GE Power & Water
Gas Engines
Waukesha* gas engines
VHP* Series Four*
enhancing the tradition
*Trademark of General Electric Company. All other trademarks are the property of their respective owners.
VHP Series Four Enhancements
GE Power & Water’s Waukesha Series Four rich-burn engines have
traditionally been the engines of choice for some of the harshest and
most demanding gas compression, power generation, and mechanical
drive applications across the world.
This tradition has been built on the Series Four engines’ ability to reliably
produce more power on hot field gases, at high altitudes, and in remote
locations, all while providing the opportunity to deliver the lowest
available emissions when paired with a 3-way catalyst (NSCR).
Series Four rich-burn engines are known for their application flexibility
and reliability. A series of upgrades to the F3524GSI, L5794GSI, and
L7044GSI now further enhance the tradition and durability of the
Series Four.
Cylinder Head Components & Valves
Rich-burn engines are about heat. The same heat and high-exhaust
gas temperature that enables the highly-effective emission reduction
capability of a 3-way catalyst must also be managed properly within
the cylinder head.
Series Four cylinder heads now incorporate intake and exhaust valves
with a new proprietary design for improved seating, sealing, and heat
transfer. Both the intake and exhaust valves now use positive valve
rotators for better temperature distribution and sealing, resulting in
lower wear and longer life.
An improved spark plug carrier sealing system ensures robustness and
long life.
These designs have been proven in multiple field tests and have
exceeded the goal of running up to full rated load for 24,000 hours.
The success of these field tests indicate the extended time-betweenoverhauls (TBO) capabilities of the new cylinder head design†. Frequent
monitoring and inspection throughout testing showed cylinder heads
to be in excellent condition after more than 30,000 hours of operating
time. Exhaust valve recession was measured at less than half of the
guideline as published by Waukesha gas engines.
Enhanced
d Air/Fuel
/
l Ratio Controll
A rich-burn engine with a 3-way catalyst (NSCR) provides a scalable
emission solution with the lowest overall emissions in the market. With
enhancements to the ESM* air/fuel ratio control system, Series Four
engines are able to achieve these low emission levels across an even
wider range of applications.
An enhanced ESM air/fuel ratio control algorithm was created to
optimize the performance of a new fuel pressure regulator. Included
in the new algorithm are updated gains in the fuel system to improve
the interaction between the regulator, engine, and controls, as well
as improved oxygen sensor signal processing specifically matched to
Waukesha’s oxygen sensor.
Together, the enhanced ESM air/fuel ratio control algorithm and new
fuel pressure regulator create up to a 17% wider air/fuel ratio range
where 3-way catalyst performance is optimized. The system also
maintains the air/fuel ratio set-point across a wide fuel quality range.
This wider “sweet spot” provides greater confidence in emissions
compliance and less frequent adjustment, resulting in lower operating
costs.
Fuel pressure regulator applies to all VHP engines.
Improved ESM air/fuel ratio control algorithm applies to F3524GSI,
L5794GSI and L7044GSI
Applies to F3524GSI, L5794GSI and L7044GSI
Time between overhauls may vary based on operating conditions and maintenace.
†
Old
New
New exhaust valves have a proprietary design
to improve robustness and reduce wear rate.
The ESM air/fuel ratio control algorithm was
enhanced to optimize the performance of the
new fuel pressure regulators.
New fuel pressure regulators provide
wider air/fuel ratio range where catalyst
performance is optimized
Cam Tappet Rollers
Front-End Gear Cover Sealing
An improved cam tappet roller design provides long life with minimal
wear. A 3-piece pin/bushing/roller design and optimized oil channels
improve lubrication for smooth operation.
Single piece gear housing and gear cover gaskets eliminate gasket
joints, providing a highly-engineered sealing system between the
crankcase and the front-end gear cover.
Applies to all VHP engines
Further gasket refinements include higher strength material and an
optimized contour, which produces a more uniform sealing pressure.
These gasket enhancements, coupled with longer bolts for better
clamp load, improve the margin against joint relaxation and minimize
opportunities for leaks.
Pistons and Cylinder Liners
The Series Four piston has been enhanced for improved scuff resistance
under even the most challenging operating conditions.
Applies to L5794GSI, L7042GSI and L7044GSI
Piston enhancement applies to F3524GSI, L5794GSI and L7044GSI
Enhancement Features Summary
New Feature
Service
Parts
L5794GSI
L7044GSI
Series Four
Cylinder Head
X
X
X
X
ESM Air/Fuel Ratio
Control Algorithm
X
X
X
X
Gas Regulator
X
X
X
X
X
X
Cam Tappets
X
X
X
X
X
X
Series Four Pistons
X
X
X
NA
X
X
Front-End Gear
Cover Sealing
Cam tappet rollers provide better lubrication
for smoother operation.
L7042GSI
All Other
VHP
F3524GSI
X
X
X
New piston design provides optimal scuff
resistance
Sealing has been enhanced through the use of
a single-piece gasket between the crankcase
and the front-end gear cover.
GE Power & Water
1101 West Saint Paul Avenue
Waukesha, WI 53188-4999
P: 1.262.547.3311
F: 1.262.549.2759
Visit us online at:
www.ge-waukesha.com
©2013 General Electric Company
All Rights Reserved
GE’s Gas Engines business
GE’s Gas Engines business is a recognized leader in the
industry for fuel flexibility, low emissions and performance
excellence with energy solutions providing efficiencies
as high as 98 percent. A specialist in combined heat and
power (CHP), mechanical drive, waste heat-to-power and
fuel rating technologies, GE’s Gas Engines business boasts
a combined 170-year legacy of technological innovations
crossing three product lines ― Jenbacher gas engines,
Waukesha gas engines and Heat Recovery Solutions.
GE’s Gas Engines business manufactures gas-fueled
reciprocating engines, generator sets, CHP modules,
ORC systems and auxiliaries for power generation and
compression, delivering cleaner, more efficient, and
affordable onsite energy with products that generate a wide
range of distributed power outputs. Our fuel-flexible engines
of up to 10 MW operate on a wide range of field and natural
gas as well as biogas and landfill, coal mine, associated
petroleum and sewage gas. The business is supported by
life-cycle service solutions such as remote monitoring and
diagnostics as well as contractual services and upgrades
that increase availability and performance and underscore
our global excellence in customer value.
Part of GE Power & Water, GE’s Gas Engines business is
headquartered in Jenbach, Austria. Its main production
facilities are located in Jenbach, Austria, and Waukesha,
Wisconsin, United States. It has more than 2,600 employees
and over 32,000 engines installed in more than 80 countries.
8060 0113
GEA-19640