GAS ENGINE POWER PLANT

Operation & Maintenance Course

18V34SG
DAFTAR ISI
A. Pendahuluan
A. Ragam jenis mesin gas
B. Proses pada mesin gas
C. Data utama mesin gas (Wartsila 18V34SG)
B. Komponen utama
A. Block bearing & oil sump
B. Head
C. Piston & Connection rod (conrod)
D. Liner
E. Crankshaft
F. Turbocharger
C. Sistem bahan bakar
D. Sistem udara / Charge air (CA) and exhaust gas (EG)
E. Sistem udara bertekanan / Compressed air system
F. Sistem pendingin / Cooling system
G. Sistem pelumas / Lubrication system
H. Prinsip operasi dan instrumentasi
Pendahuluan
Pendahuluan Klasifikasi Piston engine
Piston
engine
Piston
engine
Otto cycle
Spark ignition
Diesel cycle
Compressed ignition
Piston
engine
Four stroke
Two stroke
Four stroke
Two stroke
Teknologi bahan bakar pada gas engine
GAS DIESEL GD - Diesel principle
- High pressure gas
- Real dual fuel
SPARK IGNITED SG - Otto principle
LEAN BURN - Low pressure gas
- Mono fuel
PILOT FUEL IGNITED DF - Otto principle
LEAN BURN - Low pressure gas
- Dual fuel
Wrtsil Gas Engine Portfolio
Pendahuluan - Gas Engine
Pendahuluan Gas engine(lanjutan)
Proses Dual fuel Proses gas diesel
Pendahuluan Aplikasi gas engine
1. Pembangkit listrik
2. Otomotif
3. Perkapalan
Pendahuluan Spesifikasi teknis
1. Bore
2. Stroke
3. Rpm
4. Mean effective pressure
5. Piston speed
6. Lower heating value (LHV)




Pendahuluan Fuel technical specification
1. Lower heating value (LHV) : MJ/m3
Gas Engine Process - Spark Gas Engine Otto Cycle
General Principle
The gas is mixed with the combustion air only in the intake channels in
the cylinder head close to the air inlet Valves.
Bahan bakar gas dicampur dengan udara di saluran intake dalam
cylinder head, sebelum keluar melalui inlet valve.
This design ensures that only air is present in the charge air manifold,
and thus the risk for explosions in the engines charge air intake system is
minimised.
Design ini menjamin hanya udara yang ada dalam intake manifold,
sehingga meminimalkan resiko ledakan sistem intake manifilold

Since the gas valve can be timed independently of the inlet valve,
scavenging of the cylinder is possible without risk that unburned gas is
escaping directly from the inlet to the exhaust.










AIR & GAS
INTAKE
EX
*
*
*
*
IN
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
COMPRESSION
OF AIR & GAS
EX
IN
IGNITION
BY SPARK PLUG
EX
IN
SG-engine operating principle (W34SG)
Wrtsil Gas Engine Portfolio
Gas Engine Process - Spark Gas Engine (SG)
Gas Engine Process - Lean Burn Combustion
At higher loads a lean air-fuel mixture is also a requirement to avoid
detonation (knocking). On the other hand the misfiring limit is getting
closer, which means that the operating window is decreasing.
Gas Engine Process - Lean Burn Combustion
0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2
8
10
12
14
16
18
20
22
Air-fuel ratio
B
M
E
P

[
b
a
r
]

Detonation
Misfiring
Operating
window
N
O
x

(
g
/
k
W
h
)

< 1 g/kWh
T
h
e
r
m
a
l

e
f
f
i
c
i
e
n
c
y

(
%
)

46%
At higher loads a lean air-fuel mixture is also a requirement to
avoid detonation (knocking). On the other hand the misfiring
limit is getting closer, which means that the operating window
is decreasing.
Gas Engine Process - Cylinder Head
MAIN GAS ADMISSION VALVE
CHECK VALVE
SPARK PLUG
PRECHAMBER
Gas Engine Process - Lean Burn Combustion
IN
EX
Too Rich:
Higher NOx
Pre-ignition
Knocking
Too Lean:
Slow Combustion
Incomplete Combustion
Bad Combustion Stability
EX
IN
Gas Engine Process - Lean Burn Combustion
0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2
8
10
12
14
16
18
20
22
Air-fuel ratio
B
M
E
P

[
b
a
r
]

Detonation
Misfiring
Operating
window
N
O
x

(
g
/
k
W
h
)

< 1 g/kWh
T
h
e
r
m
a
l

e
f
f
i
c
i
e
n
c
y

(
%
)

46%
At higher loads a lean air-fuel mixture is also a requirement to
avoid detonation (knocking). On the other hand the misfiring
limit is getting closer, which means that the operating window
is decreasing.
Gas Engine Process - Lean Burn Combustion
Varying ambient conditions affects the air-fuel control
giving the same engine performance
Air-fuel ratio
1.2 1.4 1.6 1.8 2 2.2
Detonation

M
i
s
f
i
r
i
n
g


6
8
10
12
14
16
20
22
B
M
E
P

[
b
a
r
]

Varying gas quality (methane
number) affects the output of the
engine giving as high output as
possible, but with a safe margin
to detonation.

Control Strategy at varying conditions
All the cylinders have the
optimal performance
Gas Engine Process - Cylinder Control Principle
- kW
- air/fuel
- etc..
INPUT:
- rpm
WECS
MAIN GAS
ADMISSION VALVE
PRECHAMBER
CONTROL VALVE
CHECK VALVE
COMBUSTION
SENSOR
Individual adjustment of
gas feed and ignition for
every cylinder
Every cylinder equipped
with a combustion
sensor
The gas feed is adjusted
individually to get the
correct air-fuel ratio in
every cylinder
In case of knocking only
that specific cylinder is
adjusted
Gas Engine Process - Lean Burn Combustion

Several input parameters
used for wastegate control
giving same engine
performance regardless of
changing ambient conditions
Charge air temperature and
pressure used for fine tuning
giving same engine
performance regardless of
changing ambient conditions
Charge air pressure used for
fast regulation needed at
load transients

Air-Fuel Ratio Control
Air
Exhaust
WECS
P
I
Exhaust wastegate
Load
Speed
T P
Gas Explosions in a Lean Burn Engine
Gas explosions may occur in a lean burn engine
Engine start is the most hazardous stage
Preconditions:
correct concentration (3 - 17 vol% @ 400
o
C)
ignition source (spark or like)
Possible locations:
exhaust system !
air receiver
crankcase
outside engine (leaks)
Gas Explosions and fires in closed areas
Gas explosions and fires in closed areas may occur due
to gas leak
Preconditions:
concentration (5 - 14 vol% @ 20oC)
ignition source (spark or like)
Only a very small energy (1 mJ) is needed to ignite the
gas
Almost any spark or flame may ignite the gas
electric appliances, e.g. drilling machine, light
switches
cigarette, matches
even frictional electricity
General Safety Concept
Active safety features (active controlled systems
preventing dangerous gas concentration in any location)
in engine control system (valves, control procedures
etc.)
in exhaust system (ventilation fan)
Passive safety features (passive systems reacting to gas
explosion and preventing or minimizing damages)
in engine (explosion relief valves)
in exhaust system (explosion relief valves, ducting,
dimensioning...)
in buildings (collapsing structures...)
Gas Leak Test
During start:
Automatic test of the gas regulating shut-off valves'
tightness for shut down and emergency situations.
Compressed Air
Pressure
Transmitter
1
2
3
Vent Vent
Cylinder & Exhaust Manifold Ventilation
During start:
Engine is rotated five revolutions to discharge any
unburned gas in the cylinders or in the exhaust
manifold. Gas admission and ignition are not active.
Air Throttle Valve Position Control
During start and operation:
Opens the air throttle valve to pre-programmed set value to ensure
proper air-fuel ratio.
Start Fuel Limiting Function
During start:
To prevent excessive gas admission and possible misfiring, the amount
of gas is limited during start and speed increase.
M
a
x

g
a
s

a
d
m
i
s
s
i
o
n

d
u
r
a
t
i
o
n

Engine speed
0 200 400 600 800
Engine Speed Control
During start:
Engine speed is checked during start. Too slow speed increase indicates
a possible misfiring of cylinder(s) and engine will be shut down to
prevent gas from entering the exhaust system.

0
100
200
300
400
500
600
700
800
0
0
:0
0
0
0
:0
2
0
0
:0
4
0
0
:0
6
0
0
:0
8
0
0
:1
0
0
0
:1
2
0
0
:1
4
0
0
:1
6
0
0
:1
8
0
0
:2
0
0
0
:2
2
0
0
:2
4
0
0
:2
6
0
0
:2
8
0
0
:3
0
0
0
:3
2
0
0
:3
4
0
0
:3
6
0
0
:3
8
0
0
:4
0
0
0
:4
2
0
0
:4
4
0
0
:4
6
0
0
:4
8
0
0
:5
0
0
0
:5
2
0
0
:5
4
0
0
:5
6
0
0
:5
8
0
1
:0
0
Time [s]
E
n
g
i
n
e

s
p
e
e
d

[
r
p
m
]
Prelubricating of engine Gas leak test Start Acceleration Syncronisation
Exhaust Gas Temperature Monitoring
During start:
If a specified minimum exhaust gas
temperature for any cylinder is not reached in
a specified time after nominal speed is
reached, the main gas duration of that cylinder
will be immediately increased. If the cylinder
still is under the specified minimum exhaust
gas temperature after a specified time, the
engine will be shut down.
Redundant Speed Measuring SG
During operation:
SG engine speed is measured with a redundant system consisting of a
rotary encoder and a speed pick-up. The encoder signal is used to
determine the gas admission and timing.

Redundant Speed Measuring DF
During operation:
DF engine speed is measured with a redundant system consisting of
two speed pick-ups and a TDC pick-up. The main speed pick-up and
TDC pick-up signals are used to determine the gas admission and
timing.
Speed pick-up
Speed pick-up
(redundant)
TDC pick-up
Exhaust Gas Temperature Monitoring
During operation:
During engine operation the system monitors
the exhaust gas temperature of each cylinder.
If the temperature of any cylinder is lower or
higher than the specified limit a shutdown
occurs. Also, if the temperature deviates too
much from the exhaust gas average
temperature shutdown occurs.
Idling Duration Limit
During operation:
To minimize the running time with poor
combustion during no load run and
consequently the gas gathering in the exhaust
system the time for idling is limited.
Exhaust System Ventilation
After engine stop:
To discharge any unburned gas in the exhaust system the system is
ventilated by a fan.
Explos ion relief valve
Ventilation fan
Exhaus t
Control
s ys tem
Silencer
Exhaus t gas boiler
fs
Flow s witch
Ventilation valve
Exhaust System Design
Upward slopes to avoid gas pockets where
gas might get trapped
Ventilation system
Explosion relief valves, ducted outdoors and
opening at an excess pressure of 0.5 bar
Sustain an under pressure of 0.3 bar without
collapse
Gas Regulating Unit
The shut-off valves and vent valves operate fail safe.
Safety shut-off valve (optional) is closed, if gas pressure
is too high at engine. It can be reopened only manually.
Vent
Vent Vent
Ball valve Filter
Pilot operated
Downstream pipe
Electro-pneumatic
Main Pressure Regulator
shut-off valves
Control Air
Compressed Air
Start Blocking
Shutdown or emergency stop signal not reset
Exhaust system ventilation not finished
Start air pressure below the start block limit
Main and prechamber gas pressures below start
block limit
Low or high gas temperature
Safety valve in the gas regulating unit is tripped
Turning gear engaged
Alarms
Sensor failure
Low control air pressure
Low exhaust gas temperature
High exhaust gas temperature after any
cylinder
High exhaust gas temperature deviation
between cylinders
Start attempt failed
Shutdowns
Start failure
High charge air temperature
High exhaust gas temperature after any
cylinder
Low exhaust gas temperature after any
cylinder
High exhaust gas temperature deviation
between cylinders
High deviation of main gas pressure
Emergency stops
Emergency stop push button, on engine or external,
pressed
Rotary encoder sensor failure
Overspeed from rotary encoder
Overspeed from speed pick-up
Speed deviation between rotary encoder and engine
speed pick-up
Deviation in number of encoder pulses per revolution
Degassing failure in auto stop mode. Activated if the gas
pressure is still present after the shutdown control task
has disabled the inlet gas pressure control