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Jenbacher Gas Engine Basics

Engine IQ
Table of contents

Gas genset basics


− Air
− Gas
− Combustion
− Generator
− Heat
− Emissions

• Engine types & naming convention

• Basic engine components Engine IQ


• P&ID, Genset drawings



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Genset overview

Input Conversion Output

Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air (Thermal Efficiency)

Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)

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Basics… Gas

Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Therm From Rejected
al Energy via Heat
Combustion (kWth Out)
(Engine)

Air (Thermal Efficiency)

(Mechanical
Efficiency)

Mechanical
to Electrical Electric Energy
Oil Energy (KWe out)
Conversion
(Generator)
(Electrical Efficiency)

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Potential Fuel Sources…

Landfill gas
Coal mine gas
Sewage gas

Industrial power
plant options Island mode Oilfield
applications
(Associated
petroleum gas)

Special gas
Cogeneration
(Natural gas)

Biogas
Greenhouse application

Different types of gas as fuel

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Fuel Types and Chemistry

Gas Type General Chemistry Impurities

Natural Gas 95% CH4 / rest N2, O2

Hot Natural Gas 85% CH4 / >C2, C3, C4 / rest N2 H 2S

Typical Biogas 60% CH4 / 35-40% CO2 / rest N2, O2 H 2S

Typical Landfill 55% CH4 / 40% CO2 / rest N2, O2 Siloxanes, H2S

Flare Gases CH4, > C2, C3, C4, C5 H 2S

HD5 Propane 90% C3H8 / 5% C3H6 / rest C1, C2, C4, C5

Woodgas / Syngas H2 / CO / rest N2, CO2, O2, H2O Tars

TA 1000-0300 Fuel Gas and Combustion Air Requirements

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energy content of a gas
The net calorific value/lower heating value indicates the

Characteristics

Engine design and engine version are determined by the following characteristics

Coalmine gas
Pyrolysis gas

Sewage gas

Natural gas
Gases from

Landfill gas
Wood gas
chemical

Coke gas

Flare gas

Propane
City gas
industry

Bio gas

Butane
0 Logarithmic scale 5 10 15 20 30

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Characteristics

Engine design and engine version are determined by fuel

• Methane number
• Parameter determining the knocking resistance
(potential to ignite) of a gas.
• Comparable to the octane number of gasoline.

140

120

100

80

60

40

20

0
H2 Methane Propane Butan Natural Gas Biogas

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Fuel Analysis

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Fuel Analysis Tool (AVL)

• (Density (kg/m3))* (Lower Calorific Value (kJ/kg)) / (3600 KJ/KWh) = (Lower Heating Valve (KWh/m3))
• (Lower Heating Value (KWh/m3))* (1 m3 / 35.314 scft)* (3412 btu / KWh) = (Lower Heating Value (btu/scft))

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Basics - Air

Input Conversion Output

Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)

Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)

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Chemistry of Air

As elevation increase, the density of air decreases. Theoretical Combustion Air


This means you need more volume of air at higher altitudes O2 21 %
to obtain the same amount of O2. Effectively, the turbocharger N2 78 %
must pressurize and move more air at higher altitudes to achieve
Other 1%
the correct amount of O2 for combustion…
MW 28.8 g/mol
The same holds true for higher ambient temperatures.
Univ. GC 8.314 J/(mol*K)
Spec GC 287 J/(kg*K)-AIR

( MW * Pressure (Pa)) (Pressure (Pa)) Engine Standard Conditions (ISO 3046)


Density (kg/m3) = =
((Temp (°C) + 273.15)* Univ GC) ((Temp (°C) + 273.15)* spec.
Ambient
GC 25 °C
Temperature
Elevation (Sea
100 m
Altitude and Air temperature determine Level)
engine version selection and TC matching Barometric 1,000 mbar = 100000
Pressure Pa
Density dry air = 1.16 kg/m3
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Basics - Engine/Combustion

Input Conversion Output

Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)

Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)

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Four stroke method (Otto Cycle)

Each of the four working steps takes place during one stroke. In this context,
"stroke" means a travel stroke of the piston, in other words an upwards
or downwards movement by the piston. During the four strokes "intake",
"compression", "power" and "exhaust", the crankshaft rotates twice.

symbolic picture

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Combustion Basics - The Ideal Otto Cycle

0-1 Intake of Air/Fuel Mixture

1-2 Compression

2-3 Ignition

Power Stroke
3-4 (Expansion)

Heat Rejection
4-0 & Exhaust

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Combustion… Recip Engines

For illustrative purposes only

Detonation Uncontrolled combustion, rich air/fuel


advanced ignition timing

Rich-Burn
Operation
Lean Misfire
Not enough fuel to
Flexibility for fuel

BMEP
burn, lean air/fuel,
fluctuation, changes
retarded ignition
in site conditions, NO timing
changes in
X
CO, HC
speed/load
Rich
Misfir
0.75
e 1.0 1.25 1.5 1.75 2.0
Stoichiometric Lean-Burn
(Rich-Burn) Lambda (λ)

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Schematic diagram of the control system

DIA.NE*
LEANOX*
controller

P-controller
nP-controller

temperature
PIST (power)

t2' (mixture
P2' (boost
pressure)

)
exhaust
gas

fuel gas
generator
intake air
gas engine valve with
position controller heat exchanger
compressor
valve with position controller

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LEANOX Curve

Actual amount of combustion air


λ (air excess number) =
Stoichiometric amount of combustion
air

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Characteristics

Engine design and engine versions are


determined by the following characteristics:

Mean effective pressure


⁄ A useful comparison tool between different
engines Pmech
⁄ A good indicator of the level of performance bmep = 1200 x
Vtotx n
achieved
by the designer and manufacturer
⁄ Values produced by the formula are for
theoretical analysis only, and do not reflect the
actual pressures inside an individual
combustion chamber

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Characteristics

Engine design and engine version are determined


by the following characteristics:

Compression ratio
⁄ The ratio between the volume of the cylinder,
when the piston is at the bottom of its stroke,
and the volume
when the piston is at the top of its stroke.
⁄ High compression ratio is desirable, allows an
engine
to extract more mechanical energy from a
given mass
of air-fuel mixture.
⁄ High ratios place the available oxygen and fuel
molecules into a reduced space so the
combustion is done quicker (smaller volume).

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Basics - Generator

Input Conversion Output

Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)

Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)

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Basics - Generator

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Basics – Generator Voltages

Voltage - LV 50 Hz 60 Hz

Low (< 1 kV) Line to Line 380/400/415 480 V

690 575/600 (CAN)


Medium ( 1 kV) 3.300 4.160
6.300 12.470
6.600 13.200
10.500 13.800
11.000 14.400

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Basics – Generator Formulas

• Generator Output (kWe) = Engine output


(kW)* Generator efficiency @pf 1.0

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Basics – Generator Capability Curve

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Basics – Thermal Recovery

Input Conversion Output

Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)

Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)

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Basics – Performance Energy Balance

Energy input NG 100 %


HEX 1
mech. th. output intercooler heat
output ~35– ~23–50 % HEX 1 exchanger
50 % HEX 2
HEX 3 HEX 2
HEX 4
oil heat exchanger

HEX 3
losses ~10 %

jacket water heat


recoverable exchanger
electric thermal
Output output~50 % HEX 4
~35–50 % exhaust gas heat
exchanger

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Congeneration (CHP)

Use of electricity, heat & cold

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Tigeneration

Use of electricity, heat & cold

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Thermal Energy Control – JGS (Genset)

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Thermal Energy Control – JMS (CHP)

Process Outlet
Temperature

Decisive for selection of hydraulic integration variant

Mixture Temp

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Thermal Energy Control – JMS (CHP)

Options

Mid Return
Temp
Mid Outlet
Temp

Low Return
Temp
Mid Outlet
Temp

Mid Return
Temp
High Outlet
Temp

High Return
Temp
High Outlet
Temp

Mid Return
Temp
Mid Outlet
Temp

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Absorption chillers - connection capabilities

Hot water
Total heat single stage
COP 0.7 – 0.75

Exhaust gas heat


Exhaust heat
COP 1.2 – 1.35
only
Separate use of hot water

Combined exhaust gas


Total heat + hot water
COP 1.0 – 1.05

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Basics - Thermal Recovery

Input Conversion Output


Exhaust Gas
Exhaust Gas
Emissions and
Emissions and
un-utilized eat
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)

Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)

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Chemistry of Exhaust Gases

Theoretical Combustion Exhaust (ppm levels)


Theoretical Combustion Exhaust (primary)
NOx Nitrogen Oxides (NO2, NO3)
CO2 ~ 6%
CO Carbon Monoxide
O2 ~ 9%
NMHC Non-Methane Hydrocarbon
N2 ~ 73% PM Particulate Matter (PM10, PM 2.5)
H2O ~ 11% SOx Sulfur Oxides (SO2, SO3)

Ar ~ 1% CH2O Formaldehyde

Important to Understand Site Emissions Regulations

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Emissions

Available Systems to reduce emissions

System Ability Disability

OxiCat CO NOx
CH2O THC (CH4)
SCR NOx CO
CH2O
THC (CH4)
Greenhouse NOx THC (CH4)
(SCR + Oxi) CO
CH2O
C2H4v
Cl. Air CO NOx
CH2O
THC

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Emissions – Selective Catalytic Reduction System

NOx emissions:

• A. Open loop:
• Load curve needs to be adjusted during commissioning
NOx = 100mg/Nm³ @ 5% O2 possible

• B. Closed loop:
• Online NOx analytics required!
• Maintenance, calibration and higher invest will be necessary
NOx = 20mg/Nm³ @ 5% O2 possible

Toxic Non - toxic

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Basics - Performance

Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)

Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)

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Basics – Performance Calculations

Electric Output (KWe) Electric Output (KWe)


Electric Efficiency = =
Energy Input (KW) Energy Input (Mbtu/hr)

3.412 ((Mbtu/hr)/KW)

Recovered Thermal (kWth) Recovered Thermal (Mbtu/hr)


Thermal Efficiency = =
Energy Input (kW) Energy Input (Mbtu/hr)

Energy Input (kW)* 1h Energy Input (Mbtu/hr)* 1.000


Heat Rate = kWh/kWh = Btu/kWh
Specific Fuel Electric Output (KWe)* 1h Electric Output (KWe)
Consumption

Energy Input (kW)* 1h Energy Input (Mbtu/hr)* 1.000


Heat Rate = kWh/kWh = Btu/bhp-hr
Specific Fuel Mech. Output (KWm)* 1h Shaft Power (hp)
Consumption

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Basics - Customer Information

1. What type of fuel do you have and how much?


NEED: Gas Analysis

2. Where is the unit located?


NEED: Site Elevation, Design Temperature & Extremes

3. Will you be allowed to Connect to the Utility?


NEED: Connection Details (One Line Diagram)

4. Will you be allowed to Emit Gases?


NEED: Regulator Emissions Limits

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Engine types & Components
In this chapter, you’ll get an overview
of the Jenbacher engine types
System type plate and designation

Type No. of cylinders


2 8 8-cylinder in-line engine Exhaust gas purification
3 12 12-cylinder V-engine L LEANOX Engine
Manufacturer 4 16 16-cylinder V-engine LC LEANOX Engine
J Jenbacher Gas 6 20 20-cylinder V-engine with oxidation-type
Engines 9 24 24-cylinder V-engine catalytic converter

Unit type Installation type Mode of operation (e.g.) Type of fuel gas
M co-generation plant
S stationary GS Gas engine, N Natural gas
G generator set C in a container turbocharged B Biogas
L Landfill gas
P Propane gas
S Special gas
N/B Natural gas/Biogas
2-gas operation

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Basics - Customer Information

generator engine

unit

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Engine

2 3 4 5 6 7 8
1

15 16
12 13 14
11
9 10
non drive
end
drive end

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Type 2

⁄ Since 1976 in the product program, delivered engines: more Further technical data
than 1,300 ⁄ Bore: 135 mm
⁄ Electrical output from 250 to 330KW (50 Hz), 335 kW (60 Hz) ⁄ Stroke: 145 mm
⁄ 8 cylinder in-line engine ⁄ total displacement: 16.6
⁄ 1,500/1,800 rpm ⁄ Mean piston speed: 8.5 m/s (1,500 1/min)
⁄ Built into 20 ft or 40 ft container as complete set ⁄ Scope of supply: Generator set, cogeneration system;
⁄ Approx. 2 l displacement/cylinder generator set,
cogeneration system in container
⁄ Applicable gas types: Natural gas, flare gas, propane,
biogas, ⁄ Dimension l x b x h: Generator set 4,900 mm x 1,700 mm x
landfill gas, sewage gas 2,000 mm*
⁄ Weight empty: Generator set 4,900 kg*
⁄ 2 valve cylinder heads same as type 3 but narrower
⁄ electrical engine cooling water pump
⁄ single-stage intercooler
⁄ aluminium piston
⁄ ignition system: MIC940 (old: IC100) J 208
⁄ toothed con rod

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Type 2: engine views

J 208

engine cooling water return line

exhaust gas valve timing


manifold
piston
gas mixer engine cooling water
intake air filter preheating exhaust gas turbocharger mixture
cylinder head distribution
vibration coupling cylinder liner
damper
gear drive starter connecting rod
camshaft
crankcase
heat exchanger
engine oil/water
generator engine oil filter crankshaft
engine cooling water pump
oil pan
oil pump

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Type 3

⁄ Since 1988 in product program, delivered engines: more than 9,000 Further technical data (J 320)
⁄ Electric power output 526–1,063 kW (50 Hz), 633–1,059 kW (60 Hz) ⁄ Configuration: V 70°
⁄ Manufactured as V12-, V16- and V20–cylinder engine ⁄ Bore: 135 mm
⁄ 1,500/1,800 rpm ⁄ Stroke: 170 mm
⁄ Built into standard (2,5m) or wide (3m) 40 ft container as complete set
⁄ total displacement: 48.7
⁄ Approx. 2.5 l displacement/cylinder
⁄ Mean piston speed: 8.5 m/s (1,500 1/min)
⁄ applicable gas types: Natural gas, flare gas, propane, biogas, landfill gas,
sew- ⁄ Scope of supply: Generator set, cogeneration system,
age gas, special gases (e.g., coal mine gas, coke gas, wood gas, generator set,
pyrolysis gas) cogeneration system in container
⁄ Dimensions l x b x h: Generator set 5,700 mm x 1,700 mm x
⁄ Collar on crank case for longer stroke 2,300 mm*
⁄ Oil pump lifetime 60,000 oph ⁄ weight empty: Generator set
⁄ Mechanical/electrical jacket water pump

⁄ Aluminium piston

⁄ Ignition system: MIC950 (old: IC920, IC921, IC922)

⁄ Cracked con rods


J 320

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Type 3: engine views

J 320
throttle
valve intake air
line
valve
timing
intake air collector gas mixer exhaust
actuator heat exchanger gas
mixture/water throttle heat exchanger manifold
valve engine oil/water
exhaust gas
turbocharger
cylinder head piston

vibration damper cylinder


liner
connecting rod

generator camshaft
starter crankcase coupling
crankshaft
engine oil filter

oil pump

oil pan

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Type 4

⁄ Since 2002 in product program, delivered engines: more than 3,300 Further technical data (J 420)
⁄ Electric power output 844 – 1,560 kW (50 Hz), 850 – 1,426 kW (60 Hz) ⁄ Configuration: V 70°
⁄ Manufactured as V12-, V16- and V20–cylinder engine ⁄ Bore: 145 mm
⁄ 1,500/1,800 rpm ⁄ Stroke: 185 mm
⁄ Approx. 3 l displacement/cylinder
⁄ total displacement: 61.1
⁄ Applicable gas types: Natural gas, flare gas, biogas, landfill gas, sewage
⁄ Mean piston speed: 9.3 m/s (1,500 1/min)
gas, special gases (e.g., coal mine gas, coke gas, wood gas, pyrolysis gas)
⁄ Scope of supply: Generator set, cogeneration system,
⁄ Flexible bell house for J420 and J416 generator set,
cogeneration system in container
⁄ Only available with Atk-LIVC cycle
⁄ Dimensions l x b x h: Generator set 7,100 mm x 1,900 mm x
⁄ bmep = 20 bar as standard
2,200 mm
⁄ Cracked con rods
⁄ weight empty: Generator set 14,600 kg*
⁄ Electric jacket water pump
⁄ Oil pump lifetime 60,000 oph
⁄ 1 starter (2 x J420)
⁄ Ignition system: MORIS (old: MIC950/IC920))
⁄ Aluminium/steel piston
⁄ ABB TPS turbocharger
J 420

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Type 4: engine views

J 420 intake
line engine
cooling
water
manifold
valve timing
heat exchanger
blow-by
mixture/water
gas mixer intake air filter
cylinder head
housing exhaust gas exhaust gas
manifold
turbocharger

piston
cylinder
generator liner
coupling
starter actuator connecting rod
crankcase
camshaft

additional oil tank for special gas crankshaft

oil pan

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Type 6

⁄ Since 1989 in product program, delivered engines: more than Further technical data (J 620)
4,800 ⁄ Configuration: V 60°
⁄ Electric power: 1,500–4,400 kW (50 Hz) ⁄ Bore: 190 mm
⁄ V12-, V16-, V20- and V24–cylinder engine ⁄ Stroke: 220 mm
⁄ 1,500 rpm/1,800 rpm only with gear ⁄ total displacement: 124,8
⁄ Approx. 6.24 l displacement/cylinder ⁄ Mean piston speed: 11 m/s (1,500 1/min)
⁄ Applicable gas types: Natural gas, flare gas, biogas, landfill ⁄ Scope of supply: Generator set, cogeneration system
gas, sewage gas, special gases (e.g., coal mine gas, coke gas,
wood gas, pyrolysis gas) ⁄ Dimensions l x b x h: Generator set 8,900 mm x 2,200 mm x
2,800 mm*
⁄ weight empty: Generator set 28,000 kg*
⁄ Ignition system MORIS/MIC950 (old: IC920, IC922)
⁄ aluminium/steel piston
⁄ electric jacket water pump
⁄ four-valve cylinder head: centrally located purged pre-
combustion chamber
⁄ type 6 E gas mixer
⁄ type 6 F/G/H TecJet/gas metering valve
⁄ special gas mixer: specific version for special gases with low
calorific values J 616
⁄ toothed con rod
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Type 6: engine views

J 620 intake
chamber
camshaft

valve
intake air filter generator timing

gas mixer exhaust


cylinder head gas
manifold
heat exchanger
mixture/water

coupling
piston
starter blow-by
crankcas cylinder liner
exhaust gas
e connecting
turbocharger
rod
engine cooling
water pump
crankshaft

oil pan

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Type 9

⁄ Two-stage pressure charging with high- and low-pressure


turbochargers
rom ABB with intercooling
⁄ 20 cylinders
⁄ mechanical efficiency 49.7 %
⁄ electric efficiency ~48 % (50 Hz)
⁄ Pistons arranged in a V-configuration with an included angle of 50°
⁄ Speed is 1000 rpm (50 Hz) or 900 rpm (60 Hz)
⁄ Vibration damping against the foundation with spring elements
⁄ Gas-air mixture individually directly in front of each cylinder-port
injection
⁄ Fuel gas for pilot engine: Natural gas
⁄ Total weight of the module is 180 t
⁄ average piston speed 11.7 m/s
⁄ Engine rigidly mounted on the frame
⁄ Oil pan integrated in the frame

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J 920 main modules

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Main components of Genset
Engine components

Type 3 Type 4 Type 6

The case crankcase is fitted with openings to permit access for dismantling and assembly
work.

On the flywheel-side, the crankcase is sealed off (oil tight and dust proof) by the gear train
and on the opposite side by the crankcase end cover.

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Engine components

Oil pan

The oil pan is made out of welded steel


plate and closes off the bottom of the
crankcase.

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Engine components

Type 6: cylinder liners

The wet cylinder liners can be replaced individually.


They are spun cast and are inserted into the cylinder block from
above.
As they heat up, they are free to expand downwards.
The water room and the power module are separated by O-rings
on the outside of the cylinder liners.

Cylinderliners after the processing step: honing

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Engine components

Type 6: cylinder heads

The water-cooled cylinder heads - which can be replaced separately –


are all equipped with two inlet and two exhaust valves, a
precombustion chamber with a pre-combustion chamber gas valve
and a spark plug.
The intake and exhaust valves feature a valve rotation device (rotocap).
The pressed valve seat rings can be replaced.

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Type 6: crankshaft

connecting main
rod bearing oil ducts bearing

crankshaft
toothed gear counter weight

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Engine components

Type 6: connecting rods

The connecting rods are drop-forged and quenched.


They are separated diagonally across the big-end and have serrated
joins.

The big-end bearing shells are replaceable plain bearings.


The upper big-end bearing shell is designed as a sputter bearing,
the lower shell as a synthec bearing. The small-end bushings are
pressed in. The big-end bearings are lubricated via oil ducts in the
crankshaft.
The gudgeon pins are supplied with oil from the piston cooling nozzles.

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Engine components

Vibration damper

A viscous damper is used to reduce rotational vibrations


of the crankshaft.

The viscous damper is a fully closed housing containing


a flywheel. The cavities between the housing and the
flywheel are filled with silicone oil.

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Engine components

Type 6: piston

The light metal alloy or steel pistons with cooling duct


are equipped with a key stone ring, a taper face
compression ring and an oil control ring with expander.
Cooling oil is supplied via fixed spray nozzles mounted
in the crankcase.

Version E Version F
aluminium piston steel piston

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Thank you

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