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Advanced Training for Jenbacher Techs

The document outlines the FTA Advanced Field Tech Training for GE's Jenbacher gas engines, emphasizing safety, operational procedures, and technical knowledge necessary for field technicians. It includes detailed chapters on wiring diagrams, gas train adjustments, troubleshooting, and maintenance schedules. Participants must have completed basic training and possess relevant engineering qualifications to attend.

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Luis Pupiales
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0% found this document useful (0 votes)
289 views265 pages

Advanced Training for Jenbacher Techs

The document outlines the FTA Advanced Field Tech Training for GE's Jenbacher gas engines, emphasizing safety, operational procedures, and technical knowledge necessary for field technicians. It includes detailed chapters on wiring diagrams, gas train adjustments, troubleshooting, and maintenance schedules. Participants must have completed basic training and possess relevant engineering qualifications to attend.

Uploaded by

Luis Pupiales
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

GE Energy

Global Jenbacher
Training Center

FTA
Advanced Field
Tech Training
March 2012
Original document

The information in this course is FOR TRAINING PURPOSES ONLY.

For Jenbacher gas engines, only the relevant description/operation manual, the maintenance manual
and the spare parts list are valid. Neglect, misuse or improper handling may lead to damage of property
and people.

GE Proprietary Information
The information contained in this document is General Electric Company (GE) proprietary information
and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to others or
reproduced without the express written consent of GE, including, but without limitation, to creation,
manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or
configuration changes or to obtain government or regulatory approval to do so.

© GE Jenbacher GmbH & Co OG, 2012


Training Center A-6200 Jenbach / Austria [Link]
HANDOUT FTA - Advanced Field Tech Training March 2012

Chapter Page
1 3 – 10 General, safety instruction
2 Wiring diagrams and electrical components
2.1 11 – 27 Wiring diagram
2.2 28 – 30 Cable installation
3 Important information sources
3.1 31 – 37 Jenbacher web portal
3.2 38 – 41 TI-catalogue
3.3 42 – 44 Service informationen
3.4 45 – 47 Spatsl
3.5 48 – 49 Service helpdesk
4 50 – 95 [Link]®XT Parameter (Level 15)
5 Auxiliary equipment
5.1 96 – 97 Pipe work arrangements and supports
5.2 98 – 99 Expansion vessel
5.3 100 – 111 3-port-valve
6 112 – 129 Gas train: Adjustment and optimization
7 130 – 141 Controlling
8 142 – 146 Knocking
9 Generator
9.1 147 – 157 Generator
9.2 158 – 162 Generator cabling
9.3 163 – 165 Grid Code
9.4 166 – 168 Generator controller
9.5 169 – 176 Generator (diodes)
9.6 177 Synchronizing device
9.7 178 – 180 Grid monitoring device
9.8 181 – 182 MMUSyn
10 Measurements on engine
10.1 183 Ignition-coil wiring
10.2 184 – 185 Pick-up
10.3 186 – 187 Exhaust gas
11 Handling of Jenbacher analysis software tools and use of special tools
11.1 188 – 190 TecJet® Parameter
11.2 191 – 193 B&R Automation Studio
11.3 194 – 203 Connection with [Link]® WIN: Windows 7.0
11.4 204 – 217 Connection with [Link]® WIN: Windows XP
11.5 218 – 222 [Link]® WIN (Export)
11.6 223 – 225 SES – Service Expert System

Chapter 1
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Chapter Page
11.7 226 – 227 MyPlantTM (formerly Babylon)
11.8 228 – 241 Special tools
12 242 – 247 Trouble shooting
13 Additional modules
13.1 248 – 250 [Link]®
13.2 251 – 253 ORC
14 Specific inspection and maintenance works according to maintenance
schedules up to 10,000 oph
14.1 254 – 260 Maintenance schedule
14.2 261 - 264 Precombustion chamber

Chapter 1
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HANDOUT FTA - Advanced Field Tech Training March 2012
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FTA
Advanced Field Tech Training
Target group:
GE's Jenbacher and its Service Providers' Field
Techs who have completed the course module
'FTB - Basic Field Tech Training'. This training is a
prerequisite for becoming a certified Service
Engineer or Commissioning Engineer.

Prerequisites:
'FTB - Basic Field Tech Training' completed,
Degree in mechanical or electrical engineering,
IT knowledge (Windows, Office, Internet), we
recommend that a laptop is brought to the
training

GE PROPRIETARY INFORMATION GE Energy Jenbacher Gasmotoren


For GE Internal Use Only Start_FTA_EN.ppt
Index: b; 01.12.2011

Chapter 1
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FTA
Advanced Field Tech Training

Participating in this training course gives you …


- a review of the course module 'FTB - Basic Field Tech Training'
- the knowledge required to operate [Link]® XT and [Link]® WIN at level 15
- the ability to adjust and optimize the relevant control loops including adjustment of
NOx emissions
- the ability to adjust and optimize different gas trains
- the ability to localize and remedy malfunctions of the gas engine with the help of our
trouble-shooting check-list
- guidance on regular maintenance according to the 10,000 operating hours rhythm

GE PROPRIETARY INFORMATION GE Energy Jenbacher Gasmotoren


For GE Internal Use Only Start_FTA_EN.ppt
Index: b; 01.12.2011

Chapter 1
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HANDOUT FTA - Advanced Field Tech Training March 2012

Safety instructions
• The safety regulations contained in the user's manual must be observed.
• The safety regulations and regulations for the prevention of accidents set out by the law must
be observed.
• Prior to the commencement of any work the party ordering must make sure that the applying
safety regulations are observed for the work to be carried out.
• In the event of work that may only be carried out with the engine standing still, the engine
must be turned off and secured against unauthorized re-starting according to the technical
instruction no. 1100-0105.

Employee protection
Employer's duties
Employers are required to assume responsibility for the safety and health of employees in all aspects of their
work. Employers have to take any measures required to protect life, health and standards, including
measures to prevent work-related dangers, to provide information and instruction and to provide a suitable
organization and the required resources.
First and foremost, companies contracted to carry out work must comply
with all applicable country specific regulations.

Employee's duties
Employees are legally required to apply the measures to protect life, health and standards
as laid down in statutory legislation and official regulations and in accordance with their
training and their employer's instructions. They have to behave in such a way that avoids
causing danger wherever possible.
GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES
!!Safety_fuer_Handouts_EN.ppt
09.02.2010

Chapter 1
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HANDOUT FTA - Advanced Field Tech Training March 2012

Safety of machines and associated electrical equipment

After proper assembly/installation and completion of commissioning, Jenbacher


machines and the associated electrical equipment comply with all applicable EU
directives and therefore European safety and health requirements (Machinery, Electro-
Magnetic Compatibility and Low-Voltage Directives).

Personal protective equipment


Wear personal protective equipment !
Wear the personal protective equipment approved by the health and safety organizations for
body, head, eyes, ears and breathing. Never be in the vicinity of an engine when wearing loose
clothing, jewelry or long hair.

The standard equipment required for entering the engine room or approaching and working on
plant components, even outside the engine room, consists of eye protection, protective clothing,
hand protection and safety footwear.

Depending on the operational condition of the plant, the ambient conditions, the type or location
of the operation, use hearing protection, safety helmet, fall prevention equipment, gas sensors,
breathing mask or other personal protective
equipment, as appropriate.

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


!!Safety_fuer_Handouts_EN.ppt
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HANDOUT FTA - Advanced Field Tech Training March 2012

Safe engine shut-down … . TI 1100-0105

Mode of operation - MANUAL Mode of operation - AUTOMATIC


Turn the service selector switch to the MANUAL position Turn the activation mode selector to
the position OFF
Reduce the power output to approx. 10 %

Turn the generator switch to the position OFF


Turn the synchronization selector switch to the position Zero The engine will automatically
and lock it shed its load and shut down.
Engine after-cooling: let the engine cool down in idling
operation for a minute
Press the Stop key after the cool-down phase has ended

After-running of auxiliaries: up to 40 min


Turn the mode selector switch to the STOP position, shut the engine down and take out the key. Normal engine
shutdown now completed.
Close the gas tap at the entry of the gas pressure control system

Put up a warning sign to prevent inadvertent starting

Once all the auxiliaries have been automatically switched off, remove the negative battery terminal from
themodule frame, insulate the removed terminal cable and place it on the floor (LOTO)!
Isolate the main power circuit for auxiliaries, block it off and check whether the system is absolutely dead.

Check that all components are dead and sufficiently cooled off. Attention: Overpressure!

Chapter 1
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HANDOUT FTA - Advanced Field Tech Training March 2012

alle close

Electrical components
per module Power panel Module
(+L1) control panel
(+A1)
cable
Generator
circuit breaker
(GCB)

Battery
Gas train
Starter

Generator
Engine
(+G)

Module
Ignition interface (+M)
Battery
charger

Periphery
GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES
Wiring diagrams and electrical components_EN.ppt
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alle Example wiring diagram: "old" component names "new" component names close

Wiring diagram

Over view: pages, panels, software, cable …….


Designation of the components
Generator
Module interface
Module control panel
Power panel
Remote data transmission (HERMES)
Interfaces
Parts
Designation of the components

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Wiring diagrams and electrical components_EN.ppt
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Chapter 2.1
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FTA close

Over view

Cabling instruction: TA 1000-0505


Cable installation (example)

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Wiring diagrams and electrical components_EN.ppt
Index: b; 16.11.2011

Chapter 2.1
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FTA close

Over view

[Link]®-Version

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Wiring diagrams and electrical components_EN.ppt
Index: b; 16.11.2011

Chapter 2.1
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FTA close

Over view

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Wiring diagrams and electrical components_EN.ppt
Index: b; 16.11.2011

Chapter 2.1
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FTA_OPT
Designation of the components

The numbers in
the part
reference list are
in relation with
the numbers in
the interface-list
and the technical
schema.

Chapter 2.1
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FTA
Generator

Chapter 2.1
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FTA
Module interface panel

Relays and contactors

PLC remote I/O

Terminals

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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FTA
Module interface panel

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FTA
Module control panel

[Link]®XT

Service selector Demand selector


switch switch

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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FTA
Module control panel

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FTA
Power panel

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Wiring diagrams and electrical components_EN.ppt
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FTA
Power panel

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FTA
[Link]® WIN Server

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FTA
Interfaces

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FTA
Parts

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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FTA
Designation of the components

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Wiring diagrams and electrical components_EN.ppt
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H1
TA 1000-0505 close

Power cable installation


for example: Plant: landfill site ALMA (South-Italy)
The power cable was installed bundled on a length of 24 m (L1 in one bunch …). Disconnecting
and rewiring were not possible, therefore the power cable was installed ca. 2 m after the
generator switch and ca. 2 m before the mains coupling switch in four bunches with L1/L2/LR
and one bunch N.

Power cable installation before


generator switch

mains switch
GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES
cable installation_EN.ppt
09.02.2010

Chapter 2.2
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Power cable installation


for example: Plant: landfill site ALMA (South-Italy)

Measurement: generator switch outlet


Measurement without brackets = before partial correction of the cable installation
Measurement in brackets = after partial correction of the cable installation

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


cable installation_EN.ppt
09.02.2010

Chapter 2.2
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Power cable installation


for example: Plant: landfill site ALMA (South-Italy)

Power cable installation afterwards


bunch 1

bunch 2
generator switch

mains switch
bunch 3

bunch 4

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


cable installation_EN.ppt
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Customer documentation 4.1 close

Here you find "online" information about our products, drawings, service
information, SPATSL (digital spare parts catalogue), backgrounds to our
gas engine technology and so on.

[Link]

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Webportal_EN.ppt
09.02.2010

Chapter 3.1
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Jenbacher web portal


Language

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Webportal_EN.ppt
09.02.2010

Chapter 3.1
Page 2 / 7

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Jenbacher web portal


Registry

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Webportal_EN.ppt
09.02.2010

Chapter 3.1
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Jenbacher web portal


Registry

company-email-adress

Clicking on "register" will open a new mask where you have to enter your personal data.
It is important to select your contact person at GE Jenbacher.

After registration you will receive an e-mail with the link to the web portal. There you can enter
your personal password.

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Webportal_EN.ppt
09.02.2010

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Jenbacher web portal


Content

techn.
Instructions

Chapter 3.1
Page 5 / 7

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beenden

Jenbacher web portal


"tell-a-friend" / send a link

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Webportal_EN.ppt
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Chapter 3.1
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Jenbacher web portal


Email with attachments

Send email with attachments


Recipent-Email:
(multiple Email-adresses possible – semicolon-seperated)

submit

Chapter 3.1
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Jenbacher web portal


Technical instructions [Link]

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


FTA_TI catalogue_EN.ppt
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Chapter 3.2
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Jenbacher web portal


Technical instructions

Download the complete catalog


shown only for level 70 and higher
GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES
FTA_TI catalogue_EN.ppt
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Chapter 3.2
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Jenbacher web portal


Technical instructions

choose language – download starts


GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES
FTA_TI catalogue_EN.ppt
Index: a; 08.11.2011

Chapter 3.2
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Jenbacher web portal


Technical instructions

Language

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


FTA_TI catalogue_EN.ppt
Index: a; 08.11.2011

Chapter 3.2
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Jenbacher web portal


Service Information
[Link]

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Service informations_EN.ppt
09.02.2010

Chapter 3.3
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Jenbacher web portal


Service-Bulletin

Service Bulletin are information,


which could be forwarded also to
customers

Chapter 3.3
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Jenbacher web portal


Service Technician Instructions

Service Technician Instructions are


information for service technicians of
Jenbacher gas engines and their
subsidiaries and service providers 
NEVER for customers.

Chapter 3.3
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SPATSL – online spare parts manual


[Link]
Login for Jenbacher employees with company specific username and password.
Each customer/service provider has an "user name" and "password"  to get or to ask for
by the responsible service department in Jenbach resp. by the SPATSL-responsible person of
the service provider.

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Spatsl_EN.ppt
09.02.2010

Chapter 3.4
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SPATSL – online spare parts manual

Every sold plant

Every spare part


pro plant

Figure with link to part text


about the pos.-no.

Single parts pro assembly group with


part-no., amount and with link about
pos.-no. to the drawing

Chapter 3.4
Page 2 / 3

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SPATSL – online spare parts manual

The service provider only sees the plants, which are in his
responsibility.

The customer only sees his own plant .

Chapter 3.4
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Service Helpdesk
[Link]

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Service-Helpdesk_EN.ppt
09.02.2010

Chapter 3.5
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Service Helpdesk

The "Service Helpdesk" offers the


possibility to download several
tools and also to upload data
like e.g. parameter list after
start-up

Parameter upload

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Service-Helpdesk_EN.ppt
09.02.2010

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Parameter list
A Auxiliaries\Intake air temperature Ignition\Adjustments
Auxiliaries\Out door temperature Ignition\MORIS
Auxiliaries\Ventilation Isolated operation\Limits load shedding
Auxiliairies\Pre chamber gas compressor Isolated operation\Controller
E Engine data Isolated operation\Scaling external power set point
Exhaust L LEANOX\Gas type 1\Parameter
G Gas proportioning valve M Mixture temperature\Controller
Gas proportioning valve\Gas type 1 Multi measurement device\Device 1
Gas proportioning valve\Idle mode lambda controller P Plant controller\Room temperature
Gas proportioning valve\-"-\Gas type 1 Plant controller\Controller 1
Gas mixer Plant controller\Return water temperature
Gas mixer\Gas type 1 Plant controller\Return water temp. after cooler
Gas mixer\Idle mode lambda controller Power\Ramps
Gas mixer\Idle mode lambda controller\Gas type 1 Power\Controller
Gas mixer\Special gas mixer\Gas type 1 Power\Scaling external power set point
Generator R Reserve\Parameter 1-70
Generator control\Choice of set point S Special gas\CH4-content
Generator control\Time table Special gas\Gas pressure
Generator control\Generator voltage Special gas\Gas volume
Generator control\Power dependent Special gas\Gas temperature
H High voltage measurement Special gas\Calorific value
I Ignition Special gas\Suction pressure
Ignition\Analog output Speed\Controller

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

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Exhaust

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

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Plant controller\Room temperature

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

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Plant controller\Controller 1

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


page 2
Parameters Diane_EN.ppt
09.02.2010

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Plant controller\Controller

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
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Chapter 4
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Plant controller\Return water temperature

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Plant controller\Return water temperature after cooler

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Speed\Controller

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09.02.2010

Chapter 4
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Gas proportioning valve

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09.02.2010

Chapter 4
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Gas proportioning valve\Gas type 1

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Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Gas proportioning valve\idle mode lambda


controller

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09.02.2010

Chapter 4
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Gas proportioning valve\idle mode lambda


controller\gas type 1

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09.02.2010

Chapter 4
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Gas mixer

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09.02.2010

Chapter 4
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Gas mixer\Gas type 1

50

48

2,0

2,0

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Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Gas mixer\Idle mode lambda controller

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09.02.2010

Chapter 4
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Gas mixer\Idle mode lambda controller\Gas type1


10

2,0

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Gas mixer\Special gas mixer\Gas type 1

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Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Mixture temperature\Controller

page 2

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09.02.2010

Chapter 4
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Mixture temperature\Controller

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09.02.2010

Chapter 4
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Generator

Generator control\Choice of set point

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Generator control\Time table

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09.02.2010

Chapter 4
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Generator control\Generator voltage

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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09.02.2010

Chapter 4
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Generator control\Power dependent

Auxiliaries\Intake air temperature

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Auxiliaries\Out door temperature

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Auxiliaries\Ventilation

Auxiliaries\Pre chamber gas compressor

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Isolated operation\Limits load shedding

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Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Isolated operation\Controller

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Isolated operation\Scaling external power set


point

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Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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LEANOX\Gas type 1\Parameter

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Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Power\Ramps

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09.02.2010

Chapter 4
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Power\Controller

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09.02.2010

Chapter 4
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Power\Scaling external power set point

Engine data

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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09.02.2010

Chapter 4
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Multi measurement device\Device 1

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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09.02.2010

Chapter 4
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Reserve\Parameter 1 - 70

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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09.02.2010

Chapter 4
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Special gas\
CH4-content

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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09.02.2010

Chapter 4
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Special gas\
Gas pressure

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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09.02.2010

Chapter 4
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Special gas\Gas volume

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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09.02.2010

Chapter 4
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Special gas\Gas temperature

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09.02.2010

Chapter 4
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Special gas\Calorific value

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09.02.2010

Chapter 4
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Special
gas\
Suction
pressure

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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High voltage measurement

2nd page

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Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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High voltage measurement

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Ignition

2nd page

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09.02.2010

Chapter 4
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Ignition

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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09.02.2010

Chapter 4
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Ignition\Analog output

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Parameters Diane_EN.ppt
09.02.2010

Chapter 4
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Ignition\Adjustments

Ignition\MORIS

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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09.02.2010

Chapter 4
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Pipe work arrangements and supports


Examples for not so good assembled pipes resp. supports:

The clamps are dimensioned adequate but the


supports are not strong enough.

Problem: the power of the water pressure


within the pipes could be to high for the
supports.

The clamp is okay The clamps


but the bottom are to weakly
section is not and could
dimensioned break.
enough .

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


pipe work arrangements and supports_EN.ppt
09.02.2010

Chapter 5.1
Page 1 / 2

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Pipe work arrangements and supports


Examples for good assembled pipes resp. supports:

Support is robust, threaded


rods of the traction reliefs
are removed, the
Support is robust, pipes are compensator is straight and
fixed on several places. The can isolate vibrations and Support is robust, the
forces are intercepted. compensate expansions. compensators are straight
and not to much expanded
and can isolate as such
vibrations and compensate
expansions.
GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES
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09.02.2010

Chapter 5.1
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Expansion vessel
Expansion in closed cooling water circles
1. Fix the minimum process water pressure.
2. Pre gas pressure in the empty vessel ca. 0,3 bar lower than the minimum process water
pressure.
3. Fill in water (cold) with minimum process water pressure.
4. At heating the pressure should rise only lightly.
If in cold status the pressure is to low and in a warm status the pressure is to high,
the membrane is defect, the gas pressure is wrong or the vessel is to small !

water room cold

water room
hot

gas room

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Expansion vessels_EN.ppt
09.02.2010

Chapter 5.2
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Expansion vessel
Expansion in closed cooling water circles

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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09.02.2010

Chapter 5.2
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Three port valve

Siemens

Kontinentale

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Chapter 5.3
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Three port valve


Electro-hydraulic actuators for valves

Example: SKD 62 Valve closed Valve opened

AC 24 V operating voltage
DC 0 – 10 V positioning signal

Opening: 30 sec.
Closing: 15 sec.

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Index: a; 01.12.2011

Chapter 5.3
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Three port valve


Electro-hydraulic actuators for valves

Opening the valve: The hydraulic pump (6) forces oil from the suction chamber (3) to the pressure
chamber (8) and thereby moving the pressure cylinder (2) downwards. The valve stem
(11) retracts and the valve opens. Simultaneously the return spring (4) is compressed.
Closing the valve: Activating the solenoid valve (5) allows the oil in the pressure chamber to flow back
into the suction chamber. The compressed return spring moves the pressure cylinder
upwards. The valve stem extends and the valve closes.
Manual operation mode: Turning the manual adjuster (1) clockwise moves the pressure cylinder downwards
and opens the valve. Simultaneously the return spring is compressed. In the manual
operation mode the control signals Y and Z can further open the valve but cannot
move to the «0%» stroke position of the valve. To retain the manually set position,
switch off the power supply or disconnect the control signals Y and Z. The red
indicator marked «MAN» is visible..
Note: Controller in manual operation:
When setting the controller for a longer time period to manual operation, we recommend adjusting
the actuator with the manual adjuster to the desired position. This guarantees that the actuator
remains in this position for that time period. Attention: Do not forget to switch back to automatic
operation after the controller is set back to automatic control.

Automatic mode: Turn the manual adjuster counterclockwise to the end stop. The pressure cylinder
moves upward to the «0%» stroke position of the valve. The red indicator marked
«MAN» is no longer visible
Minimal volumetric flow: The actuator can manually be adjusted to a stroke position > 0 % allowing its use in
applications requiring constantly a minimal volumetric flow.

Chapter 5.3
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Three port valve


Electro-hydraulic actuators for valves
Standard electronics
SKD62 … SKD60

DIL switches
SKD62 … SKD60

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Chapter 5.3
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Three port valve


Electro-hydraulic actuators for valves

With normally-open valves, «direct-acting» means that with a signal


input of 0 V, the valve is open.
The mechanical spring-return function is not affected by the direction
of operation selected.

Calibration
SKD62.., SKD60

Chapter 5.3
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Three port valve


Electro-hydraulic actuators for valves
Indication of The LED status indication indicates operational status with dual-colored
operating state LED and is visible with removed cover.
SKD62.., SKD60 As a general rule, the LED can assume only the states shown above
(continuously red or green, flashing red or green, or off).

Orientation Connection terminals


SKD6 …

Chapter 5.3
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3 port valve
Thermostatic valve

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Index: a; 01.12.2011

Chapter 5.3
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Describtion close

3-port valve new: Kontinentale


Replacement of Siemens valves.

Actuator: Sauter
Valve: Ari Armaturen
Supplier: Kontinentale

Advantage:
The valve works with 24V DC, no 230V AC to 24V
AC transformers are necessary.

There is no possibility to use the old valves


with the new Actuator.

The valve and the actuator have to be replaced


together and an adapter ring is needed,
because of different size of the valves!

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Index: a; 01.12.2011

Chapter 5.3
Page 8 / 12

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3-port valve new: Kontinentale

The Kontinentale valves are not 1:1


interchangeable with the Siemens valves,
because of the difference in height (L3).
For service purpose an adapter ring, longer
bolts and an additional gasket is necessary.

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Index: a; 01.12.2011

Chapter 5.3
Page 9 / 12

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3-port valve new: Kontinentale

Needed Kit items for changing the Siemens valves to Kontinentale according to table 1:

There is no software change necessary after changing to the new valves, but the wiring
diagram has to be updated!

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Index: a; 01.12.2011

Chapter 5.3
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3-port valve new: Kontinentale


Permitted mounting positions Electrical connection:

24V AC operation is not suggested due


to capacitor faults because of high
vibrations!

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Three port seat valve_EN.ppt
Index: a; 01.12.2011

Chapter 5.3
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3-port valve new: Kontinentale


Calibration of the valve:

LED indicators:

Chapter 5.3
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Parts of the gas train


Pre-pressure
regulator
f.e.:

SBV (safety blow-off valve )

Gas filter

(safety shut-off valve )

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Chapter 6
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Parts of the gas train

Leak testing and gas pressure switch

valve

solenoid valve
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Chapter 6
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Parts of the gas train


DUNGS-pressure regulator

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Chapter 6
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Parts of the gas train


Pre-chamber gas

connection for ext.


disturbance

ext. impulse pipe


to pressure control

no Miller: no opening
LIVC all type 6: D=2,7 mm
EIVC (from 2009)
612 D=1,7 (F13=2,7) mm
616 D=2,0 (F13=2,7) mm
620 D=2,2 (F13=2,7) mm
624 D=2,4 (2008=3) mm

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


FTA_Adjustment and optimization …._EN.ppt
09.02.2010

Chapter 6
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Gas train
(Inlet pressure >500mbar -> additional protector necessary)

Pre-pressure
regulator Zero pressure
regulator

Ball valve Safety shut- safety Double solenoid valve


off valve blow-off with leak testing and
Gas filter (SAV) valve (SBV) gas pressure min.
switch

Valves as additional
protector
GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES
FTA_Adjustment and optimization …._EN.ppt
09.02.2010

Chapter 6
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Gas train
(Inlet pressure < 500mbar)
occasionally with flame
arrestor (with biogas
respectively coal mine
gas)

Pre-pressure
Ball valve regulator
Gas filter Double solenoid valve with
leak testing and gas Zero pressure
pressure min. switch regulator

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


FTA_Adjustment and optimization …._EN.ppt
09.02.2010

Chapter 6
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Gas train
For Tecjet®

Gas filter SBV

Ball valve SAV


Pre-pressure Double solenoid valve Gas flow control
regulator with leak testing and gas valve Tecjet®
pressure min. switch

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


FTA_Adjustment and optimization …._EN.ppt
09.02.2010

Chapter 6
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Gas train
Pre-chamber

p2´… charging pressure


2 x solenoid valve
pvk… pre-chamber pressure

Gas filter

10 mm throttle

Ball valve Pressure min. switch or Pre-chamber gas


pressure transducer pressure regulator
Medenus R101

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Gas train
The maximal distance between gas outlet of the gas train to the gas inlet of
the engine is to be kept

The distance is indicated in the technical diagram.

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Gas train
Pressure measurement with a water column

optimal gas pressure

not optimal gas pressure

regulate the gas pressure

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Gas train
Adjustment of the safety shut-off valve (SAV)

disconnect SAV

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Gas train
Adjustment of the safety shut-off valve (SAV)

Adjustment of the pressure should be


ca. 3x flow pressure (should not
activate with full load retraction)

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Gas train
Adjustment of the safety shut-off valve (SAV)

Adjustment of the lower


shut-off pressure.

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Gas train
Setting up the pressure regulator

Adjustment of the gas flow pressure by full load.


Adjust the pressure by plants with zero pressure
regulator (see technical diagram): 70 – 50 mbar

By Tecjet ®: adjust the


pressure in such a way, that
by middle gas pressure and
full load the Tecjet® is open
ca. 60 %.

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Gas train
Adjustment of the safety blow-off valve (SBV)

Adjustment of the pressure


ca. 1,5x flow pressure

ATTENTION:
should not activate in
normal mode.

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Gas train
Gas pressure max. and gas pressure min.

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Gas train
Double solenoid valve

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Gas train
Pre-chamber pressure regulator

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Schematic diagram of the control system


[Link]®

LEANOX®
controller

P-controller
nP-controller

temperature)
PIST (power)

t2' (mixture
P2' (boost
pressure)
exhaust gas

fuel gas
generator

intake air
valve with
gas engine position controller
heat exchanger
compressor

valve with position controller

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Speed control
Generator circuit breaker is open, engine is idling
Speed is controlled by opening / closing the throttle valve
The quantity of mixture into the engine is controlled

Engine idle
Consumer

Electrical power

Speed controller
Actuator

Electrical power

Speed Engine
Controlled variable Final control element
Generator
n (speed) Throttle valve

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Island control system


Generator circuit breaker is closed, mains circuit breaker is open, engine is loaded.
Speed is controlled by opening / closing the throttle valve resp. compressor bypass valve.
The quantity of mixture into the engine is controlled.

Isolated operation
Consumer

Electrical power

nP controller

Electrical
power
Controlled variable Final control element
n (speed) Compressor bypass
Mains Engine Throttle valve
Generator P (power) Compressor bypass
Throttle valve

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Power control systems


Generator circuit breaker is closed, main circuit breaker is closed, engine is loaded
Power is controlled by opening / closing the throttle valve resp. compressor bypass (turbo
bypass).
The quantity of mixture into the engine is controlled

Consumer Mains parallel operation

Electrical power

P controller

Electrical
power

Power grid Engine


Controlled variable Final control element
Generator p (power) Compressor bypass
throttle valve

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Dokumentation 5.3.1 close

LEANOX® controller
LEANOX® control is enabled when
increasing load above certain set point (30-
50%).

LEANOX® control opens / closes gas mixer


(increases / decreases lambda set point for
Tecjet®)

Misfiring range
The quality of mixture into the engine is
controlled

NOx -> TA Luft limit value


CO -> TA Luft limit value
NMHC -> TA Luft limit value
Air ratio Lambda
common operating range until now
SCR procedure
NSCR method (λ-1 concept) Lean-burn-operation

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LEANOX® curve
Boost
pressure
[mbara] LEANOX ®
lean parameter
p2´_1 P_1
+ p2‘ err p2´_1
t2´_1
n_1
(ZZPnom)

P_2
p2´_2
- p2‘ err
rich p2´_2
t2´_2
n_2
1000 Pel (ZZPnom)
[%]
30 [%] P_2 P_1
Leanox start 50 [%] 100 [%]

 (air excess number) = Stochiometric


Actual amount of combustion air
amount of combustion air

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LEANOX® adjustment
type 2, 3, 4 until 2007 (RPS 2.0), type 6 old
([Link]® blue)
• In case the engine is equipped with X20 control, the half load point [save2] can be stored
before the full load point [save1].
• Observe engine running conditions (temperatures, emissions, power,…). Ramp the engine
up to full load. Open/close the gas mixer (increase/decrease the λ value) with LEANOX ®
control in manual until the specified emission limits are achieved. Wait until all values are
stable.
• When engine running conditions are satisfactory, save full load LEANOX ® values [save1].
• Reduce engine load gradually to 40-50 %. Observe temperatures and emissions. Tune in
the gas mixer (Tecjet®) manually.
• When engine running conditions are satisfactory, save low load LEANOX ® values [save2].
• Change gas mixer (Tecjet®) into automatic. Check the emissions in full and half load. If the
actual NOx values are not exact, readjust the p2´ values in the LEANOX® recipe.
• In case the engine is equipped with KLS 98 (type4/6) the „boost pressure compensation via
ignition timing“ can be enabled. In this case it has to be tested.

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LEANOX® adjustment type 4 (> RPS 2.6x)


• The average timing during the adjustment procedere should be equal or similar the
nominal timing (22-24°CA, 1500rpm). The knock controller with cylinder optimizing must be
enabled!
• Engines with loads of built up in the combustion chamber can not be operated close to the
nominal timing. Therefore no LEANOX ® adjustment can be done at these engines!
• Compensation factors are DISABLED for type 4.
• Observe engine running conditions during the complete procedere (temperatures, emissions,
power, knocking,…).
• Ramp the engine up to full load. Increase/decrease the λ value with LEANOX® control in manual
until the specified emission limits are achieved (or leaner). Reset the knock control and wait
until all values are stable (press [Cyl] [F2] [F4]. Reset cylinder optimizing [1] [Enter]) to reset
cylinder optimizing [Link]® XT.
• When engine running conditions are satisfactory, save full load LEANOX® values [save1].
• Reduce engine load gradually to 40-50%. Observe temperatures and emissions. Tune in the λ
value manually
• When engine running conditions are satisfactory, save low load LEANOX® values [save2].
• Change Tecjet® to automatic and run the engine on full load respectively on half load.
• Repeat the complete procedere in case the measured NOx values are not satisfactory.
There is a 2nd way for LEANOX ® adjustment with password level 30:
Disable cylinder optimizing  adjust LEANOX® nominal timing  enable cylinder optimizing

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LEANOX® adjustment type 6 ([Link]® XT)


• The complete adjustment has to be done with an unvarying nominal ignition timing. All
possible ignition timing adjustments are to be blocked.
• In case the engine is equipped with X20 control, the half load point [save2] can be stored before
the full load point [save1].
• Observe engine running conditions (temperatures, emissions, power,…). Ramp the engine up to
full load. Open/close the gas mixer (increase/decrease the λ value) with LEANOX ® control in
manual until the specified emission limits are achieved. Wait until all values are stable.
• When engine running conditions are satisfactory, save full load LEANOX ® values [save1].
• Reduce engine load gradually to 40-50 %. Observe temperatures and emissions. Tune in the
gas mixer (Tecjet®) manually.
• When engine running conditions are satisfactory, save low load LEANOX ® values [save2].
• Change gas mixer (Tecjet®) into automatic. Check the emissions in full and half load. If the actual
NOx values are not exact, readjust the p2´ values in the LEANOX® recipe.
• In case the engine is equipped with KLS 98/Safi the „boost pressure compensation via ignition
timing“ must be enabled.
• To test this feature, the timing has to be altered (e.g. 5°) and the NOx values must be checked.
Possibly the compensation values have to be readjusted for full resp. half load.
• Enable all timing adjustments and observe the NOx emissions.
After completing the LEANOX ® adjustment you may not alter single parameters for the
LEANOX ® controller, for the LEANOX ® compensation or the nominal timing, without
checking/altering all the other coherent parameters.
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Compressor bypass valve


(Turbo bypass valve)

The compressor bypass connects the pressure


side and suction side of the mixture of the
exhaust gas turbocharger. The control of the
flow capacity occurs about one or several
parallel to each other located electrically
activated control valves.
J 320 with new compressor bypass valve
The duty of the compressor bypass system is
on the one hand the protection of the exhaust
gas turbocharger from pumping
operation and on the other hand
the power control.

Attention: The value shown on the display


of the engine control is no feedback signal,
but the nominal value.

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Compressor bypass valve

OLD NEW
closed dead-voltage open dead-voltage

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gas mixer position close

Compressor bypass valve (Turbo bypass valve)


Figure for engine controller

Compressor bypass position in per cent

= No feedback signal
Circuit diagram: clamp 91a and 91b

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Knocking
Knocking is the collision of two flame fronts
in the combustion chamber.
The combustion of the mixture (triggered by
the ignition system) causes a pressure wave,
which increases the pressure of the remaining
rest of the mixture and therefore spontaneous
combustion.
Knocking can be reduced by:
• Later ignition timing
• Higher Methane number
• Lower mixture temperature
• LIVC
• EIVC
• Lean engine adjustment (high λ)
• Low compression ratio ε
• Combustion chamber cleaning
• Reduction of pme (power reduction)

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Knock monitoring, knock control


KLS 90
1 knock sensor per cylinder bank
Measured mV signal is converted into mA and fed into EMS2000, EMS3000, SAM, [Link] ®
Knock limit as mA signal (5,5mA) is retarding the timing followed by power reduction and/or
engine shut down.
TA 1400-0158
ST-075 Fehlersuche KLS90

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Knock control (old version)


KLS 98
1 knock sensor per cylinder

mV signal into KLS unit – digital signal further to [Link]®,


[Link]® XT via CAN bus

Each cylinder is monitored and timing controlled individually!

Knocking only in „time window“, any noise outside this


window is something mechanical (valve noise)
TA 1400-0154

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Knock control type 4 with cylinder optimizing


KLS 98 / KLS 98s / Safi
RPS 2.1x.2.5x (since 2007)
existing knock control + beta version of cylinder optimizing (cylinder
optimizing is next to never enabled. Parameters are in reserve recipe)
RPS ≥2.6x (since Oct.2009)
existing knock control +
cylinder optimizing

Cylinder optimizing is disabled in island operation


The ignition timing of the relevant cylinder will be retarded in 0,1°CA steps by
the knock monitoring.
The ignition timing of the relevant cylinder will be retarded in 1°CA steps by
the cylinder optimizing.
The knock control freezes the timing of all cylinders at the engine shutdown.
When the engine is restarted, these timings are the initial values.

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Knock control - type 6


KLS 98 / KLS 98s / Safi
Hardware is the same like for the old version.
The adjusted nominal ignition timing should be a realistic value for
knock free operation. (e.g. 16-20°CA before TDC).
In case there is no knocking with this nominal timing, the knock
control tries to advance the timing gradually (negative knocking will
be displayed).
Max. range for advancing = offset
The timing of the relevant cylinder will be retarded in case knocking
is detected. Only when retarding the timing below the nominal
timing, knocking will be displayed.
Only then the customers will be alarmed (red bar,…).
ATTENTION: "boost pressure compensation via IP adaption" in
menue LEANOX® has to be enabled.

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Generator
Main diagram synchronous machine

automatic voltage
regulator (AVR)

permanent magnet
main-machine rectifier exciter
generator
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Generator
Operation of the Automatic Voltage Regulator

automatic
voltage
regulator
(AVR)

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Generator
Synchronous machine reactive power generator

current

cos = 1
voltage

cos = 0,8 lagging

cos = 0,8 leading

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Generator
Power factor control at generator terminals
network switch

cos regulator

cos set point

automatic voltage regulator


bus bar AVR

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Generator
Reactive power control at the grid connection point

reactive power regulator grid

common set point

cos regulator generator

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Generator
Synchronous generator operating chart

under excited limit: reverse power over excited

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Generator
Mains configuration
TNC-grid TNS-grid
Transformer grid house service connection user Transformer grid house service connection user

TNCS-grid IT-grid
Transformer grid house service connection user Transformer grid house service connection user

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Generator
Micro interruption

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Generator
Generator differential protection

Stator

I1LX = I2LW = o.k. I1LX <


> I2LX => trip

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Generator
Standard generator protection

multi measuring device with protective relays

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Generator
Surge suppressor

Peak value (kV) = 1,25 x √2 (2xU+1) 


10 kV generator: 1,25 x √2 (2x10+1) ~ 37,1 kV

Distance generator <->


Surge suppressor: <25 m

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Generator cabling
Cable connection

Rubber cable with plastic 400V cable with metallic


PC cable connection PC cable connection

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Generator cabling
Medium voltage

correct cable wrong cable

high flexible inflexible


a lot of thin wires a few, but thicker wires

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Generator cabling

Middle voltage generator Low voltage generator


with star point current transformer with star point current transformer

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Generator cabling
Cable fixing with MV/HV generator

clamps

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Generator cabling
Medium voltage
NO good solution: the material aluminum is to weak - durability 300 Bh

Good solution:
high flexible cable
to terminal box
and further with
inflexible cable.

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Grid code
Static Grid Support - Generator controller with [Link]® XT (>v2.5)
• power reduction at under / over voltage
• power reduction at under / over frequency
• power reduction at high winding temperature
• Reactive power reduction at high winding temperature
• pole angle limiting (alarm, shut down)
• setting of power factor set point
• displaying of P/Q Diagram
• calculating and limiting of reactive power

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Gridcode
Dynamic Grid Support
LVRT = Low voltage ride through = grid support at low
voltage

Effect of crash synchronizing


- Grid comes back after LVRT at a non-zero phase
- Peak electromagnetic torques at 120° phase difference
- Crash synchronizing = high stress on the shaft
(torsion forces)
- Risk of (Multiple) pole slips with repeated stress peaks
- Effect of grid transients on end-windings

• Increased inertia
• Improved shaft fixation Gridcode valid since: static dynamic
• Improved shaft key Denmark 2007 2007
• Improved varistors or snubber resistance France (>5MW) 2008 2008
Australia 2007 -
• More robust rotating diodes
Spain 2008 -
• Improved stator out hang (fixation, stress Germany 2010 2013
ropes ... ) Austria 2009 2009
Argentina 2008 -
Italy 2008 -
GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES
Gridcode_EN.ppt
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Chapter 9.3
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Gridcode monitoring

High quality criteria's for PP’11


• Two-time, repeated grid failure,
1/day
• Continuing gen set operation in
parallel, without damage
• Low number of pole slips allowed 1x (certified) Network monitoring device per system

Voltage [%]
Without change, high risk of generator or coupling losses
OLD - EN 60034-1/
IEC 34-3 conform
100
80 NEW – Grid Code
60 Frequency info Germany conform
40 2-4/a short circuit MV 0%
20 20-30/a caused HV >0%

0 150 700 1500 3000 Time [ms] 15… 20s

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Gridcode_EN.ppt
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Generator controller
Basler DECS 100 – Leroy Somer LSA 49-52

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Generator controller_EN.ppt
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Chapter 9.4
Page 1 / 3

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Generator controller
Basler DM110 - Stamford-AvK

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Generator controller_EN.ppt
Index: a; 01.03.2012

Chapter 9.4
Page 2 / 3

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Unitrol Parameter close

Generator controller
ABB Unitrol 1010 (ex. 1000-7) - CMT 1000
various generators and applications (+ customer request)

• Very precise control and considerably more features (diode monitoring, limiter, PSS)
• Built-in oscilloscope and multiple images visible.
• Reactive load distribution in the isolated operation
mode via CAN bus.
• Freely programmable inputs and outputs.

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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Chapter 9.4
Page 3 / 3

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cabeling greasing close

Generator
General

Electrical plants
With improper use every electric plant can be a potential danger
(TA 2300-0005).

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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Chapter 9.5
Page 1 / 8

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Generator: Bridge rectifier circuit for the exciter

Pilot exciter

rotating
rectifier diode

F2 F1
field winding
GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES
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Chapter 9.5
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Generator: Measurement of rectifier diodes

Attention to polarity, diode switch in


conducting direction.

The for the sillicium diode expected


measurement voltage is approx. 0,5 V=

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Generator: Measurement of rectifier diodes

Check rectifier diodes


The diodes on the main rectifier assembly can be
checked with a multimeter.
The flexible leads connected to each diode should
be disconnected at the terminal end, and the
forward and reverse resistance checked.

A faulty diode will give a full deflection reading in both


directions with the test meter on the 10,000 ohms
scale, or an infinity reading in both directions (Fluke
diodes measuring).
On a Fluke 123 a healthy diode will give a low reading
in one direction, and a high reading in the other.
For comparing it is useful to check also the resistance
measurement.
GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES
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Chapter 9.5
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Generator: Measurement of rectifier diodes

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Generator:
Measurement of rectifier diodes
Replacement of faulty diodes
The rectifier assembly is split into
two plates, the positive and
negative, and the main rotor is
connected across these plates.
Each plate carries 3 diodes, the
negative plate carrying negative
biased diodes and the positive plate
carrying positive biased diodes.
Care must be taken to ensure that
the correct polarity diodes are fitted
to each respective plate. When Main excitation windings
fitting the diodes to the plates they The exciter stator resistance is measured across
must be tight enough to ensure a leads F1 & F2 (X and XX). The exciter rotor is
good mechanical and electrical connected to six studs, which also carry the diode
contact, but should not be over lead terminals. The main rotor winding is connected
tightened. The recommended across the two rectifier plates.
torque tightening is 4 Nm. The respective leads must be disconnected before
taking the readings.

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Chapter 9.5
Page 6 / 8

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Generator: Measurement of rectifier diodes

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Chapter 9.5
Page 7 / 8

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Generator: Measurement of varistors


Surge suppressor (varistor)
The surge suppressor is a metal-oxide varistor connected across the two rectifier plates to
prevent reverse voltages in the field winding from damaging the diodes. This device is not
polarised and will show a virtually infinite reading in both directions with an ordinary
resistance meter. If defective this
will be visible by inspection, since it will
normally fail to short circuit and show
signs of disintegration.
Replace if faulty.

varistor

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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Chapter 9.5
Page 8 / 8

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Synchronisation device

Parameterisation according to start-up


checklist.

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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Chapter 9.6
Page 1 / 1

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Mains monitoring device


Software download
[Link]

Chapter 9.7
Page 1 / 3

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Mains monitoring device

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


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Chapter 9.7
Page 2 / 3

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Mains monitoring device

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Grid monitoring device_EN.ppt
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Chapter 9.7
Page 3 / 3

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TI 1000-0530 close

Multi-measurement converter
MMUSynch

The module has been specially developed to GE's


Jenbacher specifications. It contains measurement
inputs to collect the main measured quantities
from the generator, the bus bar and from two self-
contained synchronisation networks. The measured
quantities are used both to calculate electrical
power and to perform a wide variety of monitoring
functions. The two synchronisation voltages are
used to monitor the phase position, frequency and
voltage of two networks. A digital output is set to
activate a power switch in accordance with
synchronisation conditions.

New hardware X20CM0985-1 for [Link]® XT3 V3.30


(not compatible with earlier versions).

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


MMU Sync_EN.ppt
Index: a; 01.03.2012

Chapter 9.8
Page 1 / 2

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Multi-measurement converter
Use this screen to track a synchronisation process. All the measured values required to ensure
successful synchronisation are displayed.
This screen is only displayed if the synchronisation is being performed by the [Link] ® XT
control system!

This screen is used to check the three synchronisation conditions


• Voltage difference
• Frequency difference and
• Phase position

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


MMU Sync_EN.ppt
Index: a; 01.03.2012

Chapter 9.8
Page 2 / 2

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TA 1502-0038 TA 1502-0063 TA 1502-0067 close

Checking the primary ignition-coil wiring


If there is no high-voltage supply at a
few of the ignition coils, you can check
the output using the output error
detection system menu ([Shift] [M]). If
an output shows 0, you must check the
harness leading from
the ignition unit to the ignition coil.

You can also check the primary voltage


at the ignition coil using an
oscilloscope. If you do not have an
oscilloscope available, the error can be
found by exchanging the ignition coils.

If there is no high-voltage supply, even


though there is a primary voltage, then
the ignition coil is faulty.

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


FTA…..ignition systems_ignition coil wiring_EN.ppt
09.02.2010

Chapter 10.1
Page 1 / 1

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TI 1502-0038 TI 1502-0063 TI 1502-0067 close

Pick-up
If the ignition point fluctuates or the ignition constantly fails it could be, that the reset-sensor
signal and the trigger-pickup signal could be 'colliding'.

This failure normally occurs during engine start-up, on rare occasions during normal
operation under load, and can be checked using an
oscilloscope.

The failure can be caused by pickup cabling modifications


or changes to the distance between pickup and ring gear.

Following every hardware or software modification


of the ignition or the pickup cabling, check the
pickup signals using an oscilloscope and
subsequently the ignition point . If required,
the reset position must be modified.

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


FTA_Measurements at ignition systems_pick up_EN.ppt
09.02.2010

Chapter 10.2
Page 1 / 2

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Pick-up

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


FTA_Measurements at ignition systems_pick up_EN.ppt
09.02.2010

Chapter 10.2
Page 2 / 2

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Customer documentation 5.3.1 close

Exhaust gas measurement


The operation of Jenbacher gas engines
has been optimized to ensure that lowest
exhaust emission values are achieved
under full-load operation.

These optimized exhaust emissions can be


achieved only by operating lean-mix
engines with the correct air excess ratio λ

Misfiring range
(air ratio). This principle exploits the direct
link between NOx-emissions and the air
excess ratio to achieve minimum exhaust
emission values.

NOx -> TA Luft limit value


CO -> TA Luft limit value
NMHC -> TA Luft limit value
Air ratio Lambda
common operating range until now
SCR procedure
NSCR method (λ-1 concept) Lean-burn-operation

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Exhaust gas measurement_EN.ppt
09.02.2010

Chapter 10.3
Page 1 / 2

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Exhaust gas measurement

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Exhaust gas measurement_EN.ppt
09.02.2010

Chapter 10.3
Page 2 / 2

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TA 1510-0064 close

Tecjet® parameter calculation program


FuelgasV1R1

[Link]

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Analysis software_FuelgasV1R1_EN.ppt
09.02.2010

Chapter 11.1
Page 1 / 3

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Tecjet® parameter calculation program


FuelgasV1R1

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Analysis software_FuelgasV1R1_EN.ppt
09.02.2010

Chapter 11.1
Page 2 / 3

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Tecjet® parameter calculation program


FuelgasV1R1

result

insert here the


values from the
gas analysis

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Analysis software_FuelgasV1R1_EN.ppt
09.02.2010

Chapter 11.1
Page 3 / 3

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TI 1000-0528 close

Bernecker & Rainer Automation Studio:


Logbuch, Watch & Trace
- Read out logbook

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Analysis Software_B&R_EN.ppt
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Chapter 11.2
Page 1 / 3

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Bernecker & Rainer Automation Studio:


Logbuch, Watch & Trace
- Watch

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Analysis Software_B&R_EN.ppt
01.03.2012

Chapter 11.2
Page 2 / 3

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close

Bernecker & Rainer Automation Studio:


Logbuch, Watch & Trace
- Trace

GE PROPRIETARY INFORMATION GE ENERGY GAS ENGINES


Analysis Software_B&R_EN.ppt
01.03.2012

Chapter 11.2
Page 3 / 3

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*((QHUJ\ ',$1(:,1






:LQGRZV,(VHWWLQJV


‹*(-HQEDFKHU*PE+ &R2+*
$FKHQVHHVWU
$-HQEDFK $XVWULD

Chapter 11.3
(c) GE Jenbacher GmbH & Co OG, 2012 194/265 Training Center | A-6200 Jenbach | Austria
HANDOUT FTA - Advanced Field Tech Training March 2012

-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Windows 7.0 IE 8/9 settings

1. Installation guide ___________________________________________________ 3


2. FAQs _____________________________________________________________ 7
2.1 Installation 7
2.2 Configuration 7

Author: Venkatesh Mutnuri Checked: Elektronik Date: 2011-02


EN Windows7.0_IE8_IE9.doc Index: Page - No.: 2 / 10

Chapter 11.3

(c) GE Jenbacher GmbH & Co OG, 2012 195/265 Training Center | A-6200 Jenbach | Austria
HANDOUT FTA - Advanced Field Tech Training March 2012

-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Windows 7.0 IE 8/9 settings

1. Installation guide

Microsoft Internet Explorer settings


The settings described in this section are stored in the user-specific profile and must therefore be entered
separately for each user.

The [Link] WIN web application is based on technologies, which for security reasons and to prevent
misuse, should not be enabled for unknown websites. However, to ensure that your computer can be
used as a [Link] WIN operating station, you can add the address of the [Link] WIN server to the
"Trusted sites" zone and adjust it to comply with the security settings for this zone. Please note that these
settings will then be used for all "Trusted sites".

Adding the website to the "Trusted sites"


To call up the dialogue box below, choose the [Internet Options...] command in the [Tools] menu. Then
select the [Security] tab.

Click the [Sites...] button to activate the dialogue box for adding websites to the Trusted sites zone.

Author: Venkatesh Mutnuri Checked: Elektronik Date: 2011-02


EN Windows7.0_IE8_IE9.doc Index: Page - No.: 3 / 10

Chapter 11.3
(c) GE Jenbacher GmbH & Co OG, 2012 196/265 Training Center | A-6200 Jenbach | Austria
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Windows 7.0 IE 8/9 settings

Click [Add] and the address of the [Link] WIN server is added to the trusted sites. Caution: The
[Require server verification (https:) for all sites in this zone] option must be in order for the domain to
be added! Next, please exit Internet Explorer and restart. Once the [Link] WIN server has been added
to the trusted sites, Internet Explorer must display the "Trusted sites" zone at the bottom right of the
status line when the [Link] WIN server is selected.

Security settings for the "Trusted sites"


To call up the dialogue box below, choose the [Internet Options...] command in the [Tools] menu. Then
select the [Security] tab.

Select the [Trusted sites] security zone and click the [Custom Level] button. Set the security level for
this zone to the default security level "Low". If this button has been disabled, this means that the default
level is already set.

After this, click the [Custom Level...] button to reset all the user-defined settings. Next, enable the
[Initialise and script ActiveX controls not marked as safe for scripting] [Allow Scriptlets]
[Automatic prompting for file downloads] option.

Author: Venkatesh Mutnuri Checked: Elektronik Date: 2011-02


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Chapter 11.3
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HANDOUT FTA - Advanced Field Tech Training March 2012

-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Windows 7.0 IE 8/9 settings

Then close this dialogue box by clicking [OK]. Confirm the security question that appears by clicking
[Yes].

Settings for LAN or modem (intranet) connection


If a proxy server has been configured on your system for use on the Internet, it should be disabled
(circumvented) for the local connection (Intranet) to the [Link] WIN server. To do so, check the following
settings and, if necessary, change them.

To call up the dialogue box below, choose the [Internet Options...] command in the [Tools] menu. Then
select the [Connections] tab.

Click the [LAN Settings...] button to go to the following dialogue box.

Author: Venkatesh Mutnuri Checked: Elektronik Date: 2011-02


EN Windows7.0_IE8_IE9.doc Index: Page - No.: 5 / 10

Chapter 11.3
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HANDOUT FTA - Advanced Field Tech Training March 2012

-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Windows 7.0 IE 8/9 settings

If a proxy server has been entered, click the [Advanced...] button to activate the following dialogue box.
Type the address of the [Link] WIN server in the [Exceptions] edit box. If it already contains other
addresses, add the address of the [Link] WIN server, separated by a semicolon (e.g.:
"[Link];[Link]").

Next, return to the dialogue box below:

Author: Venkatesh Mutnuri Checked: Elektronik Date: 2011-02


EN Windows7.0_IE8_IE9.doc Index: Page - No.: 6 / 10

Chapter 11.3
(c) GE Jenbacher GmbH & Co OG, 2012 199/265 Training Center | A-6200 Jenbach | Austria
HANDOUT FTA - Advanced Field Tech Training March 2012

-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Windows 7.0 IE 8/9 settings

If an RDT connection has been configured, [Dial whenever a network connection is not present]
should have been selected. If not, whenever you open Internet Explorer, the RDT connection is always
selected, which then tries to reach the [Link] WIN server on the dial-up connection.

2. FAQs

2.1 Installation
Q: Do I need to install [Link] WIN Client Controls?
A: Yes, it is mandatory to install [Link] WIN Client Controls before using [Link] WIN system. This
installation is one time activity for a computer.

Q: Where can I find [Link] WIN Client Controls?


A: [Link] WIN Client Controls is available after clicking “Downloads” button on the login page.

2.2 Configuration
Q: Are there any Internet Explorer settings to be configured?
A: Yes, there are settings that required to be configured in Internet Explorer. Follow the instructions in
instruction guide. Be aware of choosing relevant Internet Explorer version setting document.

Q: Is [Link] WIN compatible with only Microsoft Internet Explorer or any other web browser?
A: [Link] WIN system is developed and tested on Microsoft Internet Explorer. It is advisable to use only
Microsoft Internet Explorer.

Q: What version of Microsoft Internet Explorer version is required for [Link] WIN system?
A: [Link] WIN system is tested on Microsoft Internet Explorer for version 6.0, 7.0, 8.0 and 9.0.

Author: Venkatesh Mutnuri Checked: Elektronik Date: 2011-02


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Chapter 11.3
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HANDOUT FTA - Advanced Field Tech Training March 2012

-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Windows 7.0 IE 8/9 settings

Q: Is Java runtime required to set in Microsoft Internet Explorer?


A: Yes, it is required to install Java runtime or Microsoft Java Virtual Machine. Refer table below.

Microsoft Java Virtual Machine Build 3810


Java Runtime 1.6 Update 18 or higher

Q: How do I check what version of Java run time installed on my system?


A: In Microsoft Internet Explorer, Tools Æ Manage Add-ons Æ Tools and Extensions. Change the
dropdown from “Currently loaded add-ons” to “All add-ons” and trace the JRE version # as shown below.

Q. My Java run time Version number is not the same as required? What do I do?
A: Download the version number by visiting the site or contact your IT administrator for a download.

Q: File download is not getting displayed?


A: Check Microsoft Internet Explorer downloads setting; Tools Æ Internet Options Æ Security Æ Trusted
Sites Æ Custom Level Æ Downloads Æ Automatic prompting for file downloads. If disabled then enable
the file download setting.

Q: Can [Link] WIN run on Microsoft Windows 7 64-bit operating system?


A: [Link] WIN can run on Microsoft Windows 7 64-bit operating system but using 32-bit Microsoft
Internet Explorer 8.0 and 9.0. [Link] WIN is not supported for 64-bit Microsoft Internet Explorer.

Q: Is there an impact of Windows Data Execution Prevention (DEP)?


A: Yes, it’s necessary to turn of DEP, otherwise especially after changing a setpoint or parameter the
following message comes up and Internet Explorer will be closed.

Author: Venkatesh Mutnuri Checked: Elektronik Date: 2011-02


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Chapter 11.3
(c) GE Jenbacher GmbH & Co OG, 2012 201/265 Training Center | A-6200 Jenbach | Austria
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Windows 7.0 IE 8/9 settings

Go to the System properties of My Computer/Advanced/Startup and Recovery/Settings

Push the Button Edit:

Author: Venkatesh Mutnuri Checked: Elektronik Date: 2011-02


EN Windows7.0_IE8_IE9.doc Index: Page - No.: 9 / 10

Chapter 11.3
(c) GE Jenbacher GmbH & Co OG, 2012 202/265 Training Center | A-6200 Jenbach | Austria
HANDOUT FTA - Advanced Field Tech Training March 2012

-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Windows 7.0 IE 8/9 settings

“/noexecute=” has to be set to “alwaysoff”

Author: Venkatesh Mutnuri Checked: Elektronik Date: 2011-02


EN Windows7.0_IE8_IE9.doc Index: Page - No.: 10 / 10

Chapter 11.3
(c) GE Jenbacher GmbH & Co OG, 2012 203/265 Training Center | A-6200 Jenbach | Austria
HANDOUT FTA - Advanced Field Tech Training March 2012


*((QHUJ\ ',$1(:,1






,QWHUQHW([SORUHU  DQG
:LQGRZVVHWWLQJV


‹*(-HQEDFKHU*PE+ &R2+*
$FKHQVHHVWU
$-HQEDFK $XVWULD

Chapter 11.4
(c) GE Jenbacher GmbH & Co OG, 2012 204/265 Training Center | A-6200 Jenbach | Austria
HANDOUT FTA - Advanced Field Tech Training March 2012

-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

1. Installation guide ____________________________________________________ 3


2. FAQs ______________________________________________________________ 7
2.1 Installation 8
2.2 Configuration 8

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


InterntExplorerW7_XP_Settings.doc Index: c Page - No.: 2 / 14

Chapter 11.4
(c) GE Jenbacher GmbH & Co OG, 2012 205/265 Training Center | A-6200 Jenbach | Austria
HANDOUT FTA - Advanced Field Tech Training March 2012

-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

1. Installation guide

Because of security reasons the Internet Explorer has implemented additional blocking mechanism which
can prevent correct running of [Link] WIN. Following settings is a guide how the settings can be done
that [Link] WIN will run. Please be in attention that the security level will be changed for all sites listed in
the trusted sites and the content advisor will be disabled.

Microsoft Internet Explorer settings


The settings described in this section are stored in the user-specific profile and must therefore be entered
separately for each user.

The [Link] WIN web application is based on technologies, which for security reasons and to prevent
misuse, should not be enabled for unknown websites. However, to ensure that your computer can be
used as a [Link] WIN operating station, you can add the address of the [Link] WIN server to the
"Trusted sites" zone and adjust it to comply with the security settings for this zone. Please note that these
settings will then be used for all "Trusted sites".

Adding the website to the "Trusted sites"


To call up the dialogue box below, choose the [Internet Options...] command in the [Tools] menu. Then
select the [Security] tab.

Click the [Sites...] button to activate the dialogue box for adding websites to the Trusted sites zone.

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

Add all site addresses used for [Link] WIN to the list of trusted sites:
*.[Link] (used for internet connection)
[Link] (used for internet connection)
10.200.200.* (used for dial in connection)
172.31.*.* (usually used for local area connection)

Click [Add] and the address of the [Link] WIN server is added to the trusted sites. Caution: The
[Require server verification (https:) for all sites in this zone] option must be in order for the domain to
be added! Next, please exit Internet Explorer and restart. Once the [Link] WIN server has been added
to the trusted sites, Internet Explorer must display the "Trusted sites" zone at the bottom right of the
status line when the [Link] WIN server is selected.

Security settings for the "Trusted sites"


To call up the dialogue box below, choose the [Internet Options...] command in the [Tools] menu. Then
select the [Security] tab.

Select the [Trusted sites] security zone and click the [Custom Level] button. Set the security level for
this zone to the default security level "Low". If this button has been disabled, this means that the default
level is already set.

After this, click the [Custom Level...] button to reset all the user-defined settings. Next, enable the
[Initialise and script ActiveX controls not marked as safe for scripting], [Allow Scriptlets] and
[Download unsigned ActiveX controls] option.

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

Then close this dialogue box by clicking [OK]. Confirm the security question that appears by clicking
[Yes].

Settings for LAN or modem (intranet) connection

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

If a proxy server has been configured on your system for use on the Internet, it should be disabled
(circumvented) for the local connection (Intranet) to the [Link] WIN server. To do so, check the following
settings and, if necessary, change them.

To call up the dialogue box below, choose the [Internet Options...] command in the [Tools] menu. Then
select the [Connections] tab.

Click the [LAN Settings...] button to go to the following dialogue box.

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

If a proxy server has been entered, click the [Advanced...] button to activate the following dialogue box.
Type the address of the [Link] WIN server in the [Exceptions] edit box. If it already contains other
addresses, add the address of the [Link] WIN server, separated by a semicolon (e.g.:
"[Link];[Link]").

Next, return to the dialogue box below:

If an RDT connection has been configured, [Dial whenever a network connection is not present]
should have been selected. If not, whenever you open Internet Explorer, the RDT connection is always
selected, which then tries to reach the [Link] WIN server on the dial-up connection.

2. FAQs

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

2.1 Installation
Q: Do I need to install [Link] WIN Client Controls?
A: Yes, it is mandatory to install [Link] WIN Client Controls before using [Link] WIN system. This
installation is one time activity for a computer.

Q: Where can I find [Link] WIN Client Controls?


A: [Link] WIN Client Controls is available after clicking “Downloads” button on the login page.

2.2 Configuration
Q: Are there any Internet Explorer settings to be configured?
A: Yes, there are settings that required to be configured in Internet Explorer. Follow the instructions in
instruction guide. Be aware of choosing relevant Internet Explorer version setting document.

Q: Is [Link] WIN compatible with only Microsoft Internet Explorer or any other web browser?
A: [Link] WIN system is developed and tested on Microsoft Internet Explorer. It is advisable to use only
Microsoft Internet Explorer.

Q: What version of Microsoft Internet Explorer version is required for [Link] WIN system?
A: [Link] WIN system is tested on Microsoft Internet Explorer for version 6.0, 7.0, 8.0 and 9.0.

Q: Is Java runtime required to set in Microsoft Internet Explorer?


A: Yes, it is required to install Java runtime or Microsoft Java Virtual Machine. Refer table below. Be sure
to have automatic updates disabled.

Microsoft Java Virtual Machine Build 3810


Java Runtime 1.6.0 Update 15 to 26
Update 27 does not work!
Highest Java Version allowed in 1.6.0 Update 21
case of using Hermes.

Q: How do I check what version of Java run time installed on my system?


A: In Microsoft Internet Explorer, Tools Æ Manage Add-ons Æ Tools and Extensions. Change the
dropdown from “Currently loaded add-ons” to “All add-ons” and trace the JRE version # as shown below.

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

Q. My Java run time Version number is not the same as required? What do I do?
A: Download the version number by visiting the site or contact your IT administrator for a download.

Q: File download is not getting displayed?


A: Check Microsoft Internet Explorer downloads setting; Tools Æ Internet Options Æ Security Æ Trusted
Sites Æ Custom Level Æ Downloads Æ Automatic prompting for file downloads. If disabled then enable
the file download setting.

Q: Values for Hermes are shown as asterics?

A: Proceed to Tools/Internet Options/Security Tab. Click the Custom Level Icon. Then scroll to Script
Active X controls marked safe for scripting and enable it .

If for instance the option Allow Scriptlets would not be enabled the same type of failure would occur.

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

Q: Each time [Link] WIN is opened a message box reagrding unsafe ActiveX control pops up and has
to be committed.

A: Proceed to Tools/Internet Options/Security Tab. Click the Custom Level Icon. Then scroll to Initialise
and script ActiveX controls not marked as safe for scripting and change the setting from prompt to
enable.

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

Q: When logging into HERMES I receive “Failed to create ASP object for :./” Error”.

A: Check Java version that it is not over version 21. Also check internet scriplets settings.

Q: Can [Link] WIN run on Microsoft Windows 7 64-bit operating system?


A: [Link] WIN can run on Microsoft Windows 7 64-bit operating system but using 32-bit Microsoft
Internet Explorer 8.0 and 9.0. [Link] WIN is not supported for 64-bit Microsoft Internet Explorer.

Q: Is there an impact of Windows Data Execution Prevention (DEP)?


A: Yes, it’s necessary to turn of DEP, otherwise especially after changing a setpoint or parameter the
following message comes up and Internet Explorer will be closed.

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

Settings for Windows XP to disable DEP:


Go to the System properties of My Computer/Advanced/Startup and Recovery/Settings

Push the Button Edit:

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

“/noexecute=” has to be set to “alwaysoff”

Settings for Windows 7 to disable DEP:


Choose Run as administrator:

Type in the command: [Link] /set {current} nx AlwaysOff and press Enter:

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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-HQEDFKHU [Link] WIN


'RFXPHQWDWLRQ Internet Explorer (7-9) and Windows settings

You should see "The operation completed successfully". (To enable DEP type in: [Link] /set {current} nx
AlwaysOn.)
After these changes a reboot of the computer is necessary!

Author: Venkatesh Mutnuri / Markus Überegger Checked: TPSS Date: 2011-09-16


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Chapter 11.4
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TI 2110-007 [Link] WIN description close

[Link]® WIN (export)


Alarm management – current datas

The most recent message appears at the top of the list. Messages can be filtered by type
(Alarm, Warning and Operating notification). The message list displayed can be exported into
a file (*.csv) for further processing.

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[Link]® WIN (export)


Alarm management - history
This screen displays the messages which are stored in the database. The entries are sorted in
accordance with the time at which they were created. The most recent message appears at the
top of the list. Messages can be filtered by type (Alarm, Warning and Operating notification). The
message list displayed can be exported into a file (*.csv) for further processing. You can specify a
time filter before loading messages from the database.

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[Link]® WIN (export)


Trend display
Use the trend menu (left-hand section of the screen) to load the desired data into the trend
display (right hand section of the screen). The message list displayed can be exported into a
file (*.csv) for further processing.

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[Link]® WIN (export)


Trend display general

All the process values are arranged into groups (trends) and saved to a database at defined
recording intervals and in defined recording cycles. Use the trend menu (left-hand section of
the screen) to load the recorded data into the trend display (right-hand section of the
screen). In addition to the analysis of historical data in the trend display, online trends are
also available for the continuous observation of real time data.

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[Link]® WIN (export)


Parameter import/export
The parameter management system contains all controller and configuration parameters,
limit values, measurement ranges of transducers, etc., arranged into groups and displayed in
tabular form.

If you have the appropriate authorisation, you can change each parameter within its entry
limits. Every change is transferred directly to the control system. There the parameter data
are stored in an area protected against power failure. Changes to parameters have a direct
effect on the operating mode of the engine or installation components!

By exporting the parameters to a file you can back up the parameters on the [Link] WIN
client. By carrying out an import you can upload the parameters back into the control
system.

By carrying out an import


you can upload the parameters
back into the control
system.

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SES_User [Link] close

SES – Service Expert System


SES is an advisory system and also a central knowledge base (e.g. to facilitate faster trouble
shooting).

SES offers …
• a step-by-step support to diagnose alarms.
• solutions for problems with engines (e.g. alarm messages with solutions).
• access to Jenbacher documents and their contents (like technical-, maintenance or service
technicians instructions, descriptions, ….).
• worldwide exchange of information between Field Service Technicians, including solution
verification by our experts.

Target group: internally selected user

SES access: [Link]

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SES – Service Expert System


[Link]

change language

choose language
choose language

Chapter 11.6
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SES – Service Expert System


SEARCH - VIDEOS
Diagnosis
Document
Solution
enter search term

further details

further details

Chapter 11.6
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myPlant TM

myPlantTM is a software based technology which securly transmits operational and service data
from Jenbacher engines to a central database hosted by GE.

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myPlant TM

The advantages are - easy connection


- reduced engine downtime
- optimized plant operation
- remote help
- information on one place
- availability of data

What data is transferred ?


All logs, alarms and operational data such as total power,
speed, operating hours and number of starts are
uploaded to the myPlantTM server every 15-60 seconds.

Customers and ITP's must buy a contract package to access


the system and data.

All communications are encrypted, and so interception/


decoding is very difficult.

Data can be exported to an Excel file.

Asset Registration
Check connection status after asset registration

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Special tool
Water column

Pressure measurement with the water


column.

e.g. crankcase pressure, gas pressure in the


gas train

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Special tool
Manometer
Pressure measurement with the
manometer

e.g. exhaust back pressure, differential


pressure ….

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Special tool
Exhaust gas measurement case

Exhaust gas measurement case for


exhaust gas measurements

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Special tool
Ignition timing strobe

Ignition timing strobe for measuring


the ignition point

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TI 1400 0151 close

Special tool
Oscilloscope: Fluke
Fluke for e.g. measurements on
the ignition system

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Special tool
High voltage clamp

High voltage clamp for measurements


on the ignition system (ignition coils,
spark plugs)

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Special tool type 3/4

Special tools type 3


Assembly tool for
crankshaft seals
type 3/4/6

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Special tool type 3/4


(Image without hoses)

Hydraulic tool for cylinder head assembling Special tools type 4


type 3/4

Hydraulic ratchet for main bearing cap


assembling type 4

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Special tool type 6 (Image without hoses)

Hydraulic tool for cylinder head assembling


type 6

Hydraulic tool for


throttle bushing
Hydraulic tool for change type 6
flywheel hub assembly
type 6
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Special tool type 6

Hydraulic tool for crankshaft gear resp.


Intermediate gears assembly type 6
Torque multiplier for tie rod
assembly type 6

Crankcase spreader type 6C/E/F-G/H

Piston/con rod lifting tool type 6E/F


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Special tool type 6

Pre chamber extraction and


seat cleaning / grinding tool Steel piston lifting Steel and aluminium
type 6E/F tool type 6 piston lifting tool
type 6

aluminium piston
lifting tool type 6

Cylinder liner extraction tool type 6E/F


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Special tool 624

Inspection tool for piston cooling jets


type 6G/H

Assembly tool for power unit type 6G/H

Piston/con rod lifting tool type 6G/H

Fixation tool for 3 part piston Tilted piston ring


cylinder liners insertion tool for pliers for
type 6G/H type 6 G/H type 6G/H
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Special tool

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Special tool
Blowby measuring instrument

With a rapid increase of the differential pressure


on the blowby filter (> 10 mbar in 2000 oh) or with
differential pressures about 25 mbar the
blowby volume should be measured 
see TI 1530-0185

Example: J312 engine


Measurement yields 90 mm water column  results in approx. 450 l/min (is OK)

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Effective problem solving

To the problem solving four questions should be asked:


What is the problem ?
When the problem has appeared ?
Where the problem has appeared ?
How important is the problem ?

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Effective problem solving


The first step to the problem solving is ...

Why is it so important ?

Everyone has a different view to the problem.


We don't know which information's are important.
We often believe in reoccurrence of the same cause .
We focus on solutions without defining the problem/cause.

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Effective problem solving

Do not use impressions like:


Hot , long, many, high etc.

Better use measurable data like:


Temperature (58°C)
Dimensions (5,8 mm long, 3,4 mm thick)
Frequency (5x)
Pressure (3,4 bar)
etc.
For collecting these data use all available tools (data
from [Link] ®, data from customer records,
worksheets, observations made by local people and
pictures)
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Effective problem solving

Problem Action
Where is ignition source ?

Condition
Which material is burning ?

Fire
Condition
How is it with the oxygen supply?

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Damage announcement
An example:
Piston damage, urgent action required because its not the first time … . engine is
overheating

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Damage announcement
Attend to the following when defect parts are to be shipped to Jenbach for
appraisal:

Always conservate properly to prevent parts from corrosion


Pack properly when part are to be shipped to prevent them
from further damages
Pull an oil sample if possible
Attach all records of oil changes
Attach the history of oil analysis results if that makes sense

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Chapter 12
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[Link]®
The use of [Link]® offers the following advantages:
▪ Low emissions in combination with the patented GE Jenbacher
▪ resistant to catalyst poisoning and therefore a non-deteriorating
after treatment concept
▪ increased heat yield due to the utilization of the chemical energy
in the pollutants
▪ minimal periodic maintenance and therefore minimal fixed costs
▪ a design lifetime

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CLAIR_EN.ppt
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Chapter 13.1
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[Link]®

1 Connection for gas injection


2 Interface for heating element
3 Connections for temperature sensors
4 Exhaust inlet
5 Cleaned exhaust gas
6 Exhaust outlet
7 Junction box

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[Link]®

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ORC – clean cycle


For many waste heat applications, we need
a fluid that boils at a lower temperature
than water

Historically, such fluids have been


hydrocarbons - hence the name Organic.

Modern Working Fluids include: Propane /


Pentane / Toluene / HFC-R245fa These
Fluids allow use of Lower-Temperature
Heat Sources because the boiling point,
occurs at a lower temperature than the
water boiling temperature.

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ORC – clean cycle

L1

capacitor
Clean L1

bank
Cycle L2 L2 grid
125kW
L3 L3

~400/560V, 380/480V,
~450Hz 50/60Hz

DC w/Ripple DC

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ORC – clean cycle


Integrated Power Module
Vapor
46 C / 1,7 bar

Liquid
R245fa 25 C
Flüssigkeit
Vapor Vapor
25 C / 1.6bara 1.6 bar
132 C 77 C
16.1 bar 1.8 bar

Economizer Tank
Evaporative condenser
ambiente air
Evaporator according to ISO (15 C, 60% RH)

Liquid
47 C
16.2 bar Liquid
Heat input 26 C Pump
924 kW 16.3 bar

Water R245fa
1 bar (0 psig) 100°C (212°F) 15,6°C (60°F)
17,1 bar (248 psig) 202°C (395°F) 132°C (270°F)

Chapter 13.2
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FTB-FTA

Inspection- and maintenance

Work at the plant must only


be carried out by specially trained, electric
and mechanic specialists.

The maintenance intervals have been


determined on the basis of
experience of maintaining average

operating levels while fully


complying with the manufacturer ’s
operating and maintenance instructions.

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Inspection- and maintenance

• The safety regulations contained in the user's manual must be observed.


• The safety regulations and regulations for the prevention of accidents set out by the law
must be observed.
• Prior to the commencement of any work the party ordering must make sure that the
applying safety regulations are observed for the work to be carried out.
• In the event of work that may only be carried out with the engine standing still, the engine
must be turned off and secured against unauthorized re-starting according to the technical
instruction no. 1100-0105.
• The LOTO Lockout/Tagout kit must be applied.

ISO 3864, ANSI Z535 ISO 3864, ANSI Z535 ISO 3864, ANSI Z535 ISO 3864, ANSI Z535 ISO 3864, ANSI Z535 ISO 3864, ANSI Z535

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Maintenance plan (natural gas)


Intervals independent of the number of operating hours
Inspection task type 2 type 3 type 4 type 6 interval
Carry out daily visual inspection
Daily inspection round I 9003 0 I 9002 0 I 9003 0 I 9003 0 daily
of the unit.
Operating data log --- --- --- --- daily Log the operating data daily.
If the manometer at the pocket
filter shows negative pressure
>10 mbar
IW 8040A0
Intake air filter-Engine IW 8040A0 IW 8040A0 IW 8041A6 daily (1 kPa), the filter needs to be
IW 8040A4
replaced, (or else replace them
after 2,000 operating hours at
the latest).
Visual inspection of the
Overvoltage suppressor IW 8048 A0 IW 8048 A0 IW 8048 A0 IW 8048 A0 daily
overvoltage deflectors.
Transmission IW 8071A0 weekly Check oil level.
The result of the ignition voltage
check to be carried out weekly,
Check ignition voltage/ IW 0309 M0 IW 0309 M0 IW 0309 M0 IW 0309 M0 weekly
serves as the indicator for the
spark plug ( Fluke ) TA 1400-0104 TA 1400-0104 TA 1400-0104 TA 1400-0104 < 250 oh
actual service life of the spark
plug.
IW 0100M2 IW 0101M0 IW 0101M0 IW 0101M6 The results from the engine
TA 1000-0099A TA 1000-0099A TA 1000-0099A TA 1000-0099A first time after lubricating oil analyses are
Lubricating oil
TA 1000-0099B TA 1000-0099B TA 1000-0099B TA 1000-0099B 150 oh decisive for the actual oil change
TA 1000-0099C TA 1000-0099C TA 1000-0099C TA 1000-0099C periods.
Check oil level and Check oil
pressure.
Pre-chamber gas compressor IW 8046 0 weekly
Check operation of float
condensate discharge unit..
Check the acid level. Check if the
Battery TA 1000-0050 TA 1000-0050 TA 1000-0050 TA 1000-0050 once in a month pole binders are properly
secured.

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Maintenance plan (natural gas)


Intervals independent of the number of operating hours
Inspection task type 2 type 3 type 4 type 6 interval
Check air filter for pollution.
Air filter in switch cabinet --- --- --- --- once in a month
If necessary, clean or replace.
Check switch cabinet cooler for
Switch cabinet cooler --- --- --- --- once in a year clogging and, if necessary, clean
using compressed air.
once a year or in
Smoke warning unit and gas accordance with Check
--- --- --- ---
warning unit official (observe the official regulations).
regulations
Heat exchangers with a water
temperature >100°C are
classified as installations
2,000 oh
requiring special supervision.
Heat exchangers
Before commissioning - and
Heat exchanger exhaust gas / >100 C water
I 0103 0 I 0103 0 I 0103 4 I 0103 6 subsequently at regular intervals
water temp. in acc.
- these installations are legally
with official
subjected to inspections by
regulations
certified inspection agencies (e.g.
operational safety regulations,
steam boiler regulations, etc.).
TA 1000-0200 TA 1000-0200 TA 1000-0200 TA 1000-0200
Concentration inspection
TA 1000-0201 TA 1000-0201 TA 1000-0201 TA 1000-0201 once in a year
TA 1000-0204 TA 1000-0204 TA 1000-0204 TA 1000-0204
Cooling water 30,000 oh after
having comple- Cooling water exchange
W 8080 A0 W 8080 A0 W 8080 A0 W 8080 A0
ted the overhaul
activities
The overriding factor for the
actual active-carbon
Activated carbon adsorber W 8074 A0 W 8074 A0 W 8074 A0 W 8074 A0 interchange intervals are the
results of the active carbon mass
increase measurements.

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Maintenance plan (natural gas)


Intervals independent of the number of operating hours
Inspection task type 2 type 3 type 4 type 6 interval
at an air humidity of:
six-monthly
>90 %rH
Cali-
Humidity sensor – intake air W 8048A4 annually between 80 and 90 %rH
bration
once every 2
up to 80 %rH
years
Condensate removal in fuel-gas
2,000 oh
system (if part of Jenbacher’s
IW 8090 A0 IW 8090 A0 IW 8090 A0 IW 8090 A0 at least 4 times Check for gas leaks
scope of supply)
a year
Automatic condensate removal
Manual condensate drains if required Condensate drain
2,000 oh at least
once a quarter
All pipes and components carrying 8,000 oh at least
IW 8049 0 IW 8049 0 IW 8049 0 IW 8049 0 Leak test
fuel gas and mixtures once a year for
natural gas
only
30,000 Oh
Compressed air starter W 8032 M0 W 8032 M0 W 8032 M0 W 8032 M0 or once every Overhaul
4years
at 30.000 operating hours or
Crankshaft main bearing/ thrust 30.000 oh (4,000
W 8050M0 W 8050M0 W 8050M0 W 8050 M6 4,000 engine starts maximum –
bearing engine starts)
replace
Battery in [Link]® module --- --- --- --- every two years Replace
Storage battery at battery charger --- --- --- --- every five years Replace
Emission measurement according to official guide-
lines. Comment: If the emission levels listed in the
Emission measurement --- --- --- --- specification are exceeded, inspect and, if
required, clean the combustion chambers (W 8056
M0).

Tip:
The maintenance operations highlighted in green in the maintenance plan are plant-specific and are incorporated into the customer-
specific maintenance plan according to engine type and version.

Chapter 14.1
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Maintenance plan
(natural gas)
Interval reference number = Operating hours/1000

Interval Maintenance task/inspection task type 2 type 3 type 4 type 6


- Maintenance after first start-up W 1000 0 W 1000 0 W 1000 4 W 1000 6
2 Valve clearance W 0400 M0 W 0400 M0 W 0400 M4 W 0400 M6
2 Ignition system (Fluke) W 0303 M0 W 0303 M0 W 0303 M0 W 0303 M0
2 Inspection I 0103 0 I 0103 0 I 0103 4 I 0103 6
2 Intake air filter-Engine IW 8041 A0 IW 8040 A4 IW 8041 A6
2 Table cooler W 8065 A0 W 8065 A0 W 8065 A0 W 8065 A0
2/8 Leak test IW 8049 0 IW 8049 0 IW 8049 0 IW 8049 0
2/20/30 Regulating rods/Throttle valve/Actuator W 0201 M2 W 0200 M0 W 0200 M4 W 0200 M6
2/30/60 Gas train W 8045 A0 W 8045 A0 W 8045 A4 W 8045 A6
4/20 Coupling housing on elastic bearings IW 8079 A4 IW 8079 A6
W 0506 M6
dif. Crankcase vent W 0508 M0 W 0507 M4
W 0508 M6
W 0701 M6
dif. Gas mixer W 0700 M2 W 0704 M0
W 0705 M6
2/4/8 Gear IW 8071 A0
2/6/10/30 Pre-chamber gas compressor IW 8046 0
4 bzw. 6 Oil filter insert W 8038 M6
6/10 Prechamber/-gas valve/Spark plug sleeve W 0501 M6
10 Crankshaft thrust bearing (with transmission only) W 8060 M6
10 Starter Bosch Iskra Bosch Iskra Bosch Iskra Bosch Iskra
10/30 Engine coolant pump W 0203 A6 W 0203 A6
W 8024 M6
W 8023 M0 W 8025 M0
dif. Turbocharger W 0203 A6 W 0202 M3
W 8025 M0 W 8025 M6
W 8026 M6

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Maintenance plan
(natural gas)
Interval reference number = Operating hours/1000

Interval Maintenance task/inspection task type 2 type 3 type 4 type 6


W 8023 M0
20 Mixture bypass valve W 0900 M0 W 8024 M0 W 0802 M4 W 0802 M6
W 8025 M0
20 Torsion vibration damper W 0802 M2 W 0802 M0 W 0601 M0 W 0601 M0
20 Jenbacher-switch cabinets W 0601 M0 W 0601 M0 W 8031 A0 W 8031 A0
30 Compressed air starter W 8031 A0 W 8031 A0 W 8032 M0
30 Gas quantity controller W 0705 M0 W 0705 M0
30 Engine oil pump W 8046 M0 W 8046 M0 W 8046 M6
30 Piston/Piston cooling W 8047 M0 W 8047 M0 W 8047 M0 W 8047 M0
30 Con rod/Con rod bearing W 8048 M0 W 8048 M0 W 8048 M0 W 8048 M0
30 Cylinder liner/Scraper ring W 8049 M0 W 8049 M0 W 8049 M0 W 8049 M0
30 Crankshaft main bearing/thrust bearing W 8050 M0 W 8050 M0 W 8050 M0 W 8050 M6
ZK 30 Camshaft/Control parts W 8052 M0 W 8052 M0 W 8052 M0 W 8052 M0
60 Plate-type heat exchanger W 8043 A0 W 8043 A0 W 8043 A0 W 8043 A0
60 Pre-lubricating pump W 8054 M0 W 8054 M0
60 Overhaul W 2100 M0 W 2100 M0 W 2100 M4 W 2100 M0
ZK Exhaust gas manifold/Isolation W 8051 M0 W 8051 M0 W 8051 M0 W 8051 M0
Leroy Somer
Stamford 5,6,7
- Generator Stamford 5, 6, 7 Stamford 5, 6, 7 AVK BR8
AVK Dig
AVK Dig
- Elastomer parts W 8033 2 W 8033 0 W 8033 4 W 8034 6
- Cylinder head replacement W 8053 M0 W 8053 M0 W 8053 M4 W 8053 M6

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Prechamber gas valves


Bott 4J 321631 - special valve for
CMG (O2 > 4%); 3-part serial number
on hexagon. Slim shaft
Assembling torque 20 Nm

Bott 2kJ 433894 - from 2009 ( "2nd


source" for ERS valve) 3-5 part serial
number on hexagon; 2 grooves
Assembling torque 30 Nm

ERS valve 389588 - standard valve


since end of 2007 for all type 6
engines (except O2 > 4%)
serial and comments on valve body
assembling torque 30 Nm

All other prechamber gas valves („Parker-ball valves“, KRS, Maier) are not allowed anymore.

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Precombustion chamber/gas valves


ppc =p2´+ 50 mbar checked and adjusted at the pre chamber gas pressure
regulator
1 mm orifice at the connection of the gas hoses at the
engine block

ASPS (LSCS) is availible at special request , but is not followed any further
anymore

8 hole swirl pre chamber 8 hole swirl pre chamber 8 hole swirl pre chamber
(NiMoNiC) (NiMoNiC) (NiMoNiC)
plugged or welded or soldered plugged onto brass spark plug plugged onto steel
onto brass spark plug sleeve, sleeve spark plug sleeve

until 2005 für natural gas from 2005 for natural gas for bio / landfill gas (7,5 cm³)
max. pme = 20 bar (6 cm³) reinforced version (6 cm³)

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Precombustion chamber
Never use different types of prechambers mixed in one engine! Take care when
changing heads! Different material thickness possible (must be for higher power
output!).

In the course of servicing the precombustion chambers and spark plug sleeves
are removed and tested for reuse.

Observe WA 0501 M6.

The precombustion chambers have to be checked visually resp. with gage.

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Spark plug sleeve


4 4 4
5
3

8 1 6 4

7
2
9
Checking the spark plug sleeves is done visually:
• Check for fretting and play on the spark plug thread. (1)
• Check for fretting on the gas valve thread. (2)
• Check for surface damages on the pre-chamber sealing. (3)
• Check for damages on the O-ring grooves. (4)
• Check for blockages in the cooling water holes. (5)
• Check for surface damages on the spark plug sealing. (6)
• Check for erosion/corrosion in the gas channel. (7)
• Check for the inner diameter on the pre-chamber mounting. (8)
• Check for cracks (especially around the pre-chamber mounting). (9)

GE PROPRIETARY INFORMATION GE Energy Jenbacher Gasmotoren


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Chapter 14.2
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For GE Internal Use Only Start_FTA_EN.ppt
Index: b; 01.12.2011

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