TA 1400-0100

Running-in procedure for GE Distributed Power

engines

Technical Instruction

© GE Jenbacher GmbH & Co OG

Achenseestr. 1-3
A-6200 Jenbach, Austria
www.gejenbacher.com
 TA 1400-0100
Running-in procedure for GE Distributed Power engines

1 Scope ...........................................................................................................................................................  1
2 Purpose .......................................................................................................................................................  1
3 Tips ..............................................................................................................................................................  1
4 Procedure ...................................................................................................................................................  2
5 Engine running-in programme...............................................................................................................  2
5.1 Running-in programme for Type 2, 3 and 4 Jenbacher gas engines ...............................................  3
5.2 Running-in programme for Type 6 Jenbacher gas engines .................................................................  3
5.3 Running-in programme for Type J 424 & J 624 Jenbacher gas engines with Miba 69 lead-
free bearings................................................................................................................................................................  4
5.4 Running-in programme for Type 9 Jenbacher gas engines .................................................................  5
6 Additional guidance for first start-up ...................................................................................................  7
7 Revision code.............................................................................................................................................  7

The target recipients of this document are:

Customer, Distribution Partners, Service Partners, Commissioning Partners, Subsidiaries/Branches, Location
Jenbach
GE Proprietary Information: CONFIDENTIAL!
The information contained in this document is General Electric Company 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. This includes but is not limited to use for the creation, manufacture,
development or derivation of any repairs, modifications, spare parts, designs or configuration changes, or for
obtaining government or regulatory approval to do so. If consent is given for reproduction in whole or in part,
this notice and the notice set forth on each page of this document shall appear in any such reproduction in
whole or in part.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY

1 Scope
This Technical Instruction applies to the following GE Distributed Power engines:
• Type 2 engines
• Type 3 engines
• Type 4 engines
• Type 6 engines
• Type 9 engines
with a coupled generator (50 Hz and 60 Hz rated frequency).

2 Purpose
This Technical Instruction describes the running-in procedure for GE Distributed Power engines.

3 Tips
Perform the running-in procedure at the appropriate rated engine speed (apart from Type 9 engines).
The purpose of carrying out the running-in programme according to the instructions is:
• to be able to observe the engine operating behaviour closely after repair or maintenance to ensure that
the work has been carried out correctly and to minimise any risk to subsequent normal operation.
• to achieve the required running-in wear of new engine components (cylinder linings, pistons, piston rings,
sliding bearings, etc.) in a controlled manner.

Author: Provin D. Responsible: Nota F. Release date: 31/03/2016

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 TA 1400-0100
Running-in procedure for GE Distributed Power engines

All new modules leaving the production plant (location Jenbach) are subjected to a mandatory running-in
procedure on the factory test stand and a functional test.
All repaired modules leaving the production plant are subjected to a mandatory running-in procedure on the
factory test stand and a functional test.
New engines which are coupled to the generator at the installation site must be run in and tested on site.
Modules which are repaired on site must be run in and tested on site.
Also perform the running-in procedure when replacing parts such as cylinder liners, pistons, piston rings,
conrods and sliding bearings.
If the engine unexpectedly shuts down during the running-in programme, the running-in programme must be
continued from where it was interrupted by the shutdown.

NOTE
Leanox setting
While the engine is running, store both points required to set the Leanox controller when half
load and full load are reached.

4 Procedure
Before carrying out the engine running-in programme, follow the Inspection instruction - Daily inspection
procedure.
Initial commissioning of new engines
Having finished the engine running-in programme according to procedure (as described in section 5), carry out
Maintenance following initial commissioning.

5 Engine running-in programme

NOTE
Potential engine damage when running in
Unusual sounds, vibrations and temperature phenomena
Ø Make sure that, if required, engine operation can be stopped immediately by pressing the
EMERGENCY STOP button.
Ø Ensure that the EMERGENCY STOP button is freely accessible at all times.

Type 2, 3, 4 and 6 engines:

The purpose of the running-in stages (five minutes each) is to check the mixture setting using the exhaust gas
emission measurement. NOx emissions must not exceed 750 mg NOx/m3N (or 5% O2 in the exhaust gas).

Type 9 engine:
The first running-in stage, with the engine delivering power, is to check the mixture setting using the exhaust
gas emission measurement. NOx emissions must not exceed 750 mg NOx/m3N (or 5% O2 in the exhaust gas).

Author: Provin D. Responsible: Nota F. Release date: 31/03/2016

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 TA 1400-0100
Running-in procedure for GE Distributed Power engines

5.1 Running-in programme for Type 2, 3 and 4 Jenbacher gas engines

Work through the running-in stages one after the other in order.
Once the rated power has been reached, maintain it for 30 minutes and then finish the running-in procedure.
Do not overload!

Type J 424 engine:

The following steps must be observed before starting the engine:
1. Switch on the prelubrication pump for 5-10 minutes to flush the oil through the engine channels and
bearings.
2. Turn the crankshaft manually through at least 2 complete rotations during the flushing process while the
prelubrication pump is in operation.
ELECTRICALPOWER
Running-in Stage running J 208 J 212 J 216/ J 316/ J 320/ J 420 J 424
stage time J 312 J 412 J 416
Min. kW kW kW kW kW kW kW
1 5 0 0 0 0 0 0 0
2 5 35 50 65 90 120 150 180
3 5 85 130 160 220 290 360 430
4 10 130 205 250 350 470 580 700
5 10 200 305 380 520 700 870 1050
6 10 265 410 510 700 930 1160 1400
7 30 Rated Rated Rated Rated Rated Rated Rated
power power power power power power power

5.2 Running-in programme for Type 6 Jenbacher gas engines

Work through the running-in stages one after the other in order. Once the rated power has been reached,
maintain it for 60 minutes and then finish the running-in procedure.
Do not overload!
ELECTRICALPOWER
Running-in Stage running J 612 J 616 / J J 620
stage time 616D
Min. kW kW kW
1 5 0 0 0
2 5 200 240 300
3 10 500 400 760
4 10 750 900 1140
5 10 1000 1200 1520
6 10 1250 1520 1900
7 10 1500 1800 2400
8 10 1750 2100 2900
9 30 Rated Rated Rated
power power power

Author: Provin D. Responsible: Nota F. Release date: 31/03/2016

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 TA 1400-0100
Running-in procedure for GE Distributed Power engines

5.3 Running-in programme for Type J 424 & J 624 Jenbacher gas engines with Miba 69 lead-
free bearings
Miba 69 Syntec + Sputter bearings can be identified by the dark grey appearance of the synthetic overlay and
the Miba 69-marking on the side.
The following steps must be observed before starting the engine:
1. Switch on both prelubrication pumps for 5-10 minutes to flush the oil through the engine channels and
bearings.
2. Turn the crankshaft manually through at least 2 complete rotations during the flushing process while the
prelubrication pump is in operation.
3. Work through the running-in stages one after the other in order. Once the rated power has been reached,
maintain it for 60 minutes. Then finish running in.
Do not overload!

NOTE
Island operation
It is not always possible to perform running-in up to the rated power on engines in island
operation. In this case, step 3 cannot be carried out.
Steps 1 and 2 are not affected by the operating conditions and must in any case be performed
before the engine is started up.

Running-in programme J 424:

ELECTRICALPOWER
Running-in Stage running J 424
stage time
Min. kW
1 5 0
2 10 180
3 20 430
4 20 700
5 20 1050
6 20 1400
7 60 Rated power

Running-in programme J 624 G and H:

ELECTRICALPOWER
Running-in Stage running J 624
stage time
Min. kW
1 5 0
2 10 400
3 20 1000
4 20 1250
5 20 1500

Author: Provin D. Responsible: Nota F. Release date: 31/03/2016

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 TA 1400-0100
Running-in procedure for GE Distributed Power engines

6 20 1750
7 20 2000
8 20 2200
9 20 2500
10 20 2750
11 20 3000
12 20 3250
13 20 3500
14*) 20 4000
15 60 Rated power
*) For J 624 G (single-stage charging), the running-in programme ends here. However, it must be run at 4000
kW for 60 minutes (instead of 20 minutes).

Once the rated power operation has finished after 60 minutes, the engine should automatically shut down.
That means removing the engine request during full-load operation and waiting until the engine has shut itself
down.

5.4 Running-in programme for Type 9 Jenbacher gas engines

Work through the running-in stages one after the other in order.
Do not overload!

Before starting the engine, the following steps must be observed (applies when starting the engine for the first
time and after replacing main or big-end bearings):
1. Switch on the prelubrication pump and set the prelubrication pressure to 1.2 bar. Oil temperature > 30°C.
2. Flush the engine channels and bearings for 30 minutes.
3. Interrupt the flushing process for five minutes.
4. Switch on the prelubrication pump again and then rotate the crankshaft through 60°.
5. Flush the engine channels and bearings for 15 minutes.
6. Repeat steps 3 through 5 a total of five times (one complete rotation of the crankshaft).

Running-in programme for new engines, or after replacing the main or big-end bearings
Running-in stage Speed P_el Stage running time Total running time
[-] [rpm] [% of the rated [min] [h]
power]
1 500 0 5 0.08
2 Rated speed 15 5 0.17
3 Rated speed 20 5 0.25
4 Rated speed 25 5 0.33
5 Rated speed 30 10 0.50
6 Rated speed 35 10 0.67
7 Rated speed 40 15 0.92
8 Rated speed 45 15 1.17

Author: Provin D. Responsible: Nota F. Release date: 31/03/2016

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 TA 1400-0100
Running-in procedure for GE Distributed Power engines

Running-in stage Speed P_el Stage running time Total running time
[-] [rpm] [% of the rated [min] [h]
power]
9 Rated speed 50 15 1.42
10 Rated speed 55 15 1.67
11 Rated speed 60 20 2.00
12 Rated speed 65 20 2.33
13 Rated speed 70 20 2.67
14 Rated speed 75 20 3.00
15 Rated speed 80 30 3.50
16 Rated speed 85 30 4.00
17 Rated speed 90 30 4.50
18 Rated speed 95 30 5.00
19 Rated speed 100 60 6.00
20 Rated speed 0 5 6.08

Running-in programme after repairs or maintenance (piston rings, pistons and cylinder liners) apart from
replacing the main or big-end bearings
Running-in stage Speed P_el Stage running time Total running time
[-] [rpm] [% of the rated [min] [h]
power]
1 500 0 5 0.08
2 Rated speed 15 5 1.17
3 Rated speed 20 5 0.25
4 Rated speed 25 5 0.33
5 Rated speed 30 5 0.42
6 Rated speed 35 5 0.50
7 Rated speed 40 5 0.58
8 Rated speed 45 5 0.67
9 Rated speed 50 10 0.83
10 Rated speed 55 10 1.00
11 Rated speed 60 10 1.17
12 Rated speed 65 10 1.33
13 Rated speed 70 10 1.50
14 Rated speed 75 15 1.75
15 Rated speed 80 15 2.00
16 Rated speed 85 15 2.25
17 Rated speed 90 15 2.50
18 Rated speed 95 15 2.75
19 Rated speed 100 60 3.75

Author: Provin D. Responsible: Nota F. Release date: 31/03/2016

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 TA 1400-0100
Running-in procedure for GE Distributed Power engines

6 Additional guidance for first start-up

Any kind of work on an engine or generator could potentially result in risk.

WARNING
Risk of injury during running-in procedure
Ø Except to conduct absolutely necessary work, nobody may be in the engine room when the
engine is started for the first time after performing relevant service jobs.
Ø Access to the engine room is only permitted after full load has been reached and the engine
has been running stably under full load for 15 minutes.

Such 'relevant' service jobs could involve either the commissioning of new and overhauled units or the repair/
replacement of rotating/oscillating parts.

7 Revision code
Revision history
Index Date Description / Revision summary Expert
Auditor
8 31.03.2016 Aktualisierung Kapitel 5.4-Punkt 4 / Update chapter 5.4-point 4 Dibiasi W.
Nota F.
Ergänzung in Kapitel 3 und Änderung Kapitel 5.2 / Gould C.
Supplementation in chapter 3 and change chapter 5.2 Nota F.
Änderung Kapitel 5.3 / Change chapter 5.3 Rangger A.
Nota F.
7 10.03.2015 Hinweis auf Leanox-Einstellung ergänzt / Added note on Leanox Provin
setting Hippmann
Aktualisierung Motoreinlaufprogramm BR 9 / Update of running- Kecht
in programme type 9 Dibiasi

Anpassung 616 Diesel Bacher

Becker
6 17.07.2013 Motoreinlaufprogramm für Gasmotoren der Baureihe 624 mit Provin
Miba 69 bleifreien Lagern ergänzt / Added 1running-in Anderson
programme for type J624 gas engines with Miba 69 lead free
bearings installed
5 04.10.2012 Gefahrenhinweise in der Umgebung des Generators ergänzt / Provin
Added safety notes for working in close proximity with a Struve, Krainz
generator added
4 16.08.2011 Ergänzt um BR 9 / Series 9 added Boxleitner
Dibiasi
3 29.04.2011 Motoreinlaufprogramm BR6 – Einlaufstufe 5 – J 616 – 1200kW -> Bilek
Running-in programe typ 6 – running in- stage 5 - J 616 – Pauer
1200kW
2 27.07.2010 Motoreinlaufprogramm BR6 -> neue Stufe/Running-in programe Schartner
typ 6 -> new stage Licht

Author: Provin D. Responsible: Nota F. Release date: 31/03/2016

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 TA 1400-0100
Running-in procedure for GE Distributed Power engines

Revision history
1 26.05.2010 Umstellung auf CMS / Change to Content Management System Schartner
SprungMarke!!!63050394812558219
ersetzt / replaced Index: g Giese

Author: Provin D. Responsible: Nota F. Release date: 31/03/2016

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