Powerful, Efficient and Reliable Liebherr Gas Engines

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1 Powerful, Efficient and Reliable

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3 Gas engines are developed and manufactured by Liebherr at the Bulle site in Switzerland. They are designed for stationary applications such as combined heat and power units and for operation with biogas or natural gas. Gas engines from Liebherr are available in various configurations from 4-cylinder inline engines up to 20-cylinder V-engines. The performance spectrum covers a mechanical output range of 145 kw to 1,070 kw at 50 Hz and 169 kw to 1,070 kw for 60 Hz applications. Advantages Reliability, availability and high efficiency are success factors that make Liebherr gas engines extremely cost-effective. The engines are required for nonstop operation and are therefore extremely reliable, durable and have a high level of quality. The gas engines are characterised by their high power density, which contributes to the high mechanical efficiency of over 43 %. Engineering competency Service and maintenance State-of-the-art development methods and decades of experience Global organisation for local availability and support Performance and efficiency Full equipment The most efficient engines of their class Plug & play solution for quick and easy installation Quality and availability More than 8,000 operating hours per year 3

4 Engineering expertise Liebherr has many years of experience in the design and manufacture of gas engines. In as early as 1996, the first 6-cylinder gas engine was produced in Bulle. The current engine generation was orientated consistently around the 4 requirements for stationary use in combined heat and power units and special gas systems. Synergy potentials with Liebherr diesel engines are used appropriately.

5 State-of-the-art development methods and decades of experience Lean-burn engine based on spark ignition principle The air-gas mixture in the cylinder is ignited externally by a spark plug. The ignition timing and ignition energy are freely adjustable for ideal combustion. This means safe operation of the engine is assured without misfiring and knocking. Optimised components During component design, recourse was taken to practical load profiles. With the aid of modern design and simulation programs (such as FEM and CFD), complete engines and individual components have been optimised in terms of strength, strain, vibrations and flow characteristics. Analyses by means of finite element method With the finite element method (FEM), the ideal strength can be achieved through optimum material distribution and improved geometry. Parts that are exposed to particularly high levels of stress, such as the conrods, pistons or cylinder head, are examined using this method in order to facilitate a long service life. Application-specific design All engine components have been examined with regard to their suitability for use in gas engines and have been optimised specifically to the application. For example, the pistons, cylinder heads, valves and mixture cooling system have been especially adapted for natural gas and biogas operation in order to achieve optimum combustion in each case. Modern test benches For optimum adaptation of all engine parameters and ideal calibration of the engines, prototypes at the Bulle site have to endure extensive trial prograes on test benches - in accordance with state-of-the-art engineering - while being run on natural gas and synthetic biogas. The operating behaviour and service life are analysed with continuous operation tests under realistic operating conditions and overload tests. CFD flow simulation Through three dimensional simulation of the flow properties and combustion processes, all of the relevant components are optimised even at the design phase. The image shows the ignition process in the combustion chamber and the sequential spread of the flame front. Test benches The test benches are used for functional testing of series production engines and for development. Continuous testing and overload tests provide information about the service life and make it possible to further improve durability. 5

6 Performance and efficiency With a mechanical efficiency rating of over 43 %, gas engines from Liebherr offer the best efficiency values of their performance category. This value is the result of many years 6 of application experience, careful selection of components, intensive development work and also a high degree of system integration in the area of hard and software.

7 The most efficient engines of their class Economic operation All components have been selected and optimised with the aim of achieving the longest possible maintenance intervals. This results in low life cycle costs. Thanks to the high efficiency and performance of the engines, operators of a combined heat and power unit or biogas plant can expect a very attractive total cost of ownership (TCO). Efficient design The constant inflow and filling of the combustion chambers with mixture ensures that all cylinders are equal. Together with optimal exchange cycles, an even load distribution and high efficiency are therefore possible. Ignition system The ignition energy and ignition phase of ignition systems in Liebherr gas engines can be adjusted according to demand. The result: a high degree of efficiency, fault-free operation and long spark plug durability. Thanks to stable ignition, emissions are also reduced. For every engine, the ideal turbocharger has been selected and adjusted optimally. The high efficiency of the turbocharger means that highly efficient exchange cycles and thereby very good overall efficiency can be achieved. Optimised combustion The combination of four-valve technology with a gas-specific ideal combustion chamber geometry encourages rapid combustion, which is as complete as possible. This increases the specific power and efficiency. The consistent reduction in cylinder clearances speeds up the start of combustion and improves the complete combustion of the gas mixture, which reduces the fuel consumption and emissions. Cylinder heads Thanks to their intelligent and robust design, the four-valve cylinder heads provide efficient combustion and are even suitable for maximum ignition pressures. Six cylinder head bolts facilitate a good distribution of the pressures on the cylinder head and ensure perfect tightness. 7

8 Quality and availability Liebherr gas engines are designed for permanent operation. Thanks to the high level of reliability and low downtimes, an availability of considerably more than 8,000 operating 8 hours per year can be achieved. With the high quality during development and production, Liebherr contributes directly to its customers success.

9 More than 8,000 operating hours per year High availability Low downtimes ensure minimal maintenance and operating costs. The key contributors to these benefits are the safe dimensioning of the engines, their sophisticated control system and engine peripherals, high mechanical strength as well as high resistance to wear. The operating status of the engine, ignition system and Lambda control is continuously monitored by the engine control system. Quality assurance throughout To safeguard quality, Liebherr employs a contemporary computer-assisted quality management system (CAQ system) that is implemented as early as the product creation process and covers the entire product life cycle. Statistical assessments, FMEA (Failure Mode and Effects Analysis) and CIP (Continuous Improvement Processes) are examples of a consistent process philosophy. Highest quality standards Quality assurance at the Bulle site is certified according to DIN EN ISO 9001/2008 and complies with VDA standards (reliability control group). Two-stage charge air cooler The two-stage intercooler, which is made entirely from stainless steel, has a high resistance to corrosion even when used with biogas. Due to the design, the heat exchanger is very efficient and well protected against contamination. One-piece steel piston To ensure a long service life, even under high combustion pressures, Liebherr gas engines are fitted with one-piece steel pistons. Their geometry has been specially optimised to achieve an ideal combustion chamber and efficient combustion. Innovative bearing materials To guarantee the durability of the crankshaft bearings under increasing loads, Liebherr uses special coatings on the composite bearing shells. The Sputter bearings are distinguished by a high resistance to corrosion. 9

10 Service and maintenance Through a high level of availability and global logistics partners, assurance is provided that Liebherr engines can be supplied with spare parts day and night. Professional staff in customer services advise competently and work out the best 10 solution for each customer in terms of costs and speed. The customer service offer is rounded off by a comprehensive training prograe.

11 Global organisation for local availability and support Fitter training courses with qualification The comprehensive training prograe prepares our customers fitters for efficient customer service tasks. Liebherr therefore offers practical basic and continuation training courses. At the well-equipped training centre, the experienced trainers can simulate even extreme repair tasks. Simple maintenance and repair To make service work as easy as possible, special attention was given to the overview and accessibility of all parts. This Global availability of spare parts Spare parts are made available around the world in a matter of hours. Competent Liebherr staff members are quickly at the scene around the world whenever they are needed. The Liebherr network is utilised optimally according to requirement. means, for example, that oil filters are easy to reach and cylinder heads can be replaced individually. The practical arrangement of maintenance and spare parts kits also contributes towards a high level of availability. Structured documentation Liebherr provides extensive documentation on the reliable planning and calculation of requisite maintenance or repair work. Well structured documents make it is easier to perform the tasks. High quality of repair Maintenance and repair kits simplify handling and ensure a high level of quality in the maintenance and repair work that needs to be carried out. Optimum accessibility Thanks to the clearly defined concept and accessibility of the parts fitted, engine maintenance is easy and efficient. 11

12 Full equipment Liebherr gas engines are distinguished by a high degree of efficiency and availability. To safeguard these attributes in the long-term, the engines are supplied fully equipped. This equipment has been optimally adapted to the engines 12 and offers a plug & play solution. All components have been validated for the engines and extensively tested. Straightforward integration in the system saves time and money.

13 Plug & play solution for quick and easy installation Gas engines from Liebherr are supplied ready for installation as complete units and can be installed as core components in combined heat and power units. The engine is connected to the alternator via a standard flange according to SAE. Equipment Starter Turbocharger Two-stage charge air cooler Gas / air mixer with actuator Thermal sensor in every cylinder head Secure attachment Spark plugs Control flap with actuator Engine control and ignition system Optimised hardware All components have been carefully selected and optimally adapted, tested and validated for the engines. Fine calibration for adaptation to the specific application is very straightforward. Sensors Coolant temperature sensor Coolant pressure sensor Gas mixture temperature sensor Gas mixture pressure sensor Engine oil temperature sensor Engine oil pressure sensor Speed sensor Ignition signal sender Electrical equipment All of the sensors installed in the engine are supplied wired. For installation in the system, they just have to be connected to the control unit. Engine control and ignition system Engine control system and colour display Ignition system Ignition control unit Knock monitoring system Electronic speed regulator Sensor technology and engine wiring More options on request Software and engine prograing The supplied engine software already contains all of the requisite parameters. With the carefully validated and adapted values, the performance values of Liebherr engines can be achieved reliably. At the same time there is enough scope for fine tuning in the field. 13

14 Full equipment Wiring harness with sensor technology Liebherr gas engines are supplied fully wired. All of the sensors are already integrated in the wiring harness. Throttle valve This compact unit with integrated actuators controls the speed and output of the engine by regulating the volume of the gas mixture. Ignition system The modern ignition system is integrated optimally in the engine concept and contributes towards steady ignition and thereby a high degree of efficiency. 14

15 Two-stage stainless steel intercooler The stainless steel, two-stage intercooler is designed for natural gas and biogas, thereby ensuring maximum energy recovery. Turbocharger The turbocharger was especially designed for gas operation and ensures that the engines run steadily and highly efficiently. Gas mixer Compact design, with integrated actuator valve and venturi, enables high resolution lambda settings. Flexible means of application are enabled by the modular venturi structure. Basic engine The basic engines impress with their sturdy design. They are tried and tested under tough conditions. 15

16 Product overview Engine Full equipment availability Configuration Capacity Bore Stroke Weight Dimensions (LxWxH) Rated speed Rated power (mech.) Max. effect. mean pressure Air ratio Flywheel housing Mass moment of inertia Mechanical efficiency Engine Full equipment availability Configuration Capacity Bore Stroke Weight Dimensions (LxWxH) Rated speed Rated power (mech.) Max. effect. mean pressure Air ratio Flywheel housing Mass moment of inertia Mechanical efficiency 16 dm3 kg rpm kw bar λ kg*m² % dm3 kg rpm kw bar λ kg*m² % G934 yes 4 in-line ,480 x 990 x Hz 60 Hz 1,500 1, ,75 SAE G946 yes 6 in-line ,250 1,800 x 990 x 1, Hz 60 Hz 1,500 1, SAE Engine Full equipment availability Configuration Capacity Bore Stroke Weight Dimensions (LxWxH) Rated speed Rated power (mech.) Max. effect. mean pressure Air ratio Flywheel housing Mass moment of inertia Mechanical efficiency dm3 kg rpm kw bar λ kg*m² % G944 yes 4 in-line ,480 x 990 x Hz 60 Hz 1,500 1, SAE

17 Engine Full equipment availability Configuration Capacity Bore Stroke Weight Dimensions (LxWxH) Rated speed Rated power (mech.) Max. effect. mean pressure Air ratio Flywheel housing Mass moment of inertia Mechanical efficiency dm3 kg rpm kw bar λ kg*m² % G9508 yes 8 in V configuration ,700 1,370 x 1,120 x 1, Hz 60 Hz 1,500 1, SAE Engine Full equipment availability Configuration Capacity Bore Stroke Weight Dimensions (LxWxH) Rated speed Rated power (mech.) Max. effect. mean pressure Air ratio Flywheel housing Mass moment of inertia Mechanical efficiency dm3 kg rpm kw bar λ kg*m² % G9512 yes 12 in V configuration ,150 1,550 x 1,200 x 1, Hz 60 Hz 1,500 1, SAE All technical information refer to ISO 3046/1 under standard conditions. For methane percentages, please refer to the technical data sheets. Version with optimised efficiency. The details in this overview serve as a means of information only and are not binding values. The details and values specified in the offer are relevant. Engine Full equipment availability Configuration Capacity Bore Stroke Weight Dimensions (LxWxH) Rated speed Rated power (mech.) Max. effect. mean pressure Air ratio Flywheel housing Mass moment of inertia Mechanical efficiency dm3 kg rpm kw bar λ kg*m² % G9620 yes 20 in V configuration ,500 2,590 x 1,340 x 1, Hz 60 Hz 1,500 1,800 1,070 1, SAE

18 Examples of use 18

19 Liebherr gas engines are suitable for operation with natural gas and biogas. They can be used in combined heat and power units, biogas systems, pump stations, gensets and other stationary applications. The engines are designed for decentralised power supply in continuous operation. Aside from their performance and reliability, customers value the engines mainly because the units are supplied ready for installation. Environmentally-friendly use Thanks to the low NOx, CO and HC emissions, Liebherr gas engines are very environmentally-friendly. They fulfil the requirements of TA Luft (technical guidance for air quality control) and 1/2 TA L for NOx emissions. The CO emissions can be further reduced by the use of an oxidation catalyst. Operation with natural gas Natural gas is used mainly to run combined heat and power units for decentralised power supply, e.g. for cogeneration of heat and power in swiing pools, hospitals and residential complexes. The composition of natural gas varies from region to region and this, along with the blending of various gases, leads to a heavy fluctuation of the methane number. Gas engines from Liebherr are also knock-resistant should gas compositions change. This is further safeguarded through knock control. Biogas The use of gas produced from biomass makes it possible to tap into previously unused energy sources. Liebherr gas engines can run on biogas and thus make a contribution to the renewable energy power supply. Operation with biogas Biogas, which results from the fermentation of organic material, is increasingly being used for environmentallyfriendly generation of power and heat. Due to the variable composition of the raw materials and variable fermentation processes, the components and properties of the biogas and the energy content of the biogas fluctuate widely and must be conditioned in certain circumstances. Thanks to their stainless steel charge air coolers and special bearing material, Liebherr gas engines are very resistant to corrosive gas components and are also suitable for use with a leaner methane content. Natural gas Natural gas impresses by its very high efficiency and low CO2 emissions. The clean combustion of the gas means a Liebherr gas engine can be operated with low maintenance costs. Special deployment Gas engines from Liebherr can also be operated with other gases, such as sewage gas or landfill gas. 19

20 Liebherr Components Gas engines Slewing bearings Diesel engines Fuel injection systems Gearboxes and winches Human-machine interfaces Control electronics and and gateways sensor technology Electric machines Power electronics From A to Z the components division of the Liebherr Group offers a broad range of solutions in the area of mechanical, hydraulic, electric and electronic drive system and control technology. The efficient components and systems are produced at a total of ten production sites around the world to the highest standards of quality. Central contact persons for all product lines are available to our customers at Liebherr- Axial piston hydraulics Control cabinets Hydraulic cylinders Remanufacturing Software Components AG and the regional sales and distribution branches. Liebherr is your partner for joint success: from the product idea to development, manufacture and coissioning right through to customer service solutions like remanufacturing. Printed in Germany by Eberl Änderungen vorbehalten. BK LMB-GM _en components.liebherr.com Liebherr-Components AG Post box 222, CH-5415 Nussbaumen / AG components@liebherr.com Liebherr USA, CO Woodland Drive, Saline, MI 48176, USA components.usa@liebherr.com