Dual fuel engine development and design

Prepared by Mika Ojutkangas Senior Manager Wrtsil Ship Power Merchant

Presented by Y Bui at LNG conference Rotterdam 15 June 2011

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Contents

DF Technology The DF advantage News

The Tarbit project

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Dual-fuel engine - operating principle

Gas mode:
Otto principle Low-pressure gas admission Pilot diesel injection

air and gas

air and gas

pilot diesel fuel

Diesel mode:
Diesel principle Diesel injection

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Fuel system in cylinder head double walled gas piping Components

Gas valve electrical connection Injection valve electrical connection

Gas manifold Main fuel quill pipe Pilot fuel quill pipe Gas bellows Fine filter Gas valve

Gas nozzle

Pilot fuel common rail 900bar Main fuel injection pipe Main fuel injection pump Inlet valve Twin nozzle injection valve

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Gas fuel system double wall piping

Compared to single-wall gas piping, the requirements to the ships engine room with respect to gas detection, ventilation, etc., become less stringent with double-wall gas piping, making the engine room less complex and thus cheaper to build.

Gas inlet Venting valve

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Wrtsil Dual-Fuel Engine Portfolio

20DF 6L20DF 1.0 MW 8L20DF 9L20DF 34DF 6L34DF 9L34DF 12V34DF 16V34DF 20V34DF 50DF 6L50DF 8L50DF 9L50DF 12V50DF 16V50DF 18V50DF 0
Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

1.4 MW 1.6 MW 2.7 MW 4.0 MW 5.4 MW 7.2 MW 9.0 MW 5.85 MW 7.8 MW 8.8 MW 11.7 MW 15.6 MW 17.55 MW 5 10 15
Higher output for 60Hz / Main engines

Dual-fuel engine characteristics

20DF

High efficiency Low gas pressure Low emissions, due to:

High efficiency Clean fuel

34DF

Lean burn combustion

Fuel flexibility
Gas LFO (DF) Bio Fuel HFO (TF)
50DF

Double wall gas piping

The engine room is a gas safe area

Three engine models

Wrtsil 20DF Wrtsil 34DF
Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Wrtsil 50DF

Contents

DF Technology The DF advantage News

The Tarbit project

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

DF Gas Trip (GAS -> MDO) on 100% load - instantaneous

No loss of power or speed at sudden transfer from gas to MDO (example 18V50DF, 17.1MW)

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Dual-Fuel advantages

Main advantages of the Dual-Fuel 4-stroke engine compared to SG (spark ignited): Simple mechanical propulsion application Full power available in both fuel operation modes Load application capability Load application capability is equal between dual-fuel and SG Dual-fuel can change to liquid fuel in case instant abnormal high load / unload
requirement (no shut-down)
Changeover point can be programmed to suit application

Improves safety
100
90
Engine 80 speed 70 60 50 40
30 20
10 0

DF & SG Normal load application application

DF change to liquid mode

DF Big instant load application (trips to liquid) SG

Instant, abnormal
high load application

DF & SG Instant load application

Time

SG
Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

DF

The DF vessel concept

The DF engines provide safety and redundancy,

inherent reliability of the diesel engine allows a simple installation

Single gas tank and gas feed system allowed

No duplicate (diesel) gensets for main propulsion

LNG

MDO

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Emissions Reduction Future Pathway

Win + Win Emissions & Cost Reduction

Best Available Technology

Paradigm Shift: Market moves to emissions reduction as key n size criteria and away and cost ay from historical efficiencies based on heavy fuel.

Mid Term Both paths are not selected to the same vessel due to SCR PM Trap Other Long Term Fuel Cell, New technology
Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Marine Fuel for Emission Control Areas (ECA)?

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

The DF vessel concept

The DF engines will only use gas fuel inside ECA areas Safety and reliability of the traditional diesel engine remain

No SCR unit, Tier III compliant

No SOx Scrubber, No sulphur in fuel

MDO as backup fuel

LNG

MDO

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

The DF vessel concept, outside ECA

The DF engines can be run on HFO outside ECA areas

No SCR unit
No SOx Scrubber

Optional HFO flexibility when allowed when allowed

LNG

MDO/HFO

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

The DF vessel concept, outside ECA

HFO can be used to extend range ensure availability of fuel improve total economy

Optional HFO flexibility when allowed when allowed

LNG

MDO/HFO

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Contents

DF Technology The DF advantage News

The Tarbit project

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Wrtsil is a system integrator

SYSTEM INTEGRATION

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

LNGPac
A complete and modularized solution for LNG fuelled ships

A. Storage tanks B. Evaporators C. Dual-Fuel Main engine D. Dual-Fuel Aux engines E. Bunkering station(s) F. Integrated control system
Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

A C

What is a gas valve unit?

The main functions of the GVU: Pressure regulation to the engine, according to engine load. One unit is required per engine. Safety (block valves, filters, inerting and venting)

A GVU is located between the LNG storage system and the engine Max. recommended distance from engine is 10 m

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Installations today

Forced ventilation Single wall fuel gas pipe Double wall fuel gas pipe Gas safe area Gas hazardous area

gas sa e area
Air in *

GVU room, Ex Zone 1 Fuel Gas Tank GVU

Air out

* to double wall fuel gas feed pipe annular space

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Conventional GVU installed in a separate space

A separate GVU room add complexity and installation costs:

Require dedicated compartment, including explosion duct from the room Lightning and other equipment has to be Ex Zone 1 compatible Airlock is required between GVU room and surrounding space Recommended maximum distance from GVU to engine 10 m, difficult to achieve in practice

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Gas Valve Unit in enclosure

Main features
Can be located in the same engine room still being compliant with IGC and (future) IGF codes. Integrated ventilation system when combined with LNGPac Compact design and easy installation Lower total investment cost compared to a conventional GVU installation Is delivered in a containerized form (plug-and-play concept)

T E

P T

P T

P T

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Installation with GVU enclosure

Forced ventilation Double wall fuel gas pipe Gas safe area Enclosure

Engine room, gas safe area Air in G V U

Saved space: -GVU room -Airlock between the GVU room and the engine room Savings -Less Ex certified equipment -Easy installation at yard, ready module

Fuel Gas Tank

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Contents

DF Technology The DF advantage News

The Tarbit project

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

TARBIT PROJECT
Vessel delivery date Vessel typology Owner Ship Builder Flag Class 17.09.2007 25'000 dwt Chemical tanker Tarbit Shipping AB Shanghai Edward Shipbuilding Co Ltd Sweden Germanischer Lloyd

20 May 2011

DWT GT Displacement Length p.p. Length o.a. Keel To Mast Height Draught Breadth Extreme Breadth Moulded Speed

24783 ton 17757 ton 33788 ton 166.99 m 177.02 m 44.85 m 9.7 m 26.3 m 26 m 16 kn

Main facts

Vessel owned by Tarbit Shipping AB (Sweden)

Operated under time charterer by Statoil

Sailing in Norwegian waters

Conversion partially financed by Norwegian Nringslivets Hovedorganisasjon (Confederation of Norwegian Business and Industry) Designed by Wrtsil Ship Design (former Skipskonsulent )

Built by Edward Shipbuilding Co Ltd (Hudong-Zhong JV)

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Main engine conversion

TODAY
2 x W6L46B 5850 kW each
CPP PTO 1500 kW

WRTSIL 8L20 1200 kW

CPP WRTSIL 8L20 1200 kW

PTO 1500 kW

Tomorrow
2 x 6LW50DF 5700 kW each

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Many different firsts

First Dual-Fuel engine in Mechanical drive application First LNGPac delivered by Wrtsil First Gas Valve Unit in enclosure

First Dual-Fuel engine marine conversion

First Dual-Fuel single main engine approval

LNGPac LNG

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Scope of conversion
Scope of supply
Ship Design Engine conversion Gas tanks; LNGPac system (2 x 500m3) Gas piping (single and double walled) Bunkering system Gas supply units Torque meter for power measurement Exhaust system Fire-fighting upgrade Gas detection system Electrical system

Additional
NOx measurement during sea trial DF and LNGPac training for personnel

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Placement of equipment

LNG tanks

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Placement of equipment

LNG pipes

Water/Glycol

LNG tanks

Cold box

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Placement of equipment

Ventilation

LNG

GVU

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Placement of equipment

GVU

GVU

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

References
Sold engine conversions worldwide
Project Name
Tintrofa Almeida Tearfil Century Power Denizli Cerestar Batamindo I Batamindo II

Country
Portugal Portugal Portugal Pakistan Turkey German Indonesia Indonesia

Year
2004 2004 2005 2005 2006 2006 2005 2006 1x 1x 1x 3x 1x 1x 5x 7x

Conversion type
12V32 HFO 12V34SG 12V32 HFO 12V32DFc 12V32 HFO 12V32DFc 12V32 HFO 12V32DFc 16V46 HFO 16V50DF 16V46 HFO 16V50DF 18V32 HFO 18V32DFc 18V32 HFO 18V32DFc

Status
Finalized Finalized Finalized Finalized Finalized Finalized Finalized Finalized

Batamindo III
Arenko Crescent Textile Mills Bilag Lucky Cement Lucky Cement Gera Manuara Christino Roha Aksa Takna Cengiz

Indonesia
Turkey Pakistan India Pakistan Pakistan Brazil Brazil Brazil Turkey Peru Turkey

2007
2006 2007 2007 2008 2008 2009 2009 2009 2009 2009 2010

4x
2x 1x 1x 3x 7x 5x 5x 5x 6x 4x 7x

18V32 HFO 18V32DFc

18V32 HFO 18V34SG 16V32 HFO 16V32DFc 18V32 HFO 18V32DFc 12V46 HFO 12V50DF 18V32 HFO 18V32DFc 18V46 HFO 18V46GD 18V46 HFO 18V46GD 18V46 HFO 18V46GD 18V46 HFO 18V46GD 18V32 HFO 18V34SG 18V46 HFO 18V50DF

Finalized
Finalized Finalized Finalized Finalized Finalized Ongoing Ongoing Ongoing Ongoing Finalized Ongoing

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Dual-Fuel engines - References

NewordersannouncedSept.2010

Power plant 28 installations 84 engines >640 000 running hours LNG carriers >68 installations 254 engines > 900000 running hours OSV - FPSO 8 installations 28 engines >226 000 running hours

Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

Viking Line STX Europe

Breaking news !!!!!!

Wrtsil's scope of supply :

-four Wrtsil 8L50DF main engines, tunnel thrusters, and two stainless steel
fixed pitch, built-up main propellers with complete propeller shaft lines and
environmentally sound shaft line seal systems (Press release 03 March 2011)
- Two LNGPacs (Press release 21 March 2011)
This unique and groundbreaking vessel will be the most environmentally sound large passenger ferry in the world. Thanks to Wrtsil's technology, this ship will meet and even exceed the most stringent known future IMO and EU environmental regulations for maritime applications. Wrtsil's long experience and strong competence in dual-fuel technology, with some 300 such engines already sold, was an important reason for Wrtsil being awarded this order," says Tony hman, Senior Vice President, Marine Operations & Newbuilding, Viking Line Abp
Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011

 Wrtsil Mika Ojutkangas pres Y Bui 15 06 2011