GAS ENGINE POWER PLANT

Operation & Maintenance Course

18V34SG
DAFTAR ISI
A. Pendahuluan
A. Ragam jenis mesin gas
B. Proses pada mesin gas
C. Data utama mesin gas (Wartsila 18V34SG)
B. Komponen utama
A. Block bearing & oil sump
B. Head
C. Piston & Connection rod (conrod)
D. Liner
E. Crankshaft
F. Turbocharger
C. Sistem bahan bakar
D. Sistem udara pembakaran dan gas buang / Charge air (CA) and
exhaust gas (EG)
E. Sistem udara bertekanan / Compressed air system
F. Sistem pendingin / Cooling system
G. Sistem pelumas / Lubrication system
H. Prinsip operasi dan instrumentasi
Operation
Operation Engine Control System
Operation Safety
Reminder
Despite the safety system, there is a risk of gas
explosion. To avoid possible accidents, no-one
should remain in the engine room and
boiler/silencer room during an engine start.
Operation Start, Stop and Operation
Turning device
Starting air system
maximum pressure 30 bar
compressor starts at 24 bar
alarm at 18 bar
draining of the system
Starting motors
design
Control air system
wastegate
Operation Start
Start:
The start signal is given in the WOIS
The HT-water temperature should be 50C
minimum
The ventilation of the exhaust pipe after the
engine starts
The test procedure for the gas regulating unit
starts. When finished, the shutoff valves on the
gas regulating unit will open.
Operation Start
Required starting air pressure min. about 20 bar.
Both starting motors have to be connected before
they are able to rotate.
At 50 rpm the gasvalves start to open and the
ignition starts to work
Check of speed increase will start
At 150 rpm the starting motors will disconnect
At 250 rpm the startmode is changed to runmode
At 350 rpm the prelub. pump stops. The HT-water
and alternator preheating will switch off.
750 rpm or 720 rpm = nominal speed
Operation Start
Exhaust temperature check takes place after
reaching nominal speed
If the alternator does not synchronize within one
minute, the engine stops. Otherwise the engine
continues to run and a 500 kW baseload is
immediately applied.
If the base load is not reached in one minute the
engine stops.
The loading time to 100 % is about 15 minutes
Operation Stop
Stop:
The stop signal is given from the WOIS
The load decreases to baseload within 7,5 minutes
The gasvalves on the gasregulating unit and on the
engine close when the stopsignal is given. If there is
an emergency stop, the ignition will stop at the same
time
At 350 rpm the lub.oil priming pump starts. The HT-
water and alternator preheating will switch on.
At 250 rpm the mode is changed from runmode to
stopmode
At 50 rpm the ignition stops
Operation Operation
Normal operation supervision
take performance data regularly
exhaust temperatures, check the trends
listen to the engine, knocking etc.
check the wastegate function
use a gas leak detector regularly
check for cooling water and lube oil leaks
check that the drain pipes of the charge air cooler
housing is open
drain the starting air system before every start
Operation Running-In
Running after overhaul
run the engine for about 5 minutes after first
start, check the temperatures of the con.rod and
main bearings
check for leakages
running-in programme
Control system
WECS 3000
This topic describes the basics of WECS 3000
engine control & monitoring system. WECS
stands for Wrtsil Engine Control System. It
individually controls and monitors each engine
cylinder.
Control system Presentation on WECS 3000 on W34SG
Control system Wartsila Operator Interface System
Control system WECS 3000 Layout
Control system Component Layout of WECS 3000
Control system Side Covers for WECS Units
Control system WECS 3000
Function
Start and stop control
Run control
Engine load & speed control
Air-fuel ratio control
Combustion control
Monitoring and safety system handling
Communication with external systems
Control system WECS 3000
Main Components of WECS 3000
Main Control Unit (MCU x 1)
Cylinder Control Unit (CCU x 18)
Knock Detection Unit (KDU x 2)
Distributed Control Unit (DCU)
Sensor Multiplexing Unit (SMU)
Control system Block Layout Connection of WECS 3000
Control system Main Control Unit (MCU)
The MCU is the brain in the system. It receives and
interprets information sent by units controlling
references for ignition, gas pressure, gas injection
timing and duration.
It also handles tasks as the start and stop sequences,
speed/load control, charge air control, and the engine
safety system and monitoring.
The MCU also communicates with the plant control
system (PLC & WOIS).
Function of MCU
Control system Main Control Unit (MCU)
Basic Specs
Single height euroboard VME system including:
Rack with VMEbus Backplane
Processor Board
Digital I/O Board
Analogue I/O Board
CAN Interface Board
Power Supply
32-bit MC68EC030 running at 40 MHz is responsible for
the engine control
16-bit MC68302 running at 16 MHz is responsible for the
Communication to/from the MCU
Operating temperature: -40...+85 C
Resilient mounting on the engine
Control system Main Control Unit (MCU)
Summary of Functions
Start control
Stop control
Run control
Gas supply pressure control
Throttle valve control
Waste gate control
Engine load & speed control
Knock control
Safety handling
Fault shutdowns
Emergency stop
Alarm handling
Communication to external systems ( PLC & WOIS)

Control system Main Control Unit (MCU)
Control system Main Control Unit (MCU)
Control system Cylinder Control Unit (CCU)
Control system Cylinder Control Unit (CCU)
Control system Cylinder Control Unit (CCU)
Basic Specs
Comprises:
the CPU Board
the I/O Board
32-bit microprocessor MC68332 16 MHz
CAN-controller i82527
The CCU controls two cylinders, each
Cylinder Comprising:
one Ignition Unit
two Exh. Gas Temp. Sensors (in parallel)
two Cyl. Liner Temp. Sensors (in parallel)
the Main Gas Control Valve
the PCC Gas Control Valve
Engine position signals to each CCU
Operating temperature: -50...+85 C
Control system Cylinder Control Unit (CCU)
Handles all cylinder control and monitoring
CCU controls and monitors two engine
cylinders
It consists of CPU Board and Input/Output
Board
It contains switch for checking condition of
main gas valve, pcc valve and spark plug. Also
contain 2 switches for ID.
Engine position signals to each CCU
Operating temperature: -50 to +85 oC
General Information
Control system Cylinder Control Unit (CCU)
Function of Cylinder Control Unit
Control of gas injection of 2 main gas admission
valves
Control of gas injection of 2 pre combustion
chamber admission valves
Control of ignition of 2 spark plugs
Measuring of 2 exhaust gas temperatures
Measuring of 2 cylinder liner temperatures
Reading of engine angular position and speed
send by rotary encorder
Reading of fuel demand (from the MCU)
Control system Cylinder Control Unit (CCU)
Control system Cylinder Control Unit (CCU)
Control system Potentiometers
Control system Potentiometers
Control system Potentiometers
Control system Knock Detection Unit (KDU)
Function of Knock Detection Unit
Used to measure the knock signals from
accelerometers mounted on each cylinder head.
The KDU filtrates, amplifies and converts these
signals to digital information and sends it over the
CAN-bus to the MCU for further processing.
One KDU is designed to handle up to nine
cylinders.

Control system Knock Detection Unit (KDU)
Basic Specs
Input signal from rotary encoder
Knock intensity value to MCU
Comprises:
The CPU Board
Memory
A/D-converters
32-bit microprocessor MC68332 16 MHz
CAN-controller i82527
The I/O Board
filtering
integration
Operating temperature: -50...+85 C
Control system Knock Detection Phenomenon
Control system Knock Sensor
Cylinder Head
Knock Sensor
Control system Distributed Control Unit and Sensor Multiplexing Unit
Function of Distributed Control Unit and
Sensor Multiplexing Unit

Used for measuring purposes (measuring of
sensors).
They convert different types of sensor signals to
digital information which is sent over a network to the
MCU for further processing (data handling for Local
Display Unit).

Control system Distributed Control Unit and Sensor Multiplexing Unit
Control system DCU and SMU Enclosure
Control system Sensor Multiplexing Unit (SMU)
Basic Specs
Microprocessor based
10 analog inputs: pt100, t/c, 4-20 mA,
0-10 V, on/off, etc.
8 digital I/O connections
2 frequency inputs
1 current output 0-20 mA
All channels software configurable
Power supply: 24 VDC
RS-485 serial interface
Operating temperature: -50...+100 C
Control system Distributed Control Unit (DCU)
Basic Specs
Microprocessor based
Comprises all features of the SMU
Several serial interfaces:
CAN bus to other DCUs and to the MCU
RS-485 bus to SMU chain
RS-232 to PC / LDU
Power supply: 24 VDC
Operating temperature: -50...+85 C
Control system Location of Rotary Encoder
Control system Rotary Encoder
The rotary encoder is mechanically adjusted to give the
synchronization pulse when piston number A1 is in Top Dead
Centre (TDC) position at power stroke. This pulse is then used to
synchronize the ignition and the gas admission valve timing for all
cylinders.
.
Control system Camshaft with Rotary Encoder
1. Camshaft piece 2. Bearing journal
3. Screw 4. Fixing pin
5. Rotary Encoder 6. End cover
7. Axial Bearing
Control system Measuring Engine Speed
Control system Measuring Engine Speed
Two Engine Speed Sensors
1. Rotary Encoder
A rotary encoder connected to the camshaft is the
master unit. The rotary encoder is used to
calculate engine angular position as well as engine
speed.
2. Engine Speed Pick-Up
The other speed sensor is an inductive proximity
switch installed at the camshaft gear.
This speed sensor is used as a redundant
overspeed protection device.
Control system Measuring Engine Speed
Two Engine Speed Sensors
Speed measured from the rotary encoder is
compared with the speed signal from the inductive
proximity switch in the MCU.
A shutdown is activated if a deviation in speed signals
is over 50 rpm.

Control system Rotary Encoder
Control system Rotary Encoder
Function
The encoder has two signal outputs.
1. One which provide 900 pulses/camshaft revolution
and
2. the other one providing one synchronization
pulse per camshaft revolution.
One revolution on camshaft is the same as two on
the crankshaft. This gives an resolution of 450
pulses/rev on crankshaft, i.e. 0.8 crank angle
/encoder pulse
Control system Engine Speed Pick-Up
Control system Engine Speed Pick-UP
Function
The engine speed measured with this pick-up is used
for:
1. redundant engine overspeed protection purposes,
and
2. also to verify the engine speed signal from the
rotary encoder on the camshaft.
The sensor is an inductive proximity switch with built-
in signal amplifier which provides a square-wave
output signal.
Control system Engine Speed Pick-UP
Function
The sensor is directly connected to the Overspeed
Trip Module in the MCU cabinet, from which it is
supplied with 24 VDC.
The sensor gives one pulse for each cog on the
camshaft gear passing the head of the sensor.
Control system Engine Speed Pick-UP
Function
The output of the sensor is providing a speed
proportional pulse train which is opto-coupled and
transduced into an analogue 4-20 mA signal in the
Overspeed Trip Module.
This signal is connected to the MCU, which monitors
the signal and compares it with the calculated speed
value from the CCUs.
If there is a deviation between these values, the MCU
will initiate an alarm.

Control system WECS Equipment as seen in Parts Manual
Control system WECS Equipment as seen in Parts Manual
Control system Ignition System
Ignition Coil
High Tension
Extender
Spark Plug
CCU
Ignition
Module
Old Version
Inside Hot Box
Control system Ignition System
Main Components
1. Ignition Module
2. Ignition Coil
3. High Tension Extender and
4. Spark Plug
Control system Ignition Coil and Spark Plug
Ignition Coil
Ignition Trig Module
Spark Plug
Control system Ignition System
Control system Ignition System
Flow Diagram
Control system High Voltage Circuit
Control system Engine Speed and Load Control