pltmg prabumulih 18v34sg rev.3 operasi
TRANSCRIPT
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GAS ENGINE POWER PLANT
Operation & Maintenance Course
18V34SG
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DAFTAR ISI
A. PendahuluanA. Ragam jenis mesin gas
B. Proses pada mesin gasC. Data utama mesin gas (Wartsila 18V34SG)
B. Komponen utamaA. Block bearing & oil sump
B. Head
C. Piston & Connection rod (conrod)
D. Liner
E. Crankshaft
F. Turbocharger
C. Sistem bahan bakar
D. Sistem udara pembakaran dan gas buang / Charge air (CA) and
exhaust gas (EG)
E. Sistem udara bertekanan / Compressed air system
F. Sistem pendingin / Cooling systemG. Sistem pelumas / Lubrication system
H. Prinsip operasi dan instrumentasi
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Operation
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OperationEngine Control System
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OperationSafety
Reminder Despite the safety system, there is a risk of gas
explosion. To avoid possible accidents, no-one
should remain in the engine room and
boiler/silencer room during an engine start.
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OperationStart, Stop and Operation
Turning device Starting air system maximum pressure 30 bar
compressor starts at 24 bar
alarm at 18 bar draining of the system
Starting motors
design
Control air system wastegate
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OperationStart
Start:
The start signal is given in the WOIS The HT-water temperature should be 50C
minimum
The ventilation of the exhaust pipe after theengine starts The test procedure for the gas regulating unit
starts. When finished, the shutoff valves on the
gas regulating unit will open.
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OperationStart
Required starting air pressure min. about 20 bar.
Both starting motors have to be connected beforethey are able to rotate.
At 50 rpm the gasvalves start to open and theignition starts to work
Check of speed increase will start At 150 rpm the starting motors will disconnect At 250 rpm the startmode is changed to runmode
At 350 rpm the prelub. pump stops. The HT-waterand alternator preheating will switch off. 750 rpm or 720 rpm = nominal speed
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OperationStart
Exhaust temperature check takes place afterreaching nominal speed
If the alternator does not synchronize within oneminute, the engine stops. Otherwise the enginecontinues to run and a 500 kW baseload is
immediately applied.
If the base load is not reached in one minute theengine stops.
The loading time to 100 % is about 15 minutes
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OperationStop
Stop:
The stop signal is given from the WOIS The load decreases to baseload within 7,5 minutes The gasvalves on the gasregulating unit and on the
engine close when the stopsignal is given. If there is
an emergency stop, the ignition will stop at the sametime
At 350 rpm the lub.oil priming pump starts. The HT-water and alternator preheating will switch on.
At 250 rpm the mode is changed from runmode tostopmode
At 50 rpm the ignition stops
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OperationOperation
Normal operation supervision
take performance data regularly exhaust temperatures, check the trends listen to the engine, knocking etc. check the wastegate function use a gas leak detector regularly check for cooling water and lube oil leaks check that the drain pipes of the charge air cooler
housing is open drain the starting air system before every start
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OperationRunning-In
Running after overhaul run the engine for about 5 minutes after firststart, check the temperatures of the con.rod andmain bearings
check for leakages running-in programme
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Control system
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WECS 3000
This topic describes the basics of WECS 3000
engine control & monitoring system. WECS
stands for Wrtsil Engine Control System. Itindividually controls and monitors each engine
cylinder.
Control systemPresentation on WECS 3000 on W34SG
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Control systemWartsila Operator Interface System
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Control systemWECS 3000 Layout
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Control systemComponent Layout of WECS 3000
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Control systemSide Covers for WECS Units
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Control systemWECS 3000
Function
Start and stop control Run control
Engine load & speed control
Air-fuel ratio control Combustion control
Monitoring and safety system handling
Communication with external systems
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Control systemWECS 3000
Main Components of WECS 3000
Main Control Unit (MCU x 1)
Cylinder Control Unit (CCU x 18)
Knock Detection Unit (KDU x 2)
Distributed Control Unit (DCU)
Sensor Multiplexing Unit (SMU)
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Control systemBlock Layout Connection of WECS 3000
C C ( C )
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Control systemMain Control Unit (MCU)
The MCU is the brain in the system. It receives and
interprets information sent by units controlling
references for ignition, gas pressure, gas injection
timing and duration.
It also handles tasks as the start and stop sequences,
speed/load control, charge air control, and the engine
safety system and monitoring.
The MCU also communicates with the plant control
system (PLC & WOIS).
Function of MCU
C t l t M i C t l U it (MCU)
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Control systemMain Control Unit (MCU)
Basic Specs Single height euroboard VME system including:
Rack with VMEbus Backplane
Processor Board
Digital I/O Board
Analogue I/O Board
CAN Interface Board Power Supply
32-bit MC68EC030 running at 40 MHz is responsible forthe engine control
16-bit MC68302 running at 16 MHz is responsible for the
Communication to/from the MCU Operating temperature: -40...+85 C Resilient mounting on the engine
C t l t M i C t l U it (MCU)
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Control systemMain Control Unit (MCU)
Summary of Functions
Start control Stop control Run control
Gas supply pressure control
Throttle valve control
Waste gate control Engine load & speed control
Knock control
Safety handling Fault shutdowns
Emergency stop Alarm handling Communication to external systems ( PLC & WOIS)
C t l t M i C t l U it (MCU)
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Control systemMain Control Unit (MCU)
Control s stem Main Control Unit (MCU)
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Control systemMain Control Unit (MCU)
Control system Cylinder Control Unit (CCU)
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Control systemCylinder Control Unit (CCU)
Control system Cylinder Control Unit (CCU)
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Control systemCylinder Control Unit (CCU)
Control system Cylinder Control Unit (CCU)
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Control systemCylinder Control Unit (CCU)
Basic Specs Comprises:
the CPU Board the I/O Board
32-bit microprocessor MC68332 16 MHz CAN-controller i82527
The CCU controls two cylinders, each Cylinder Comprising: one Ignition Unit
two Exh. Gas Temp. Sensors (in parallel)
two Cyl. Liner Temp. Sensors (in parallel)
the Main Gas Control Valve the PCC Gas Control Valve
Engine position signals to each CCU Operating temperature: -50...+85 C
Control system Cylinder Control Unit (CCU)
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Control systemCylinder Control Unit (CCU)
Handles all cylinder control and monitoringCCU controls and monitors two engine
cylinders
It consists of CPU Board and Input/Output
Board
It contains switch for checking condition of
main gas valve, pcc valve and spark plug. Also
contain 2 switches for ID.
Engine position signals to each CCU
Operating temperature: -50 to +85 oC
General Information
Control system Cylinder Control Unit (CCU)
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Control systemCylinder Control Unit (CCU)
Function of Cylinder Control Unit
Control of gas injection of 2 main gas admissionvalves
Control of gas injection of 2 pre combustionchamber admission valves
Control of ignition of 2 spark plugsMeasuring of 2 exhaust gas temperatures
Measuring of 2 cylinder liner temperatures
Reading of engine angular position and speed
send by rotary encorderReading of fuel demand (from the MCU)
Control system Cylinder Control Unit (CCU)
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Control systemCylinder Control Unit (CCU)
Control system Cylinder Control Unit (CCU)
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Control system Cylinder Control Unit (CCU)
Control system Potentiometers
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Control system Potentiometers
Control system Potentiometers
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Control system Potentiometers
Control system Potentiometers
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Control system Potentiometers
Control systemKnock Detection Unit (KDU)
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y ( )
Function of Knock Detection Unit
Used to measure the knock signals fromaccelerometers mounted on each cylinder head.
The KDU filtrates, amplifies and converts thesesignals to digital information and sends it over theCAN-bus to the MCU for further processing.
One KDU is designed to handle up to ninecylinders.
Control systemKnock Detection Unit (KDU)
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y ( )
Basic Specs Input signal from rotary encoderKnock intensity value to MCUComprises:
The CPU Board
Memory
A/D-converters
32-bit microprocessor MC68332 16 MHz
CAN-controller i82527
The I/O Board
filtering integration
Operating temperature: -50...+85 C
Control systemKnock Detection Phenomenon
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y
Control systemKnock Sensor
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y
Cylinder Head
Knock Sensor
Control systemDistributed Control Unit and Sensor Multiplexing Unit
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Function of Distributed Control Unit and
Sensor Multiplexing Unit
Used for measuring purposes (measuring of
sensors).
They convert different types of sensor signals todigital information which is sent over a network to the
MCU for further processing (data handling for Local
Display Unit).
Control systemDistributed Control Unit and Sensor Multiplexing Unit
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Control systemDCU and SMU Enclosure
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Control systemSensor Multiplexing Unit (SMU)
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Basic Specs Microprocessor based 10 analog inputs: pt100, t/c, 4-20 mA,
0-10 V, on/off, etc.
8 digital I/O connections
2 frequency inputs 1 current output 0-20 mA All channels software configurable Power supply: 24 VDC RS-485 serial interface Operating temperature: -50...+100 C
Control systemDistributed Control Unit (DCU)
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Basic Specs
Microprocessor based Comprises all features of the SMU Several serial interfaces:
CAN bus to other DCUs and to the MCU RS-485 bus to SMU chain RS-232 to PC / LDU
Power supply: 24 VDC
Operating temperature: -50...+85 C
Control systemLocation of Rotary Encoder
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Control systemRotary Encoder
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The rotary encoder is mechanically adjusted to give the
synchronization pulse when piston number A1 is in Top Dead
Centre (TDC) position at power stroke. This pulse is then used to
synchronize the ignition and the gas admission valve timing for allcylinders.
.
Control systemCamshaft with Rotary Encoder
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1. Camshaft piece 2. Bearing journal
3. Screw 4. Fixing pin
5. Rotary Encoder 6. End cover7. Axial Bearing
Control systemMeasuring Engine Speed
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Control systemMeasuring Engine Speed
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Two Engine Speed Sensors
1. Rotary EncoderA rotary encoder connected to the camshaft is themaster unit. The rotary encoder is used tocalculate engine angular position as well as enginespeed.
2. Engine Speed Pick-Up
The other speed sensor is an inductive proximityswitch installed at the camshaft gear.
This speed sensor is used as a redundantoverspeed protection device.
Control systemMeasuring Engine Speed
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Two Engine Speed Sensors Speed measured from the rotary encoder is
compared with the speed signal from the inductiveproximity switch in the MCU.
A shutdown is activated if a deviation in speed signals
is over 50 rpm.
Control systemRotary Encoder
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Control systemRotary Encoder
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Function
The encoder has two signal outputs.1. One which provide 900 pulses/camshaft revolutionand
2. the other one providing one synchronization
pulse per camshaft revolution.One revolution on camshaft is the same as two onthe crankshaft. This gives an resolution of 450pulses/rev on crankshaft, i.e. 0.8 crank angle/encoder pulse
Control systemEngine Speed Pick-Up
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Control systemEngine Speed Pick-UP
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FunctionThe engine speed measured with this pick-up is usedfor:
1. redundant engine overspeed protection purposes,and
2. also to verify the engine speed signal from therotary encoder on the camshaft.
The sensor is an inductive proximity switch with built-in signal amplifier which provides a square-waveoutput signal.
Control systemEngine Speed Pick-UP
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Function
The sensor is directly connected to the OverspeedTrip Module in the MCU cabinet, from which it issupplied with 24 VDC.
The sensor gives one pulse for each cog on thecamshaft gear passing the head of the sensor.
Control systemEngine Speed Pick-UP
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Function
The output of the sensor is providing a speedproportional pulse train which is opto-coupled andtransduced into an analogue 4-20 mA signal in theOverspeed Trip Module.
This signal is connected to the MCU, which monitorsthe signal and compares it with the calculated speedvalue from the CCUs.
If there is a deviation between these values, the MCUwill initiate an alarm.
Control systemWECS Equipment as seen in Parts Manual
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Control systemWECS Equipment as seen in Parts Manual
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Control systemIgnition System
Ignition Coil
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Ignition Coil
High Tension
Extender
Spark Plug
CCU
Ignition
Module
Old Version
Inside Hot Box
Control systemIgnition System
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Main Components
1. Ignition Module2. Ignition Coil
3. High Tension Extender and4. Spark Plug
Control systemIgnition Coil and Spark Plug
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Ignition Coil
Ignition Trig Module
Spark Plug
Control systemIgnition System
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Control systemIgnition System
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Flow Diagram
Control systemHigh Voltage Circuit
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Control systemEngine Speed and Load Control
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