2012 ME-GI MAN Diesel & Turbo ME-GI Design, June 2012 Presentation for Croatian Register, 30 th August 2012 1
Presentation 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 2
ME-GI: ME-ECS and GI-ECS Injection control How ME-GI to control: ME-GI? Injection amount, division and timing ME-ECS GI-ECS Fuel oil High pressure gas Hydraulic oil LNG tank Crankshaft position and speed 3
ME-GI Development ME-GI concept: Combustion Principles Diesel process: 4
ME-GI Development ME-GI concept: Combustion Principles Diesel process: 5
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. 6
ME-GI gas injection Hydraulic oil LNG tank 7
Inert gas system - for purging of gas pipes Hydraulic oil Inert gas system LNG tank 8
Double pipes and ventilation system Hydraulic oil Inert gas system LNG tank 9
Sealing oil system Hydraulic oil Inert gas system LNG tank 10
Hydraulic activation of blow-of and purge valves Hydraulic oil Inert gas system LNG tank 11
ME-GI overview 12
ME-GI Gas control block ELWI ELGI 13
ME-GI Gas Injection System Gas injection valve Connection flanges Blow-off valve Purge valve Connection block 14
ME-GI Gas control block Material S45R (393 kg) H=396.5mm ;W=505mm; D=340 Acc. volumen for 20 gas injections. 15
ME-GI DSME FGS System Layout 16
GI engine, injection control Injection amount, division and timing ME-ECS GI-ECS Fuel oil High pressure gas Hydraulic oil LNG tank Crankshaft position and speed 17
ME-GI Engine Control System Environment GI Engine Control System ECS MOP GMOP ME-ECS Alarm System GI control system GI Safety system Gas supply control system Engine Safety System ME HPS ME Tacho & Crankshaft position Double Pipe Ventilation Inert Gas System Seal Oil System HC Sensors LNG tank Gas Supply System 18
GI-ECS configuration Control Units GMOP GECU GPCU GCCU Gas Main Operation Panel Gas Engine Control Unit Gas Plant Control Unit Gas Cylinder Control Unit Safety Units GPSU GCSU Gas Plant Safety Unit Gas Cylinder Safety Unit MPC MPC DASU GMOP GPCU GCCU GCCU GCCU GECU GPSU GCSU GCSU GCSU GCSU 19
Controllers of the system 20
ME-GI GMOP Main dashboard display 21
ME-GI GMOP Gas supply overview 22
ME-GI GMOP Double pipe ventilation system 23
ME-GI GMOP Hydraulic- and Seal oil display 24
Gas injection - safety 25
ME-GI Gas Injection Control 26
ME-GI Gas Injection Control Step 1 27
ME-GI Gas Injection Control Step 2 28
ME-GI Gas Injection Control Step 3 29
ME-GI Gas Injection Control Step 4 30
Gas injection - safety 31
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 32
Combustion monitoring - Compression pressure Fast integrated supervision: Cylinder pressure monitoring: Compression pressure monitoring Cylinder pressure [bar] Min. Pcomp pressure limit Angle for Pcomp check 300 320 340 0 Angle [degrees] 20 40 60 80 100 120 33
Cylinder pressure [bar] Combustion monitoring - Maximum pressure Max pressure limit Fast integrated supervision: Cylinder pressure monitoring: Compression pressure monitoring Maximum pressure monitoring 300 320 340 0 Angle [degrees] 20 40 60 80 100 120 34
Combustion monitoring - Expansion pressure Fast integrated supervision: Cylinder pressure [bar] Angle ranges for Pexp check Cylinder pressure monitoring: Compression pressure monitoring Maximum pressure monitoring Expansion pressure monitoring: Σ Pafter TDC Σ Pbefore TDC 300 320 340 0 Angle [degrees] 20 40 60 80 100 120 35
Expansion pressure monitoring, 50% load, missing pilot oil injection 36
Expansion pressure monitoring, - Missing pilot oil injection & cyl. lube Oil 37
Expansion pressure monitoring, 25% load, missing pilot oil injection 38
Expansion pressure monitoring, 25% load, missing pilot oil injection Expansion calculation over 100 revolutions Misfiring 39
Expansion pressure monitoring, 5% Pilot injection combustion detection Cylinder pressure if no combustion Cylinder pressure at 5% pilot injection and no gas 40
Expansion pressure monitoring, 5% Pilot injection combustion detection Misfiring detection limit 41
GI valve and Window-valve leakage detection Gas channel pressure sensor Hydraulic oil Inert gas system LNG tank 42
GI valve and Window-valve leakage detection methods, principle 43
Window-valve leakage 44
Gas injection valve leakage 45
ME-GI Combustion & Leakage: Supervision Fast integrated 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 Result of single failure Gas shut down or gas stop Engine changes to fuel mode Continuous operation without loss of power 46
Port to port operation Speed reduction => Windmilling RPM Fuel index Scavenging air press. Stop => Windmilling Low load sailing Reversing 47
Gas stand-by Hydraulic oil 48
Port to port operation GPCU: Gas Plant Control State Machine Main States Gas Shut Down / Gas Stop Prepare Gas Supply Gas Train Test Prepare For Gas MS_3 MS_4 MS_5 MS_6 Gas On Engine Gas Standby MS_2 Purged Not Purged MS_1 MS_8 Gas Running MS_7 Purging Blow Off MS_10 MS_9 49
Port to port operation 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 50
Port to Port Operation Change over to gas operation 51
Port to Port Operation - Mixed mode 52
Port to port operation 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 53
Port to port operation 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 54
Port to port operation Tests 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 55
Change-over from gas to fuel oil during load variations 56
Change-over from fuel oil to gas during load variations 57
Gas return system - to minimize methane slip Gas return tank Hydraulic oil Inert gas system LNG tank 58
Next step: ME-GI ECS integration with PMI Autotuning ME Engine Engine Monitoring System Gas System Gas Safety System PMI + CoCoS EMS-MOP PMI DAU PMI sensor data DASU Window valve MAN LAN Fuel Injection/ Exh. valve timing Gas Injection MAN LAN ECS-MOP z MPC Engine Control System Hardwired signals MPC Gas Control System GI-MOP 59
Main electronic components of the ME-GI-ECS Component name ME-ECS New 1 MPC: Multi Purpose Controller X 2 EC-MOP X 3 Approved PCs X 4 Control Network PCI Board X 5 DASU: Data Acquisition & Supervision Unit X 6 TSA: Tacho Signal Amplifier X 7 Angle Encoders X 8 Proportional - directional control valves, version with digital X input (e.g. Parker) 9 Keyboards and track-balls X 10 11 Combustion pressure sensors and amplifiers (X) 12 Gas channel pressure sensors X 13 Seal oil pressure control valves X 14 etc. 15 Gas supply system and gas train components are the responsibility of the gas supply system supplier. 60
ME-GI Engine Control system Development proces 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 61
ME-GI Engine Control System System test, automated test system 62
ME-GI Engine Control System System test, automated test system 63
Thank You for Your Attention! 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. 64