Thermal energy balance

                                                                      kW                              4706
Intercooler                                                       kW                              475
Lube oil                                                           kW                              245
Jacket water                                                    kW                              394
Exhaust gas total                                             kW                             1371
Gear box                                                         kW                              24
Exhaust gas cooled to 180 °C                           kW                              832
Exhaust gas cooled to 100 °C                           kW                              1112
Radiation Heat (engine)                                    kW                              127
Balance heat                                                   kW                               94

Exhaust gas data
                                                                                         °C                         410
Exhaust gas mass flow rate, wet                                          kg/hr                     11.771
Exhaust gas mass flow rate, dry                                          kg/hr                    11.010
Exhaust gas volume, wet                                                     Nm3/h                   9.314
Exhaust gas volume, dry                                                      Nm3/h                    8.368
Max.admissible exhaust back pressure after engine               mbar                      60
Combustion air mass flow rate                                              kg/h                     11.432
Combustion air volume                                                         Nm3/h                  8.842

Max. admissible pressure drop in front of intake-air filter ___ mbari __________ 10
base for data: natural gas: 100% CH4; biogas 65% CH4, 35% CO2

Output / fuel consumption
                                                                                                 kW                     2000
Mean effe. press. at stand. power and nom. speed                         bar                     16,03
Fuel gas type                                                                                                        NATURAL GAS
Based on methane number                                                          MN d)                  75
Compression ratio                                                                       Epsilon                11.00
Min. fuel gas pressure for the pre chamber                                    bar                       2,7
Min./Max. fuel gas pressure at inlet to gas train                             mbar                    80 - 200
Allowed Fluctuation of fuel gas pressure                                        %                        ± 10
Max. rate of gas pressure fluctuation                                            mbar/sec              10
Maximum Intercooler 2nd stage inlet water temperature                 °C                         40
Specific fuel consumption of engine                                              kWh/kWh              2,35
Specific lube oil consumption                                                       g/kWh                   0.3
Max. Oil temperature                                                                   °C                         80
Jacket-water temperature max.                                                     °C                         95
c) Lower gas pressures upon inquiry
d) based on methane number calculation software AVL
3.1

Sound pressure level
                                                                             dB(A) re                                   101
                                                                                20µPa

31,5 Hz                                                                  dB                                            83
63 Hz                                                                     dB                                            90
125 Hz                                                                   dB                                            96
250 Hz                                                                   dB                                            98
500 Hz                                                                   dB                                            97
1000 Hz                                                                 dB                                            95
2000 Hz                                                                 dB                                            94
4000 Hz                                                                 dB                                            94
8000 Hz                                                                 dB                                            92

                                                                            dB(A) re                                    119
                                                                               20µPa

31,5 Hz                                                                 dB                                             109
63 Hz                                                                    dB                                             119
125 Hz                                                                  dB                                             128
250 Hz                                                                  dB                                             117
500 Hz                                                                  dB                                             115
1000 Hz                                                                dB                                             114
2000 Hz                                                                dB                                             111
4000 Hz                                                                dB                                             106
8000 Hz                                                                dB                                             91

Agg regate                                                            dB(A) re 1 pW                               123
Measurement surface                                             m2                                            130
Exhaust gas                                                         dB(A) re 1 pW                                127
Measurement surface                                             m2                                             6

a) average sound pressure level on measurement surface in a distance of 1 m according to DIN 45635, precision class 2.
b) average sound pressure level on measurement surface in a distance of 1 m(converted to free field) according to DIN 45635, precision class 3.
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
                                                                                                                             STAMFORD
Type                                                                                                                      LVSI 814 D2
Type rating                                                             kVA                                          3,375
Driving power                                                          kW                                           2000
Ratings at p.f.= 1.0                                                 kW                                           1938
Ratings at p.f.= 0.8                                                 kW                                           1928
Rated output at p.f.= 0.8                                         kVA                                           2410
Rated current at p.f.= 0.8                                        A                                               2902
Frequency                                                             Hz                                             50
Voltage                                                                 V                                              400 - 480
Speed                                                                   rpm                                          1,500
Permissible overspeed                                            rpm                                          2,160
Power factor lagging                                                                                               0,8 - 1,0
Efficiency at p.f.= 1.0                                             %                                             96.9%
Efficiency at p.f.= 0.8                                             %                                             96.4%
Moment of inertia                                                  kgm2                                         107,80
Mass                                                                   kg                                              5955
Radio interference level to VDE 0875                                                                        N
Construction                                                                                                          B3/B14
Protection Class                                                                                                    IP 23
Insulation class                                                                                                      F
Maximum ambient temperature                              °C                                              40
Total harmonic distortion                                        %                                              1.5

Reactance and time constants
                                                                            p.u.                                           1.38
xd' direct axis transient reactance                           p.u.                                           0.16
xd'' direct axis sub transient reactance                    p.u.                                           0.11
Td'' sub transient reactance time constant               ms                                             20
Ta Time constant direct-current                              ms                                             80
Tdo' open circuit f, ield ,, tim,, e constant                         s                                               3.90

0.03.01 TECHNICAL DATA OF GEAR, BOX
                                                                                                                             EICKHOFF
Type                                                                                                                     ANO - 090
Gearbox ratio                                                                                                        1:1.2
Efficiency                                                             %                                              appr. 98.30
Mass                                                                   kg                                              appr. 1043

0.5 COOLING WATER CIRCUIT
Nominal output                                                                          kW                        126
Max. inlet cooling water temperature (intercoole r)                        °C                          40
Aftercooler water flow rate                                                           m3/h                      30
Design pressure of cooling water                                                 bar                        16
Intercooler water pressure drop                                                    bar                        0,20
Intercooler water connection                                                        in                          2½''

Nominal output
Max. Oil temperature                                                                  kW                        245
Design pressure of cooling water                                                  °C                         80
Loss of nominal pressure of cooling water                                     bar                        16
Cooling water connection                                                             bar                        0,40

                                                                                                   in                         4''                                                                                       
Nominal output                                                                            kW                       394
Max. engine jacketwater temperature (outlet en gine)                      °C                         90
Engine jacket water flow rate                                                         m3/h                     60
Loss of nominal pressure of engine jacket water                              bar                        0,4
Design engine jacket water pressure                                              bar                        16
Engine jacket water connection                                                     in                           4''
Intercooler - heat 2nd stage without gearbox
                                                                                                  kW                        349
Design pressure of cooling water                                                   bar                        16
Cooling water connection                                                              in                           4''


0.10 TECHNICAL PARAMETERS
All data in the technical specification are based on engine full load (unless stated otherwise) at specified temperatures as well as the methane number and subject to technical development and modifications. For isolated operation an output reduction may apply according to the block load diagram. Before being able to provide exact output numbers, a detailed site load profile needs to be provided (motor starting curves, etc.).

All pressure indications are to be measured and read with pressure gauges.
(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%
(3)Average value between oil change intervals according to maintenance schedule, without oil change amount
(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

Radio interference level
The ignition system of the gas engines complies the radio interference levels of CISPR 12 and EN 55011 class 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 the manufacturer. Power determined under the operating conditions of the manufacturer’s test bench and adjusted to the standard reference conditions.
-  Standard reference conditions:
       Barometric pressure:                   1000 mbar or 100 m above sea level
       Air temperature:                          25°C or 298 K
       Relative humidity:                        30 %

Output adjustment for turbo charged engines:
Altitude:                                            0.7% for every 100 m above 500 m
Air temperature:                                 0.5% for every 1°C above 25°C

In special cases the engine may be adjusted to the conditions of the installation site (i.e., temperature, altitude).

If the actual methane number is lower than the specified, the knock control responds. First the ignition timing is changed at full rated power. Secondly the rated power is reduced. This functions are done by the engine management.

Parameters for the operation of Jenbacher AG gas engines
The following "Technical Instruction of JENBACHER AG" forms an integral part of a contract and must be strictly observed: TI 1100-0110-TI 1100-0112

1.00 SCOPE OF SUPPLY - GENSET
Design:
The genset is built as a compact package.
Engine and generator are connected through coupling and are mounted to the base frame. To provide the best possible isolation from the transmission of vibrations the engine is mounted to the frame by means of anti-vibrational mounts. The remaining vibrations are eliminated by mounting the module on isolating pads (e.g. Sylomer). This, in principle, allows for placing of the genset to be 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 and electronically controlled air/gas mixture system. The engine is equipped with the mostadvanced
                          LEANOX® LEAN-BURN COMBUSTION SYSTEM
developed by JENBACHER AG.

1.01.01 ENGINE DESIGN
Engine block
Single-piece crankcase and cylinder block made of special casting, crank case covers for engine inspection, welded steel oil pan.

Crankshaft and main bearings
Drop-forged, precision ground, surface hardened, statically and dynamically balanced; main bearings (three-component friction bearings) arranged between crank pins, drilled oil passages for forced-feed lubrication of connecting rods.

Vibration damper
Maintenance free viscous damper

Flywheel
With ring gear for starter motor

Connecting rods
Drop-forged, heat-treated, big end diagonally split and toothed. Big end bearings (three-component friction bearing) and connecting rod bushing for piston pin.

Cylinder liner
Chromium alloy gray cast iron, wet, individually replaceable.

Cylinder head
Specially designed and developed for JES-lean burn engines with optimized fuel consumption and emissions; water cooled, made of special casting, individually replaceable; Valve seats and valve guides and spark plug sleeves individually replaceable; exhaust and inlet valve made of high quality material.

Crankcase breather
Connected to combustion air intake system

Valve train
Camshaft, with replaceable bushings, driven by crankshaft through intermediate gears, valve lubrication by splash oil through rocker arms.

Combustion air/fuel gas system
Motorized carburetor for automatic adjustment according fuel gas characteristic. Exhaust driven turbocharger, mixture manifold with bellows, water-cooled intercooler, throttle valve and distribution manifolds to cylinders.

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

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

Engine cooling system
Jacket water pump complete with distribution pipe work and manifolds.

Exhaust system
Turbocharger and exhaust manifold

Exhaust gas temperature measuring
Thermocouple for each cylinder

Electric actuator
For electronic speed and output control

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

Starter motor
Engine mounted electric starter motor

1.01.02 ENGINE ACCESSORIES
Insulation of exhaust manifold:
Insulation of exhaust manifold is easily installed and removed

Sensors at the engine:
 Contact less magnetic inductive impulse sensor
 Jacket water temperature sensor
 Jacket water pressure sensor
 Lube oil temperature sensor
 Lube oil pressure sensor
 Mixture temperature sensor
 Charge pressure sensor
 Minimum and maximum lube oil level switch
 Exhaust gas thermocouple for each cylinder
 Knock sensors
 Carburetor position control
 Throttle valve position control

Actuator at the engine:
 Actuator - throttle valve
 Bypass-valve for turbocharger
 Carburetor drive

Commissioning spare parts:
First equipment with necessary spare parts for operation after commissioning.
 Spark plug sealing rings (20 pieces)
 Spark plugs (6 pieces Denso or 1 set RB75N)
 Spark plug carrier (1 piece)
 Ignition coil (1 piece)
 Valve (1 piece)
 Thermo element (Cylinder exhaust gas temperature
     ( 1 piece)
 Sealing ring (1 piece)

1.01.03 STANDARD TOOLS (1/PLANT)
Standard tools
    •  Tools for spark plugs (special socket, extension, torque
     wrench)
•  Tools for removal of oil filter cartridges
    •  Feeler gauges
    •  Feeler gauge 0.35 mm
    •  1 wrench 7 x 19
    • Screwdriver 10
    • Grease gun
    • Measuring device for valve wear
    • est equipment for DISN-ignition
    • Strobe light
    • Digital hand manometer
    • Oscilloscope
    • Adapter for measurements (BNC-BNC, MIL-ZZP)
    • Never-Seez Nickel Special Grade
    • Pointed pliers (cornered)
    • Box for tools

1.02 SELF-EXCITED SELF-REGULATED THREE PHASE GENERATOR
The generator consists of the main generator (built as rotating field machine), the exciter machine (built as rotating armature machine) and the voltage regulator with cos. phi-regulator, which is powered by a permanent magnet pilot exciter.

Main components
• Main stator with frame
• Main stator with 2/3 pitch winding to eliminate neutral currents of 3rd order
• Terminal box includes main terminals plus auxiliary terminals for thermistor connection and control of 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 with permanent pilot exciter
• Power factor controller
• Voltage regulator

Electrical data and features
• Voltage adjustment:                                               400 �?480 Volt
• 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 34 - I/VDE 0530
• According 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 thermistors for winding temperature monitoring

1.03 MODULE ACCESSORIES
Base frame
Welded of structural steel to mount engine, generator, and jacket water heat exchangers.

High elastic coupling
To couple engine with gear box. The coupling isolates the major sub harmonics of engine alternating torque from gear box.

Coupling
With torque limiter to couple gear box with alternator.

Coupling housing
To cover the two couplings

Anti-vibration mounts
Arranged between engine/generator assembly and base frame. Insulating pads (SYLOMER) for placement between base frame and foundation, delivered loose.

Gear box:
Single-stage spur gear with overhead shaft and lube oil system, completely mounted on the base frame. The lube oil heat exchanger is integrated with the warm/cooling water circuit.
The gear transmission ratio is 1:1.2

Exhaust gas connection
Connection of exhaust gas turbocharger; including flexible connection to compensate for expansions and vibrations.

Combustion air filter
Dry type air filter with replaceable filter cartridges, including flexible connection to carburetor and service indicator.

Interface panel
The following description represents Jenbacher standards. Options which have been included in our offer are not necessarily listed below.
Totally enclosed sheet steel cubicle with front door, wired to terminals, ready to operate. Cable entry at bottom.
Painting:                                                              RAL 7032
Protection:                                                           IP 54 external
                                                                           IP 10 internal
                                                                           (protection against direct contact with alive parts)
Design according to IEC 439-1 (EN 60 439-1/1990) and DIN VDE 0660 part 500, respectively.
Ambient temperature: 5 - 40 °C
                                70%

• Height:                                      1000 mm
• Width:                                       1000 mm
• Depth:                                       300 mm
Power supply from the starter battery charger.

Power distribution to the engine mounted auxilliaries (power input from the supplier of the auxiliaries power supply):
3 x 480/480 V, 270 Hz, 50 A

Essential components installed in interface panel: x
Strip terminal
• Decentralized input and output cards, connected by an RS 485 interface to the central engine control at the module control panel.
• Speed monitoring with switch point for overspeed (monitored by overspeed relays and the central engine control)
• Relays, contacts, fuses, engine contact switches to control valves, and auxiliaries.
• Measuring transducer for excitation voltage

1.03.01 ENGINE JACKET WATER SYSTEM
Engine jacket water system Closed
cooling circuit, consisting of:
• Expansion tank
• Filling device (check and pressure reducing valves, pressure gauge)
• Safety valve(s)
• Thermostatic valve
• Required pipe work 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 be provided for engine shut-down at lube oil levels "MINIMUM" and "MAXIMUM". Solenoid valve in oil feed line is only activated during engine operation. Manual override of the solenoid valve, for filling procedure during oil changes is included.

Oil drain
By set mounted cock; carried out with a separate flexible tube

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.
Consisting of:
• 1 piece oil pump 1500 W, 400V
• 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:
- Manual ball valve
- Gas filter, filter fineness <3 µm
- Adapter with dismount to the pre-chamber gas train
- Gas admission pressure regulator
- Pressure gauge with push button valve; 0-87 psi (0-6 bar)
- High pressure regulator with safety-cut-off-valve (SAV)
- Calming distance with reducer
- Safety-blow-off-valve (SBV)
- Pressure gauge with push button valve; 0-1.45 psi (0-100 mbar)
- Solenoid valves
- Gas pressure regulator
- Gas pressure switch (min., max.)
Maximum distance from gas train outlet to gas entry on engine, including flexible connections, is
78 in (2 m).
• Pre chamber gas train:
- Manual ball valve
- Gas filter, filter fineness <3 µm
- Solenoid valve
- Pressure regulator
- Calming distance with reducer
- Pressure gauge with push button valve; 1-5 bar

1.07 PAINTING
• Quality:                                     Oil resistant prime layer
                                                   Synthetic resin varnish finishing coat
• Color:                                       Engine:                            RAL 6018 (green)
                                                   Base frame:                     RAL 6018 (green)
                                                   Generator:                       RAL 6018 (green)
                                                   Module interface panel:     RAL 7032 (pebble gray)
                                                   Control panel:                   RAL 7032 (pebble gray)


1.11 ENGINE GENERATOR CONTROL PANEL - DIA.NE
delivered loose
Dimensions:
• Height: 2200 mm [including 200 mm pedestal]
• Width: 800 mm
• Depth: 600 mm
External supply of control power from starter and control batteries.
Battery is rated at 24 V DC (tolerance: min. 22 V, max. 30 V, including waviness Uppmax. 3.6 V)
Consisting of:
• Dia.Ne (Dialogue Network) motor management system
System elements:
                                                            a) Visualization PC
                                                            b) Central engine and module control
  a) Visualization PC:
      Industrial PC (80486) with 10�?VGA TFT color graphics display, 10 function keys, display*
      selection keys, 10-key numeric keyboard for parameter input, auxiliary keys for START,
      STOP, lamp test and special functions.
      RS 485 Interfaces to the central computer and multi-transducer
      System of protection: IP 65 (front), acc. IEC
      Dimensions: W x H x D= approx. (310 x 470 x 95 mm)
A clear and functional graphic compilation of measured values is displayed on the screen. User prompts are by means of direct-acting display* selection keys and function keys.

      Main displays:
      Generator interconnection, with electrically measured variables and display of excitation voltage, Option: (generator winding temperature and generator bearing temperature displays.)
      Oil and engine cooling water circuits, with displays of oil pressure and temperature, and cooling water pressure and temperature.
      Exhaust gas temperatures in a column graph which also displays the average temperature.
      Main engine controller
      Module auxiliary controller
      Auxiliary systems (status display)
      Operational data, i.e. operating hours, service hours, number of starts, active power demand (kWh), reactive power demand (kVArh), and measured values for operational logbook.
      System display, i.e. time, password, brightness, contrast, diagnostics.
      Graphic trending display of up to 16 measured values:
      Long term trending (1 month at a storage interval of 30 sec.)
      Short term trending (20 min. at a storage interval of 1 sec.) - stopped and stored in the event of a malfunction.

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

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

  b) Central engine and module control:
      A real-time, modular industrial control system which handles all jobs for module and engine-side sequencing control (start preparation, start, stop, aftercooling, control of auxiliaries), as well as all control functions.
Interfaces:
RS 485 to the decentralized I/O component group in the module interface panel.
RS 485 to the visualization processor and multi-transducer

     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 setpoint 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
  Connection to the central computer is through an RS 485 interface.
  An additional 0 - 20 mA output is produced for active power, as well as a pulse output for active power demand.
  The following alternator supervisions are integrated with the multi-transducer (max. 8
  functions simultaneous):
  - Overload/short-circuit [51], [50]
  - Over voltage [27]
  - Undervoltage [59]
  - Asymmetric voltage [64], [59N]
  - Unbalance current [46]
  - Failure Exitation [40]
  - Overfrequency [81>]
  - Underfrequency [81 <]
• Lockable operation mode selector switch positions:
    "OFF" No operation is possible, running set will shut down;
    "MANUAL" Manual operation using start stop buttons; set is not available for fully
    automatic operation.
                                         "AUTOMATIC" Fully automatic operation, according to
                                         remote demand signal:
                                                  Automatic start
                                                  Fully automatic operation at full load
                                                  Stop with cooling down run for 1 minute
                                                  Continuous operation of auxiliaries for 5 minutes after
                                                  engine shutdown
• Demand switch with the posit, ions:
   External demand OFF
   External demand
   Override external demand

 Shut-down functions with display:
• Low lube oil pressure x Low lube oil
level
• High lube oil level
• High lube oil temperature
• Low jacket water pressure
• High jacket water pressure
• High jacket wat, e, , r tem, perature
• Overspeed
• Emergency stop/safety loop
• Gas train failure
• Start failure
• Stop failure
• En, gine 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
• Synchronizing 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 "ON"

Interfaces �?engine generator control panel
Remote signals (potential free contacts)
1 NO = 1 normally open
1 NC = 1 normally closed
1 COC = 1 change over contact
Ready for automatic start (to Master control)    &, nbsp;                                                  1NO
Operation (engine runs)                                                                                      1NO
Collective signal "shut down"                                                                              1NC
Collective signal "warning"                                                                                  1NC

External (by others) provided command/status signals:
• Engine starting demand (from Master control)                                                      1NO
• Low warm water flow                                                                                          1COC
• High warm water temperature, if applicable                                                          1COC
• High warm water pressure, if applicable                                                               1COC

1.20.01 STARTING SYSTEM
Starter battery
4 piece flooded lead acid battery with 12 cells, 24 V, 330 Ah (according to DIN 72311), complete with cover plate, terminals and acid tester

Battery charging equipment (JES LTD)
For boost and trickle charging of the lead acid battery with 12 cells and for the automatic supply of all connected D.C. consumers with a constant voltage in the load range of 0-100 % nominal current, equalizing at the same time variations of mains supply voltage and frequency. The equipment works according to a I/U characteristic (UL listed). The trickle charging voltage is automatically kept constant up to the level that overload provokes a limitation of current.

                                                                                                                 240 V, +/- 10 %
  Frequency                                                                                                50 Hz, +/-5 %

• Battery connection
     Nominal D.C. voltage                                                                             24 V
     Constant voltage for trickle charging                                                        26.8 V +/-1 %
     Constant voltage for boost charging                                                         28.2 V +/-1 V
     Max. charging voltage for automatic recharging                                        28.2 V
     Max. charging voltage for manual charging                                              33 V
     Changing of characteristic                                                                     automatic
     Nominal current (max.)                                                                         50 A +/-2 %
     Output ripple                                                                                         < 1200 mV

• General data
  Dimensions (for reference only)                                                                 406x483x313mm
  Ambient temperature                                                                               -5 °C to +40 °C
  Protection                                                                                               IP 21
  Cooling                                                                                                   self ventilated
  Color                                                                                                       ANSI grey
  Installation                                                                                               dry,dust-free to 4921 ft
                                                                                                                (1500 m)

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 56°C and 60°C, to allow for immediate loading after engine start.

1.20.04 FLEXIBLE CONNECTIONS
delivered loose
Following flexible connections per module are included in the Jenbacher AG -scope of
supply:
Connection                                          Unit                       Dimension                 Material
2 Warm water in-/outlet                        in/lbs                     4''/232                       Stainless steel
1 Exhaust gas outlet                            in/lbs                     20''/145                     Stainless steel
1 Fuel gas inlet                                    in/lbs                     3''/232                       Stainless steel
2 Intercooler in-/outlet (2)                      in/lbs                     2½''/232                    Stainless steel
2 Lube oil connection                           in                                1                         Hose
Sealings and flanges for all flexible connections are included.

2.00 ELECTRICAL EQUIPEMENT
2.01 MULTIPLE SYNCHRONIZING AUTOMATIC
delivered loose
With voltage balance
For automatic synchronization of 2-5 modules with the mains in PLC-technology.
Dimensions:
• Height:                                            2200 mm [including 200 mm pedestal]
• Width:                                             800 mm
• Depth:                                             600 mm
Consisting of:
• Lockable synchronizing mode selector switch with positions "MANUAL-0FF-AUTOMATIC"
- AUTOMATIC:    Automatic module synchronization after synchronizing release from the control panel
- MANUAL:         Module must be actuated for synchronization by the synchronization selector push button; the synchronization procedure is carried out automatically
- 0FF:                Synchronization is locked out.
• Freely programmable microprocessor, for fully automatic demand synchronizing, synchronization of each module and monitoring of "CIRCUIT BREAKER ON" signals.
  Logic for monitoring of:
  - Non-logic breaker positions
  - Switch "ON" trouble
  - Switch "OFF" trouble
• Automatic synchronizing device with three-point output for electronic speed governor adjustment with double voltmeter, double frequency meter and synchronoscope
• Luminous headed push button for synchronizing selection. To indicate the synchronizing selection with synchronizing mode selector switch in the AUTOMATIC position. To select synchronization with synchronizing mode selector switch in the MANUAL position
• Control switch for manual operation of the generator circuit breaker, with the synchronizing mode selector switch in the MANUAL position
• Required relays for control and monitoring

Operational indications for:
  • Generator circuit breaker CLOSED
  • Synchronizing selection
  • Mains circuit breaker CLOSED
  • Mains in order

Fault indications for:
  • Mains failure
  • Circuit breaker failure, i.e. switching ON / switching OFF problem

Remote signals
Dry contacts
• Generator circuit breaker CLOSED                                                  1 NO

The following signals must be made available by the supplier of the generator
switchgear:
    Generator circuit breaker ON                                                           1 NO
  • Generator circuit breaker OFF                                                         1 NC
  • Utility tie breaker ON                                                                      1 NO
  • Utility tie breaker OFF                                                                    1 NC
  • Generator circuit breaker READY TO CLOSE                                   1 NO
  • Mains voltage 3 x 120 V
  • Bussbar voltage 3 x 120 V
  • Generator voltage 3 x 120 V
The following signals are wired potential free to terminals by Jenbacher AG for the
supplier of the generator switchgear:
  • CLOSING/OPENING command for generator circuit breaker (permanent contact)  1 NO + 1 NC
  • Trip signal connected to undervoltage trip of C.B.                                        1 NO
Voltage converter at star-star connection with min. 50 VA and Kl.1.

2.01.01 RESYNCHRONIZING AUTOMATIC
(Built into the synchronizing module)
For automatic resynchronizing of 5 modules with the mains, using PLC-technology.
Control switch for manual opening and first closing of the mains circuit breaker with the mode selector switch in the MANUAL position.
Function:
Automatic resynchronizing of the modules after return of the utility power supply, with the mode selector switch in the AUTOMATIC position.
Manual initiation of resynchronizing of the modules is by push button, after which resynchronizing is done automatically.
Automatic closing of the mains circuit breaker at the moment of synchronizing.
Operational indications for:
  • Mains circuit breaker                   CLOSED
  • Resynchronizing selection
Fault indications for:
Overload/short circuit mains circuit breaker
Remote signals
(Potential free contacts)
(Maximum contact load: 3 A at 24 V DC)
Mains circuit breaker                      CLOSED                               1 NO
Mains disturbed                                                                          1 NO
The following signals must be made available by the supplier of the main circuit breaker
board:
     Mains circuit breaker                 Ready for CLOSURE               1 NO
   • Mains circuit breaker                CLOSED                                 1 NO
   • Mains circuit breaker                OPENED                                 1 NC
   • Mains circuit breaker                Overload/short circuit                1 NO
   • Mains circuit breaker                Local/remote selector switch      1 NO
   • Mains voltage 3 x 120 V

The following signals are wired potential free to terminals by Jenbacher AG for the
supplier of the mains circuit breaker board:
  • Closing/opening command for mains circuit breaker (permanent contacts)        1 NO + 1 NC

2.02 GRID MONITORING DEVICE
Function:
For immediate disconnection of the generator from the grid power, in case of grid failures.
Consisting of:
  • High/low voltage monitoring
  • High/low frequency monitoring
  • Protection monitoring against micro-interruptions of the grid
Scope of supply:
Digital grid protecting relay with storage of defect datas, indication of reference dimensions as well as monitoring by itself.

2.04 GENERATOR SWITCHGEAR (LOW VOLTAGE)
Delivered loose
Enclosure & Mounting
  • Single freestanding Nema 1 enclosure painted ASA61 Grey
  • Silver plated copper bus
  • Full length copper ground bus
  • Fully rated solid neutral
  • Provision for front and LHS access only c/w top entry and bottom exit
  • Internal DC Panel light
Protective Relays
  • GE/Multilin SR489 Multifunction Generator Protection Relay c/w
    24, 27, 32, 40, 46, 47, 49, 51 V, 51 G, 59, 81 O/U, 87G
    Analog O/P signals wired to terminals
    RS 232/485 Communication ports c/w Modbus RTU protocol
  • 86 Lockout relay
Circuit Breaker
• Merlin Gerin Masterpact 3000Amp, 3P, 480V Drawout Type Air Circuit Breaker c/w
-UL489listed
- Safety shutters
- 65KAIC at 480VAC
- 24VDC motor operator
- 24VDC shunt trip and close coil
- 24VDC undervoltage release
- Cradle switch
- Auxiliary contacts (2 N/O, 2 N/C)
- Line and Load Lugs
Measurement
• 400/480:120VAC, 500VA thermal, line side potential transformer, accuracy 0.3 W, X, M and 0.6Y(Qty. 2)
• 400/480:120VAC, 500VA thermal, load side potential transformer, accuracy 0.3 W, X, M and 0.6Y(Qty. 2)
• Current Transformer, Relay Class C50 (Qty. 6)
• PT test block (Qty. 2) and CT shorting type terminals
• Miscellaneous wire, terminal blocks and fuses etc. as required

2.06 MOTOR CONTROL PANEL
delivered loose Nema
standard design
• Electrical engine prehating control
• Pre lub pump control
• Jacket water and jacket water bybass control
Gear box cooling water pump and contol

2.10 MASTER CONTROL
delivered loose
Base procedure
                                              P R I O R I T Y E L E C T R I C I T Y
                                              M A I N S I M P O R T / E X P O R T �?P OWE R C O N T R O L
Dimensions:
  • Height:                               2200 mm [including 200 mm pedestal]
  •Width                                 1200 mm (two doors)
  • Depth                                 600 mm
Control power supply (by supplier of the control power supply unit) from the battery 24 V DC, 16
A(tolerance: min. 22 V, max. 30 V, including waveness Upp 3.6 V minus-grounded).
Auxiliary power supply (by the supplier of the auxiliary power supply unit): 400/230V, 50Hz, 16 A.

Purpose:
The "Master control" is assigned for automatic starting/stopping of the individual modules, and for the unit control power default, with respect to the plant’s mains power consumption.
Scope of supply:
The following essential components are included:
• Programmable controller
• Necessary coupling relays
• Visualization
• Terminal strip for incoming and outgoing cables (scope of supply)
Visualization PC:
Graphical operating and display area for the display of messages and measured data of the master control and for the display and input of adjust parameters for the master control.
Hardware:
  • Industrial PC (80486) for the installation in the switch cabinet
  • 10,4" VGA TFT color graphics display
  • 10 function keys, display selection keys, 10-key numeric keyboard for parameter input
  • Interface to the PLC
  • Protection class: IP 65 (front)
  • Dimensions: W x H x D= approx. 310 x 385 x 140mm (12 x 15 x 5,5 in)
Software:
    A clear and functional graphic compilation of measured values is displayed on the screen. User prompts are by means of direct-acting display selection keys and function keys.
Assumptions:
  • The hydraulic integration of the units, the bypass of the surplus heat as well as the complete heater control must be finalized on-site, per JENBACHER-hydraulic diagram E 9684.
  • Return temperature: the nominal value may not be exceeded. Permissible deviation (-20°C).
    Permissible change velocity max. (10°C)/minute.
Function:
  • Addition and shutdown of the units
     Addition and shutdown of the units is performed in accordance with the current demand of
     the plant with the
                                            TOTAL CONSUMERS POWER
    of the plant as switching criteria.
    The measured value acquisition of the mains power consumption is performed by an on-site measuring transducer (0/4 - 20 mA, potential free measured signal). The total consumers power of the plant is formed at the PLC by summation of the actual mains power consumption and the output of the modules. The setpoints for switching on and off each module are adjustable, depending on the total consumers power
  • Power adjustment:
    The power adjustment of the units is performed such that the mains import/export power is used on a constantly adjustable set value. The running units perform within the load range of 50 - 100 % nominal load, with equal load distribution between the units.
  • Time intervals:
    Between two additions and shutdowns of the units, minimum (adjustable) dead time is observed.
  • Unit sequencing:
    The unit sequencing is based upon operating hours and availability.
Monitoring / fault messages, displays/operational messages:
  • Monitoring / fault messages
    - Measuring signal fault
    - High unit return temperature (on-site sensor with potential free contact)
    - Low PLC buffer battery voltage
    - Bus system failure *)
    - Message printer failure *)
    - CPU fault master control
  • Displays / operational messages
    - For each unit:
      Operational hours (with possibility of correction of the counter quantity)
      Electrical output -set value and actual value
    - Operational condition of the plant:
      Mains import/export power - set and actual values
      Total power consumers
Remote control messages
(potential free contacts):
CPU fault master control
Collect fault master control
Only with "Protocol printer and data bus " option! (not possible at J 156 !)

3.01 LUBE OIL SYSTEM (1/PLANT)
delivered loose
Consisting of:
  • 1000 l waste oil tank
  • 1000 l fresh oil tank
  • level switches

3.03.01 EXHAUST GAS SILENCER
Delivered loose
Residual sound pressure level:
Critical grade
Material:
carbon steel
Consisting of:
• Exhaust gas silencer
• Flanges, seals, fixings

4.00 DELIVERY, INSTALLATION AND COMMISSIONING
4.01 Carriage/ prepaid port
Carriage of the complete scope of supply to the installation site is not included in our price.

4.02 Unloading
Unloading, moving of equipment to point of installation, mounting and adjustment of delivered equipment on intended foundations is not included in our price.

4.03 Assembly and installation
Assembly and installation of all components is not included in our scope of supply.

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

4.05 Start-up and commissioning
Start-up and commissioning with the M+M start-up and commissioning checklist is included.

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

4.07 Emission measurement (exhaust gas analyser)
Emission measurement by M+M personnel, to verify that the guaranteed toxic agent emissions have 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 water
At inlet and outlet flanges on genset
Exhaust gas
At outlet flange of the genset
Combustion air
The air filters are set mounted
Fuel gas
  • At inlet and outlet flange of gas train
  • At inlet flange of gas pipework on genset
Lube oil
At lube oil connections on genset
Draining connections and pressure relief
At genset
Insulation
Insulation of heat exchangers and pipework is not included in our scope of supply and must be provided locally.
First filling
The first filling of genset, (engine jacket water, lube oil, anti freeze-, anti corrosive agent, battery acid) is not 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.
Cables from the genset must be flexible.

5.02 FACTORY TESTS AND INSPECTIONS
The individual module components has undergone the following tests and inspections:
5.02.01 Engine tests
Carried out according to DIN 3046 at Ge JENBACHER test brench. The following tests are made at 100%, 75% and 50% load.
  • 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 tests
Has been carried out on the premises of the generator supplier.
5.02.03 module tests
Has been carried out with module control panel at Ge JENBACHER test bench, according to DIN 6280, DIN 8528. The following tests are made and the results are reported in 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)

5.03 DOCUMENTATION
  • Appr. 6 weeks after meeting with the customer on site: (when we can get all necessary information we need to know!!)
    - plant layout
    - Module drawing
    - Technical diagram
    - Drawing of control panel
    - List of electrical interfaces
    - Technical specification of control system
    - Assembly drawings for auxiliaries
    - Cable list
    - Technical drawing auxiliaries (if included in Ge Jenbacher -limit of delivery)
  • At delivery:
    - Wiring diagrams
  • At start-up and commissioning (or on clients request):
    - Operating and maintenance manual
    - Spare parts manual
    - Operation report log