Jenbacher Technical Instruction No.

: 1100-0111
Documentation General Conditions - Operating and Maintenance

1. General Conditions - Operating and Maintenance: ________________________1

1.1 Marginal conditions: 1
1.2 Cooler/heat exchanger(GE Jenbacher supply quantity): 1
1.3 Supply limits Interfaces: 1
1.4 Maintenance Maintenance personnel: 1
1.5 Safety regulations: 2
1.6 Start conditions: 2
1.7 Malfunctions: 2
1.8 Registering operational data, Maintenance protocol: 2
1.9 Spare parts: 3
1.10 Lubricating oil: 3
1.11 Ignition plug: 3
1.12 Elastomer components: 3
1.13 Decommissioning the installation: 3
1.14 Components coming into contact with exhaust gas: 3
1.15 Operating supplies: 4
1.16 Quality of propellant: 4

1. General Conditions - Operating and Maintenance:

1.1 Marginal conditions:

The specified properties of the product can only be guaranteed, if the reconditions for GE Jenbacher gas
engines as described in Technical Description No. 1100-0110 are met, all compulsory activities are
carried out in accordance with the operational-data sheet and this sheet is filled in correctly, all
compulsory maintenance activities are carried out on time, and a knock-free operation is guaranteed.

1.2 Cooler/heat exchanger(GE Jenbacher supply quantity):

When incorporated into the heating water system these components must be protected at the upstream
side against deposits/soiling by taking adequate measures.

1.3 Supply limits Interfaces:

The conditions and devices pre-determined in the technical scheme, the wiring diagram, the interface list
and the technical specification of the control at the supply limits/interfaces must be fulfilled or available
respectively. Deviations from these can affect guaranteed characteristics of the product and safe
operation and finally lead to a restriction or extinction of warranty claims.

1.4 Maintenance Maintenance personnel:

Work at the plant must only be carried out by specially trained, electric and mechanic specialists. It is
possible to conclude service contracts with GE Jenbacher, GE Jenbacher subsidiaries or authorized and
specialized companies.The intervals in the servicing schedule represent maximum periods that occur
when the system is properly run and serviced. If there are deviations (such as improper oil care, a large
amount of dust or other problematic circumstances), the service jobs must be carried out before the given
time.The above can only be judged by the operator. In case of irregularities during the daily inspection,
especially during the warrantee period (abnormal sounds or noises etc.), the operator shall act so as to
minimise any damage (e.g. immediately switching off the engine, tracking the cause of the irregularity and

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 Jenbacher Technical Instruction No.: 1100-0111
Documentation General Conditions - Operating and Maintenance

remedying it, and/or notifying the customer-service department).Upcoming service work is to be carried
out before the service deadline for the sake of smooth operation or to avoid interruptions in operation,
such as in the heating season. The service intervals may not be extended to avoid downtime during the
heating season.All parts that contact exhaust are correspondingly not bound to fixed, predetermined
useful lives.

1.5 Safety regulations:

The safety regulations contained in the user's manual must be observed The safety regulations and
regulations for the prevention of accidents set out by the law must be observed. Prior to the
commencement of any work the party ordering must make sure that the applying safety regulations are
observed for the work to be carried out. In the event of work that may only be carried out with the engine
standing still, the engine must be turned off and secured against unauthorized re-starting according to the
technical instruction no. 1100-0105.

1.6 Start conditions:

All GE Jenbacher engines are equipped with a preheating system for the engine cooling water. Only
preheated engines with a engine cooling water temperature of >55°C may be started, loaded and run to
full-load, otherwise the engine may be damaged.

1.7 Malfunctions:
When a failure results in the installation automatically being switched off by the engine control, the cause
of the failure should be remedied first before the installation is started again! It is forbidden simply to reset
a failure and then re-start the engine, as critical or wear-induced damage could possibly result in
premature wear-induced replacement of various components.
Remote resetting: The following failures, if they result in the installation being switched off, can be max. 3
times in 24 hours (remote) reset without too much risk, even if the cause of the failure has not been
remedied.

MALFUNCTIONS: Diane no:

MISFIRING FAILURE 1047, 3005-3024
JACKET WATER TEMPERATURE HIGH 1021
ROOM TEMPERATURE HIGH 1135
FAILURE WITH AUXILIARIES 1129
SYNCHRONIZING FAILURE 1039
HEATING WATER SUPPLY TEMPERATURE HIGH 1063

Resetting (single or multiple resetting) all other failures that have resulted in the installation being
switched off without remedying the cause first will result in a considerable potential risk, endangering
human life and possibly damaging the installation. The client (or the party responsible for the remote
resetting) will be entirely responsible for such damage.

1.8 Registering operational data, Maintenance protocol:

It is compulsory that all operational data are registered and that all special events are described.
Attention:
Just registering the facts in writing is insufficient. The data should be compared with the commissioning
data and be checked for plausibility. In case of deviations, abnormal noises etc. the cause should be
tracked and remedied. If you cannot find the cause, the GE Jenbacher customer-service department
should be notified immediately.
Maintaining and filling in operational data (maintenance protocol, operational data journal, data
registration in the “Maintenance directory”) is in the best interest of the operator. Correctly filled-in

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 Jenbacher Technical Instruction No.: 1100-0111
Documentation General Conditions - Operating and Maintenance

operations journals and data registration sheets are important documents, enabling analysis and support
in case of failures. Moreover, these documents are also important when deciding on warranty claims.

1.9 Spare parts:

Only use original GE Jenbacher spare parts (attention: e.g. oil filter!). Defects and damage caused by the
use of non-original parts are not covered by the warranty.
Important: In order to avoid unexpected standstills due to maintenance work, you are strongly advised to
keep the respective spare parts in store.

1.10 Lubricating oil:

No specific maintenance interval is determined for lubricating oil. It lies within the responsibility of the
operator to take measures necessary for the protection and the safe operation of the plant and which
guarantee the plant's availability.
The oil's service life (depending on gas quality, middle pressure, engine type, oil consumption, oil
temperature and oil type) can be prolonged by an additional oil container. The results of the lubricating oil
analysis with the observation of the limits according to the technical instruction no. 1000-0099B must be
presented in a complete manner also after the warranty period has expired, if premature wear is claimed.

1.11 Ignition plug:

No specific maintenance interval is determined for ignition plugs. It lies within the responsibility of the
operator to take measures necessary for the protection and the safe operation of the plant and which
guarantee the plant's availability. The ignition plugs' service life depends on the marginal conditions of the
plant (e. g. type of ignition plugs, gas type, middle pressure, gas mixing temperature, ignition system,
emission limits).

1.12 Elastomer components:

Elastomer components age and become brittle, even when the engines are not operational.That is why
the service life of these components does not depend on the on-stream service time of the module, the
cooling-water temperature and pressure etc. At normal annual on-stream service times of 5000-6000
operating hours and a cooling-water temperature of 90°C, all elastomer components are exchanged at
the normal intervals as described in the maintenance schedule. If this number of operating hours is not
reached, the elastomer components (e.g. O-rings at cylinder liners, elastic couplings etc.) should still be
replaced as a precautionary measure after a maximum of 5 years.

1.13 Decommissioning the installation:

For long planned or unplanned downtimes such as after the heating season for power plants, the engine
systems need to be prepared for downtime (preservation measures, change old lubricating oil, separate
the chimney connection, etc.) depending on the geographic location (climate, proximity to ocean, type of
gas, etc.).
Since situations can differ greatly, it is recommendable that an appropriate professional company be
consulted or be entrusted with implementing the necessary measures.
Of course, it must be ensured that the system is made ready for use when it is started up again.

1.14 Components coming into contact with exhaust gas:

GE Jenbacher uses only high-grade materials that correspond to the latest state of the art. Due to the
different operating situations and different contents (including traces of pollutants) in the fuel gas, no
binding guarantee can be made on the life of the components such as the exhaust manifold, etc. In the
case of silencers arranged in the open without external heat insulation, even installations without heat
exchanger (hot exhaust gasses) can produce condensate (acid, water) which can shorten the service life.

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 Jenbacher Technical Instruction No.: 1100-0111
Documentation General Conditions - Operating and Maintenance

This also applies to silencers insulated internally where the dew point temperature may be underrun in
the rock wool insulation.

1.15 Operating supplies:

Service life and safe operation of the plant strongly depend on the operating supplies that are used. Only
use operating supplies such as propellants, engine cooling water, warm water, frost protection agent,
anticorrosive agent, lubricating oil etc. corresponding to the respective technical instructions of
GE Jenbacher.

1.16 Quality of propellant:

The operator is obliged to regularly check the quality of the propellant as for its thermal value, methane
number and contents of harmful substances. If these values differ from the values stipulated in the
contract, immediate measures must be taken in agreement with the GE Jenbacher customers service. If
the contents of harmful substances increase (e. g. sewage gas, waste dump gas) the lubricating oil can
be heavily acidified within a fraction of the normal oil change interval and acute or irreparable damage
and increased wear occur all of a sudden e. g. on cylinder liners and bearings and/or the oil consumption
increases. In the event of variations of the methane number downwards (within the range stipulated in the
contract) the engine is protected against harmful knock operation by the control (automatic ignition
control, efficiency decrease).

Note:
During the start-up the engine is optimally set according to the methane number given at that time.
If the methane number increases after the start-up (for a longer or decisive period of the operation time of
the plant) the engine setting should be changed in the sense of an operation type optimizing the
efficiency. This task is to be carried out by specialized personnel.

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