1 Technical Description MWM 2032v16 2
1 Technical Description MWM 2032v16 2
1 Technical Description MWM 2032v16 2
TCG 2032V16
The compliance with maintenance intervals and emissions can only be guaranteed if the "Minimum
characteristics for fuel gases" are complied with, the required minimum water qualities are observed and
oil services are performed in accordance with the manufacturer's instructions.
Technical Circular 0199-99-2105 must be observed for the use of lubricating oils.
Technical Circular 0199-99-02091 is binding for the engine coolant water quality to be used for MWM
engines and quality of water used in heating circuits.
Technical Circular 0199-99-3017 is binding for the released fuel gas qualities to be used for the
operation of MWM engines.
The requirements of Technical Circular 0199-99-2132 must be complied with for the combustion and
intake air.
All Technical Circulars (TR) mentioned in this document have been enclosed.
The operator must document and, where requested by the manufacturer, prove the compliance with the
maintenance, repair and fuel specifications. Where such proof cannot be delivered, this will restrict the
warranty obligation of the manufacturer.
The violation of the guideline "Layout of Power Plants driven by Gas and Diesel Engines" (status 01-
2008) can cause damages or failure of the functions of the gensets or the installation for which MWM
can not accept warranty claims.
Crankcase
Sphero casting casing with attached cooling water jacket, maintains its rigid shape due to steep side
walls and diagonally screwed bearing blocks; suspended crankshaft; short uncut lubricating oil supply
bores from the hollow camshafts as main oil distributing lines to all lubricating points; lateral drive
chamber apertures with quick-release covers; wet cylinder bushings made of highly wear-resistant
special centrifugal casting; rotation-symmetrical undeformable bushing support; crank chamber
ventilation via oil trap.
Power unit
Crankshaft made of chromium molybdenum steel with screwed-on counterweights and hardened main
and connecting rod bearing necks; full-shaft connecting rods made of steel alloy, forged with inclined
toothed separating level; oil supply of the piston bolt and the piston through the bored connecting rod,
progressive piston pin bearing for reduced piston load, crankpin with guides for the connecting rod;
electron-beam welded light metal piston with asymmetrical crowned compression ring, tapered
compression piston ring and a narrow-land drain oil-control ring, all piston rings with highly wear-
resistant coating; main and connecting rod bearings made of wear- and corrosion-resistant alloys,
sputtered bearing layer; cams made of high-strength steel, bearings and cams hardened, bushings
made of aluminium alloy, drive via gearwheels; flywheel of sphero cast (GGG-50).
Cylinder head
Single cylinder heads made of special cast iron with intermediate bottom and cooling bores in the
combustion chamber plate to reduce mechanical and thermal load; four valves and inserted, hardened
seat rings, outlet seat rings water-cooled; mixture supply from the distributor manifold in the combustion
chamber; exhaust gas discharge to the same side upwards in the combustion chamber; novel unit
comprising cylinder head, bushing and intermediate casing with piston and connecting rod as well as
the intake, exhaust gas, lubricating oil and cooling water line segments for easy assembly and
convenient service; chamber sparkplugs centrically in the combustion spaces with intensive plug seat
cooling.
Valve train
One toothed wheel driven hollow-bored camshaft comprising individual elements for each cylinder bank
on each side of the engine, simultaneously main lubricating oil distribution; valve operation for
respectively 2 inlet and outlet valves by roller tappet, push rod, rocker lever and valve bridge; O ring oil
gaskets at the valve stems.
Antiknock control
Knock sensor monitoring for each cylinder; ignition control for the individual cylinders, gas-air mixture
and engine power adjustment; knock-free operation at maximum power with best degrees of efficiency
while complying with emission thresholds.
Starter
Compressed-air starter turbine with integrated gear and 24 V magnetic valve; pressure reduction station
with ball valve and filter, as well as connection option for compressed-air supply of the engine flywheel
turning device and the electro-pneumatic valves of the gas control train; flanged on crankcase.
Test - general
Engine assembly and cabling according to assembly plan
Engine installation on test stand with cold functional test
Engine run-in according to run-in programme
Engine acceptance
60 min 100% power at rated speed 2 measurements
20 min 50% power 1 measurement
Controller test 100% at zero load
Preservation
Standard preservation of the engine to protect against corrosion during transport and possible
subsequent storage at the place of destination. Maximum protection period of 6 months after delivery,
for storage in a closed dry room.
Design
Generator comprising the main generator as internal pole machine and the exciter generator as external
pole machine. The power supply of the voltage regulator depends on the rated voltage.
The generators are equipped with an auxiliary exciter machine.
Rotor
The rotor comprises the shaft and the main pulse wheel. The main pulse wheel – in salient pole design
– consists of hydraulically pressed sheets or steel plates. By standard, a copper dampening cage is
installed that is electrically connected in the pole shoes and between the poles.
The coils of the main rotor are made of flat copper and are protected by suitable components against
centrifugal forces. The rotor coil corresponds to insulation class F according to VDE 0530/IEC 34. By
standard, the rotor is balanced with half feather key according to VDE 0530/IEC 34, Part 34.
Bearing shields
The bearing shields are welded or made of cast iron. According to the design, the generator feet are
attached underneath the bearings.
Storage
Antifriction bearings are designed as loose bearings on the drive side and as fixed bearings on the
counter-drive side.
Specifications, norms
Design specifications: VDE 0530, IEC 34 (EN 60034), ISO 8528-3
Components/subassemblies/standard design
Terminal box generously dimensioned for installation of current transformers.
Terminal boxes with cable inlet connections and cable strain relief
Electronic control
Basic module MEC 100 D, including failure monitoring:
highly constant voltage regulation
reactive-current dependent static
Underspeed protection by U/F function
Function blocks
Cos-phi regulator: Cos-phi balancer
o The power factor of the controlled generator is the same as that of the entire current or of
the current of the other generators (depending on the current transformer connection)
o Suitable for parallel operation with generators without linear voltage static
o Generators protected by adjustable over- and under-excitation limits
o Target value setting by potentiometer or by current signal 4 20 mA
Exciter and diode monitoring: Exciter system monitoring – direct current relay; delivery loose for
installation in the control/switch panel
o Recording of over- and under-excitation states
o Recording of faults of the rotating diodes by means of unevenness of the direct current of
the exciter
Static transformer: for parallel operation with the mains and with each other, installed in the
generator
Temperature monitoring
o 6 PT 100 sensor for coil
o 1 PT 100 sensor for each bearing
Base frame
Bending and torsion resistant steel construction for supporting the engine and the generator. Elastic
bearing elements are mounted underneath the support frame.
Coupling
Highly elastic, axial plug-type flange coupling for torsion-elastic connection of motor and generator. The
disk-shaped rubber body dampens torsional vibrations to a high degree. The rubber element is radially
dismountable.
Pre-lubrication pump
Pre-lubrication by electric pump at the plant; depletion option with the same pump after changing the
attached three-way valve.
unit comprising two casings (one casing for each cylinder row) in that an air-water-heat exchanger and
respectively 4 filter cartridges slabs are mounted. The filter slabs are to be equipped with quick-release
fasteners for quick and easy tool-less replacement. The casing contains a maintenance indicator that
indicates low pressure for easy monitoring of soiling of the filter cartridge
2 pieces resistant special hoses for connection between gas mixer and air pre-heating unit + hoses
clamps
1 piece three-way valve DN 32 + counter flanges for controlling the air-temperature quantity in the air-
water-heat exchanger
2 pieces valve flaps DN 40 + counter flanges
2 pieces throttle valves + counter flanges
1 piece floating air valve
1 piece water pump + counter flanges
Assembly
Gas engine and generator are coupled elastically, mounted on the common support frame, for vibration-
insulated installation using feather elements on appropriate foundation at the customer's.
Paint
Resistant paint coating comprising:
Wash primer coating for non coated components made of stainless steel, non-ferrous metals,
galvanised and chromated parts, dry coat thickness 10+5 µm
Priming coat for complete unit, dry coat thickness 40+30 µm
Top coat in colour RAL 5010 for complete unit, dry coat thickness 90+40 µm
Cabling
Complete cabling of the plant to terminal strips and terminal box
The gas control train is designed for a gas flow pressure of 300 mbar with a permissible variation of ±
10%, variation frequency < 1/6 min.
The equipment of the gas control train might vary, depending on the type of gas or operation. The
separate parts list as listed upon placement of the order is binding.
Setup
I/O controller
For installation in the control cabinet of the auxiliary power unit.
Workstation
The system can flexibly be adjusted to the local conditions. Susceptibility to failure and cabling
expenditure for the plant is minimised.
The unit control cabinet is installed in direct vicinity to the unit. The engine cables are tested at the
factory and the cables are tested and fully connected to the unit control cabinet to ensure trouble free
commissioning and high operational reliability.
The signals that are relevant to the power stack are exchanged directly with the TEM-EVO system via
the I/O controller in the auxiliary power unit control cabinet. Data are transmitted to the unit control via a
highly fault free CAN bus connection.
The workstation can be placed anywhere on the plant, at the unit or in the switch room, at the
customer's choice.
Operation
An intelligent workstation provides access to all functions ensuring easy operation of the TEM EVO
system The workstation is equipped with a 15" TFT touch monitor. The touch function of the workstation
ensures easy and intuitive operation of the unit. Using the navigation bar, the user can operate the unit
by quick and direct changing between screens. Each workstation screen provides the user with
information on the state of the connected unit. All regulation, service, control and monitoring functions
can conveniently be operated without the need for long training.
Communication with the user can be in one of many available national languages of the TEM EVO
system. The language can quickly be changed at any time by pressing a button. In the event of a
service, a different language than the one used by the plant staff may temporarily be set. All information
that is important for normal operation and operating options are clearly summarised on the "Operation"
screen (Fig. 1) (the figure below also contains options).
Operation diary
With its recording function, the electronic operation diary (Fig. 2) of the TEM-EVO system makes the
operation of the gas engine plant and its peripheral devices transparent. All operation messages and
switching actions that are important for the operation as well as any changes to the configuration are
recorded with the exact time stamp (date/time). In total, the TEM-EVO system can monitor and
distinguish more than 600 different incidents. This allows for quick and detailed analysis of the operation
of the unit incl. the auxiliary functions controlled by the TEM EVO.
The curves can be followed with the cursor; the respective measured value is depicted as numeric value
with exact time stamp. In the event of a failure, the recording will stop automatically after 40s to facilitate
failure diagnosis. The "Real-time scope" function allows for continuous monitoring of measured values
and control function.
These measured values can optionally be saved for further analysis and re-read at a later time.
The delivery of each plant includes 2 copies of the documentation in English. Comprising:
Gas engine operating instructions
Gas engine spare parts list
Gas engine test stand protocol
Exhaust gas turbocharger operating instructions
TEM system operating instructions
System manual for data exchange via serial interface
Generator operating instructions
Generator drawing and generator shaft drawing
Generator circuit diagrams
Generator test stand protocol
Coupling operating instructions
Elastic bearing assembly notes
Assembly notes for rubber compensators for engine connections cooling water/oil
Assembly notes for compensator engine connection exhaust
Circuit diagram for unit cabling
Circuit diagram for plant cabling (for MWM delivery scope)
Circuit diagram for TEM system
Gas control train operating instructions
Gas control train test certificate
Gas control train drawing
Drawing and technical data of the magnetic valves for lubricating oil line
Drawing and technical data of the pre-lubrication pump
Technical description of the plant components delivered by MWM
RI flow diagram
Unit drawing
Plant diagram (option)
Foundation load calculation sheet
Manufacturer's Declaration
Compressed-air operated drive for turning the engine flywheel during maintenance and repair
Comprising:
Compressed air motor
Operating device
2. System components
The following components are included in the delivery scope and are delivered as a "loose" item.
In the intercooling system, the heat that was generated during compression of the fuel gas mixture in
the exhaust gas turbocharger is extracted in a specially designed heat exchanger.
Floating air valve in hot-pressed brass design with red brass effect, with caulked shut-off device and
corresponding shut-off valve.
Maximum temperature 120 °C
Maximum pressure 10 bar
Connection size 1/2 G
Water level limiter with glass floater as glandless device with magnetic transmission of the floater
movement to a micro switch.
Protection type 65 IP
Micro switch Single-pole change-over contact
Max. operating overpressure 10 bar
Max. operating temperature 120 °C
Installed position Main axle vertical
Membrane safety valve with upstream seat gasket separate from the membrane, liftable by rotary
handle.
Casing made of hot-pressed brass/red brass, spring cap made of GD Zn/hot-pressed brass/MS cast,
inner parts made of Ms 58, membrane and gasket made of high-temperature resistant non-ageing
rubber elastic plastic, spring made of corrosion-resistant spring steel wire
Response overpressure 3 bar
Operating temperature max. 140 °C
Control valve
maintenance-free soft-sealing heating control valve, casing made of GG-25, 3-way valve shape, spindle
made of 1.4571, tight-closing.
Connections* 80 / 16 DN / PN
Water level limiter with glass floater as glandless device with magnetic transmission of the floater
movement to a micro switch.
Protection type 65 IP
Micro switch Single-pole change-over contact
Max. operating overpressure 10 bar
Max. operating temperature 120 °C
Installed position Main axle vertical
Membrane safety valve with upstream seat gasket separate from the membrane, liftable by rotary
handle, casing made of hot-pressed brass/red brass, membrane and gasket made of high-temperature
resistant non-ageing rubber elastic plastic.
Response overpressure 3 bar
Operating temperature max. 140 °C
Control valve
maintenance-free soft-sealing heating control valve, casing made of GG-25, 3-way valve shape, spindle
made of 1.4571, tight-closing.
Connections* 125 / 16 DN / PN
Actuating drive
electric actuator drive, 5 kN, permissible ambient temperature -20°C to +70°C, protection type IP 65,
mechanical stroke indicator, manual override.
Motor voltage/frequency 230 / 50 / 60 V/Hz
Capacity 53 VA
1" R
3. Services
3.1 Packing
Standard foil packing for truck land transport.