Technical Specifiaction of Control System

GE Power
Technical specification
of the control system
1 x JGS 320 GS-B.L

Project Name: Euroasiatic prelimenary
J U309
Index: -
Technical changes reserved!
GE Jenbacher GmbH & Co OG

Achenseestr. 1-3
A-6200 Jenbach, Austria
Technical specification of the control system
1. Brief description of the plant __________________________________________________ 4

1.1 Plant concept 4
1.2 Fuel gas 4
1.3 Principal electrical diagram 4
1.4 Heat recovery diagram 4
2. Auxiliaries __________________________________________________________________ 5
2.1 Starting equipment 5
2.2 Control voltage 5
2.3 Cooling water preheating system M.04-W-002 5
2.5 Charge cooling water pump P.07-M-003 5
2.10 Prelubrication and cool-down oil pump 5
2.12 Temperature control 6
2.13 Engine room ventilation 6
2.14 Smoke and gas alarm installation (Customer scope) 7
2.15 Cooling system 7
2.16 Flat-bed cooler for charge cooler 2nd stage P.07-W-002[xx] (Customer scope) 7
2.19 Single-circuit cooling 7
3. CHP module functions ________________________________________________________ 8

3.2 Activation by on-site equipment with power output setpoint set by customer 8
3.5 Emergency power supply 8
3.6 Engine controller functions 8
3.7 Generator controller functions 10
4. Requirements ______________________________________________________________ 11
4.1 Parallel operation 11
4.2 Mains monitoring/isolation 11
4.3 CHP module safety loop 11
4.4 Third party cabling requirements for GE Jenbacher electrical distribution system 11
4.6 Requirements on customer's on-site master synchronisation (mains breaker synchronisation ) 12
5. CHP module operating modes _________________________________________________ 15

5.1 Fully automatic CHP module operation 16
5.2 Manual CHP module operation 18
5.3 Automatic synchronisation 20
5.4 Manually activated automatic synchronisation 20
5.5 Emergency power supply 21
5.6 Automatic synchronisation of the mains switch 22
5.7 Manually activated automatic synchronisation of the mains breaker 23
7. Electrical switchgear ________________________________________________________ 24

7.1 Module control cabinet for each module 24
7.2 Module interface cabinet 29
7.5 Generator field +GENCB. 30
8. Remote Data Transmission with DIA.NE XT4 _____________________________________ 32

8.1 DIA.NE XT4 HMI 32
8.2 myPlant Discovery 33
8.3 Mobile internet 33
8.4 Network diagram 33
Identification: Unit No.: J

Generator type: 1 x JGS 320 GS-B.L
Author: TPE | Frantisek Pataki Checked: Electrical Engineering Date: 18.03.2016

Index: - Page no.: 2 | 34
Appendix: "ERROR MESSAGE LIST"


Changes:
Index Date Re point Remark Author
1. Brief description of the plant
1.1 Plant concept

1 unit CHP module (gas engine and generator)
Fitted with 3-phase synchronous generator 400 kV/230 V 10 %, 50 Hz.
Total electric power: 1067 kW at cos phi 1
1058 kW at cos phi 0.8
1.2 Fuel gas

Biogas
1.3 Principal electrical diagram

See J U309 +U/page 5.
1.4 Heat recovery diagram

To be supplied by the customer and GE Jenbacher hydraulic diagram J U309 00 0


2. Auxiliaries
2.1 Starting equipment
Starter batteries: lead (Pb)

24 V, 200Ah per module.
For a detailed description see TI No. 1000-0050.
Charger: 24 V, 40 A
with integrated control system 24 V =, 18 Ah. Used for module control.
2.2 Control voltage

24 V=, min. 22 - max. 30 V at GEJ terminals incl. ripple. Ripple: max. USS 2.4 V.
2.2.1 Control voltage for module control cabinet

Control voltage for module control cabinet, via module interface panel from starter batteries.
2.3 Cooling water preheating system M.04-W-002

3 x 400/230 V, 50 Hz, 9 kW:
(Electric heating element, circulating pump and safety thermostat).
Controlled between 56 and 60C by ECW temperature.

Operating messages (MAIN screen => Auxiliaries)
"PREHEATING WATER PUMP ON/OFF"
"PREHEATING ON/OFF"
When the engine is at a standstill and the "Manual" or "Automatic" operating mode is selected, the modules are
continuously preheated as function of the set temperature limit value.
If the selected operating mode is "Off", the preheating system is switched off.
2.3.1 Cooling water circulation pump M.04-M-002

230 V, 50 Hz, 70 W:
The pump operates during module standstill and during the 5-minute after-running phase.
If the selected operating mode is "Off", the cooling water circulation pump is switched off.
2.5 Charge cooling water pump P.07-M-003

3 x 400 V, 50 Hz, 1500 W:
The pump operates during module operation and during the 5-minute cool-down phase.
2.10 Prelubrication and cool-down oil pump

1 x direct current 24 V, 180 W, M.03-M-003
Activated by the PLC.
Pump running time > 1 minute before engine start.
When an engine speed of 800 rpm is exceeded, the pump is switched off.
After the module has shut down, the pump runs for 40 minutes with KBB turbochargers and 20 minutes with TPS
turbochargers to cool them.


2.12 Temperature control
2.12.1 Return temperature control: hot-water circuit

PID controller unit to ensure that the return temperature does not drop below its set level, consisting of - 3-
way valve, P.04-YTC-001
- Pt100 temperature sensor P.04-TI-012
- PID controller
Displays on the controller screen: x = actual return temperature
Y = control variable for 3-way valve
w = setpoint return temperature
2.12.2 Charge temperature control using control valve

PID controller unit to ensure that the charge (cooling water) temperature does not drop below or exceed its set
level, consisting of - 3-way valve, P.07-YTC-001
- Pt100 temperature sensor (charge temperature) E.08-TI-001
- PID controller
Displays on the controller screen: x = actual charge temperature
Y = control variable for 3-way valve
w = setpoint charge temperature
2.13 Engine room ventilation
2.13.3 Air intake fans 3 x 400 V, 2x 2 kW: WITH STEPPED SPEED CONTROL, P.17-M-2xx (Customer scope)
The operation condition for step 1 is that the intake and outlet louvres must be opened. Step 2 is switched in
when: all the inlet and outlet louvres are open, the generator breaker is closed and the ambient temperature is
30C.
(With a gas pre-alarm/gas alarm all the fan(s) are switched on.

Operating messages (MAIN screen => Auxiliaries)
"AIR INTAKE FAN 1 ON/OFF"
"AIR INTAKE FAN 2 ON/OFF"
The module is shut down if a room temperature of 50C is reached.
"ROOM TEMPERATURE MAX." error message


2.14 Smoke and gas alarm installation (Customer scope)

a) One P.17-JI-21x sensor each in the engine and switchgear cabinet room as well as an electric alarm and
shut-down system.
In the event of a Fire Alarm the entire installation is tripped by an emergency stop. All louvres are closed and
the engine room air circulation fans are switched off.
If the "Fire Alarm" and "Gas Pre-alarm"/"Gas Alarm" are activated simultaneously, the "Gas Pre-alarm" or "Gas
Alarm" has priority over the "Fire Alarm".
"FIRE ALARM" error message
b) One P.17-JI-100[xx] gas sensor per module in the engine room as well as an electric alarm and shut-down
system.
In the case of "gas pre-alarm" at 20% LEL the module is stopped. The louvres are opened or remain open and
the room air circulation air fans are run and/or keep running at maximum speed!
"GAS PRE-ALARM" error message
In the event of a "gas alarm" at 40% LEL, the louvres remain open and the room air circulation air fans keep
running at maximum speed.
Proposal:
In the case of a "gas alarm" at 40% LEL, the plant should be electrically isolated by the on-site equipment.
The 24 V DC control voltage remains activated, however, to enable signals to be sent.
"GAS ALARM" error message
2.15 Cooling system
2.15.1 Flat-bed cooler 8 x _ kW, 400 V, 50 Hz, P.04-W-001[xx] (Customer scope)

Flat-bed cooler with 8 fans for high-temperature circuit. The fans are controlled in 8 steps.
They are activated according to the position of the cooler control valve or as function of the engine cooling water
temperature, the charge temperature or the oil temperature.
A combination of the various activation methods is also possible.
A fixed number of fans can already be switched on when the auxiliary equipment is activated.
The fan sequence is changed following every activation.
2.16 Flat-bed cooler for charge cooler 2nd stage P.07-W-002[xx] (Customer scope)
3 x 400 V, 50 Hz, 2 x . kW:
Flat-bed cooler with 2 fans for low-temperature circuit. The fans are controlled in 8 stages.
The 1st stage is activated following an auxiliary equipment request. The following stages are activated according to
the position of the charge temperature control valve or the charge temperature.
A fixed number of fans can already be switched on when the auxiliary equipment is activated.
The fan sequence is changed following every activation.
2.19 Single-circuit cooling

Solenoid valve M.04-YCS-001: 1 x 24 VDC, 22 W
When the engine starts up and the cooling water temperature is < xx C the valve is open.
When the engine is running and the cooling water temperature is > xx C the valve closes. When the cooling
water temperature falls below xx C the valve is open.
The valve is also open during the 5 minute auxiliary equipment after-running period.


3. CHP module functions
Refer to TI No. 1100-0110 "Boundary conditions for GE Jenbacher gas engines".
3.2 Activation by on-site equipment with power output setpoint set by customer
The module is activated by means of an on-site potential-free contact (interface No. 15).
Contact closed = module in operation
Contact open = module stops
The power is controlled as function of an on-site potential-free and linear mA signal
(0/4 - 20 mA = 50 - 100% Prated, interface No. 28).
3.5 Emergency power supply

Surplus heat is removed:
by on-site emergency cooling
3.5.1 Emergency power supply - without master synchronisation

- Emergency power supply with uninterrupted transition to island mode and black start.
Mode of operation during mains failure

See Section 5.5 for more information.
3.6 Engine controller functions

3.6.1 Knock control system:
Specific cylinders are fitted with an analogue knock sensor (E.00-AI-101[xx]) which generates a 4-20 mA signal, as
function of the knock intensity of the cylinder concerned.
This knocking signal is analysed and a knock control system created.
If the knocking signal exceeds a background noise level, the ignition point value is adjusted first. As an additional
measure (if applicable), the charge temperature is lowered and, finally, the engine power during mains parallel
operation is reduced by a specified time constant, until the knocking signal falls below the background noise level.
Once the knocking signal has fallen below the background noise level, the engine power is returned to the rated
power by increasing the time constant. If the engine power is reduced by the knocking signal to 50% of rated
power, the engine is shut down on safety grounds.
"KNOCKING" error message
"KNOCKING CYLINDER XX" error message


3.6.2 Power reduction as function of charge temperature

If the charge temperature (E.08-TI-001) exceeds the applicable limit value, the power output in mains parallel
operation will be continuously reduced by the parameterised value for every C deviation in the charge
temperature. If a further limit value is exceeded, however, the engine will be tripped with the error message
"CHARGE TEMPERATURE MAXIMUM".
"CHARGE TEMPERATURE MAXIMUM" error message
3.6.3 Power reduction due to misfiring

Every misfire occurrence recorded is displayed. They are detected on the basis of power drops. Function: All
detected misfires are added together by the "misfire integrator". Parameters can be set for the speed at which the
integrator rises and falls. If the integrator indicates a value of 50% or more, the engine power is reduced. At an
integrator level of 100%, the rated load will be reduced to 50% and the engine will then be shut down. In addition,
a misfiring pre-alarm will appear at a pre-settable integrator value.

"POWER REDUCTION MISFIRE" message (MAIN screen => General)
If the engine power is reduced by misfiring to 50% of rated power, the engine is shut down on safety grounds.
"MISFIRING" error message
3.6.5 Gas supply blocked to gas engine

If the gas supply to the engine is blocked (Interface no. 60.1), the engine is shut down without any cool-down run.
The engine can be restarted after the blockage has been lifted and a minimum standstill period of 5 minutes has
been observed.
"MODULE BLOCKING" message
3.6.6 The engine controller with "Gas type 1-2"

An optimum start position is calculated from the calorific value of the gas by interpolating the gas types to the
engine control system (GAS 1-2). The calculation is based on a customer provided CH4 signal or calorific value
signal. If the CH4 signal or signal calorific value is not provided, the engine is started by a predetermined starting
position of the gas mixer.
Note: The CH4 signal or calorific value signal must actually say something about the gas quality that enters the
engine (usually this must be met only in relation to scavenging lines).


3.7 Generator controller functions
3.7.1 Reductions in active power

To protect the generator, the active power generated can be reduced within certain limits.
A reduction occurs in the event of:
- undervoltage (average voltage)

"POWER REDUCTION DUE TO UNDERVOLTAGE" message
- overvoltage (average voltage)
"POWER REDUCTION DUE TO OVERVOLTAGE" message
- underfrequency
"POWER REDUCTION DUE TO UNDERFREQUENCY" message
- overfrequency

"POWER REDUCTION DUE TO OVERFREQUENCY" message
- winding temperature too high (only if winding Pt100 is installed)
"POWER REDUCTION DUE TO WINDING TEMPERATURE" message
3.7.2 Reductions in reactive power
- Limit on the reactive power/cos phi at high winding temperatures

The highest of the 3 measured phase temperatures is taken as the actual value of the winding temperature.
This reduction is only activated if the assembled winding Pt100s are activated (not with PTC resistors).
"REACTIVE ENERGY REDUCTION DUE TO WINDING TEMPERATURE" operating message
(ALARM screen)
- Generator operation at the underexcited stability limit using pole wheel angle reduction
"REACTIVE ENERGY REDUCTION DUE TO POLE WHEEL ANGLE" operating message
(ALARM screen)
3.7.3 Reactive energy / cos phi control

External setpoint:
The cos phi is adjusted as function of an external mA signal or is set as function of digital inputs with fixed
setpoints.


4. Requirements
4.1 Parallel operation

The modules operate in parallel with the public mains supply. Parallel operation with the electricity utility
company mains supply is subject to the relevant regulations. The engine and exhaust heat is fed into the
customer's heating system.
Power transmission point:
4.2 Mains monitoring/isolation

The mains monitoring values refer to circuit diagram +U.
When the mains monitor is activated due to a mains failure, the plant is isolated from the mains by opening the
generator breaker.
Break time of the circuit breaker: min. 60 ms
4.3 CHP module safety loop
4.3.1 Safety loop for the complete plant

For the complete plant, a common closed current safety loop is provided for:
- emergency stop circuits (external contact and/or GE Jenbacher)
- gas alarm (external contact and/or GE Jenbacher)
- fire alarm (external contact and/or GE Jenbacher) installed
The entire plant is stopped immediately if the safety loop trips.
4.3.2 Gas engine safety loop

A closed current safety loop is incorporated for each engine which monitors for:
- emergency stop
- overspeed
- ignition monitoring
- activation of undervoltage detection by
generator reverse power
shutdown failure
power signal missing
power signal overload
The tripping of the safety loop only stops the appropriate gas engine.
4.4 Third party cabling requirements for GE Jenbacher electrical distribution system
See TI No. 1000-0505.
The power cable cross-section must be determined or checked in accordance with IEC 60204-1 and/or IEC 60364-
5-52 and/or VDE 0298-4 and/or VE-EN 1 Part 3 (Section 41) with VE/NORM E 8001-3-41 (laying method,
bundling, etc.) by the firm carrying out the work.
4.4.1 Generator power cables:

See TI no. 1100-0112 "Installation of GE Jenbacher modules"!
Rated generator current: IN = 1908 A, where cos phi = 0.8.
Cable designed so that the danger of a short-circuit is minimised and the cables are not in the vicinity of flammable
material.
4.4.2 Only flexible cables are permitted.


4.6 Requirements on customer's on-site master synchronisation (mains breaker synchronisation )
4.6.1 Interfaces
Master synchronisation interfaces Module control:

SSL: Signal: Function:
110.1 Status: Mains OK

Contact closed: Mains OK, from mains monitoring device
Contact open: Mains failure
110.3 Status: Mains breaker closed

Contact closed: Mains breaker closed, mains connected
Contact open: Mains not connected
110.4 Status: Generator synchronisation selected

Contact closed: Synchronisation/Synchline module activated
Module speed adjustment activated
Contact open: Synchronisation/Synchline module not activated
110.5 Speed adjustment for synchronisation increase speed

Contact closed: Increase speed command for mains breaker synchronisation
Contact open: No increase speed command
110.5 Speed adjustment for synchronisation reduce speed

Contact closed: Reduce speed command for mains breaker synchronisation
Contact open: No reduce speed command
110.6 Voltage adjustment for synchronisation voltage higher

Contact closed: Increase generator voltage activation
for mains breaker synchronisation
Contact open: No increase generator voltage activation
110.6 Voltage adjustment for synchronisation voltage lower

Contact closed: Reduce generator voltage activation
for mains breaker synchronisation
Contact open: No increase generator voltage activation
110.7 Island mode only

Contact closed: Island mode only, no mains parallel operation of the plant
Contact open: Island mode and mains parallel operation


110.8 Status: Island mode enable

Contact closed: Island mode enabled
The mains breaker must open in the event of mains failure if a
module is running (not relevant with "Island mode only" (SSL 110.7))
To ensure uninterrupted operation in the event of mains failure
during mains parallel operation of the module, the contact must
be closed.
Contact open: Generator breaker opens in the event of mains failure
110.10 Emergency power activation

Contact closed: Module activation for black start / island mode
(not relevant if "Island mode only" has been selected (SSL 110.7)).
To ensure uninterrupted operation in the event of mains failure
during mains parallel operation of the module, the contact must
be closed.
Contact open: No module activation for black start / island mode
110.13 Status: Another generator breaker closed and module activated

Contact closed: Another generator is in parallel with module activation,
module is shut down with smooth load shedding
Contact open: No other generator is in parallel with module activation,
module is shut down without smooth load shedding
110.14 Status: All other generator breakers are open

Contact closed: All other generator breakers are open
to enable the generator breaker to connect to a dead
busbar
Contact open: 1 or more generator breakers is (are)
closed
110.16 Generator breaker blocking activation

Contact closed: Generator breaker blocking activation
Generator breaker connecting to dead busbar blocked
Generator breaker opening activation (e.g. in the event of
opening failure by other generator breakers) + blocking
Module
Contact open: Module enabled, generator breaker enabled
for synchronisation by module control
110.18 Status: Generator breaker connecting to dead busbar enabled

Contact closed: Generator breaker connecting to dead busbar enabled
(all other generator breakers are
blocked)
Contact open: Generator breaker connecting to dead busbar
not enabled
110.19 Power control activation

Contact closed: Command to switch to power control in island mode
(Power mode)
Contact open: Command to switch to speed control in island mode
(Speed mode)


Module control interfaces Master synchronisation

SSL: Signal: Status: Function:
110.2 Status: Generator breaker closed

Contact closed: The generator breaker is closed
Contact open: Generator breaker is open
110.9 Status: Module is ready for automatic island mode

Contact closed: Module is ready for master synchronisation (island mode)
Module can be activated by master sync for island mode
Contact open: Module not ready for master sync (island mode)
Module cannot be activated by master sync for island mode
110.11 Status: Speed > 360 rpm

Contact closed: Module start speed exceeded/engine running
for mains breaker opening in the event of mains failure
for mains breaker opening in the event of a black start
Contact open: Engine standstill
110.12 Status: Module activated

Contact closed: Module activated
Contact open: Module not activated
110.15 Block command to other breakers for connecting generator breaker to dead
busbar
Contact closed: Generator breaker activation to connect to
dead busbar, activation to connect
other generator breakers blocked
Contact open: No activation to connect generator breaker to
dead busbar
110.17 Status: Generator breaker is blocked

Contact closed: Generator breaker blocked
from enabling other generator breakers to connect to
dead busbar
Contact open: Generator breaker not blocked
110.20 Generator breaker opening failure

Contact closed: Generator breaker opening failure present,
all generator breakers and mains breakers must be opened!
Contact open: No generator breaker opening failure present
4.6.2 Manual synchronisation function

A synchronisation lockout relay must be provided for manual synchronisation.
4.6.3 Synchronisation
The synchronisation must include signal monitoring to ensure the plant is safely isolated in the event of non-logical
signal states and switch opening failure!


5. CHP module operating modes
Functions of a touch control panel for operating modes and activations:

Note: Every change in operating mode and activation on the touch control panel must be
confirmed with YES or NO.
Selected Selected Start Stop Setpoint value for engine

mode of activation power control
operation
OFF - - - -
MAN - START button on STOP button on internal
(MANUAL) touch control panel touch control panel
AUTO OFF - Module is -
deactivated
REMOTE Activation by Activation by Version: internal
customer or master customer or master
Var.: external by customer
control control is cancelled
or master control
ON Module activated internal
Generator breaker is controlled according to the type of module control synchronisation selected on the touch
control panel.
Note: Every change of synchronisation type and the associated activation of the
generator breaker on the touch control panel must be confirmed with YES or NO.
Selected Connecting Generator breaker Synchronisation / generator

synchronisation generator breaker to disconnection breaker
type dead busbar
MAN Press generator Press generator breaker Press generator breaker "On" button
breaker "On" button "Off" button on touch on touch control panel
(MANUAL) on touch control control panel Synchronisation selection.
panel The generator breaker is closed
Interrupts an active automatically.
manual synchronisation
OFF - Press generator breaker Generator breaker synchronisation
"Off" button on touch is aborted / blocked
control panel
AUTO automatic automatic automatic


5.1 Fully automatic CHP module operation

Depends on the CHP functions for the available modules
with "REMOTE" selected via interface no. 15 from on-site equipment or the station control
with "ON" selected
Conditions for automatic start:

"Automatic" mode selected
The safety circuit enables operation.
No operating errors (specific to the gas engine).
Cooling water temperature (M.04-TI-001) > 40C
Engine at standstill.
Status display "READY FOR AUTOMATIC START ENGINE AT STANDSTILL"
Potential-free remote message "Ready for automatic start".
Command: "Start" activated by master control / by on-site equipment.
- Contact closed: gas engine starts.
- Contact open: Module shuts down.
This activation triggers:

Status display "START PROGRAM RUNNING"
Preheating (M.04-W-002) Off.
6 seconds after release for start:

Status display "AUTOMATIC START IS RUNNING"
Starter (E.00-M-001[xx]) On; Ignition On

If the speed exceeds 80 rpm the gas valves (P.01-YCZ-xxx) are opened.
The engine starts and runs up to rated speed.

The starter (E.00-M-001[xx]) is disengaged as soon as the starting speed is reached.
Status display "START PROGRAM: ENGINE RUN-UP"
If the engine does not start, the second start attempt begins.
If the gas engine fails to start after three attempts, the

"START UP FAILURE" error message appears and any new start attempts are prevented.
Operating messages:
10 seconds after engine start, the lubrication oil pressure monitoring system (M.03-PI-001) is activated.

Status display "ENGINE IDLE OPERATION ........."
Potential-free remote message "Operation/Engine running" to station control / to customer.
Status display "ENGINE IDLE OPERATION SYNCHRONISATION /
LOADING ENABLE"


Synchronisation:
Synchronisation of the module is fully automatic if the selected type of synchronisation is "Automatic".
"MAINS PARALLEL OPERATION" status display
Automatic loading:
Following activation, the module is powered up according to the load application ramp. Operating range during
automatic operation 50 100% of rated power.
Possible shut-down options during "Automatic" operation:

"Activation module" from station control or from customer is cancelled if the selected activation mode is
"REMOTE" or the module is deactivated by the "OFF" command.
The load is reduced. If the load falls below 10% of rated power, the generator breaker is opened by the circuit
breaker control.
Status display "SHUT-DOWN PROGRAM: ENGINE COOL-DOWN RUNNING"
The gas valves (P.01-YCZ-xxx) close after one-minute of cool-down running.

"Operation" message is cancelled
Status display "SHUT-DOWN PROGRAM: ENGINE SHUTDOWN SEQUENCE"
Ignition Off if engine speed is less than start speed

Status display "READY FOR AUTOMATIC START ENGINE AT STANDSTILL"
Gas train shut-down check (gas leakage check P.01-US-xxx)
Engine auxiliaries cool-down phase according to Point 2
The auxiliaries will stop 5 minutes after the engine (heating-water pump (P.06-M-001), ....)


5.2 Manual CHP module operation

The CHP modules can be operated manually by selecting "Manual" operating mode. Loading and load
shedding of the module is also performed manually.
The operation of the plant synchronisation system is either completely automatic or manual (manually activated
automatic synchronisation) depending on the type of synchronisation selected.
Conditions for manual start on-site:

"Manual" mode selected.
The safety circuit enables operation.
No operating errors (specific to the module).
Engine at standstill.
"READY FOR MANUAL START ENGINE AT STANDSTILL" status display
Push start button for "start preparation".
This activation triggers:
Status display "START PROGRAM RUNNING"
Preheating (M.04-W-002) Off.
If all the conditions are OK, the

"START ENGINE (PUSH START BUTTON)" status display appears.
Push the start button.
Starter (E.00-M-001[xx]) On; Ignition On

If the speed exceeds 80 rpm the gas valves (P.01-YCZ-xxx) are opened.
The engine starts and runs up to rated speed:

The starter (E.00-M-001[xx]) is disengaged as soon as the starting speed is reached.
"START PROGRAM: ENGINE RUN-UP" status display
The start preparation program begins again if the engine does not start.
If all the conditions are OK, the

"START ENGINE (PUSH START BUTTON)" status display appears.
Push the start button.
If the gas engine fails to start after three attempts,

"START UP FAILURE" error message appears and any new start attempts are prevented.


Operating messages:
10 seconds after engine start, the lubrication oil pressure monitoring system (M.03-PI-001) is activated.

"ENGINE IDLE OPERATION ........." status display
Potential-free remote message "Operation/Engine running" to station control / customer.
LOADING ENABLE"
Synchronisation:
Synchronisation is either automatic or manual (manually activated automatic synchronisation) depending on the
type of synchronisation selected.
Manual loading (output control):

Loading/load reduction with manual setting of power setpoint via DIA.NE engine management system.
Shut-down during "Manual" operation (on-site):

Before shutting down the engine, shed the load via the DIA.NE.
Synchronisation type selected as "Manual" or "Off"
Open the generator breaker as soon as the power reaches 10% of rated power.
When the synchronisation type is "Manual", open the generator breaker with the "Off" button
LOADING ENABLE"
Push the stop button after one-minute cool-down.
The "Generator breaker enable" is overridden and the engine is shut down.
"READY FOR MANUAL START ENGINE AT STANDSTILL" status display
Gas train shut-down check (gas leakage check P.01-US-xxx)
Engine auxiliaries cool-down phase according to Point 2
The auxiliaries will stop 5 minutes after the engine (heating-water pump (P.06-M-001), ....)


5.3 Automatic synchronisation

Selected synchronisation type is "Automatic"
Enable given by the engine control system (synchronise/loading enable)
- Engine in operation
- Cooling water temperature (M.04-TI-001) above 55C (in "Automatic" operation)
Generator breaker is open
Generator breaker ready to close
Automatic synchronisation selected

"GENERATOR BREAKER SYNCHRONISATION RUNNING" status display
- Select busbar voltage
- Select generator voltage
- Prepare synchroniser
- Select generator breaker
- Select speed adjustment
Generator voltage automatically adjusted to the busbar voltage
Generator frequency automatically adjusted to the busbar frequency by the synchroniser.
ON-pulse sent to the generator breaker by the synchroniser at the time of synchronisation.
"GENERATOR BREAKER CLOSED" operating message
5.4 Manually activated automatic synchronisation

Selected synchronisation type is "Manual"
Enable from the engine control system (synchronisation/loading enable)- Engine running
Generator breaker open
Generator breaker ready to close
Press generator breaker "On" button on touch control panel

"GENERATOR BREAKER SYNCHRONISATION RUNNING" status display
- Select busbar voltage
- Select generator voltage
- Select generator breaker
Generator voltage automatically adjusted to the busbar voltage
Generator frequency automatically adjusted to the busbar frequency by the synchroniser.
ON-pulse sent to the generator breaker by the synchroniser at the time of synchronisation.
"GENERATOR BREAKER CLOSED" operating message


5.5 Emergency power supply

Generally:
- In the event of a mains failure and the resultant change from mains parallel to island mode, the on-site load-
shedding device (preferable relay-controlled and capable of directly tripping the consumer groups) must limit
the power to consumers to the emergency power provided by the available module within 50 ms of the mains
coupler breaker opening. Make sure that the load reduction during the transition from mains parallel to
island mode does not exceed approx. 10% for Type 3 engines, and . This can be achieved by using a mains
supply control, for example. If this is not possible, the consumer output must be reduced to approx. 35% of
the rated power of the generating set. Subsequently, the total isolated load can be built up in accordance with
the load diagram. . After additional module(s) is/are switched in, the consumer output can be switched off in
accordance with the load diagram.
- The engine must be given between 1 and 2 minutes for thermal and control stabilisation before applying the
load each time. This must be taken into account, especially when the engines have not yet reached their
operating temperature.
- The DIA.NE engine management system will balance the effective loads of the modules in operation.
- The reactive load must be balanced via the droop setting of the generators (in multiple-engine plants the
voltage droop must be set to the same value for all the generators).
- Compensators should be switched off when the plant is running on emergency power in order to avoid the risk
of overvoltages and capacitive generator operation. The power factor should be between cos = 1 and 0.8
ind.
- Module power range:
During island mode, the modules must be operated in the range of 40%-100% of their rated power.
- Load-adding curves in accordance with TI 2108-0025 for type 3 engines
TI 2108-0029 for type 4 engines
TI 2108-0026 for type 6 engines
5.5.1 Emergency power supply in automatic operation:

Mains failure during module operation:

- Mains breaker opens automatically
- Potential-free "Mains failure" remote message to the on-site equipment

"MAINS FAILURE operating message (ALARM screen)
- Module continues to run
- The consumer load on the modules which are running must be reduced
by means of the load-shedding device.
- Activate additional consumers in phases.
"ISLAND MODE - SPEED MODE" status display
Mains failure during module standstill:

- Potential-free "Mains failure" remote message to the on-site equipment

- The module is activated and the mains breaker opens when the starting speed is reached. At
the end of the switch-on / selection period, the first module is connected to the dead busbar.

- After the mains is restored and after a mains stabilisation period of 5 minutes,
the mains breaker is synchronised.


5.5.2 Emergency power supply in manual mode:

Selected type of synchronisation and operating mode is "Manual"
Mains failure during module operation:

- Potential-free "MAINS FAILURE" remote message to the on-site equipment

- Mains breaker opens automatically
- Module continues to run and the load is shed down to the available module power output (on-site equipment)

- When the mains is restored, the mains breaker synchronisation must be
initiated manually by actuating the rotary switch "MAINS SWITCH ON / SELECTED".
Mains failure during module standstill:

Emergency power start is not activated automatically.
The module can be started manually if desired.
5.6 Automatic synchronisation of the mains switch

Mains is available again, mains breaker is open
Mains breaker ready to close
The generator breaker is closed
Automatic synchronisation selected for synchronising the mains switch

"MAINS BREAKER SYNCHRONISATION RUNNING" status display
- Select mains voltage
- Select busbar voltage (generator)
- Select mains breaker
Generator frequency is automatically adjusted to the mains frequency.
Generator voltage is automatically adjusted to the mains voltage.
ON-pulse sent to the mains breaker by the synchroniser at the time of synchronisation.
"MAINS BREAKER CLOSED" feedback message (ALARM screen)


5.7 Manually activated automatic synchronisation of the mains breaker

Selected synchronisation type is "MANUAL"
Module runs in manual mode
Mains is available again, mains breaker is open
Mains breaker ready to close
Generator breaker is closed
Press mains breaker "On" button on touch control panel

"MAINS BREAKER SYNCHRONISATION RUNNING" status display
- Select mains voltage
- Select busbar voltage (generator)
- Select mains breaker
Generator voltage is automatically adjusted to the mains voltage.
Generator frequency is automatically adjusted to the mains frequency.
ON-pulse sent to the mains breaker by the synchroniser at the time of synchronisation.
"MAINS BREAKER CLOSED" operating message (ALARM screen)


7. Electrical switchgear
Design of switchgear cabinets:

Fully enclosed sheet steel upright cabinet with a door at the front with
a rubber sealing strip, ready for operation and connected to terminals, for installation above a cable duct (double
floor) to be provided on-site. Cable exit downwards.
Ambient temperature -5 - 40C
Cabinets: Rittal, type TS 8
Paint colour RAL 7035
7.1 Module control cabinet for each module
Components:
DIA.NE engine management system
Design:
a) Touch Display visual display unit
b) Central engine and generating set control
a) Touch Display visual display unit
15 industrial colour graphics display with resistive touch screen.
Interfaces:
- 24 V voltage supply
- VGA display connection
- USB interface for resistive touch screen
Protection class for DIA.NE XT Front: IP 65

dimensions: W x H x D = approx. 410 x 310 x 80 mm
The screen contains a clear and functional summary of the measured values. All values are presented graphically
as well.
The system is operated by touching on-screen buttons.

Numeric inputs (setpoints, parameters, etc.) are made on a touch numerical keypad or slider.
The operating mode and synchronisation type are selected on a touch button panel that can be pinned
permanently on each screen.


Main screens:
Main: Provides an overview, operating status of auxiliaries, engine start and operational data,
customer-specific displays (optional)
ELE: Shows the integrated generator with electrical measured variables, synchronisation and
OPTION: generator winding temperature and generator bearing temperature
HYD: Engine oil/cooling-water circuit with oil pressure/temperature and cooling-water
pressure/temperature displays
oil quality sensor

GAS: Shows the gas train with measurement values, gas type selection and associated components
ENG: Shows an overview and details of engine management (speed, power, island), emission control
(Leanox), power reductions, knocking and ignition control
Two-stage pressure charging, display and details of charge temperature controller,
shows measured values for humidity control (optional)
CLY: Shows cylinder measurement values such as knocking intensity, ignition point, ignition voltage
(optional), etc.
EXH: Shows components and associated measured variables in the exhaust system
CTR: Shows a summary and details of auxiliaries controllers (cooling water, room temperature, charge
air cooling circuits, etc.)
Panel: The operating mode and synchronisation type are selected on a touch button panel that can be
pinned permanently on each screen.
Alarm: Powerful diagnostic tool that lists all outstanding and historical error messages chronologically in
tabular form with time stamp.
Notes: This message portal can be used to send and receive notes.
User: Password-protected user access rights with various user levels
Each screen allows the user to switch between the screen view, the associated parameters in tabular form,
powerful measured value trend displays, and, if available, system information.
b) Central engine and generating set control:
A real-time, modular industrial control system based on an industrial PC which handles all activities for module and
engine-side sequencing control (start preparation, start, stop, cool-down run, control of auxiliary systems), as well
as all control functions.
Interfaces:
- Ethernet (twisted pair) for remote maintenance access
- Ethernet (twisted pair) for interconnecting a number of engines
- Ethernet (twisted pair) for the Powerlink connection to the control inputs and outputs
- USB interface for software updates


Control functions:
- Speed control when idling and in island mode
- Power output control in mains parallel operation, based on an internal or external setpoint depending on
the project
- LEANOX control system to control the boost pressure as function of the generator terminal power and the
charge temperature of the motorised gas mixer
- Knock control system: adjustment of ignition point, power output and (insofar as possible on-site) the
drop in charge temperature if knocking is detected
- Active load sharing where several engines are running in island mode
- Linear reduction of power output in the event of excessive charge temperature and misfiring
Interface relays as per the interface list

Multi-function transducer to record the following electric generator variables:
Phase currents (with slave pointer)
Neutral conductor current
Ph/Ph and Ph/N voltages
Active power (with slave pointer)
Reactive power
Apparent power
Power factor
Frequency
Active and reactive energy meter
An additional 0 (4) 20 mA output is available for active power, as well as a pulse output for active energy.
The following generator monitoring operations are integrated into the multi-function transducer:
- Overload current/short circuit [51], [50]
- Overvoltage [59]
- Undervoltage [27]
- Asymmetric voltage [64], [59N]
- Unbalanced load [46]
- Exciter failure [40]
- Overfrequency [81>]
- Underfrequency [81<]
Blockable operating mode selection by touch with the following selection options:
"OFF" no start-up possible, running module is
shut down immediately;
"MANUAL" full manual operation possible (start, stop), module at rest
is not available for fully automatic operation;
"AUTOMATIC" fully automatic operation following activation by an incoming
external signal:
- automatic start
- fully automatic operation with appropriate power setpoint
- shut-down with one-minute engine cool-down run and 5-minute cool-down run for the
auxiliaries


Activation selection by touch with the following selection possibilities:

"OFF" External activation off
"REMOTE" External activation
"ON" External pulse activation
Auxiliary mains disconnection device with lockable isolating switch
Status displays
The current operational status of the module is displayed in the
status line,
e.g.:
OPERATION MODE SELECTOR OFF
OPERATION MODE SELECTOR MANUAL - NOT READY
OPERATION MODE SELECTOR AUTOMATIC - NOT READY
READY TO START MANUAL - ENGINE AT REST
READY TO START AUTOMATIC - ENGINE AT REST
START PREPARATION IN PROGRESS
START ENGINE (PUSH START BUTTON) (in manual mode)
AUTOMATIC START IN PROGRESS (in automatic mode)
START PROGRAM ENGINE RUN-UP
ENGINE IDLING - NO SYNCHRONISATION/LOADING ENABLE
ENGINE IDLING - SYNCHRONISATION/LOADING ENABLE
SYNCHRONISATION IS RUNNING
MAINS PARALLEL OPERATION
ISLAND MODE - SPEED MODE
ISLAND MODE - POWER MODE
MAINS BREAKER SYNCHRONISATION RUNNING
SHUT-DOWN PROGRAM: ENGINE COOL-DOWN RUN
SHUTDOWN PROGRAM: ENGINE SHUTDOWN SEQUENCE
MODULE BLOCKED
ERROR MESSAGES ON MODULE CONTROL CABINET (ALARM MANAGEMENT SYSTEM):

refer to attached "ERROR MESSAGE LIST" !


Synchronisation of generator breaker (and mains breaker in the event of a purely single synchronisation)
Synchronisation elements:
Blockable synchronisation type selection by touch with the following selection options:
"MAN"
"OFF"
"AUTO"
Synchronisation function - with frequency adjustment and the following displays:
Double voltmeter for monitoring the busbar and generator voltage.
Double frequency meter for monitoring the busbar and generator frequency.
Synchronoscope for monitoring synchronising conditions during synchronisation.
Including all required command, reporting and control systems

Generator breaker "ON" selection button on touch control panel
Generator breaker "OFF" selection button on touch control panel
Mains breaker "ON" selection button on touch control panel
Mains breaker "OFF" selection button on touch control panel
Synchronisation monitored in accordance with error message list
Mains isolation/generator protection
Dimensions:
H = 2200 mm (incl. 200 mm socket)
W = 1000 mm
T = 600 mm


7.2 Module interface cabinet

Two-door fully enclosed sheet steel upright cabinet with a door at the front with a rubber sealing strip. Installed
and wired on the module, ready for operation.
Paint colour RAL 7035
Protection class: IP 54 outdoors.
Control current supplied from the battery charger.

Power supply to the auxiliaries: (by the supplier of the power units for the auxiliaries)
3 x 400/230 V, 50 Hz, 20 A
Components:
Terminal strip with cable exits at the bottom
Decentralised inlet/outlet system connected via a serial interface to
the central engine control unit in the module control cabinet
Measurement transducer for excitation voltage
Relays, fuses, overload cut-outs, motor protective circuit breakers for controlling valves and
Auxiliaries
With control cabinet fan P = 41 W thermostatically controlled.
Dimensions:
W = 1000 mm
H = 1000 mm
D = 300 mm


7.5 Generator field +GENCB.
Rated voltage: 230/400 V, 50 Hz

Rated current: 2500A
Mains configuration: TN-C-S
Protection class: IP54 outdoors, IP20 indoors
Ambient temperature: +5 to 40C (50C with reduction)
Standards: IEC/EN 61439-2 and IEC/EN 60204-1
Cabinet colour: RAL 7035
Dimensions: See circuit diagram
Function:
In the event of a fault, and when the gas engine is stopped in an orderly manner, the generator breaker isolates
the generator from the mains The only way of closing the generator breaker is via the gas engine control
system.
Length of cable between generator field and module control cabinet: < 50 m
The following elements are installed in the cabinet:

- 1 power breaker:
3-pole, motor-operated,
Fixed installation,
Integrated electronic trip unit consisting of:
adjustable long-time delay trip for overload protection
adjustable selective trip for short-circuit protection
Undervoltage trip, shunt trip, closing coil: 24V DC
Status messages, commands and signals are applied to terminals.
Lockable with padlock
Make time <70 msec
Break time <60 msec
Breaking capacity Icu; Ics (440 V AC): 100 kA
Making capacity Icm (440 V AC): 220 kA
Short-time withstand current lcw (1 sec.): 85 kA
- 3 current transformers: 2500 /1 A, 1FS5, 30 VA (0.5FS5, 15 VA) applied to terminals
- 1 five-pole copper busbar system (L1, L2, L3, PE, N + PEN jumper) for connecting cables
Rated Ambient Ambient Max. cables per Max. N, PE, PEN

current temperature temperature phase cables
AT: 40C AT: 50C
A A A mm (Cu) mm Cu
800 800 750 4 * 240 2 * 240
1200 1200 1175 4 * 240 2 * 240
1600 1600 1510 4 * 240 2 * 240
2000 2000 1880 8 * 240 4 * 240
2500 2500 2350 8 * 240 4 * 240
3200 3200 3010 12 * 240 6 * 240
3800 3800 3572 16 * 300 8 * 300
4400 4400 4400 16 * 300 8 * 300
Reduction as specified in IEC 61439-1: Tab. 6


- Control cable terminal strip

- Control cabinet fan, thermostatically controlled
- Type 2 surge arrester EN 61643-11, Up max. 2.5 kV for auxiliaries
- Generator voltage for synchronisation and measuring purposes applied to terminals
- Busbar voltage for synchronisation purposes applied to terminals
- Outlet for the GEJ auxiliaries (3-pole with 125 A, only with 3 x 400/230 V, 50 Hz)
-2. Outlet for the GEJ auxiliaries (3-pole with 125 A, only with 3 x 400/230 V, 50 Hz)


8. Remote Data Transmission with DIA.NE XT4
General
DIA.NE XT4 offers remote access via an Ethernet network as an option.
Applications:
OPTION:
8.1 DIA.NE XT4 HMI
DIA.NE XT4 HMI is the human-machine interface of the
DIA.NE XT4 module control and visual display system for GE Jenbacher gas engines.
The system offers a wide range of functionalities for plant commissioning, monitoring, maintenance and diagnostic
purposes.
Installation of the DIA.NE XT4 HMI Client Programmes allows a connection to plants to be established provided
that existing network connections and access rights allow this. The system operates with Microsoft Windows
operating systems (Windows XP, Windows 7, Windows 8).
Functionality
Visual display functions at the engine control cabinet can be utilised remotely. These include control actions and
observations, trend representations, alarm management, parameter management, and access to long-term data
analysis. Access to more than one plant, including with several clients in parallel, enables additional useful
functions such as multiple users, remote control, printing and export functions and data backup. DIA.NE XT4 is
available in several languages.
OPTION:
Remove activation/blocking
In "Automatic" mode with "Remote" activation, a module can be enabled (activated) or blocked (de-activated)
using a control element (button) on the DIA.NE XT4 HMI.
Note:
An additional customer on-site activation (via hardware or a data bus) or self-controlled operation (GE Jenbacher
station control, mains supply control, etc.) is pointless with this option.
OPTION:
Remote reset (see TI 1100-0111, Sections 1.7 and 1.9)
Scope of supply:
DIA.NE XT4 HMI Client Setup software package (download)
Number of DIA.NE XT4 HMI Client licence (simultaneous access by one user to the plant server) as
option/licence
Number of Access
licences
0 Panel in the switchgear cabinet
1 1 user can be logged on at the same time with one PC
(workplace, control room or at home)
2 2 users can be logged in at the same time with one PC
(workplace, control room or at home).
If two users with locally-connected
computers (office, control room) are logged on,


nobody else can log on from home.

The number always refers to the DIA.NE XT4 server, in other words the engine, and must be set up
separately on each server. If the number 2 is set on engine no. 1 and engine no. 2, then two users
can be logged on to each engine at the same time.
To be supplied by the customer

Broadband network connection via Ethernet (100/1000BASE-TX) to an RJ45 connector (ETH3) on the DIA.NE
XT4 Server in the module control cabinet.
Standard PC with keyboard. mouse or touch, screen (min. resolution 1024 x 768)
Windows XP SP3, Windows 7, Windows 8 operating system
DirectX 9.0c-compatible or more recent 3D Display Adapter with 64 MB or more RAM
8.2 myPlant Discovery
Web application with the following functions:

Visual display of the current engine status (available, in operation, fault)
View of various measured values of the generator set
Visual display of counter readings as a trend graph (if the plant is available on-line, or by manual input of the
counter readings)
Power output trend graph (low resolution; only if the plant is available on-line)
Access to a future spare parts shop
OPTION:
8.3 Mobile internet
Plant - customer connection via secure Internet connection
see also Technical Instruction TI 2300 - 0006
Scope of supply
Mobile Internet router including aerial for connecting to the DIA.NE XT4 server
To be supplied by the customer

SIM card for 3G
8.4 Network diagram
For information!





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GE Power

1 x JGS 320 GS-B.L

GE Jenbacher GmbH & Co OG

1. Brief description of the plant __________________________________________________ 4

3. CHP module functions ________________________________________________________ 8

5. CHP module operating modes _________________________________________________ 15

7. Electrical switchgear ________________________________________________________ 24

8. Remote Data Transmission with DIA.NE XT4 _____________________________________ 32

Identification: Unit No.: J

Author: TPE | Frantisek Pataki Checked: Electrical Engineering Date: 18.03.2016

Appendix: "ERROR MESSAGE LIST"

Identification: Unit No.: J

Author: TPE | Frantisek Pataki Checked: Electrical Engineering Date: 18.03.2016

Index Date Re point Remark Author

1. Brief description of the plant

1.1 Plant concept

1.2 Fuel gas

1.3 Principal electrical diagram

1.4 Heat recovery diagram

Identification: Unit No.: J

Author: TPE | Frantisek Pataki Checked: Electrical Engineering Date: 18.03.2016

2.1 Starting equipment

Starter batteries: lead (Pb)

2.2 Control voltage

2.2.1 Control voltage for module control cabinet

2.3 Cooling water preheating system M.04-W-002

2.3.1 Cooling water circulation pump M.04-M-002

2.5 Charge cooling water pump P.07-M-003

2.10 Prelubrication and cool-down oil pump

Identification: Unit No.: J

Author: TPE | Frantisek Pataki Checked: Electrical Engineering Date: 18.03.2016

2.12 Temperature control

2.12.1 Return temperature control: hot-water circuit

2.12.2 Charge temperature control using control valve

2.13 Engine room ventilation

Identification: Unit No.: J

Author: TPE | Frantisek Pataki Checked: Electrical Engineering Date: 18.03.2016

2.14 Smoke and gas alarm installation (Customer scope)

2.15 Cooling system

2.15.1 Flat-bed cooler 8 x _ kW, 400 V, 50 Hz, P.04-W-001[xx] (Customer scope)

2.19 Single-circuit cooling

Identification: Unit No.: J

Author: TPE | Frantisek Pataki Checked: Electrical Engineering Date: 18.03.2016

3. CHP module functions

Refer to TI No. 1100-0110 "Boundary conditions for GE Jenbacher gas engines".

3.5 Emergency power supply

3.5.1 Emergency power supply - without master synchronisation

Mode of operation during mains failure

3.6 Engine controller functions

Identification: Unit No.: J

Author: TPE | Frantisek Pataki Checked: Electrical Engineering Date: 18.03.2016

3.6.2 Power reduction as function of charge temperature

3.6.3 Power reduction due to misfiring

3.6.5 Gas supply blocked to gas engine

3.6.6 The engine controller with "Gas type 1-2"

Identification: Unit No.: J

Author: TPE | Frantisek Pataki Checked: Electrical Engineering Date: 18.03.2016

3.7 Generator controller functions

3.7.1 Reductions in active power

- undervoltage (average voltage)