18V34SG DAFTAR ISI A. Pendahuluan A. Ragam jenis mesin gas B. Proses pada mesin gas C. Data utama mesin gas (Wartsila 18V34SG) B. Komponen utama A. 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 system G. Sistem pelumas / Lubrication system H. Prinsip operasi dan instrumentasi Operation Operation Engine Control System Operation Safety 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. Operation Start, 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 Operation Start Start: The start signal is given in the WOIS The HT-water temperature should be 50C minimum The ventilation of the exhaust pipe after the engine starts The test procedure for the gas regulating unit starts. When finished, the shutoff valves on the gas regulating unit will open. Operation Start Required starting air pressure min. about 20 bar. Both starting motors have to be connected before they are able to rotate. At 50 rpm the gasvalves start to open and the ignition 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-water and alternator preheating will switch off. 750 rpm or 720 rpm = nominal speed Operation Start Exhaust temperature check takes place after reaching nominal speed If the alternator does not synchronize within one minute, the engine stops. Otherwise the engine continues to run and a 500 kW baseload is immediately applied. If the base load is not reached in one minute the engine stops. The loading time to 100 % is about 15 minutes Operation Stop 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 same time 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 to stopmode At 50 rpm the ignition stops Operation Operation 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 Operation Running-In Running after overhaul run the engine for about 5 minutes after first start, check the temperatures of the con.rod and main bearings check for leakages running-in programme Control system WECS 3000 This topic describes the basics of WECS 3000 engine control & monitoring system. WECS stands for Wrtsil Engine Control System. It individually controls and monitors each engine cylinder. Control system Presentation on WECS 3000 on W34SG Control system Wartsila Operator Interface System Control system WECS 3000 Layout Control system Component Layout of WECS 3000 Control system Side Covers for WECS Units Control system WECS 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 Control system WECS 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) Control system Block Layout Connection of WECS 3000 Control system Main 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 Control system Main 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 for the 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 Control system Main 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)
Control system Main Control Unit (MCU) Control system Main Control Unit (MCU) Control system Cylinder Control Unit (CCU) Control system Cylinder Control Unit (CCU) Control system Cylinder 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) Handles all cylinder control and monitoring CCU 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) Function of Cylinder Control Unit Control of gas injection of 2 main gas admission valves Control of gas injection of 2 pre combustion chamber admission valves Control of ignition of 2 spark plugs Measuring of 2 exhaust gas temperatures Measuring of 2 cylinder liner temperatures Reading of engine angular position and speed send by rotary encorder Reading of fuel demand (from the MCU) Control system Cylinder Control Unit (CCU) Control system Cylinder Control Unit (CCU) Control system Potentiometers Control system Potentiometers Control system Potentiometers Control system Knock Detection Unit (KDU) Function of Knock Detection Unit Used to measure the knock signals from accelerometers mounted on each cylinder head. The KDU filtrates, amplifies and converts these signals to digital information and sends it over the CAN-bus to the MCU for further processing. One KDU is designed to handle up to nine cylinders.
Control system Knock Detection Unit (KDU) Basic Specs Input signal from rotary encoder Knock intensity value to MCU Comprises: 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 system Knock Detection Phenomenon Control system Knock Sensor Cylinder Head Knock Sensor Control system Distributed Control Unit and Sensor Multiplexing Unit Function of Distributed Control Unit and Sensor Multiplexing Unit
Used for measuring purposes (measuring of sensors). They convert different types of sensor signals to digital information which is sent over a network to the MCU for further processing (data handling for Local Display Unit).
Control system Distributed Control Unit and Sensor Multiplexing Unit Control system DCU and SMU Enclosure Control system Sensor Multiplexing Unit (SMU) 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 system Distributed Control Unit (DCU) 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 system Location of Rotary Encoder Control system Rotary Encoder 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 all cylinders. . Control system Camshaft with Rotary Encoder 1. Camshaft piece 2. Bearing journal 3. Screw 4. Fixing pin 5. Rotary Encoder 6. End cover 7. Axial Bearing Control system Measuring Engine Speed Control system Measuring Engine Speed Two Engine Speed Sensors 1. Rotary Encoder A rotary encoder connected to the camshaft is the master unit. The rotary encoder is used to calculate engine angular position as well as engine speed. 2. Engine Speed Pick-Up The other speed sensor is an inductive proximity switch installed at the camshaft gear. This speed sensor is used as a redundant overspeed protection device. Control system Measuring Engine Speed Two Engine Speed Sensors Speed measured from the rotary encoder is compared with the speed signal from the inductive proximity switch in the MCU. A shutdown is activated if a deviation in speed signals is over 50 rpm.
Control system Rotary Encoder Control system Rotary Encoder Function The encoder has two signal outputs. 1. One which provide 900 pulses/camshaft revolution and 2. the other one providing one synchronization pulse per camshaft revolution. One revolution on camshaft is the same as two on the crankshaft. This gives an resolution of 450 pulses/rev on crankshaft, i.e. 0.8 crank angle /encoder pulse Control system Engine Speed Pick-Up Control system Engine Speed Pick-UP Function The engine speed measured with this pick-up is used for: 1. redundant engine overspeed protection purposes, and 2. also to verify the engine speed signal from the rotary encoder on the camshaft. The sensor is an inductive proximity switch with built- in signal amplifier which provides a square-wave output signal. Control system Engine Speed Pick-UP Function The sensor is directly connected to the Overspeed Trip Module in the MCU cabinet, from which it is supplied with 24 VDC. The sensor gives one pulse for each cog on the camshaft gear passing the head of the sensor. Control system Engine Speed Pick-UP Function The output of the sensor is providing a speed proportional pulse train which is opto-coupled and transduced into an analogue 4-20 mA signal in the Overspeed Trip Module. This signal is connected to the MCU, which monitors the signal and compares it with the calculated speed value from the CCUs. If there is a deviation between these values, the MCU will initiate an alarm.
Control system WECS Equipment as seen in Parts Manual Control system WECS Equipment as seen in Parts Manual Control system Ignition System Ignition Coil High Tension Extender Spark Plug CCU Ignition Module Old Version Inside Hot Box Control system Ignition System Main Components 1. Ignition Module 2. Ignition Coil 3. High Tension Extender and 4. Spark Plug Control system Ignition Coil and Spark Plug Ignition Coil Ignition Trig Module Spark Plug Control system Ignition System Control system Ignition System Flow Diagram Control system High Voltage Circuit Control system Engine Speed and Load Control