Regent Energy & Power Limited

Assignment
Discuss About Jenbacher 620 Engine Important
Parts

PREPARED BY:
Abdul Hannan Chowdhury
Id# 18107056
Program: BSME

DEPARTMENT OF MECHANICAL ENGINEERING

IUBAT-INTERNATIONAL UNIVERSITY OF BUSINESS AGRICALTURE

AND TECHNOLOGY

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Jenbacher Type-6 Engine

The Jenbacher type 6 engines are reliable, advanced products serving the 1.8 to 4.5 MW power
range. It’s 1,500 rpm engine speed results in a high power density and low installation costs. The
type 6 pre-combustion chamber achieves maximum efficiency with low emissions. Proven
design and optimized components enable a service life of 60,000 operating hours before the first
major overhaul.
 Highest levels of electrical efficiency
 Highest levels reliability
 Long development history
 Robust design for a variety of gases
 High output density at 1,500 rpm
 LEANOX® lean burn control ensures minimal emissions
 Pre-chamber combustion ensures maximum efficiency
 Turbocharger bypass evens out extreme operating conditions
 External dry exhaust manifold ensures long cylinder head life
 Selective knocking control for each cylinder ensures optimal protection

Specification of Jenbacher type 6 engines

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 Low installation and operating costs
 Low specific fuel consumption
 High power density
 High heat recovery rate
 3356 kw electrical output
 Lean burn, turbo charged, mixture cooled
 24-cylinders @ 1,500 rpm
 Compact package design
 Vibration decoupled system
 Thermal efficiency: 25.5%
 Electrical efficiency: 43.2%
 Total efficiency: 68.7%
 Mechanical power output: 3431 kw
Technical specifications
 Electrical output-3047-3356kw
 No.of cylinder /arrangement - 20/v60
 Combustions –lean burn principles
 Bore -190mm(7.48”)
 Stock -220mm(8.86”)
 Speed-1500 rpm (60Hz), 1500rpm(50Hz)
 Dimension :8900(length),2200(widths ),2800(height)
 Gen-set weight-28000kg

MAINTENANCE
40.000 HOURS MAINTENANCE CHECKLIST ON JENBACHER J620 GAS ENGINE

 Replacement of pre-combustion chambers with their respective O-rings. Removal of cylinder

heads on the engine is excluded.
 Replacement of the rocker cover gaskets.
 Intake and exhaust valve timing
 Replacement of the rubber springs which have not able for being installed again.

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 Renew the actuator linkage.
 Replacement of the main lubricating oil filter.
 Renew throttle valves.
 Replacement of air filters.
 Renew 2x vibration dampers.
 Replacement of the elastic coupling generator-engine.
 Renew crankcase ventilation filters.
 Checking of high connections and wiring.
  Disassembly of the exhaust gas turbocharger and subsequent mounting on the engine.
 Cleaning the battery connection terminals.
  Overhaul of the main lubricating oil pump with bushings replacement (*). Optional.
 Replacement of gaskets, screws and other minor spare parts.
  Complete engine assembly.
 Engine connection, commissioning and subsequent checking of control parameters through
DIA.NE control system.(Note-DIA.NE is a user-friendly engine management system. A color
graphic display provides a clear overview of all information. This diagnostic instrument features
an effective alarm management system with all error messages date stamped and clearly
presented in tabular form to identify the sequence of events)
 Disassembly of the intercooler
1. Preliminary visual inspection and exterior appearance check.
2. Preliminary hydraulic test to verify absence of leaks.
3. Dismantling of all covers.
4. Replacement of fixing elements.
5. Repair of female threads of the intercooler tube bundle.
6. Cleaning of tube bundle and covers by using an ultrasonic cleaning machine.
7. Renew of water side gaskets.
8. Inner and outlet painting of water side covers.
9. Complete assembly of the intercooler, respecting the recommended tightening according to the
standard requirements.
10. Final hydraulic test for 8-12 hours for product validation, prior to its assembly and installation on
the engine.

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Spare Parts

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 Jenbacher cylinder head
 Jenbacher cylinder head overhaul kit
 Jenbacher piston
 Jenbacher gasket kit
 Jenbacher Bearing
 Shortblock Jenbacher
 Longblock Jenbacher
 Jenbacher valve
 Actuator Jenbacher
 Jenbacher Starter
 Jenbacher Intercooler
 Jenbacher camshaft
 Jenbacher crankshaft
 Jenbacher oil filter
 Jenbacher air cleaner
 Jenbacher Blow-by filter
 Jenbacher Engine valve
 Jenbacher gas admission valve
 Jenbacher spark plug
 Jenbacher ignition cable
 Jenbacher ignition wire
 Jenbacher Turbocharger
 Jenbacher Gear train
 Jenbacher Actuators
 Jenbacher Rocker arm
 Jenbacher Vibration damper
 Jenbacher Pumps
 Jenbacher Pre-chamber gas valve
 Crankcase housing
 Radiator
 Butterfly valves

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(Pressure adjusting vessels, Compensators ALTERNATOR, ROTOR, Roller tappet)

Cylinder head
Jenbacher Cylinder head key to controlling air flow in and out of the cylinders and fuel
deployment. The cylinder head also holds the injectors and valves – and contains more moving
parts than any other part of the engine. Although largely unnoticed

Materials - Jenbache Cylinder heads are made from either cast iron
Cylinder head type – Jenbacher Cylinder head type Loop-flow type
Jenbacher cylinder head overhaul kit
Jenbacher cylinder head offer complete systems and single components as well including
 Valve spindles
 Guides
 Springs

 Seats
 Rotators
 Clamping cones,
 Inlet valve
 Exhaust valve
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Jenbacher piston

A sliding piece moved by or moving against fluid pressure which usually consists of a short
cylindrical body fitting within a cylindrical chamber or vessel along which it moves back and

forth
The 5 parts of a piston: Piston features include the piston head, piston pin bore, piston pin, skirt,
ring grooves, ring lands, and piston rings. The piston head is the top surface (closest to the
cylinder head) of the piston which is subjected to tremendous forces and heat during normal
engine operation.
Materials: Pistons are made from either a low carbon steels or aluminum alloys, Pistons are
produced from cast or forged. The standard piston alloy is a eutectic Al-12%Si alloy containing
in addition approx. 1% each of Cu, Ni and Mg.
The 4 stages of a piston engine: A four-stroke cycle engine is an internal combustion engine that
utilizes four distinct piston strokes (intake, compression, power, and exhaust) to complete one
operating cycle.
Inside the piston: Pistons are equipped with piston rings. They seal the combustion and working
chamber in relation to the crankcase. They also remove the oil from the cylinder walls, thus
controlling the oil consumption.

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parts are in a piston: It has two parts, one side is attached to the gudgeon pin which is fixed, and
the other side keeps the piston moving. The side that remains fixed is called non-thrust, which
means it does not feel thrust and the opposite side is called the thrust side.

Jenbacher Gasket
Their purpose is to seal the space between two components and prevent leaks while in operation.
Gaskets come in numerous shapes and sizes, but are largely produced in a circle form and
applied to seal pipes and connections that would normally leak without them

Causes an engine gasket to fail: A perforation to gasket, or a dreaded blown head gasket,
usually occurs through overheating. However, pre-ignition trouble could see fuel combusted at
the wrong time, sending large amounts of pressure into the cylinder head and causing
perforations further down the line
Material : Gaskets are normally made from a flat material, a sheet such as paper, rubber,
silicone, metal, cork, felt, neoprene, nitrile rubber, fiberglass, plastic polymer

Jenbacher Bearing
Bearing is a device that is used to reduce friction between moving parts of machine elements to
provide movement in a desired way with minimum power losses
Main bearings: Main bearings are usually plain bearings or journal bearings, held in place by
the engine block and bearing caps. The number of main bearings per engine varies between

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engines, often in accordance with the forces produced by the operation of the engine

Material : Aluminum based bearing materials. Mono-metal (solid) bearings (eg. Al11Si) Bi-
metal bearings. Soft tin containing alloys (AlSn) .
Copper based bearing materials. Mono-metal (solid) bearings. Bi-metal bearings (Cu10Pb10Sn,
CuAl) Cast copper alloy. Sintered copper alloy.
Guide bearing:

A guide bearing is a roller, plate or block that reduces wear, maintains

alignment and minimizes friction of moving parts. Guide bearings are commonly found on saws,
machining tools and other equipment where alignment of moving parts is needed.
Material : These bearings are usually made of materials like steel and PTFE composite, PTFE
fabric or copper alloy. these bearings have lower friction
Rod Bearing:

An engine rod bearing is a split-sleeve type of bearing

(meaning it has two separate semicircular halves or shelves) that keeps the crankshaft and
connecting rod in place as they rotate.
Material : Bearing alloys commonly used as linings in these applications are copper-based

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Or aluminum-based (aluminum–tin or aluminum–tin–silicon).

Thrust bearing
A thrust bearing, a type of rotary bearing, rotates between parts reducing friction and is designed
to support an axial load (mostly in low-speed applications).
Four types of thrust bearings
Balls, cylindrical rollers, tapered rollers, spherical rollers and needle rollers are the most
common rolling elements used for thrust applications.

Shortblock Jenbacher

short Blocks are a non-running engine. They consist of an engine block, crankshaft and
connecting rods. A short block however does not consist of a cylinder head, liners, gaskets, rings
a timed gear-train or any kind of ancillary parts including the fuel system

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materials’ : Cylinder blocks are normally made of cast iron or aluminum alloy. The aluminum
block is much lighter. Various types of materials are combined to increase strength

Long block Jenbacher

A long block engine includes all of the parts of the short block package with the addition of a
cylinder head, camshaft, and valve-train. A turn-key or crate engine is a fully assembled engine
usually shipped from the manufacturer to the installer in a crate.
Material : The concrete commonly used to make concrete blocks is a mixture of powdered
portland cement, water, sand, and gravel. This produces a light gray block with a fine surface
texture and a high compressive strength

Jenbacher Engine valve

Engine valves are mechanical components used in internal combustion engines to allow or
restrict the flow of fluid or gas to and from the combustion chambers or cylinders during engine
operation. The valves are installed in a part of the engine called the head and are responsible for
letting air and/or fuel into the cylinders to be combusted -- those are called intake valves -- and
for letting the exhaust from that combustion out of the cylinders -- those are called exhaust
valves.

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1:valve guid
6:valve spring
7:intake valve
4:exhaust valve
{6}: Pre-
combustion
chamber gas
valve
9:valve seat

Materials used in Engine Valves

The intake valves are mainly made of chrome, nickel, or tungsten steel, and the exhaust valves
are primarily made of high heat resistant metals such as nichrome, silicon-chromium, or cobalt-
chromium alloys.
Types of Engine Valves
 Monometallic engine valves
 Bimetallic engine valves
 Hollow engine valves

Jenbacher Actuators

Jenbacher electric actuator

allows intake manifold throttles or turbo charge guide vanes. They perform a variety of
performance and convenience functions, from controlling the throttle to directing airflow in the
climate control system, and operating power seats and lift gates
Jenbacher Starter motors

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The starter has a small starting gear that,
when turn the key or press the engine start button, engages the engine's flywheel. Then it delivers
power, getting the engine rotating. This allows it to suck air and fuel into the cylinders and begin
the combustion process that allows it to run on its own. The engine has three electric sliding gear
starter motors. These are 24V DC motors which
have toothed gears. The starter motors are operated by a starting relay which engages the
motors with the main gear to initially rotate the crankshaft and disengages the motors when
ignition starts (normally at 190-210 r.p.m.).
Jenbacher Intercooler

Jenbacher intercoolers (Charge

Air Coolers) are designed to reduce fuel consumption while increasing the engine power and
efficiency. The intercooler's task is to reduce the temperature of the inlet gas and thus densify the
air required which optimises the combustion.
purpose of intercooler in turbocharger
The main role of the intercooler is to reduce the temperature of the hot air compressed by the
turbocharger, before it reaches the engine's combustion chamber. This has a significant impact
on the charge effect, as the cooled air has a much higher density in terms of air molecules per
cubic centimeter.
Materials:
Jenbacher engine intake air intercoolers are almost exclusively made from aluminum alloy

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Jenbacher oil pumps
The oil pumps primary purpose is to circulate engine oil under pressure to the bearings, pistons
and the camshaft. This lubricates these systems, allows the use of higher-capacity fluid bearings
and also assists in engine cooling.
TYPE: “Pleated air filters”

Jenbacher air cleaner

Jenbacher air cleaner TYPES Pleated air filters
Pleated air filters are effective at capturing small particles and have high filtration efficiency to
greatly improve indoor air quality as they can capture pollutants such as odor, bacteria, pollen
grains, molds, and other allergens.
(Pleated paper elements are designed to remove contaminates from hydraulic oils, lube oils,
insulating oils, gear oils, quench oils, fuels, coolants, solvents and water.)

Jenbacher Blow-by filter

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The filter for cleaning the blow-by gas. Characteristic of the Blow-by Gas
Filter. The filter separates the gas and the oil mist in order to clean the exhaust fumes. When the
filter is clogged, the oil mist badly affect on the engine, boost sensor, inner cooler.

Pre-chamber gas valve and Spark plug socket 9029957 : A pre-chamber gas valve including a
valve body, at least one valve spring and at least one valve needle, wherein the valve body has a
lower space which is acted upon with gas in the operating condition and an upper space in which
the valve spring is arranged, wherein the upper space is closed by way of a pressed plug.

Jenbacher spark plug

A device for firing the explosive mixture in an internal

combustion engine. As their name suggests, spark plugs are the spark of electricity that ignites

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the combustion needed to start your vehicle. Spark plugs emit a bolt of electricity across a small
gap igniting the fuel and air mixture that puts the pistons in motion and gets your vehicle up and
running.
Material : common spark plug as a “copper” spark plug. Normal: 'Normal' or 'standard' spark
plugs are generally tipped witha copper coating

Jenbacher Ignition cable

Ignition cables connect a distributor, or ignition coil, to the spark plugs. The
high voltage spark needed for combustion travels through these cables. Spark plug wires (also
referred to as ignition wiring) transfer the spark from the distributor or ignition coil to the plugs.
The subsequent spark ignites the air-fuel mixture in the combustion chamber of your engine
3 types of ignition system: distributor-based, distributor-less, and coil-on-plug (COP)
Jenbacher Ignition wire
Spark plug wires (also referred to as ignition wiring) transfer the spark from the distributor or
ignition coil to the plugs. The subsequent spark ignites the air-fuel mixture in the combustion
chamber of your engine
Gear train

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The gear driving the engine oil pump and the camshaft can be found on the flywheel side. The
crankshaft toothed gear, the intermediate gears and the camshaft timing gear all have timing
marks to ensure that the timing is correctly adjusted.
1. Camshaft timing gear
2. Intermediate gear
3. Driving gear of engine oil pump
4. Crankshaft toothed gear

Camshaft:

The camshaft runs on 11 bearings in

replaceable bearing bushes and is driven by the

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crankshaft via intermediate gears. The rocker arms on the intake and exhaust valves are
operated by the camshaft by means of tappets and push rods. An adjustment bolt on each

Rocker arm

Rocker arm is used for accurate adjustment of the tappet clearance.

The rocker arm is the part responsible for transmitting the movement of the camshaft towards the
intake and exhaust valves of the engine, a process that occurs through the direct contact of these
parts with the tappets and according to the movement of the shaft
Vibration damper

A viscous damper is used to reduce rotational

vibrations of the crankshaft. The viscous
damper is a fully closed housing containing a flywheel. The cavities between the housing and
the flywheel are filled with silicone oil.
Pumps

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Fo
r engine lubrication system of JMS 620, there are three different pumps. Two are pre
lubrication pumps and the other is a mechanical gear type pump. The mechanical gear type pump
is connected to the main crankshaft toothed gear via an intermediate gear. One of the pre
lubrication pumps is AC powered (3 phase 400 V, 50 Hz, 1.5 kW) and the other is DC powered
(24 VDC, 1.5 kW).Both pumps operate for normal start. Only DC pump operates for black start.
Operating time of pumps > 1 minute before engine starts. Once engine speed exceeds 800 rpm,
these pre lubrication pumps are switched off and mechanical gear type pump takes over.
Additionally, the pumps can be manually controlled in order to preheat the lube oil.

Turbocharger:

The exhaust gases entering the turbine

housing drive the turbine wheel, and therefore also the compressor impeller which sits on the
same shaft as the turbine wheel. The compressor impeller draws in the gas/air mixture from the
gas/air mixer and pushes it into the engine intake chamber via the mixture cooler (mixture/water
heat exchanger) and the throttle valve.The exhaust gas turbocharger is lubricated by the engine
lubricating system.

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Jenbacher oil filter

The oil filter cartridge is changed when the

differential oil pressure reaches a value of 2.00 bar.
When a new filter cartridge is placed, the differential oil pressure is 0.6-0.8 bar.

Crankcase housing
In a piston engine, the crankcase is the housing that surrounds the crankshaft. In most modern
engines, the crankcase is integrated into the engine block.

PISTON COOLING NOZZLE

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Piston cooling nozzle is located in the cylinder of an engine. Its main
function is to cool the piston by spraying the cool- ant through the nozzle of this piston cooling
device in order to avoid overheating.

Radiator
Radiators work to eliminate heat from the engine. The process begins when the thermostat in the
front of the engine detects excess heat. Then coolant and water get released from the radiator and
sent through the engine to absorb this heat
As dump radiator a table cooler with 10 fans is used, which is controlled in 10 steps. The steps
are switched depending on the position of the control valve. The on off sequence of the fans
will be changed after every cycle
Butterfly valves:
A number of butterfly valves which can be operated manually depending on
various situations are used in LT water circuit

Pressure adjusting vessels:

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A pressure adjusting vessel is used in each of the
cooling water
circuit. The vessels maintain the water pressure in case of any sudden pressure changes. The
vessel contains a diaphragm. The upper portion is filled with pressured air and the lower half
remains connected to the water circuit. The diaphragm separates the air from water. The
diaphragm expands in both way to compensate any pressure change.
Compensators:

Some metal compensators are used in different

places of the piping’s of both
jacket and LT water circuit. These compensators play a vital role as they are responsible for
the high pressure containment of the cooling water circuit.
Temperature, pressure and flow switches : There are temperature, pressure and flow
switches in different points of cooling water circuit. These switches are come into operation
during the startup process of the engine.

ALTERNATOR:
An alternator is an electrical generator that converts mechanical energy to electrical
energy in the form of alternating current. For reasons of cost and simplicity, most
alternators use a rotating magnetic field with a stationary armature. Occasionally,
a linear alternator or a rotating armature with a stationary magnetic field is used. In
principle, any AC electrical generator can be called an alternator, but usually the term
refers to small rotating machines driven by automotive and other internal combustion
engines. An alternator that uses a permanent magnet for its magnetic field is called a
magneto. Alternators in power stations driven by steam turbines are called turbo alternators.
Large 50 or 60 Hz three phase alternators in power plants generate most of

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the world's electric power, which is distributed by electric power grids.
ROTOR:

Cylindrical type: Cylindrical type

rotors are used in high speed alternators,
especially in turbo alternators. This type of rotor consists of a smooth and solid
steel cylinder having slots along its outer periphery. Field windings are placed in
these slots. The DC supply is given to the rotor winding through the slip rings and
brushes arrangement.
Roller tappet

Roller tappets are the point-of-entry for reducing internal friction in an

engine, but there's more. Roller rocker arms reduce friction at the valves. Roller tappets allow
faster, "steeper" opening and closing ramps. This allows the cam to produce more lift for a given
duration. They are not limited to a particular lifter diameter to obtain higher cam lifts.

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