Leanox® Controller

Orient Energy Systems (Pvt.) Ltd. Pakistan.

 Leanox® Controller
 LEANOX is a lean-mixture combustion control. It was
developed by GE Jenbacher and has been patented
worldwide.
 The system ensures the correct air to gas ratio under all
operating conditions. This has the benefit of minimizing
exhaust gas emissions while maintaining stable engine
operation.
 The LEANOX control system corrects engine parameters to
ensure the engine permanently meets the required
nitrogen oxide emission level.
 What is Nox…?
 Nitrogen oxides (NOx) Nitric oxide and nitrogen dioxide are
together known as NOx and often pronounced “nox.”
 NOx is a generic term for mono-nitrogen oxides NO and
NO2 (nitric oxide and nitrogen dioxide). They are produced
from the reaction of nitrogen and oxygen gases in the air
during combustion, especially at high temperatures.
 NOx gases are emitted from high temperature combustion.
Although most of the NOx gases are generated from the
combustion of nitrogen present in the air, some are produced from
the oxidation of nitrogen contained in fuels. Nitrogen generates
various nitrogen oxides including nitrogen monoxide or NO,
nitrogen dioxide or NO2. Both are the most prominent nitrogen
oxides and are often referred to as NOx. NO is easily oxidized to
NO2, which is then dissolved in water to make HNO3. Like sulfur
oxides, nitrogen oxides are the sources of acid rain.
 How Nox Produced..
In most industrial applications (boilers , engines) air is the source of
oxygen (O2). In air, each mole of oxygen is mixed with approximately
3.76 mole of nitrogen. Nitrogen does not take part in combustion, but at
high temperatures, some nitrogen will be converted to NOx, usually
between 1% and 0.002% (2 ppm). Furthermore, when there is any
incomplete combustion, some of carbon is converted to carbon
monoxide. A more complete set of equations for combustion of methane
in air is therefore:
CH4 + 2(O2 + 3.76N2) -> CO2 + 2H2O + 7.52N2
If more air is supplied some of the air will not be involved in the reaction.
The additional air is termed excess air, The chemical equation for
methane burned with 25% excess air can be expressed as
CH4 + 1.25 x 2(O2 + 3.76 N2) -> CO2 + 2H2O + 0.5O2 + 9.4N2
• Excess Air and O2 and CO2 in Flue Gas Source of nitrogen oxides.
N2 + O2 -> 2NO & 2NO+ O2=> 2NO2
• Nitrogen dioxide readily dissolves in water producing a mixture of
nitric and nitrous acids.
2NO2 + H2O ==> HNO3 + HNO2
 Why we control the Nox
 Requirement of Environment Protection Authority.
 EPA require nox in control limit due to nox causes of.
 Helps form acid rain
 It contributes to global warming
 It hampers the growth of plants
 Nox can form with other pollutants to forms toxic chemicals
 Breathing in high level of nox can lead to: swelling of throat , reduced oxygen intake , a larger
buildup of fluids in lungs and burning spasms.
 Small level of nox can cause irritated eyes , nose , fluid forming in lungs and shortness of
breath.
(Max. limit of Nox in Pakistan for natural GAS engines = 400 mgm3).

 To Lean the engine

 To getting Better efficiency

 To control the fuel

 To control the knocking / detonation

 To maintain stable engine operation

Why we control the Nox
 How we can Control the Nox
Generally We can control the Nox of a GAS engine by several methods such as

 By control the quantity of gas (fuel)

 Reducing Temperature

 Selective catalytic reduction ( SCR )

 Chemical Reduction of Nox

 Oxidation of Nox

 But here we will discuss only those which related our system.
 How we can Control the Nox

1- By control the quantity of Fuel

(gas).

 If we increase the quantity of gas

in fuel system then the value of
NOX should be increased.

 If we decreased the quantity of

gas in fuel system then the value of
NOX should be goes down.
 Air Ratio (Lambda) (λ)
 Lambda (λ) is the ratio of actual AFR to stoichiometry AFR for a
given mixture.
 Lambda of 1.0 is at stoichiometry,
 rich mixtures are less than 1.0.
 lean mixtures are greater than 1.0.
 There is a direct relationship between lambda and AFR. To
calculate AFR from a given lambda, multiply the measured
lambda by the stoichiometric AFR for that fuel. The above
equation is often used as the definition of lambda.
 The value of lambda for JGS 320 = 1.6
 The value of lambda for JGS 420 = 1.6
 The value of lambda for JGS 620 = 1.92
 Air Fuel Ratio (AFR)
• Air–fuel ratio (AFR) is the mass ratio of air to fuel present in an internal
combustion engine. These engines burn fuel to create kinetic energy. The
burning of fuel is basically the reaction of fuel with oxygen in the air. The
amount of oxygen present in the cylinder is the limiting factor for the
amount of fuel that can be burnt. If there’s too much fuel present, not all
fuel will be burnt and un-burnt fuel will be pushed out through the
exhaust valve.
• When building an engine, it’s very important to know the air-fuel ratio at
which exactly all the available oxygen is used to burn the fuel completely
or at least to the best possible value. This ratio is called the stoichiometric
air-fuel ratio.
• Theoretically, this ratio will exist only for a stoichiometric mixture, which is
an ideal mixture and in practice this mixture has never been formed for
any machine.
• AFR = lambda x Stoichiometrically required air charge
 Stoichiometrically required air charge for burning of CH4 = 17.45 ( for λ = 1)
 Air fuel ratio for JGS 320 = 1.6*17.45 = 1:27.92
 Air fuel ratio for JGS 420 = 1.6*17.45 = 1:27.92
 Air fuel ratio for JGS 620 = 1.92*17.45 = 1:33.50
 Nox Control in GE Jenbacher
 In GE Jenbacher Gas engines use Leanox® Controller for control the
NOX.
• The task of the LEANOX controller is to calculate and set the
optimum boost pressure, based on the current power output
and the current air-gas mixture temperature. The linear
relationship between these quantities is calculated
automatically by dia.ne after two of the operating points have
been stored to memory.
• The actuator is a gas volume controller, which regulates the
gas volume to control the air ratio λ.
 Advantages of Leanox® Controller
 No hardware installation
 Totally software base control
 Reliable control of Nox-emissions even under fast changing fuel
characteristics
 Corrects engine parameters to ensure the engine permanently
meets the required nitrogen oxide emission
 Eliminates the need to monitor oxygen in the exhaust, using a
Lambda probe
 Combustion control system directly links power output, boost
pressure, fuel temperature, and nitrogen oxide emission
 Ensures continuous control of peak combustion temperatures
and pressures, as well as component lifetimes
 Activation Of Leanox® Controller
 The LEANOX controller switches itself on automatically once
the actual power output exceeds a threshold
value (approx. 30% of the total power output).
 When genset takes 30% actual power of rated output that
time LEANOX controller switched on.
Inputs & Outputs of Leanox® Controller
Leanox® Controller has following inputs and outputs.
INPUTS:
 Power set point value
Power set point value which we have feed the power value in DIA.NE.XT.
 Actual power
Real power/ running load on genset
 Actual Boost pressure
Boost / after turbo charger mixture pressure. We take this value in absolute pressure value.
 Actual Mixture temperature
Mixture temperature before in the intake manifold/ cylinder head.
OUTPUTS:
 Gas mixer
• In the gas mixer, a fuel gas is added to the intake air via a variable gas aperture in order
to create a combustible air-gas mixture. The size of the gas aperture is
increased/decreased by a servomotor, as a result of which the amount of gas and hence
the air ratio λ can be varied.
• The size of the gas aperture is increase/decreased by a servomotor (60,000 steps).
Inputs & Outputs of Leanox® Controller
 Parameters of Leanox® Controller
 Lenox Controller has following same parameters in two
different set points positions.
 1- Set point 1 / 100% load parameters
 2- Set point 2 / 50% load parameters
Parameters are:
 Power set point
 Speed set point
 Boost pressure Set point
 Mixture temperature Set point
 We can re adjust / over write these parameters easily.
 With the help of these parameters we can control the exact
air fuel ratio (NOX ) of genset for smooth operation.
Parameters of Leanox® Controller
 How Leanox® Controller Work
If load/boost pressure change

 As we know the LEANOX controller's

parameter .i.e. power and boost pressure
set point. These set points make a span
between load (power) and boost pressure
. shown in graph.
 when load increased on genset also
increase the boost pressure with the help
of turbo charger then engine governor.
 Gas mixer working on venturi principle.

 Venturi principle:
A constricted throat in the air passage of a
carburetor, causing a reduction in
pressure that result in fuel vapor being
drawn out of the carburetor bowl. In
venture / nozzle pressure drop by
increasing restricted area for gas.
 How Leanox® Controller Work

 The diagram shown gas mixer with venturi , servo motor and turbo
charger compressor side for understanding the operation of gas
mixer/venturi. In venturi principle if suction increased then area should be
decreased. when boost pressure increased (suction increased) then area
of gas flow (gas mixer)decreased by Leanox controller.
 How Leanox® Controller Work
 As we already discussed that when load increased on the genset also increase
the boost pressure
 When boost pressure increased it mean's that suction increased from
compressor side of turbo charger then engine governor. Now the gas mixer
installed at compressor side when suction increased also compressor suck
extra gas from gas mixer at same opening point. Let suppose.
 Load =600kw , P2 = 1800mbar , Gas mixer = 21.8%
Gas flow through gas mixer = 120m3
 Now load increased i.e. 800kw, P2 = 2200mbar , GAS mixer = 21.3%
Gas flow through Gas mixer = 190m3
 Now 190m3 gas flow provide extra fuel to genset as compare to required and
create trouble for smooth operation. Now LEANOX controller working for exact
air fuel ratio for smooth operation. For this Leanox controller close the gas
mixer till required fuel. Now gas mixer for 800kw load is 21.3%.
 How Leanox® Controller Work
If mixture temperature change:
If mixture temperature increase due to following reasons.
 Intake air temperature high
 Fuel mixture cooling system not working properly
 Gas temperature high

 When mixture temperature increased that time also increased the volume
of mixture.
 Then molecules of gas and air also expand and not make the
homogeneous mixture.
Or Fuel (gas ) molecules separate then each others.
 That time genset going to lean mixture fuel and need to fuel for
trouble free operation.
At this position Leanox controller open the gas mixer for exact
air /fuel ratio.
 How Leanox® Controller Work
If power set point change:
 As we know that power set
point and boost pressure set
point make a span shown in
graph:
 If we increase the set point of
power then also change the
span between power and boost
pressure and genset going to
rich fuel mixture i-e.
engine take extra fuel.
 At this position LEANOX
controller close the gas mixer
and make exact air fuel ratio for
trouble free operation.
 Adjustments of NOX
 For adjusting the nox in Leanox controller parameters we have
parameters of boost pressure and power.
If we want Reduce the NOX:
 If we increase the set point of boost
pressure that mean we are doing lean the
genset and That time actual boost pressure
increase and the value of fresh air include in
the fuel and reduce gas mixer by Leanox
controller. Resultant nox goes to down/ reduce.
 same as if we increase the set point of power that time we r also
doing lean genset through change the span between power and
boost pressure.
 Adjustments of NOX
If we want increase the NOX:
 If we decrease the set point of boost
pressure that mean we are doing rich the
genset and That time actual boost pressure
decrease and the value of fresh air reduce
in the fuel and increase the value of gas
mixer by Leanox controller. Resultant nox goes to up/
increase.

 same as if we decrease the set point of power that time

we r also doing rich genset through change the span
between power and boost pressure.
Troubleshooting's of Leanox® Controller

• We face several troubleshooting’s related with

Lenox Controller like..
• Lenox controller deviation
• Turbo by pass goes to zero%
• Knocking
• Ignition point reduction
• Misfiring
 Leanox Controller deviation
Deviation = difference between set point value and actual value.

This fault occurred when boost pressure actual value differ as compare to set
point value. max. limit of difference +/-300mbar.

Checks.
 Boost pressure sensor working
 Boost pressure set point value in parameters
 Analog input card of boost pressure sensor

Remedies.
 If boost pressure sensor not working properly or malfunction then replace
 If boost pressure set point value not ok then re adjust the set point value
 If analog input card not working properly then replace it.
 Turbo by pass goes to zero %
 This fault occurred when required fuel quantity not available for
engine operation.
Possible Causes:
 Intake air filters chocked
 Wrong calibration of gas mixer
 Turbo charger overhauling due*
 After cooler core chocked
 Turbo by pass valve faulty
 Analog output card faulty
 Boost pressure sensor faulty
 LENOX controller parameters need to be adjusted
 Leakage from exhaust manifold
 Ignition point need to be adjusted
 KNOCKING
 Knocking: Generally caused by fuel with a low methane rating) is the tendency
for the fuel to pre-ignite or auto-ignite in an engine's combustion chamber.
This early (before the spark plug fires) ignition of fuel creates a shock wave
throughout the cylinder as the burning and expanding fuel air mixture collides
with the piston that is still traveling towards top-dead-center. The resulting
knock is the sound of the pistons slamming against the cylinder walls. Severe
knocking can break pistons and destroy engines.

 Possible Causes:
 mixture too rich
 Pre Ignition
 Any abnormal sound / vibration create through moving parts(v/v lash not corrected)
 The cylinder liner not properly getting lubricated
 Mixture temperature increased.
 Faulty knocking sensor
 Faulty knocking sensor cable
 Faulty analog input card
 Cylinder head not properly torque.
 Ignition point Reduction
Ignition Point:
 That point where The spark plug ignites an air-gas mixture in the
combustion chamber before top dead center. It is also known as Crank
angle °.
Ignition point reduction:
 When engine appears knocking due to abnormal combustion, mixture
temperature increase, turbo by pass goes to zero, or in case of other
abnormality engine try to recover the efficiency through reduce
ignition point.
Possible causes:
 knocking
 Mixture temperature high
 Turbo by pass goes to zero %
 Mixture rich / lean
 MISFIRING
Misfire:
 when the fuel in an internal-combustion engine fails to ignite
properly or when expected.
 Poor air-fuel mixture exceeding the lean combustion limit.
Depending on the type of combustion system and fuel the engine
can't support the flame development when the ratio between air
and fuel becomes too great.
 Possible Causes:
• Mixture rich / lean
• Weak spark plugs
• Ignition coil / lead faulty
• Ignition timing disturb
• Too late ignition point
ANY
QUESTION………???
Βγ:
Muhammad Sohail
Service tech.(Product support)
muhammad.sohail@orient-power.com
Orient energy systems (pvt.) ltd.