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ENGINE AUTOMATION

GAS ENGINE

Shakil Shaikh
21st May 2017

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Contents

Introduction
Wartsila Power Plant Electrification
Plant Automation
System Layout
Engine Control System
UNIC system
UNIC C3 system ( Gas Engine )

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WARTSILA POWER PLANT ELECTRIFICATION

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PLANT AUTOMATION SYSTEM

PLANT AUTOMATION SYSTEM

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PLANT AUTOMATION SYSTEM

Common Genset 1 Genset 2 Genset 3 Genset 4

Switch Switch Switch Switch Switch Switch


CFA901 CFA901 CFC011 CFC021 CFC031 CFC041

Switch Switch Switch Switch


BJA011 BJA021 BJA031 BJA041

UNIC C3 UNIC C3 UNIC C3 UNIC C3


G1 G2 G3 G4
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PLANT AUTOMATION SYSTEM

Main Products :
Siemens PLC System S7-300 Series
VAMP \ ABB make Power monitor & Protection Relay
VAMP260 Power Monitor Unit
VAMP210- Generator Protection Relay
VAMP265 Differential Current Protection Relay
Wartsila Design SCADA system- WOIS
Wartsila Design Reporting Station WISE
ABB Make Digital AVR Unitrol 1020
Dedicated Synchronization hardware for Auto & Manual Synchronization

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ENGINE AUTOMATION SYSTEM

ENGINE CONTROL SYSTEM


UNIC

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ENGINE AUTOMATION SYSTEM

UNIC One system for One Wrtsil

EFIC = Electronic Fuel Injection


Control
CR = Common rail
DF = Dual Fuel
SG = Spark ignite Gas engine

Fig. name: UNIC configurations

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ENGINE AUTOMATION SYSTEM

UNIC One system for One Wrtsil


UNIC version
UNIC C1 UNIC C2 UNIC C3
Main components Main components Main components
ESM ESM ESM
LCP LCP + LDU LCP + LDU
MCM * MCM MCM
Sensors Sensors Sensors
Actuators Actuators Actuators & valves/injectors
IOM IOM
CCM
(WCD on SG)

Main features Main features Main features


Fundamental on-engine safety Complete on-engine safety Complete on-engine safety
Basic local monitoring Complete local monitoring Complete local monitoring
Hardwired ext. interface Speed/load control Speed/load control
Speed/load control Advanced engine control Advanced engine control
Waste-gate control Alarm handling Alarm handling
Optional start/stop system Full diagnostics & integrated test Full diagnostics & integrated test
routines routines
Bus interface Bus interface
EFIC (CR & gas), including cylinder
balancing
*) Only if speed/load control or integrated start/stop system

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ENGINE AUTOMATION SYSTEM

The sensors in the UNIC C3 system are of a flying lead design (where
applicable) to avoid failure prone connectors .

Operating temperature of UNIC Modules : -25 deg C to +85 deg C

All hardware is verified and tested through HALT ( Highly Accelerated Life
test ) to ensure reliable operations in harsh environments in which the
engines operate.

Features :
Latest Technology Hardware
Service Support availability
Increases the reliability and availability

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ENGINE AUTOMATION SYSTEM

ENGINE CONTROL SYSTEM


UNIC C3

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UNIC C3

System architecture of UNIC C3


UNIC C3 is a modular system, which consisting of the following
major parts:
LDU = Local Display Unit
LCP = Local Control Panel
ESM = Engine Safety Module
MCM = Main Control Module
PDM = Power Distribution Module
CCM = Cylinder Control Module
IOM = Input/Output Module
WCD = Wrtsil Coil Driver

Hardwired
Ethernet
Power 24VDC, system supply
Power 110VDC , driver supply
Load sharing CAN
CAN bus
Ignition voltage
System platforms of UNIC C3

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UNIC C3

UNIC C3 main components Hardwired


Ethernet
Power 24VDC, system supply
LCP-Local control panel WCD-Wrtsil coil driver Power 110VDC, driver supply
Backup instruments SG-engines only Load sharing CAN
CAN bus
Monitoring
Local controls
LDU-Local display unit
Local parameter display
Logging
Ethernet gateway

MCM-Main control module


Engine management
Speed/load control
I/O interface
Engine balancing
UNIC main components

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UNIC C3

UNIC C3 main components Hardwired


Ethernet
Power 24VDC, system supply
ESM-Engine safety module Power 110VDC, driver supply
Safety functions Load sharing CAN
CAN bus
Engine shutdowns
Backup operation
Speed monitoring
CCM-Cylinder control module
Fuel injection, combustion
control
Cylinder measurements
Fast measurements (knock,
pressure)
IOM-Input/Output module
Measurements
Analogue control
Binary control
UNIC main components

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UNIC C3

UNIC C3 main components Hardwired


Ethernet
Power 24VDC, system supply
PDM-Power distribution module Power 110VDC, driver supply
Filtering Load sharing CAN
CAN bus
Protection
Earth fault detection
WECSPlorer UT, Tool
Engine tuning
Trending
Advanced diagnostics
Software updates
Troubleshooting

UNIC main components

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UNIC C3
Local control panel and Display Unit
Local Display unit
System components
01 Graphic display
02 Main page
03 Alarm log
04 Help page
05 Back command
06 Navigation
07 Enter command
08 Engine temperatures
09 Lube oil system Local control panel

10 Fuel system
11 Cooling water system
12 Charge air system
Local Display Unit (LDU)
13 F6 + F1 Miscellaneous
measurements
14 F6 + F2 Knock measurement

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UNIC C3
Cylinder control module (CCM-20)
The module processes locally functions
related to fuel injection control and cylinder-
specific measurements.
The cylinder control module handles the
injection control of 1-3 cylinders and can be
used as backup-controller up to 3 other
cylinders.
Module features:
Diagnostics
Safety
Position and speed measurement
Torsional vibration monitoring
Ignition control in SG engines
(driving WCD)
Speed governor in limp mode

CCM module

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UNIC C3
Input/Output module (IOM-10)
The I/O unit is used for data
acquisition of analogue/
binary/frequency signals, but
also for control, such as:
waste-gate control
by-pass control
LT/HT-water thermostat
valve control

IOM module

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UNIC C3
Power distribution module (PDM-20)
Purpose of the module is used
to distribute the power supply
to all electronic equipment on
the engine.

The following features are


provided
Monitoring of voltages
Short circuit protection
EMC filter Principal internal scheme of PDM
PDM-20 module
Over-voltage protection
Transient suppressors
Power failure detection
Earth fault detection
Reverse polarity protection
Separate modules for 24VDC
and 110VDC

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UNIC C3

Other parts of UNIC C3


Wrtsil CAN-switch (WCS-10)
The service tool (WECSPlorer UT) is connected to this module. The WCS-10
takes care of forwarding CAN-messages and data contents according to the
configuration. The WCS-10 support bit rate configurations on each CAN-port.

Oil mist detector


Oil mist detector monitors crankcase and trips the engine to prevent major
engine damage.

Maintenance Tools- WECSplorer

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UNIC C3
Waste-gate control
On gas engines the waste-gate is used
for control i.e. air/fuel ratio control.

Waste-gate control

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UNIC C3
Gas feed system
The gas supplied to the engine
passes at first a gas regulating
unit (GRU). The gas regulating
unit consists of a filter,
temperature/pressure sensors, a
pressure regulating valve, safety
(shut-off) valves and ventilation
valves.

Gas feed system

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UNIC C3
Cylinder control and measurements
System components
01 Main gas admission valve
02 Diesel injector with pilot valve
03 Pilot fuel pump
04 Knock sensor
05 Exhaust gas temperature sensor
06 Cylinder liner temperature sensor
07 Pilot gas pressure
08 Main gas pressure
09 Charge air pressure

Cylinder control

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UNIC C3
Exhaust gas balancing
The CCM compares cylinders
exhaust gas temperature with the
average exhaust gas temperature of
the entire engine.
The CCM balances the engine with
help of exhaust gas temperature while
engine load is less than 70-75 %
(adjustable limit).
Knock sensor as protection against
knocking.

Cylinder control

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UNIC C3

Knock control
While operation on gas an uncontrolled
combustion may occur, i.e. knocking.
The knock monitoring is activated on the
engine start.
When knocking would get severe, i.e.
heavy knock, knock control will activate.

Cylinder control

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UNIC C3

Engine speed measurement


The purpose of this measurement in UNIC C3 is:
As position feedback to provide accurate gas ignition
As speed feedback to the internal speed controller
As speed feedback in internal parameters tables
For safety
Both the speed and phase measurements are redundant.
The speed signal pulse train contains a missing pulse, used for determining the Top Dead
Center of cyl. (A)1.
The purpose of the phase measurement is to determine the compression phase for TDC
of cyl. (A)1.

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UNIC C3
Engine speed measurement
Speed and phase signal connections on engine
The engine speed is measured,
based on the signal from two
speed sensors.
Both speed sensors are
connected directly to the main
control module (MCM-11),
where the speed calculation is
carried out in.

Engine speed- and phase signal distribution

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UNIC C3
Engine speed measurement
Speed and TDC measurement
As UNIC must detect the
accurate engine angular
position, one missing hole is
arranged in both speed sensing
hole-peripheries on the flywheel.
The speed sensors use
separate holes, but the holes
are in parallel, thus the phase
difference between the two
signals is negligible.

120 1 bored speed-sensing holes in the flywheel

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UNIC C3
Engine speed measurement
Speed and TDC measurement
The sensing gap for these
engine speed sensors has to
be 2,0 mm 0,5 mm.
The signal is connected to all
cylinder control modules, as
well as to the main control
module.

Missing hole location, and speed signal pulse train

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UNIC C3

Engine speed measurement


Engine phase measurement
Two phase sensors are
Location of phase sensors
provided of redundancy
reasons.
These sensors are mounted
at the driving end of the
camshaft of the engine.

Speed and phase signal traces

Speed and phase signal traces

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UNIC C3
Engine speed measurement
Speed signal connections on engine
For injection timing processing,
the cylinder control modules
(CCM-20) need accurate
information about the engine
speed and engine angular
position.
For redundancy reasons two
speed sensors and two phase
sensors are connected to each
cylinder control module.

Speed- and phase signal distribution

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UNIC C3
Main controller/speed governor (MCM)
Handles all strategic control functions
(such as start/stop sequencing and
speed control) of the generating set.
Speed controller
The main task of the MCM module is
acting as the speed/load controller for
the engine.
Two speed sensors are simultaneously
used by the controller.

Speed control, general


In the speed control algorithm the speed reference is compared with
the measured engine speed. MCM-11 module
Dynamics
Limiters
The PID-controller uses different sets of dynamic parameters for operation Three fuel limiters are available:
under different conditions, to obtain optimal stability at all times.
A start fuel limiter
A charge air pressure limiter
A load dependent fuel limiter
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UNIC C3
Engine speed
2 x speed sensor inputs for engine speed.
The higher input frequency is converted and used for speed
controller and to an analogue output signal.
Engine speed 1 output is an isolated analogue output for
external systems, (isolation is common with TC speed 1
outputs).
Engine speed 2 output is a non-isolated analogue outputs for
local indication.
Output range set by trimming output value for nominal engine
speed.
Speed switch 1-4
Potential free outputs.
Max. resistive load 110 VDC / 0,2 A.
Speed switch 1
Adjustable set point up to 50% of nominal engine speed.
Set point for engine running information.
Set point for shutdown blocking functions.
Running hour counter output utilises same set point.
Speed switch 2 4
Adjustable set point up to 120% of nominal engine speed.
Speed switch 4 has also on-delay setting 0, 2, 5 or 10 seconds.
Used for what?
Speed switch 1 - engine running information.
Speed switch 2-4 e.g. AVR activation.
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UNIC C3
Speed Window 1-2
Potential free outputs.
Max. resistive load 110 VDC / 0,2 A.
2 seconds delay before output is activated.
Upper limit of speed window is adjustable up to 120%
of nominal engine speed.
Lower limit of speed window is adjustable up to ~2%
below upper limit.
Used for what?
e.g. clutch-in permission.

Overspeed shutdown
Two redundant speed sensor inputs
Push-pull sensors.
PNP sensors.
Over speed trip limits are adjusted according to plant documents.
Each input has own:
Power supply.
f/U conversion.
Over speed trip circuit.

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Thanks

THANK YOU

SHAKIL SHAIKH
Email :shakil.shaikh@wartsila.com
Mobile : +971 565396313

Learn more about us at www.wartsila.com


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