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ReDuceD emissioNs, betteR peRfoRmANce, LoNgeR Lifetime

cAse stoRY: Dm-4 gAs

Refitting an existing gas engine control system with an innovative DEIF solution can make good financial sense and be a green advantage.

The gains are significant and tangible in the form of immediate improved engine performance and reduced emissions. The refitting has a short to medium term return on investment time, and in the longer perspective improved engine performance and a reduced need for servicing means a longer operation life for the generator.

A recent project in the Gabonese Republic’s isolated wet forest region of the Middle-Ogooué saw DEIF replace the control systems of a set of hardworking Deutz engines at the Batanga onshore and offshore oil field. Fuelled by the oil production wells’ waste gas, the power generators provide electricity both for production at the remote facility and for the 80 or so homes of a nearby village.

The Deutz type TBG 632 16 cylinder generator set has a nominal power output of 3,500 kWe. Because of instabilities in the turbo charger activation, over the years the generators’ output was effectively limited to 2,000

kWe when running in island mode. Anything above 2,000 often resulted in unwanted blackouts and production downtime.

the Deif solutionBecause of the distance between switchboard and engines, DEIF’s DM-4 systems were separated into two modules per generator set: one for engine and generator control and one for plant control.

The engine controls were fitted in the new local engine panels, and the plant controls were installed in the existing control room’s main switchboard. A twisted pair cable for communication between the two modules limited wiring work between the engines and the control room. The operator terminal was replaced by a standard Windows touch panel PC in the control room, with the DM-4’s standard graphic interface as the local control.

engine controlCompared to other suppliers, DEIF has unique competences and expertise on gas setups and particular insights into the deep workings of gas engines.

New engine room panel with DM-4 Gas and AKR anti-knocking system.

Optimising performance, at the Batanga site the DEIF solution interfaces directly to the existing mixer stepper motor. For increased emission control, the mixer position control is based on measuring combustion chamber temperature for each cylinder.

In the case of TBG632, two mixer control loops run independently of each other for the engine’s A and B sides, interfacing separately to the two mixers.

To prevent lubrication oil film breakdown on the cylinder walls with subsequent damage to cylinder wall and piston/piston rings, cylinder wall temperatures are monitored to ensure that the combustion chamber temperature does not get too high.

The throttle (power output) is controlled by the DM-4 Gas interfacing to the existing Heinzmann actuator. Engine knocking is monitored on a cycle to cycle basis by communicating with a new AKR anti-knocking system.

Communication with the existing Altronic ZS-3 ignition system enables individual control of ignition firing angle for each cylinder. Among other things, the firing angle control is used

to prevent knocking, and the anti-knocking system data are used to help determine the optimal firing angle for all cylinders within one working cycle of the engine. Exhaust temperatures, oil pressures, coolant temperatures, etc. are also monitored.

generator control•   Measuring of all 3-phase electrical values

(voltage, current, power, etc.)

•   Synchronising with voltage matching

•   Load sharing between generators

•   Generator protection (reverse power, overcurrent, etc.)

the Deif advantageFollowing the DEIF refit, the TBG 632 16 cylinder generator now uses less gas to produce more power.

The previous black-out risk has been eliminated, and the engine is now able to reach up to 3,500 kWe in fixed power and above 3,000 kWe in load sharing mode under safe, protected conditions.

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DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · info@deif.com · www.deif.com

Founded in 1933, DEIF has more than 75 years of experience. Today,

we are active on the international markets for engine & genset con-

trols, marine bridge instrumentation, switchboard instrumentation

and renewable energy controls.

It is our ambition to maintain and expand our position as one of the

most trusted suppliers within our fields of operation. This goal will

be reached by ensuring that DEIF continues to offer real competitive

advantages to our customers by supplying superior product quality, the

best and most flexible features and competitive pricing.