Engine power plant
operation and maintenance


KEEP IT RUNNING

































HOW DO YOU OPERATE AND MAINTAIN
AN ENGINE-BASED POWER PLANT?


Wärtsilä 50SG

To meet the electricity demand at all times in the most optimal way, a power plant should be easy to operate. Wärtsilä’s engine-based Smart Power Generation plants are designed to be simple to operate and enable smart maintenance planning: fix one engine at the time, and keep the others running.

In Wärtsilä power plants the operator supervises and controls the plant mainly from one or more workstations in the plant control room. Normally, the plant is operated in automatic mode: control system takes care of the start and stop processes, synchronization and output control. If needed, the operator can control the output manually. With remote monitoring services, the plant can be monitored from a remote location via a secure internet connection. Remote control and dispatch can also be implemented.




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“According to our service agreement with Wärtsilä, the
plant availability guarantee was 95 percent. Thanks to
the harmony between Wärtsilä and our technical staff,
the plant availability today is actually even higher.“

BERKAN ÇAĞATAY, SITE MANAGER, CAN ENERJI ENTEGRE ELEKTRIK ÜRETIM, TURKEY 







START AND STOP

The operator starts and stops the plant from a workstation. The auxiliary units are generally kept in an automatic mode, where they are started and stopped automatically. For emergency stop, engine-specific emergency stop buttons and buttons for stopping the entire plant are located in the control room. Each engine has an emergency stop button also in the engine hall. Plant emergency stop buttons can be installed.

 





Total lifecycle costs of Wärtsilä engine
power plant including return demand
over 15 years.




MONITORING AND CONTROL


When the plant is in operation, personnel is either present at site, or, if the plant is remotely controlled, on-call personnel should be stationed close enough to reach the plant at short notice when needed. The control system records alarms and events in the workstation.

The operators make daily checks around the plant to check local meters, drain points, vibrations, etc. Abnormal conditions requiring prompt operator efforts are noted by alarms, which are indicated by sound and light signals. Engine alarms may also be indicated by status and alarm annunciator lights in the engine hall.

monitoring & control












Wärtsilä has service agreements in 11 GW
worth of engine power plants around the world.




FLEXIBLE MAINTENANCE


The maintenance of internal combustion engines requires minimum downtime. Keeping strategic spare parts on site considerably reduces the downtime required for maintenance. OEM maintenance ensures high reliability and availability of the power plant and keeps the plant performance on a continuously high level. Routine checks are conducted by plant personnel, for example assistant operators. Typically, the OEM is contracted for conducting maintenance every 4000 running hours.


engine maintenance schedule

 







Engines should be dispatched in such a way that the running hours are unequally spread on each unit. This concept allows for scheduling the maintenance on one or several units at a time, maximizes the available power generation at any given time and minimizes lost profits from trading.

The maintenance window can be as wide as +/– 1000 Rhrs.




MAINTENANCE OF THE WÄRTSILÄ 18V50SG ENGINE



Maintenance staff


  • Responsible for checks, adjustments and change-outs
  • Examples of minor checks and maintenance conducted by plant personnel:
    • Check water quality
    • Clean turbocharger air filters
    • Water-cleaning of compressors
    • Change spark plugs
    • Check yoke and adjust valve clearances

Operations staff


  • Daily routines and checks are performed by plant personnel
  • Examples of daily checks of various plant systems:
    • Engine charge air
    • Exhaust gas
    • Engine and plant cooling
    • Starting air

Minor maintenance


  • Examples of maintenance and inspections conducted by OEM:
    • Check cylinder tightness
    • Clean charge air cooler
    • Inspect turbocharger bearings
    • Replace lubricating oil filter candles

Major maintenance


  • Examples of major maintenance conducted by OEM: 
    • 18 000 Rhrs
    • 24 000 Rhrs
    • 36 000 Rhrs
    • 48 000 Rhrs


Maintenance schedule for Wärtsilä 18V50SG


Major maintenance

18 000 Rhrs


24 000 Rhrs


36 000 Rhrs



48 000 Rhrs

Replacement of parts (examples)

Piston rings, main gas admission valves, ignition coils, pre-chamber tips, pre-chamber valves, spark plugs

Spark plugs, gas filter cartridges, oil mist detector filters, expansion bellows, flexible pipe connections

Piston rings small end bearing big end bearing, valves, turbocharger bearings, charge air coolers, ignition coils, spark plugs

Turbocharger rotor, charge air bellow, spark plugs, gas filter cartridges, oil mist detector filters, expansion bellows, control system modules, drive electronics

Overhaul & maintain (examples)

Cylinder heads, gas system


Main starting valves, waste gate valve, turbocharger, and actuator

Vibration damper, cylinder head, waste gate valve and actuator, gas system, starting air distributor


Main starting valves, waste gate valve and actuator

1. Parts listed as well as overhaul & maintain activities are examples only
2. Scope of multiple checks per major maintenance job is not listed in this view
3. Complete maintenance schedule available separately


Read more about Wärtsilä’s power plant services here.



 

LET'S TALK


Wärtsilä’s ultra-flexible engine power plants offer new business opportunities for IPPs and utilities in North America. They are used, for example, to create revenue by following electricity price in real time and to integrate more wind power.

Please contact us for more information.


Contact request






Andreas Granlund

ANDREAS GRANLUND
General Manager Technical Support,
Americas