wärtsilä’s Gas portfolio The road to a greener worldScavenging/ compression ... in prechamber...

KARL.HINKS@WARTSILA.COM

30 March 2015 1 © Wärtsilä

Content

• Gas Engine technologies

• 4-stroke Dual fuel

• LNGPAC

• Engine conversion

Wartsila Ship Power

Shipping until recently…

30 March 2015 Dual fuel - P.Bodman 4 © Wärtsilä

Shipping from now on…

Established Emissions Controlled Areas

Emissions Controlled Areas under consideration

Shipping critical points

Why Natural Gas – The emission advantage

Particulates

Dual-Fuel engine

in gas mode

Diesel

engine

Emission

values [%] -25%

Content

• Introduction

• LNGPAC

The gas engine history

FUEL (DF) GAS-DIESEL

SPARK-IGNITION

GAS (SG)

1987 1992 1995

Gas burning technologies

Gas-diesel (GD) engines:

• Runs on various gas / diesel

mixtures or alternatively on diesel.

• Combustion of gas, diesel and air

mixture in Diesel cycle.

• High-pressure gas injection.

Dual-fuel (DF) engines:

• Runs on gas with 1% diesel (gas

mode) or alternatively on diesel

(diesel mode).

• Combustion of gas and air mixture

in Otto cycle, triggered by pilot

diesel injection (gas mode), or

alternatively combustion of diesel

and air mixture in Diesel cycle

(diesel mode).

• Low-pressure gas admission.

Spark-ignition gas (SG) engines:

• Runs only on gas.

• Combustion of gas and air mixture in

Otto cycle, triggered by spark plug

ignition.

• Low-pressure gas admission.

32GD/46GD

Dual-fuel (DF) engines

Spark-ignition gas (SG) engines

Gas-diesel (GD) engines

32DF/34DF/50DF

Doc.ID: Revision: Status: © Wärtsilä

Wärtsilä Dual-Fuel Application References

30 March 2015 DF reference

>1,300 engines >12,000,000 running hours

LNG Carrier

Multigas Carrier

Product tanker

Bulk tanker

CNG carrier

Offshore supply

Platform

Ferries

Icebreaker

Guide ship

168 vessels

8 vessels

2 vessels

1 vessel

Chemical tanker

Ferries

Chemical tanker

Container vessel

LNG Carrier

4 vessels

3 vessels

Plants 75

Output 4877 MW

Online since 1997

24 vessels

5 vessels

4 vessels

2 vessels

1 vessel

9 vessels

6 vessels

3 vessels

1 vessel

4 vessels

2 vessels

1 vessel

732 engines

123 engines

61 engines

28 engines

11 engines

352 engines

Wärtsilä 4-S DF engine portfolio

6L20DF 1.0 MW

8L20DF 1.4 MW

9L20DF 1.6 MW

6L34DF (SP) 3.0 MW

8L34DF (SP) 4.0 MW

9L34DF (SP/PP) 4.5 MW

12V34DF (SP) 6.0 MW

16V34DF (SP/PP) 8.0 MW

20V34DF (PP) 10.0 MW

6L50DF 5.9 MW

8L50DF 7.8 MW

9L50DF 8.8 MW

12V50DF 11.7 MW

16V50DF 15.6 MW

18V50DF 17.55 MW

5 10 15 MW

DBAD263346 Product Review Wärtsilä 34DFB

46DF 6L46DF 6.9 MW

8L46DF 9.2 MW

9L46DF 10.3 MW

12V46DF 13.7 MW

14V46DF 16.0 MW

16V46DF 18.3 MW

7L46DF 8.0 MW

DF-engine

* * * * * * * *

* * * * * *

* * * *

Intake of

air and gas

Compression of

air and gas

Ignition by

pilot diesel fuel

Otto principle

Low-pressure gas admission

Pilot diesel injection

Gas mode: Ex. In. Ex. In. Ex. In.

Intake of

Compression of

Injection of

diesel fuel

Diesel principle

Diesel injection

Diesel mode: Ex. In. Ex. In. Ex. In.

The marine favourite technology?

* * * * * * * * * * *

* * * * * * * * *

GAS INJECTION

DUAL-FUEL (DF) Meets IMO Tier III on Gas

Back-up mode - MDF

Low pressure

SPARK-IGNITION GAS (SG) Meets IMO Tier III

No redundancy

No HFO flexibility

GAS-DIESEL (GD) Does NOT meet IMO Tier III

High gas pressure

Requires Exh Gas After-treatment

Otto or Diesel cycles: effects on NOX

Big temperature

difference

NOx formation!

Diesel, max flame temp.

Otto, max flame temp.

Wärtsilä‘s DF

* * * * * * * * * * *

GAS INJECTION

DUAL-FUEL (DF)

1 IMO Tier III compliant on Gas

2 Port to Port Operations on Gas

3 Low pressure gas ~4 Bar at the Engine

4 High Thermal Eff ~ 48% - 49% (46DF~50.1%)

5 Fuel flexibility; GAS, MDO and HFO

6 Back-up is MDF.

Content

• Introduction

• Gas Engine Technologies

• LNGPAC

4-stroke fuel inlet system 20DF

Pilot fuel common

rail 900bar

Main fuel

injection pipe

Main fuel

injection pump

Pilot fuel quill pipe

Main fuel quill pipe

Twin nozzle

injection valve

Inlet valve

Gas manifold

Gas bellow

Fine filter

Gas valve

Gas nozzle

Gas valve electrical connection

Injection valve electrical connection

Fuel injection 50DF

Pilot solenoid valve

Pilot needle

Main needle

Operating Modes

• Gas Mode – Gas & Pilot fuel.

– Pilot Fuel ~ 1%

• Diesel Mode – Jerk Pump & Pilot Fuel.

– Pilot Fuel maintains Injector nozzle is clean.

• Back-up Mode – Jerk Pump only.

– Enables Rapid Black-out Start.

Start Sequence 50DF

Transfer - MDO to GAS at 80% load

Receiver pressure

Gas pressure

Pilot fuel pressure

Diesel actuator

Transfer of Modes - GAS to MDO at 100% load

Receiver pressure

Gas pressure

Pilot fuel pressure

Diesel actuator

Operating window / Control System

Operating

window

BMEP [ bar ]

Air / Fuel ratio

Knocking

firing

Optimum performance

for all cylinders

Cylinder Control Unit – Controls GAV, Pilot Injection, duration/timing

Stop/Shut Down & Emerg Stop

• Stop (Operator) :

– In Gas – Unload engine.

– GVU shut off/GAV de-activated.

– Pilot active during run-down initially.

– Pilot de-activated.

– Exhaust ventilated.

• Shut Down (Automatic):

– Engine unloaded immediately.

– Stop signal initiated.

– If overspeed - Pilot Fuel stopped.

• Shut-Down – typically

– LO/HT Pres/Temp.

– Bearings or Cyl Liner Temp.

– Gas Leak

– Crankcase Pressure

– Speed sensor failure

– Oil Mist

• Emerg Stop (Operator):

– Stop initiated – engine & aux.

– Pilot fuel stopped immediately.

Typical ER Arrangement

• ER is Gas Safe if Double Walled Pipes

• Electrical Equipment not Ex proof.

• GVU can be in ER or external.

• Engines can suck from ER or outside –

IMO/IGC or IGF.

Ventilation Layout

Content

• Introduction

4-stroke dual fuel

• LNGPAC

2-stroke GD-concept HIGH PRESSURE

Scavenging/

compression

Pilot fuel & HP

gas injection, ign Expansion

Principles:

• Engine operating accordingly to

Diesel process

• Injection of gas close to TDC.

Air is completely compressed

and, therefore, high pressure

gas injection (300 bar) is

required.

• No significant NOX reduction

• Requires SCR or EGR (not

proven) in order to meet IMO

Tier III levels

2-stroke DF-concept LOW PRESSURE

Principles:

• Engine operating accordingly

to Otto process

• Injection of gas at mid-stroke.

Low pressure gas injection

(<16 bar)

• High impact on NOX reduction

• Meets IMO Tier III without

after treatment

Scavenging Compression/

gas admission

Ignition

expansion

The 2-stroke DF concept

The Principle:

• Engine operating

according to the Otto

process

• Pre-mixed ‘Lean

burn’ technology

• Low pressure gas

admission at ’mid

stroke’

• Ignition by pilot fuel

in prechamber

Low pressure Dual Fuel

12 November 2013 33 © Wärtsilä

Engine Design

Wärtsilä two-stroke DF engines have the

same footprint as a conventional HFO engine

No SCR, Scrubber or EGR required in order

to meet upcoming emission regulations

No parasitic loads introduced thanks to low

pressure gas injection

Lower Opex compared to HP Gas engine

No HP cryo-pumps, HP evaporators,

“heavy” double wall piping

Minimization of hazards due to low pressure

gas injection

THINK ABOUT OVERALL SYSTEM

EFFICIENCY

RTX – 5 (RTFlex50DF)

6X72DF 2-S Engine – 19350kw

Content

• Introduction

• 4-stroke dual fuel

• 2-stroke R&D dual fuel

Dual Fuel installation

C. Dual-Fuel Main engine

A. Storage tanks

B. Evaporators

A complete and modularized

solution for LNG fuelled ships

D. Dual-Fuel Aux engines

E. Bunkering station(s)

F. Integrated control system

Complete solution – Viking Grace

Gas solution components

Bunkering

Station Main Engine Gas

Bunkering line,

insulated pipes

Bottom tank

filling

Pressure build

up evaporator

LNG – gas evaporator

Water/Glycol

system

LNGpac

Gas valve unit

• Regulating the gas pressure to the engine

• One unit per engine

• Enclosed type, no separate room needed

• Vertical and horizontal designs

• Ideally less than 10m away from the engine

• Compact

• Integrated ventilation with the engine

Viking Grace – Stockholm - Turku

Viking Grace

Tank Spray Arrangements

LNGpac Bit Viking - Retrofit

• Liquid LNG at -162 C

• 2 x 500 CBM Type C Tanks

• Various sizes designed &

Patented by Wärtsilä

Viking Grace - Bunkering

Emissions – The Reality

Really!!

“Other tank technologies are available”

“IMO Type C” “Membrane” “IMO Type A - B”

LNG tank technologies

“IMO Type C” “Membrane” “IMO Type A - B”

Non-self-supporting

tanks which consist on a

thin layer (membrane)

supported through

insulation by the adjacent

hull structure.

Tanks which are

designed using model

tests, refined analytical

tools and analysis

methods to determine

stress levels, fatigue life

and crack propagation

characteristics.

Are also referred as

pressure vessels and are

tanks meeting IGC code

pressure vessels criteria

(accepting overpressure).

Optimum space

utilization (prismatic)

They need to be built

by the Shipyard

(quality/experience/cost)

They do not accept

pressure increases.

NBOG and FBOG

handling

Optimum space

utilization (prismatic)

They can be build in a

separate environment

They do not accept

pressure increases.

NBOG and FBOG

handling

NOT optimum space

utilization (cylindrical)

They can be build in a

separate environment

They accept pressure

increases so higher

flexibility in NBOG

handling. Available

“holding time”

* NBOG = Natural Boil-Off Gas ; FBOG = Forced Boil-Off Gas

Content

• Introduction

• 4-stroke dual fuel

• 2-stroke R&D dual fuel

• Integrated products

4-S Convertable products

Wärtsilä 20 Diesel Wärtsilä 20DF

4-S DF conversion – Parts to be exchanged

Turbochargers

modified for DF

operation

Camshaft

pieces for

DF Miller

valve timing

Cylinder

Pistons &

piston

Cylinder liner

& anti-

polishing ring

Connecting

(upper part)

needle

injection

Control

system

30 March 2015

DF conversion – Components to be added

Gas rail pipe

Gas admission

valves

Exhaust gas

waste gate

Pilot fuel system:

- Pilot fuel oil filter

- Common rail piping

- Pilot fuel oil pump

30 March 2015

Retrofit - Diesel to dual-fuel

66 © Wärtsilä

RT-flex50DF and X- type DF RT-flex50

X-type

2-S Retrofit - DF System Layout

Main fuel injector:

• L’Orange-type with built-in solenoid

Gas admission valves:

• Servo activated

• controlled by rail valve UNIC

cylinder module

Exhaust

• 2/3x Pilot fuel injectors

• Adapted cylinder cover design

• 2x Gas Admission Valves (GAV)

• Adapted cylinder liner design or

remachined cylinder liner

• 2x Gas rail double walled

• MDO Supply Unit

• Support platform for MDO SU

• MDO Pipes to injectors

Pilot fuel injector:

• L’Orange-type with built-in solenoid

67 © Wärtsilä

wärtsilä’s Gas portfolio The road to a greener worldScavenging/ compression ... in prechamber...

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