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

ME-GI

MAN Diesel & Turbo

20

12

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

LNG

tank

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 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

LNG

tank

Hydraulic oil


Inert gas system

- for purging of gas pipes

LNG

tank

Inert gas

system

Hydraulic oil


Double pipes

and ventilation system

LNG

tank

Inert gas

system

Hydraulic oil


Sealing oil system

LNG

tank

Inert gas

system

Hydraulic oil


Hydraulic activation of blow-of and

purge valves

LNG

tank

Inert gas

system

Hydraulic oil


ME-GI

overview


ME-GI

Gas control block

ELWI

ELGI


ME-GI

Gas Injection System

Gas injection valve Connection flanges

Blow-off valve

Purge valve

Connection block


ME-GI

Gas control block

Material S45R (393 kg)

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

Acc. volumen for 20 gas injections.


ME-GI

DSME FGS System Layout


GI engine, injection control

Fuel oil

ME-ECS GI-ECS

LNG

tank

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

GMOP

GI Safety

system

HC

Sensors

Engine

Safety

System

Seal Oil

System

ME-ECS

Double Pipe

Ventilation

Alarm

System

Inert Gas

System

ME

HPS

ECS MOP

Gas supply

control

system

LNG

tank

GI Engine Control System

ME Tacho

&

Crankshaft

position


GI-ECS configuration

GPCU

GMOP

GCCU GCSU

GCSU

GCSU

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

GCCU

GCCU

DASUMPC

MPC


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


<

ME-GI

Gas Injection Control


<

ME-GI

Gas Injection Control Step 1


<

ME-GI



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]

Cylin

de

r p

ressu

re [b

ar]

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]

Cylin

de

r p

ressure

[ba

r]

300 320 340

Max pressure

limit Fast integrated supervision:



Maximum pressure monitoring



- Expansion pressure

20 40 60 80 100 1200

Angle [degrees]

Cylin

de

r p

ressu

re [b

ar]

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

LNG

tank

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


ME-GI

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

RPM

Fuel index

Scavenging air press.


Gas stand-by

Hydraulic oil



PurgedNot

Purged

Gas Train

Test

Prepare

For Gas

Gas On

Engine

Gas

Running

Blow OffPurging

Gas Shut Down / Gas Stop

Gas

Standby

Prepare

Gas

Supply

MS_2 MS_1

MS_3 MS_4 MS_5

MS_6

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

LNG

tank

Inert gas

system

Hydraulic oil

Gas

return

tank


Next step: ME-GI ECS integration with PMI Autotuning

z

PMI sensor data

MPC

Gas

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

PMI +

CoCoS

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.

15

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!

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