Tech Description Cogen Unit

11.01.2012/WS TD_NAVIGAT 620 F111 NL_3349 kW_JAN2012 Copyright (rg)1/32

Technical Description

Cogeneration Unit

JMS 620 GS-N.Lwith Island Operation

NAVIGAT 620 F111 JAN2012

Electrical output 3349 kW el.

Thermal output 1826 kW

Emission valuesNOx < 500 mg/Nm (5% O2)

Notes:- ICW1 and ICW2 already recalculated to 40C (F111, tropical version)


0.01 Technical Data (at module) _________________________________________ 4Main dimensions and weights (at module) 5Connections 5Output / fuel consumption 5

0.02 Technical data of engine ___________________________________________ 6Thermal energy balance 6Exhaust gas data 6Combustion air data 6Sound pressure level 7Sound power level 7

0.03 Technical data of generator_________________________________________ 8Reactance and time constants 8

0.04 Technical data of heat recovery _____________________________________ 9General data - Hot water circuit 9Mixture Intercooler (1st stage) 9Mixture Intercooler (2nd stage) (Intercooler separate) 9Heat exchanger lube oil 9Heat exchanger engine jacket water 9

connection variant B _________________________________________________ 100.10 Technical parameters_____________________________________________ 111.00 Scope of supply - module _________________________________________ 121.01 Spark ignited gas engine__________________________________________ 121.01.01 Engine design ________________________________________________ 121.01.02 Engine accessories Commissioning spare parts __________________ 141.01.03 Standard tools (1/plant) ________________________________________ 141.02 Generator-medium voltage ________________________________________ 141.03 Module accessories ______________________________________________ 151.03.01 Engine jacket water system _____________________________________ 161.03.02 Automatic lube oil replenishing system ___________________________ 171.05 Gas train _______________________________________________________ 171.07 Painting ________________________________________________________ 181.11 Engine generator control panel DIA.NE XT__________________________ 181.11.01 Monic _______________________________________________________ 231.11.03 Remote Data-Transfer with DIA.NE XT - HERMES ___________________ 231.20.01 Starting system _______________________________________________ 251.20.03 Electric jacket water preheating__________________________________ 261.20.04 Flexible connections___________________________________________ 26


1.20.26 Warm water pump _____________________________________________ 271.20.27 Return temperature control _____________________________________ 271.20.28 Pressure compensation reservoir ________________________________ 272.00 Electrical equipment _____________________________________________ 272.02 Grid monitoring device ___________________________________________ 282.03.02 Power control ________________________________________________ 283.10 Cooling system (WITHOUT RADIATOR)______________________________ 284.00 Delivery, installation and commissioning ____________________________ 294.01 Carriage 294.02 Unloading 294.03 Assembly and installation 294.04 Storage 294.05 Start-up and commissioning 294.06 Trial run 294.07 Emission measurement (exhaust gas analyser) 29

5.01 Limits of delivery - Genset_________________________________________ 295.02 Factory tests and inspections______________________________________ 305.02.01 Engine tests 305.02.02 Generator tests 315.02.03 Module tests 31

5.03 Documentation (1/plant) __________________________________________ 31


0.01 Technical Data (at module)

Data at: Fullload

Part Load

Fuel gas LHV kWh/Nm 9,5100% 75% 50%

Energy input kW [2] 7.790 6.005 4.219Gas volume Nm/h *) 820 632 444Mechanical output kW [1] 3.431 2.573 1.715Electrical output kW el. [4] 3.349 2.509 1.661Recoverable thermal output~ Intercooler 1st stage 40C kW 963~ Lube oil kW 318~ Jacket water kW 545~ Exhaust gas cooled to 390 C kW ~Total recoverable thermal output kW [5] 1.826Total output generated kW total 5.175

Heat to be dissipated~ Intercooler 2nd stage 40C kW 203~ Lube oil kW ~~ Surface heat ca. kW [7] 215~ Balance heat kW 78

Spec. fuel consumption of engine kWh/kWh [2] 2,27Lube oil consumption ca. kg/h [3] 1,03Electrical efficiency % 43,0%Thermal efficiency % 23,4%Total efficiency % [6] 66,4%

Hot water circuit:Forward temperature C 90,0Return temperature C 70,0Hot water flow rate m/h 79,1*) approximate value for pipework dimensioning[_] Explanations: see 0.10 - Technical parameters

All heat data is based on standard conditions according to attachment 0.10. Deviations from the standard conditions can result in achange of values within the heat balance, and must be taken into consideration in the layout of the cooling circuit/equipment(intercooler; emergency cooling; ...). In the specifications in addition to the general tolerance of +/- 8% on the thermal output afurther reserve of 10% is recommended for the dimensioning of the cooling requirements.


Main dimensions and weights (at module)Length mm ~ 8.900Width mm ~ 2.200Height mm ~ 2.800Weight empty kg ~ 30.300Weight filled kg ~ 31.300

ConnectionsHot water inlet and outlet DN/PN 100/10Exhaust gas outlet DN/PN 600/10Fuel gas (at gas train) DN/PN 100/16Fuel Gas (at module) DN/PN 100/10Water drain ISO 228 G ''Condensate drain DN/PN 50/10Safety valve - jacket water ISO 228 DN/PN 2x1''/2,5Safety valve - hot water DN/PN 80/10Lube oil replenishing (pipe) mm 28Lube oil drain (pipe) mm 28Jacket water - filling (flex pipe) mm 13Intercooler water-Inlet/Outlet 1st stage DN/PN 100/10Intercooler water-Inlet/Outlet 2nd stage DN/PN 65/10

Output / fuel consumptionISO standard fuel stop power ICFN kW 3.431Mean effe. press. at stand. power and nom. speed bar 22,00Fuel gas type Natural gasBased on methane number MZ d) 70Compression ratio Epsilon 10,50Min. fuel gas pressure for the pre chamber bar 3,7Min./Max. fuel gas pressure at inlet to gas train mbar 3000-8000Allowed Fluctuation of fuel gas pressure % 10Max. rate of gas pressure fluctuation mbar/sec 10Maximum Intercooler 2nd stage inlet water temperature C 50Spec. fuel consumption of engine kWh/kWh 2,27Specific lube oil consumption g/kWh 0,30Max. Oil temperature C 80Jacket-water temperature max. C 95Filling capacity lube oil (refill) lit ~ 765c) Lower gas pressures upon inquiryd) based on methane number calculation software AVL 3.1 (calculated without N2 and CO2)


0.02 Technical data of engine

Manufacturer GE JenbacherEngine type J 620 GS-F111Working principle 4-StrokeConfiguration V 60No. of cylinders 20Bore mm 190Stroke mm 220Piston displacement lit 124,75Nominal speed rpm 1.500Mean piston speed m/s 11,00Length mm 5.542Width mm 1.900Height mm 2.540Weight dry kg 12.000Weight filled kg 13.000Moment of inertia kgm 69,21Direction of rotation (from flywheel view) leftFlywheel connection SAE 24''Radio interference level to VDE 0875 NStarter motor output kW 20Starter motor voltage V 24

Thermal energy balanceEnergy input kW 7.790Intercooler kW 1.166Lube oil kW 318Jacket water kW 545Exhaust gas total kW 2.116Exhaust gas cooled to 180 C kW 1.238Exhaust gas cooled to 100 C kW 1.694Surface heat kW 133Balance heat kW 78

Exhaust gas dataExhaust gas temperature at full load C [8] 390Exhaust gas mass flow rate, wet kg/h 19.093Exhaust gas mass flow rate, dry kg/h 17.884Exhaust gas volume, wet Nm/h 15.026Exhaust gas volume, dry Nm/h 13.574Max.admissible exhaust back pressure after engine mbar 50

Combustion air dataCombustion air mass flow rate kg/h 18.509Combustion air volume Nm/h 14.318Max. admissible pressure drop in front of intake-air filter mbar 10


Sound pressure levelAggregate b) dB(A) re 20Pa 10131,5 Hz dB 8863 Hz dB 95125 Hz dB 101250 Hz dB 99500 Hz dB 941000 Hz dB 932000 Hz dB 924000 Hz dB 948000 Hz dB 95Exhaust gas a) dB(A) re 20Pa 12331,5 Hz dB 11263 Hz dB 121125 Hz dB 131250 Hz dB 119500 Hz dB 1171000 Hz dB 1182000 Hz dB 1174000 Hz dB 1128000 Hz dB 98

Sound power levelAggregate dB(A) re 1pW 122Measurement surface m 144Exhaust gas dB(A) re 1pW 131Measurement surface m 6,28a) average sound pressure level on measurement surface in a distance of 1m according to DIN 45635, precision class 2.b) average sound pressure level on measurement surface in a distance of 1m (converted to free field) according to DIN 45635,precision class 3.The spectra are valid for aggregates up to bmpe=20 bar. (add savety margin of 1dB to all values per increase of 1 bar pressure).Operation with 1200 rpm see upper values, operation with 1800 rpm add 3 dB to upper values.Engine tolerance 3 dB


0.03 Technical data of generator

Manufacturer AVK e)Type DIG 142 e/4 e)Type rating kVA 4.450Driving power kW 3.431Ratings at p.f. = 1,0 kW 3.349Ratings at p.f. = 0,8 kW 3.328Rated output at p.f. = 0,8 kVA 4.160Rated current at p.f. = 0,8 A 218Frequency Hz 50Voltage kV 11Speed rpm 1.500Permissible overspeed rpm 2.250Power factor lagging 0,8 - 1,0Efficiency at p.f. = 1,0 % 97,6%Efficiency at p.f. = 0,8 % 97,0%Moment of inertia kgm 177,00Mass kg 10.250Radio interference level to VDE 0875 NConstruction IMB 24Protection Class IP 23Insulation class FTemperature (rise at driving power) FMaximum ambient temperature C 40Total harmonic distortion % 5,0

Reactance and time constantsxd direct axis synchronous reactance p.u. 2,27xd' direct axis transient reactance p.u. 0,22xd'' direct axis sub transient reactance p.u. 0,16Td'' sub transient reactance time constant ms 20Ta Time constant direct-current ms 120Tdo' open circuit field time constant s 3,70e) GE Jenbacher reserves the right to change the generator supplier and the generator type. The contractual data of the

generator may thereby change slightly. The contractual produced electrical power will not change.


0.04 Technical data of heat recovery

General data - Hot water circuitTotal recoverable thermal output kW 1.826Return temperature C 70,0Forward temperature C 90,0Hot water flow rate m/h 79,1Nominal pressure of hot water bar 10Pressure drop hot water circuit bar 1,30Maximum Variation in return temperature C +0/-20Max. rate of return temperature fluctuation C/min 10

Mixture Intercooler (1st stage)Type gilled pipesNominal pressure of hot water bar 10Pressure drop hot water circuit bar 0,50Hot water connection DN/PN 100/10

Mixture Intercooler (2nd stage) (Intercooler separate)Type gilled pipesNominal pressure of hot water bar 10Pressure drop hot water circuit bar 0,60Hot water connection DN/PN 65/10

Heat exchanger lube oilType plate heat exchangerNominal pressure of hot water bar 10Pressure drop hot water circuit bar 0,40Hot water connection DN/PN 100/10

Heat exchanger engine jacket waterType plate heat exchangerNominal pressure of hot water bar 10Pressure drop hot water circuit bar 0,40Hot water connection DN/PN 100/10

connection variant B


0.10 Technical parameters

All data in the technical specification are based on engine full load (unless stated otherwise) at specifiedtemperatures and the methane number and subject to technical development and modifications.

All pressure indications are to be measured and read with pressure gauges (psi.g.).

(1) At nominal speed and standard reference conditions ICFN according to DIN-ISO 3046 and DIN 6271,respectively

(2) According to DIN-ISO 3046 and DIN 6271, respectively, with a tolerance of + 5 %.Efficiency performance is based on a new unit (immediately upon commissioning).Effects ofdegradation during normal operation can be mitigated through regular service and maintenance work.

(3) Average value between oil change intervals according to maintenance schedule, without oil changeamount

(4) At p. f. = 1.0 according to VDE 0530 REM / IEC 34.1 with relative tolerances(5) Total output with a tolerance of +/- 8 %(6) According to above parameters (1) through (5)(7) Only valid for engine and generator; module and peripheral equipment not considered(8) Exhaust temperature with a tolerance of +/- 8 %

Radio interference levelThe ignition system of the gas engines complies the radio interference levels of CISPR 12 and EN 55011class B, (30-75 MHz, 75-400 MHz, 400-1000 MHz) and (30-230 MHz, 230-1000 MHz), respectively.

Definition of output ISO-ICFN continuous rated power:

Net break power that the engine manufacturer declares an engine is capable of delivering continuously,at stated speed, between the normal maintenance intervals and overhauls as required by themanufacturer. Power determined under the operating conditions of the manufacturers test bench andadjusted to the standard reference conditions.

Standard reference conditions:Barometric pressure: 1000 mbar (14.5 psi) or 100 m (328 ft) above sea levelAir temperature: 25C (77F) or 298 KRelative humidity: 30 %

Volume values at standard conditions (fuel gas, combustion air, exhaust gas)Pressure: 1013 mbar (14.7 psi)Temperature: 0C (32F) or 273 K

Output adjustment for turbo charged enginesStandard rating of the engines is for an installation at an altitude 0 m and an air intake temperature 40C.

If the actual methane number is lower than the specified, the knock control responds. First the ignitiontiming is changed at full rated power. Secondly the rated power is reduced. These functions are carriedout by the engine management system.Exceedance of the voltage and frequency limits for generators according to IEC 60034-1 Zone A will leadto a derate in output.


Parameters for the operation of GE Jenbacher gas enginesThe genset fulfills the limits for mechanical vibrations according to ISO 8528-9.If possible, railway trucks must not be used for transport (TI 1000-0046).The following "Technical Instruction of GE JENBACHER" forms an integral part of a contract and must bestrictly observed: TI 1100-0110, TI 1100-0111, and TI 1100-0112.

1.00 Scope of supply - module

Design:The module is built as a compact package. Engine and generator are connected through a coupling andare mounted to the base frame. To provide the best possible isolation from the transmission of vibrationsthe engine is mounted to the frame by means of anti-vibrational mounts. The remaining vibrations areeliminated by mounting the module on isolating pads (e.g. Sylomer). This, in principle, allows the moduleto be placed directly on any floor capable of carrying the static load. No special foundation is required.Prevention of sound conducted through solids has to be provided locally.

1.01 Spark ignited gas engine

Four-stroke, air/gas mixture turbocharged, aftercooled, with high performance ignition system andelectronically controlled air/gas mixture system.The engine is equipped with the most advanced

LEANOX LEAN-BURN COMBUSTION SYSTEM

developed by GE JENBACHER.

1.01.01 Engine design

Engine blockSingle-piece crankcase and cylinder block made of special casting; crank case covers for engineinspection, welded steel oil pan.

Crankshaft and main bearingsDrop-forged, precision ground, surface hardened, statically and dynamically balanced; main bearings(upper bearing shell: grooved bearing / lower bearing shell: sputter bearing) arranged between crankpins, drilled oil passages for forced-feed lubrication of connecting rods.

Vibration damperMaintenance free viscous damper

FlywheelWith ring gear for starter motor and additionally screwed on.

Pistons


Single-piece made of steel, with piston ring carrier and oil passages for cooling; piston rings made of highquality material, main combustion chamber specially designed for lean burn operation.

Connecting rodsDrop-forged, heat-treated, big end diagonally split and toothed. Big end bearings (upper bearing shell:sputter bearing / lower bearing shell: sputter bearing) and connecting rod bushing for piston pin.

Cylinder linerChromium alloy gray cast iron, wet, individually replaceable.

Cylinder headSpecially designed and developed for GE JENBACHER-lean burn engines with optimized fuelconsumption and emissions; water cooled, made of special casting, individually replaceable; Valve seats,valve guides and spark plug sleeves individually replaceable; exhaust and inlet valves made of highquality material; Pre-chamber with check-valve.

Crankcase breatherConnected to combustion air intake system.

Valve trainCamshaft, with replaceable bushings, driven by crankshaft through intermediate gears, valve lubricationby splash oil through rocker arms.

Combustion air/fuel gas systemMotorized carburetor for automatic adjustment according to fuel gas characteristic. Exhaust driventurbocharger, mixture manifold with bellows, water-cooled intercooler, throttle valve and distributionmanifolds to cylinders.

Ignition systemMost advanced, fully electronic high performance ignition system, external ignition control.

Lubricating systemGear-type lube oil pump to supply all moving parts with filtered lube oil, pressure control valve, pressurerelief valve and full-flow filter cartridges. Cooling of the lube oil is arranged by a heat exchanger.

Engine cooling systemJacket water pump complete with distribution pipework and manifolds.

Exhaust systemTurbocharger and exhaust manifold

Exhaust gas temperature measuringThermocouple for each cylinder

Electric actuatorFor electronic speed and output control

Electronic speed monitoring for speed and output controlBy magnetic inductive pick up over ring gear on flywheel


Starter motorEngine mounted electric starter motor

1.01.02 Engine accessories Commissioning spare parts(1 set perengine)

Commissioning spare parts:Initial equipment with necessary spare parts for operation after commissioning.

Spark plug (1 item) Sealing ring (20 items) Spark plug holder (1 item) Pre-combustion chamber gas valve.(1 item) Thermocouple (1 item) Sealing ring (1 item)

1.01.03 Standard tools type 6 (1/plant)

Standard tool set (1 item) Lubricant (1 item) Key to tighten the valve in the cylinder head Turning rod (1item) Hose pipe (1 item, length 400mm)

Standard tool set GE Jenbacher consisting of:

126197 1,000 pcs Socket 200432 1,000 pcs Screwdriver156858 1,000 pcs Socket 200433 1,000 pcs Screwdriver294768 1,000 pcs Key 249533 1,000 pcs Pliers126291 1,000 pcs Measurement device 314941 1,000 pcs Socket156798 1,000 pcs Screwdriver 295249 1,000 pcs Pressure vessel156806 1,000 pcs combination wrench 1205087 1,000 pcs Safety gloves183978 1,000 pcs Measure equip.Gauge 1205088 1,000 pcs Safety glasses283376 1,000 pcs Grease gun 1205089 1,000 pcs Safety ear plug

1.02 Generator-medium voltage

The generator consists of the main generator (built as rotating field machine), the exciter machine (builtas rotating armature machine) and the voltage regulator with cos. phi-regulator. The regulator is poweredby an auxiliary winding at the main stator.

Main components Main stator with frame Winding at two layers Terminal box includes main terminals plus auxiliary terminals for thermistor connection and control for

regulator Main rotor with sufficiently sized shaft dynamically balanced as per VDI 2060, Grade Q1


Drive end bracket with bearing Non-drive end bracket with bearing Exciter unit Power factor controller Voltage regulator Anti-condensation heater

Electrical data and features Voltage adjustment: +/- 10% rated voltage Static voltage accuracy: +/- 1% at no load to full load and power factor 0.8-1 speed variation +/- 3%, cold and hot machine Maximum deviation of wave form according to VDE is 5% phase to phase at open circuit Generator suitable for parallel operating with mains and other generators Sustained short circuit current at 3-pole terminal short circuit: minimum 3 times rated current for 5

seconds. Overload capacity according. to IEC 32 - I/VDE 0530According to VDE 0530 the overspeed test ensues with 1.2 times of rated speed for 2 minutes.

Additional components: Electronic voltage regulator Electronic power factor regulator 3 Pt 100 for winding temperature monitoring 2 Pt 100 for bearing temperature monitoring Current transformer for protection and measuring uses

1.03 Module accessories

Base frameWelded structural steel to accommodate engine, generator and heat exchangers.

Flexible couplingWith torque limiter to couple engine with generator. The coupling isolates the major subharmonics ofengine firing impulses from the generator.

Bell housingTo connect engine with generator housing. With two ventilation and control windows.

Anti-vibration mountsArranged between engine/generator assembly and base frame. Isolating pads (SYLOMER) for placementbetween base frame and foundation, delivered loose.

Exhaust gas connectionConnection of exhaust gas turbocharger; including flexible connection to compensate for expansions andvibrations.

Combustion air filterDry type air filter with replaceable filter cartridges, including flexible connection to carburetor and serviceindicator.


Interface panelTotally enclosed sheet steel cubicle with front door, wired to terminals, ready to operate. Cable entry atbottom.

Painting: RAL 7035

Protection: IP 54 external, IP 10 internal (protection against direct contact with live parts)

Design according to IEC 439-1 (EN 60 439-1/1990) and DIN VDE 0660 part 500, respectively.Ambient temperature: 5 - 40 C (41 - 104 F), Relative humidity: 70 %

Dimensions: Height: 1300 mm (51 in) Width: 1200 mm (47 in) Depth: 400 mm (16 in)

Power supply from the starter battery charger.

Power distribution to the engine mounted auxiliaries (power input from the supplier of the auxiliariespower supply):3 x 400/231 V, 50 Hz, 50 A

Essential components installed in interface panel: Terminal strip Decentralized input and output cards, connected by a data bus interface to the central engine control of

the module control panel. Speed monitoring Relays, contacts, fuses, engine contact switch to control valves and auxiliaries Measuring transducer for excitation voltage Air conditioning system (option)

Exhaust gas scavenging blowerThe exhaust gas scavenging blower is used to scavenge the remaining exhaust gas out of the exhaustgas pipe work, to prevent the appearance of deflagrations.

Function:Before each start scavenging by blower is done for app. 1 minute (except at black out start)

Supervisions: Scavenging air fan failure Scavenging air flap failure

Consisting of: Fan Exhaust gas flap Temperature switch Compensator and pipe work

1.03.01 Engine jacket water system


Engine jacket water systemClosed cooling circuit, consisting of: Expansion tank Filling device (check and pressure reducing valves, pressure gauge) Safety valve(s) Thermostatic valve Required pipework on module Vents and drains Electrical jacket water pump, including check valve Jacket water preheat device

1.03.02 Automatic lube oil replenishing system

Automatic lube oil replenishing system:Includes float valve in lube oil feed line, including inspection glass. Electric monitoring system will beprovided for engine shut-down at lube oil levels "MINIMUM" and "MAXIMUM". Solenoid valve in oil feedline is only activated during engine operation. Manual override of the solenoid valve, for filling procedureduring oil changes is included.

Oil drainBy set mounted cock

Pre-lubrication- and aftercooling oil pump:Mounted on the module base frame; it is used for pre-lubrication and aftercooling of the turbochargers.Period of operation: Pre-lubrication: 1 minute both pumps

Aftercooling: 15 minutes from engine stop only the 400/231 V pumpConsisting of: 1 piece oil pump 1500 W, 400/231 V 1 piece oil pump 1500 W, 24 V All necessary vents Necessary pipework

1.05 Gas train

Pre-assembled, delivered loose, for installation into gas pipework to the module.

Consisting of: Main gas train: Shut off valve Gas filter, filter fineness


Gas flow meter (option) p/t compensation (option)

The gas train complies with DIN - DVGW regulations.Maximum distance from TEC JET outlet to gas entry on engine, including flexible connections, is 1 m(39,37 in).

Pre-chamber gas train: Ball valve Gas filter, filter fineness


Industrial control with 10,4 QVGA TFT colour graphics display and 8 function keys.10-key numeric keyboard for parameter input.Keys for START, STOP, Generator circuit breaker OPEN, Generator circuit breakerCLOSED/SELECTED, display selection keys and special functions.Interfaces: Ethernet (twisted pair) for connection to DIA.NE WIN server CAN-Bus: bus connection to the intelligent sensors and actuators Data bus connection to the control in- and outputs

OPTION: Interfacing with the customers plant management according to GE JENBACHER list ofoptions (MODBUS-RTU slave, PROFIBUS-DP slave)

Protection class: IP 65 (front)Dimensions: W x H x D = approx. 212 x 255 x 95 mm (8,4 x 10 x 3,75 in)

A clear and functional graphic compilation of measured values is displayed on the screen. User promptsare by means of direct-acting display selection keys and function keys.

Main displays: Electrical schematic Oil and hydraulic schematic Gas data Engine controllers Cylinder data Exhaust gas data Auxilliaries controllers Spare screen for customer specific purposes System display screens Parameter manager User setting Alarm management

Recipe handling:Setting, display and storage of all module parameters

Alarm management:Efficient diagnostic instrumentation listing all active fault messages both tabular and chronologically, withthe recorded time.

2) Central engine and module control:A real-time, modular industrial control system which handles all jobs for module and engine-sidesequencing control (start preparation, start, stop, synchronizing, after-cooling, control of auxiliaries), aswell as all control functions.

Control functions: Speed control in no-load and isolated operation Power output control in parallel operation system; job-specific with respect to internal and external set

point values. LEANOX control system for control of boost pressure; dependent upon the generator terminal power

and the mixture temperature via the engine-driven air-gas mixer Knocking control: adjustment of the ignition point, power output and (insofar as is locally possible) the

mixture temperature in the event of detection of knocking.


Load sharing between several modules in isolated operation Linear reduction of power output in the event of excessive mixture temperature and ignition failures

Interface relays as per the interface list Multi-transducer, to record the following electrically measured variables of the generator:

Phase current (with slave pointer) Neutral conductor current Voltages Ph/Ph and Ph/N Active power (with slave pointer) Reactive power Apparent power Power factor Frequency

An additional 0 - 20 mA output is produced for active power, as well as a pulse output for active powerdemand.The following alternator supervisions are integrated with the multi-transducer (max. 8 functionssimultaneous): Overload/short-circuit [51], [50] Over voltage [59] Undervoltage [27] Asymmetric voltage [64], [59N] Unbalance current [46] Failure Exitation [40] Overfrequency [81>] Underfrequency [81


Overspeed Emergency stop/safety loop Gas train failure Start failure Stop failure Engine start blocked Engine operation blocked Misfiring High mixture temperature Measuring signal failure Overload/output signal failure Generator overload/short circuit Generator over/undervoltage Generator over/underfrequency Generator asymmetric voltage Generator unbalanced load Generator reverse power High generator winding temperature Synchronising failure Knocking failure

Warning functions with display: Low jacket water temperature CPU battery failure

Operational functions with display: Ready to start Operation (engine running) Generator circuit breaker "CLOSED"

Remote signals:(volt free contacts)

1NO = 1 normally open1NC = 1 normally closed1 COC = 1 change over contact

Ready for automatic start (to Master control) 1NO Operation (engine runs) 1NO Collective signal "shut down" 1NC Collective signal "warning" 1NC

External (by others) provided command/status signals: Engine demand (from Master control) 1NO

Single synchronizing AutomaticWith voltage balance

For automatic synchronizing of the module with the generator circuit breaker to the grid by PLC-technology, integrated within the module control panel.


Consisting of: Lockable synchronizing mode selector switch, with positions "MANUAL - 0FF - AUTOMATIC" AUTOMATIC:

Automatic module synchronization, after synchronizing release from the control panel MANUAL:

Manual initiation of synchronizing by push button. Speed adjustment and closing of the circuit breakeris automatically controlled via microprocessor

OFF:Synchronization is disabled

Additional PLC hardware for the fully automatic synchronizing of each module, and monitoring of the"CIRCUIT BREAKER CLOSED" signal.Logic for monitoring of: Non-logic breaker positions Switch ON trouble Switch OFF trouble

Automatic synchronizing device to control the electronic speed governor adjustment, double voltmeter,double frequency meter and synchronoscope

Automatic voltage balancing Luminous push button GENERATOR CIRCUIT BREAKER OPEN / SELECT To indicate synchronizing mode To indicate Generator circuit breaker closed For manual synchronizing selection with the synchronizing mode selector switch in the MANUAL

position For manual closing of the generator circuit breaker to the voltage free bus bar (first connection) with

synchronizing mode selector switch in the MANUAL position Luminous push button GENERATOR CIRCUIT BREAKER OPEN To indicate Generator circuit breaker open To manually open the generator circuit breaker

Control switch Required relays for control and monitoring Voltage relay for monitoring of bussbar voltage (only for island operation)

Operational indications for: Generator circuit breaker CLOSED Generator circuit breaker OPEN

Fault indications for: Generator circuit breaker return signal fault Generator circuit breaker closing fault Generator circuit breaker opening fault

Remote signals(Volt free contacts)

Generator circuit breaker CLOSED 1 NO

The following reference and status signals must be provided by the switchgear supplier:


Generator circuit breaker CLOSED 1 NOGenerator circuit breaker OPEN 1 NOGenerator circuit breaker READY TO CLOSE 1 NOMains circuit breaker CLOSED 1 NOMains circuit breaker OPEN 1 NO

Mains voltage 3 x 400/231V or 3x 110V/v3 other measurement voltages available on request Bus bar voltage 3 x 400/231 V or 3x 110V/v3 other measurement voltages available on request Generator voltage 3 x 11 kV or 3x 110V/v3 other measurement voltages available on request

Voltage transformers in star point with minimum 50VA, Class 1

The following volt free interface-signals will be provided by GE Jenbacher to be incorporated inswitchgear: CLOSING/OPENING command for generator circuit breaker

(permanent contact) 1 NO + 1 NC Signal for circuit breaker undervoltage trip 1 NO

1.11.01 Monic

MonicThe monic (monitoring ignition control) is used to measure and evaluate automatically the ignitionvoltage of the gas engine cylinders.With the aic (active i-coil) the ignition voltages are measured by the monic hardware and the measuredvalues are transmitted by CAN-Bus to the DIA.NE XT resp. to the msd (monic sparc display) Visualisation of the ignition voltages with bar chart display Evaluation of the measuring values with signalisation when exceeding

1.11.03 Remote Data-Transfer with DIA.NE XT - HERMES

GeneralHERMES is the remote data transfer solution for DIA.NE XT. HERMES is available via three connectionmethods and two applications.

Connections methods

1.) ModemSite - Customer connection via a Modem (analogue, ISDN, GSM).

Scope of supply DIA.NE WIN Server (Industrial PC without display, keyboard or mouse, built into the control panel,

including operating system) Modem (analogue, ISDN, GSM)

Customer Requirements Modem (analogue, ISDN, GSM) in the customers PC Public telephone connection with connection port for the DIA.NE WIN Server (in the control panel)

including over-voltage protection corresponding to the local telecommunication regulations.


Public telephone connection with connection port for the customers PC corresponding to the localtelecommunication regulations.

2.) LANSite - Customer connection via a local network.

Scope of supply DIA.NE WIN Server (Industrial PC without display, keyboard or mouse, built into the control panel,

including operating system) Ethernet Network card (10/100 BASE T)

Customer Requirements Ethernet Network card (10/100 BASE T) Ethernet Cabling between the DIA.NE WIN Server the customers PC.

3.) Internet (OPTION)Site Customer connection via secure Internet accessSee comments under Technical instruction TI 2300 - 0006

Scope of Supply DIA.NE WIN Server (Industrial PC without display, keyboard or mouse, built into the control panel,

including operating system) EthernetNetwork card (10/100 BASE T) FirewallAppliance with connection feasibility to a customer network with a maximum of 10 Hosts

(Installation and service by GE Jenbacher; during warranty period included, afterwards as a servicepackage with costs) (built into the control panel)

Feature service package (access monitoring, clock synchronization for server)

Customer Requirements Broad band Internet access with at least two official IP addresses.

Connection feasibility for the FirewallAppliance to the InternetRouter via Ethernet(RJ45 Connector, Network Address Translation (NAT) is not permitted)

Applications

1.) DIA.NE WIN (OPTION)DIA.NE WIN is the Windows based man-machine interface for GE Jenbacher gas engines. The systemoffers extensive facilities for commissioning, monitoring, servicing and analysis of the site. The optionDIA.NE WIN extends the visualization of DIA.NE XT with respect to user friendliness, historical analysisand remote use. Several service stations can be independently operated in parallel. The system consistsof a central PC (DIA.NE WIN Server) which is built in to the control panel and one or more servicestations (DIA.NE WIN Clients). The system runs on a Microsoft Internet Explorer platform.

FunctionService and monitoring, trend analysis, alarm management, parameter management, long-term dataanalysis, multi-user system, remote control, OPC (OLE for process control), print and export functions,operating data protocols, available in several languages.

Scope of supply Software package DIA.NE WIN on the DIA.NE WIN Server


DIA.NE WIN Client License (Right to access of the user to the server on site)

Customer requirements Standard PC with keyboard, mouse and monitor (min. resolution 1024*768) 231 V supply for the customers PC Operating system Windows 98, Windows NT, Windows 2000 or Windows XP Microsoft Internet Explorer (min. Version 6.0) including Java support

2.) DIA.NE RMC (OPTION)DIA.NE RMC (Remote Message Control) is the automatic alarm system for DIA.NE XT. DIA.NE RMC canfully automatically transmit essential operational information from the DIA.NE XT Alarm Management to aremote station. The messages can be forwarded to an e-mail address, fax machine or mobile phone(SMS). Furthermore the stored messages can be visualized at the remote station. The system consists ofa central PC (DIA.NE WIN Server) which is built into the control panel and one or more customerremote stations.

FunctionAutomatically transfer of messages to the customer via email, fax or SMS. Display and printing of themessages (also distributed via LAN). Automatically and manually transfer of messages, trend data andoperating data protocols.

Scope of supply Software package DIA.NE message on the DIA.NE WIN Server Software package DIA.NE control and DIA.NE report on the remote stationOnly for connection method Internet: FirewallAppliance for customer computer with connection feasibility to a customer network with a

maximum of 10 Hosts (Installation and service by GE Jenbacher; during warranty period included,afterwards as a service package with costs)

Customer requirements Standard PC with keyboard, mouse and monitor (min. resolution 1024*768) 231 V supply for the customers computer. Operating system Windows 2000 (Professional and Server), Windows XP Professional or

Windows Server 2003. Internet connection (provider account) for the case that messages from the RMC should be forwarded

to an email receiver (incl. SMS for mobiles and pagers). (Mobiles and pagers to be provided by thecustomer).

Customer fax software for message forwarding via faxOnly for connection method Internet: Broad band Internet access with at least two official IP addresses.

Connection feasibility for the FirewallAppliance to the InternetRouter via Ethernet(RJ45 Connector, Network Address Translation (NAT) is not permitted)

1.20.01 Starting system

Starter battery:2 x 2 piece Pb battery with 12 cells, 2 x 12 V, 400 Ah (according to DIN 72311), complete with coverplate, terminals and acid tester.


Battery voltage monitoring:Monitoring by an under voltage relay.

Battery charging equipment:Capable for charging the starter battery with I/U characteristic and for the supply of all connected D.C.consumers.Charging device is mounted inside of the module interface panel or module control panel.

General data: Power supply 3 x 320 - 550 V, 47 - 63 Hz max. power consumption 2120 W Nominal D.C. voltage 24 V(+/-1%) Voltage setting range 24V to 28,8V ( adjustable) Nominal current (max.) 2 x 2 x 40 A Dimensions 240 x 125 x 125 mm Degree of protection IP20 to IEC 529 Operating temperature 0 C - 60 C Protection class 1 Humidity class 3K3, no condensation. Natural air convection Standards EN60950,EN50178

UL/cUL (UL508/CSA 22.2)

Signalling:Green Led: Output voltage > 20,5VYellow Led: Overload, Output Voltage < 20,5VRed Led: shutdown

Control accumulator: Pb battery 24 VDC/18 Ah

1.20.03 Electric jacket water preheating

Installed in the jacket water cooling circuit, consisting of: Heating elements Water circulating pump

The jacket water temperature of a stopped engine is maintained between 56C (133 F) and 60C(140F), to allow for immediate loading after engine start.

1.20.04 Flexible connections

Following flexible connections per module are included in the GE Jenbacher -scope of supply:

No. Connection Unit Dimension Material

2 Warm water in-/outlet DN/PN 100/10 Stainless steel


1 Exhaust gas outlet DN/PN 600/10 Stainless steel1 Fuel gas inlet DN/PN 100/16 Stainless steel2 Intercooler in-/outlet DN/PN 100/10 Stainless steel2 Lube oil connection mm 28 Hose

Sealings and flanges for all flexible connections are included.

1.20.26 Warm water pump

Consisting of: 1 Pump with constant speed, delivered loose for circulation of the required warm water flow per module,

3 x 400/231 V, 50 Hz 2 Manometers, at inlet and outlet of pump 1 balancing valve to control the warm water flow rate

The pump will be dimensioned upon the pressure drop of delivered GE Jenbacher parts in the warmwater circuit and max. 0.5 bar (7.2 PSI) for the customer circuit.

1.20.27 Return temperature control

Control of the return temperature ensures a constant warm water temperature at the inlet of the module.This is made possible by mixing warm water from the outlet flow into the return flow.

Consisting of: 1 x 3-way valve with electrical regulating control (delivered loose) 1 PT 100 (delivered loose) 1 PID-regulation (installed in the control panel)

1.20.28 Pressure compensation reservoir

The Expansion Tank is designed for the warm water circuit of the respective module.

Scope of supply: Size of the expansion tank: 200 l (delivered loose) Pressure gauge (delivered loose)

2.00 Electrical equipment

Totally enclosed floor mounted sheet steel cubicle with front door wired to terminals. Ready to operate,with cable entry at bottom. Naturally ventilated.

Protection: IP 40 externalIP 10 internal (protection against direct contact with live parts)


Design according to EN 60439-1 / IEC 60439-1 and ISO 8528-4.Ambient temperature 5 - 40 C (41 - 104 F), 70 % Relative humidity

Standard painting: Panel: RAL 7035Pedestal: RAL 7020

2.02 Grid monitoring device

Function:For immediate disconnection of the generator from the grid in case of grid failures.

Consisting of: High/low voltage monitoring High/low frequency monitoring Specially adjustable independent time for voltage and frequency monitoring Vector jump monitoring or df/dt monitoring for immediate disconnection of the generator from the grid

for example at short interruptions Indication of all reference dimensions and adjustable parameters for normal operation and at the case

of disturbance over LCD and LED Adjusting authority through password protection against adjusting of strangers

Scope of supply:Digital grid protection relay with storage of defect data, indication of reference dimensions as well asmonitoring by itself.

The 3 x 400/100 V voltage signal must be made available by the customer to the GE Jenbacher terminalstrip.

2.03.02 Power control

According to external signalFunction:An external potential free (0/4 - 20 mA = 50 - 100 % of nominal power) signal is a set value for the powercontrol.

At plants with multiple modules, this signal can be used in a series loop on every Engine ManagementSystem. This provides an equal load sharing between all modules.

3.10 Cooling system (WITHOUT RADIATOR)

The heat produced by the engine (jacket water, lube oil, intercooler) is dumped through a radiator,installed outside.

LOW TEMPERATUR CIRCUIT consisting of: Hot Water Pump


Electrical 3-way valve Expansion tank Safety Valve

HIGH TEMPERATURE CIRCUIT consisting of: Hot Water Pump Electrical 3-way valve Expansion tank Safety Valve

4.00 Delivery, installation and commissioning

4.01 CarriageCFR Jakarta according to INCOTERMS 2000.

4.02 UnloadingUnloading, moving of equipment to point of installation, mounting and adjustment of delivered equipmenton intended foundations is not included in GE Jenbacher scope of supply.

4.03 Assembly and installationAssembly and installation of all GE Jenbacher -components is not included in GE Jenbacher scope ofsupply.

4.04 StorageThe customer is responsible for secure and appropriate storage of all delivered equipment.

4.05 Start-up and commissioningStart-up and commissioning with the GE Jenbacher start-up and commissioning checklist is not included.

4.06 Trial runAfter start-up and commissioning, the plant will be tested in an 8-hour trial run. The operating personnelwill be introduced simultaneously to basic operating procedures.

4.07 Emission measurement (exhaust gas analyser)Emission measurement by GE Jenbacher personnel, to verify that the guaranteed toxic agent emissionshave been achieved (costs for measurement by an independent agency will be an extra charge).

5.01 Limits of delivery - Genset

Electrical: Genset: At terminals of genset interface panel At terminals of generator terminal box

(screwed glands to be provided locally) Genset control panel:

At terminal strips


Auxiliaries:At terminals of equipment which is supplied separately

Cooling waterAt inlet and outlet flanges on genset

Exhaust gasAt the exhaust gas exit of the engine

Combustion airThe air filters are set mounted

Fuel gas At inlet and outlet flange of gas train At inlet flange of gas pipework on genset At outlet flange of the pre-chamber gas train At inlet flange of pre-chamber gas pipework on genset At connection for boost pressure compensation on genset At connection for boost pressure compensation on gas pressure regulator of the pre-chamber gas train

Lube oilAt lube oil connections on genset

Draining connections and pressure reliefAt genset

InsulationInsulation of heat exchangers, pipework and exhaust gas silencer is not included in our scope of supplyand must be provided locally.

First fillingThe first filling of genset, (lube oil, engine jacket water, anti freeze-, anti corrosive agent, battery acid) isnot included in our scope of supply.

The composition and quality of the used consumables are to be strictly monitored in accordance with the"Technical Instructions" of GE JENBACHER.

Suitable bellows and flexible connections must be provided locally for all connections.Cables from the genset must be flexible.

5.02 Factory tests and inspections

The individual module components shall undergo the following tests and inspections:

5.02.01 Engine testsCarried out as combined Engine- and Module test according to DIN ISO 3046 at GE Jenbacher testbench. The following tests are made at 100%, 75% and 50% load, and the results are reported in a testcertificate: Engine output


Fuel consumption Jacket water temperatures Lube oil pressure Lube oil temperatures Boost pressure Exhaust gas temperatures, for each cylinder

5.02.02 Generator testsCarried out on test bench of the generator supplier.

5.02.03 Module testsThe engine will be tested with natural gas (Russian Natural gas with methane number 94). The technicaldata according to the specification can only be demonstrated to a certain extent with the available naturalgas.Carried out as combined Engine- and Module test commonly with module control panel at GE Jenbachertest bench, according to ISO 8528, DIN 6280. The following tests are made and the results are reportedin a test certificate:Visual inspection of scope of supply per specifications. Functional tests per technical specification of control system. Starting in manual and automatic mode of operation Power control in manual and automatic mode of operation Function of all safety systems on module

Measurements at 100%, 75% and 50% load: Frequency Voltage Current Generator output Power factor Fuel consumption Lube oil pressure Jacket water temperature Boost pressure Mixture temperature Exhaust emission (NOx)

The module test for operating frequenzy 50 Hz and 6,3-6,6kV / 10,5kV-11kV will be carried out with theoriginal generator, except it is not possible because of the delivery date. Then a test generator will beused for the module test.To prove characteristics of the above components, which are not tested on the test bench by GEJENBACHER, the manufacturers certificate will be provided.

5.03 Documentation (1/plant)

Preliminary documentation 60 days after receipt of a technically and commercially clarified order: Module drawing 1) Technical diagram 1) Drawing of control panel 3) List of electrical interfaces 2) Technical specification of control system 2)


Technical drawing auxiliaries (if included in GE Jenbacher-limit of delivery) 1)

At delivery: Wiring diagrams 3) Cable list 3)

At start-up and commissioning (or on clients request): Operating and maintenance manual 4) Spare parts manual 4) Operation report log 4)

Available Languages

1) GBR2) GBR3) GBR4) GBR

Documents

Tech Description Cogen Unit