MTU Fluids and Lubricants Specifications for Series 400 Gas Engine-Generator Sets ( pdf , 282 KB)

Fluids and Lubricants
Specifications
MTU Fluids and Lubricants Specifications for Series 400 Gas EngineGenerator Sets
A001066/01E
© 2015 MTU Onsite Energy GmbH, Augsburg
The original document was created in the German language.
This publication including all of its parts is protected by copyright. Each instance of use requires the prior written consent of
MTU Onsite Energy GmbH. This applies in particular to duplication, dissemination, editing, translation, microfilming, and storage and/or processing in electronic systems, including databases and online services.
All of the information presented in this publication was current and up-to-date at the time of publishing. MTU Onsite Energy
GmbH reserves the right to make changes to, delete, or supplement the provided information and data as needed.
Table of Contents
1 Confirmation for Fluids and Lubricants
1.1 Confirmation by the operator
5.7 Approved corrosion inhibitors / antifreezes
4
2 Preface
2.1 General information
5
3 Liquid Fuels
3.1 General information
3.2 Natural gas
3.3 Biogas
7
8
9
4 Inlet Air and Combustion Air
4.1 General information
13
5 Coolants
5.1
5.2
5.3
5.4
General information
Requirements imposed on engine coolant
Requirements imposed on mixture coolant
Requirements for the quality of water for
the gas sequential heater
5.5 Requirements for the quality of water for
the gas cooler and gas sequential heater
5.6 Treatment with corrosion inhibitor /
antifreeze
6 Heating Water
6.1 General information
6.2 Requirements imposed on heating water up
to 100 °C
6.3 Requirements imposed on heating water
above 100 °C
17
18
19
21
22
23
7 Lubricating Oil
7.1 General information
7.2 Approved lube oils
7.3 Lube oil change intervals
24
25
28
8 Exhaust Condensate
8.1 General information
14
15
16
20
30
9 Appendix A
9.1 Abbreviations
9.2 Conversion table of SI units
9.3 MTU Onsite Energy contact person / service
partner
31
32
33
10 Appendix B
34
DCL-ID: 0000033512 - 002
10.1 Index
A001066/01E 2015-06 | Table of Contents | 3
1 Confirmation for Fluids and Lubricants
1.1 Confirmation by the operator
The plant must not be commissioned without this confirmation.
Plant description:
Plant consisting of:
Factory / SAP no.:
Customer:
Operator:
MTU Project Manager:
We hereby confirm that the quality of the fluids and lubricants (coolant, gas, lubricating oil, heating water,
etc., where applicable) conforms to the Fluids and Lubricants Specifications of MTU Onsite Energy.
MTU Onsite Energy does not provide any warranty for damage incurred as a result of deviating fluid and lubricant quality.
City / date
TIM-ID: 0000051982 - 001
Legally binding signature (customer)
4 | Confirmation for Fluids and Lubricants | A001066/01E 2015-06
2 Preface
2.1 General information
Used symbols and means of representation
The following instructions are highlighted in the text and must be observed:
This symbol indicates instructions, tasks, and activities that must be complied with to avoid
danger for personnel, as well as damage or destruction of the material.
Note:
A note indicates whether special attention is required when executing a task.
Fluids and lubricants
The service life, operational reliability and function of the drive systems are largely dependent on the fluids
and lubricants employed. The correct selection and treatment of these fluids and lubricants are therefore
extremely important. This publication specifies which fluids and lubricants are to be used.
Test standard
Designation
DIN
Federal German Standards Institute
EN
European Standards
ISO
International Standards Organization
ASTM
American Society for Testing and Materials
IP
Institute of Petroleum
DVGW
Deutsche Vereinigung des Gas- und Wasserfaches e.V.
Table 1: Test standards for fluids and lubricants
Approved fluids and lubricants may not be mixed.
The customer must comply with the instructions specified in the safety data sheets of the respective manufacturers.
Applicability of this publication
TIM-ID: 0000051765 - 001
The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using them,
make sure you have the latest version. The latest version is also available at:
http://www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation
If you have further queries, please contact your MTU representative.
Warranty
Use of the approved fluids and lubricants, either under the brand name or in accordance with the specifications given in this publication, constitutes part of the warranty conditions.
The supplier of the fluids and lubricants is responsible for the worldwide standard quality of the named products.
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Fluids and lubricants for drive plants may be hazardous materials. Certain regulations must be
obeyed when handling, storing and disposing of these substances.
These regulations are contained in the manufacturers' instructions, legal requirements and technical guidelines valid in the individual countries. Since there can be major differences from country to country, it is not
possible to provide a universally applicable statement on the rules to be observed within the framework of
these Fluids and Lubricants Specification.
Users of the products named in these specifications are therefore obliged to inform themselves of the locally
valid regulations. MTU accepts no liability whatsoever for improper or illegal use of the fluids and lubricants
that it approves.
When handling fluids and lubricants the "Rules for the protection of the environment (see Safety Regulations,
Disassembly and Disposal)" are to be adhered to, since they are hazardous to health and flammable.
Incorrect use of fluids and lubricants causes environmental pollution.
• Fluids and lubricants must not enter the ground or the sewerage system.
• Used fluids and lubricants must be disposed of through used oil recycling or hazardous waste disposal.
• Used filter elements and cartridges must be disposed of with hazardous waste.
The customer / operator bears the responsibility for adhering to the fuel values.
Preservation
All information concerning corrosion protection, reapplication of corrosion inhibitors and removal of corrosion inhibitors, including the approved corrosion inhibitors is provided in the MTU Corrosion Inhibitor and
Subsequent Application of Corrosion inhibitor Guidelines. The latest version is also available at:
TIM-ID: 0000051765 - 001
http://www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation
6 | Preface | A001066/01E 2015-06
3 Liquid Fuels
3.1 General information
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
Moisture in the fuel / air mixture
Damage / destruction of the catalytic converter / destruction of the gas train
• It must be ensured that the limit values of the moisture in the fuel as well as the intake air are not
exceeded at any time!
Harmful substances / contamination in the fuel
Long-term damage due to corrosion
• It must be ensured that no corrosive compounds (e.g. siloxane, phosphor, arsenic, heavy metal, sulfur, ammonia, chlorine, fluorine, bromine, iodine compounds) enter the fuel lines. Or their limit values
must not be exceeded. Exceeding the limit values voids the warranty.
Harmful substances / contamination in the intake air
Long-term damage due to corrosion
• It must be ensured that no corrosive compounds (e.g. siloxane, phosphor, arsenic, heavy metal, sulfur, ammonia, chlorine, fluorine, bromine, iodine compounds) enter the intake air. Or their limit values
must not be exceeded. Exceeding the limit values voids the warranty.
Harmful substances / contamination in the exhaust gas
Long-term damage due to corrosion
• It must be ensured that no metal such as iron, nickel, chromium, copper, zinc and tin enters the exhaust gas system / catalytic converter. If the cumulative quantity of these metals together with the
heavy metals exceeds the total limit value of 350 g/m3 of the catalytic converter space volume, this
voids the warranty of the catalytic converter.
Exceeding the temperature in the exhaust gas system
Damage / destruction of the catalytic converter
• It must be ensured that the maximum operating temperature of 600 °C is not exceeded. Exceeding
the limit values voids the warranty.
It is essential to make sure - at the latest prior to commissioning and by consulting the relevant gas supply
company - that the minimum methane number specified in the respective data sheet and the calorific value
range are observed. It is also necessary here to inquire about the occasional admixture of butane- or propane-air mixtures.
TIM-ID: 0000051919 - 001
The fuel must be technically free of mist, dust and liquid. Condensation in the gas system is to be prevented
by suitable measures (dehumidification, protection against cooling down, heating, etc.). Corrosive constituents may only be present in the concentrations set out below.
Any damage due to humidity, especially in association with sulfur compounds, is not be covered by the guarantee.
It has to be ensured that no catalyst poisons (phosphorus, arsenic, sulfur, ammonia, and chlorine, fluorine,
bromine, iodine and zinc compounds) reach the exhaust gas via fuel or intake air.
If the cumulative amount of these poisons exceeds the total limit value specified by the catalyst manufacturer, the guarantee shall be declared null and void.
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3.2 Natural gas
Fuel specifications to be complied with
The following fuel specifications that apply at the inlet of the gas train (supplied by MTU Onsite Energy) are
to be complied with:
Minimum methane number
Minimum calorific value
See Technical Description
Rate of change, calorific value
% per min
1
Rate of change, methane number
Change in MN per min
5
Minimum gas flow pressure (overpressure)
mbar
20
Maximum gas flow pressure (overpressure)
mbar
50
Max. gas pressure variation (brief control fluctuation)
mbar
±5
Max. rate of change of gas pressure
mbar/s
1
Gas temperature
°C
5 - 45
Max. water vapor content
% by vol.
Dust particle size > 3 µm
Oily constituents
0.5
3
5
3
0.4
mg/m i.N CH4
mg/m i.N CH4
Table 2: Fuel specifications to be complied with
A max. total sulfur content of 30 mg / m3i and, for brief periods, 150 mg / m3i, are permissible, but otherwise no corrosive constituents may be present (analogous to DVGW Sheet G 260).
TIM-ID: 0000053740 - 001
Important: The supplied gas filter (mesh size: 50 µm) installed at the inlet of the gas train does not ensure
compliance with the dust limit value specified above and is used solely to protect the gas fittings.
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3.3 Biogas
It is not possible to avoid variations in gas quality for biogas, sewage gas and landfill gas.
Also, the presence of harmful impurities cannot be avoided.
In order to allow trouble-free operation and avoid damage, however, certain limit values have to be complied
with.
If, during commissioning, it transpires that the quality requirement for the fuel is not met, we reserve the
right to charge for the aborted commissioning procedure.
Compliance with the emission and consumption values specified in the data sheet applies only to the specified reference gas compositions for biogas, sewage gas and landfill gas. The CO2 / CH4 volume quotient is of
importance here.
The listed constituents / limit values listed are relevant for biogas engines. Other constituents / limit values are not permitted.
Fuel specifications to be complied with
The following fuel specifications that apply at the inlet of the gas train (supplied by MTU Onsite Energy) are
to be complied with:
Minimum methane number
TIM-ID: 0000053741 - 002
Minimum calorific value
See Technical Description
Rate of change, calorific value
% per min
1.0
Rate of change, methane number
Change in MN per min
5
CO2 / CH4 volume quotient
-
<= 0.65
Methane content, moist
% by vol.
See TD
Minimum gas flow pressure (overpressure)
mbar
30
Maximum gas flow pressure (overpressure)
mbar
50
Max. gas pressure variation (brief control fluctuation)
mbar
±5
Max. rate of change of gas pressure
mbar/s
1
Max. gas temperature (no derating)
°C
35
Max. oxygen content
% by vol.
2
Max. water vapor content
% by vol.
3.1
Max. temperature of cooled gas
°C
25
Dust particle size > 3 µm
mg/m i.N CH4
5
Oily constituents
mg/m3i.N CH4
0.4
3
Table 3: Fuel specifications to be complied with
Important: The supplied gas filter (mesh size: 50 µm) fitted at the inlet of the gas train does not ensure compliance with the dust limit value specified above and is used solely to protect the gas fittings.
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Harmful impurities (pollutants)
The following application-dependent maximum limits for permissible pollutant concentrations in the fuel are
to be complied with:
Oxidizing catalytic converter
Absent
Exhaust gas heat utilization
Special
Special
180 °C / 120 °C / None
None
180 °C
180 °C
None
1200
Sum over all sulfur compounds (calculated as S)
mg/m3 (normal
state) CH4
Corresponding hydrogen
sulphide (H2S)
ppm for 50 % CH4 420
Sum over all chlorine compounds (calculated as CI)
mg/m3 (normal
state) CH4
Sum over all fluorine compounds (calculated as F)
Present
Present
20
200
300
750
7
70
105
262
100
0.5
0.5
0.5
0.5
mg/m3 (normal
state) CH4
50
0.5
0.5
0.5
0.5
Sum over all silicon compounds (calculated as Si)
mg/m3 (normal
state) CH4
5
0
0
0
0
Ammonia (NH3)
ppm for 50 % CH4 30
30
30
30
30
Heavy metals (Pb, Hg, As,
Sb, Cd)
µg/m3 (normal
state) CH4
10
10
10
10
-
Table 4: Pollutant concentrations in fuel
If the quality of the raw gas exceeds the appropriate limit value for sulfur, a gas desulfurization system, designed according to the quality of gas in the system, has to be installed.
With the special sulfur-resistant MTU oxidizing catalytic converter, operation without fine desulfurization is
permissible, so long as the specified limit value for sulfur in the fuel is complied with.
In the case of active exhaust gas heat utilization, if limit values are exceeded during operation there will be
an increased build-up of corrosive deposits. Consequently, the exhaust gas heat exchanger has to be
cleaned earlier than otherwise.
Since in practice the sulfur content varies greatly, MTU cannot provide any guarantees with regard to the
cleaning intervals.
TIM-ID: 0000053741 - 002
Concerning operation with the oxidizing catalytic converter without exhaust gas heat utilization, the exhaust
gas temperature at the exhaust gas system opening must definitely be above 300 °C. If necessary, the exhaust pipe must be insulated.
10 | Liquid Fuels | A001066/01E 2015-06
Silicon compounds in the fuel gas
The presence of organic silicon compounds in the fuel gas leads to major problems with wear-inducing deposits in the engine. Even catalytic converters will be irreversibly damaged in a very short space of time.
Based on experience, wear-related damage at the engine occurs for silicon concentrations in the fuel gas in
excess of 5 mg Si/10 kWh. The catalytic-converter-damaging effect is present for concentrations as low as 1
mg Si/10 kWh, approx. (detection limit).
MTU Onsite Energy does not accept claims for damage at the engine and catalytic converter
caused by silicon.
Determination of silicon concentration in fuel gas from gas analysis
In determining the atomic silicon concentration, the measured concentrations of the individual compounds
are multiplied by the Si mass fractions.
The result is based on the calorific value of the fuel gas and normalized according to an energy content of 10
kWh (corresponding to 1 m3 i.N. CH4)
KSi 10 kWh = K Si (mg/m3i.N.)
x
10 (kWh/m3i.N.)
Hu (kWh/m3i.N.)
Table 5: Determination of normalized silicon concentration in fuel gas from gas analysis
Determination of normalized silicon concentration from gas analysis
Concentration of silicon atoms in sewage
gas
K Si
5.1 mg/m3 i.N.
CH4 concentration of sewage gas
K CH4
65 %
Calorific value of sewage gas
Hu
6.5 kWh/m3 i.N.
KSi 10 kWh = 5.1 (mg/m3i.N.)
x
10 (kWh/m3i.N.)
= 7.8 mg/m3i.N.
6.5 (kWh/m3i.N.)
Table 6: Example for determining normalized silicon concentration in fuel gas from gas analysis
TIM-ID: 0000053741 - 002
If planning to set up a gas engine system with the potential presence of organic silicon compounds (landfill
gas, sewage gas, cofermentation and feed waste plants), the current situation is to be established first by
means of evaluation of relevant gas analyses. The evaluation mechanism is indicated in Table 6. A gas cleaning system (e.g. active carbon filter) can subsequently be designed, if necessary.
Silicon content in gas
KSi10 kWh
> 5 mg/m3 i.N.
< 5 mg/m3 i.N.
Not detectable
Wear on engine
Increasing
Acceptable
Ideal
State of catalytic converter
Rapid deterioration
Rapid deterioration
Acceptable but no guarantee proper state will be
maintained
Table 7: Evaluation mechanism concerning silicon compounds in fuel gas
Guarantee basis: silicon rating SiB
A001066/01E 2015-06 | Liquid Fuels | 11
Gas analyses provide only temporary results, which can in addition be inaccurate due to unfavorable sampling. It is possible that concentration peaks will be ignored.
As a consequence, the concentration of silicon compounds in lube oil is primarily used as the evaluation
quantity of relevance for the guarantee. Experience demonstrates that the increase in the measurement
quantity of elementary silicon concentration in lube oil correlates with the increased Si concentrations in the
fuel gas. The increase in silicon concentration in the oil therefore provides an indication of the increase in
concentration and silicon mass flux in the fuel gas.
In order for the guarantee to remain valid, the operating authority must demonstrate continued compliance
with the MTU limit values during operation based on lube oil analyses.
The index value SiB for elementary silicon in the lube oil is relevant here. In this regard, normalization is applied to the difference in silicon content concerning two oil analyses, the oil fill quantity, the oil refill quantity
and the generated electrical work:
SiB = Delta Si (Si value from oil analysis B - Si value from oil analysis A)
[ppm]
x
(oil fill quantity + oil refill quantity)
[dm3]
generated electrical work [kWh]
Table 8: Formula for calculating the silicon rating SiB
Example for determining silicon rating SiB
Delta Si (difference in Si value from oil analyses A and B)
20
ppm (mg/kg)
Oil fill quantity in circuit
800
dm3
Oil refill quantity
200
dm3
Generate electrical work concerning oil analyses A and B
2000000
kWh
SiB = 20 [ppm]
x
(800 + 200) [dm3]
2000000 [kWh]
=0.01
Table 9: Example calculation of silicon rating SiB
Limit values SiBG
With regard to the silicon limit values SiBG, a distinction is made between operating with a catalytic converter
and operating without one.
SiBG
With catalytic exhaust gas cleaner
0
Without catalytic exhaust gas cleaner
< 0.02
Concerning the use of oxidizing catalytic converters, non-detection is required according to experience (SiB =
0).
Nonetheless, due to the high sensitivity of the catalytic converters, a premature loss of activity (especially
with formaldehyde conversion) can occur.
The findings of the manufacturer of the catalytic converter are then critical for a guarantee claim.
12 | Liquid Fuels | A001066/01E 2015-06
TIM-ID: 0000053741 - 002
Table 10: Silicon limit values SiBG for two different types of operation.
4 Inlet Air and Combustion Air
4.1 General information
CAUTION
Harmful substances / contamination in the intake air
Long-term damage due to corrosion
• It must be ensured that no corrosive compounds (e.g. siloxane, phosphor, arsenic, heavy metal, sulfur, ammonia, chlorine, fluorine, bromine, iodine compounds) enter the intake air. Or their limit values
must not be exceeded. Exceeding the limit values voids the warranty.
When operating the plant in swimming pool facilities or in the vicinity of refrigerating installations, it is important to bear in mind that even small traces of halogen compounds (chlorine, fluorine) in the intake air may
cause corrosion in the engine or on peripheral components (e.g. on electric motors). It must likewise be noted that even cleaning agents may also contain aggressive substances that encourage corrosion.
The input in the engine in total (fuel and air) must not exceed the limit values specified under fuels.
TIM-ID: 0000051960 - 001
In case of doubt, MTU Onsite Energy, Augsburg, is to be consulted.
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5 Coolants
5.1 General information
CAUTION
Liquid hazardous to the environment
Environmentally hazardous
• Avoid release into the environment.
• Do not dispose of in the sewerage system; dispose of correctly by observing the local regulations of
the authorities.
• Adequate barriers must be ensured.
Coolant definition
TIM-ID: 0000051961 - 001
Coolant = coolant additive (concentrate) + freshwater in the specified mixing ratio ready for use in the engine.
14 | Coolants | A001066/01E 2015-06
5.2 Requirements imposed on engine coolant
Requirements for the quality of heating water above 100 °C apply when an exhaust heat exchanger has been installed in the engine cooling circuit or the heating circuit.
For the engine coolant system, it is imperative to use filling and top-up water which complies with the following stipulations and which has been premixed with approved corrosion inhibitor/antifreeze:
General requirements
Clear, colorless and free from
undissolved substances
pH-value (25 °C)
8.2 - 9.0
Electric conductivity (25 °C)
< 300
mS/m
Sum total, alkaline earths
1.0 - 1.5
5.6 - 8.4
mmol/l
°dH
Chlorides
< 80
mg/l
Sulfates
< 70
mg/l
Iron
< 0.2
mg/l
TIM-ID: 0000052013 - 001
Table 11: Requirements imposed on engine coolant
A001066/01E 2015-06 | Coolants | 15
5.3 Requirements imposed on mixture coolant
For the engine coolant system, it is imperative to use filling and top-up water which complies with the following stipulations and which has been premixed with approved corrosion inhibitor/antifreeze:
General requirements
Clear, colorless and free from
undissolved substances
pH value (25 °C)
8.2 - 9.0
Electric conductivity (25 °C)
< 300
mS/m
Sum total, alkaline earths
1.0 - 1.5
5.6 - 8.4
mmol/l
°dH
Chlorides
< 100
mg/l
Sulfates
< 70
mg/l
Iron
< 0.2
mg/l
TIM-ID: 0000052015 - 001
Table 12: Requirements imposed on mixture coolant
16 | Coolants | A001066/01E 2015-06
5.4 Requirements for the quality of water for the gas sequential
heater
The requirements of the quality of the water for the gas sequential heater with temperatures up
to 60 °C must be complied with.
For the engine coolant system, it is imperative to use filling and top-up water which complies with the following stipulations and which has been premixed with approved corrosion inhibitor/antifreeze:
General requirements
Clear, colorless and free from
undissolved substances
pH value (25 °C)
8.2 - 9.0
Electric conductivity (25 °C)
< 300
mS/cm
Sum total, alkaline earths
1.0 - 1.5
5.6 - 8.4
mmol/l
°dH
Chlorides
< 100
mg/l
Sulfates
< 70
mg/l
Iron
< 0.2
mg/l
TIM-ID: 0000052019 - 001
Table 13: Requirements for the quality of water for the gas sequential heater
A001066/01E 2015-06 | Coolants | 17
5.5 Requirements for the quality of water for the gas cooler and
gas sequential heater
The requirements for the quality of the water of the water source for gas coolers and gas sequential heaters with temperatures > 60 °C must be complied with.
The operator must specially prepare and monitor the initial water and the filling and top-up water. As filling
and top-up water, low-salt water or desalinated water (e.g. permeate) or faultless condensate must be used.
The cold-water system and the sequential circuit may only be filled with the antifreeze Antifrogen N from the
company Hoechst AG.
We recommend (bearing in mind the VdTÜV instructions TCh 1466) adherence to the following requirements
for a low-salt operating mode:
General requirements
Clear, colorless and free from
undissolved substances
pH value (25 °C)
9.0 -10.5
Electric conductivity (25 °C)
< 100
µS/cm
Oxygen
< 0.05
mg/l
Chlorides
< 20
mg/l
Sum total, alkaline earths
< 0.02
(< 0.1)
mmol/l
°dH
Phosphate
5 - 10
mg/l
TIM-ID: 0000052024 - 001
Table 14: Requirements for the quality of water for the gas cooler and gas sequential heater
18 | Coolants | A001066/01E 2015-06
5.6 Treatment with corrosion inhibitor / antifreeze
Add corrosion inhibitor/antifreeze to the water with a concentration of at least 40 % by volume when frost
protection down to minus 25 °C is sufficient. If lower ambient temperatures are expected, increase the concentration accordingly, but do not under any circumstances increase to values in excess of 50 % by volume.
Mixtures containing a proportion of antifreeze below 40 % by volume do not guarantee adequate corrosion
protection.
Use the treated water in both summer and winter operation. Compensate for coolant losses in such a way as
to maintain the frost concentration.
TIM-ID: 0000061507 - 001
Check the concentration at regular intervals in accordance with the maintenance schedule. The coolant
should be checked once a year or each time it is added, whichever comes first. Due to antifreeze aging,
change the coolant after 12,000 operating hours or after 2 years, whichever comes first.
A001066/01E 2015-06 | Coolants | 19
5.7 Approved corrosion inhibitors / antifreezes
Information on guarantee
The use of products other than those listed below will invalidate the warranty
Type NF (nitrite-free)
Manufacturer / Supplier
Designation
BayWa AG
Tectrol Coolprotect MIX3000
Montana
Kühlerfrostschutz BHKW -25 °
Valentin
Coolant Plus -25 °
Table 15: Ready mixture: Silicate-free
Manufacturer / Supplier
Designation
BASF
Glysantin G30
Aral
Antifreeze Silikatfrei
Table 16: Concentrates
It is strongly recommended to use ready corrosion inhibitor / antifreeze mixtures for the engine cooling circuit.
Using such ready mixtures will guarantee that
• the water : corrosion inhibitor / antifreeze mixture ratio is correctly set
• the used (fresh) water complies with the specifications set out in “Requirements for the engine cooling
water”.
The service lives of components will be shortened if the water used does not comply with the specifications.
In such a case, there is a risk of deposits forming for many components, which can lead to a reduction in
heat transfer and hence a reduction in functionality (heat exchanger) or to an overheating of the components.
TIM-ID: 0000053805 - 001
Consequently, as far as “self-mixture” of the coolant is concerned,
• only the permissible silicate-free corrosion inhibitor / antifreeze mixture is to be used and only according
to the correct ratio with water
• a form is to be signed confirming that the water used fulfils the requirements set out in the Fluids and
Lubricants Specifications
20 | Coolants | A001066/01E 2015-06
6 Heating Water
6.1 General information
CAUTION
Inadequate preparation / ventilation of water circuits
Long-term damage to water conveying components
• It must be ensured that the specifications of MTU Onsite Energy for the preparation / ventilation of
the water are observed. Failure to comply with specifications voids the warranty.
Supplementary notes
It is pointed out as a precaution that generally costs for foreseeable damage, e.g. by unsuitable water quality,
are not absorbed by machine breakdown insurance either.
The term "Sum total, alkaline earths" refers to the content of hardness-forming, dissolved calcium and magnesium salts. To convert to the former standard unit of measurement of "Total hardness", the following applies:
• 1 mol/m 3 = 5.6 dH
• The pH value is a measure of the acidity or alkalinity of a solution.
• pH = 7 neutral, < 7 acid, > 7 alkaline.
TIM-ID: 0000051994 - 001
Max. permissible fluctuation of the heating water inlet temperature: Max. 3 K / min.
A001066/01E 2015-06 | Heating Water | 21
6.2 Requirements imposed on heating water up to 100 °C
Requirements for the quality of heating water above 100 °Capply when an exhaust heat exchanger has been installed in the heating circuit.
Filling and top-up water, permissible flow temperatures up to 100 °C
VDI Directive 2035 Sheet 1 (December 2005) and Sheet 2 (September 1998) is definitive. "Prevention of
damage by corrosion and scale formation in water heating installations“ with the following guide values (see
also the corresponding explanations in the original):
General requirements
Clear, colorless and free from
undissolved substances
pH value (25 °C)
8.2 - 9.0
Electric conductivity (25 °C)
10 - < 500
μS/cm
Sum total, alkaline earths
1.0 - 1.5
5.6 - 8.4
mmol/l
°dH
Chlorides
< 80
mg/l
Sulfates
< 70
mg/l
Oxygen content when using oxygen binding agents
< 0.1
mg/l
Iron
< 0.2
mg/l
Table 17: Requirements imposed on heating water up to 100 °C
TIM-ID: 0000051996 - 001
If the above limit values are not adhered to, it will be necessary to introduce measures against scale formation, either through water treatment (softening, demineralization, reverse osmosis) or hardness stabilization
(ST-DOS-H products), and against corrosion processes through inhibiting or oxygen binding (ST-DOS-H products).
22 | Heating Water | A001066/01E 2015-06
6.3 Requirements imposed on heating water above 100 °C
Requirements for the quality of heating water above 100 °Capply when an exhaust heat exchanger has been installed in the engine cooling circuit or the heating circuit.
Filling and top-up water, permissible flow temperatures over 100 °C and for large heating systems or longdistance heating systems.
The base alkalization must occur with trisodium phosphate.
The definitive specification is the VdTÜV Directive TCh 1466 governing the quality of water in heating installations which are operated with a supply temperature above 100 °C. The following guide values subsequently
apply for low-salt method of operation:
General requirements
Clear, colorless and free from
undissolved substances
pH value (25 °C)
8.2 - 9.0
Electric conductivity (25 °C)
10 - < 250
μS/cm
Sum total, alkaline earths
< 0.02
< 0.10
mmol/l
°dH
Chlorides
< 20
mg/l
Sulfates
< 5 - 10
mg/l
Oxygen content
< 0.05
mg/l
Phosphate
5 - 10
mg/l
Iron
< 0.2
mg/l
Table 18: Requirements imposed on heating water above 100 °C
TIM-ID: 0000051997 - 001
Measures against scale formation are necessary, either through water treatment (softening, demineralization, reverse osmosis) or hardness stabilization (ST-DOS-H products), and against corrosion processes
through inhibiting or oxygen binding (ST-DOS-H products).
A001066/01E 2015-06 | Heating Water | 23
7 Lubricating Oil
7.1 General information
The selection of a suitable engine oil for gas engines depends primarily on the type of gas used to power the
engine. The gas engine must only be operated with approved lubricating oil. The engine oils that must be
used are listed in the approved lubricants table. Another significant factor is the quality of the gas regarding
its purity. This requires that the operator regularly carries out gas checks. The gas engine oils used are characterized by the lowest possible ash content. This prevents increased ash deposits which can lead to reduced catalytic converter performance, or knocking combustion.
When operating biogas (with corrosive contaminants), the lubricating oil is subjected to corrosive contaminants which are created when the pollutants contained in the gas (chlorine, fluorine and sulfur compounds)
are burned. These corrosive constituents can only be neutralized to a limited extent even by special additives
in the lubricating oil. Corrosion damage to the oil-lubricated engine components can only be avoided by more
frequent oil changes.
To better buffer concentration peaks when lubricating oil is subjected to corrosive contaminants, an increased lubricating oil volume is recommended.
Dispose of used fluids and lubricants in accordance with local regulations.
Mixing different engine oils is strictly prohibited!
Changing to another oil grade can be done together with an oil change. The remaining oil quantity in the engine oil system is not critical in this regard.
TIM-ID: 0000051962 - 001
When using biogas, sewer gas or landfill gas the quantity of oil in the engine oil sump is not
adequate. A larger volume of oil is required!
24 | Lubricating Oil | A001066/01E 2015-06
7.2 Approved lube oils
Lube oils for naturally aspirated engines
Manufacturer / Supplier
Designation
Addinol Lube Oil GmbH
MG 40 Extra LA
AUTOL
ELA 40
AVIA Mineralöl AG
SAE 40 1)
M
E,
SAE 40
1)
M
E, P
LA 40
SAE 40
1)
M
E, P
Castrol
Duratec HPL 40
SAE 40 1)
M
E, P
Castrol
Duratec XPL
SAE 40 1)
S
E, P
BayWa AG
TECTROL Methaflexx HC Premium
SAE 40 1)
M
E, P
BayWa AG
TECTROL Methaflexx NG
SAE 40
1)
M
E, P
Eurolub
LA
SAE 40
1)
M
E, P
ExxonMobil
Pegasus 1
SAE 40
1)
S
E, P
ExxonMobil
Pegasus 605
SAE 40
1)
M
E, P
ExxonMobil
Pegasus 705
SAE 40 1)
M
E, P
ExxonMobil
Pegasus 805
SAE 40 1)
M
E, P
ExxonMobil
Pegasus 1005
SAE 40 1)
M
E, P
Fuchs Europe Schmierstoffe GmbH
Titan Ganymet LA
SAE 40
1)
M
E, P
Fuchs Europe Schmierstoffe GmbH
Titan Ganymet Ultra
SAE 40
1)
M
E, P
Kuwait Petroleum
PEAK Navitus MA
SAE 40
1)
M
E, P
Kuwait Petroleum
Q8 Mahler MA
SAE 40
1)
M
E, P
Petro Canada Europe
Sentron LD 5000
SAE 40 1)
M
E, P
WIPA Chemicals International
Ecosyn GE 4004
SAE 40 1)
S
E, P
Table 19: Lube oils for naturally aspirated engines
1)
Approval conditional on ambient temperature at engine being > +10 °C
S = synthetic lube oil
M = mineral lube oil
E = natural gas
P = propane gas
B = biogas
TIM-ID: 0000053541 - 001
Lube oils for turbocharged engines
Manufacturer / Supplier
Designation
AUTOL
BGJ 40
SAE 40 1)
M
B
K
AUTOL
ELA 40
SAE 40
1)
M
E, P
K
AVIA Mineralöl AG
HA 40
SAE 40 1)
M
B
K
AVIA Mineralöl AG
LA 40
SAE 40 1)
M
E, P
K
Addinol Lube Oil GmbH
MG 40 Extra Plus
SAE 40 1)
M
B
K
Addinol Lube Oil GmbH
MG 40 Extra LA
SAE 40
1)
M
E, P
K
NILS
Burian
SAE 40
1)
M
B
K
BayWA AG
TECTROL Methaflexx D
SAE 40
1)
M
B
K
A001066/01E 2015-06 | Lubricating Oil | 25
Designation
BayWA AG
TECTROL Methaflexx HC Plus
SAE 40 1)
M
B
K
BayWA AG
TECTROL Methaflexx HC Premium
SAE 40 1)
M
E, P
K
BayWA AG
TECTROL Methaflexx HC Premium
SAE 40
M
B
2*
BayWA AG
TECTROL Methaflexx NG
SAE 40 1)
M
E, P
K
Castrol
Duratec HPL
SAE 40 1)
M
E, P
K
Castrol
Duratec XPL
SAE 40
1)
S
E, P
K
ChevronTexaco
Geotex LA 40
SAE 40
1)
M
E, P
K
ChevronTexaco
Geotex LF 40
SAE 40
1)
M
B
K
Eurolub
LA
SAE 40
1)
M
E, P
K
Eurolub
HGM Plus
SAE 40 1)
M
B
K
ExxonMobil
Pegasus 1
SAE 40 1)
S
E, P
K
ExxonMobil
Pegasus 605
SAE 40 1)
M
E, P
K
ExxonMobil
Pegasus 610
SAE 40
1)
M
B
K
ExxonMobil
Pegasus 705
SAE 40
1)
M
E, P
K
ExxonMobil
Pegasus 710
SAE 40
1)
M
B
K
ExxonMobil
Pegasus 805
SAE 40
1)
M
E, P
K
Fuchs Europe Schmierstoffe GmbH
Titan Ganymet
SAE 40 1)
M
B
K
Fuchs Europe Schmierstoffe GmbH
Titan Ganymet LA
SAE 40 1)
M
E, P
K
Fuchs Europe Schmierstoffe GmbH
Titan Ganymet Plus
SAE 40 1)
M
B
K
Fuchs Europe Schmierstoffe GmbH
Titan Ganymet Ultra
SAE 40
1)
M
E, P
K
Fuchs Europe Schmierstoffe GmbH
Titan Ganymet Ultra
SAE 40
1)
M
B
2*
Hessol Lubrication GmbH
Hessol Gasmotorenöl SAE 40
SAE 40
1)
M
B
K
Kuwait Petroleum
PEAK Navitus HA 40
SAE 40
1)
M
B
K
Kuwait Petroleum
PEAK Navitus MA 40
SAE 40 1)
M
E, P
K
Kuwait Petroleum
Q8 Mahler HA 40
SAE 40 1)
M
B
K
Kuwait Petroleum
Q8 Mahler MA 40
SAE 40 1)
M
E, P
K
OMV Refining & Marketing
HD 40
SAE 40
1)
M
B
K
Petro Canada Europe
Sentron CG 40
SAE 40
1)
M
B
K
Petro Canada Europe
Sentron LD 5000
SAE 40
1)
M
E, P
K
Total Deutschland
Nateria MH 40
SAE 40
1)
M
E, P
K
Total Deutschland
Nateria MJ 40
SAE 40 1)
M
B
K
WIPA Chemicals International
Ecosyn GE 4004
SAE 40 1)
S
E, P
K
Table 20: Lube oils for turbocharged engines
1)
Approval conditional on ambient temperature at engine being > +10 °C
S = synthetic lube oil
M = mineral lube oil
E = natural gas
P = propane gas
B = biogas
26 | Lubricating Oil | A001066/01E 2015-06
TIM-ID: 0000053541 - 001
Manufacturer / Supplier
K = suitable for catalytic converter
-- = not suitable for catalytic converter
TIM-ID: 0000053541 - 001
2* = ceramic catalytic converter
A001066/01E 2015-06 | Lubricating Oil | 27
7.3 Lube oil change intervals
Mineral oil, lube oil system with oil bleed system and additional capacity
If the additional capacity is increased, e.g. to 800 l for the E3066Dx, the oil change interval will increase
proportionally, so that for the given example, the interval is increased 4-fold in comparison to the case where
the additional capacity is 200 l.
Oil analyses need to be carried out at regular intervals in such cases.
Designation
Lube oil system with oil bleed system and additional capacity
Module / engine-generator set
with engine model
Oil change interval (in operating
hours)
Min. additional capacity
E3066D1-D3
2500
200 l
E3066D4
3000
200 l
E3066Lx/Zx
1000
120 l
E3042D1-D3
1250
200 l
E3042D4
1500
200 l
E3042Lx/Zx
1000
200 l
E3042Lx/Zx
5000
1000 l
B3066Lx/Zx
600
120 l
B3042Lx/Zx
600
200 l
Table 21: Mineral oil, lube oil system with oil bleed system and additional capacity
Mineral oil, oil lube system with fresh-oil replenishment function only (no oil
bleed system)
Designation
Oil lube system with fresh-oil replenishment function only (no oil
bleed system)
Module / engine-generator set
with engine model
Oil change interval (in operating
hours)
Recommended capacity of freshoil tank
E3066D1-D3
600
200 l
E3066Lx/Zx
300
200 l
E3042D1-D3
600
200 l
E3042Lx/Zx
300
200 l
Table 22: Mineral oil, oil lube system with fresh-oil replenishment function only (no oil bleed system)
If the additional capacity is increased, e.g. to 800 l for the E3066Dx, the oil change interval will increase
proportionally, so that for the given example, the interval is increased 4-fold in comparison to the case where
the additional capacity is 200 l.
Oil analyses need to be carried out at regular intervals in such cases.
Designation
Lube oil system with oil bleed system and additional capacity
Module / engine-generator set
with engine model
Oil change interval (in operating
hours)
Min. additional capacity
E3066Lx/Zx
2000
200 l
28 | Lubricating Oil | A001066/01E 2015-06
TIM-ID: 0000053502 - 001
Synthetic oil, lube oil system with oil bleed system and additional capacity
Designation
Lube oil system with oil bleed system and additional capacity
E3042Lx/Zx
1000
160 l
E3042Lx/Zx
6000
1000 l
Table 23: Synthetic oil, lube oil system with oil bleed system and additional capacity
Synthetic oil, oil lube system with fresh-oil replenishment function only (no oil
bleed system)
Designation
Oil lube system with fresh-oil replenishment function only (no oil
bleed system)
Module / engine-generator set
with engine model
Oil change interval (in operating
hours)
Recommended capacity of freshoil tank
E3066D1-D3
1250
200 l
E3066D4
1500
Minimum additional oil capacity of
50 l
E3066Lx/Zx
600
200 l
E3042D1-D3
1250
200 l
E3042D4
1500
Minimum additional oil capacity of
90 l
E3042Lx/Zx
600
200 l
TIM-ID: 0000053502 - 001
Table 24: Synthetic oil, oil lube system with fresh-oil replenishment function only (no oil bleed system)
A001066/01E 2015-06 | Lubricating Oil | 29
8 Exhaust Condensate
8.1 General information
DANGER
Liquid hazardous to the environment
Environmentally hazardous
• Avoid release into the environment. Do not dispose of in the sewerage system; dispose of correctly
by observing the local regulations of the authorities. Adequate barriers must be ensured.
When fuel is burned in the engine, nitrogen oxides NOx are created in addition to carbon dioxide and water
vapor. These transform into nitric acid in the downstream components in the presence of condensed water.
Other inorganic and organic acids, e.g. sulfuric acid or sulfurous acid, can likewise be created depending on
the fuel composition. Condensate samples therefore display a lightly pungent smell and dissolved iron as a
corrosion product. The hydrogen ion concentration, i.e. the pH value of such condensate samples, is usually
in the strong to weak acid range of pH = approx. 0.5 ... 4.
Condensate starts to form, depending on the acid-forming constituent, at exhaust temperatures below approx. 160 °C.
Theoretically, 1.5 kg condensate can be created from 1 m3 NTP. of natural gas.
In the case of gensets with exhaust cooling in a heat exchanger, at exhaust temperatures not below 110 °C,
with properly insulated exhaust lines and with a normal number of start/stop procedures (ratio of operating
hours to starts at least 2:1), the condensate accumulation in the heat exchanger and in the downstream silencer is reduced to a few kilograms per day.
A free discharge via a siphon at a height of approx. 300 mm1) must be provided for the condensate to prevent exhaust gas from escaping from the condensate line. The exhaust condensate should be neutralized in a
neutralization plant before being discharged into the sewerage system. An oil separator is additionally required.
Exhaust condensate may only be discharged into the sewage system without being treated after consultation
with the local waste water authority, and must not under any circumstances be discharged to atmosphere.
Municipalities in Germany, or the authorities instructed by them, are obliged to remove accumulated waste
water which also contains condensate. Condensate can also be classified in the "Special waste" category.
At least 50 mm above the corresponding max. exhaust backpressure according to the module
TIM-ID: 0000051981 - 001
1)
30 | Exhaust Condensate | A001066/01E 2015-06
9 Appendix A
9.1 Abbreviations
Explanation
Abbreviation
Meaning
ASTM
American Society for Testing and Materials
Oh
Operatiung hours
BR
Baureihe
Series
BV
Betriebsstoffvorschrift
Fluids and Lubricants Specifications
DIN
Deutsches Institut for Normung e. V.
At the same time identifier of German standards (DIN = “Deutsche Industrie-Norm”)
DVGW
Deutsche Vereinigung des Gas- und
Wasserfaches e.V.
German technical and scientific association for
gas and water
EN
Europäische Norm
European standard
ICP
IR
Method
IP
Institute of Petroleum
ISO
International Organization for Standardi- International umbrella organization for all nazation
tional standardization institutes
MN
Methane number
OEG
Onsite Energy
MTU Onsite Energy
Society of Automotive Engineers
U.S. standardization organization
RFA
SAE
ST-DOS-H
Products
Guideline
VdTÜV
Guideline
Vol.
Volume
TIM-ID: 0000053479 - 001
VDI
A001066/01E 2015-06 | Appendix A | 31
9.2 Conversion table of SI units
SI unit
US unit
conversion
°C
°F
°F = °C*1.8+32
kWh
BTU
1 BTU = 0.0002930711 kWh
kWh/m3 NTP
BTU/ft3
1 BTU/ft3 = 00.010349707 kWh/m3
kW
kBTU/h
1 kBTU/h = 0.2928104 kW
kW
bhp
1 bhp = 0.7457 kW
l
gal
1 gal = 3.785412 liters
mm
inch
1 inch = 25.4 mm
m
ft
1 ft = 0.3048 m
m/s
ft/s
3
3
1 ft/s = 0.3048 m/s
m NTP
ft NTP
ft3 = 0.02831685 m³ NTP
bar
psi
1 psi = 0.06894757 bar
kg
lb
1 lb = 0.4535924 kg
TIM-ID: 0000053888 - 001
Table 25: Conversion table
32 | Appendix A | A001066/01E 2015-06
9.3 MTU Onsite Energy contact person / service partner
Service
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and customer service centers ensure fast and direct support on site and ensure the high availability of our products.
Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For our locally available support, go to MTU's Internet site:
• http://www.mtuonsiteenergy.com/haendlersuche/index.de.html
24-h Hotline
With our 24-h hotline and the flexibility of our service staff, we are always ready to assist you - either during
operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply.
For our locally available support, go to MTU's Internet site:
• http://www.mtuonsiteenergy.com/haendlersuche/index.de.html
Your contact at Headquarters:
• [email protected]
Spare Parts Service
Quick, easy and correct identification of the spare part required for your system. The right spare part at the
right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system.
Your contact at Headquarters:
Germany:
• Phone: +49 821 74800
• Fax: +49 821 74802289
• E-mail: [email protected]
TIM-ID: 0000002624 - 005
Worldwide:
• Phone: +49 7541 908555
• Fax: +49 7541 908121
• E-mail: [email protected]
A001066/01E 2015-06 | Appendix A | 33
10 Appendix B
10.1 Index
A
G
Abbreviations 31
Approval – Lube oil 25
Approved corrosion inhibitors / antifreezes – Coolant 20
– Ready mixtures 20
Gaseous fuels – Biogas 9
– Natural gas 8
– Silicon content 7
H
Biogas – Fuels 9
– Gaseous fuels 9
Heating water – General information 21
– Requirements above 100 °C 23
– Requirements up to 100 °C 22
– Supplemental notes 21
C
I
Change intervals – Mineral oil 28
Confirmation – Operator 4
Contact person – MTU Onsite Energy 33
Coolant – Approved corrosion inhibitors / antifreezes 20
– Corrosion inhibitor / antifreeze – Treatment 19
– Definition 14
– Engine coolant – Requirements 15
– General information 14
– Mixture coolant – Requirements 16
– Water quality for gas cooler and gas sequential heater
– Requirements 18
– Water quality for gas sequential heater – Requirements 17
Corrosion protection of the engine 5
Intake air and combustion air 13
D
Definition – Coolant 14
E
Exhaust condensate 30
F
Fuels 7
– Biogas 9
– Natural gas 8
34 | Appendix B | A001066/01E 2015-06
L
Lube oil – Approval 25
Lubricating oil – General information 24
M
Mineral oil – Change intervals 28
MTU Onsite Energy – Contact person 33
– Service partner 33
N
Natural gas – Fuels 8
– Gaseous fuels 8
Notices concerning use 5
O
Operator – Confirmation 4
R
Ready mixtures – Approved corrosion inhibitors / antifreezes 20
Requirements – Engine coolant 15
– Mixture coolant 16
– Water quality for gas cooler and gas sequential heater
18
– Water quality for gas sequential heater 17
Requirements above 100 °C – Heating water 23
Requirements up to 100 °C – Heating water 22
DCL-ID: 0000033512 - 002
B
S
Service partner – MTU Onsite Energy 33
Silicon content – Gaseous fuels 7
Supplemental notes – Heating water 21
T
DCL-ID: 0000033512 - 002
Topicality of the publication 5
Treatment – Corrosion inhibitor / antifreeze 19
A001066/01E 2015-06 | Appendix B | 35