pltmg prabumulih 18v34sg rev.3 operasi

7/21/2019 PLTMG Prabumulih 18V34SG Rev.3 Operasi

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GAS ENGINE POWER PLANT

Operation & Maintenance Course

18V34SG


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DAFTAR ISI

A. PendahuluanA. Ragam jenis mesin gas

B. Proses pada mesin gasC. Data utama mesin gas (Wartsila 18V34SG)

B. Komponen utamaA. Block bearing & oil sump

B. Head

C. Piston & Connection rod (conrod)

D. Liner

E. Crankshaft

F. Turbocharger

C. Sistem bahan bakar

D. Sistem udara pembakaran dan gas buang / Charge air (CA) and

exhaust gas (EG)

E. Sistem udara bertekanan / Compressed air system

F. Sistem pendingin / Cooling systemG. Sistem pelumas / Lubrication system

H. Prinsip operasi dan instrumentasi


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Operation


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OperationEngine Control System


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OperationSafety

Reminder Despite the safety system, there is a risk of gas

explosion. To avoid possible accidents, no-one

should remain in the engine room and

boiler/silencer room during an engine start.


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OperationStart, Stop and Operation

Turning device Starting air system maximum pressure 30 bar

compressor starts at 24 bar

alarm at 18 bar draining of the system

Starting motors

design

Control air system wastegate


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OperationStart

Start:

The start signal is given in the WOIS The HT-water temperature should be 50C

minimum

The ventilation of the exhaust pipe after theengine starts The test procedure for the gas regulating unit

starts. When finished, the shutoff valves on the

gas regulating unit will open.


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OperationStart

Required starting air pressure min. about 20 bar.

Both starting motors have to be connected beforethey are able to rotate.

At 50 rpm the gasvalves start to open and theignition starts to work

Check of speed increase will start At 150 rpm the starting motors will disconnect At 250 rpm the startmode is changed to runmode

At 350 rpm the prelub. pump stops. The HT-waterand alternator preheating will switch off. 750 rpm or 720 rpm = nominal speed


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OperationStart

Exhaust temperature check takes place afterreaching nominal speed

If the alternator does not synchronize within oneminute, the engine stops. Otherwise the enginecontinues to run and a 500 kW baseload is

immediately applied.

If the base load is not reached in one minute theengine stops.

The loading time to 100 % is about 15 minutes


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OperationStop

Stop:

The stop signal is given from the WOIS The load decreases to baseload within 7,5 minutes The gasvalves on the gasregulating unit and on the

engine close when the stopsignal is given. If there is

an emergency stop, the ignition will stop at the sametime

At 350 rpm the lub.oil priming pump starts. The HT-water and alternator preheating will switch on.

At 250 rpm the mode is changed from runmode tostopmode

At 50 rpm the ignition stops


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OperationOperation

Normal operation supervision

take performance data regularly exhaust temperatures, check the trends listen to the engine, knocking etc. check the wastegate function use a gas leak detector regularly check for cooling water and lube oil leaks check that the drain pipes of the charge air cooler

housing is open drain the starting air system before every start


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OperationRunning-In

Running after overhaul run the engine for about 5 minutes after firststart, check the temperatures of the con.rod andmain bearings

check for leakages running-in programme


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Control system


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WECS 3000

This topic describes the basics of WECS 3000

engine control & monitoring system. WECS

stands for Wrtsil Engine Control System. Itindividually controls and monitors each engine

cylinder.

Control systemPresentation on WECS 3000 on W34SG


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Control systemWartsila Operator Interface System


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Control systemWECS 3000 Layout


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Control systemComponent Layout of WECS 3000


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Control systemSide Covers for WECS Units


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Control systemWECS 3000

Function

Start and stop control Run control

Engine load & speed control

Air-fuel ratio control Combustion control

Monitoring and safety system handling

Communication with external systems


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Control systemWECS 3000

Main Components of WECS 3000

Main Control Unit (MCU x 1)

Cylinder Control Unit (CCU x 18)

Knock Detection Unit (KDU x 2)

Distributed Control Unit (DCU)

Sensor Multiplexing Unit (SMU)


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Control systemBlock Layout Connection of WECS 3000

C C ( C )


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Control systemMain Control Unit (MCU)

The MCU is the brain in the system. It receives and

interprets information sent by units controlling

references for ignition, gas pressure, gas injection

timing and duration.

It also handles tasks as the start and stop sequences,

speed/load control, charge air control, and the engine

safety system and monitoring.

The MCU also communicates with the plant control

system (PLC & WOIS).

Function of MCU

C t l t M i C t l U it (MCU)


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Basic Specs Single height euroboard VME system including:

Rack with VMEbus Backplane

Processor Board

Digital I/O Board

Analogue I/O Board

CAN Interface Board Power Supply

32-bit MC68EC030 running at 40 MHz is responsible forthe engine control

16-bit MC68302 running at 16 MHz is responsible for the

Communication to/from the MCU Operating temperature: -40...+85 C Resilient mounting on the engine



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Summary of Functions

Start control Stop control Run control

Gas supply pressure control

Throttle valve control

Waste gate control Engine load & speed control

Knock control

Safety handling Fault shutdowns

Emergency stop Alarm handling Communication to external systems ( PLC & WOIS)



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Control s stem Main Control Unit (MCU)


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Control system Cylinder Control Unit (CCU)


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Control systemCylinder Control Unit (CCU)



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Basic Specs Comprises:

the CPU Board the I/O Board

32-bit microprocessor MC68332 16 MHz CAN-controller i82527

The CCU controls two cylinders, each Cylinder Comprising: one Ignition Unit

two Exh. Gas Temp. Sensors (in parallel)

two Cyl. Liner Temp. Sensors (in parallel)

the Main Gas Control Valve the PCC Gas Control Valve

Engine position signals to each CCU Operating temperature: -50...+85 C



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Handles all cylinder control and monitoringCCU controls and monitors two engine

cylinders

It consists of CPU Board and Input/Output

Board

It contains switch for checking condition of

main gas valve, pcc valve and spark plug. Also

contain 2 switches for ID.

Engine position signals to each CCU

Operating temperature: -50 to +85 oC

General Information



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Function of Cylinder Control Unit

Control of gas injection of 2 main gas admissionvalves

Control of gas injection of 2 pre combustionchamber admission valves

Control of ignition of 2 spark plugsMeasuring of 2 exhaust gas temperatures

Measuring of 2 cylinder liner temperatures

Reading of engine angular position and speed

send by rotary encorderReading of fuel demand (from the MCU)



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Control system Potentiometers


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Control systemKnock Detection Unit (KDU)


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y ( )

Function of Knock Detection Unit

Used to measure the knock signals fromaccelerometers mounted on each cylinder head.

The KDU filtrates, amplifies and converts thesesignals to digital information and sends it over theCAN-bus to the MCU for further processing.

One KDU is designed to handle up to ninecylinders.

Control systemKnock Detection Unit (KDU)


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y ( )

Basic Specs Input signal from rotary encoderKnock intensity value to MCUComprises:

The CPU Board

Memory

A/D-converters

32-bit microprocessor MC68332 16 MHz

CAN-controller i82527

The I/O Board

filtering integration

Operating temperature: -50...+85 C

Control systemKnock Detection Phenomenon


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y

Control systemKnock Sensor


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y

Cylinder Head

Knock Sensor

Control systemDistributed Control Unit and Sensor Multiplexing Unit


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Function of Distributed Control Unit and

Sensor Multiplexing Unit

Used for measuring purposes (measuring of

sensors).

They convert different types of sensor signals todigital information which is sent over a network to the

MCU for further processing (data handling for Local

Display Unit).

Control systemDistributed Control Unit and Sensor Multiplexing Unit


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Control systemDCU and SMU Enclosure


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Control systemSensor Multiplexing Unit (SMU)


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Basic Specs Microprocessor based 10 analog inputs: pt100, t/c, 4-20 mA,

0-10 V, on/off, etc.

8 digital I/O connections

2 frequency inputs 1 current output 0-20 mA All channels software configurable Power supply: 24 VDC RS-485 serial interface Operating temperature: -50...+100 C

Control systemDistributed Control Unit (DCU)


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Basic Specs

Microprocessor based Comprises all features of the SMU Several serial interfaces:

CAN bus to other DCUs and to the MCU RS-485 bus to SMU chain RS-232 to PC / LDU

Power supply: 24 VDC

Operating temperature: -50...+85 C

Control systemLocation of Rotary Encoder


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Control systemRotary Encoder


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The rotary encoder is mechanically adjusted to give the

synchronization pulse when piston number A1 is in Top Dead

Centre (TDC) position at power stroke. This pulse is then used to

synchronize the ignition and the gas admission valve timing for allcylinders.

.

Control systemCamshaft with Rotary Encoder


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1. Camshaft piece 2. Bearing journal

3. Screw 4. Fixing pin

5. Rotary Encoder 6. End cover7. Axial Bearing

Control systemMeasuring Engine Speed


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Two Engine Speed Sensors

1. Rotary EncoderA rotary encoder connected to the camshaft is themaster unit. The rotary encoder is used tocalculate engine angular position as well as enginespeed.

2. Engine Speed Pick-Up

The other speed sensor is an inductive proximityswitch installed at the camshaft gear.

This speed sensor is used as a redundantoverspeed protection device.



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Two Engine Speed Sensors Speed measured from the rotary encoder is

compared with the speed signal from the inductiveproximity switch in the MCU.

A shutdown is activated if a deviation in speed signals

is over 50 rpm.



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Function

The encoder has two signal outputs.1. One which provide 900 pulses/camshaft revolutionand

2. the other one providing one synchronization

pulse per camshaft revolution.One revolution on camshaft is the same as two onthe crankshaft. This gives an resolution of 450pulses/rev on crankshaft, i.e. 0.8 crank angle/encoder pulse

Control systemEngine Speed Pick-Up


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Control systemEngine Speed Pick-UP


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FunctionThe engine speed measured with this pick-up is usedfor:

1. redundant engine overspeed protection purposes,and

2. also to verify the engine speed signal from therotary encoder on the camshaft.

The sensor is an inductive proximity switch with built-in signal amplifier which provides a square-waveoutput signal.



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Function

The sensor is directly connected to the OverspeedTrip Module in the MCU cabinet, from which it issupplied with 24 VDC.

The sensor gives one pulse for each cog on thecamshaft gear passing the head of the sensor.



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Function

The output of the sensor is providing a speedproportional pulse train which is opto-coupled andtransduced into an analogue 4-20 mA signal in theOverspeed Trip Module.

This signal is connected to the MCU, which monitorsthe signal and compares it with the calculated speedvalue from the CCUs.

If there is a deviation between these values, the MCUwill initiate an alarm.

Control systemWECS Equipment as seen in Parts Manual


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Control systemWECS Equipment as seen in Parts Manual


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Control systemIgnition System

Ignition Coil


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Ignition Coil

High Tension

Extender

Spark Plug

CCU

Ignition

Module

Old Version

Inside Hot Box



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Main Components

1. Ignition Module2. Ignition Coil

3. High Tension Extender and4. Spark Plug

Control systemIgnition Coil and Spark Plug


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Ignition Coil

Ignition Trig Module

Spark Plug



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Flow Diagram

Control systemHigh Voltage Circuit


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Control systemEngine Speed and Load Control


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pltmg prabumulih 18v34sg rev.3 operasi

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