ENGINE AUTOMATION

GAS ENGINE

Shakil Shaikh
21st May 2017

1 © Wärtsilä PUBLIC 25.5.2017 @ Wärtsilä

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 Wärtsilä”

 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 Wärtsilä”

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

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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 = Wärtsilä 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-Wärtsilä 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

 Wärtsilä 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 cylinder’s
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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