron
(CGI compacted graphite iron). The valve seat
rings are made of specially alloyed cast iron with
good wear resistance. The inlet valves as well as
exhaust valves have stellite-plated seat faces and
chromium-plated stems.
Camshafts
The camshafts are made up of one-cylinder pieces
with integrated cams. The camshafts are driven by
the crankshaft through a gear train.

Figure 20. Camshaft driving gears
2.2.3 Gas injection and ignition
In a lean burn gas engine, the air-fuel mixture in the
cylinders contains more air than necessary for com-
bustion. The ignition is initiated by spark plugs in
the pre-chamber, where a richer fuel mixture is
used. The gas flame from the pre-chamber ignites
the gas blend in the cylinder. The ignition system
consists of two ignition coil drivers, one for each
bank, and ignition coils located on top of the cylin-
der head covers.
EX
IN

Figure 21. Ignition
Gas is mixed with combustion air only in the intake
channels in the cylinder head, thus ensuring that
only air is present in the intake air manifold.
Page 19
2.2.4 Engine mounted equipment
Flywheel
The flywheel is fastened to the crankshaft with fit-
ted bolts. The generator is connected to the fly-
wheel with a flexible coupling fastened to the fly-
wheel.
Turbochargers
The 16V and 20V engines have two turbochargers,
one per bank, the 9L engine has one turbocharger
located at the free end of the engine. The turbo-
chargers utilize the energy of the engine exhaust
gases to feed air to the engine, thus, raising the effi-
ciency of the combustion. The turbochargers are of
axial turbine type, each with an exhaust gas driven
turbine and a centrifugal compressor mounted on
the same shaft.
The turbochargers are equipped with a water wash-
ing device which can be used during operation.
Regular cleaning delays the formation of deposits.
Exhaust gas waste-gate
The waste-gate valve in the exhaust gas system acts
as a regulator that limits the charge air pressure at
high loads. When opened, the valve lets part of the
exhaust gases by-pass the turbocharger, thus reduc-
ing the turbocharger speed and the intake air pres-
sure in the receiver.
Anti-surge device
An anti-surge device can be installed for applica-
tions where rapid load reductions may occur. The
function of the anti-surge device is to keep suffi-
cient air flow through the turbochargers at sudden
load reductions.
Turning device
The engine is fitted with an electrically driven turn-
ing device to allow slow turning of the engine. For
fine adjustment of the crankshaft position there is a
hand wheel. Engine start-up is prohibited while the
turning device is being used.
2.2.5 I nternal and engine mounted
auxiliary systems
Fuel Gas system
The fuel gas systemconsists of a main gas line that
provides gas to the cylinders and a pre-chamber line
that provides gas to the pre-chambers. The main
gas valves are opened and closed by the engine con-
trol system. The pre-chamber gas injection valves
are mechanically operated by the camshaft.
Figure 22. Gas admission system
Gas is supplied to the engine through the gas regu-
lating unit with separate outlets for main gas and
pre-chamber gas. A gas filter mounted on the en-
gine performs a final filtration of the main chamber
gas.
The main gas line on the engine has a vent valve
controlled by the engine control system.
Lubricating oil system
The lubricating oil system lubricates the bearings
and cylinder liners in the engine. Besides lubricating
the engine, the lubricating oil has a cooling func-
tion.
Lubricating oil is circulated by an engine driven gear
pump. Besides the pump, the lube oil system com-
prises an automatic oil filter and a centrifugal filter
for cleaning the back-flush oil from the automatic
filter, a lubricating oil cooler with a thermostatic
valve, and an electrically driven pre-lubricating
pump.
From the oil sump at the bottom of the engine, oil
is pumped at a pressure of 4 - 5 bar via the cooler
and the filter, through the hydraulic jacks (fitted for
maintenance purposes) to the main bearings,
through the connecting rods, to the gudgeon pins,
and partly to the piston skirts. Finally, it is sprayed
on the piston crown cooling surfaces.
Page 20
Figure 23. Internal and built on lube oil system
Lube oil is also conducted to other lubricating
points, like camshaft bearings, rocker arm bearings,
valve mechanism gear wheel bearings, and the tur-
bocharger.
The electrically driven pre-lubricating pump is used
for filling the engine lube oil system before start,
and for continuous lubrication of stand-by engines.
The engine is equipped with a wet oil sump. The
sump is equipped with high and low level switches,
an oil dipstick indicating maximum and minimum
oil levels and remote level indication
Compressed air starting system
The engine is started by direct injection of com-
pressed air into the cylinders. Starting air is admitted
to the cylinders through pneumatically controlled
starting air valves in the cylinder heads (see Figure
24).
Control air to the starting air valves is fed through a
camshaft driven distributor. Control air feed is
blocked when the turning gear is engaged, thus pre-
venting start.
The main starting valve that admits air to the start-
ing system is activated by the engine control system.
Figure 24. Starting air system
Cooling system
The main function of the engine cooling water sys-
tem is to remove the heat generated by the engine.
The cooling water is cooled in an external cooling
system.
The cooling water system is divided into a high
temperature (HT) circuit and a low temperature
(LT) circuit. The HT circuit comprises the engine
block (cylinder jacket and cylinder heads) and the
first stage charge air cooler. The LT circuit com-
prises the lube oil cooler and the second stage
charge air cooler.
Two engine driven centrifugal pumps circulate the
cooling water through the engine and the external
cooling system. The water temperatures in the two
circuits are controlled by two temperature control
valves.
Intake air system
The intake air system comprises the compressor on
the turbocharger and a two-stage intake air cooler
of tube type located after the turbocharger. When
compressed in the turbocharger, the air is heated. In
the charge air cooler, it is cooled with cooling water
to optimal level before entering the charge air re-
ceiver in the engine block.
Page 21
Exhaust gas system
The exhaust gases are led from the cylinders,
through multiducts to common exhaust pipes, one
per bank, leading the exhaust gases to the turbo-
chargers. The exhaust pipes are designed to provide
an equal flow of gases to the turbochargers without
disturbing gas pulses to the cylinders.
The exhaust pipes are cast of special alloy nodular
cast iron, with separate sections for each cylinder.
Metal bellows of multiple type absorb the heat ex-
pansion. The complete exhaust system is enclosed
by an insulation box of steel sheets.
Figure 25. Exhaust manifold
Exhaust gas temperature sensors are mounted after
each exhaust valve, and before and after the turbo-
chargers.
2.2.6 Engine control system
General
Monitoring and control of the engine is handled by
the engine mounted UNIC (UNIfied Controls) en-
gine control system. The main functions of the sys-
tem are:
- Start and stop management
- Engine speed and load control
- Speed measuring and over-speed protection
- Gas pressure control and air-fuel ratio control
- Cylinder control: gas injection, ignition and
knock control
- Safety functions: start blocking, alarm activation,
load reduction, and shutdown.
The Wrtsil UNIC control system is a distributed
and redundant control system composed of several
hardware modules which communicate through two
redundant communication buses using the CAN
protocol. The main modules are mounted in the
control cabinet at the driving end of the engine. The
I/ O modules and the cylinder control modules are
mounted along the engine side close to the sensors
and actuators they are monitoring and controlling.
The main control module is responsible for all con-
trol functions. It communicates with the plant con-
trol system through the plant network.
Figure 26. UNIC main system components
The system is specifically designed for the demand-
ing environment on engines. Special attention has
been paid to temperature and vibration endurance.
The rugged design allows the system to be directly
mounted on the engine, and the engine can be fully
tested at factory before delivery.
UNIC collects signals from the engine sensors,
processes them and compares them with given con-
trol parameters. All data collected by UNIC can be
transferred to the plant control system.
The local control panel on the engine mounted con-
trol cabinet contains two graphical displays, one
static display showing the most important engine
parameters, and one interactive, menu based display
where all engine data as well as the control system
status can be viewed.

Page 22
Local display unit
Push buttons
Emergency stop button
Local display unit
Local control panel
Main control
module (MCM)
Power distribution
module (PDM)
Engine safety
module (ESM)
Opto-couplers
Terminals

Figure 27. Engine mounted control cabinet
The engine control system has two engine control
modes: speed control and load control. The active
mode is selected with the plant control system.
A PID type controller controls the fuel injection
based on the difference between measured speed or
load, depending on the active control mode, and the
respective set point. In speed control mode, a fixed
speed based on the engine rated speed is used as set
point. The internal engine speed reference is de-
creased linearly at increased load (speed droop). In
load control mode, the load reference is set by the
plant control system.
Engine speed measuring and over-speed
protection
The engine speed and phase are measured with two
speed and phase sensors located on the flywheel.
The speed and phase signals are used to determine
the timing and duration of the gas injection and
ignition. Using the speed signals, UNIC calculates
measured engine speed, which is used as feedback
for the internal speed controller and for over-speed
protection. UNIC calculates the speed in several
different units, and the results are cross-checked.
In case of an engine over-speed, UNIC initiates an
instant emergency stop. A safety module in UNIC
provides an independent second over-speed protec-
tion based on two back-up speed sensors.
Gas pressure and fuel-air ratio control
Gas pressure is monitored and controlled to ensure
proper gas supply and air - fuel ratio. Taking into
account the engine load and the air receiver pres-
sure, UNIC calculates and sends a pressure refer-
ence signal to the Gas Regulating unit.
The actual gas pressure is measured on the engine
and compared to the reference pressure. If the gas
pressure is too low or high related to the charge air
pressure, the engine is shut down. If the pressure is
too high, the control system will open safety valves
on the engine and the gas regulating unit to evacu-
ate excess gas pressure.
The air pressure in the air receiver is controlled with
the waste-gate valve.
Cylinder control
Each engine has several cylinder control modules
which control the gas injection and timing of the
main gas valve, and the ignition timing. They also
monitor the exhaust gas temperature, cylinder
knocking, cylinder liner and main bearing tempera-
tures.
UNIC controls the duration and timing of the gas
injection to each cylinder main combustion cham-
ber and the timing of the spark. The timing can be
set individually for each cylinder.
Knocking is due to the auto-ignition of gas before
or after the spark ignition. This is harmful to the
engine. Knock sensors are mounted on each cylin-
der head, and if knocking is detected, UNIC takes
appropriate actions adjustments, load reduction or
shutdown depending on the knock intensity.
During operation, the system monitors the exhaust
gas temperature of each cylinder and the average
temperature. Deviations may lead to load reduction
or shutdown.
Safety functions
The safety functions include start blocking, alarm
activation, load reduction, shut-down and emer-
gency stop.
Before the plant control system activates a start re-
quest, it checks with UNIC that the engine is ready
for start. UNIC will not allow start if, for instance,
the lubricating oil pressure is too low, the HT cool-
ing water temperature is too low, the exhaust gas
ventilation has not been performed, or the engine
turning device is engaged.
UNIC generates a number of alarms, all of which
are transmitted to the plant control system, for in-
stance:
Sensor failure or wire break
Gas pressure deviation
Page 23
- High exhaust gas temperature after a cylinder
- Failed start attempt
- High charge air temperature
- High crankcase pressure
- De-rating caused by knocking
- Engine overload.
Some alarms, for instance, heavy knocking, gas
pressure deviation, and high exhaust gas tempera-
ture will initiate a load reduction. More serious inci-
dents, like CAN bus failure, high crankcase pres-
sure, high exhaust gas temperature after cylinder,
high cylinder liner temperature, and high main bear-
ing temperature will activate an immediate engine
shut-down.
At an emergency stop, the engine will be shut down
immediately. An automatic emergency stop will be
executed, for instance, at engine overload, engine
over-speed, or if both speed sensors have failed.
2.3 Generator
2.3.1 General
The generator converts the mechanical power of
the engine into electrical power.
The standard generators used with Wrtsil 34SG
engines are medium voltage synchronous AC gen-
erators with a brushless excitation system, horizon-
tally mounted, and provided with two sleeve bear-
ings. The generators are connected to the engine
flywheels by means of flexible couplings. The stator
frames rest on machined feet.
The generators are air-cooled with a shaft-mounted
fan which takes cooling air from the engine hall. An
electrical anti-condensation heater prevents water
condensation in a stand-by generator.
The generators follow the design criteria described
by IEC (International Electrical Commission).
2.3.2 Generator type and size
Generators are typically operated at nominal speed.
The output frequency is determined by the number
of pole pairs and the engine speed.
Frequency 50 Hz 60 Hz
Engine speed, rpm 750 rpm 720 rpm
Number of poles 8 (4 pairs) 10 (5 pairs)
Table 7. Number of poles in 50 Hz and 60 Hz
applications
The rotor construction is salient pole. A fully inter-
connected damper winding stabilizes the rotor dur-
ing load changes. This makes the generator suitable
for operation in parallel with other generating sets.
The generator is sized for the engine power at the
site where the engine generator set will be installed.
2.3.3 Excitation system
While the active power output from the generator
depends on the engine power and the generator
efficiency, the voltage and reactive power is regu-
lated by the excitation system.
The brushless excitation and voltage regulation sys-
tem consists of an automatic voltage regulator
(AVR), an exciter and a rotating diode bridge. Exci-
tation power is taken from voltage transformers or
auxiliary windings mounted on the generator. Due
to a permanent magnet pole in the exciter, no ex-
ternal power source is required for the initial excita-
tion at start-up.
Figure 28. Principle scheme of the excitation sys-
tem
At full load, the power plant has an operating range
from a power factor of 0.95 leading (under-excited)
to a power factor of 0.8 lagging (over-excited).
The automatic voltage regulator is contained in the
generator set control cabinet.
Stator windings
Page 24
2.3.4 Main terminal box
All stator winding ends and the neutral point cable
are brought into the main terminal box, which is
mounted on the generator side or on top of the
generator.
2.3.5 I nstrumentation
The generator has current and voltage measurement
transformers which provide measured data for con-
trol and protection functions. In addition, the stator
windings and the bearings are equipped with tem-
perature sensors. All signals from the sensors are
connected to a connection box on the generator.
2.3.6 Protection
The generator is protected by the protection relays
in the generator set control cabinet.
If the generator circuit breaker in the MV switch-
gear is of vacuum breaker type, the generator must
be equipped with surge protection (surge arresters
and surge capacitors).
Wrtsil 34SG Power Pl ant Product Guide 3. ENGINE AUXILIARY SYSTEMS
Page 25
3. ENGI NE AUXI LI ARY SYSTEMS
3.1 Overview
Figure 29 shows an overview of the engine auxiliary system equipment.
Figure 29. Overview of 20V34SG engine auxiliary system equipment
Wrtsil 34SG Power Plant Product Guide 3. ENGINE AUXILIARY SYSTEMS

Page 26
Each engine has its own gas regulating unit (GRU),
engine auxiliary module, exhaust gas module, intake
air filter, exhaust gas silencer and radiator(s). The
maintenance water tank(s), compressed air units,
storage tanks, and lube oil pump units are common
to several engines or the whole plant.
3.2 Standard modules
3.2.1 Engine auxiliary module
(EAM)
General
The Wrtsil 34SG Engine Auxiliary Module (EAM)
(Figure 30) is a prefabricated module composed of
pipes, pumps, heaters, valves, instrumentation and
control for handling the flows of cooling water, lubri-
cating oil and compressed air to and from the engine.
The EAM module is available in four models for 16V
and 20V34SG engines according to Table 8.
A separate jacket water cooler is required with one-
circuit models in arctic conditions where high glycol
content in the LT-circuit calls for separate LT and
HT-circuits.
The EAM module is built within a rigid steel frame
and is equipped with an auxiliary platform.

HT preheating unit
Instrument air panel Control panel
Hose reel, air gun
Temperature control valves
Expansion water pump (option)
LT preheating unit
(option)
Header pipes

Figure 30. Engine auxiliary module viewed from the engine side
Page 27
Model Descri ption Ambient temp. range
EAM 1C MC One common external cooling water circuit. -8
o
C - +44
o
C
EAM 1C J C One cooling water circuit, but separate cooling of
the jacket water.
-35
o
C - +44
o
C
EAM 2C Two cooling water circuits. The model supports
HT water heat recovery.
-35
o
C - +44
o
C
EAM CHP Two cooling water circuits with connections to the
CHP module (page 51).
-35
o
C - +44
o
C
Table 8. The EAM models for 16V and 20V34SG engines
Lube oil system equipment
The EAM module comprises pipes for transporting
lube oil to the engine, and connections for pumping
lube oil from the engine.
Compressed air system equipment
Starting air pipes within the EAM convey starting air
to the engine, and control air pipes convey control air
(instrument air) to the consumers. Control air is dis-
tributed through one or more pressure reduction
units, containing an air pressure regulating valve, a
filter and a water separator. The EAM module is also
equipped with aservice air outlet.
To protect the most sensitive engine components at a
malfunction of a compressor filter or drier, there is a
safety filter (micro filter) in the EAM module close to
the engine. Immediately before the engine, there are a
non-return valve and a blow-off valve.
Cooling water system equipment
The EAM module contains anHT pre-heating unit
for heating the high temperature (HT) cooling water
before engine start-up. The unit consists of a cen-
trifugal pump and an electrical heat exchanger de-
signed to heat the cooling water to about 70
o
C and to
keep it at this temperature when the engine is
stopped.
For cold climates, the module may also contain a
similar LT pre-heating unit for pre-heating the low
temperature (LT) water, which preheats the intake air
in the intake air cooler.
The module contains two temperature control
valves, one for the LT and one for the HT circuit.
An expansion water pressure increasing pump
with variable speed control can be included in cases
where the HT expansion vessel (in two-circuit sys-
tems and systems with a separate jacket cooler) can-
not be placed high enough, that is, at least 7 meters
above the engine HT cooling water pump.
I nstrumentation and control
The control cabinet of the EAM module contains
pump motor starters, relays, switches, timers and
logical circuits. It also contains aremote I/ O which
communicates with the generator set PLC in the con-
trol room.
The sensors, switches and actuating devices in the
EAM module are all connected to the remote I/ O. In
addition, the sensors and actuators in the exhaust gas
module (see below) and the intake air filter are con-
nected to the remote I/ O.
In automatic mode, the pumps and heaters in the
module are started and stopped automatically based
on the engine running signal, level switches or ther-
mostats.
3.2.2 Exhaust gas module
General
The exhaust gas module contains an optimized ex-
haust gas branch pipe, intake air silencers, one or two
expansion vessel(s), an exhaust gas ventilation fan,
and an oil mist separator unit . In plants with an SCR
type emission control system, the module may in-
clude a platform for the reagent dosing unit.
Intake air silencers
The charge air silencers, which are of absorption
type, are available in two sizes. The smaller charge air
silencers are designed to give about 35 dB(A) attenua-
tion in the high frequency band, which is enough in
most cases. The larger silencers give about 45 dB(A)
attenuation.
Page 28
Figure 31. Exhaust gas module
Cooling water expansion vessel(s)
The expansion vessel(s) compensate for volume
changes in the cooling water system due to tempera-
ture changes. They also provide continuous air vent-
ing of the engine cooling water circuit(s) and static
pressure at the inlet of the engine mounted cooling
water pumps.
In two-circuit installations and one-circuit installa-
tions with separate jacket cooler, there are two vessels
of 300 litres each, one for HT water and one for LT
water. In one circuit installations with mixed HT and
LT water, there is one expansion vessel of 600 litres.
The expansion vessels are equipped with low level
switches for activating low level alarm, and local level
indicators.
Exhaust gas vent fan
The exhaust gas vent fan purges the exhaust gas sys-
tem from any accumulated unburned gas. The fan is
of radial type and is driven by an electrical motor. It
is started automatically by the plant control system
after the engine has stopped. A flow switch ensures
that the fan is running.
Oil mist separator unit
The oil mist separator unit removes the oil particles
from the crankcase vent gases utilizing the centrifugal
force principle. The separated oil flows back to the
oil sump via the crankcase ventilation pipe.
3.3 Fuel gas system
3.3.1 System description
System overview
The purpose of the fuel gas system is to supply the
engine with a constant gas feed of suitable pressure,
temperature and cleanness. It should also shut off the
gas supply if any problem arises, and provide ventila-
tion of trapped gas.
Fuel gas is supplied to the engine from the gas distri-
bution system through an engine-specific gas regu-
lating unit (GRU), or gas train, which includes a
particle filter, pressure control valves, safety shut-off
valves and vent valves. The gas regulating unit is al-
ways supplied by Wrtsil along with the engine.
Gas is supplied to the power plant through a com-
mon gas pipe which splits into engine-specific gas
pipes in a header pipe. To enable gas shut off, there
must be one or moremain shut off valves outside
the engine hall. Generally, the valves are located in
the common gas pipe. Alternatively, there may be
main shut-off valves in each of the engine-specific
gas pipes.
Gas flow metering unit can be installed in the
common gas pipe for measuring the gas consumption
of the plant. Engine-specific flow meters may also be
included in the gas regulating unit.
The common fuel gas system can also include the
following equipment:
- A pressure reduction station if the pressure
supplied by the gas company is higher than maxi-
mum allowed pressure to the GRU
- A gas compressor if the fuel gas pressure sup-
plied by the gas company is too low
- A filtration unitif the gas may contain impurities,
oil, water or condensed hydrocarbons
- A heating unit if the gas temperature may drop
below the dew point
- A venting valve to depressurize the fuel gas pipes
inside the engine hall
The filtration and heating units may be included in
the pressure reduction station as shown in the figure
below.
Page 29
Figure 32. Diagram of a fuel gas system with common gas shut off and flow metering, and a pressure reduction
station with filtration and heating
Fuel gas pressure requirements
The required fuel gas pressure to the engine depends
on the engine configuration and the heating value of
the gas. The exact minimum pressure must therefore
be determined case by case.
Normally, the inlet pressure to the GRU is 4.5-6.0
bar(g). The maximum pressure to the GRU is about
10 bar(g) in ANSI/ ASME design and 6 or 16 bar(g)
in DIN design. Typical pressure drop over the GRU
is 50 kPa.
The required fuel gas pressure to the plant is the
minimum GRU pressure, plus the pressure drop over
the upstream units, plus a safety margin.
Temperatures
The fuel gas temperature before the engine must be
high enough to avoid condensation and icing. The
recommended minimum temperature is +5
o
C, and a
minimum of +15
o
C over the hydrocarbon and water
dew points.
Gas filtration
The mechanical components in the engine fuel gas
system are sensitive to particles. Particles must there-
fore be removed before the engine. The following
table gives typical filtration properties for the gas fil-
ters in different locations of the system.
Particle
size
Filtration
efficiency
Location
m %
Plant filter unit 5 95
Flow metering unit 2 95
Gas regulating unit 2 95
Engine gas pipe inlet
(main pipe)
0.5 98.5
Metal net at engine main
gas valve inlet on the
engine (safety filtration)
90 NA
Table 9. Particle filtration efficiency
3.3.2 Gas regulating unit (GRU)
General
The skid mounted gas regulating unit (GRU), which
is always supplied by Wrtsil, provides correct fuel
supply to the engine by regulating the gas feed pres-
sure according to the engine load.
Page 30
Figure 33. Gas regulating unit
The GRU has two pipe connections to the engine: a
larger line to the main combustion chambers, and a
smaller one to the pre-combustion chambers. The
lines may have different pressures.
The main components of the GRU are:
- A manual ball valve for closing the gas inlet line
- An inert gas line for purging the unit when re-
quired for maintenance purposes
- A particulate filter
- Two pressure regulating valves, one per line
- Two main shut-off valves (blocking valves) per
line, and three vent valves per line
- A safety relief valve per line (in ANSI design)
- Optionally, a flow meter with a flow computer
- Instrumentation such as pressure and temperature
gauges and transmitters.
The pressure regulating valves are controlled by the
engine control system. The plant control system con-
trols the shut-off and ventilation valves and monitors
the unit.
The electrical components are EX-classified to be
suited for installation in zone 2 (class I division 2).
Particulate filter unit
Typically, the particle filters have a separation effi-
ciency of over 95 % of particles down to 2 m.
Pressure regulating valves
The pilot operated pressure regulating valves are of
diaphragm type. They are operated with control air
supplied through an I/ P converter controlled by the
engine control system. If the inlet pressure is in the
range 6 - 16 barg (DIN design), the regulating valves
are supplied with safety shut-off valves.
Shut-off valve and vent valves
The GRU is equipped with four shut-off valves, two
in the main gas line and two in the pre-chamber gas
line. The valves, which are doubled for safety reasons,
are mounted in series. The shut-off valves are opened
pneumatically, and closed by a spring.
Gas trapped in the pipes at shut off is vented to the
atmosphere through solenoid operated vent valves
three for the main gas line and three for the pre-
chamber gas line. During operation the shut-off
valves are open and all the vent valves are closed.
When the engine is stopped (normal stop or engine
shut-down), the shut-off valves are closed, and the
vent valves are opened and closed according to a de-
fined sequence to prevent air from replacing gas in
the pipes. At an emergency stop, all the valves will go
to their fail-safe positions.
The vent pipes must be pulled as two separate lines
up to the roof, grouped according to Figure 32.
I nstrumentation and control
The measurements and control signals from and to
the unit are collected in electrical cabinets or switch
boxes mounted on the unit.
3.3.3 Main shut-off valve(s)
To enable fuel gas shut off, there must be one or
more main shut off valves outside the engine hall. In
the event of a gas leak, fire or gas explosion inside the
building, the gas flow must be shut off automatically.
It must also be possible to shut off the gas flow
manually outside the building. It is therefore recom-
mended to have two valves in series, one manually
and one automatically operated. The automatic valve
must be of fail-safe type with a limit switch for re-
mote indication.
Minimum performance requirements for large valves
>DN200 :
Shut off: < 4 seconds
Open: ~30 seconds
Page 31
For smaller valves, shorter closing time is recom-
mended.
Generally, the main shut off valves are located in the
common gas pipe before the header pipe. Alterna-
tively, there may be main shut-off valves in each of
the engine-specific gas pipes. The latter design may
be preferable in cold climates as it allows engine ven-
tilation to be shut off during standby.
In plants with a common main shut-off valve, the
automatic valve is closed by the control system at a
plant emergency stop. In plants with engine specific
valves, the valve is closed at stop, shut-down, or
emergency stop of the respective engine. All valves
are closed in case of a plant emergency stop.
3.3.4 Vent valve
A vent valve may be installed outside the engine hall
between the main shut-off valve and the wall. The
valve is opened in case of a plant emergency shut
down to let pressurized fuel gas out of the fuel gas
pipes. The valve should be of fail-safe type and
closed by a spring in loss of power or control air.
3.3.5 Pressure reduction station
General
The design of a pressure reduction station can vary.
In addition to the pressure regulator, the station may
include a filter, a gas flow meter, a heater, and a gas
chromatograph for measuring the gas quality.
Pressure regulating valves
To secure the availability, the pressure regulating
valves should be doubled, one valve being in opera-
tion and one in stand-by. The valves can be con-
nected in parallel or in series. If the valves are parallel,
both lines are designed for 100 % capacity and
equipped with safety shut-off valves. An automatic
duty/ slave control switches to the slave line if the
duty line fails. With two valves in series, the set
points are adjusted so that if one regulator fails, the
other one takes over.
Heating
When the pressure is reduced, the fuel gas tempera-
ture will drop. The size of the drop depends on the
gas composition. A rule of thumb is 0.5
o
C/ bar. The
temperature drop may cause condensation, icing and
hydrate formation. If a risk for malfunction arises,
heating is required. Electrical heaters are recom-
mended. The components must be EX-classified.
Safety devices
Depending on the inlet and outlet pressures, one or
more safety devices are required. The minimum re-
quirement is a monitoring regulator or safety shut off
valve. When activated (closed), the safety shut-off
valve must remain closed until it is opened manually.
3.3.6 Gas filtration unit
General
A gas filtration unit is needed if the gas contains or
may contain high concentrations of impurities in the
form of particles rust, debris, sand, etc. oil, or
moisture and hydrocarbon condensate. If there is a
gas compressor, it may leave traces of lubrication oil
in the gas stream. Liquid removal and also gas heating
may be required depending on the inlet temperature
and pressure, and the hydrocarbon and water dew
points of the gas. The filter type may be, for instance,
a particle, coalescing, vane, or demister filters. All
electrical devices must be EX-classified.
Liquid separation
Natural gas containing traces of C4 - C7 hydrocar-
bons and a slight amount of water vapour normally
needs no liquid separation. However, if the gas con-
tains higher hydrocarbons, C12 or higher, liquid sepa-
ration will be necessary as these compounds may
cause condensation problems even in small concen-
trations (e.g. 0.5 ppm).
Liquids can be separated, for instance, with gravity
separators, centrifugal separators, vane separators,
mist eliminator pads and coalescing filters. Generally,
the liquid present in the gas stream is a very fine fume
with a droplet diameter < 1m. For removing such
small droplets, a coalescing filter is normally required.
Page 32
Design principles
The filtration unit should have full stand-by capacity
and be designed for maximum flow (the flow at the
minimum operating pressure and maximum tempera-
ture). The filter must be equipped with differential
pressure measurement and filter switch over. There
should also be manual venting and isolation valves or
three way valves. If liquid is removed, a manual or
automatic drain and possibly a collector will be
needed. If the filter is installed indoors, normal car-
bon steel can be used.
3.3.7 Flow metering unit
General
The gas flow is metered for determining the fuel con-
sumption. The gas flow meter can be an industrial
meter or a custody transfer meter approved for bill-
ing purposes. The flow meter must be equipped with
a flow corrector or a computer to change the actual
flow to standard conditions. For more exact flow
determination, the compressibility of the gas should
be taken into account.
Design
The plant specific flow meter includes:
- A flow meter, normally a turbine meter, with a
flow corrector or computer
- High accuracy pressure and temperature sensors
- A particulate filter
- A by-pass line, a vent connection, isolation valves,
and straight pipe sections before and after the me-
ter
The meter shall be the same size as the gas pipe. Re-
stricting or enlarging cones are not recommended.
The valves must be designed for gas applications.
3.4 Lube oil system
The lubrication oil system includes tanks for storing
new and used lube oil, pumps for emptying and fill-
ing lube oil, and loading/ unloading pump units in the
tank yard. The pump for filling lube oil can be com-
mon for the entire plant. A common mobile pump
can be used for emptying the system.
Figure 34. A typical lube oil system
The new lube oil tank stores fresh lubricating oil for
oil changes and for compensating oil consumption
(topping up). The used lube oil tank contains used
lube oil stored for disposal. There may also be a ser-
vice tank for storing lube oil temporarily for reuse.
The required size for the fresh lube oil tank depends
on the lube oil delivery interval. Generally, the tank is
sized for 28 days consumption or as a minimum, the
tank should contain a sufficient quantity of lubricat-
ing oil for an oil change in one engine.
Page 33
The lube oil tank for used lube oil and the service
tank must be able to store oil from at least one en-
gine, plus a 15 % safety margin.
When sizing the pumps, the lube oil quality and vis-
cosity should be considered. To avoid emulsification
of water, the lube oil pumps should be of screw
pump type.
The reciprocating movements of the engine pistons
and the slight pressure leakage past the piston rings
give rise to crankcase gases, which may contain lube
oil. The crankcase gases are led to the oil mist separa-
tor, where the lube oil traces are minimized. The
condensate is drained back to the engine oil sump.
3.4.2 Lube oil storage tanks
According to tank standards, vertical cylindrical tanks
are typically used for volumes >35m
3.
Smaller tanks
are normally horizontal. Large storage tanks are usu-
ally built on site while smaller ones can be prefabri-
cated elsewhere.
The standard tanks delivered by Wrtsil are made of
steel. Each tank has inlet and outlet connections, a
drain pipe, a vent pipe, an overflow pipe and a man-
hole.
Vertical tanks have slightly sloping bottoms with wa-
ter collecting pockets from where the drain tubing is
conducted. The filling pipe inlet is turned to the tank
wall to give a smooth flow. The tanks are equipped
with level switches.
C
Figure 35. Temperature viscosity diagram for SAE 30 and SAE 40
Page 34
Figure 36. An example of a vertical tank
If needed, the tanks are equipped with heating coils.
Note that if a tank contains an electrical heating coil,
the level in the tank must always cover the coil to
protect it from overheating.
3.4.3 Lube oil pump units
The standard transfer pump unit consists of a suction
filter, one or two electrically driven screw pumps,
valves, and a control panel. To protect the pumps
from over pressure, they are equipped with built on
overflow valves.
Figure 37. Lube oil pump unit (single pump)
3.5 Compressed air systems
General
Compressed air is used to start the engines (starting
air), and as actuating energy in pneumatic safety and
control devices (instrument and control air). Instru-
ment and control air can also be used as working
air in diaphragm pumps and in pneumatic tools. The
nominal starting air pressure is 30 bar and minimum
pressure is 15 bar. The instrument air pressure is 7
bar. While starting air is required only during start-up,
instrument air is required for operating the engine
and the gas regulating unit.
Compressed air is produced in compressor units,
generally with automatic pressure control. The air is
stored in compressed air tanks, which serve as buff-
ers. The starting and instrument air units can also be
interconnected, enabling the starting air unit to be
used as back-up for the instrument air unit.
To ensure the functionality of the components in the
compressed air system, the air has to be dry, clean
and free from solid particles and oil.
Starting air quality requirements
Starting air should be cleaned with an oil and water
separator. Normally there is no need for a dryer.
I nstrument air quality requirements
The instrument air is to meet the requirements in
Contaminants and quality Class 343 as specified in
the ISO:8573-1 standard. With this, it also meets
Quality standard for Instrument air by ANSI MC
11.1-1975, considering an ambient temperature of
min. 11C (52F).
Maximum particle size: 3 micron
Maximum particle concentration: 5 mg/m
3
Maximum pressure dew point: +3C (37F)
Maximum oil content: 1 mg/m
3
Table 10. Instrument air quality requirements
The strict requirements imposed on instrument air
make an air filter and drier necessary. In addition,
water separators should be installed before instru-
ments that are sensitive to water.
Page 35
Starting air system sizing principles
The required capacity of the starting air units, and the
number and size of the starting air tanks depend on
the required start-up time of the plant. The standard
principle is to size the tanks for three start attempts
per engine in small plants, and two starts per engine
in larger plants.
If the requirement is three start attempts per engine,
the minimum starting air tank volume is 4.4 m
3
per
engine. The starting air compressor is typically di-
mensioned to fill the tanks from minimum pressure
(15 bar) to nominal pressure (30 bar) in one hour.
With this principle, required compressor capacity for
4.4 m
3
tank volume would be 4.4 x 15 = 66 Nm
3
/ h at
30 bar.
Instrument air system sizing principles
The control and instrument air unit(s) should have
sufficient capacity to supply the peak consumption of
the plant, even in case of a leakage. The required ca-
pacity depends on the size of the plant and the type
of installed equipment. Instrument air is consumed at
least by the engines, the gas regulating units, the fuel
gas shut-off valve(s), and the exhaust gas system ven-
tilation valve. Minimum capacity is typically 1.1
Nm
3
/ min for a one engine plant and 2 x 2.7
Nm
3
/ min for a plant with ten engines.
In plants with one to three engines, an air receiver of
200 litres and a design pressure of 10 bar is recom-
mended. In larger plants, and in plants with irregular
air consumption, more receivers may be needed. Big
consumers, for example soot blowers, may need their
own local air receivers.
Figure 38. Compressed air system diagram
Page 36
3.5.2 Starting air unit
General
Wrtsils standard starting air unit consists of the
following main components mounted on a common
steel frame:
- one or two compressors with a control panel
- an oil and water separator
- a pressure reducer for connection to the control
and instrument air system.
Vibration dampers are mounted between the com-
pressor unit and the floor.
Figure 39. Starting air unit with two compressors
If there are two compressors, one compressor is
working while the other one is stand-by. Both com-
pressors may be electrically driven, or one of them
may be a diesel driven emergency unit. The air outlets
are connected in parallel. For fast production, both
compressors may be used simultaneously.
The compressor is of two-stage type with intermedi-
ary air cooling. It is designed for 40 bar maximum
operating pressure and includes a pressure release
valve. The compressor is started and stopped auto-
matically by the signals from a pressure switch. It is
started at about 23 bar and stopped at 30 bar. A low
pressure alarm signal is activated at 18 bar.
Oil and water separator
An oil and water separator and a non-return valve are
located in the feed pipe between the compressor and
the starting air receiver..
3.5.3 Control and instrument air
unit
General
The standard control and instrument air unit deliv-
ered by Wrtsil contains the following equipment
built on a common steel frame:
- an electrically driven compressor with a control
panel
- a compressed air receiver
- an air cooled refrigeration dryer
- a filter for removal of oil, water and particles
Compressor
Wrtsils standard control and instrument air com-
pressor is a single-stage air-cooled screw compressor
designed for a working pressure of 7 bar and maxi-
mum pressure of 10 bar. The compressor is equipped
with a suction filter and a suction silencer.
The pressure is controlled automatically by opening
and closing the air intake valve while the compressor
is continuously running. The compressor is stopped
automatically after some time of inactivity.
Air dryer
The air dryer removes water from the compressed air
before it leaves the unit. In most cases, a refrigeration
dryer gives sufficiently high air quality and is the pre-
ferred type of dryer.
3.5.4 Compressed air tanks
The air receivers are to be equipped with at least one
manual valve for condensate drainage. Horizontally
mounted air receivers must be inclined 3-5 towards
the drain valve. Being pressure vessels, they must be
tested and stamped for the design pressure according
to locally valid regulations.
Page 37
3.6 Cooling water system
General
Heat removed from the engine must be dissipated
through an external cooling system, either radiators
or central coolers. Radiators provide a closed system
and require no secondary cooling. With central cool-
ing, a secondary cooling circuit is required with an
external source of cooling such as cooling tower or
raw water. The choice of cooling method depends on
the ambient conditions, water availability, and envi-
ronmental requirements.
Cooling water quality requirements
For the required cooling water quality, refer to sec-
tion 12.3. Note that neither sea water nor rain water
must be used. Sea-water would cause severe corro-
sion and deposits. Rain water is unsuitable due to its
high oxygen and carbon dioxide content.
To prevent corrosion, corrosion inhibitors are always
mandatory. Water additives may also be required to
prevent freezing, deposit formation, or cavitation.
LT and HT circuits
The engine cooling water system is divided into a low
temperature (LT) circuit and a high temperature (HT)
circuit. The LT circuit includes the lube oil cooler and
the second stage, low temperature charge air cooler
(LTCAC). The HT circuit includes the first stage,
high temperature charge air cooler (HTCAC) and the
engine jacket. The water is circulated by two engine-
driven pumps, and the temperatures are regulated by
two three-way temperature control valves.
One and two circuit systems
Outside the engine, the cooling system may be ar-
ranged as a one-circuit system, where the LT and HT
circuits are joined to one flow through the radiators,
or as a two-circuit system, which has two separate
flows through the radiators. One-circuit systems are
suitable in most cases, but two-circuit systems are
usually preferred in heat recovery applications.
Figure 40. Cooling water system (one-circuit system with mixed cooling).
Page 38
If the ambient temperature may drop below 0
o
C, an
anti-freeze agent, generally ethylene glycol must be
added to the outdoor circuits. The required amount
depends on the minimum ambient temperature.
Maximum allowed glycol content in the water that
cools the engine jacket is 20% without de-rating. If
this is not enough to prevent freezing, a two-circuit
system or a separate jacket water cooler must be used,
or the engine must be de-rated. The de-rating limit
for the LT water is 50% glycol.
Cooling water temperature control
The performance of the engine relies on a stable and
correctly set charge air receiver temperature, which,
in turn, depends on the cooling water temperatures.
The temperatures in the HT and LT cooling water
circuits are controlled by two three-way valves. The
valves control the flow through the external cooling
equipment.
The LT temperature control loop controls the cool-
ing water temperature at the inlet to the LT charge air
cooler according to a load-dependent set-point curve
provided by the engine control system. The default
set point range is 36 - 43C.
The HT temperature control loop controls the HT
water temperature at the outlet from the engine. The
default set point is 85C in one-circuit systems and
91C in two-circuit systems.
Pre-heating
For pre-heating the engine block before start, there is
a preheating unit in the EAM module. The unit heats
the HT water to the required temperature before en-
gine start. In cold climates, there may also be a LT-
water preheating unit.
Expansion vessel(s)
Volume changes due to changes in water temperature
are compensated by one or two expansion vessels
two vessels in two-circuit systems and one-circuit
systems with jacket cooler. The expansion vessels
also serve as continuous air venting points.
In two-circuit systems and one-circuit systems with
jacket cooler, a pressure increasing pump is required
if a static pressure of 0.7 bar cannot be obtained be-
fore the HT cooling water pump by an elevated loca-
tion of the HT expansion vessel. The required static
pressure for the LT pump is 0.3 bar.
Maintenance water tank(s)
One or more maintenance water tanks are recom-
mended for emptying and filling the cooling water
circuits during maintenance. In systems where glycol
is added only to the LT water, two tanks are needed,
one for water and one for glycol mixed water.
3.6.2 Radiators
General
In radiators, fans draw air through a tube bundle
where the cooling water flows in one or two closed
circuits.
Radiators must be installed outdoors with a suffi-
ciently large space around. The primary design pa-
rameters are the heat load and the ambient condi-
tions. In addition, possible noise emission limitations,
corrosive environment, high site altitude or glycol
content of the cooling water can have a significant
impact on the radiator size and design.
Radiator design
The recommended radiator type is the horizontal
type with induced draft and direct-driven fans.
The standard radiators delivered by Wrtsil are of
one or two circuit type. The two circuit radiators have
one LT and one HT circuit in the same body but with
independent and separated heat transfer areas. The
radiators have copper tubes equipped with aluminium
fins. In maritime climates with salt-laden air, and in
acid polluted areas, corrosion protection of the fins is
required.
Figure 41. Air flow through a radiator (horizontal
induced draft, 2 circuit type)
Page 39
Sizing radiator systems
The size of the radiators and the number of radiators
per engine depend on the ambient conditions and
required heat transfer.
The radiators are sized for a certain approach tem-
perature (temperature difference) between ambient
air and water. The ambient air temperature to be used
for the LT circuit is the maximum ambient tempera-
ture, but no higher than the temperature at which de-
rating starts. The temperature to be used for sizing
HT radiator sections in two-circuit systems is the
maximum ambient temperature.
The heat transfer area must be increased if glycol is
used in the cooling water.
Radiator arrangements
If multiple radiators are installed, it is recommended
to group them tightly in order to minimize recircula-
tion of hot air between the radiators. The radiators
should be installed at such a height that the vertical
air inlet area equals or exceeds the radiator footprint
area, but, in any case, no lower than 2 m above
ground. They can also be installed on the roof of the
power house.
Noise emission considerations
The noise from the radiator field depends on the
amount of radiators and radiator type. Emissions can
be lowered by selecting a lower rotation speed, and
possibly a smaller fan diameter. Both measures will
have a negative effect on the air flow through the fan,
which must be compensated with larger heat transfer
area and/ or more fans.
Standard radiators:
The sound power levels presented in Table 11 below
correspond to A-weighted sound pressure levels of
61 dB per radiator at 40 meters distance.
Engine Qty / Eng. Fans / Rad. L
w,A
[dB] / radiator
9L34SG 1 7 105
16V34SG 2 5 103
20V34SG 2 6 104
Table 11 Typical sound power level per standard
radiator
Low noise radiators:
The sound power levels presented in Table 12 below
correspond to A-weighted sound pressure levels of
56 dB per radiator at 40 meters distance
Engine Qty / Eng. Fans / Rad. L
w,A
[dB] / radiator
9L34SG 2 4 97
16V34SG 2 6 99
20V34SG 3 5 98
Table 12 Typical sound power level per low-noise
radiator
The values are indicative. Actual design will be ad-
justed to suit project specific conditions.
Using frequency converters
By controlling the fan operation using variable fre-
quency converters, a considerable reduction of aver-
age noise level and power consumption can be ob-
tained when the ambient temperature and cooling
requirements so allow. The frequency converters are
sized for the current required by the load, and re-
quired spare capacity (about 5 10%).
3.6.3 Central coolers
General
In a central cooler, the engine cooling water is cooled
by a secondary cooling circuit, which may be raw wa-
ter or water cooled in cooling towers. Cooling towers
are needed if raw water of suitable quality is not avail-
able, or if it is not permissible to discharge heated
water. Cooling towers are not recommended if the
ambient temperature may fall below 5
o
C.
Central cooler design
A central cooler is a plate type heat exchanger, which
can be installed either inside the power house or out-
doors. In one-circuit systems, only the LT circuit is
cooled in the central cooler. In two-circuit systems,
the HT and LT circuits can either have separate cool-
ers, or they can be joined in the cooler and divided to
two circuits after the cooler.
If raw water is used in the secondary cooling circuit,
the cooler will be exposed to fouling. Fouling can be
avoided by keeping the water temperature low and by
using softened or treated water. If fouling cannot be
avoided, heat exchangers which can be cleaned
should be used.
Wrtsil 34SG Power Plant Product Guide 3. ENGINE AUXILIARY SYSTEMS

Page 40
Cooling towers
The cooling effect of a cooling tower is based 95%
on the evaporation of water. The heated water from
the secondary circuit of a central cooler is lead to the
top of the cooling tower and injected by nozzles. The
water is cooled by the upward air flow, and then
pumped back to the central cooler.
The water losses in a cooling tower are mainly caused
by evaporation and bleed off. Bleed off is necessary
to prevent the build up of impurities and high salt
concentration. When designing cooling towers, care
should be taken to allow for replenishment of fresh
water.
Cooling towers must be installed outdoors with a
sufficiently large space around.
Raw water systems
If raw water from sea, river or lake of suitable quality
is available close enough to the power plant, it can be
used in the secondary circuit of the central cooler.
The water has to be filtered and cleaned before use.
Raw water intake and discharge systems should be
designed to avoid blockage during all operating con-
ditions, reduce biological growth in the cooling sys-
tem and in accordance with local rules and regula-
tions for water usage and discharge.
3.6.4 Maintenance water tank
General
The maintenance water tank is used for retrieving and
storing the cooling system water while the engine is
emptied for maintenance work. Clean water and
chemicals can be added in the tank and mixed by cir-
culating the tank content. A pump is needed for emp-
tying and filling the cooling water circuits.
Pump
Hose for chemical dosing

Figure 42. Maintenance water tank
Tank design
The standard maintenance water tank unit delivered
by Wrtsil is a tank with an electric pump. The tank
has connections for filling fresh water, emptying and
filling the cooling water system, a drain valve, and a
vent/overflow pipe.
Sizing maintenance water tanks
The maintenance water tank must be sized to store at
least the entire water volume in the HT and LT cool-
ing water systems of one engine, including the engine
itself, the external piping systems, the pre-heater, the
expansion vessels, and the radiators. If the tank will
be equipped with a secondary containment for leak-
age collection, the containment should be sized to
hold the total volume of the tank.
The recommended number of tanks is one tank for 1
to 3 engines, and two tanks for 4 to 10 engines.
3.7 I ntake air system
General
The design of the intake air system depends on the
ambient temperature, altitude, particle content in the
ambient air, and noise level allowed outside the plant.
Possible extreme conditions, such as sand storms,
snow storms, and heavy rain must also be considered.
Page 41
Combustion air to the engine is generally taken from
outdoors through an intake air filter. Air filtration is
required to protect the turbochargers and to remove
particles in the air that may cause deposit formations
or damage the engine.
When measuring the concentration of dust and
chemicals in the air, the worst scenario should be
taken into account. A detailed investigation of the air
filtration must be done in areas where the air includes
caustic, corrosive or toxic components.
Air filtration requirements
The highest permissible dust concentration at the
turbocharger inlet after filtration is 3 mg/ m
3
, and the
filter should be able to separate 70% of particles
above 5m.
Other air quality requirements
Component Maximum value
Sulphur Dioxide (SO2) 0.43 vol-ppm
Hydrogen Sulphide (H2S) 0.25 vol-ppm
Chlorides (Cl
-
) 1.16 mass-ppm
Ammonia (NH3) 0.125 vol-ppm
Table 13. Maximum content of chemicals
Temperature requirements
While too high an inlet air temperature will cause an
excessive thermal load on the engine and requires the
engine to be de-rated, cold suction air with a high
density will cause high firing pressures.
The following graph illustrates minimum continuous
intake air temperature as a function of the load.
Temporary operation below the minimum tempera-
ture is possible.
Figure 43. Minimum continuous air temperature
before the turbocharger at different
loads
By preheating the LT water, the engine can be started
at combustion air temperatures below 5
o
C. An LT
pre-heater can be included in the EAM module.
Other solutions for starting as well as operating the
engine at low ambient air temperatures are:
- Taking the intake air from the engine hall
- Heating the intake air, for instance, with electrical
coils or by using heat recovered from the engine
cooling circuits.
Air humidity
At high ambient air humidity, the high pressure in the
charge air system (about 3.5 bar(a) at 100 % load)
can cause the airborne humidity to condensate at
normal charge air temperatures. In these cases, the
charge air temperature should be raised in order to
avoid corrosion of the charge air cooler and intake
valves. See the dew point temperature curve in Figure
44. De-rating of the engine may be necessary due to
the increased temperature.
Figure 44. Dew point temperature curve at 3.5
bar(a)
Pressures and flows
Maximum allowed pressure drop in the intake air sys-
tem up to the turbochargers, including pipes, filters
and silencers, is 2000 Pa. The system should prefera-
bly be designed to not exceed half the limit at full
load. The air flow depends on the air temperature and
the altitude.
Page 42
Noise
The charge air sound pressure level at the turbo-
charger inlet is typically 120 dB(A) and very high fre-
quency distributed. To dampen the noise, charge air
silencers should be installed.
Figure 45. Typical combustion air system
3.7.2 I ntake air filters
Filter types
The following filter types are most commonly used:
- Dry type filters. These filters are static filters with
filter elements which must be regularly replaced.
- Oil wetted filters. The oil wetted filters have a
moving screen which is washed in an oil bath at
the bottom of the filter.
- Jet pulse filter.
Figure 46. Dry type charge air filter
Figure 47. Cutaway of an oil wetted filter
In most cases, dry type filters (EN 779 filter class G4)
are suitable. Oil wetted filters are suitable in areas
with high dust load and coarse particles. In these
cases, the oil wetted filter (EN 779 class G2/ G3) is to
be combined with a secondary dry filter (EN 779
class F5).
In desert conditions, jet pulse filters or sand separator
pre-filters are recommended.
Page 43
Lovers and hoods
The air intakes must be protected from heavy rain,
snow, insects, etc. The standard intake air filters used
by Wrtsil include a vertical weather louver (Figure
46) which removes most water droplets. In heavy rain
areas, a rain hood must be used.
Figure 48. Rain hood for intake air filters (example)
I ce prevention
Ice on the intake air filter can result in a very high
pressure drop in the charge air system and trip the
engine. Ice may be formed if the air temperature
drops below the dew point and the surface tempera-
ture is at or below the freezing point. The critical
temperature range is -5C to +3C. Ice formation can
be avoided with heating arrangements.
I nstrumentation
The intake air filter should be equipped with a differ-
ential pressure alarm.
3.8 Exhaust gas system
General
The main function of the exhaust gas system is to
lead exhaust gases safely out from the power plant.
Each engine must have its own exhaust gas system.
The main components besides the ducts are an ex-
haust gas silencer, an exhaust gas stack, and safety
equipment, such as an exhaust gas ventilation fan and
rupture disks.
Design pressures
Allowed maximum back pressure at the outlet of the
turbochargers is 5000 Pa (0.05 bar). However, the
system components shall be capable of tolerating
higher pressure due to the risk for exhaust gas defla-
grations. Thus, the design pressure for the exhaust
gas system is minimum 0.1 bar(g), and the system
must be able to sustain 0.5 bar(g) peak pressure for at
least one second.
Due to gas velocities created by a possible gas defla-
gration, under-pressure (partial vacuum) may occur.
Therefore, the stack must be sized to sustain an un-
der pressure of 0.3 bar without collapse.
Safety arrangements
In case of a malfunction or incomplete combustion,
the exhaust gas may contain unburned components,
which may ignite upon contact with hot surfaces. The
resulting deflagration may cause damage to the ex-
haust gas system. Unburned gas in the exhaust gases
may also damage a catalytic converter, if installed.
The following protection methods are required:
- Minimizing the risk of gas build-up by designing
the pipe system with only upward slopes
- Ventilating the exhaust gas system to discharge
any unburned gas after the engine has stopped
- Relieving the pressure at a possible deflagration
with rupture disks.
The exhaust gas ventilation system consists of a cen-
trifugal fan, a flow switch and a butterfly valve. The
valve is opened and the fan started after each engine
stop. The flow switch monitors the fan operation and
activates an alarm in case of a malfunction. The fan is
designed to change the volume in the exhaust gas
system at least three times during a ventilation run.
Page 44
Figure 49. Typical exhaust gas system
3.8.2 Exhaust gas silencers
The exhaust gas silencers must be effectively purged
during the exhaust gas system ventilation. Silencers of
absorption, reactive or combination type can be used.
The required attenuation of the silencers is deter-
mined by the environmental noise requirements.
The standard exhaust gas silencers delivered by Wrt-
sil are of combination type, giving a noise attenua-
tion of 35 dBA or 45 dBA. The silencers are provided
with a water drain. A soot collector and a spark arres-
tor are optional.
The exhaust gas silencers can be mounted either
horizontally or vertically, inside or outside the build-
ing. Generally, they are installed in the stack.
3.8.3 Rupture disks
Design
Rupture disks are the only approved pressure relief
devices. The rupture disks shall be designed to open
at an excess pressure of 0.5 0.05 bar at the operat-
ing temperature. Spring loaded devices are not al-
lowed to be used.
The diameter of the rupture disks should be at least
the same as the exhaust gas pipe diameter. The disks
must be installed directly in the main duct.
Location of rupture disks
On a straight pipe, the rupture disks shall be installed
at a distance of maximum ten pipe diameters apart.
The first rupture disk is to be placed within ten pipe
diameters after the turbocharger and so arranged that
material from the rupture disk will not fall into the
turbocharger. The rupture disks must not be exposed
to dynamic pressure pulses.
The inlet and outlet of the silencer shall be equipped
with rupture disks, but the rupture disk in the inlet
may be omitted if the distance from the previous disk
is less than 5 times the pipe diameter. If the silencer is
the last component in the piping before the stack, the
outlet needs not be protected with a rupture disk.
A possible exhaust gas boiler can be equipped with
integrated rupture disks, or the rupture disks can be
located in the exhaust gas duct close to the inlet and
outlet pipes of the boiler. Catalytic converters in-
stalled in the exhaust gas system, should be fitted
with rupture disks in a similar way.
Outlet ducts
The outlets of the rupture disks are to be ducted out-
doors with pipes of the same size as the rupture
disks. The length of the duct should be minimized
and not longer than six meters. The duct is to be
covered with a lightweight noise insulation material
and to be weather protected. The outlets should be
placed where no personnel are present during plant
operation. A 5 m wide and 10 m long zone continued
in the direction of the outlet duct must be marked as
a hazardous, possibly lethal zone.
Page 45
3.9 Emission control
systems
3.9.1 General
If required by local environmental regulations secon-
dary emission control equipment can be installed.
SCR is rarely used today for gas engine applications;
only in bigger plants or/ and if ambient air is de-
graded, the SCR unit is typically demanded.
Emissions of Carbon Monoxide (CO), Formaldehyde
(CH2O) and Volatile Organic Compounds (VOC) are
typically controlled using an oxidation catalyst. The
recommended secondary method for reducing the
NOX emissions of a lean burn gas engine is Selective
Catalytic Reduction (SCR).
3.9.2 Oxidation catalyst
Functional description
Using the oxidation catalyst, carbon monoxide (CO),
formaldehyde (CH2O), and volatile organic com-
pounds (VOC) are oxidized to carbon dioxide and
water according to the following simplified formulas:
CO + O2 CO2
CmHn + O2 CO2 + H2O
CmHnO + O2 CO2 + H2O
The reactions take place at the surface of the catalyst,
the function of which is to reduce the activation en-
ergy required for the oxidization reaction. No re-
agents are needed, that is, no consumables are re-
quired, and no by-products are formed.
The catalyst is optimized by choosing the correct ac-
tive material, substrate and wash coat. The active
catalyst is typically a noble metal such as platinum
(Pt), or palladium (Pd), or a combination of them.
Performance
The performance of the catalyst depends on the size
and composition of the catalyst. The performance
demand is set by the project-specific requirements.
Compound Unit Standard ULE
CO ppm-v, 15
% O2, dry
90 15
CH2O (for-
maldehyde)
ppm-v, 15
% O2, dry
14 1 5
VOC (vola-
tile organic
compo-
nents)
ppm-v, 15
% O2, dry,
as CH4
Low reduc-
tion
20 40
Depends
strongly on
natural gas
composi-
tion
Table 14. Typical emission levels achieved for gas
engines with oxidation catalyst
3.9.3 Selective catalytic reduction
(SCR)
Functional description
In the selective catalytic reduction (SCR) method,
NOx reacts with ammonia (NH3) forming water and
atmospheric nitrogen according to the following sim-
plified formula:
NOx + NH3 N2 + H2O
The reaction takes place on the surface of a catalyst in
the presence of a reducing agent, which is injected
into the flue gas before the catalyst. For the reducing
agent, aqueous ammonia, aqueous urea or urea granu-
lates can be used. When urea is used, it decomposes
to ammonia (NH3) in the flue gas.
Due to the hazardous and explosive nature of am-
monia, urea solution often is preferred.
Performance
A SCR system is often designed for 90 % NOX emis-
sion reduction, i.e. the level of less than 10 ppm, dry,
15 % O2 is reachable in stable running conditions.
Main components
The catalysts are installed in a reactor designed ac-
cording to the project requirements. The SCR catalyst
typically consists of honeycomb blocks of ceramic
material arranged in layers. If the emission control
system includes oxidation catalysts, the oxidation
catalyst elements are typically located in the SCR re-
actor, downstream of the SCR elements.
The reagent solution is sprayed into the flue gas with
a dosing unit using compressed air to achieve a
good atomization.
Page 46
A mixing duct ensures that the reducing agent is
completely vaporized and mixed with the exhaust gas.
In the first section of the duct, the reducing agent will
vaporize, and if urea is used it will decompose to
ammonia (NH3). The second section is equipped with
static mixers to ensure a homogeneous distribution of
NH3.
Figure 50. Typical SCR emission control system setup for gas engine applications
Consumables
The consumption of the reducing agent
depends on the NOX emission level from
the engine and the target level. Operating
conditions and the choice of catalyst mate-
rial may also influence the consumption of
the reducing agent. When using SCR, it is
generally more economic to tune the engine
for optimal heat rate instead of low NOX
emission.
An indicative value for reducing agent con-
sumption for one 20V34SG engine is 15 -
25 kg/ h (25 % ammonia water or 40 % urea
water). The ammonia or urea must be of at
least technical grade.
Typically, the useful lifetime of the SCR
catalyst elements is several years. The possi-
bility to replace individual catalyst layers
enables the development of an optimal cata-
lyst exchange strategy.
Storage of reducing agents
For gas engine applications ammonia or
urea is typically brought to site as a ready
made water solution. The tank material for
urea solutions is often stainless steel tanks
while black steel tanks (DIN ST37-2 or
better) can be used for aqueous ammonia
solutions. If there is a risk for freezing or
precipitation of urea solution (depends on
the concentration and the temperature), the
tanks must be insulated and either heated or
equipped with a circulation system. Atten-
tion must be paid to the safety issues related
to the handling of ammonia.
Page 47
The storage space is typically sized for two
weeks consumption. In addition, the size of
one truck load must be taken into account.
Control and instrumentation
There may be one control unit per engine,
or a unit can control the emissions from
several engines. The local control panels can
be located e.g. in the engine hall or in the
control room. The control unit calculates
the set point to the reducing agent dosing
unit based on the engine load and the NOX
measurements, if analyzer(s) are provided in
the system.
3.9.4 I ntegration in exhaust
gas system
Placement
The SCR and the oxidation catalyst should
be located before a possible heat recovery
system and before any exhaust gas silencer
containing wool. The oxidation catalyst
must not be placed between the reducing
agent injection point and the SCR reactor.
Space requirements
The required space depends on the emission
reduction requirements and the design of
the emission control system. The compact
oxidation catalysts for low emission reduc-
tion demands can be integrated in the ex-
haust gas duct with negligible impact on the
plant layout while the big combined SCR
oxidation catalyst reactors might have a
length up to 6 meters or even more.
Special attention should be put on having
sufficient space for the mixing duct in case a
SCR system is required. In systems where
the oxidation catalyst is integrated into the
SCR, the catalyst elements are placed as an
additional layer in the reactor.
Temperatures and pressures
The SCR and oxidation catalyst have a tem-
perature window for optimal operation. The
normal operating temperature of the 34SG
engine fits well with the typical operating
windows. The efficiency of the oxidation
catalyst increases with higher exhaust gas
temperature.
The design pressure for the catalysts is
minimum 0.1 bar(g), but they shall be capa-
ble of tolerating 0.5 bar(g) peak pressure.
Typically, the emission control system cre-
ates a back pressure of maximum 2000 to
3000 Pa.
3.9.5 Emission testing
Emission tests and measurements are an
integral part of the performance testing and
the environmental management of the
power plant. Emission tests for commis-
sioning and reporting purposes are typically
performed by impartial emission testing
consultants. The source testing should be
performed using methods that are proven
for gas engine applications. The common
parameters for the emission tests of gas
fired units are NOX, CO and O2. In some
cases hydrocarbons are to be tested accord-
ing to the national requirements.
Sampling ports and access to the sampling
location must be part of the of the exhaust
gas system design.
If specifically required by authorities, a con-
tinuous emission monitoring system
(CEMS) can be installed. For gas engine
plants, the monitored parameters are typi-
cally NOX, CO and O2. Other components
are either not present in relevant concentra-
tions in the exhaust gas, or they cannot be
monitored due to the lack of proven moni-
toring methods.
Page 48
Typical legislative requirements
In Table 15 typical requirements (status
January 2008) are depicted as examples for
gas fired engines in different countries and
by International Finance Corporation (IFC,
a part of the World Bank Group). The IFC
Guidelines are more and more commonly
applied for power generation projects, in
which international financing or export
credits is given.
Note that the limits below are given on the
federal level. Local requirements, ambient
air quality or other project-specific issues
might call for more stringent requirements.
Note also that the values are converted to
the same units and reference oxygen condi-
tions for comparison purposes.
No secondary control No secondary control Oxidation catalyst Oxidation catalyst Oxidation catalyst Wrtsi l sol uti on
-
14
-
-
169
Japan, 1991
a) Efficiency corr ecti on based on the r efer ence effi ciency of 30 % Li mi t = effi ci ency % / 30 x 1050
b) Efficiency corr ect i on based on the refer ence effi ci ency of 37 % (no cogenerat ion) or 63 % (wi th
cogenerati on) Li mi t = effi ci ency % / reference ef fi ciency % x base l i mi t
c) Normal i zed to 0 C and 101.3 kPa
d) International Fi nance Insti tute, General EHS Gui del ines, pl ants 3 50 MWt h
Notes
- 8
(b
- - SO
2
emissions, ppm
- 49
(b
- - PM emi ssions, mg/ m
3 ( c
- - 1050 as THC (as C
1
)
(a
17 for formaldehyde HC emi ssions, ppm
- 195
(b
150 90 CO emissi ons, ppm
97 91
(b
100 91 NO
X
emi ssi ons, ppm
IFC, 2007
(d
Turkey, 2004 Denmark, 1998 Germany,
TA-Luft 2002
No secondary control No secondary control Oxidation catalyst Oxidation catalyst Oxidation catalyst Wrtsi l sol uti on
-
14
-
-
169
Japan, 1991
a) Efficiency corr ecti on based on the r efer ence effi ciency of 30 % Li mi t = effi ci ency % / 30 x 1050
b) Efficiency corr ect i on based on the refer ence effi ci ency of 37 % (no cogenerat ion) or 63 % (wi th
cogenerati on) Li mi t = effi ci ency % / reference ef fi ciency % x base l i mi t
c) Normal i zed to 0 C and 101.3 kPa
d) International Fi nance Insti tute, General EHS Gui del ines, pl ants 3 50 MWt h
Notes
- 8
(b
- - SO
2
emissions, ppm
- 49
(b
- - PM emi ssions, mg/ m
3 ( c
- - 1050 as THC (as C
1
)
(a
17 for formaldehyde HC emi ssions, ppm
- 195
(b
150 90 CO emissi ons, ppm
97 91
(b
100 91 NO
X
emi ssi ons, ppm
IFC, 2007
(d
Turkey, 2004 Denmark, 1998 Germany,
TA-Luft 2002
Table 15 Emission limits for spark-ignited lean-burn gas engines (dry @ 15 % O2)
Wrtsil 34SG Power Pl ant Product Guide 4. HEAT RECOVERY SYSTEM
Page 49
4. HEAT RECOVERY SYSTEM
4.1 General
Heat recovery systems utilize the heat generated by
the engine which would otherwise be wasted. Heat
can be recovered from the exhaust gases and from
the engine cooling system (charge air, lubricating oil,
and jacket cooling). The following table gives a rough
indication of the temperatures of the engine circuits
and the available energy amounts.
Energy source Temperature
(approx.)
Portion of
fuel energy
(approx.)
Exhaust gas ~400 C 32 -33 %
J acket water ~85 C 5.8 %
HT charge air ~90 C 9.0 %
Lubricating oil ~60 C 4.7 %
LT charge air ~40 C 1.8 %
Generator cooling ~35 C 1.4 %
Table 16. Different energy sources
The heat is normally used to produce hot water,
steam or thermal oil. The amount of recovered heat
depends on the ambient temperature and the tem-
perature of the heated media. The following table
shows typical values for steam and hot water when
utilizing heat from exhaust gases, lubricating oil and
cooling water 20V34SG engine.
Heated media Generator
power
Recoverable
heat
Plant
effi-
ciency
Steam 8 bar(a) 8730 kW 3000 kW 59 %
Hot water 75
105 C
8730 kW 6400 kW 76 %
Hot water 45 -
75 C
8730 kW 7800 kW 83 %
Hot water 45 -
75 C
(no heat recov-
ery from ex-
haust gases)
8730 kW 3700 kW 63 %
Table 17. Typical values for different types of heat
carrying media. Except for the last row
the values apply when heat is recovered
from both exhaust gases and cooling
water.
4.2 Heat recovery from ex-
haust gases
A typical exhaust gas heat recovery system for steam
production consists of an exhaust gas boiler, a steam
drum, one or more pumps and one or more water
tanks. On the consumption side, there is a steam
header and one or more heat exchangers.
The exhaust gas steam boiler contains evaporator
pipes, where the feed water is heated to its saturation
point. The mixture of saturated water and steam is
lead to the steam drum, where steam is separated
from water. The steam drum is typically integrated in
the boiler. The boilers should be equipped with a by-
pass line to avoid boiler overheating on the water
side.
The steam can be further heated in a super-heater, or
conducted to the consumers. The condensate from
the consumers is circulated back to the boiler via a
condensate water tank.
The feed water tank, the feed water pumps, and the
condensate return tank are usually common for the
whole plant. The steam boilers are engine specific.
Figure 51. A simplified example of steam produc-
tion in an exhaust gas boiler
In order to intensify the heat transfer and improve
the efficiency, the boiler can be equipped with an
economiser for pre-heating the water.
Page 50
If the steam drum is located higher than the boiler,
no circulation pump is needed (natural circulation
boiler). Otherwise, there must be a circulation pump
(forced circulation boiler).
To avoid corrosion in the pipes, steam systems must
be equipped with deaeration, and the feed water tem-
perature should be at least 105
o
C.
In district heating and warm water applications, there
is only a hot water boiler with a by-pass line and a
main water pump. Alternatively, water can be heated
in a condenser.
The design pressure on the exhaust gas side is mini-
mum 0.1 bar(g), but the system must be capable of
tolerating a peak pressure of 0.5 bar(g).
4.2.2 Heat recovery boiler
Heat recovery boilers are heat exchangers, where the
exhaust gas transfers some of its thermal energy to
the heat transfer media, most commonly water. Typi-
cally full capacity boilers are used to maximize the
heat recovery from the exhaust gases.
The boilers can be divided into two groups:
- Smoke tube boilers, where the exhaust gas flows
through pipes surrounded by water
- Water tube boilers, where the exhaust gas flows
through finned pipes in which water circulates.
The choice of boiler type depends on many factors,
e.g. the heat recovery application that is being used.
The energy recovered depends directly on the
amount of exhaust gas and the temperature drop
across the boiler. In steam production, the tempera-
ture is limited by the steam saturation temperature.
The pinch point (minimum temperature difference
between heating and heated media) is the difference
between the saturation temperature and the exhaust
gas temperature at the outlet of the evaporation sec-
tion.
4.2.3 Arrangements to decrease
boiler fouling
A common phenomenon with exhaust gas boilers is
boiler fouling. It is caused by soot, unburned hydro-
carbons, lubrication oil residues, etc. which comes
with the exhaust gases and forms layers on the heat
exchanger surfaces. This results in reduced and in-
efficient heat transfer. The fouling rate depends on
the temperature. The most critical area is on heat
transfer surfaces, where the water side temperature is
50 - 80C.
Methods to decrease the fouling rate and keep the
boiler clean involve:
- Avoiding water temperatures between 50 and 80
C
- Using soot blowing equipment (for instance, wa-
ter spray, pressurized air or steam blowers)
- Using Oxi-Catalyst (HC)
Off-line cleaning is needed periodically, typically two
to four times a year.
4.2.4 Safety arrangements
The heat recovery boiler should be protected with
rupture disks installed in the exhaust gas duct before
and after the boiler. In some cases, there might be
additional explosion vents in the boiler casing.
The heat recovery boiler should be designed accord-
ing to applicable rules and regulations.
4.3 Heat recovery from
cooling water and lube
oil
4.3.1 General
Heat for hot water production can be recovered from
the HT cooling water and from the lube oil.
Page 51
For hot water applications with heat recovery from
both lube oil and HT water, a pre-designed, pre-
tested, and skid mounted heat recovery module is
available, the CHP module (CHP = combined heat
and power). The CHP module is designed for 16 bar
hot water heating systems. It is used along with the
EAM module designed for CHP applications.
When heat recovery systems are used for cooling the
HT water, there could be a back-up HT cooler for
cooling the engine in cases when it is impossible to
lead the heat into the heat recovery system. A back-
up HT cooler can be included in the CHP module.
4.3.2 Standard modules for hot wa-
ter production
The EAM and CHP modules (Figure 53) for hot wa-
ter production contain the following equipment:
- Two heat exchangers for heat recovery from HT
water and lube oil.
- An optional HT back-up cooler cooled with LT
cooling water from the engine.
- Two parallel hot water circulating pumps with
frequency converter control, one working, one
stand-by for internal circulation
- Six 3-way temperature control valves (four in
EAM, two in CHP)
- Flow meter (optional)
Figure 52. Typical arrangement of combined lube oil, cooling water and exhaust gas heat recovery using the
CHP module
Page 52
Figure 53. EAM and CHP modules for hot water applications
Wrtsil 34SG Power Pl ant Product Guide 5. PIPING SYSTEMS
Page 53
5. PI PI NG SYSTEMS
5.1 Design principles
5.1.1 General principles
The following general principles should be consid-
ered in the piping system design:
- The pipes must be designed for the maximum and
minimum pressures and temperatures they will
experience during operation or upset conditions.
- The risk for pump cavitation the formation of
bubbles at the suction side of the pump, which
reduces pump efficiency and harms the pump
must be minimized. The suction pipes to pumps
should be as short as possible and have suffi-
ciently large diameters.
- The pipes must be fitted without tension. Flexible
pipe connections must be used between pipes and
units where vibrations or thermal expansion may
occur.
- Each pipe must have sufficient pipe supports.
Weak supports may cause operational problems or
damages.
- All pipes must have provisions for drainage and
venting.
- Pockets should be avoided, or, if they cannot be
avoided, be equipped with drain plugs or air vents.
- Drain pipes must be continuously sloping, and
vent pipes continuously rising.
- All pipe work must follow local rules and regula-
tions.
5.1.2 Pressure and temperature rat-
ings
Design pressures
For estimating the design pressure, the following rule
of thumb can be used:
design pressure = 1.1x max. working pressure
The maximum working pressure in a circuit is equal
to the setting of the safety valves in the system.
Nominal pressures
The nominal pressure of a pipe should be equal to or
higher than the design pressure of the pipe.
According to European standards, the pressure rat-
ings of piping systems are given as PN numbers
(Pressure Nominale), for instance, PN6, PN10,
PN16, where the number indicates the nominal pres-
sure in bar up to a given maximum temperature.
The nominal pressures of the pipe connections on
the engine and the standard modules are found in the
section below. The nominal pressure of a connection
may be higher than the nominal pressure required for
the pipe.
Test pressures
Typical test pressure according to the applicable EN
standards is 1.43 times the design pressure The test
pressure to be used at actual operating conditions
must always be checked with the respective stan-
dards.
5.1.3 Pipe materials
For guidance, Table 19 lists the pipe material nor-
mally used in different systems in Wrtsil designed
plants.
Page 54
Nominal pressure System Max work-
i ng pres-
sure (g)
Design
pressure
(g)
Test
pressure
(g)
1)
Max work-
ing temp.
Design
temp.
DIN/EN
Fuel gas system
before gas regulat-
ing unit
6/16 bar 8/20 bar
Case by
case
Ambient 50C
PN16
Fuel gas system
after gas regulat-
ing unit
4 bar 6 bar 10 bar Ambient 50C
PN16
Starti ng ai r system
30 bar 33 bar 48 bar 75C 75C
PN40
Instrument air sys-
tem
PN16
Lube oil system
6 bar 10 bar 12 bar 90 C 120C
PN16
Sludge and oily
water systems
6 bar 8 bar 12 bar 90 C 120C
PN16
Cool i ng water sys-
tem (LT and HT)
5 bar 5.5 bar 8 bar 98C 120C
PN16
Intake air system
0 1 bar No Ambient 75C
PN2,5
Exhaust gas sys-
tem
0.07 bar 0.5 bar No 450C 480C PN2,5
Water supply sys-
tem
PN16
Fire water system
9 bar 10 bar 15 bar Ambient -
PN16
Emi ssi on treat-
ment systems
0.07 bar 0.5 bar No 450C 480C
PN2,5
Table 18. Pressures and temperatures which can be used as guidelines in the piping system design
1)
= Typical test pressure according to EN 13840-5 1
System Fl ow medi a Pipi ng material
Fuel gas system Natural gas or similar AISI 304L
Lube oil system Lubricating oil St 37.0 (St 35.8)
Cool i ng water system Cooling water St 37.0 (St 35.8)
Water suppl y system Fresh water
Treated water
St 37.0 (St 35.8), St 37.0 Zn, Cu
AISI 304L
Starti ng ai r system Compressed air St 37.0
Heat recovery system Steam
Fresh water
Treated water
St 35.8
Distri ct heating system Fresh water St 37.0
Exhaust gas system Exhaust gas St 37.0/ Corten
Charge air system Air St 37.0
Table 19. Standard pipe material used by Wrtsil
Page 55
5.1.4 Pipe dimensions
General
The pipes used in the Wrtsil designed engines,
standard modules and standard units follow applica-
ble parts of the DIN/ EN standards. To ensure com-
patibility, the Wrtsil engines, standard modules and
units are delivered with companion flanges, which
can be welded to the mating pipes during installation.
The nominal pipe diameter is given as DN (Diametre
Nominale). The nominal values do not generally co-
incide with the actual pipe diameters in mm. See the
conversion table in appendix B.
Pipe diameters
When sizing pipes, the required flow, the velocity,
and the length of the pipe must be considered. The
higher the velocity in a pipe, the higher is the pres-
sure drop per unit length.
Wall thickness
When deciding the wall thickness, the pipe material,
the type of media in the pipe, the pressure and tem-
perature of the transported media, and the outside
temperature must be considered.
5.1.5 Flexible pipes and
pipe supports
Flexible pipe connections
To compensate for movements due to thermal ex-
pansion, and to prevent the engine vibrations from
being transferred to the pipe system, pipes must be
connected with the engine by means of flexible bel-
lows rubber or steel bellows or hoses.
Figure 54. Flexible bellow
Bellows and hoses may also be required at other loca-
tions.
Pipe supports
The recommended distances between pipe supports
depend on the size of the pipe, and the weight of the
substance, liquid or gas, transported in the pipe.
Figure 55. Pipe supports
If the temperature of the pipes may vary, the support
must allow for thermal movement. If needed, heat
expansion must be enabled with bends, bellows,
flexible hoses, or loops.
Figure 56. Pipe loop for enabling heat expansion
5.1.6 Trace heating
To avoid freezing and ensure pumpability in cold
climates, the following pipes may need to be
equipped with trace heating:
- Oily water pipes
- Urea solution pipes (if urea solution is used)
- Lubricating oil pipes.
Most commonly, electrical heating is used, but also
steam, thermal oil or hot water can be used provided
that it is continuously available.
The trace heating system is sized based on the esti-
mated heat losses in the pipes. To minimize heat
losses, trace heated pipes should be insulated. The
heating must be so arranged that it can be shut off.
Electrical trace heating cables can be of self-
regulating type or thermostat regulated.
Page 56
Figure 57. Trace heated and insulated pipe
5.1.7 I nsulation
Generally, the following pipes should be insulated:
- All trace heated pipes
- All pipes included in heat recovery system
- The indoor portions of the exhaust gas pipes (and
outdoors up to SCR if SCR used).
In addition, the risks of fire and personnel injury due
to hot surfaces must be considered. All pipes with a
surface temperature over 60
C should be insulated if
they are in the reach of the operating personnel.
Suitable insulation material is mineral wool. To pro-
tect the insulation, it should be covered with alumin-
ium sheets. The sheets should be at least 1 mm thick.
5.1.8 Pipe instrumentation
Thermometers should be installed wherever needed,
for instance, before and after heat exchangers. By
using thermo wells (metal housings), replacement of
defect thermometers is possible without draining the
system.
Pressure gauges can, for instance, be installed on the
suction and/ or discharge sides of pumps.
Local indication is sufficient if the instrument is ac-
cessible for reading and no central supervision is
needed.
System specific notes
5.1.9 Fuel gas pipes
General
The fuel gas system includes the following pipes:
- The common gas supply pipe from the gas grid to
the gas manifold
- The engine specific gas lines from the gas mani-
fold to the gas regulating units
- The pipes from the gas regulating units to the en-
gines
- Vent pipes, at least two pipes from each gas regu-
lating unit and one from each engine.
Design notes
In fuel gas pipes, the amount of welded joints should
be minimized. Bent pipes and tee connections should
be used when possible. Flanged connections should
be avoided.
Fuel gas supply pipes
The main fuel gas supply pipe should be sized for a
gas velocity of about 20 m/ s. The required pipe size
depends on the pressure and flow requirements.
The gas flow in the engine-specific supply pipes de-
pends on the engine output, the LHV (lower heating
value) of the gas and the heat rate of the engine.
Table 20 shows data for determining the pipe size in
relation to gas flow and pressure.
Gas vent pipes
For safety reasons, and to prevent any back pressure
release, the gas vent pipes must be individually routed
out into open air. The pipes must be of the same size
as the vent pipe connections. The outlets must be
protected from becoming blocked.
Page 57
Pi pe si ze DN80 DN100 DN125 DN150 DN200 DN250 DN300
Pressure Fl ow rate
Bar(g) Nm
3
/h Nm
3
/h Nm
3
/h Nm
3
/h Nm
3
/h Nm
3
/h Nm
3
/h
3.5 1600 2690 4060 5940 9980 15870 22450
4.0 1770 2990 4510 6600 11090 17640 24940
4.5 1950 3290 4970 7260 12200 19400 27440
5.0 2130 3580 5420 7920 13310 21160 29930
5.5 2310 3880 5870 8580 14420 22920 32420
6.0 2480 4180 6320 9240 15530 24690 34920
6.5 2660 4480 6770 9900 16640 26450 37410
7.0 2840 4780 7220 10560 17740 28210 39910
7.5 3010 5080 7670 11220 18850 29980 42400
8.0 3190 5370 8120 11880 19960 31740 44890
8.5 3370 5670 8570 12540 21070 33500 47390
9.0 3540 5970 9020 13200 22180 35270 49880
9.5 3720 6270 9480 13860 23290 37030 52380
10.0 3900 6570 9930 14520 24400 38790 54870
10.5 4080 6860 10380 15180 25510 40560 57360
11.0 4250 7160 10830 15840 26610 42320 59860
11.5 4430 7460 11280 16500 27720 44080 62350
12.0 4610 7760 11730 17160 28830 45840 64840
12.5 4780 8060 12180 17820 29940 47610 67340
13.0 4960 8360 12630 18480 31050 49370 69830
13.5 5140 8650 13080 19140 32160 51130 72330
14.0 5310 8950 13530 19800 33270 52900 74820
14.5 5490 9250 13990 20460 34380 54660 77310
15.0 5670 9550 14440 21120 35480 56420 79810
15.5 5840 9850 14890 21780 36590 58190 82300
16.0 6020 10150 15340 22440 37700 59950 84800
Table 20. Pipe sizes for gas at varying gas flows and pressures. Maximum velocity: 20 m/ s.
5.1.10 Lube oil pipes
The piping must be built so that it can be dismantled
in suitable parts to make cleaning and pickling possi-
ble. Flanged connections and tee connections should
be used. All branches should be equipped with flange
connections.
To keep the pressure drop in the pipes within accept-
able limits, the following velocities are recommended:
Suction Deli very Pipe dimen-
si on, DN
m/s m/s
25 0.3-0.5 0.7-0.9
32 0.4-0.6 0.8-1.0
40 0.5-0.7 1.0-1.2
50 0.6-0.8 1.2-1.4
65 0.6-0.8 1.3-1.5
80 0.7-0.9 1.4-1.6
100 0.8-1.0 1.5-1.7
125 0.8-1.0 1.5-1.7
150 0.8-1.0 1.5-1.7
200 0.8-1.0 1.5-1.7
250 0.9-1.0 1.5-1.7
300 1.0-1.1 1.5-1.7
Table 21. Recommended velocities in lube oil
pipes
Page 58
For determining pipe diameter, the following diagram
can be used:
Figure 58. Diagram for determining lube oil pipe
dimensions
5.1.11 Compressed air pipes
Compressed air pipes include:
- Starting air pipes
- Instrument air pipes
To prevent possible water condensate from entering
the engines or collecting onto pockets, the com-
pressed air pipes should have a continuous slope of
min. 1/ 100 to manual or automatic drain outlets lo-
cated at the lowest points. Swan necks (see Figure 59)
must be used on all branches to the distribution
pipes.
Figure 59. Compressed air pipes
If the instrument air system contains an air dryer, no
condensate will normally form in the piping system.
However, for the event of the air dryer being out of
order, the same arrangements with sloping pipes and
swan necks should be employed in the instrument air
system.
If flexible hoses are used in the compressed air sys-
tem, there must be a closing valve in front of each
hose to allow shutting off the air flow.
5.1.12 Cooling water pipes
The following table shows recommended velocities,
and the figure shows the flow for different pipe sizes.
HT and LT circuits Raw water Pi pe di-
mension,
DN
m/s m/s
25 1.5-1.7
32 1.7-1.9
40 1.9-2.1
50 2.1-2.3
65 2.3-2.5
80 2.5-2.7
100 2.7-2.9 2.2-2.4
125 2.9-3.1 2.3-2.5
150 3.0-3.2 2.5-2.7
200 3.0-3.2 2.7-2.9
250 3.1-3.3 2.9-3.0
300 3.2-3.4 3.0-3.1
Table 22. Recommended velocities in cooling wa-
ter pipes
Page 59
Figure 60. Water flow/ velocity diagram
The cooling water vent pipes from the engine and the
expansion pipes from the engine auxiliary module
must be run separately to the expansion vessel(s) and
be continuously rising with a slope of min. 1/ 100.
Welded connections should be used, but flanged
connections can also be used if the installation, main-
tenance, cleaning or pipe material so demand.
5.1.13 I ntake air ducts
Each engine must have its own intake air ducting.
The permissible pressure drop in the entire intake air
system, including the intake air filter and the silencers,
is max 2000 Pa. The maximum permissible total pres-
sure drop in the intake air and the exhaust gas sys-
tems together is 7000 Pa.
Design velocities: 20 -30 m/ s.
The intake air ducts should be as short and straight as
possible. Any bends shall be made with the largest
possible bending ratio R/ D, or at least 1.5.
Figure 61. Bending ratio
Flanged connections should be used.
When using the exhaust gas module, the steel support
for the intake air ducts is the same as for the exhaust
gas system. The intake air ducts in the exhaust gas
module are connected to the turbochargers with
flexible connection pieces.
5.1.14 Exhaust gas ducts
General
To prevent exhaust gases from entering an engine
that is out of service, each engine must have its own
exhaust gas duct system all the way from the engine
into open air via the stack. In the exhaust gas module,
the branch pipes from the two turbochargers of the
engine are joined to a common exhaust gas pipe.
Any bends shall be made with the largest possible
bending ratio R/ D, or at least 1.5.
The design velocity in the common pipe is 20 30
m/ s.
Maximum back pressure
The entire exhaust gas line must be designed as short
and straight as possible to minimize flow restrictions.
The limit of the total pressure drop for the exhaust
gas system, the maximum back pressure, is 5000 Pa.
The maximum permissible total pressure drop in the
intake air and the exhaust gas systems together is
7000 Pa.
Bellows and pipe supports
Besides the engine being connected to the branch
pipes with flexible bellows, bellows may also be
needed before and after the silencer.
Page 60
The pipes have to be properly supported with fixed
supports and sliding supports that allow the duct to
move in axial direction. The exhaust gas module in-
cludes one fixed and one sliding support. Other sup-
port locations must be determined case by case.
Figure 62. Examples of fixed and sliding supports
for exhaust gas ducts
I nsulation
The indoor exhaust pipes must be insulated all the
way from the turbocharger, and the insulation must
be protected by metal cladding or similar. At the part
closest to the turbocharger, the insulation and clad-
ding should be made as a removable piece to facilitate
maintenance.
There must be no risk for the insulation material
being drawn into the turbocharger during opera-
tion.
If the plant contains SCR, also the outdoor pipes up
to the SCR should be insulated.
Water drainage
To prevent water from entering the engine, the ex-
haust gas pipes shall be provided with water drains at
the lowest points. Normally, the system is drained
from the silencers.
Exhaust gas stack
Each engine must have its own exhaust gas stack, but
in installations with two or more engines, several ex-
haust gas ducts may be conducted to a common
multi-pass chimney or cluster chimney, which gener-
ally gives better lift of the emissions.
The stack should be sized for a velocity of about 20 -
30 m/ s at the end. Higher exhaust gas velocity may
cause noise emissions.
In case the inner surface temperature of the stack is
below 50
o
C, there is a risk for condensation in the
pipes. Insulation may therefore be needed in plants
where heat is recovered from the exhaust gases.
5.1.15 Miscellaneous
Crankcase vent pipes
The crankcase vent pipe from the engine is con-
ducted to the oil mist separator. The pipe must be
connected to the engine with a flexible connection.
The crankcase gases from the oil mist separator must
be led out to open air. The outlet should be equipped
with a condensate trap (oil trap) so arranged that any
residual oil flows back to the oil mist separator.
Wrtsil 34SG Power Pl ant Product Guide 6. ELECTRICAL SYSTEM
Page 61
6. ELECTRI CAL SYSTEM
6.1 General
6.1.1 System overview
Below is an overview of the electrical system in a
typical Wrtsil 34SG power plant.
The main components are:
- The engine driven medium voltage generators
- The medium voltage switchgear for connecting
the generators and the outgoing feeders
- Possibly one or more step-up transformers in the
switchyard for raising the generated voltage
- A station transformer (step-down transformer) for
the internal power consumption
- Low voltage power distribution system compris-
ing the main LV switchgear, motor control cen-
tres (MCC), distribution boards and panels (in this
guide all called LV switchgear)
- DC power supply system
- Grounding system
- Cables.
Figure 63. Typical electrical system overview
Page 62
Each engine generator set delivers power through a
circuit breaker in the medium voltage switchgear,
which distributes the generated power to a national
grid, a local grid, and/ or directly to local consumers
(factory or utility), possibly via a step-up transformer.
The station transformer lowers the generated me-
dium voltage power to the voltage level used in the
power plant. The low voltage switchgear distributes
electricity to the plant power consumers. There may
be separate MCC (motor control centre) cabinets or
the motor control may be included in the plant LV
switchgear and in local control cabinets.
Figure 64. Principle diagram of a medium voltage
power plant
6.1.2 Basic system design
The design of the electrical system depends on size of
the system, the number of connected generators and
number of transformers.
It may be built up as shown in Figure 64. The me-
dium voltage generators are connected to medium
voltage switchgear. In a big plant with many genera-
tors it may be necessary to divide the generators in
several groups and connect each group to electrically
isolated bus bars in the switchgear. The system set up
is dependant on the specific circumstances at the
plant and is a design issue to be agreed between seller
and plant owner, taking into account the load flow,
full load current and level of fault current. The
power is evacuated trough one or several feeders ei-
ther on the same voltage level or the voltage is raised
to a higher level by means of one or several trans-
formers.
The main low voltage 400V switchgear is fed trough
one or several station service transformers. The
switchgears may be divided in several bus bars de-
pending on size and logical structure of the system.
The latest electrical IEC standards are followed.
Selection of main components and sizing of different
current currying part like bus bars and cables are
based on ambient conditions and system calculations.
6.1.3 Protection relays
The protection relays used are selected to give a full
coverage and include all necessary features in the me-
dium voltage distribution protection systems. Addi-
tionally the relays may include a number of other in-
novative and unique features, such as comprehensive
and versatile setting and programming possibilities,
programmable blocking and output matrix, distur-
bance recorder, evaluation software and continuous
self-supervision.
Several communication protocols are available in the
relays. Maximum demand measurement quantities
and disturbance recorder are available for load profil-
ing and fault evaluation.
Thanks to optional integrated transducers, any meas-
ured and calculated values can freely be connected to
the mA outputs.
The numerical generator protection relay includes all
the essential functions needed for protection of small
or medium-sized power generators in modern fully
automatic power plants. Further the relay includes
several programmable protection functions, trip cir-
cuit supervision, circuit breaker protection and com-
munication protocols for various protection and
communication situations.
Page 63
6.1.4 Protection classes of electrical
equipment
Enclosure protection class
The electrical equipment used in dry, indoor condi-
tions should be of class IP20 or IP2X according to
the Ingress protection codes defined in the IEC 529
standard. The minimum requirement for equipment
installed outdoors is IP23, but normally equipment
intended for outdoor installations should be of class
IP34 or IP54.
Table 23 shows typical applications for various IP
codes
IEC
cl assi fi cati o
n
Name Typical applicati on
IP20 Ordinary Indoors, dry ambient
IP22 Drip proof Humid ambient
IP23 Rain proof Outdoors
IP34 Splash proof Wet or humid ambient
IP54 Dust proof Dusty ambient
IP55 J et proof Wet ambient
IP67 Water tight Dusty ambient
IP68 - Under water
Table 23. Typical ingress protection applications
Hazardous area classification
The electrical equipment in a hazardous area must be
designed for the classification of the area.
Minimum seismic design
The equipment is designed in order to resist the ef-
fects of seismic ground motions acc. to UBC 97
6.1.5 I nternal power consumption
The following table lists the main power consumers
along with rough estimations of the power consump-
tion in a plant with seven 20V34SG engines. The val-
ues used in the table are maximum values based on
the nominal power of the motors. In practice, how-
ever, the motors will never be running at 100% si-
multaneously.
Note! The power consumption depends
largely on the plant configuration and the ambi-
ent conditions. The values in the table must not
be used as design data.
Consumer Power Type of use
Engine-specific consumers
Engine auxiliary module 7 x 90 kW Stand-by engine
(mainly pre-heating and pre-lubrication)
Radiator fans 7 x 100 kW Continuous
Ventilation 7 x 20 kW Continuous
Common auxil iary systems
Starting air compressor 50 kW Intermittent
Instrument air compressor 20 kW Intermittent
Maintenance water pump 2 kW Intermittent
Lubricating oil transfer pump 2 kW Intermittent
Trace heating, heating of tanks 30 kW Seasonal
Common electri cal systems
Heaters, battery chargers, etc. 20 kW Intermittent
Common civil systems
Ventilation (switchgear rooms, control room,
workshop, etc)
200 kW Continuous
Lighting 50 kW Continuous
Miscellaneous (cranes, workshop, etc.) 150 kW Intermittent
Table 24. Main power consumers and estimated consumption in a plant with seven 20V34SG engines
Page 64
6.2 Generator system
6.2.1 Measurement and protection
The generator is equipped with measuring transform-
ers for differential protection and generator protec-
tion. The differential protection relay and generator
protection relay are located in the generator set con-
trol cabinet.
6.2.2 Neutral grounding
Neutral grounding cubicles, one per generator, are
used for grounding the generator neutral points. The
neutral points are normally high resistance grounded.
The neutral grounding cubicles delivered by Wrtsil
are equipped with current measuring transformers for
earth fault protection and differential earth fault pro-
tection. Earth fault current is typically limited to 5A.
An earthing transformer serving several generators
can also be employed.
6.3 Medium voltage switch-
gear
6.3.1 General
The medium voltage switchgear consists of a row
cubicles installed side by side with a common main
busbar running horizontally along the row.
Figure 65. Medium voltage switchgear
The main busbar runs through the main busbar com-
partments of the cubicles.
Figure 66. Cross section of a medium voltage
switchgear cubicle (example)
The medium voltage main circuit and equipment in a
cubicle is supported by a secondary circuit housed in
a low voltage compartment. The secondary apparatus
comprise control equipment, meters, switches, actua-
tors, protection equipment, and terminal blocks for
remote connections.
Generally, the medium voltage switchgear has the
following cubicles:
- Incoming feeders from the generators (one per
generator set)
- Outgoing feeders to power transmission systems
(possibly via a step-up transformer) or local con-
sumers
- Outgoing feeder to the low voltage station service
system (station transformer)
- Possibly a busbar measurement transformer.
(Busbar measurement may also be included in a
station transformer feeder cubicle.)
- Possibly one or more bus tie cubicles if the busbar
is composed of two or more sections.
6.3.2 General design principles
Basic requirements
The medium voltage switchgear and all components
are designed, manufactured, assembled and tested in
accordance with the latest applicable IEC standards.
Page 65
The required withstand capability and interrupting
ratings of the busbars, circuit breakers and other
equipment shall be based on the system studies.
All cubicles must be equipped with earthing switches.
Circuit breakers
The circuit breakers are of three pole truck type (that
can be withdrawn) to support interchange and main-
tenance of the breakers. For economical and practical
reasons, circuit breakers of equal rating should be
interchangeable.
Enclosure
The medium voltage switchgear is designed to be
located indoors. It is typically metal-enclosed and air-
insulated. Typically, control and auxiliary power ca-
bles are connected from the top and power cables
from the bottom.
Power supply
Generally, 110 VDC is required for breaker control
motors, protection relays, etc. Low voltage power
needed for lighting and heating (230 VAC) can be
taken from the low voltage power system.
Heating and cooling
To prevent condensation, anti-condensation heaters
controlled by thermostats are installed to ensure that
the inner parts of the cubicles are kept above the am-
bient temperature.
The switchgears should be placed in rooms with air
conditioning. Forced air cooling within the switch-
gear is normally not needed.
6.3.3 Medium voltage busbars
The main busbars are located in a separate compart-
ment isolated from the other compartments by metal
walls. The compartment contains copper or alumi-
num busbars, which are supported by cast resin insu-
lators to withstand dynamic forces caused by short
circuit currents. Busbars are rated for nominal- and
short circuit currents.
6.3.4 I ncoming feeder cubicles
Generator circuit breaker
Wrtsil recommends using SF6 circuit breakers (cir-
cuit breakers isolated with SF6 gas). If vacuum circuit
breakers are used, the generators should be equipped
with surge arresters and surge capacitors.
The generator circuit breakers are operated by a
stored energy spring, charged by an electrical motor.
For emergency cases, there must also be a manual
handle to manually charge the spring
Other main circuit apparatus
The generator feeder cubicles contain current and
voltage measuring transformers for the protection
functions and the power monitoring unit. Besides for
protection, the voltage measurements are also used
for synchronization.
Secondary apparatus
The breakers have coils for breaker remote controls,
generator breakers are also provided with an under
voltage coil which will trip the breaker if the control
voltage is lost, at a breaker trip an alarm signal is to
be sent to the plant control system.
The breakers have position indicators for remote su-
pervision. They also have interlocks that prevent mal
operation of the breaker
The generator circuit breaker protection relay, differ-
ential protection relay, and power monitoring unit are
included in the generator set control cabinet.
6.3.5 Main outgoing feeder cubicles
The grid feeder circuit breaker is of the same type as
the generator breakers. Loss of control voltage
should generate an alarm signal. SF6 type breakers are
recommended.
The grid feeder cubicle is be equipped with current
and voltage measuring transformers, Minimum pro-
tection requirements for the grid feeder circuit are:
Protection Symbol ANSI No.
Over current (I >)(I>>) 50
Earth fault (Io >) 50N
Table 25. Minimum protection requirements for
the grid feeder circuit
Page 66
6.3.6 Station transformer
feeder cubicles
The station transformer feeder circuit breaker is of
the same type as the grid feeder circuit breaker, and
has the same protection.
6.3.7 Busbar voltage measurement
The main busbar is equipped with voltage transform-
ers for synchronization of the generators and for sys-
tem voltage- and frequency protection relays.
Minimum protection requirements are:
Over/under frequency
(typically alarm only)
f>, f< 81H, 81L
Over/under voltage
(typically alarm only)
U>, U< 27, 59
Residual voltage
(earth fault)
U0> 59N
Table 26. Minimum protection for busbar voltage
measurement transformers
6.4 Transformers
6.4.1 General
A transformer consists of a three-legged magnetic
core in a transformer tank with primary and secon-
dary windings around the core, bushings, and an tap
changer. The function of the transformer is to supply
the load to another voltage level.
The primary- and secondary windings have no gal-
vanic connection and thus form two different electri-
cal systems.
6.4.2 Power (step-up) transformer
The step-up transformer(s) is to be sized for the rated
power of the generators connected to the trans-
former.
The power transformers used by Wrtsil are oil im-
mersed, conservator transformers with Oil Natural
Air Forced (ONAF) cooling.
The transformer is equipped with surge arresters to
protect the transformer against atmospheric over
voltage.
The transformer is equipped with a tap changer.
6.4.3 Station transformer
The required capacity of the station transformer (aux-
iliary transformer) depends on the power consump-
tion of the equipment connected to the system.
The main design alternatives for station transformers
are:
- dry type transformers (cast resin transformers)
- oil immersed transformers, either hermetically
sealed or conservator type
The transformers delivered by Wrtsil are either dry
type transformers or oil insulated, hermetically sealed
transformers with mineral oil as insulation and cool-
ing medium.
Table 27. Hermetically sealed transformer (exam-
ple)
Dry type transformers are placed indoors, preferably
close to the plant LV switchgear. The oil insulated,
hermetically sealed transformers can be placed out-
doors.
The transformers are cooled by natural circulation.
When located in a switchgear room, or in a separate
area, it is important to provide the transformer with
sufficient cooling air.
Page 67
6.5 Low voltage switchgear
6.5.1 Overview
The low voltage power distribution system in the
plant provides the power supply to the engine auxil-
iary equipment, such as pumps, fans, heaters and
compressors, the ventilation system and the building
electricity system. The system includes:
- A main low voltage switchgear (main distribution
switchboard), which distributes power to possible
motor control centres, control panels, and sub-
distribution boards.
- Possibly one or more motor control centres
(MCCs), which supply motors
- Radiator switchgear
- Control panels and sub-distribution boards, which
supply motors and other electrical consumers in
the plant.
Table 28. Low voltage switchgear (example)
Generally a low voltage switchgear, motor control
centre, sub-distribution board or panel contains the
following equipment and apparatus:
- A common busbar
- One or more incoming feeders. The main LV
switchgear is fed from the MV switchgear via the
station transformer, possibly also from an emer-
gency generator or other alternative feed lines.
Other switchgears are fed from the main LV
switchgear.
- Outgoing feeders to motor control centres, con-
trol panels, sub-distribution switchboards, motors
and other consumers
- Possibly a busbar voltage metering transformer
- Secondary equipment for measurements and pro-
tection.
All motor control centres and auxiliary control panels
are supplied by three phase low voltage.
6.5.2 Design principles
Enclosure
The switchgears are designed for indoor use, except
the radiator switchgear which is designed for outdoor
use.
The low voltage standard switchgears delivered by
Wrtsil are metal enclosed with natural ventilation.
The compartmentalization is usually FORM4A (metal
clad), and the assembly is type tested according to
EN60439-1.
Power supply
Generally, 110 VDC is required for breaker control
motors, protection relays, etc. Power needed for
lighting and heating can be taken from the low volt-
age power system.
Secondary wiring
The switchgear includes necessary numbers of termi-
nal blocks for signal wiring to the plant control sys-
tem.
Heating and cooling
To prevent condensation, anti-condensation heaters
controlled by thermostats are installed to keep the
inner parts of the cubicles above the ambient tem-
perature.
If the switchgear is placed in rooms with air condi-
tioning, forced air cooling is normally not needed.
Standards
The LV switchgear, switchboards, and motor control
centres shall be designed, manufactured, assembled
and tested in accordance with the latest applicable
IEC standards.
Page 68
6.5.3 Busbars and conductors
Each switchgear, switchboard and MCC contains a
common busbar or terminal. The ratings of the bus-
bar is selected to match the connected load.
The switchgear is provided with separate busbars for
neutral and protective earth.
6.5.4 I ncoming feeders
General
Typically, there is one incoming feeder per switchgear
or switchboard. The feeders shall be sized for the
maximum power load. The main low voltage feeder,
which is supplied from the station transformer, must
be rated to match the rating of the station trans-
former.
Circuit breakers
The feeder circuit breakers are fixed mounted
moulded case circuit breakers or air circuit breakers.
Measurements and protection
Voltage measurement is required if synchronization
will be needed. Possible synchronization is handled
by the plant control system.
Circuit breaker protection is generally incorporated in
the breaker.
6.5.5 Outgoing feeders
Feeder types
The most common feeder types are direct feeders,
heater feeders and motor starters.
Direct feeders
Feeders to control cabinets and lighting are direct
feeders equipped with switch fuses, or alternatively,
MCCB:s or MCB:s.
Motor starters
Motor starters are typically of direct on-line type. A
motor starter contains at least:
- A contactor that switches the power on and off
- A circuit breaker, either a miniature circuit breaker
(MCB) or moulded case circuit breaker (MCCB)
for breaking the circuit at over-current
- A thermal overload relay
- A control switch
- Running and fault signal lamps
- Terminal blocks for remote supervision and con-
trol.
Each motor starter is equipped with auxiliary contacts
to indicate the contactor closed/ open status, and
contacts to indicate the tripped status.
Other feeder types
Heater feeders have protection and control.
Protection
Outgoing feeders shall be equipped with protection
suitable for the load. The basic protections which
must be included for outgoing feeders are:
Over current (I >) 50
Short-circuit (I >>) 51
6.5.6 Busbar voltage measurement
Busbar voltage measurement is needed if two busbars
or a busbar and an incoming feeder will be synchro-
nized. This is the case, for instance, if there is a black-
start unit.
6.5.7 Emergency generator
An emergency generator (black start unit) is used to
supply power in case of a black-out situation. The
generator should be sized to supply at least the power
needed for starting one main engine generator set.
See the table below. The required power is much
higher if the emergency generator is to also supply
the ventilation systems and emergency lighting.
Page 69
Consumer Power
Engi ne speci fi c auxi li ary systems
Pre-lubrication pump 30 kW
Preheating unit(s) 50 kW
(+50 kW)
Common auxili ary systems (seven engines)
Starting air compressor 50 kW
Instrument air compressor 20 kW
Common electrical systems (seven engines)
Battery charging 20 kW
Table 29. Estimated power requirements for start-
ing one engine generator set
6.5.8 Emergency busbar
The main LV switchgear can be equipped with an
emergency busbar fed from an emergency generator
(black start unit). Besides for the emergency start-up
of engine generator sets, the emergency busbar may
feed highly critical consumers, such as emergency
lighting. The emergency busbar is connected to the
LV busbar with a bus tie breaker.
Figure 67. Emergency busbar and black start gen-
erator set (BS)
6.6 DC system
6.6.1 DC power consumers
DC (direct current) power is used by the control and
automation systems, the protection relays, and the
switchgears. Using DC power for the control system
and generator breaker control ensures that vital func-
tions will work in case of failure in the auxiliary AC
voltage supply. Two voltage levels are used:
- 24 VDC is used by the engine control system
(nominal current: 2x40 A + 1x40 A stand-by), the
plant control system, and the gas regulating units
- 110 VDC is used in the switchgears for control-
ling circuit breakers (nominal current: 2x15 A +
1x15 A stand-by) and for the instrumentation.
The 24 VDC consumption can be estimated as fol-
lows:
Consumer Estimated
consumption
Common control panel 300 W
Generator set control panels 100 200 W / panel
EAM control panels 100 W / panel
Engine control system
(main and backup supply)
2 x 500 W /engine
Gas regulating units 100 W / unit
Fire detection system 100 W
Table 30. Estimated 24 VDC consumption
For switchgears, the DC power consumption de-
pends on how frequently the circuit breakers are op-
erated. Generally, the consumption under normal
operating conditions can be estimated to 20 VA per
cubicle, plus the power consumed by protection re-
lays, transducers, etc.
6.6.2 DC system design
General
A DC system consists of batteries, battery charger(s)
(rectifiers), and a DC distribution system. The system
can be built as one compact DC unit.
Figure 68. An example of a DC unit
Page 70
Normally, the rectifiers supply the load. The battery
bank supplies the load for a limited time if the mains
supply is interrupted.
Batteries
Lead acid batteries are the preferred battery type.
Nickel-cadmium batteries can also be used.
The required operating time with batteries is normally
5 - 10 hours.
Battery chargers (rectifiers)
The charger capacity is selected so that the charger is
capable of feeding the total plant load while simulta-
neously charging the batteries. The charger is also
capable of supplying load if the battery is discon-
nected.
The DC system is normally provided with redundant
chargers
DC distribution system
The DC-distribution system consists of miniature
circuit breakers (MCB:s) for the batteries, battery
chargers and outgoing feeders.
6.7 Grounding
6.7.1 General
The general purpose of the grounding system is to
protect life and property in the event of short-
circuits, earth faults, or transient occurrences (for
instance, caused by lightning or switching opera-
tions). The protection is arranged by preventing a
dangerous potential difference between the reference
earth and the accessible conductive (metallic) equip-
ment and structures.
There are the following three types of grounding
connections in a plant:
- Neutral point grounding for establishing a com-
mon ground reference within a connected grid
- Safety grounding of system parts that are normally
not energized but may become energized under
abnormal or fault situations
- Equipment grounding for ensuring a low imped-
ance path for the ground current, and a fast trip of
the faulty circuit in case of an earth fault.
Figure 69. Grounding types (TN-S system)
The main components of the grounding system are:
- The grounding grid
- The main grounding bar
- Grounding cables
- Lightning protection electrodes
Page 71
Figure 70. A simplified grounding diagram for a power plant (example)
The grounding system is designed according to the
IEEE 80 standard.
6.7.2 Grounding grid
The grounding grid is a copper grid installed under
the foundation of the engine hall and possibly the
surrounding site area. The design of the grounding
and the required area of the grid depend on the soil
qualities, maximum earth fault current and time, the
network configuration, and the number of incoming
lines and grounding wires.
The impedance of the grounding grid must be such
that it ensures safe step and touch voltages. The most
suitable impedance value depends on the soil proper-
ties.
Figure 71. An example of a grounding grid
The recommendation is to ground at sufficient depth
to ensure moisture during dry seasons and to avoid
freezing in winter. If needed, vertical grounding elec-
trodes can be installed under the grid to improve the
earth contact.
Inadequate soil around the power plant may make it
necessary to install the grounding grid at a distance
from the plant.
Page 72
6.7.3 Main grounding bar
The main grounding bar is a copper bar which is di-
rectly connected to the grounding grid. All major
equipment, and possible other grounding bars, should
be connected to the main grounding bar.
The main grounding bar must be sized according to
national standards.
6.7.4 Neutral point grounding
The main alternatives for neutral point grounding are
illustrated below. The type of grounding to be used
depends on the grid, the power feed, possible trans-
formers, etc.
Figure 72. Neutral grounding, main alternatives
The generator neutral point is typically high resistance
grounded. Other types are used when required.
Station service systems equipped with neutral con-
ductor are always solidly grounded. The recom-
mended grounding method is TN-S (separate neutral
and protective earthing conductors). 110 VDC sys-
tems are floating provided with earth fault monitor-
ing, 24VDC systems directly grounded.
Neutral grounding systems shall ensure the efficient
protection of equipment and personnel.
6.7.5 Lightning protection
For lightning protection, lightning rods with lightning
down conductors of copper from the rods down into
the earth must be installed in all high structures.
The underground lightning conductors should be
connected to the plant grounding system in order to
prevent the build up of potential differences, which
could damage sensitive components, or cause per-
sonal injury or loss of life.
6.8 Cabling
6.8.1 General
The plant comprises medium voltage cables, low
voltage cables, DC cables and grounding conductors.
The required amount of cables depends on the extent
of the plant and the plant layout. The required cable
size (diameter) for a connection depends on the volt-
age, current, temperature, mounting method, number
of cables within the same conduit, type of cable, type
of fed equipment, and cable length.
Power cables must fulfil the following basic require-
ments:
- The cable dimension must be selected so that ca-
ble losses are acceptable.
- The cable insulation level must withstand existing
system voltages.
- The cable must withstand existing short-circuit
currents in the system.
- The voltage drop in the cable must not exceed
acceptable limits. For maximum allowed voltage
drops in cables for various applications and loads,
refer to applicable standards.
- The cable temperature in all operating conditions
must remain under acceptable limits.
- The cable must fulfil requirements regarding fire
withstand capability.
- The cables must withstand existing mechanical
loads and vibrations.
Cabling routes and cable qualities must be selected in
such a way that they do not cause disturbances to
other systems.
To determine the technically and commercially most
suitable cables for each case, Wrtsil performs a ca-
ble optimization study. The calculations are based on
standards such as IEC 60364 guidelines.
Page 73
6.8.2 Medium voltage cables
Single core medium voltage cables are pulled from
each generator set to the respective generator breaker
cubicle in the medium voltage switchgear, from the
medium voltage switchgear to the station trans-
former, and from the medium voltage switchgear to
the step-up transformer in the switchyard. Neutral
point ground cables are pulled from each generator to
the neutral grounding cubicle or possible grounding
transformer.
6.8.3 Low voltage cables
3-phase low voltage cables are pulled from the main
low voltage switchgear to all motor control centres,
switchgears and control panels containing motor con-
trols, and to the building switchboard.
1-phase low voltage cables are pulled from the main
low voltage switchgear to the one phase consumers.
6.8.4 DC cables
DC cables are pulled from the DC cabinet(s) to the
medium voltage switchgear, to the main low voltage
switchgear, to the UNIC main units on the engines,
and to the control cabinets in the control room.
6.8.5 Grounding conductors
Grounding conductors are pulled between the
grounding bar and the grounded equipments, for in-
stance, switchgears, control panels, engine generator
sets, and auxiliary units.
The material and cross-section area of the grounding
conductors depend on the earth resistance and power
system arrangements and must be decided from case
to case.
Wrtsil 34SG Power Pl ant Product Guide 7. PLANT CONTROL SYSTEM
Page 74
7. PLANT CONTROL SYSTEM
7.1 Overview
Figure 73 shows a simplified picture of the system architecture of a standard plant control system. The generator
set control cabinets, the common control cabinet and the workstations are typically located in a control room.
Figure 73. Plant control system architecture (simplified)
Page 75
Each engine generator set has a generator set con-
trol cabinet. It handles the following functions:
- Engine start and stop
- Engine speed and load control via UNIC
- Generator set voltage and reactive power control
through the automatic voltage regulator
- Supervision and control of engine auxiliary
equipment via the EAM module
- Alarm activation and indication
- Safety functions, such as start blocks, shutdowns,
control of gas shut-off and vent valves in the gas
regulating units, and control of possible engine-
specific main shut-off valves
- Control of engine-specific ventilation units and
roof monitors if they are remotely controlled.
The common control cabinet, generally one per
plant, has the following main functions:
- Synchronization and control of outgoing feeder
breakers
- Monitoring of common auxiliaries (lube oil tanks
and pumps, compressed air systems, etc.)
- Control of a common main gas shut-off valve (if
installed)
- Power management functions, such as load shar-
ing, load shedding, automatic start/ stop, and load
following (options)
- Monitoring of the transformers, the plant LV
switchgear, and the DC system
- Control of a possible black start unit
- Gas supply measuring (option)
- Supervision of fire and gas detection systems
- Supervision of environmental parameters.
At the WOIS and WISE workstations, the operator
can start and stop the engine generator sets, change
set values, and supervise the plant through process
displays, alarm and event lists, graphical trends and
reports.
The control system is always delivered by Wrtsil,
but the customer can use existing user interfaces as a
complement to the Wrtsil workstations. Third party
connections are supported over Ethernet OPC
through a firewall.
7.2 Generator set control
cabinet
7.2.1 Overview
Figure 74 shows the front of the standard generator
set control cabinet. The cabinet is typically located in
the control room.
Figure 74. Generator set control cabinet
The front panel contains frequency, current, voltage,
power factor and active power meters, an emergency
stop button, and a manual control unit with start and
stop buttons and control switches. It also contains
the front panels of the power monitoring unit, the
generator protection relay, and the differential protec-
tion relay located in the cabinet. Inside the cabinet,
are the generator set PLC and the automatic voltage
regulator (AVR).
Page 76
Figure 75. Devices and communication inside the
generator set control cabinet
7.2.2 Generator set PLC
The PLC (programmable logical controller) is the
core of the generator set control system. The PLC
includes a CPU (central processing unit), which con-
tains the control functions, and I/ O cards of various
types for collecting and transmitting process signals.
The PLC collects data from all I/ O:s connected to
the IO cards, executes controls, and generates output.
7.2.3 Manual control unit
The manual control unit contains selector switches
for choosing the control mode, start and stop but-
tons, manual output control switches, button and
indication lamp for closing and opening the generator
breaker, and alarm lamps.
Figure 76. Manual control unit
7.2.4 Automatic voltage regulator
(AVR)
The automatic voltage regulator (AVR) controls the
output voltage from the generator by controlling the
DC field current in the rotor of the excitation system.
The AVR detects changes in the terminal voltage
(caused, for example, by a sudden load change) and
varies the field excitation as required to restore the
terminal voltage of the generator. The excitation is
automatically switched on and off at a specified en-
gine speed.
Under steady loading conditions, the regulator main-
tains a constant and stable generator voltage within
+/ -1% of the set value. The operating range of the
generator voltage is +/ -5% of the nominal voltage.
The adjustment rage for AVR is +/ - 10%
The AVR has two main control modes: voltage
droop control mode and power factor control mode.
In addition, voltage droop compensation is available.
Power System Stabilizer (PSS) is available as an op-
tion.
7.2.5 Protection relays
Generator protection relay
When a fault is detected the generator protection re-
lay opens the generator breaker in the main switch-
gear. Wrtsil typically uses a multi function relay
containing the following functions:
Page 77
Protection Symbol ANSI No
Over voltage, two
stages
U>, U>> 59
Under voltage U< 27
Reverse power, two
stages
P
>, P
>> 32R
Under, and over fre-
quency
f<, f> 81H, 81L
Under excitation, two
stages
X<, X<< 40
Voltage dependent
over-current
Iv> 51V
Residual voltage, two
stages
Uo>, Uo>> 59N
Unbalanced load I2/I> 46
Stator overload > 49
Over current, two
stages
3I>, 3I>> 50, 51
Earth fault Io>, Io>> 50N, 51N
Table 31. Generator protection relay functions
The generator protection relay also provides transient
recording by 12 channels with a cycle of 20 ms. Re-
cords from eight seconds before to eight seconds
after a breaker trip are stored.
Differential relay
The differential relay provides differential protection
of the generator, based on measurements in the MV
switchgear and in the generator.
Power monitoring unit
The power monitoring unit measures the phase cur-
rents and voltages, the frequency and running hours,
and calculates the active, reactive and apparent
power, the power factor, and the active and reactive
energy. The active power is shown on the indicator
on the front panel of the generator set cabinet.
7.3 Common control
cabinet
7.3.1 Overview
Main components
The common control panel contains:
- a PLC unit for centralized supervision and control
of the common plant systems
- an auto synchronizer for automatic synchroniza-
tion
- a manual synchronization unit containing a syn-
chronoscope, and double frequency and voltage
meters (source and target)
Figure 77. Common control cabinet, front panel
(example)
In addition to the manual synchronization equip-
ment, the front panel contains a mimic diagram of
the plant power distribution system, and plant emer-
gency stop and reset buttons. The plant emergency
stop will affect all engine generator sets in the plant.
If the plant contains an emergency engine generator
set (black start unit), the common control cabinet
could also contain the starting logic for the unit.
7.3.2 Common PLC
The common PLC is similar to the generator set
PLCs but handles functions and units that are com-
mon to the entire plant. The common PLC commu-
nicates with the generator set PLCs and the operator
stations via the plant network.
Page 78
7.3.3 Synchronization units
Auto synchronizer
The auto synchronizer compares the generator fre-
quency and voltage to the frequency and voltage of
the busbar, and adjusts the engine speed and genera-
tor excitation to equalize them. When the deviations
are within preset limits and the phase difference is
also within preset limits, the auto synchronizer issues
a breaker close signal. To compensate for the breaker
closing time and the operation time of the output
relay, it calculates required advance phase angle.
Manual synchronization set
The synchroscope measures the phase difference
between the generator and the busbar and indicates
with LEDs when the breaker can be closed. It also
indicates when the generator frequency needs to be
raised or lowered, and if the voltage difference is
within set limits. The operator controls the voltage
and frequency manually with switches and by super-
vising thedouble voltage and frequency meters on
the common panel.
A sync check relay prevents breaker closing if no
synchronization has been done, or if the synchroniza-
tion has failed.
7.4 Workstations
7.4.1 General
A workstation is a PC computer with a monitor, key-
board and mouse, and HMI (Human Machine Inter-
face) type software. There are two types of worksta-
tions:
- The Wrtsil Operator Interface Station (WOIS),
which is a graphical user interface for supervising
and controlling the plant.
- The Wrtsil Information System Environment
(WISE), which handles the long term data storage
and report functions of the power plant.
The control system may comprise one or more
WOIS workstations, a WISE workstation, and one or
more printers for hardcopy and report printing. The
workstations must always be kept running and cannot
be used for other purposes.
The workstations enable remote monitoring and data
sharing with external systems.
7.4.2 Operator station WOI S
General
At the WOIS workstation, the operator can monitor
the plant and take actions, such as starting and stop-
ping the engine generator sets, and changing the set
values used in the engine and generator control. The
operator can supervise plant key data, such as various
temperatures and pressures, as well as measurements
of electrical variables, for instance, generator output,
voltage and frequency.
WOIS provides process displays, alarm and event
handling, process trends, instant reports, and control
system supervision. The user selects displays by click-
ing on buttons in dynamic menus at the top and bot-
tom of the screen, or by clicking in the process dis-
plays. The most important displays are always acces-
sible at the top of the screen.
Process displays
In the process displays, the process components are
illustrated by graphical objects, such as images of
pumps and valves, with dynamic status indication
implemented as change of symbol or colour. By se-
lecting an object, the operator can access more de-
tailed data on the object, for instance, trend data of
measured values. A plant overview display provides a
clear and concise view of the entire plant.
Page 79
Figure 78. A plant overview display, a generator set
temperature display, and an object data
window
Alarm and event handling
An alarm banner, which is always visible in the up-
permost part of all displays, informs about the latest
alarm that has occurred. The operator sees a compre-
hensive view of the alarm situation from the active
alarm list, which contains all active or unacknow-
ledged alarms. The alarms can also be acknowledged
from this list.
A further evaluation of historical alarms can be done
in the event list. In addition to the alarms, the event
list contains all normal changes of operational state,
for instance, engine start and stop and change of
breaker status. WOIS events, such as change of
power setpoint, can also be seen in the event list.
Figure 79. Event list
Process trends
The graphical trends show measured values such as
pressures, temperatures, speed, engine generator set
load, etc., on a time axis. To get a comprehensive
view of the process, the operator can combine the
values of up to six features in one graph. The trends
are stored for up to 180 days.
Figure 80. A process trend
System security
The WOIS workstation security system prevents un-
authorized use by requesting a password at user log
in. Each user is associated with a certain authoriza-
tion level, which determines the allowed operations.
There are three different authorization levels: Opera-
tor, Manager and Administrator.
Wrtsil 34SG Power Plant Product Guide 7. PLANT CONTROL SYSTEM

Page 80
7.4.3 Reporting station WI SE
Using WISE, the operator can view and print out
daily, monthly and yearly reports produced by the
reporting program. WISE keeps the engine and pro-
duction reports available for later study and archiving.
WISE gets the information from WOIS.
WISE provides the following functionality:
Production reports of generated active and reac-
tive energy along with the hourly fuel consump-
tion. Daily production reports are stored for one
year. Monthly production reports (on daily level)
are stored for 5 years and yearly production re-
ports for 10 years. The production reports include
minimum, maximum, average and total sum calcu-
lations for the period.
Daily engine and plant reports of measured values,
such as bearing temperature and lubrication oil
temperature. Daily minimum, maximum and aver-
age values are generated and stored for one year.
The measurements can be viewed as trend dis-
plays, which enables long term follow-up of the
plant performance.
Electronic log book with search possibilities for
recording of operation and maintenance activities.
The logbook automatically inserts events like en-
gine starts and stops into the logbook, along with
timestamps. The operator can also enter events
into the log book.
Support for storage and viewing electronic plant
documentation (manuals, layouts and drawings).

Figure 81. A typical daily operation data report

Figure 82. A production report

Figure 83. Log book
7.4.4 Remote monitoring
Provisions for Remote Monitoring services are in-
cluded in the WOIS and WISE applications. Depend-
ing on the communication lines and infrastructure at
the plant, these services can be offered based on a
separate Support Agreement.
The Remote Monitoring system allows the plant per-
sonnel to access the power plants control network
from a PC via Internet. The system only allows read
only access, that is, any control actions are prohib-
ited. The service includes:
Real-time access to all the process information in
WOIS
Access to all historical trends stored in WOIS and
WISE
Access to active and historical alarm information
Access to the log book, including present and his-
torical log book events
Page 81
Remote monitoring uses standard Internet related
protocols and widely used services for secure and
reliable communication. Supported techniques for the
physical connection to the system are DSL or leased
line communication.
7.4.5 Data sharing with external sys-
tems
Plant control system signals available in WOIS and
WISE can be transferred to external systems, for in-
stance, an existing control system or an ISO dispatch
centre, using Ethernet TCP/ IP communication with
a firewall between the Wrtsil control system and
the external system. For transferring WOIS real-time
data, the OPC protocol is used on top of Ethernet,
with WOIS acting as an OPC Server. For reading the
WISE reporting database, ODBC-SQL requests are
used.
The connection point for the external system is the
firewall, which is to be located in the Wrtsil control
room. The firewall is supplied and configured by
Wrtsil, while cabling and communication onwards
from the firewall is the customers responsibility.
Alternatively, data can be transferred through cus-
tomer-supplied RTUs.
7.4.6 Condition based maintenance
The WOIS and WISE applications contain provisions
for Condition Based Maintenance (CBM) services
offered by Wrtsil. The extent of the services de-
pends on the communication lines and infrastructure
available at the plant. If applicable communication
lines and transfer methods are available, the meas-
urement data of the plant is automatically sent to
Wrtsil on regular basis. Alternatively, the data can
be sent manually. A separate CBM agreement should
be made for this service. The CBM agreement can
also cover on-line monitoring with trouble-shooting
support.
7.5 Signal and data com-
munication
7.5.1 General
In a typical power plant, the control system handles
about 150 200 process signals per engine and
about 100 1000 common signals, depending on
the size of the plant.
The majority of the signals communicated between
the engine control system (UNIC), PLCs and remote
I/ Os are transferred via communication buses. How-
ever, all primary control signals such as AVR, speed,
synchronization and breaker trip signals are hard-
wired. Likewise, the safety related signals, such as
emergency stop signals and critical alarm signals are
hardwired.
7.5.2 Signal types
The signals handled by the plant control system are
of the following types:
- Analogue input signals (AI), for instance, pressure
and temperature measurements. The control sys-
tem recognizes AI signals scaled to 4 20 mA,
and PT100 and thermocouple temperature meas-
urements.
- Analog output signals (AO), for instance, set
points to thermostatic valves. AO signals are
scaled to 4 20 mA.
- Digital input signals (DI), for instance level
switches. The digital input signals must be ar-
ranged as potential-free contacts.
- Digital output signals (DO), for instance
start/ stop signals. The digital output signals are
arranged as potential-free contacts.
7.5.3 Communication buses
The communication between the control room PLCs
and the engine control systems go through the plant
network. The plant network is a standard local area
network using Ethernet TCP/ IP and twisted pair
cables, or fibre optics if the distances are longer than
100 meters. The Ethernet switches are located in the
control cabinets.
Page 82
Most data and signals from UNIC to the generator
set PLC, for instance, engine measurements, and
status and alarm signals, go through the Ethernet
plant network. Likewise, the set values from the PLC
to UNIC go through the Ethernet plant network.
Also, the protection relays delivered by Wrtsil
communicate with the PLCs via the Ethernet plant
network.
The communication between the engine generator set
PLC and the remote I/ O in the EAM module goes
through a communication bus using a high level
standard protocol.
7.5.4 Hard-wired signals
Engine-specific signals
The following figure illustrates the engine-specific
hard-wired signals.
Figure 84. Overview of engine-specific hard-wired
signals (example)
The hard-wired signals between the instrumentation
within the EAM module and the EAM cabinet are
factory installed and not shown in Figure 84.
Common signals
The following figure illustrates the amount of hard-
wired signals that are common to the plant.
Figure 85. Overview of common hard-wired signals
(example)
7.5.5 Control cables
The cables should be PVC insulated copper cables.
They must not absorb static or magnetic noise signals
from the surroundings.
Signals of the same type can be contained in the same
cable. Signals of different voltages require separate
cables.
Page 83
7.6 Functional description
7.6.1 Start and stop processes
Start
At an engine start command, the generator set PLC
checks that the generator, engine and auxiliary sys-
tems are ready for start, for instance, that the genera-
tor breaker is open, starting air and control air is
available, lube oil inlet pressure is high enough, HT-
water outlet temperature is high enough, and the
turning gear is not engaged. Provided that all start
conditions are fulfilled, the PLC activates gas system
tightness check, and sends a start command to the
engine control system (UNIC).
Normal stop
At a normal stop request, the generator set PLC
unloads the engine according to a specified ramp and
opens the generator breaker. Then it shuts off the gas
supply from the gas regulating unit to the engine, and
sends a shut-down command to UNIC. When the
engine has stopped, the PLC starts the exhaust gas
vent fan, and ensures that the ventilation is done. The
engine cannot be restarted until the exhaust gas venti-
lation fan has been operated.
Synchronization
In AUTO mode, the PLC initiates synchronization
when it detects that the engine is running and a ter-
minal voltage exists. The auto-synchronizer matches
busbar and generator voltages, frequencies and phas-
ing and issues a generator breaker close command as
described earlier.
Synchronization and breaker control can also be
manually initiated from the mimic diagram.
7.6.2 Output control
The PLC controls the engine speed and load by send-
ing set values to UNIC according to the active con-
trol mode: kW control mode or speed droop.
Inspeed droop control mode, the speed - load rela-
tionship will follow a linear speed droop curve de-
fined in UNIC. Generally, the speed droop setting is
4%.
Figure 86. Speed droop graph (speed droop 4%,
speed set point 51Hz)
The operator can change the setpoint at a work-
station or with a switch at the control panel. Auto-
matic fine tuning of the frequency is available as an
option in the generator set PLC.
In thekW mode, UNIC maintains the engine power
constant. The set value can be changed from an op-
erator station or the control panel.
In isochronous load sharing control, the genera-
tors sets will operate at a constant frequency regard-
less of the load they are supplying, up to the full load
capability of the generators. Load sharing lines
(CAN-bus) are required between the speed control-
lers (UNIC) in order to share the load between the
paralleled units.
Speed droop control is enabled in island operation,
and in the MANUAL mode, also in parallel opera-
tion. The kW control mode is enabled in parallel op-
eration only. The isochronous mode is only enabled
in island operation. The operator selects a control
mode on the control panel. The control system will
also automatically switch control mode when the grid
breaker is opened or closed.
Generator output control
The generator voltage and reactive power (power
factor) are controlled by the automatic voltage regula-
tor (AVR) according to the chosen mode voltage
droop, voltage droop compensation, or power factor
control mode and set values from the generator set
PLC.
Page 84
In thevoltage droop control mode, the relationship
voltage - reactive load follows a linear droop curve.
The droop setting, that is, the voltage drop when the
reactive load is increased from 0 to 100%, is adjust-
able and is normally in the range 1 ... 10 %. To main-
tain the voltage at an increased load, the operator can
change the voltage reference (set value) in WOIS or
with a control switch. The optional Master Voltage
Control function changes the voltage reference
automatically.
Voltage droop compensation is used to share the
reactive power equally between parallel engine gen-
erator sets in the island mode. The AVR compensates
for the voltage droop to keep the voltage at 100%.
Voltage droop compensation requires an RS-485 bus
connection between the AVRs.
Power factor control means that the AVR will adjust
the generator excitation current in such a way that the
Power factor (cosine phi) of the generator output
remains constant at a set value.
The power factor control mode can be used only dur-
ing parallel operation. Voltage droop can be used in
both parallel and island operation modes, but is nor-
mally used only during island operation. Voltage
droop compensation is only available in the island
mode. The operator selects a control mode from the
control panel. The control system will also automati-
cally switch the control mode based on the grid
breaker position.
Power management functions
With the power management functions, the operator
can order a plant output power at a workstation. The
control system shares the ordered power equally be-
tween the running generator sets, and sets the engine-
specific load references accordingly.
If the ordered load exceeds the capacity of the run-
ning generator sets, there will be an alarm requesting
the operator to start up more generator sets. As an
option, automatic start and stop of generator sets
may be included.
Another power management option is the load fol-
lowing system. Load following helps the operators
plan the generation load pattern according to the
power need, the imported energy, and other factors
such as system losses. The system is implemented in
WISE, WOIS and the common PLC.
Load shedding
The plant can be provided with a load shedding
scheme, which will be activated when the consump-
tion tends to increase over the capacity of the plant.
Load shedding is applicable during island operation
only.
7.6.3 Control of auxiliary systems
Engine specific auxiliary systems
The engine specific auxiliary equipment, except for
the radiators, are supervised and controlled via the
control panel in the engine auxiliary module (EAM).
The panel controls start and stop of pumps and heat-
ers. The thermostatic valves in the cooling water sys-
tem are controlled centrally from the engine genera-
tor set PLC. The PLC receives cooling water tem-
peratures from the EAM module and sends set points
to the three way valves.
The radiators are controlled directly from the genera-
tor set PLC. The PLC sends set points to the fre-
quency converters in the radiator control panels
based on measured temperature in the return line.
Common auxiliaries
Common auxiliaries are controlled by local panels.
Running signals and alarm signals are sent to the
common plant control panel.
7.6.4 Safety functions
General
The automatic safety functions work in the same way
in manual and automatic mode.
Alarm sources and alarm indication
Alarms can be initiated in the control room panels, in
UNIC, in the EAM panel, and in the local panels of
the common auxiliary equipment. All alarms are indi-
cated in the control room, either as individual alarms
or group alarms (common alarm), and local alarms
are also indicated at the local panels. Engine alarms
are also indicated by light signals in the engine hall.
Page 85
Engine load reduction and derating
Bad operating conditions that do not require an en-
gine stop will activate a load reduction alarm upon
which the operator should reduce load. Automatic
load reduction (derating) takes place when derating is
required due to ambient conditions. The PLC will
lower the load setpoint sent to UNIC. UNIC can also
activate a load reduction in risky situations.
Automatic shutdown
Highly critical or urgent occurrences will activate an
immediate shut-down of the engine without unload-
ing. A shutdown may be initiated by UNIC or by the
generator set control system. In case of an engine
initiated shutdown, the PLC shuts off the gas supply
to the engine immediately. The main consequences of
a shut-down are:
- Generator breaker opens.
- Stop command is sent to UNIC.
- Gas regulating unit is closed.
The shut down cause will be noted in the WOIS
alarm list.
Emergency stop
An emergency stop activates an immediate shut-
down of the engine. An emergency stop of an engine
can be activated with a push button on the generator
set panel. An emergency stop is automatically acti-
vated when an emergency mode has been activated in
UNIC, for instance at over-speed. An automatic
emergency stop is also activated if a wire break is de-
tected in an emergency stop cable.
A plant emergency stop can be activated from the
common control panel and will affect all engines.
Depending on local rules and regulations, the control
system can be programmed for an automatic plant
emergency stop in the following situations:
- a gas detector senses 20 % of LEL (lower explo-
sion limit)
- a fire detector is activated
Alternatively, the activation of a detector only causes
an alarm and the operator takes the necessary actions.
Wrtsil 34SG Power Pl ant Product Guide 8. PLANT LAYOUT
Page 86
8. PLANT LAYOUT
8.1 Site layout
8.1.1 Site Layout principles
The following primary facts should be considered
when arranging the site layout:
- The size, shape and topography of the site
- The location of the power transmission lines
- Soil conditions
- The location of the gas supply pipe.
The location of the power transmission lines may be
decisive when determining the placement of the
switchyard, and it may affect the orientation of the
entire plant. Generally, the switchyard is located on
the generator side of the engine hall and the radiators
on the engine side of the engine hall.
Space should be reserved for:
- The power house including the engine hall and
possibly service rooms, administration rooms and
electrical rooms
- Any separate service buildings, like administration
building, electrical room, workshops, and storage
- Exhaust gas pipes and stacks, including possible
heat recovery and emission control equipment
- The radiator field with switchgears and frequency
converters, or possible cooling tower
- The switchyard and possible outdoor transformers
- Tank yard and unloading pump station
- Oily water sumps
- Gas pipes above ground, main valves and a possi-
ble pressure reduction station
- Fire equipment house, and possibly a fire fighting
water tank and pumps
- Fire protection spaces
- A possible black start unit with fuel storage tank
- Stormy water pond if needed
- Possible water treatment unit and water tank
- Possible sewage water treatment
- Roads and parking lots, access roads, and turning
places for transport vehicles
- Reservations for possible future expansions.
8.1.2 Site layout notes
Radiator field
The performance of the cooling radiators, and thus
the performance of the plant, is greatly affected by
the airflow to the radiator field.
To ensure the air flow to the radiators, they should be
installed at such a height that the vertical radiator air
inlet face area equals or exceeds the horizontal radia-
tor inlet face area (=radiator footprint). However, the
minimum height above ground should be 2m.
In case of possible noise walls around the radiator
field, they have to be placed at a distance of 3 times
the radiator installation height.
The distance between radiator field and adjacent size-
able objects (like the powerhouse) should be as long
as possible. For plants with less than 5 gensets, the
minimum recommended length = 2,5 times the build-
ing height. For larger plants the following formula is
recommended, which yields a longer distance
7 tan
h p
d

> , dmin = 2.5 x p
where
d = distance between power house and radiator field
[m]
p = power house height [m]
h = radiator field free height above the ground [m]
Page 87
7
h
d (= min 2.5 x p)
l
w
!
p
7
h
d (= min 2.5 x p)
l
w
!
p
The possible re-circulation of hot air will reduce the
capacity of the cooling radiators and must therefore
be avoided. A reduced air flow will also increase the
risk of re-circulation and combined, these issues
would affect the cooling capacity considerably.
In order to minimise the risk for hot air recirculation,
the radiators should be grouped together tightly to
form a uniform field. If gaps between the radiators
can not be avoided, they should be covered with
horizontal metal sheets or similar.
Other factors that affect both the air flow and possi-
ble re-circulation are
- Wind speed and direction
- Site topography
- Buildings, vegetation, tanks etc
Tank yard and unloading station
The tank yard and unloading pump station should be
located in an area where the risk of fire is small. It
must also be ensured that it will impose no hindrance
for the operation of the fire protection system in case
of a fire accident. Fire fighting regulations as well as
local regulations must be followed.
Other factors to consider are the location of other
buildings nearby, and access from road, railway or
waterway for filling the tanks.
The unloading station must be located in the open air
next to the tank yard.
Administration buildings
If the control room is placed in a separate building,
maximum control cable length must be considered.
8.1.3 Site layout examples
Figure 87 and Figure 88 show typical site layouts for
power plants with 6 x Wrtsil 20V34SG and 20 x
20V34SG respectively. Smaller plants usually have
one common building including engine hall, control
room, electrical room, and a possible workshop. Big-
ger plants usually have separate administration build-
ing with control room, electrical room and workshop.
Page 88
Figure 87 Typical site layout example for a plant with six engines and integrated service rooms, control room and
switchgear rooms
Page 89
Figure 88 Typical site layout for a plant with 20 engines in two separate engine halls and separate service building
Page 90
8.2 Engine hall layout
8.2.1 Engine bays
The following figure shows the space required for the
engine generator sets. The recommended distance
between adjacent engine generator sets, from centre
to centre, is 5400 mm.
Figure 89. 20V34SG Engine bays with service
platforms
The standard modules are designed to be intercon-
nected with service platforms in between the engine
auxiliary modules on floor level and the exhaust gas
modules above. About five EAM modules can be
connected in parallel and use common header pipes.
The gas regulating units must be placed close to the
engines
8.2.2 Other space requirements
Space must also be reserved for:
- Common auxiliaries, as compressor units and
compressor air tanks, maintenance water tank(s),
lube oil pump unit(s), etc.
- Pipes, cables, pipe and cable supports, fire fighting
hoses, sprinklers, electrical fittings, etc.
- Maintenance areas and transportation routes.
8.2.3 Layout notes
Air intakes
Air intakes should be in a dust free location and
therefore as high as possible, still accessible for main-
tenance. The intake should be placed away from heat
sources such as exhaust gas pipes, ventilation outlets,
etc.
Expansion vessels
The expansion vessels must be located above the
highest part of the cooling water system. If needed,
they must be moved from the exhaust gas modules to
a higher location.
Air compressors and tanks
Air compressors must be installed in a well ventilated,
dust free, freezing free and water free area. The com-
pressed air tanks should be located close to the con-
sumers to avoid large pressure drops in the pipes.
Lube oil pump unit
The lube oil pump unit should be situated as close as
possible to the lube oil storage tank.
Maintenance water tank
The maintenance water tank should be placed as low
as possible to allow drainage of the water.
Transportation and maintenance space
The engine hall should have space for transporting
main components to and from the engine.
The possibility should be maintained to make an
opening in the wall on the generator side of the en-
gine hall for replacing a generator or entire engine
generator set. There should be no fixed structures,
such as pipes or cable ladders mounted on this wall.
8.2.4 Layout example
Figure 90 shows a layout example of an engine hall
and the exhaust gas systems. The engine generator
sets along with their gas regulating units, engine auxil-
iary modules, and exhaust gas modules are grouped
three and three, each group having common header
pipes in the EAM modules. The space between the
groups is utilized for maintenance water tanks and air
bottles, and as maintenance and lay down area.
Page 91
Figure 90 Typical Engine hall layout
Page 92
8.3 Service rooms or
buildings
8.3.1 General
The requirements for other spaces in the power plant
building switchgear rooms, control room, offices,
workshop, social rooms, etc. depend on the owner's
requirements and the operating profile of the plant.
The service rooms can be incorporated in the power
house building, or they can be located in separate
buildings.
Figure 91 shows an example of service rooms incor-
porated in the power house.
8.3.2 Electrical rooms
The medium voltage switchgear, the main LV switch-
gear, distribution boards, possible motor control cen-
tres and the DC system must all be situated indoors
in electrical rooms with air conditioning. To permit
shortest possible wiring between the generators and
the medium voltage switchgear, it is recommended to
locate the switchgear at the generator side of the en-
gine hall.
Depending on the type, the station transformer can
be placed indoors or outdoors.
Figure 91. Service rooms (example)
Page 93
8.4 Tank yard and
unloading station
8.4.1 Tank yard
The tank yard contains the lubricating oil tanks, the
oily water tanks, and possible reagent tanks for SCR.
The water tanks may be located in the tank yard.
The distance between the tanks, as well as the dis-
tance between storage tanks and the toe of the stor-
age tank area dike wall must obey the applicable stan-
dards and local regulations.
There should be separate containment areas for tanks
containing oil and water solutions (SCR reagents) as
they should not be mixed in case of a leakage.
Figure 92. Tank yard example
8.4.2 Unloading pump station
The unloading pump station contains unloading
pumps with control panels for lube oil and sludge,
possibly also Urea or ammonia in plants with SCR.
8.5 Pipes and cables
8.5.1 Pipe layout
To minimize the pressure drop in the pipes, pipe runs
should be as simple and direct as possible. To sim-
plify supporting and improve appearance, the pipes
are generally arranged parallel to building steel work.
Factors to consider when reserving space for pipes
are the pipe diameter, possible insulation, minimum
distance between pipes, and minimum distance be-
tween pipes and walls or bars. Also the need for
maintenance space and access to equipment should
be regarded.
8.5.2 Cabling
Cabling routes must be selected in such a way that
the cables will not cause disturbances to other sys-
tems. It is recommended to run the cables between
the generators and the main switchgear in cable con-
duits under the floor
Low voltage cables and control system cables are car-
ried by cable ladders, separate ladders for control sys-
tem cables and power feeder cables. Where applica-
ble, the pipe supports can be used as supports for the
cable ladders.
Figure 93. Cable ladders
8.6 Hazardous areas
8.6.1 General
A hazardous area is a location where the atmosphere
contains or may contain a combustible material, such
as fuel gas, in sufficient concentration to form an
explosive or ignitable mixture.
Page 94
In hazardous areas, it is important to avoid all poten-
tial ignition sources, including electrical and mechani-
cal equipment which could form sparks and hot sur-
faces. The primary recommendation is not to install
or use any electrical equipment in these areas. When
this is not practicable, certified equipment must be
used.
The hazardous areas are classified to determine the
level of safety required for the electrical and me-
chanical equipment installed or used in the areas. The
classification and the required or recommended pro-
tection methods are based on standards and direc-
tives. In Appendix A are listed the most commonly
used standards for the classification of hazardous
areas and for the requirements placed on electrical
apparatus installed or used in classified areas. In addi-
tion, local requirements must always be met.
8.6.2 Classification of hazardous
areas
The classification of hazardous areas is based on the
likelihood of an ignitable gas mixture being present.
Table 32 lists the principles for defining hazardous
areas according to European and American stan-
dards, IEC and NFPA 70 (NEC) respectively. Class
I in the NEC designations refers to gas (class II is
dust and class III fibres).
IEC NEC 505 NEC 500 Expl anati on
Zone 0 Class I,
zone 0
An ignitable mixture
is present continu-
ously
Zone 1 Class I,
zone 1
Class I,
division 1
is present intermit-
tently
Zone 2 Class I,
zone 2
Class I,
division 2
is not normally pre-
sent, but may be
present under ab-
normal conditions
Table 32. Classification according to the IEC and
NFPA70 (NEC) standards
Figure 94 shows a typical example of the hazardous
area classification of an engine hall with lean burn gas
engines. The indicated hazardous areas are spheres
around the potential release points.
Figure 94. Classification of hazardous areas during operation in a gas engine power plant according to the IEC
and NFPA standards (example)
Page 95
In a gas fuelled power plant, all flange joints and
valves in the fuel gas system should be considered
potential sources of release. Generally, in a Wrtsil
designed power plant, the only units inside the engine
hall containing these components are the gas regulat-
ing units (GRUs). The hazardous area around a
flange joint is a sphere with a radius of typically 1
meter (3.3 feet), provided that the ventilation is ade-
quate. The radius should be determined for each in-
stallation individually, if needed, in consultation with
local authorities.
Outside the engine hall, the spaces around the gas
system vent pipe outlets are hazardous areas.
In a gas plant, the tank yard is not a hazardous area.
During maintenance and repair work, additional areas
may need to be classified as hazardous.
If the plant contains other sources of release not re-
lated to the Wrtsil engines, they must be analyzed
and considered as well.
8.6.3 Protection methods in hazard-
ous areas
Within hazardous areas, it is mandatory to use only
suitable, certified devices. The requirements are de-
termined by the properties of the gas. The normal
gaseous fuel, natural gas, is classified as a group IIA
(IEC / NEC 505) or group D (NEC 500) flammable
gas. The auto-ignition temperature for natural gas is
often considered to be the same as for the base com-
ponent, methane, which is 537C (999F). The actual
auto-ignition temperature for most natural gases is
higher due to inert constituents.
There are different explosion-protection techniques
for electrical equipment. Unless local rules impose
stricter requirements, Wrtsil follows either the IEC
or NFPA standards. Table 33 shows some typical
protection methods for equipment installed or used
in hazardous areas in a gas power plant.
Device Typical protection method
Instruments and
control devices
Ex i Intrinsic safety
Electrical motors Ex d Flameproof
Electrical heaters Ex d Flameproof
J unction boxes Ex d
Ex e
Flameproof and
Increased safety
Table 33. Typical protection in hazardous areas
Wrtsil 34SG Power Pl ant Product Guide 9. SITE, CIVIL WORKS AND STRUCTURES
Page 96
9. SITE, CIVIL WORKS AND STRUCTURES
9.1 Site considerations
9.1.1 Site selection criteria
The following factors, which may have an impact on
the construction costs, plant performance, and pro-
duction economy, should be considered when evalu-
ating the appropriateness of a site:
- Size requirements
The size requirements are determined by the site lay-
out. On the other hand, the site layout can be ad-
justed to suit the available site.
Also to be considered is the need for a laydown area
and space for site offices in the immediate vicinity of
the plant during the construction phase.
- Proximity to power and heat consumers
For economical reasons, the plant should be located
as close as possible to the load centres, electrical
transmission lines, and potential users of waste heat
(if heat recovery is included).
- Environmental issues and building permits
The type of neighbourhood industrial area or hous-
ing area, for instance has a considerable impact on
allowed noise, air emission levels, rain water issues,
aesthetic values, acceptable levels of pollutants during
the construction phase, etc.
- Available connections
The nearness to fuel gas pipes is of vital importance.
Important, although less crucial, is the existence of
utility connections, such as clean water and sewage
water pipes, and telephone communication.
- Seismic conditions
Risk for seismic activity will have a considerable im-
pact on all plant design and installations. All build-
ings, structures and installations must be designed
according to applicable regulations for the seismic
conditions.
- Soil conditions
The soil conditions should appear from the geotech-
nical investigation, see below. Local soil improvement
or piling may be needed.
- Ambient conditions
Possible risks for hurricanes, flooding and sand
storms must be regarded in the design of the plant.
Also, in coastal areas with salt laden air, additional
corrosion protection of outdoor structures may be
needed.
- Access by road, railroad, or waterway
When evaluating road connections, the largest trans-
portation weights and sizes, required road width, pos-
sible sharp curves, and the bearing capacity must be
taken into account. The roads must fulfil local trans-
portation regulations regarding design width and
minimum radius of road curves.
9.1.2 Geotechnical investigation
A detailed geotechnical investigation, including in-
formation on topography, terrain, seismic conditions
and soil conditions is necessary for evaluating the site
and deciding on required earth work.
The topography is of importance for the site layout,
grading and drainage. The risk for earthquakes in an
area is indicated by the seismic zone, zone 0 repre-
senting the lowest risk level and zone 4 the highest.
The soil investigation should determine the following
soil conditions:
- Density and bearing capacity
- Dynamical properties
- Hydrocollapse potential and liquefaction
- Potential to corrode steel, or to adversely react
with concrete
- Soil resistivity (suitability for electrical earthing)
- Presence of groundwater, percolation.
Minimum allowable soil bearing pressure must be
determined from case to case.
Page 97
9.2 Earthworks and site
works
9.2.1 General
The required earth works is based on the geotechni-
cal investigation and locally valid regulations. Earth
works generally comprise excavating and compacting
soil, and grading. Depending on the soil quality, it
may also involve soil replacement, blending and pil-
ing, as well as the use of a geomembrane between
layers of different soil types. If the soil quality so al-
lows, the foundations can be laid on well drained and
compacted structural fill.
Regarding roads and pavements, they must fulfil lo-
cally valid rules and transportation regulations.
9.2.2 Site drainage
The objective of the drainage is a controlled removal
of rainwater from the site. Local regulations may re-
quire the rainwater be collected to a retention pond.
The drainage system, and the rain water pond (if re-
quired), should be sized for the design rain in the re-
gion according to local regulations.
The site should be sloped to carry all surface water
off the site or to the retention pond. In case of a flat
site, the powerhouse must be raised above the exist-
ing ground level according to local regulations. If the
site is located in a flood area, all structures must be
raised above the maximum flood height.
9.2.3 Underground utilities
Underground utilities include:
- Gas pipes
- Pure water, fire water and sewage pipes
- Oily water pipes for conducting oily water to the
oily water sumps
- Underground conduits for electrical cables, with
support structures if valid regulations so require
- Grounding grid.
Local regulations must be followed.
9.3 Engine hall foundation
9.3.1 General
As standard, Wrtsil uses a shallow foundation with
reinforced ground floor slabs strengthened with
beams along the column lines of the building. This
solution is suitable at sites where the bearing capacity
is at least 150 kN/ m
2
at 0-level and there is no set-
tlement risk.
Figure 95. Engine generator set foundations and
beam strips
The static loads on the foundation are the weight of
the equipment and the support reactions from the
buildings and structures.
Note! The planned route for hauling in the
engine generator sets during installation must be
strengthened to carry the engine generator sets.
9.3.2 Engine generator set founda-
tion
With steel springs under the engine generator sets,
the dynamic forces and vibrations acting on the
foundation are close to zero.
The foundation of the engine generator set must be
in accordance with Wrtsils design or approved by
Wrtsil.
The engine generator set foundation is a block, which
is cast in a single continuous pour. It is separated
from the surrounding floor slab with an elastic joint.
A drain channel connected to an oily waste collection
sump runs around the block. See Figure 97.
For dimensions and details, see Figure 98. The figure
applies at sites where no piling is needed. A deeper
block is required at sites where piling is necessary.
Page 98
Figure 96. Typical engine hall foundation
Figure 97. Cross section of the engine hall foundation
Page 99
Figure 98. Engine generator set foundation drawing
9.3.3 Material and strength
Unless local exposure conditions or local regulations
set stricter requirements, the foundations shall be
made of grade C20/ 25 concrete reinforced with high
yield deformed reinforcing bars with minimum yield
strength fy = 414 N/ mm
2
.
The required load bearing capacity of the floor slabs
outside the engine generator set foundations is 10
kN/ m
2
for spread loads and 40 kN/ m
2
for point
loads.
For quality requirements, refer to applicable building
codes.
9.3.4 Floor tolerances
The following figure shows the tolerance require-
ments for the zones under the engine generator set
feet.
For the foundation under the auxiliary module, the
tolerance is 10 mm.
Page 100
Figure 99. Floor tolerance for the engine generator
set (helical springs = hatched area)
9.3.5 Floor drains
For drain collection, there are the following alterna-
tives:
- A long drain channel running under the row of
EAM modules with one or several collection pits
- A short channel with a collection pit per engine.
The floor should slope slightly towards the floor
drains.
Typical dimensions of the drain channels:
width = about 300 mm
depth = about 200 mm with a slope of 1:100 to
the collection pit.
9.3.6 Surface treatment
The upper surface should be coated with an Epoxy
paint (or hydrocarbon resistant paint) to prevent con-
tamination of the concrete.
9.4 Other foundations
9.4.1 Tank yard and pump station
The tank foundations are normally ring beams filled
with fine sand or similar material. They are made of
concrete and about 200 - 500 mm (8 - 20 inch) thick,
depending on whether anchorage is needed or not.
The need for anchorage is determined by local regula-
tions and depends on the height of the tank, wind
conditions and seismic conditions, etc.
Generally, according to applicable standards and
building regulations, the tanks must be located inside
a concrete basin type containment area sized to hold
the volume of the biggest tank plus a safety margin.
There should be two different collecting systems, one
for drained water and possible oil leakages, and one
for rain water. The operator decides whether to
empty the containment area to the rain water drain
system or the oily water sump.
Figure 100. Tank yard oily water and rain water col-
lecting systems
The platform of the pump station must be designed
with drain grooves and drain pit according to local
standards and regulations.
9.4.2 Stacks, radiators and trans-
formers
The stack, radiator field and transformer foundations,
are sized in accordance with the soil study results and
the weight of the equipment.
The foundations of oil filled transformers are typi-
cally built as a containment area. Depending on local
regulations, a containment area may also be required
under the radiator field if glycol mixed water is used.
Page 101
9.5 Frames, outer walls and
roofs
9.5.1 General
Local building regulations determine the loadings that
the building must be designed to withstand. Factors
to be considered include local weather conditions,
risks for earthquake and hurricanes, as well as other
dead loads, live loads and design loads.
The fire resistance of the building must fulfil national
or local regulations.
9.5.2 Engine hall
The Wrtsil standard engine hall building is normally
a steel structure with a moment resisting frame where
both ends of the columns are rigidly connected in
transversal direction, and a braced frame is used in
longitudinal direction. Two rows of columns in the
centre of the hall.
Alternatively, a frame is used instead of columns
(Figure 102), and the ends are fastened with joints
(Free standing building).
The standard wall panel used by Wrtsil is an insu-
lated, lightweight, sandwich type construction where
the surface metal sheets are bonded to the rock wool.
The exterior surface is made of galvanized, substrate
coated, mouldable steel sheet with polyvinylchloride
coating. The wall is fire resistant and non-
combustible.
Figure 101. Standard wall panel
The standard roof consists of load bearing steel
sheets, noise and heat insulation and water proofing
corrugated steel sheet.
Figure 102. Steel structures for free standing building
Page 102
9.5.3 Auxiliary structures
Stacks
The main function of the stack is to conduct the ex-
haust gases to such a height that the emissions meas-
ured for a specific area are according to the local
regulations. Required stack height depends on the
dispersion of the stack emission, which depends on
the stack design, topography, wind conditions, and
number of engines in the plant.
Stacks can be arranged as a clustered stack with sev-
eral exhaust gas pipes grouped together or individual
stacks for each engine.
Exhaust gas pipe support structures
The exhaust gas pipes must be supported as required
by the load of the pipes considering the static forces
from the weight of the pipes, the vibrations from the
engine, and thermal and pulsating forces.
9.6 I nterior structures
9.6.1 I nner walls, floors, and ceilings
Wrtsil typically designs switchgear floors with
raised floor with at least 1600 mm space underneath
to pull cables, etc.
9.6.2 Lifting and transportation ar-
rangements
For maintenance purposes, it is recommended that
the engine hall is equipped with a suspended travel-
ling overhead crane that reaches all engines, with a
capacity of minimum 2 tons.
Figure 103. Travelling overhead crane
9.6.3 Support structures
Exhaust gas module supports
Supports for the exhaust gas are constructed as be-
low.
Figure 104. The exhaust gas module supports
Stairs, catwalks and landings
As standard, stairs catwalks and landings are con-
structed of galvanized steel gratings built on frames.
Applicable labour codes and standards must be fol-
lowed.
Gratings and ladders must not be fixed to the engine
generator set.
Wrtsil 34SG Power Plant Product Guide 9. SITE, CIVIL WORKS AND STRUCTURES

Page 103
9.7 Heating, ventilation and
air conditioning
9.7.1 Process ventilation
General
The ventilation of the engine hall can be classified as
process ventilation. The basic design principles are:
to remove the heat produced by the engines, gen-
erators, auxiliary equipment and electrical equip-
ment
to change air according to applicable standards
to prohibit environmental dust from entering by
keeping the hall slightly pressurized.
Air intakes and outlets
The engine hall in a Wrtsil designed plant has two
ventilation units per engine generator set, one at the
engine side and one at the generator side of the build-
ing and one air outlet per engine, generally located on
the roof. The ventilation outlets can be continuously
open, manually opened and closed, or opened and
closed with locally or remotely controlled motors,
dependent on the climate.
Ventilation units
Figure 105. Ventilation of engine hall
If the outlets cannot be placed on the roof, exhaust
air fans are needed. In these cases, the inlet and outlet
fans must be interlocked to ensure that the exhaust
air flow follows the intake air flow. Maximum over
pressure in the engine hall is 60 Pa.
The air intake louvers should be designed to prevent
rain water and dust from entering the system. If the
environment is heavily polluted, a high performing
filtering system is needed. In arctic climate, a heater
element can be placed in the inlet chamber to preheat
the ventilation air to about +5

C.
Air change rate
The prerequisite for the engine hall being unclassified
area regarding explosion safety is that the ventilation
shall be adequate at all times according to valid regu-
lations. According to API500, the minimum demand
is 6 air changes/hour and 18m
3
/h per m
2
building
area. To meet the heat evacuation demand, described
in the following section, the ventilation in a Wrtsil
designed plant normally achieve up to 50 room vol-
umes air changes per hour.
The minimum ventilation must be on at all times as
long as the equipment in the enclosed classified area
contains gas. However, if the gas supply to the engine
is closed outside the engine hall, no ventilation is re-
quired of an engine in stand by mode.
Heat evacuation
The Wrtsil design target is to restrict the tempera-
ture increase in the occupied zones of the engine hall
to 10C above the maximum ambient temperature in
hot climates. Due to stratification, 10C temperature
increase in the occupied zone means that the total
temperature increase in the hall from inlet to outlet is
in the range 14 - 17C.

Figure 106. Computerized modelling of engine hall
temperatures related to the intake air
temperature
The ventilation air should be equally distributed in
the engine hall considering air flows from points of
delivery towards the outlets.
Page 104
For estimating the total heat to be evacuated, all heat
sources should be considered. The heat losses from
the engine generator set depend largely on the load.
For an estimation of the heat radiation, see the tech-
nical data tables in chapter 11. The heat emission
from the engine auxiliary module can be estimated to
be 10 kW.
Process ventilation units
In plants built by Wrtsil, the engine hall ventilation
units are equipped with axial fans, which are compact
and easy to maintain. The inlet fans can either be
started manually, or each fan can be started automati-
cally at start-up of the respective engine. The engine
ventilation fans can be equipped with frequency con-
verter control, which gives enhanced flexibility, re-
duced electricity consumption and increased comfort.
9.7.2 Comfort ventilation and
air conditioning
General
The comfort ventilation covers the control room,
possible offices and restrooms, and the electrical
rooms. The main task of the comfort ventilation is to
restrict the temperature and maintain air-changes.
The basic design principles are:
- to change air according to the rate prescribed in
locally applicable laws or regulations (for instance,
American Society of Heating, Refrigerating and
Air-Conditioning Engineers, ASHRAE)
- to remove the heat dissipated by the electrical
equipment and heat loads caused by sun radiation
and people
- to keep the air-conditioned rooms slightly pressur-
ized to prohibit moisture from condensing in the
constructions.
Ventilation of electrical rooms
The electrical rooms must be equipped with air con-
ditioning systems if the temperature cannot otherwise
be kept below 30C. These rooms are not considered
as continuously occupied. The air conditioning sys-
tem is generally handled by roof top units with back-
up arrangements, usually two independently operat-
ing units. The AC system is to be sized according to
the heat dissipation from the electrical equipment.
Ventilation of DC room
During the charging process, hydrogen gases will be
released from the DC batteries. If the batteries are
metal enclosed, the gases must be conducted to well
ventilated surroundings. Due to the explosion risks,
the ventilation air from the DC enclosures or DC
room should have separate outlet ducts.
The medium voltage switchgear may require arc gas
exhaust ducts depending on local standards and the
manufacturers recommendations.
Ventilation of control rooms and offices
Control rooms and offices are considered as normal
offices, and the comfort ventilation is handled ac-
cording to the requirements in valid regulations (for
instance, ASHRAE 55 and 62). The air conditioning
is handled either by a roof top unit arrangement or by
a separate, modular, unit. Generally, the design prin-
ciple is to maintain a temperature of 20 - 25C.
9.7.3 Air filtering and silencers
Air filtering
Air filtering is needed to prevent dust particles from
entering the building. Filtering panels are designed
for particles of a given size and should be sized to
allow acceptable ventilation even when the filter me-
dia is clogged. The air filters should be equipped with
local differential pressure meters, optionally with re-
mote supervision in the plant control system.
The filters used by Wrtsil are changeable bag filters
with filter media made of fibre. Standard filtration
class is Eurovent 779 G4 or ASHRAE 52.2 MERV 8
for the process ventilation and F5 or MERV 10 for
the comfort ventilation. On locations with high con-
centrations of dust in the outside air, various types of
pre-filtration systems are used.
Silencers
Project specific noise calculations give the allowable
noise emission to the surroundings from the ventila-
tion system. As a rough assumption, total allowed
sound level for all ventilation units can be regarded to
be 65 dB(A) at 100 m distance.
Page 105
9.8 Fire protection
9.8.1 General
Fire protection is a combination of passive and active
methods. Passive fire protection comprises safety
distances and fire barriers to ensure structural integ-
rity and limit the spread of fire. Active fire protection
includes detection and alarm systems as well as fire
extinguishing systems.
Wrtsil defines two standard levels of fire protec-
tion, base level and extended level, which differ
mainly in the extent and capacity of the fire extin-
guishing system. In a gas plant, the extended level is
recommended. The fire protection system design is
based on a fire risk evaluation and the NFPA stan-
dards which are used as guidelines.
Each country has its own fire protection legislation
and practices. Fire protection design must, therefore,
always be reviewed with local authorities. In addition,
the insurance companies may require a certain fire
protection level, or may offer reduced fees for plants
with a high protection level.
9.8.2 Fire areas
In order to limit the spread of fire, protect personnel
and limit the consequential damages in case of a fire,
the power plant should be subdivided into separate
fire areas. Different fire areas should be separated
with fire barriers, spatial separation or other approved
means.
Fire barriers are typically used to separate the control
room, oil filled transformers, electrical rooms and the
battery room. Spatial separation is used between en-
gine halls, maintenance shops, tank areas, fire pumps,
warehouses, and offices. Typical minimum space is
9.1 meters.
9.8.3 Fire alarm system
General
The purpose of the fire alarm system is to give people
in the building enough time to escape in case of a
fire, and to start the fire extinction as early as possi-
ble. Fire detectors and alarm devices must be installed
throughout the plant. In hazardous areas, explosion
proof equipment must be used.
The plant control system can be programmed to initi-
ate a plant shut down on a specific fire alarm.
Fire alarm centre
The fire alarm centre should be centrally located,
preferably in the control room. The alarm centre
must be equipped with a DC system as reserve power
supply.
Fire detectors and manual call points
The engine hall should be provided with optical
smoke detectors, differential heat detectors or flame
detectors. In other rooms, heat detectors or ionisa-
tion smoke detectors can be used. The number of
detectors depends on their coverage area or allowed
spacing, the size, shape and height of the rooms, the
ventilation, and the air change rate. To avoid false
alarms, the intended use of the room must be consid-
ered when designing the fire detection system.
Manual call points should be provided at critical
points and exit points.
Fire alarm signalling devices
Alarm devices should be so placed that they can be
seen or heard in all locations where people stay more
than temporarily. Alarm lights are obligatory inside
the engine hall where the sound level is high. Outside
the buildings, sound alarm can be used.
Fire alarm cables
The system suppliers recommendations should be
followed. In addition, locally valid standards, rules
and regulations must be followed. Local fire regula-
tions may, for instance, require the use of fire resis-
tant cables. Unless EMT conduits are required, Wrt-
sil uses aluminium tubes around indoor cables not
running on cable ladders.
9.8.4 Gas detection system
Gas detectors are required in the engine hall to detect
any gas leak. The detectors, at least two per engine,
should be located where gas most likely will be pre-
sent in case of a leakage, that is, normally above the
gas regulating units and at the ventilation air outlets at
roof level.
Page 106
Figure 107. Gas detectors
The gas detection system should be connected to the
plant control system, which activates an alarm when a
gas detector is sensing 10 % of the lower explosion
limit (LEL). When a gas detector is sensing 20 % of
LEL or more, the gas supply is shut off. If the gas
detectors have only one alarm level, 20 % of LEL is
used for initiating shut-off of the gas supply.
9.8.5 Fire extinguishing systems
General
Water-based, gas-based, or dry chemical fire extin-
guishing systems can be used. Chemical systems are
mainly used locally and in small spaces. Gas-based
systems are used in small enclosed spaces. Water-
based systems can also be used in an optional sprin-
kler system in the engine hall.
A water-based fire fighting system consists of:
- A water supply source, possibly a fire water tank
and pumps
- A fire water piping system, fire hydrants, loose fire
hose equipment, permanently connected fire hose
reels, and mobile foam units
- Possibly an automatic sprinkler system
- Portable extinguishers.
Primarily, a burning gas flame should be extinguished
by shutting off the gas flow. Otherwise, remaining
unburned gas may explode on contact with hot sur-
faces. A sprinkler system cools the hot surfaces and
so reduces the risk for re-ignition.
Fire fighting water supply requirements
The fire fighting water source should supply the fire
hydrants, hoses and sprinklers with adequate amount
of water. Unless local regulations impose stricter re-
quirements, the system should be sized for two hours
of operation for both hydrant and sprinkler systems
in accordance with NFPA 850-4-2.1.
Required flow in hoses according to NFPA 850 is
1900 l/ min. The flow required for the sprinkler sys-
tem calculated according to NFPA 13 Area/ density
method and Extra Hazard Group I, is about 3000
l/ minute (for one engine generator set). As both
should be able to operate simultaneously, required
minimum flow is about 5000 l/ minute.
At the rated flow, the pressure must be at least 8 bar,
but not exceeding the design pressure of the pipe
system at zero flow, max. 12 bar.
If fire brigade services are available, there should be
at least one fire department connection to allow for
additional water supply.
Fire water tank and pumps
A fire water tank and fire fighting pumps are required
if the regular water supply system cannot be relied
upon to supply water for the required flow and pres-
sure.
According to the Wrtsil base level system design,
the water capacity of the fire water tank is at least 240
m
3
and according to the extended level systems, at
least 600 m
3
. For filling the tank, raw water must be
available, and possibly one or more pumps. Accord-
ing to NFPA22, the tank must be filled within eight
hours.
There should be two fire fighting pumps of adequate
capacity, one electric and one diesel engine driven,
either one able to deliver the required amount of wa-
ter. The pumps should be located near the fire water
tank and so that they are not exposed to fire in the
surrounding areas.
Wrtsil can provide a standard fire fighting pump
container including a control system. The container
has two fire fighting pumps, one diesel driven and
one electrically driven, and a jockey pump that main-
tains the system pressure in the pipes. The fire fight-
ing pumps are started automatically when the pres-
sure drops below a certain limit.
Page 107
Fire water pipes, hydrant posts, hoses and
mobile foam units
The fire service piping conducting water to the hy-
drants, hoses and foaming units is a closed loop sys-
tem consisting of pipes, valves, elbows, branches,
reducers and shut-off valves. To ensure adequate
pressure at the outlet points, the pressure drop in the
system must be calculated and checked.
Generally, Wrtsil uses standpipes of class II in ac-
cordance with NFPA 14. The main pipe from the fire
water source is built with NFPA24 as guideline (pri-
vate fire service main).
Hydrant posts and hose reels shall be located in ac-
cordance with locally valid laws and regulations. Ac-
cording to NFPA 14, maximum distance between
hydrant posts is 40 m.
Mobile foam units are used to suppress possible oil
fires.
Automatic sprinkler system
Wrtsils extended level fire fighting system includes
a wet type sprinkler system. The system is heat acti-
vated sprinklers in the fire area are activated by the
heat and equipped with a flow activated alarm. To
avoid accidental release, temperature class high (blue
bulb) is used.
When designing a sprinkler system, note that the pipe
support structures must be substantial enough to
carry the piping system filled with water.
The sprinkler system must be supplied directly from
the fire service main pipe.
Portable extinguishers
Carbon dioxide extinguishers are used in electrical
spaces, the control room, and accommodation
spaces. Powder extinguishers are used in the engine
hall, auxiliary hall and workshop.
9.9 Water supply system
9.9.1 General
The water used in the plant can be taken from a mu-
nicipal water supply system or ground water well if
reliable supply of sufficient quality, amount and pres-
sure is available. In areas where this is not the case, a
water tank and possibly a water treatment unit will be
needed. The need for water treatment depends on the
raw water quality, which must be investigated by a
raw water analysis.
The water should fulfil the highest requirements for
any process in the plant. Possible seasonal changes in
the raw water quality must be considered.
The following scheme gives an overview of the water
supply system in a plant with water treatment.
Figure 108. Water treatment and storage
Even though no water treatment is needed, a pure
water tank and booster pumps may be needed for
peak consumption.
The plant is designed for a water pressure of at least 4
bar. Water boosters are needed if this water pressure
is not otherwise obtained.
9.9.2 Water consumption
Process water is consumed by the following proc-
esses:
- Make up water in the primary cooling water sys-
tem, and make up water in the secondary cooling
water system if central cooler is used
- Heat recovery system (if included)
Page 108
In addition, water is needed for the fire fighting sys-
tem, washing, and for sanitary water in toilets and
personnel rooms. In a gas plant with radiator cooling,
the largest water consumer is the sanitary system.
In a plant without heat recovery, the water supply
system should be sized for a consumption of 4 li-
tres/ MWhe. Heat recovery requires min. 10 % of the
steam production when there is full condensate re-
turn (boiler feed water quality).
If water treatment is employed, the continuous aver-
age raw water consumption will be higher due to wa-
ter rejected from the treatment process. Typically,
there should be raw water available 1.7 times the pure
water consumption as continuous average.
9.9.3 Water treatment unit
Water can be treated in several different stages de-
pending on the purpose of the water. Rough particles
are separated by screening. Metals and organic matter
are removed by sedimentation and/ or flotation. If a
higher level of cleanness is required, e.g. softening,
evaporation, reverse osmosis and disinfection can be
utilised.
Wrtsil offers a standard water treatment plant
comprising filtration, softening, and Reverse Osmosis
(demineralisation). The plant is available in four sizes:
1, 2, 4 and 6 m
3
/ h. A treatment plant with a capacity
larger than the calculated demand should be chosen,
including a safety margin of at least 20%.
For big power plants two smaller water treatment
plants can be considered instead of one big system.
Using two plants provides redundancy and ensures
water supply for critical process equipment.
For quality requirements, see section12.3.
9.9.4 Water booster unit
In a power plant there are several small water con-
sumptions that require water only for short periods.
On the other hand, the pipe connections can be rela-
tively long and tortuous. This exposes pumps to ex-
cessive wearing and pressure strokes. In order to pro-
tect the pump from ageing too fast, pressure balanc-
ing water tanks can be installed close to the consump-
tion points. A pressure balancing tank is basically a
small tank, about 100 120 l (26 32 gallons) with
a certain water level that is divided by a diaphragm.
Compressed air is fed into the tank in order to
achieve the start pressure level of the pump.
9.9.5 Water storage tanks
The pure water tank should be sized to allow for 8
hours stop in the water supply. Likewise, in a plant
with water treatment, the recommended volume of
the raw water tank is 8 hours raw water demand or
minimum 5 m
3
.
The water tanks can be fibreglass, plastic or stainless
steel tanks, or carbon steel tanks with immersion
proof epoxy paint inside.
9.10 Waste water systems
9.10.1 Sewage system
The sewage water comprises water from toilets,
washing basins, and washing water from drainage.
The amount of sewage water can be estimated to be
the same as the sanitary water consumption.
If local laws and regulations so require, the sewage
water must be treated before discharged to the mu-
nicipal water treatment plant or nature. The sewage
water treatment should be chosen based on the local
outlet water requirements.
For treating sewage water, Wrtsil can deliver a
standard unit including a septic tank and sewage wa-
ter pumps.
9.10.2 Oily water system
General
Oil contaminated water from the floor drains in the
engine hall, workshop, tank yard and unloading pump
station should be collected by gravity to oily water
collecting sumps, generally concrete tanks situated
below ground. See Figure 100. From the collecting
sumps oily water is pumped to the oily water tank,
where it is stored until transportation for disposal or
treatment.
Local regulations may require double containment of
tanks and pipes.
Oily water sumps
Oily water sumps are available in three standard sizes:
2.5 m
3
, 5 m
3
and 10m
3
.
Page 109
Figure 109. Oily water sump
The sumps are equipped with upper and lower level
switches for automatic control of the transfer pumps.
The needed number of sumps depends on the plant
size and layout.
Oily water transfer pump unit
The standard oily water pump unit for transferring
sludge from the sludge sumps to the oily water tank is
an air-driven diaphragm pump mounted on a frame.
The typical pump unit has a capacity of 6 m
3
/ h.
The transfer pump unit can be configured for manual
or automatic operation. In automatic operation it is
equipped with a control panel.
Figure 110. Membrane pump
Oily water unloading pump unit
The oily water unloading pump unit for pumping oily
water from the oily water tank to a truck is similar to
the oily water transfer pump unit described above.
The pump is started and stopped manually.
Oily water tank
The standard oily water tank delivered by Wrtsil is a
vertical cylindrical tank made of carbon steel, which is
placed above ground. To prevent freezing in cold
climates, the oily water tank should be equipped with
a heating coil.
When sizing the oily water tank, the factors to con-
sider are the amount of oily water produced per day
and the appropriate emptying interval. Note that, in
order to protect a possible heating coil from over-
heating, the tank should not be emptied completely.
The available standard tank sizes are 35, 55 and 80
m
3
.
9.11 Lighting
General
The requirements set by local laws and regulations
must be followed. If needed, all equipment on the
site, indoors and outdoors, should be illuminated.
Figure 111. Site lighting example
Lighting levels
As standard Wrtsil uses the following lighting lev-
els:
Engine hall: 300 lux
Control rooms: 500 lux
Electrical rooms: 200 lux
Other rooms: 100 lux
Outdoors: 20 lux
Table 34. Lighting levels
Emergency lighting
Emergency lights should be installed at all exit doors.
In hazardous areas, emergency lighting shall be ex-
classified.
Page 110
Aviation obstruction lighting
If local regulations so require, the stacks must be
equipped with obstruction lights.
Wrtsil 34SG Power Pl ant Product Guide 10. INSTALLATION AND COMMISSIONING
Page 111
10. I NSTALLATI ON AND COMMI SSI ONI NG
10.1 Delivery and storage
10.1.1 Engine generator set
Transportation
The engine generator set is usually delivered and
transported as one unit covered by a tarpaulin.
Storage
It is recommended to store the generator sets in-
doors. If stored outdoors, the original covering of the
engine generator sets must be kept unbroken.
Lifting the engine generator set
If needed, the engine generator set can be lifted with
a crane.
Figure 112. Lifting the engine generator set with a
crane
The engine generator set can be lifted on and off the
trailers using hydraulic jacks placed in the four jacking
points, two on each side of the engine generator set.
Figure 113. Lifting engine generator set by jacking
10.1.2 Engine auxiliary equipment
and pipes
The auxiliary modules and units are delivered in con-
tainers or boxes. It is recommended to store them
indoors. If stored outdoors, they should be kept un-
packed or covered with a tarpaulin. Pipes must be
stored indoors in dry and warm conditions.
10.1.3 Electrical and control system
equipment
The electrical equipment should be stored indoors in
dry and warm conditions according to the manufac-
turers instructions. In cold climates, also the cables
need to be stored in a warm location for 24 hours
before installation.
The equipment must be lifted in accordance with the
manufacturers instructions.
Page 112
10.2 I nstallation
10.2.1 General
The installation of the engine generator sets and the
auxiliary equipment must be done in accordance with
the drawings and installation instructions provided
for the specific project in the installation file. Before
starting the installation work, all necessary documents
are given to the client and to the subcontractors at
site.
The site manager and his supervisors follow up that
the quality instructions, installation instructions and
contract requirements are followed at site.
The mechanical installation involves the following
main work phases (not necessarily in this order):
- Installation of the engine generator sets
- Installation of the standard modules and other
auxiliary units
- Pipe installation and flushing
- Installation of maintenance platforms
The installation of the electrical systems and control
systems involves lifting and placing switchgear, con-
trol cabinets, transformers, etc., cable pulling, and
connecting the cables.
To enable the installation of the engine generator
sets, a sufficient large opening should be left in the
wall at the generator side. Alternatively, the entire
wall may be left open until the engine generator sets
have been installed.
If there is restricted space in the auxiliary area, it may
be most practical, or even necessary, to place the en-
gine auxiliary modules and exhaust gas modules in
their approximate positions before installing the en-
gine generator sets. However, the modules cannot be
aligned and mounted until the engine generator set is
placed in its final position.
10.2.2 I nstallation of engine genera-
tor set
Moving the engine generator set to its posi-
tion
The engine generator set can be brought into the en-
gine hall and positioned on the foundation using rails.
Positioning and aligning generator set
The engine generator set must be installed exactly in
accordance with the installation drawings.
The vibration mounts must be fixed to the common
base frame in exact positions in accordance with the
drawings. For aligning the generator set horizontally
shim plates are to be used.
Figure 114. Spring elements
Anchorage to foundation
The engine generator sets are mounted on anti-
vibration mounts and do not need an anchorage onto
the foundation, except in earthquake sensitive areas.
In earthquake sensitive areas, the anchorage for per-
manent equipment shall be designed to resist the lat-
eral seismic forces prescribed in national standards.
The lateral anchorage to the concrete foundation
must be arranged with chemical anchor bolts.
10.2.3 I nstallation of auxiliary
equipment
Engine auxiliary modules
The engine auxiliary module must be exactly aligned
with the engine and is therefore installed after the
engine, although it may be necessary to place it
roughly in its position before the engine is installed.
The module is mounted to the floor with bolts, and
the feet are welded to the module frame after the
module is finally aligned in its position.
Page 113
Exhaust gas module
Like the engine auxiliary modules, the exhaust gas
modules should be lifted on their stands before the
engine generator sets are brought to their places. The
exhaust gas modules are lifted on to the stands with a
crane or fork-lift truck.
Other auxiliary units
Generally, standard auxiliary units are skid mounted
for easy installation.
10.2.4 I nstallation of piping systems
I nstallation procedure
The following aspects shall be taken into considera-
tion when planning the installation:
- Install all units and major equipment before start-
ing to install the pipes.
- Install larger pipes prior to smaller ones and main
lines before branches.
- Technically more difficult systems should be built
before simpler systems.
Cleaning procedures
All pipes must be inspected and ensured to be clean
from debris before installation and joining. Espe-
cially, all fuel gas and lubricating oil pipes must be
well cleaned to ensure that no sand, rust, slag, etc. will
enter the engine.
The following cleaning methods should be used:
Pipe A B C D F
Fuel gas pipes x x x x x
Lube oil pipes x x x x x
Starting air pipes x x x
Cooling water pipes x x x
Exhaust gas pipes x x x
Charge air pipes x x x
where:
A = Degreasing by washing with alkaline solution in
hot water at 80
o
C (if the pipe has been greased)
B = Removal of rust and scale with steel brush (not
required for seamless precision tubes)
C = Purging with compressed air
D = Pickling
F = Flushing with lube oil
The pipes included in the standard modules are
cleaned and plugged in the shop. If a pipe inspection
at site shows that no dirt or rust has been formed in
the pipes during transportation and storage, a final
flushing of the lube oil pipes is enough.
I nstallation of flexible pipe connections
Great care must be taken to ensure the proper instal-
lation of flexible pipe connections between resiliently
mounted engines and fixed piping. The flexible bel-
lows and hoses included in the engine delivery must
be used.
Note, for instance, the following:
- Flexible pipes must not be twisted.
- The installation length must be correct.
- Minimum bending radius must be respected.
- Piping must be concentrically aligned.
- Mating flanges shall be clean from rust, burrs and
anticorrosion coatings.
- Flexible elements must not be painted.
- The piping must be rigidly supported close to the
flexible piping connections.
10.2.5 I nstallation of electrical and
control systems
General
The installation of the electrical and control systems
must be done by authorized electricians.
The installation of boards, panels and cabinets can be
started when the installation site is dry, painted and
finished. The cabling can be done when the equip-
ment has been installed and the conduits and cable
ladders are in place. Cable racks are generally installed
after the process piping and ventilation ducts to en-
sure future accessibility.
Page 114
The electrical contractor should supervise the con-
struction of elevated floors, cable trenches, and open-
ings to ensure trouble free installation of the electrical
equipment, and to ensure that trays and racks are
lifted in before the routes are blocked.
I nstallation of equipment
Electrical equipment, such as switchgear, transform-
ers, control cabinets, neutral point cubicles, and DC
cabinets are assembled, mounted and fixed in accor-
dance with the manufacturers instructions, the elec-
trical drawings and the layout drawings.
Before installing the switchgear, the positions and
dimensions of the foundations and cable openings
must be verified. During the installation, the arc dis-
charge channels must be regarded.
I nstallation of electrical cables
When installing the cables, cooperation with the me-
chanical installation personnel is required in order to
avoid encounters with piping or other structures.
Borings for small penetrations through the walls are
carried out by the installer. Larger openings are re-
served in the construction drawings.
Cable pulling must be done in controlled circum-
stances, and not in too low ambient temperatures,
according to the manufacturers instructions. To re-
duce friction, the cables should be lubricated with
appropriate grease.
All cables connected to the engine generator set must
be cut, laid and fastened with slack so as to allow the
movements of the engine generator set without caus-
ing stress on cables and terminals.
Marking of cables
The cables must be marked in both ends with the
identification number in accordance with the cable
lists. Each cable core is marked with the codes of the
terminals to which it is connected.
10.3 Commissioning
10.3.1 General
The term commissioning means the activities nec-
essary to bring the power plant into operation after
the installation. It can be divided into the following
phases:
- Pre-commissioning before first start-up of the
engine generator sets
- First start-up, running in and fine tuning
- Performance tests.
Part of the activities can be performed simultane-
ously; part of them must be performed sequentially.
10.3.2 Pre-commissioning
Pre-commissioning covers all the mechanical and
electrical inspections and tests required to prepare the
plant before the plant is energized.
Pre-commissioning involves, for instance:
- Pressure tests and cleaning procedures
- Functional tests of protection relays
- Tests of main and control circuits
- Voltage tests of generators and power cables.
The tests must be done in accordance with applicable
standards.
Pre-commissioning involves also the inspections and
tests related to civil works, such as buildings,
grounds, heating, ventilation, etc. These activities
start already during the construction phase and con-
tinue through the installation phase.
When the plant electrical systems are energized for
the first time, the power is usually supplied by an ex-
ternal source, normally back-fed from the grid. When
energizing equipment, the correct voltage and phase
rotation must be checked and verified.
Page 115
10.3.3 Running in and fine tuning
Engine generator sets
First start-up and running in of a new engine must be
performed according to the program provided for the
engine. Functional tests must be done and recorded.
Required adjustments of the engine generator sets
and gas regulating units should be done by qualified
personnel from Wrtsil.
Auxiliary systems
Before starting the auxiliary systems, they must be
filled. During first start-up, they are verified for cor-
rect function. The commissioning staff should fine
tune and record the process values. Fine tuning re-
quired on the auxiliary systems at site involves cool-
ing system flow adjustments.
10.3.4 Performance tests
General
Performance tests are conducted to demonstrate and
verify compliance with the performance guarantees in
the contract. The test parameters, guaranteed per-
formance values, and the performance tests proce-
dures are project-specific and specified in the con-
tract.
The tests may include the following performance pa-
rameters:
- Power output, from individual engine generator
sets and/ or from entire plant
- Heat rate
- Lube oil consumption
- Power consumption of plant auxiliaries
- Voltage and frequency variations
- Noise emissions
- Stack emissions.
The tests are documented in a commissioning file and
a handing over certificate. Any open items will be
listed in a punch list, and a schedule for corrective
actions is made.
Performance tests can be done when the installation
is completed, and all pipe systems, auxiliary units,
electrical systems, and control equipment are adjusted
and calibrated for correct operation.
Wrtsil 34SG Power Pl ant Product Guide 11. TECHNICAL DATA
Page 116
11. TECHNI CAL DATA
The following data is based on 100% load (power factor = 0.8), standard reference conditions according to ISO
3046
1
and defined at generator terminals.
Table 35 Electrical Output and -heat rate for 50 Hz
Engine type Wrtsil 9L34SG Wrtsil 16V34SG Wrtsil 20V34SG
NOX setting mg/Nm 250 500 250 500 250 500
Compression ratio 11:1 12:1 11:1 12:1 11:1 12:1 11:1 12:1 11:1 12:1 11:1 12:1
Electrical Power kW 3888 3888 3888 3888 6970 6970 6970 6970 8730 8730 8730 8730
Electrical heat rate kJ /kWh 8254 8065 7986 7817 8186 7999 7920 7753 8169 7982 7904 7737
Electrical efficiency % 43,6 44,6 45,1 46,1 44,0 45,0 45,5 46,4 44,1 45,1 45,5 46,5
Table 36 Electrical Output and -heat rate for 60 Hz
Engine type Wrtsil 9L34SG Wrtsil 16V34SG Wrtsil 20V34SG
NOX setting mg/Nm 250 500 250 500 250 500
Compression ratio 11:1 12:1 11:1 12:1 11:1 12:1 11:1 12:1 11:1 12:1 11:1 12:1
Electrical Power kW 3758 3758 3758 3758 6737 6737 6737 6737 8439 8439 8439 8439
Electrical heat rate kJ /kWh 8254 8065 7986 7817 8186 7999 7920 7753 8169 7982 7904 7737
Electrical efficiency % 43,6 44,6 45,1 46,1 44,0 45,0 45,5 46,4 44,1 45,1 45,5 46,5
Including engine driven pumps, heat rate and efficiency includes 5% tolerance according to ISO 3046-1
1
Except for charge air coolant temperature, which is 35 C
Wrtsil 34SG Power Plant Product Guide 11. TECHNICAL DATA

Page 117

11.2 Engine Technical data
Engine type
Wrtsil
9L34SG
Wrtsil
16V34SG
Wrtsil
20V34SG
Engine speed rpm 750 720 750 720 750 720
Fuel gas system
Pressure before engine, typical kPa (bar) 450 (4,5)
Gas inlet temperature C 0 - 60
Lubricating oil system
Specific consumption, max g/kWh 0,4
Pressure before engine, nominal kpa (bar) 450 (4,5)
Pressure before engine, alarm kpa (bar) 300 (3,0)
Pressure before engine, stop kpa (bar) 200 (2,0)
Oil volume, wet sump (nom) m 2,7 4,4 5,2
Pump capacity, main m/h 110 105 158 152 180 173
Pump capacity, priming m/h 19,5 23,5 52 63 52 63
Starting air system
Pressure before engine,
nominal maximum Mpa (bar) 3 (30)
Pressure before engine,
minimum for succesful start Mpa (bar) 1,5 (15)
Air consumption per start
attempt, average at 20C Nm/h 8 11 13
Engine Control air system
Consumption at high load Nm 8,3 2
Cooling water system
Pump capacities (LT & HT),
nominal flow m/h 90 90 135 135 150 150
Pump differential pressure
(LT & HT) kPa 283 251 255 226 265 235
LT water volume in engine m 0,18 0,27 0,31
HT water volume in engine m 0,56 0,84 0,94
HT temp after engine, nom.
1-C system / 2-C system C 85 / 92
Static pressure before HT-pump, min. (g) C 70 - 150 (0,7-1,5)
Static pressure before LT-pump, min. (g) kPa (bar) 70 - 150 (0,7-1,5)
Pressure drop over engine, LT kPa (bar) 150 (1,5) 150 (1,5) 180 (1,8)
Pressure drop over engine, HT kPa (bar) 150 (1,5) 150 (1,5) 150 (1,5)
Table 37 Technical data
Page 118
11.3 Engine heat balances
The heat balances are based on standard reference conditions as defined in ISO3046-1, except for charge air
coolant temperature which is 35C. Output, BSEC and efficiency are declared at the flywheel.
The following tolerances will apply: BSEC and efficiency 5% (ISO 3046-1), flows 5%, Exhaust gas tempera-
ture 10C, Charge air temperature after compressor 5C, Heat loads 10%, Radiation 20%.
Table 38 9L34SG, 50 Hz, NOX = 500 mg/ Nm, CR=12:1
Load % 100 90 75 50 30
Rated output kW 4050
Brake mean effective
pressure, BMEP bar 19,83 17,84 14,87 9,91 5,95
Brake specific energy
consumption, BSEC kJ /kWh 7505 7581 7771 8381 8893
Efficiency % 48,0 47,5 46,3 43,0 40,5
Engine output kW 4050 3645 3037,5 2025 1215
Lube oil kW 430 420 390 340 280
J acket water kW 570 530 480 420 360
Air temp. after comp. C 183 169 149 115 74
Charge air HT kW 540 400 270 110 -30
Charge air LT kW 330 300 230 140 100
Charge air total kW 870 700 500 250 70
Charge air flow kg/s 6,4 6,0 5,3 4,0 3,1
Radiation kW 130 120 120 120 110
Exhaust gas flow after TC kg/s 6,46 5,8 4,9 3,7 2,6
xh. gas temp after TC C 400 415 435 440 440
Page 119
Table 39 9L34SG, 60 Hz, NOX = 500 mg/ Nm, CR=12:1
Load % 100 90 75 50 30
pressure, BMEP kPa 19,96 17,97 14,97 9,98 5,99
Efficiency % 48,0 47,5 46,3 43,0 40,5
Engine output kW 3915 3523,5 2936,25 1957,5 1174,5
Lube oil kW 420 410 380 330 270
J acket water kW 550 510 470 400 350
Air temp. after comp. C 184 169 150 116 74,7
Charge air HT kW 520 390 260 110 -20
Charge air LT kW 320 290 220 140 100
Radiation kW 120 120 120 110 110
Exh. gas temp after TC C 400 415 435 440 440
Table 40 16V34SG, 50 Hz, NOX = 500 mg/ Nm, CR=12:1
Load % 100 90 75 50 30
Efficiency % 48,0 47,5 46,3 43,0 40,5
Engine output kW 7200 6480 5400 3600 2160
Lube oil kW 770 750 700 610 500
J acket water kW 1020 950 860 740 640
Charge air HT kW 950 720 480 190 -50
Charge air LT kW 590 530 400 250 180
Radiation kW 230 220 210 210 200
Page 120
Table 4116V34SG, 60 Hz, NOX = 500 mg/ Nm, CR=12:1
Load % 100 90 75 50 30
Efficiency % 48,0 47,5 46,3 43,0 40,5
Engine output kW 6960 6264 5220 3480 2088
Lube oil kW 750 720 680 590 480
J acket water kW 980 910 830 720 620
Charge air HT kW 930 700 470 190 -40
Charge air LT kW 570 510 390 240 170
Radiation kW 220 210 210 200 190
Exhaust gas flow after TC kg/s 11,1 10 8,4 6,3 4,4
Load % 100 90 75 50 30
Efficiency % 48,0 47,5 46,3 43,0 40,5
Engine output kW 9000 8100 6750 4500 2700
Lube oil kW 970 930 870 760 620
J acket water kW 1270 1180 1070 930 800
Charge air HT kW 1190 900 600 240 -60
Charge air LT kW 740 660 500 320 220
Radiation kW 290 280 270 260 250
Exhaust gas flow after TC kg/s 14,36 13 10,9 8,1 5,7
Page 121
Load % 100 90 75 50 30
Efficiency % 48,0 47,5 46,3 43,0 40,5
Engine output kW 8700 7830 6525 4350 2610
Lube oil kW 930 900 850 730 600
J acket water kW 1230 1140 1040 900 770
Charge air HT kW 1170 880 590 230 -60
Charge air LT kW 720 640 490 310 210
Radiation kW 280 270 260 250 240
11.4 Generator data (typical)
Engine Wrtsil 9L34SG Wrtsil 16V34SG Wrtsil 20V34SG
Frequency 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz
Rated output KVA 5428 5211 8712 8422 10913 10549
Power factor cos phi 0,8 0,8 0,8 0,8 0,8 0,8
Rated voltage V 11000 13800 11000 13800 11000 13800
Rated current A 285 218 457 352 573 441
Insul.class/Temp.rise F/F F/F F/F F/F F/F F/F
r.p.m. 750 720 750 720 750 720
Enclosure IP23 IP23 IP23 IP23 IP23 IP23
Standard IEC60034
Ambient C 50 50 50 50 50 50
Altitude m 1000 1000 1000 1000 1000 1000
Table 44 Technical data for medium voltage generators
Wrtsil 34SG Power Pl ant Product Guide 12. FLUID REQUIREMENTS
Page 122
12. FLUI D REQUI REMENTS
12.1 Fuel gas requirements
The Wrtsil 34SG engine is designed to operate without derating on natural gas qualities according to the fol-
lowing specification.
In addition, to ensure the long term performance of the emission control system (if included), the concentrations
of sulphur components and catalyst poisons must be within the limits specified by the catalyst supplier.
Quality Limi t val ues Notes
Lower Heating Value (LHV) 28 MJ /Nm
3
Lower Heating Valuecorresponds to the energy content of
the gas. If the LHV is too low, the engine output has to be
reduced, or the gas pressure to the engine must be raised.
Methane number (MN) 55 - 80 Dependent on engine optimisation and ambient conditions.
Methane content, CH4 70 vol. %
Hydrogen sulphide, H2S 500 ppm Hydrogen sulphide H2S may cause corrosion on the gas
handling equipment.
Hydrogen, H2 3 vol. % Any higher hydrogen contents must be agreed upon case
by case.
Water and hydrocarbon conden-
sates before the engine
Not allowed The dew point of natural gas is below the minimum operat-
ing temperature and pressure.
Ammonia, NH3 25 mg/Nm
3
Chlorines +Fluorines 50 mg/Nm
3
Particles or solids, content 50 mg/Nm
3
Particles or solids, size 5 m
At the engine inlet.
Particles can be the reason for improper sealing and func-
tion of the gas handling equipment.
Gas inlet temperature 0 60 C
Table 45. Fuel gas quality requirements
The Methane Number provides a scale for evaluating the knock resistance of the fuel gas. Methane number
(MN) indicates the percentage by volume of methane in blend with hydrogen that exactly matches the knock
intensity of the gas mixture in question under specified operating conditions in a knock testing engine. A higher
methane number means better knock resistance. If the components of the fuel gas are known, the methane
number can be calculated. Heavier hydrocarbons as ethane, propane and butane will lower the methane number.
Carbon dioxide and nitrogen will increase the methane number.
Page 123
12.2 Lubricating oils
12.2.1 General requirements
The lubricating oil should fill the following general
requirements:
Viscosity class SAE 40
Viscosity index (VI) Minimum 95
Alkalinity (BN) 4 - 7 mg KOH/g
Sulphated ash level Maximum 0.6 weight %
Too high ash content can cause
pre-ignition, knocking and spark
plug fouling, while too low ash
content can lead to increased
valve wear.
Foaming character-
istics according to
the ASTMD 892-92
test method (fresh
lube oil)
Sequence I (24
o
C): 100/0 ml,
Sequence II (93.5
o
C): 100/0 ml,
Sequence III (24
o
C): 100/0 ml
Table 46. Lube oil requirements
For the speed governor, both turbine and normal
system oil can be used. Turbine oil must not be used
in the engine.
Recycled or re-refined base oils are not allowed.
12.2.2 Additives
The oils should contain additives that give good oxi-
dation stability, corrosion protection, load carrying
capacity, neutralization of acid combustion and oxi-
dation residues, and should prevent deposit forma-
tion on internal engine parts (piston cooling gallery,
piston ring zone and bearing surfaces in particular).
12.2.3 Approved lubricating oils
Lubricating oils approved by Wrtsil should be used.
See Table 47. The use of approved lubricating oils is
mandatory during the warranty period and is also
strongly recommended after the warranty period has
expired.
Supplier Brand name Vi scosi ty BN Sulphated ash
(w-%)
BP Energas NGL SAE 40 4.5 0.45
Castrol Duratec L SAE 40 4.5 0.45
ChevronTexaco Geotex LA
Low Ash Gas Engine
Oil SAE 40
SAE 40
SAE 40
5.2
4.2
0.45
0.50
ExxonMobil Pegasus 705
Pegasus 805
Pegasus 905
Pegasus 1
SAE 40
SAE 40
SAE 40
SAE 40
5.3
6.2
6.2
6.5
0.49
0.50
0.49
0.49
Idemitsu Kosan Co.
Ltd.
Apolloil GHP 40L SAE 40 4.7 0.45
Petro-Canada Sentron 445 SAE 40 4.7 0.40
Shell Mysella LA 40
Mysella XL 40
SAE 40
SAE 40
5.2
4.5
0.45
0.50
Total Nateria X 405 SAE 40 5.2 0.45
Table 47. Approved lubricating oils
Page 124
12.3 Water quality requirements
Parameter Uni t
Engine
cooling
water
Turbi ne
washing
Cooli ng
tower
(circula-
tion)
Boi l er
make-up
Boi l er
feed
Boi l er
water
(p<15bar)
Oil y water
treatment
General appearance Visually clear and colourless. No smell.
pH at 25 C >6,5 7 to 8 9 to 9.5 9,5 to 11 6 to 8
Conductivity
at 25 C
mS/m <100 <75 <20 <500
TDS mg/l <500 <130 <2600
Total Hard-
ness TH
dH <10 <10 4.5 - 28
(1)
<0.4 <0.1
Alkalinity
HCO3
mg/l <300 <100 <25 <500
TH +Alkalinity
as CaCO3
mg/l <650
p - alkalinity mg/l 5 - 15
Oxygen O2 mg/l <0,005
Iron Fe and
Copper Cu
mg/l <0,1 <0,2 <0,1 <0,5
Silicate SiO2 mg/l <50 <50 <150 <20 <5 <100
(2)
Organics
(KMnO4
value)
mg/l (<30) (<15) <300
(3)
<15
Oil mg/l <5 ND <1 <1
Chlorides Cl mg/l <80 <80 <450
(4)
<40 <10 <200 <100
Phosphates mg/l
(5)
20 40
Sulphates
SO4
mg/l <150 <1200
Sodium +Po-
tassium Na+K
mg/l <160 <40 <800
Suspended
solids
mg/l <10 <10 <80 <5 <2 <10
Table 48. Water quality requirements
(1) Maximum hardness in the cooling tower circuit water without chemical scaling inhibitors. Minimum
hardness requirement to prevent corrosion.
(2) Maximum silicate content in the boiler is pressure dependent. The limit is lower for steam turbine instal-
lations.
(3) Organic matter in the boiler water may lead to water bursting with steam resulting bad condensate qual-
ity
(4) The maximum allowed chloride content in the cooling tower circuit can vary from 100 to 600 mg/l or
even higher depending on construction. Note that the maximum recommended chloride content in for
the stainless steel plate heat exchanger is only 300 mg/l.
(5) Phosphates are added to the boiler feed water for binding hardness of the water. It will also raise pH
slightly. The final adjustment of pH is done by sodium hydroxide to maintain p- value. The activated so-
dium sulphite or other oxygen binding chemical is also dosed to boiler feed water.
Wrtsil 34SG Power Pl ant Product Guide 13. DIMENSIONS AND WEIGHTS
Page 125
13. DI MENSI ONS AND WEI GHTS
Figure 115 9L34SG Generating set
Figure 116 16V34SG Generating set
Figure 117 20V34SG Generating set
Page 126
13.2 Standard auxiliary equipment
13.2.1 Gas regulating unit
Dimensi on / Pi pe DIN desi gn ANSI desi gn Notes
Length 2850 mm 117
Width 600 mm 26.5
Height 1430 mm 50
Weight (gross) 730 kg
Fuel gas inlet DN80 3
Fuel gas outlet, main DN100 3 or 4 Depends on the manufacturer and components
Fuel gas outlet, pre-
chamber
DN25 1
Venting 1 EO 12 1
Venting 2 DN25 2
Control air NPT NPT
Inert gas EO 12 1
Table 49. Typical GRU dimensions
Page 127
13.2.2 Engine auxiliary module (EAM)
Figure 118 Wrtsil 16V and 2034SG EAM module dimensions
13.2.3 Exhaust gas module
Figure 119 Wrtsil 16V and 20V34SG Exhaust gas module dimensions
Page 128
13.2.4 Standard auxiliary units
Maintenance water tanks
Tank
volume
Pump flow
50 / 60 Hz
A B C D E
2.5 m
3
5.4 / 6.5 m
3
/h 1206 mm 1500 mm 1209 mm 2000 mm 2527 mm
4 m
3
5.4 / 6.5 m
3
/h 1206 mm 1800 mm 1509 mm 2500 mm 3027 mm
6 m
3
9 / 10.8 m
3
/h 1636 mm 1800 mm 1509 mm 2500 mm 3027 mm
10 m
3
9 / 10.8 m
3
/h 2036 mm 1800 mm 1509 mm 3400 mm 3927 mm
Figure 120. Dimensions of standard maintenance water tanks
Exhaust gas silencers
Engine Type Attenuation [dB (A)] L [mm] D [mm] a [mm] b [mm] c [mm] d [mm] Weight
[kg]
9L34SG 35 5 770 1700 2120 550 1020 1730 2860
9L34SG 45 7 520 1900 2320 550 1120 1930 4170
16V34SG 35 7 020 2000 2440 780 1140 2030 4970
16V34SG 45 10 020 2100 2540 780 1140 2130 7050
20V34SG 35 8 280 2300 2740 900 1320 2330 7170
20V34SG 45 9 270 2450 2890 900 1395 2480 8840
Figure 121. Typical dimensions of exhaust gas silencers
Page 129
I ntake air filter (example)
Figure 122. Intake air filter dimensions 20V34SG (example)
Page 130
Radiators (example)
Figure 123 Radiator field
Engine
Type
Fans / Radiator
[Qty]
Radiators / Engine
[Qty]
Radiator field / engine
L x W [m]
L1
[mm]
L
[mm]
W1
[mm]
W
[mm]
9L34SG 7 1 12.0 x 2.5 1650 11950 2520 2520
16V34SG 5 2 10.4 x 5.4 2000 10400 2520 5040
20V34SG 6 2 12.4 x 5.4 2000 12400 2520 5040
Table 50 Typical dimensions of Standard radiator field
Engine
Type
Fans / Radiator
[Qty]
Radiators / Engine
[Qty]
Radiator field / engine
L x W [m]
L1
[mm]
L
[mm]
W1
[mm]
W
[mm]
9L34SG 4 2 8.4 x 5.1 2000 8400 2520 5040
16V34SG 6 2 12.4 x 5.1 2000 12400 2520 5040
20V34SG 5 3 11.4 x 7.6 2200 11400 2520 7560
Table 51Typical dimensions of low-noise radiator field
Wrtsil 34SG APP A. STANDARDS AND CODES
Product Guide
Page 131
APP A. STANDARDS AND CODES
General
This appendix lists the most significant standards
and codes that Wrtsil follows, where applicable, in
the manufacturing, design and engineering of Wrt-
sil 20W34 power plants.
Explanation of abbreviations:
API American Petroleum Institute
ASHRAE American Society of Heating, Refriger-
ating and Air-Conditioning Engineers
EN European standard
IEC International Electrotechnical Commis-
sion
ISO International Organization for Stan-
dardization
NFPA National Fire Protection Association
OSHA Occupational Safety & Health Admini-
stration
Engine generator set
IEC 34-1
(EN 60034-1)
Rotating electrical machines
ISO 3046, 1 - 6 Specification for reciprocating in-
ternal combustion engines
ISO 8178 Reciprocating internal combustion
engines. Exhaust gas emission
measurement.
ISO 8528 Reciprocating internal combustion
engine driven alternating current
generating sets
EN 1834-1 Resiprocating internal combustion
engines. Safety requirements for
design and construction of engines
for use in potentially explosive
atmospheres.
EN 60204-1 Safety of machinery. Electrical
equipment of machines. General
requirements.
NFPA 37 Standard for the installation and
use of stationary combustion en-
gines and gas turbines
Fuel gas system
NFPA 54 Fuel gas code
Standard auxiliary modules and units
EN 292 Safety of machinery. Basic con-
cept, general principles for design.
Piping systems
EN 13480-3 Metallic industrial piping. Design
and calculation
EN 1591-1 Flanges and Their J oints - Design
Rules for Gasketed Circular
Flange Connections
Electrical and control systems
IEC 298 A.C. Metal Enclosed Switchgear
and Controlgear for Rated Volt-
ages Above 1 kV and Up to and
Including 52 kV
IEC 56
IEC502
EN 60439-1 Specification for low-voltage
switchgear and controlgear as-
semblies. Type-tested and partially
tested assemblies.
Fire protection
NFPA 10 Standard for portable fire extin-
guishers
NFPA 13 Installation of sprinkler system
NFPA 14 Standard for the installation of
standpipe and hose system
NFPA 15 Water spray fixed systems for fire
protection
NFPA 22 Standard for Water tanks for Pri-
vate FM Protection
NFPA 24 Standard for the Installation of
Private Fire Service Mains and
Their Appurtenances
NFPA 30 Flammable and combustible liq-
uids Code
NFPA 37 Standard for the Installation and
Use of Stationary Combustion
Engines and Gas Turbines
NFPA 101 Life Safety Code
NFPA 850 Recommended practice for fire
protection for electric generating
plants and high voltage direct cur-
rent converted stations
CEA 4001 Sprinkler System Planning and
Installation
Wrtsil 34SG APP A. STANDARDS AND CODES
Product Guide
Page 132
API 650 Tank Design Standard
Classification of hazardous areas
Ameri can codes
API 500 Recommended Practice for Classifica-
tion of Locations for Electrical Installa-
tions at Petroleum Facilities Classified
as Class I, Division 1 and Division 2.
API 505 Recommended Practice for Classifica-
tion of Locations for Electrical Installa-
tions at Petroleum Facilities Classified
as Class I, Zone 0, Zone 1, and Zone 2
NFPA 30 Flammable and Combustible Liquids
Code
European Codes
EN-60079-
10
Electrical apparatus for explosive gas
atmospheres; part 10 Classification of
hazardous areas
EN-1834-1 Reciprocating internal combustion en-
gines Safety requirements for design
and construction of engines for use in
potentially explosive atmospheres
Part II engines for use in flammable
gas and vapour atmospheres.
Platforms and staircases
ISO 14122 Safety of machinery permanent
means of access to machinery,
part 1 - 4
OSHA 1910 Occupational safety and health
standard, sub part D Walking-
working surfaces
OSHA 1926 Safety and health regulations for
construction, subpart X - Stair-
ways
Ventilation and air conditioning
ASHRAE 55 Thermal environmental conditions
for human occupancy
ASHRAE 55 Compliant Ventilation System.
:
Wrtsil 34SG APP B. UNIT CONVERSIONS
Product Guide
Page 133
APP B. UNI T CONVERSI ONS
Length units
Length m i n ft
m 1 39.370 3.2808
in 0.0254 1 0.083333
ft 0.3048 12 1
mile 1609.3 63360 5280
Table 52. Conversion table for length units
Length m In ft
m 1 1/0.0254 1/(12*0.0254)
in 0.0254 1 1/12
ft 0.0254*12 12 1
mile 0.0254*63360 63360 5280
Table 53. Formulas for converting length units
Volume units
Volume cubi c m l (li ter) cubi c foot Imperial
gal lon
US gallon
cubic m 1 1000 35.315 219.97 264.17
l (liter) 0.001 1 0.35315 0.21997 0.26417
cubic foot 0.028317 28.317 1 6.2288 7.4805
Imperial gallon 0.0045461 4.5461 0.16054 1 1.2009
US gallon 0.0037854 3.7854 0.13368 0.83267 1
Table 54. Conversion table for volume units
Volume cubi c m l (li ter) cubi c foot Imperial gallon US gallon
cubic m 1 1000 1 / (12 * 0.0254)
3
1/0.00454609 1/(231 * 0.0254
3
)
l (liter) 0.001 1 1 / (12 * 0.254)
3
1/4.54609 1 / (231 * 0.254
3
)
cubic foot (12 * 0.0254)
3
(12 * 0.254)
3
1 (12 * 0.254)
3
/
4.54609
12
3
/ 231
Imperial gallon 0.00454609 4.54609 4.54609 /
(12*0.0254)
3
1 4.54609 /
(231*0.254
3
)
US gallon 231 * 0.0254
3
231 * 0.254
3
231 / 12
3
231* 0.254
3
/
4.54609
1
Table 55. Formulas for converting volume units
Product Guide
Page 134
Normal cubic meter (Nm
3
) Standard cubic foot (SCF)
j
, )
j
, )
j
, )
j
, )
336 , 37
(a) psi 14.7 F, 60
SCF
kPa(a) 325 . 101 , 0
Nm
336 , 37 * kPa(a) 325 . 101 , 0
Nm
(a) psi 14.7 F, 60
SCF
3
3
=
=
F
C
F
C
F F
Mass units
Mass kg l b oz
kg 1 2.2046 35.274
lb 0.45359 1 16
oz 0.028350 0.0625 1
Table 56. Conversion table for mass units
Density units
Density kg / cubi c m l b / US gal l on lb / imperial gallon lb / cubic ft
kg / cubic m 1 0.0083454 0.010022 0.062428
lb / US gallon 119.83 1 0.83267 0.13368
lb / imperial gallon 99.776 1.2009 1 0.16054
lb / cubic ft 16.018 7.4805 6.2288 1
Table 57. Conversion table for density units
Energy units
Energy J BTU cal lbf ft
J 1 9.4781e-04 0.23885 0.73756
BTU 1055.06 1 252.00 778.17
cal 4.1868 3.9683e-03 1 0.32383
lbf ft 1.35582 1.2851e-03 3.0880 1
Table 58. Conversion table for energy units
Power units
Power W hp US hp
W 1 0.0013596 0.0013410
hp 735.499 1 1.0136
US hp 745.7 0.98659 1
Table 59. Conversion table for power units
Product Guide
Page 135
Pressure units
Pressure Pa bar mmWG psi
Pa 1 0.00001 0.10197 0.00014504
bar 100000 1 10197 14.504
mmWG 9.80665 9.80665e-05 1 0.0014223
psi 6894.76 0.0689476 703.07 1
Table 60. Conversion table for pressure units
Mass flow units
Mass fl ow kg/s l b/s
kg/s 1 2.2046
lb/s 0.45359 1
Table 61. Conversion table for mass flow units
Volume flow units
Volume
fl ow
cubi c m/s l / min cubi c m/h cubi c ft/s cubi c ft/h USG / s USG / h
cubic m / s 1 60000 3600 35.315 127133 264.17 951019
l / min 1.6667e-05 1 0.06 1699.0 0.47195 227.12 0.063090
cubic m / h 0.00027778 16.667 1 101.94 0.028317 13.627 0.0037854
cubic ft / s 0.028317 0.00058858 0.0098096 1 0.00027778 0.13368 3.7133e-05
cubic ft / h 7.8658e-06 2.1189 35.315 3600 1 481.25 0.13368
USG / s 0.0037854 0.0044029 0.073381 7.4805 0.0020779 1 0.00027778
USG / h 1.0515e-06 15.850 264.17 26930 7.4805 3600 1
Table 62. Conversion table for volume flow units
Temperature units
Temperature K
o
C
o
F
K 1 value[C] +273.15 5 / 9 * (value[F] - 32) +273.15
o
C value[K] - 273.15 1 5 / 9 * (value[F] - 32)
o
F 9 / 5 * (value[K] - 273.15) +32 9 / 5 * value[C] +32 1
Table 63. Temperature conversion formulas
Prefixes
T = Tera = 1 000 000 000 000 times
G = Giga = 1 000 000 000 times
M = Mega = 1 000 000 times
k = kilo = 1 000 times
m = milli = divided by 1 000
= micro = divided by 1 000 000
n = nano = divided by 1 000 000 000
Product Guide
Page 136
Pipe dimensions metric - imperial
Europe USA
DN OD/mm NPS OD/Inch OD/mm
DN 15 21.3 0.840 21.3
DN 20 26.9 1.050 26.7
DN 25 33.7 1 1.315 33.4
DN 32 42.4 1 1.660 42.2
DN 40 48.3 1 1.900 48.3
DN 50 60.3 2 2.375 60.3
DN 65 76.1 2 2.875 73.0
DN 80 88.9 3 3.500 88.9
DN 100 114.3 4 4.500 114.3
DN 125 139.7 5 5.563 141.3
DN 150 168.3 6 6.625 168.3
DN 200 219.1 8 8.625 219.1
DN 250 273.0 10 10.750 273.0
DN 300 323.9 12 12.750 323.8
DN 350 355.6 14 14.000 355.6
DN 400 406.4 16 16.000 406.4
DN 450 457.2 18 18.000 457.0
DN 500 508.0 20 20.000 508.0
DN 600 609.6 24 24.000 610.0
DN 900 914.4 36 36.000 914.0
DN1000 1016.8 40 40.000 1016
DN1100 1118.0 44 44.000 1118
DN1200 1219.0 48 48.000 1219
DN1300 1320.0 52 52.000 1321
DN1400 1420.0 56 56.000 1422
Table 64. Pipe dimensions according to European and American standards and outer pipe diameters (O

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