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Control System Upgrade for Wärtsilä 34SG Gas Engines


PROJECT OVERVIEW:

Due to obsolescence of the existing WECS3000 engine control and lack of local support, the customer hired GCS to upgrade two Wärtsilä 34SG gas engines, each rated at 6350kW. The site usually parallels with the grid in baseload mode and power factor control. The controls communicate with each other to perform active and reactive load sharing while in island mode, supplying local city power.

Picture of a Wartsila Gas Engine
TYPE OF PLANT
  • Power Plant (Natural Gas)
PRIME MOVERS
  • 2x Wärtsilä 34SG 18V 6350kW
SYSTEM COMPONENTS
  • Woodward Atlas-II
  • Woodward LECM (Large Engine Control Module)
  • Woodward LECM Coil
  • Woodward SOGAV MCC and PCC
  • Woodward Waste-gate Valve/Actuator
  • Woodward Spark Plug Extender
  • Basler DECS 250 Automatic Voltage Regulator
  • Engine Sequencing Logic - Allen Bradley Control Logix PLC
  • SEL 700G Protection Relay
  • Allen Bradley Control Logix PLC Balance of Plant
SCADA SYSTEM
  • Redundant Servers
  • Five HMI thin-clients



GCS designed and supplied control cabinets with Woodward LECM A-bank, LECM B-bank, LECM C-ignition, and Woodward Atlas-II, as well as upgrading or replacing the Siemens PLC S7-300 to state of the art Allen Bradley Control Logix. The voltage regulator modernized to Basler DECS 250 providing advanced communication and logging to the monitoring & control system. The generator protection relay upgraded to SEL 700G.

The new control system provides automatic start sequence, synchronization, active/reactive load control, engine safeties, auxiliary controls, and comprehensive control & monitoring system including five thin-client HMIs and two redundant servers, improving the availability of the power plant with more reliable energy.

The new control system provides many more tools for engine testing and calibration: PCC and MCC SOGAV actuation, LECM Coil/Spark Plug test, waste-gate actuator stroke test, manual cylinder temperature balancing; this gives operations far superior interrogation and diagnostic tools to keep the plant at optimum performance.




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