Jenbacher J420
Jenbacher J420
Jenbacher J420
Technical Description
Genset
EA
Emission values
NOx < 500 mg/Nm³ (5% O2)
Spec. fuel consumption of engine electric kWh/kWel.h [2] 2.36 2.42 2.56
Spec. fuel consumption of engine kWh/kWh [2] 2.30 2.36 2.49
Lube oil consumption ca. kg/h [3] 0.31 ~ ~
Electrical efficiency % 42.4% 41.3% 39.0%
*) approximate value for pipework dimensioning
[_] Explanations: see 0.10 - Technical parameters
All heat data is based on standard conditions according to attachment 0.10. Deviations from the standard conditions can result in a
change of values within the heat balance, and must be taken into consideration in the layout of the cooling circuit/equipment
(intercooler; emergency cooling; ...). In the specifications in addition to the general tolerance of ±8 % on the thermal output a further
reserve of +5 % is recommended for the dimensioning of the cooling requirements.
Connections
Jacket water inlet and outlet DN/PN 80/10
Exhaust gas outlet [D] DN/PN 300/10
Min./Max. fuel gas pressure at inlet to gas train mbar 120 - 200 c)
Allowed Fluctuation of fuel gas pressure % ± 10
Max. rate of gas pressure fluctuation mbar/sec 10
Maximum Intercooler 2nd stage inlet water temperature °C 55
Spec. fuel consumption of engine kWh/kWh 2.30
Specific lube oil consumption g/kWh 0.20
Max. Oil temperature °C 85
Jacket-water temperature max. °C 95
Filling capacity lube oil (refill) lit ~ 437
c) Lower gas pressures upon inquiry
d) based on methane number calculation software AVL 3.2
The final pressure drop will be given after final order clarification and must be taken from the P&ID order documentation.
All pressure indications are to be measured and read with pressure gauges (psi.g.).
(1) At nominal speed and standard reference conditions ICFN according to DIN-ISO 3046 and DIN 6271,
respectively
(2) According to DIN-ISO 3046 and DIN 6271, respectively, with a tolerance of +5 %.
Efficiency performance is based on a new unit (immediately upon commissioning).Effects of
degradation during normal operation can be mitigated through regular service and maintenance work;
reference value --> 65%CH4
(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 (at p. f. = 0,8)
,(guiding value)
(8) Exhaust temperature with a tolerance of ±8 %
(9) Intercooler heat on:
* standard conditions (Vxx) - If the turbocharger design is done for air intake temperature > 30°C
w/o de-rating, the intercooler heat of the 1st stage need to be increased by 2%/°C starting from 25°C.
Deviations between 25 – 30°C will be covered with the standard tolerance.
* Hot Country application (Vxxx) - If the turbocharger design is done for air intake temperature >
40°C w/o de-rating, the intercooler heat of the 1st stage need to be increased by 2%/°C starting from
35°C. Deviations between 35 – 40°C will be covered with the standard tolerance.
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 (14.5 psi) or 100 m (328 ft) above sea level
Air temperature: 25°C (77°F) or 298 K
Relative humidity: 30 %
Volume values at standard conditions (fuel gas, combustion air, exhaust gas)
Pressure: 1013 mbar (14.7 psi)
Temperature: 0°C (32°F) or 273 K
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. These functions are carried
out by the engine management system.
Exceedance of the voltage and frequency limits for generators according to IEC 60034-1 Zone A will lead
to a derate in output.
Failure to adhere to the requirements of the above mentioned TA documents can lead to engine damage
and may result in loss of warranty coverage.
Parameters for the operation of control unit and the electrical equipment
Relative humidity 50% by maximum temperature of 40°C.
Altitude up to 2000m above the sea level.
developed by GE JENBACHER.
Vibration damper
Maintenance free viscous damper
Flywheel
With ring gear for starter motor
Pistons
Single-piece, made of light metal alloy, with piston ring carrier and oil passages for cooling; piston rings
made of high quality material, main combustion chamber specially designed for lean burn operation.
Connecting rods
Drop-forged, heat-treated, big end diagonally split and toothed. Big end bearings (upper bearing shell:
sputter bearing / lower bearing shell: sputter bearing) and connecting rod bushing for piston pin.
Cylinder liner
Chromium alloy gray cast iron, wet, individually replaceable.
Cylinder head
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.
Ignition system
Most advanced, fully electronic high performance ignition system, external ignition control.
MORIS: Automatically, cylinder selective registration and control of the current needed ignition voltage.
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.
Exhaust system
Turbocharger and exhaust manifold
Electric actuator
For electronic speed and output control
Starter motor
Engine mounted electric starter motor
Main components
Enclosure of welded steel construction
Stator core consist of thin insulated electrical sheet metal with integrated cooling channels.
Stator winding with 2/3 Pitch
Rotor consists of shaft with shrunken laminated poles, Exciter rotor, PMG (depending on Type) and fan.
Damper cage
Excitation unit with rotating rectifier diodes and overvoltage protection
Dynamically balanced as per ISO 1940, Balance quality G2,5
Drive end bracket with re greaseable antifriction bearing
Non-drive end bracket with re grease antifriction bearing
Cooling IC01 - open ventilated, air entry at non-drive end , air outlet at the drive end side
Main terminal box includes main terminals for power cables
Regulator terminal box with auxiliary terminals for thermistor connection and regulator.
Option:
Current transformer for protection and measuring in the star point
xx/1A, 10P10 15VA , xx/1A, 1FS5, 15VA
Digital Excitation system ABB Unitrol 1010 mounted within the AVR Terminal box with following
features:
Compact and robust Digital Excitation system for Continuous output current up to 10 A (20A Overload
current 10s)
Fast AVR response combined with high excitation voltage improves the transient stability during LVRT
events.
The system has free configurable measurement and analog or digital I/Os. The configuration is done via
the local human machine interface or CMT1000
Power Terminals
3 phase excitation power input from PMG or auxiliary windings
Auxiliary power input 24VDC
Excitation output
Measurement terminals: 3 phase machine voltage, 1 phase network voltage, 1 phase machine current
Analog I/Os: 2 outputs / 3 inputs (configurable), +10 V / -10 V
Digital I/O: 4 inputs only (configurable), 8 inputs / outputs (configurable)
Serial fieldbus: RS485 for Modbus RTU or VDC (Reactive power load sharing for up to 31 GEJ engines
in island operation), CAN-Bus for dual channel communication
Regulator Control modes: Bump less transfer between all modes
Automatic Voltage Regulator (AVR) accuracy 0,1% at 25°C ambient temperature
Field Current Regulator (FCR)
Power Factor Regulator (PF)
Reactive Power Regulator (VAR)
Limiters: Keeping synchronous machines in a safe and stable operation area
Routine Test
Following routine tests will be carried out by the generator manufacturer
Measuring of the DC-resistance of stator and rotor windings
Check of the function of the fitted components (e.g. RTDs, space heater etc.)
Insulation resistance of the following components
Stator winding, rotor winding
Stator winding RTDs
Bearing RTDs
Space heater
No Load saturation characteristic (remanent voltage)
Stator voltage unbalance
Direction of rotation, phase sequence
High voltage test of the stator windings (2 x Unom. + 1000 V) and the rotor windings (min. 1500 V)
Flexible coupling
With torque limiter to couple engine with generator. The coupling isolates the major subharmonics of
engine firing impulses from the generator.
Bell housing
To connect engine with generator housing. With two ventilation and control windows.
Anti-vibration mounts
Arranged between engine/generator assembly and base frame. Isolating pads (SYLOMER) for placement
between base frame and foundation, delivered loose.
Interface panel
Totally enclosed sheet steel cubicle with front door, wired to terminals, ready to operate. Cable entry at
bottom.
Protection: IP 54 external, IP 20 internal (protection against direct contact with live parts)
Design according to IEC 439-1 (EN 60 439-1/1990) and DIN VDE 0660 part 500, respectively.
Ambient temperature: 5 - 40 °C (41 - 104 °F),Relative humidity:70 %
Dimensions:
Height: 1000 mm (39 in)
Width: 800 mm (32 in), [-> at type 4 1000 mm (39 in)]
Depth: 300 mm (12 in)
Power distribution to the engine mounted auxiliaries (power input from the supplier of the auxiliaries
power supply):
3 x 400/230 V, 50 Hz, 16 A
Oil drain
By set mounted cock
Consisting of:
Shut off valve
Gas filter, filter fineness <3 µm
1.07 Painting
Quality: Oil resistant prime layer
Synthetic resin varnish finishing coat
1.11 Engine generator control panel per module- Dia.ne XT4 incl.
Single synchronization of the generator breaker
Dimensions:
Height: 2200 mm (including 200 mm (8 in) pedestal *)
Width: 800 -1200mm*)
Depth: 600 mm *)
Protection class:
external IP42
Internal IP 20 (protection again direct contact with live parts)
*) Control panels will be dimensioned on a project specific basis. Actual dimensions will be provided in the
preliminary documentation for the project.
Control supply voltage from starter and control panel batteries: 24V DC
Consisting of:
Motor - Management - System DIA.NE
Interfaces:
24V voltage supply
VGA display connection
USB interface for resistive touch
The screen shows a clear and functional summary of the measurement values and simultaneously shows
a graphical summary.
ELE: Display of the generator connection with electrical measurement values and synchronization status
Measurement values:
510 data points are stored
Measurement interval = 100ms
Raw data availability with 100ms resolution: 24 hours + max. 5.000.000 changes in value at shut
down (60 mins per shut down)
Compression level 1: min, max, and average values with 1000ms resolution: 3 days
Compression level 2: min, max, and average values with 30s resolution: 32 days
Compression level 3: min, max, and average values with 10min resolution: 10 years
Messages:
10.000.000 message events
System messages:
100.000 system messages
An industrial PC- based modular industrial control system for module and engine sequencing control
(start preparation, start, stop, aftercooling and control of auxiliaries) as well as all control functions.
Interfaces:
Ethernet (twisted pair) for remote monitoring access
Ethernet (twisted pair) for connection between engines
Ethernet (twisted pair) for the Powerlink connection to the control input and output modules.
USB interface for software updates
Connection to the local building management system according to the GE Jenbacher option list
(OPTION)
MODBUS-RTU Slave
MODBUS-TCP Slave,
PROFIBUS-DP Slave (160 words),
PROFIBUS-DP Slave (190 words),
ProfiNet
OPC
Control functions:
Speed control in idle and in island mode
Power output control in grid parallel operation, or according to an internal or external set point value
on a case by case basis
LEANOX control system which controls boost pressure according to the power at the generator
terminals, and controls the mixture temperature according to the engine driven air-gas mixer
Knocking control: in the event of knocking detection, ignition timing adjustment, power reduction and
mixture temperature reduction (if this feature is installed)
Load sharing between engines in island mode operation (option)
Linear power reduction in the event of excessive mixture temperature and misfiring
Linear power reduction according to CH4 signal (if available)
Linear power reduction according to gas pressure (option)
Linear power reduction according to air intake temperature (option)
Additional 0 (4) - 20 mA interface for active power as well as a pulse signal for active energy
Remote signals:
(volt free contacts)
For automatic synchronizing of the module with the generator circuit breaker to the grid by PLC-
technology, integrated within the module control panel.
Consisting of:
Hardware extension of the programmable control for fully automatic synchronization selection and
synchronization of the module and for monitoring of the generator circuit breaker closed signal.
Lockable synchronization selection via touch screen with the following selection modes:
"MANUAL" Manual initiation of synchronization via touch screen button followed by fully
automatic synchronization of the module
"AUTOMATIC" Automatic module synchronization, after synchronizing release from the module
control
"OFF" Selection and synchronization disabled
Control of the generator circuit breaker according to the synchronization mode selected via
touch screen.
"Generator circuit breaker CLOSED/ Select" Touch-button on DIA.NE XT
"Generator circuit breaker OPEN" Touch-button on DIA.NE XT
Status signals:
Generator circuit breaker closed
Generator circuit breaker open
The following reference and status signals must be provided by the switchgear supplier:
Voltage transformer in the star point with minimum 50VA and Class 0,5
Maximum distance between module control panel and engine/interface panel: 30m
Maximum distance between module control panel and power panel: 50m
Maximum distance between module control panel and master control panel: 50m
Maximum distance between alternator and generator circuit breaker: 30m
Applications:
If the service selectors switch at the module control panel is in pos."Automatic" and the demand-selector
switch in pos."Remote", it is possible to enable (demanded) or disable (demand off) the module with a
control button at the DIA.NE XT4 HMI
Note:
With this option it makes no sense to have an additional clients demand (via hardware or data bus)
or a self-guided operation (via GE Jenbacher master control, grid import /export etc.).
Scope of supply
Software package DIA.NE XT4 HMI Client Setup (Download)
Number of DIA.NE XT4 HMI - Client user license (Simultaneous right to access of one user to the
engine control)
Caution! This option includes the DIA.NE XT4 HMI client application and its license only – NO secured,
encrypted connection will be provided by GE Jenbacher! A secured, encrypted connection – which is
mandatory – has to be provided by the customer (via LAN connection or customer-side VPN), or can be
realized by using option myPlant™.
Customer requirements
Broad band network connection via Ethernet(100/1000BASE-TX) at RJ45 Connector (ETH3) at
DIA.NE XT4 server inside module control panel
Standard PC with keyboard, mouse or touch and monitor (min. resolution 1024*768)
Operating system Windows XP, Windows 7, Windows 8
DirectX 9.0 c compatible or newer 3D display adapter with 64 MB or higher memory
2.) myPlant™
Scope of supply
Access to myPlant™
Connection between plant server and myPlant™ system
Customer requirements
Permanent Internet line (wired or mobile, (see option 4))
See technical instruction TA 2300-0008
Outbound data connectivity (from plant server to Internet) ONLY – INBOUND connections must
NOT be allowed!
CAUTION!
It is in the responsibility of the customer to prevent direct access from the Internet to the plant server
using technical equipment like firewalls.
GE Jenbacher does not provide such security devices and services as part of this option!
Scope of delivery
Mobile Internet router with antenna to connect to the DIA.NE Server XT4
Signalling:
Green Led: Output voltage > 20,5V
Yellow Led: Overload, Output Voltage < 20,5V
Red Led: shutdown
Control accumulator:
Pb battery 24 VDC/18 Ah
The jacket water temperature of a stopped engine is maintained between 56°C (133 °F) and 60°C
(140°F), to allow for immediate loading after engine start.
Protection: IP 42 external
IP 20 internal (protection against direct contact with live parts)
Function:
For immediate disconnection of the generator from the grid in case of grid failures.
Consisting of:
High/low voltage monitoring
High/low frequency monitoring
Specially adjustable independent time for voltage and frequency monitoring
Vector jump monitoring or df/dt monitoring for immediate disconnection of the generator from the grid
for example at short interruptions
Indication of all reference dimensions for normal operation and at the case of disturbance over LCD and
LED
Adjusting authority through password protection against adjusting of strangers
Scope of supply:
Digital grid protection relay with storage of defect data, indication of reference dimensions as well as
monitoring by itself.
Or Or 0,8ind (overexcited)
[ANSI 78]
The radiator is integrated with a glycol circuit which itself is integrated in the warm water circuit by means
of a plate type heat exchanger.
Consisting of:
Heat exchanger for warm water/glycol circuit
Pump
Electrical control
Expansion tank
4.02 Unloading
Unloading, moving of equipment to point of installation, mounting and adjustment of delivered equipment
on intended foundations is not included in GE Jenbacher scope of supply.
4.04 Storage
The customer is responsible for secure and appropriate storage of all delivered equipment.
Cooling water
At inlet and outlet flanges on 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
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, (lube oil, engine jacket water, 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.
Suitable bellows and flexible connections must be provided locally for all connections.
Cables from the genset must be flexible.
The module test will be carried out with the original generator, except it is not possible because of the
delivery date. Then a test generator will be used for the module test.
To prove characteristics of the above components, which are not tested on the test bench by GE
JENBACHER, the manufacturers’ certificate will be provided.
5.03 Documentation
Preliminary documentation 60 days after receipt of a technically and commercially clarified order:
Module drawing 1)
Technical diagram 1)
Drawing of control panel 3)
List of electrical interfaces 2)
Technical specification of control system 2)
Technical drawing auxiliaries (if included in GE Jenbacher-limit of delivery) 1)
At delivery:
Wiring diagrams 3)
Cable list 3)