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Gas as a Means for Ship Propulsion

Dr. Hans J. Gtjens


Vice President Marine Regional Chief Executive for North - Central - Europe, Baltic Region and Russia

BUREAU VERITAS S.A.

The Propeller Club of Geneva Htel Bristol, Geneva


Thursday, 25 April 2013

Bureau Veritas Bureau Veritas and Gas a long History

Bureau Veritas & Gas Carrier Development


1962: Supervision of the prototype tests of the experimental LNG carrier "Beauvais", and first Rules for LNG Carriers published by BV.

1965: Classification of "Jules Verne", 25,000m3 LNG ship.

1971: Classification of "Descartes", 50,000m3 LNG Carrier, Technigaz type Classification of "Hassi R'Mel", 40,000m3 LNG Carrier of Gaz Transport type.

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Bureau Veritas & Gas Carrier Development

1972: BV chairmanship of the IACS Group on Unified Regulations for Liquefied Gas Tankers, which has been the basis for the IMO Gas Codes. Classification of the first membrane LNG Carrier of the 125,000 m3 size, Technigaz type "Ben Franklin".

1995: Classification of the first membrane LNG carrier built in Korea Hanjin Pyeong Taek

2005: Classification of the worlds first LNG RV vessels

2006: Classification of the worlds first DFDE LNG carriers Classification of the worlds first CS1 containment system
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Bureau Veritas & Gas Carrier Development

2007: Classification of the first LNG carrier with MAN DFDE propulsion LNG STS transfer in the GoM 2007- 2010: BV involvement in the IGC code revision 2008-2009: Classification of the worlds first multipurpose gas carrier Coral Methane (capacity 7,500m3) built to transport LNG/LPG & LEG 2012 : Delivery of a 15,000m3 LNG/LPG & LEG carrier for Anthony Veder from Meyer Werft The first LNG Carrier with dual fuel engines and direct propulsion

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Selected References in LNG Carriers


72 LNG C delivered, on order or in service with BV class

(approx.20%).
BV active with all technologies of LNG containment:

Membrane GTT (Mark III, NO96, CS-1), and Korean KC-1, Moss, IHI SPB, Wadan & Aker LNG ADBT system, type C tanks.
Active with the major shipbuilders worldwide, including:

DSME, SAMSUNG, HYUNDAI, HANJIN, STX, MITSUBISHI, UNIVERSAL, KAWASAKI, STX EUROPE, AKER, NAVANTIA, HUDONG, NACKS, DALIAN, JIANGNAN, SWS, RONGSHENG, MARIC.
BV is active on LNG FPSO and FSRU projects. BV has classed the first LNG RV (8 ships) BV is presently working on 12 projects for container

vessels, ferries, cruise vessels with LNG as fuel

LNG RV Excellence
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Gas : A well proven Technology


The first LNG carrier fitted with dual fuel engines has been delivered in 2006 with BV class (GDF SUEZ GLOBAL ENERGY). Since this first application, more than 50 additional LNG carriers have been ordered with dual fuel diesel electric propulsion, 19 of which are with BV class. We have also seen the delivery in 2009 of one LNG carrier with single gas fuel engines.

157,000m3 LNG CSERI BALHAF BUILT BY MHI FOR MISC IN 2009

7,500m3 LNG C CORAL METHANE

BUILT BY REMONTOWA FOR ANTHONY VEDER Propeller Club Geneva 25.04.2013

Bureau Veritas Which Fuels are used in Shipping ?

Present Situation
World-wide the merchant fleet consists of abt. 120.000 vessels (>100 GT) >99% are equipped with diesel engines and burn Intermediate Fuel Oil (IFO), Marine Diesel Oil (MDO) and Gasoil (MGO) abt. 400 LNG tankers are burning natural gas in steamplants or dual fuel engines abt. 30 other vessels are using gas as fuel sailing ships are only used for training and cruises Fuels used presently in shipping IFO MDO + MGO Natural Gas abt. 80% abt. 20% < 1%

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Production of Fuel (2011)


Production per year Oil Gas Coal Bio Fuels Ethanol, Biodiesel Palmoil (< 10% used as fuel) Refinery utilization abt. 60 mio t abt. 50 mio t 81,2% (source: BP)
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RP rate 54,2 years 63,6 years 112 years

abt. 4000 mio t abt. 3000 mio t (oil equivalent) abt. 4000 mio t (oil equivalent)

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Residual Fuel Oil as a Percentage of all Oil Products


(BP Statistical Review 2010, TUHH)

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Present Fuel Consumption in Shipping


Estimates and predictions about the annual total consumption of bunker fuel for ships vary from 220 mio t (IEA) to 330 mio t (IMO 2009). Rough Estimation for 2011 for Intermediate Fuel Oil (IFO) Consumption: Assumptions: IFO consists of Residual Fuel blended with destillates abt. 12% of the oil production are residuals abt. 35 % is used in shipping annual oil production 2011 = 4000 mio t abt. 480 mio t residuals abt. 170 mio t for shipping blended with 17 mio t destillates (10%) annual IFO consumption abt. 187 mio t
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MDO and GO Consumptions


Estimation of DO / GO consumption in shipping: abt. 27% of the oil production are Diesel Oil and Gas Oil abt. 4% of the DO / GO production is used for shipping abt. 1080 mio t abt. 43 mio t DO / GO for shipping

Total Consumption: IFO DO / GO Total: abt. 187 mio t abt. 43 mio t abt. 230 mio t

Shipping is responsible for 2%-3% of all hydrocarbons burned.

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Use of Heavy Fuel Oil


Production of Residual Fuel Oil will decline because it is commercially more attractive for producers to sell destillates than desulferized Heavy Fuel Oil. old refineries will close down some new refineries produce no Residual Fuel Oil at all the residual is petrol coke existing refineries will be upgraded by installation of crackers and flexi cokers If the percentage of RFO production decrease as in the last century and oil production will remain on 2011 level: 160 mio t less RFO production per year in 2020 compared to 2011 The present RFO consumption in shipping is abt. 170 mio t.

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Consequences for shipowners


Prices for HFO will increase 2005 : 60% of crude oil price 2011 : 80% of crude oil price 2020: For ECAs Installation of scrubbers Installation of SCR Exhaust gas recirculation Use of MGO Use of natural gas from 2015 onwards for newbuildings 2016 for newbuildings 2016 from 2015 onwards from 2015 onwards 100% ?

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Is enough gas available ?

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Gas Reserves and Production (source BP)


Natural gas 2011 World reserves World production Trade movements between countries (pipeline) Trade movements between countries (LNG) Gas Prices per million Btu (average) 2011 Japan LNG Germany UK US Crude oil 14,73 10,61 9,03 4,01 18,56 1998 3,05 2,36 1,86 2,08 2,16 208400 3276 695 331 billion cbm billion cbm billion cbm billion cbm (2955 mill toe)

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Natural gas reserves

5.2 3.6 7.0 8.0

Middle East
38.4

Europe & Eurasia


2011 Total 208.4 Trillion cubic metres

Asia Pacific Africa North America S. & Cent. America

37.8

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LNG Trade Volumes 2011

LNG Imports

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Shale Gas Resources

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Bureau Veritas LNG Infrastructure and Bunkering

LNG Terminals

abt. 100 large LNG Import and Export Terminals under operation more than 100 LNG Import and Export Terminals planned or under construction only a few are laid out to handle small volumes

Terminals in Europe able to handle small volumes: Norway: Stavanger for vessels, trucks, containers Belgium: Zeebrgge for vessels, trucks, containers Sweden: Nynshamn for vessels, trucks, containers Spain: Barcelona, Cartagena, Huelva for trucks, containers

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Use of natural gas as fuel for ships: selected issues


Bunkering arrangements
For small capacities, non-fixed tanks located onboard the ship may be considered, such as containerized tanks or vehicle-tanks. Bunkering from land based LNG storage facility may also be considered. For larger capacities, bunkering from a dedicated bunker ship will be used. Alternatively, bunkering from LNG terminals may also be considered subject to relevant agreements and safety analysis.

Ship-to-ship LNG transfer system type-approved by BV


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Use of natural gas as fuel for ships: selected issues


Bunkering stations

Specific requirements are to be developed for enclosed and semi-enclosed bunkering stations (in particular for ventilation, gas detection). Devices are to be fitted on the manifold to prevent hose break in case of unexpected extreme ship movement or emergency (such as break-away couplings with quick-closing shut-off valves).
Control panel Communications, alarms, ESD Vapor return LNG HFO/MDO, lub.oil and sludge manifolds with separate spill tray

Air lock

Overboard discharge from spill tray


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Bunkering (Artist impression) - (Source: TGE Marine Gas Engineering)

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Norwegian Solutions (Source: TGE Marine Gas Engineering)

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Bunkering v/s Containers (Source: Marine Service GmbH)


Bunkering:
- LNG transfer with spill risk; most

Containerized LNG:
- No bunkering transfer of LNG - Handling of IMDG containers is standard practice in container ports - Uses existing multi-modal infrastructure

LNG incidents have occured during LNG cargo handling - LNG bunkering: special permission in port

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40 ISO LNG Tank Container (Source: Marine Service GmbH)


The type approval for the LNG fuel gas container is in progress at BV. A prototype of the container has been produced in 2012 and is tested beginning 2013.

1. GENERAL DATA: TYPE OF PRODUCT: 40 ISO tank ct; LNG fuel tank for ships GROSS CAPACITIES: 100% filling = 40 460 l; 82% filling = 33 200 l MAX. GROSS WEIGHT: 30 800 kg DESIGN CODES:ADR / IMDG / RID / IMO / IGC code & MSC.285 / BV rules NR529 2. INTERNAL PRESSURE VESSEL: MATERIAL: Stainless steel DESIGN PRESSURES: MAWP: 152,3 psi / 10,5 bar FILLING PRESSURE: 0.0 0.3 bar (g) 3. EXTERNAL PRESSURE VESSEL: MATERIAL: Stainless steel DESIGN PRESSURES: MAWP: 116 psi / 8.0 bar 4. INSULATION: TYPE OF INSULATION: Vacuum with multi-layer insulation reflection foil 5. EQUIPMENT: MATERIAL: Stainless steel TYPE OF CONNECTIONS: Dry quick coupling with dry emergency release

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LNG Gas Handling System (Source: Marine Service GmbH)

LNG gas heater

Glycol water heating system

LNG vapourizer LNG, gas, power, control connectors LNG pumps

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Bureau Veritas Gas Fueled Engines for Ship Propulsion

Natural gas engines: an available technology


Technical solutions to install gas fuel engines in various types of vessels are in place. Safety and dependability aspects of Natural Gas as fuel have been extensively studied. Bureau Veritas has developed rules and regulations to address Natural Gas propulsion of ships.

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Use of LNG as fuel for ships: rules & regulations

BV specific rules:
Rule note NR 481, Design and installation of dual fuel engines using low pressure gas Rule Note NR 529, Safety of gas-fuelled engines installation on ships. BV Guidance Notes for LNG ship to ship transfer

IMO codes:
IGC code for reference Interim Guidelines on safety for natural gas-fuelled engine installations in ships, adopted on 01/06/2009 by Resolution MSC.285(86). International code for the safety of gas fuelled ships (IGF Code) in preparation on the basis of the Interim guidelines (expected to come along with SOLAS 2014). It will address natural gas and other gases (butane, propane, hydrogen) and energy conversion systems (e.g. fuel cells).

Industry guidelines
SIGTTO guidelines for ship to ship LNG transfer

Other involved parties


Flag state, Port authorities,

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Use of natural gas as fuel for ships: selected issues


Engine design and lay out:

Gas piping arrangement Double wall piping arrangement on the engine versus single wall piping :double piping is easier to implement, it avoids to consider machinery space as an hazardous space

Safety of the crankcase Presence of gas in normal operations. Issue to be clarified with engine makers.

Operation of dual fuel engines at low loads Inability of dual fuel engines to run at low load (< 15% of the nominal load) with gas is to be taken into account.

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Use of natural gas as fuel for ships: selected issues


Gensets and diesel electric propulsion :

Four stroke dual fuel engines Injection of gas in inlet air on each cylinder at low pressure (around 7 bars) Combustion induced by pilot fuel injected close to top dead center of cylinder course. Pilot fuel may be injected by additional injector or by injector for classic liquid fuel Compression unit required in order to compress boil-off gas or forced evaporated gas to engine room

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Dual Fuel Engines (Source: MAN)

Major modifications are: Double-walled gas piping Pilot fuel injection system Larger bore new piston & liner Modified rocker arm casings Slight power reduction Same speeds and cylinder numbers available as for original diesel engine Retrofit possible

All DF-engines are based on well established diesel engines

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Use of natural gas as fuel for ships: selected issues


Direct propulsion (FPP or CPP) :

Four stroke dual fuel engines as shown previously Two stroke engines : two solutions

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Use of natural gas as fuel for ships: selected issues


Two stroke dual fuel engines : nowadays industrial projects

Low pressure (around 7 bars) : WARTSILA is developing such an engine. Compression unit for gas has a similar design than what can be found for 4 stroke dual fuel engines

High pressure (around 300 bars) : MAN Diesel and Turbo is close to industrialize such engines (first tests with Class Societies took place in November in Korea) as an option available for the family of electronically controlled 2 stroke engines Retrofit is possible on already installed electronically controlled engines. Compression unit for fuel gas needs to be designed to raise pressure of fuel gas up to 300 bars and piping system up to engines accordingly.

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Use of natural gas as fuel for ships: selected issues

Protection of LNG tanks from external damage (collision / grounding): Minimum distance between gas storage tank and ship side / ship bottom is under discussion within the IMO CG Group. Proposed requirement: - the lesser of B/5 and 11.5 m from ship side - the lesser of B/15 and 2 m from ship bottom - at least 0.76 m from shell plating would be applicable to both cargo ships and passenger ships. Formulae based on tank volume have also been proposed on the scope of IGC revision V 1,000m3 1,000 m3 < V 5,000 m3 5,000 m3 < V 30,000 m3 V > 30,000 m3 d = 0,80 m d = 0,75+ V x 0,20/4,000 d = 0,8 + V/25,000 d=2m

Tanks may be located closer to the hull if it is demonstrated that the ship structure outside the tank is able to absorb a sufficient amount of energy.

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Bureau Veritas Selected Projects

Example of project : BV AIP (Approval In Principle granted)


JIP: DSME CMA-CGM and BUREAU VERITAS

MAN ME-GI engine

2 stroke dual fuel engine Natural gas high pressure supply

Four dual fuel gen sets

More than 22,000 m3 LNG

storage tanks

HIVAR fuel gas system with

BOG re-condensation

Courtesy DSME (gastech 2011)


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Project in progress: JIP with same type of ship but other engine concept
JIP: partners want to keep project confidential by now

Main engine : 2-stroke low pressure dual fuel engine

Four dual fuel gen sets four stroke

More than 20,000 m3

LNG membrane storage tank

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SECA Feeder Project


Project Partner: VEGA Reederei Marine Service GmbH Bureau Veritas S.A.

Start in June 2010 Use of an existing design Storage of LNG in containers on deck Use of dual fuel engine for main propulsion and auxiliaries Gas treatment unit containerized

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Proposed fuel supply system - LNG in tank containers place of stowage: Most aft container bay
Stowage on deck gives easy access and minimum interference with normal vessel operation Short pipes to engine room Combination with available vaporizing units in container dimensions possible With strengthening of structure stackload can be increased in order to stow 6 gas containers

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LNG storage and supply system principle solution

1.000-TEU-Feeder

LNG container (FEU)


weight: 31t capacity:15-18m3

ventmast auxiliary engines LNG pumps


6-8bar

drip tank main engine

vaporizer

buffering

LNG feed line

fuel gas line

gas / container pressurization

New keel-layed vessels can be equipped with Dual Fuel Engines and switch to gas operation, while operating in SECAs Instead of installing voluminous LNG storage tanks on board of the vessel, LNG container tanks can be used and stored on deck

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Main alterations of the design


A60 insulation of front side of accommodation A60 insulation of deck above engine room Cell guides for gas containers Drip tray below gas containers Vent mast Lashing bridges for gas containers Piping for natural gas, liquid, vapor, venting Double walled gas piping in the engine room Air intake behind accommodation Provisions for gas heating

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Operational aspects
LNG container can be filled in existing terminals (i.e. Zeebrugge) and transported to the desired terminal LNG container can be handled by standard container bridges 3 LNG container stacks within B/5 Each container stack (6 or 7 containers) constitute one LNG storage tank Containers are connected by hose pipes to piping system of the vessel Containers will be disconnected before cargo operations start and connected after leaving from the terminal Access to container via lashing bridges

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LNG Container / Lashing Bridges

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Natural Gas as Fuel


Different fuel types in comparison (April 2012)
Fuel type: Net Calorific Value: [MJ/kg] MGO 42 MDO 42 IFO 380 39,5 LNG 48,5

Density [t/m]:

0,89

0,9

0,95

0,41 439 (9.55US$/mmBTU W.Europe 13.04.12) Heating

997 Bunkerprice [US$/ton]: (24.04.12 Rotterdam)

960 (23.04.12 Gothenburg

684 (24.04.12 Rotterdam) Purifying + Heating

Fuel conditioning:

Heating

Heating

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SECA Feeder Estimated Range


Max. Range with 17 LNG Tank Containers

Hamburg St.Petersburg Hamburg:

abt. 1900nm in 5 days at sea


Tank Container has filling volume of

(Results incl. 2 port days; 1 TC in reserve; average aux. power demand of 1MW)

design conditions hull resistance increased by 15%


3500

38m3 at

a max. gross weight of abt. 32 tons (abt. 18 t LNG per container)


One tank container could supply

63% MCR

1000kW auxiliary power demand for 3.8 days


One tank container is sufficient to
Range: [nm]

3000

74% MCR 90% MCR


2500

operate 170nm at 17knots


8 tank containers are sufficient for

propulsion 2 tank containers are sufficient for auxiliaries 1 tank container reserve = 11 tank containers total for a trip Hamburg St.Petersburg - Hamburg

100% MCR

2000 17knt 15knt

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Estimation of fuel cost savings on route: Hamburg St.Petersburg - Hamburg


Fuel costs savings using LNG for M/E and A/E on a single trip Hamburg / St.Petersburg / Hamburg
HFO: 684 US$/ton, MGO: 997 US$/ton, LNG: 9.55 US$/mmBTU (439US$/ton)

120000

Fuel costs savings: [US$]

100000 80000 60000 40000 20000 0


LNG instead of MDO LNG instead of IFO 380

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Example of Ro-Ro Vessel with LNG Fuel Containers


LNG Fuel Tank Containers on closed/semiclosed deck

Ventmast

Garage with venting

LNG-Fuel Tank-Container

GHC

Gas-Handling-Container

For Vent-Mast: 6m or B/3 above working or weather deck 10 m from air Intakes, air outlets or opening to accommodation, service and control spaces or other gas safe spaces, exhaust outlet from machinery or from furnace Propeller Club Geneva 25.04.2013 installations

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Project FERING Vessel Specifications


Starting in August 2014 two LNG Hybrid ferries will be serving the towns of Dagebll Wyk Wittdn.

Length: Width: Draught: Load capacity: Capacity: Crew: Speed:

Output: Class: Ice Class:

70.99 m 15.30 m 1.50 m 250 t 52 cars or 12 trucks, 480 passengers 6 approx. 10 knots 2x 630 kW drive output 3x 300 kW LNG generator sets 2 MW Hybrid battery packs Bureau Veritas Yes

LNG semi-trailer concept: - An LNG semi-trailer is accommodated in a garage on deck - One LNG semi-trailer contains enough LNG for 3-4 days of ferry operation - They are swapped out at night - LNG is the only fuel on board

(source: www.lng-hybrid.com)
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The LNG HYBRID Barge Project The Concept


Liquefied natural gas (LNG) will be used to generate energy in combined heat and power units and generators aboard the floating LNG HYBRID Barge (a lighter). The electricity thus generated will be fed into the cruise ships power supply as needed. A clear benefit to people and nature.

(source: www.lng-hybrid.com)

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Cost Comparison IMO Tier III Technologies Case study RoPax Ferry (Source: MAN)
Overhead costs
300%
LNG System's

250%

Main Scrubber's

200%
SCR`s

150%

Baseline: Tier II
Dual Fuel Equipment

100%
2-stage TC

50%
Engines (without propulsion pack)

0% IMO Tier II IMO Tier III IMO Tier III LNG fuelled 1-stage 2-stage 2-stage vessel SCR - MGO SCR + Scrubber

DF engine & LNG system* highest first cost due to extra expenses for large LNG tanks & dual fuel equipment LNG tank size is main cost driver, which is mainly depending on voyage time (respectively intervals between refuelling)
* Total investment (incl. Installation costs, LNG tanks, all equipment) Hint: Optimal solution highly dependent on operating pattern of a ship

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Bureau Veritas Conversion to Gas-Fueled Propulsion


Class related documents

Examples of details to be considered for conversion to gasfueled propulsion


A preliminary Gas-Hazardous Zone Plan indicating the location of

LNG-Fuel-Tanks, the refitting of A-60 insulation if necessary, the location of Gas-Ventilation Heads, the location of the Gas-ValveUnits and Gas/LNG piping
ESD protected or gas-safe machinery space Routing of LNG/ Fuel Gas piping Capacity of Fire Fighting System Capacity of ventilation system if forced ventilation is required Deck load and expected accelerations in way of LNG fuel tanks Thermal load and insulation in case of fire around the fuel tanks/

containers determines the size of the tank ventilation piping


Safety-Plan related modifications in the general and engine room

arrangement
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Documents of Propulsion System to be submitted


Generally all documents and systems, which are not in scope of

the engine Type Approval Certificate and which were alternated or added in course of the refitting as for example:
Arrangement of foundation bolts and chocking resins Hull-side structure of engine foundation Schematic layout or other equivalent documents for starting air

system, fuel oil system, lubricating oil system and cooling water system
Schematic diagram of engine control and safety system Flexible couplings, reduction gear, shafting and propeller Shaft alignment details Torsional Vibration Analysis Energy Balance Calculation
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Documents of Dual Fuel Engine to be submitted


Drawings concerning new engine type as listed in BV Rules NR 481

(June 2007), Sec 1 [Table 1]:

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Documents of LNG / Fuel-Gas System to be submitted


Drawings concerning LNG / Fuel-Gas System as listed in BV Rules

NR 529 (May 2011), Sec 1 [Table 1]:

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Procedures and manuals concerning the Fuel-Gas System


Procedures and manuals

concerning LNG / Fuel-Gas System as listed in BV Rules NR 481 (June 2007), Sec 1 [Table 2] on the right side:

Procedures and manuals

concerning LNG / Fuel-Gas System as listed in BV Rules NR 529 (May 2011), Sec 1 [Table 2] below:

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MERCI POUR VOTRE ATTENTION !

GRAZIE PER LA VOSTRA ATTENZIONE !

DANKE FR IHRE AUFMERKSAMKEIT !

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