Comprehensive Refurbishment of a Gas Engine Power Plant in Gyula

Project presentation

As part of a long-term cooperation with E.ON Energiatermelő Kft., Plant Industrial Engineering successfully completed a comprehensive refurbishment and recommissioning project at the E.ON Gyula gas engine power plant. The project focused on restoring and upgrading a Deutz TBG 620 FV20 gas engine-generator unit, originally commissioned in 2003 and previously taken out of operation for economic reasons.

The refurbishment aimed to return the unit to reliable, long-term operation while meeting current technical, safety, and operational standards.

Project Background and Objectives

The gas engine power plant, located in Gyula, Hungary, is equipped with a 1.84 MW Deutz gas engine operating in decentralized power generation. Following an extended period of shutdown and an initial condition assessment, it became clear that a major overhaul exceeding standard maintenance scope was required.

Based on the findings and in agreement with the client, an E-60 level refurbishment was carried out, ensuring the restoration of mechanical integrity, operational reliability, and full functional compliance of the unit.

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The project covered an extensive range of mechanical, electrical, and control system activities, including:

Full refurbishment of the gas engine core components
Overhaul of turbochargers, cylinder heads, pistons, liners, and crankshaft-related systems
Renewal and cleaning of lubrication, cooling, and gas supply systems
Generator inspection, bearing replacement, and shaft alignment
Replacement and calibration of sensors and safety devices
Upgrading and testing of electrical, ignition, and control systems
Environmental and safety improvements, including oil containment solutions

All work was carried out in accordance with manufacturer specifications and documented through detailed service and test reports.

Scope of Work

Technical Challenges and Solutions

During the disassembly and refurbishment process, several previously hidden technical issues were identified, including contamination in oil and cooling circuits, component wear due to prolonged downtime, and control system failures. These challenges were addressed through targeted corrective actions, close coordination with the client, and continuous engineering support throughout the project.

Special attention was given to system integration, ensuring that refurbished mechanical components, upgraded electrical systems, and modernized control functions operate as a unified and stable power generation unit.

Commissioning and Performance Testing

Following completion of the refurbishment, the gas engine underwent cold and hot commissioning phases, including full-load testing at rated output. After final adjustments and a controlled running-in period, the unit was successfully handed over for unrestricted commercial operation.

The commissioning confirmed stable performance, proper safety behavior, and compliance with operational requirements defined by the client and applicable standards.

Value Delivered to the Client

Through this refurbishment project, the client achieved:

Extension of the power plant’s operational lifetime
Restored base-load power generation capability
Improved reliability and safety of critical systems
Reduced risk of unplanned outages
Compliance with current technical and environmental expectations

The project demonstrates how a structured refurbishment approach can unlock additional value from existing assets, even after long periods of inactivity.

A Proven Partner in Gas Engine Power Plant Lifecycle Support

This reference project highlights Plant Industrial Engineering’s capability to manage complex gas engine refurbishment projects, from initial assessment through execution and recommissioning. Our integrated engineering, mechanical, and control system expertise enables us to support power plant owners across the full lifecycle of their assets.

From preventive maintenance to full-scale overhauls, we deliver solutions designed for long-term performance, safety, and sustainability in decentralized energy generation.