Title of presentation - · PDF fileMAN Diesel & Turbo JNA/LDE 2012.06.14 1 ME-GI 2012 MAN...

1MAN Diesel & Turbo JNA/LDE 2012.06.14

MAN Diesel & Turbo

ME-GI Design, June 2012Presentation for Croatian Register, 30’th August 2012

• Gas injection system

• Principles

• Control system, control system components

• Combustion monitoring

• Port to port gas sailing

• Fuel gas return system – minimization of methan-slip

• Development proces: System test

Presentation

ME-GI: ME-ECS and GI-ECS

Injection control

How to control ME-GI?

Fuel oil

ME-ECS GI-ECS

High pressure gas

Hydraulic oil

Crankshaft position and speed

Injection amount, division and timingME-GI control:

ME-GI Development

ME-GI concept: Combustion Principles

Diesel process:

ME-GI Development

ME-GI concept: Combustion Principles

Diesel process:

ME-GI Safety principle

• In case of a problem in the gas injection system, the use of gas is stopped

and the engine is changed-over to fuel oil operation.

• The non-controlled state is:

• that gas supply to engine is blocked

• the system is de-pressurized

• Fail-safe state is the same.

ME-GI gas injection

Hydraulic oil

Inert gas system

- for purging of gas pipes

Inert gas

system

Hydraulic oil

Double pipes

and ventilation system

Inert gas

system

Hydraulic oil

Sealing oil system

Inert gas

system

Hydraulic oil

Hydraulic activation of blow-of and

purge valves

Inert gas

system

Hydraulic oil

overview

Gas control block

Gas Injection System

Gas injection valve Connection flanges

Blow-off valve

Purge valve

Connection block

Gas control block

Material S45R (393 kg)

H=396.5mm ;W=505mm; D=340

Acc. volumen for 20 gas injections.

DSME FGS System Layout

GI engine, injection control

Fuel oil

ME-ECS GI-ECS

High pressure gas

Hydraulic oil

Crankshaft position and speed

Injection amount, division and timing

ME-GI Engine Control System

Environment

Gas Supply System

GI control

system

GI Safety

system

Sensors

Engine

Safety

System

Seal Oil

System

ME-ECS

Double Pipe

Ventilation

System

Inert Gas

System

ECS MOP

Gas supply

control

system

GI Engine Control System

ME Tacho

Crankshaft

position

GI-ECS configuration

GCCU GCSU

GPSUGECU

Safety UnitsControl Units GMOP Gas Main Operation Panel

GECU Gas Engine Control Unit

GPCU Gas Plant Control Unit

GCCU Gas Cylinder Control Unit

GPSU Gas Plant Safety Unit

GCSU Gas Cylinder Safety Unit

DASUMPC

Controllers of the system

ME-GI GMOP

Main dashboard display

ME-GI GMOP

Gas supply overview

ME-GI GMOP

Double pipe ventilation system

ME-GI GMOP

Hydraulic- and Seal oil display

Gas injection - safety

Gas Injection Control

Gas Injection Control Step 1

Gas injection - safety

ME-GI Development

Gas Injection Control: Safety

Built-in design safety:

Architectural safety

Separate controllers

for ELWI and ELGI

Safety on gas injection

Window/gas shutdown valve

Safety on control oil

Interlock W-valve and GI-valve

Electrical safety

ELWI enable

ELWI/ELGI electronically ok

Combustion monitoring

- Compression pressure

20 40 60 80 100 1200

Angle [degrees]

300 320 340

Angle for

Pcomp check

Min. Pcomp

pressure limit

Fast integrated supervision:

Cylinder pressure monitoring:

Compression pressure monitoring

- Maximum pressure

20 40 60 80 100 1200

Angle [degrees]

ressure

300 320 340

Max pressure

limit Fast integrated supervision:

Maximum pressure monitoring

- Expansion pressure

20 40 60 80 100 1200

Angle [degrees]

300 320 340

Angle ranges for

Pexp check

Maximum pressure monitoring

Expansion pressure monitoring:

Σ Pafter TDC – Σ Pbefore TDC

Expansion pressure monitoring,

50% load, missing pilot oil injection

Expansion pressure monitoring, - Missing pilot oil injection & cyl. lube Oil

Expansion calculation

over 100 revolutions

Misfiring

5% Pilot injection combustion detection

Cylinder pressure

if no combustion

Cylinder pressure

at 5% pilot injection

and no gas

5% Pilot injection combustion detection

Misfiring

detection limit

GI valve and Window-valve

leakage detection

Inert gas

system

Hydraulic oil

Gas channel

pressure

sensor

GI valve and Window-valve

leakage detection methods, principle

Window-valve leakage

Gas injection valve leakage

Combustion & Leakage: Supervision

Cylinder pressure testing

Cylinder compression test

Maximum cylinder pressure test

Cylinder expansion pressure

Leakage testing

Leaking gas injection

Leaking window valve

Gas pressure sensor failure detection

Gas shut down or gas stop

Engine changes to fuel mode

Continuous operation without loss of power

Result of single failure

Port to port operation

Speed reduction => Windmilling

Stop => Windmilling

Reversing

Low load sailing

Fuel index

Scavenging air press.

Gas stand-by

Hydraulic oil

PurgedNot

Purged

Gas Train

Prepare

For Gas

Gas On

Engine

Running

Blow OffPurging

Gas Shut Down / Gas Stop

Standby

Prepare

Supply

MS_2 MS_1

MS_3 MS_4 MS_5

MS_8MS_7

MS_9MS_10

GPCU: Gas Plant Control State Machine

Main States

Gas stand-by

Automatic change-over to gas running when engine load is above lowest

limit for gas operation.

Automatic change-over to fuel oil running, when engine load is below

lowest limit for gas operation.

Keep pilot-fuel injection until after gas pressure blow-off

Prepare gas supply before engine start

Fast engine load up

Manoeuvring

Mixed mode

Rough weather conditions

Port to Port Operation

Change over to gas operation

Port to Port Operation

- Mixed mode

Fast load up during gas operation

Load up tests:

Engine speed & load

Fast RPM and load increase

Governor index

Gas index is supported by

added fuel index

Gas pressure

Gas pressure build-up is

supported by added fuel

Rough weather conditions

Measurements from LNG Tanker in service:

Rolling ship with twin engine

Propeller torque variations

Wind speed: Up to 18 m/s.

Waves: 9.5 metres from portside aft on ship

Port to port operationTests similar to rough weather conditions

Load variation tests:

Speed set point variations

+/- 10%

Wave periodic time approx. 12 sec

Index variations

+/-25%

Gas pressure

Constant set-point

Variations approx.: +/- 3 bar

Change-over from gas to fuel oil during

load variations

Change-over from fuel oil to gas during

load variations

Gas return system

- to minimize methane slip

Inert gas

system

Hydraulic oil

return

Next step: ME-GI ECS integration with PMI Autotuning

PMI sensor data

Safety System

PMI DAU DASU

Engine Control

System

Engine

Monitoring System

Fuel Injection/

Exh. valve timing

Gas Control

System

ECS-MOP

ME Engine Gas System

MAN LAN

Window valve

GI-MOPMPC

Hardwired signals

EMS-MOP

MAN LAN

Gas Injection

Main electronic components of the ME-GI-ECS

Component name ME-ECS New

1 MPC: Multi Purpose Controller X2 EC-MOP X3 Approved PCs X

4 Control Network PCI Board X5 DASU: Data Acquisition & Supervision Unit X

6 TSA: Tacho Signal Amplifier X7 Angle Encoders X

8 Proportional - directional control valves, version with digital

input (e.g. Parker) X

9 Keyboards and track-balls X10

11 Combustion pressure sensors and amplifiers (X)12 Gas channel pressure sensors X13 Seal oil pressure control valves X

14 etc.

Gas supply system and gas train components are the responsibility

of the gas supply system supplier.

• SW configuration management tool: IBM Rational Synergy

(- as used for all SW systems, e.g. the ME-ECS)

• Automated module tests

• Automated system test

• Functional verification and validation on 4T50ME-GI test engine

ME-GI Engine Control system

Development proces

System test, automated test system

All data provided in this document is non-binding.

This data serves informational purposes only and is

especially not guaranteed in any way. Depending on the

subsequent specific individual projects, the relevant

data may be subject to changes and will be assessed and

determined individually for each project. This will depend

on the particular characteristics of each individual project,

especially specific site and operational conditions.

Thank You for Your Attention!

Title of presentation - · PDF fileMAN Diesel & Turbo JNA/LDE 2012.06.14 1 ME-GI 2012 MAN...

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