WRTSIL 2-STROKE GAS

Ship Power
March 2013

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

Natural Gas as marine fuel

60s-70s

Today

-25%

Emission
values [%]
100
90
80

4 stroke DF results

70
60

-85%

50
40

-100%

CO2

30

NOx
SOx

10

Particulates
1965-72: low pressure loop scavenged engine 6RD76 tested in Winterthur
7RNMD90 installed in 29400m 3 LNG-carrier MV Venator in 1972

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

20

-99%

Dual-Fuel engine
in gas mode

Diesel
engine

Basic concept (2 stroke low pressure)

Pre-mixed lean-burn combustion

Principles:
Engine operating accordingly
to Otto process
Injection of gas at mid-stroke.
Low pressure gas injection
(<10 bar) sufficient
High impact on NOX reduction
Meets IMO Tier III without
after treatment

Scavenging

Wrtsil

Compression/
gas admission

Ignition
expansion

Wrtsil 2-stroke / Gas Engine / September 2012

Other concept (2 stroke high pressure)

Direct injection, diffusion combustion

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

Scavenging/
compression

Wrtsil

Pilot & HP gas

injection

Requires SCR or EGR (not

proven) in order to meet IMO
Tier III levels
Expansion

Wrtsil 2-stroke / Gas Engine / September 2012

Otto & Diesel cycle: effects on NOX

Big temperature
difference
NOx formation!

Diesel, max flame temp.

Otto, max flame temp.
5

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

Technical features Gas admission

Gas admission system
2 x GAV (gas admission valve) per cylinder
GAV actuated by hydraulically fast-switching solenoid
valves
Hydraulic power supply from exhaust valve servo oil
system

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

Technical features Pilot fuel system

Pilot fuel system
Pilot fuel utilized for ignition
(as in four-strokes DF engines)
Micro pilot valves utilization. Pilot fuel consumption
< 1% of BSFC
Pre-chamber technology for best ignition and
combustion stability
Fuel supply based on common-rail technology
(as in four-strokes DF engines)
Pilot fuel injectors

Pre-chamber

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

Technical features Pilot fuel system

Pilot fuel system
Single fuel oil pump serving all cylinders
(common-rail technology)
Filters and pressure regulation included
Pilot fuel pump can be electrically or mechanically
driven

UNIC

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

Technical features Gas feed system

Gas Valve Unit (GVU)
Wrtsil standardized and proven design applied
Pressure regulation, gas filtering and safety valves
included
Emergency venting procedure and leakage test features
introduced

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

Technical features Automation

Engine automation and control system
UNIC based control system
Individual control of combustion related parameters
Safety functions related to gas operation included

Exhaust valve
(Pilot fuel pressure)
Gas pressure
Engine speed/CA-signal

Control
system

Engine stop signal

Gas duration

Pilot fuel injectors

2x Gas admission valves
Test
cylinder
running
on gas

Pilot fuel injector

Gas admission valves
Exhaust valve drive

10

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

Performance targets (<10bar)

Operational features
Dual Fuel operation (HFO,Gas)
Low gas feed pressure
Tier III compatible in gas mode
without exhaust gas after treatment
Pilot fuel required when in gas mode
1% of BSFC at 100% engine load
Idling speed on gas operation
(Verification required in all cylinder operation)

11

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

Project overall time schedule

Project activities

2010

2011

2012

2013

Pre-study
Concept evaluations

Product requirement spec.

Technology development
Simulations & design for 1 cyl
Engine tests 1 cyl

Industrialisation
6 cylinder engine design
Full scale engine tests

Introduction
Concept release

Pilot installation data release:

information release
installation manual (MIM)

Full scale engine testing:

customer demo (lab engine)
validation at licensee

First sailing validation

Design, development, preparation
Engine testing
12

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

2014

2-stroke gas engine development

2-stroke gas engine development based on vast

experience from 4-stroke dual fuel engines/installations

4-stroke dual fuel references: Power plants, Merchant, Offshore, Cruise & Ferry, Special
~190 installations
> 5,000,000 running hours
13

Wrtsil

Wrtsil 2-stroke / Gas Engine / September 2012

Minimum gas quality requirements

Property

Unit

Lower heating value (LHV), min 1)

MJ/m3N

Value
2)

28

Methane number (MN), min 3)

90 (IMO Tier 1)

Methane (CH4), min

% volume

80 (IMO Tier 2)
70

Hydrogen sulphide (H2S), max

% volume

0.05

Hydrogen (H2), max 4)

% volume

Ammonia, max

mg/m3N

25

Chlorine + Fluorines, max

mg/m3N

50

Particles or solids at engine inlet, max

mg/m3N

50

Particles or solids at engine inlet, max size

um

Gas inlet temperature

060

Water and hydrocarbon condensates at engine inlet not allowed 5)

1)

The required gas feed pressure is depending on the LHV (see section Gas feed pressure in chapter Fuel system).

2)

Values given in m are at 0C and 101.3 kPa.

3)

The methane number (MN) is a calculated value that gives a scale for evaluation of the resistance to knock of gaseous fuels. Above table is valid for a
low Methane Number optimized engine. Minimum value is depending on engine configuration, which will affect the performance data.

4)

Hydrogen content higher than 3% volume has to be considered project specifically.

However, if the total content of hydrocarbons C4 and heavier is more than 1% volume Wrtsil has to be contacted for further evaluation.

14

Wrtsil

BSFC characteristics for W5X72

6

144

LNG BSFC [g/kWh]

142
141

140
3

139
138

137
136

135
0

134
30

40

50

60

70

Engine load [%]

LNG consumption [g/kWh]

High efficiency turbocharger ABB A100 or MET MB / ISO, LCV of 42700 kJ/kg
Tol. +5% between 85 to 100% load, +6% between 65 to 84% load, +7% between 50 to 64% load
15

Wrtsil

80

90

Pilot fuel MDO [g/kWh]

100

110

Pilot fuel MDO [g/kWh]

143

Fuel Gas Handling System

Low pressure
compressor set
Heater

Qh

LNG FUEL
GAS MODULE

Evaporator
Qv

LNG tank

Low pressure
feed pump
16

Wrtsil

WRTSIL 2-STROKE GAS

RT-flex engine conversion to gas (DF)
RT-flex

17

Wrtsil

RT-flex (Dual Fuel)

Wrtsil 2-stroke / Gas Engine /

RT-flex engine conversion to gas

Exhaust
valve

CCM-20
(Additional)

2/3 Pilot fuel injectors & Pre-chambers

Replacement of cylinder cover

2 x Gas Admission Valves (GAV)

Extra machining of cylinder liner
2 x Gas Rail

Cylinder

MDO supply unit

Support platform for MDO SU
MDO pipes to injectors

PRELIMINARY
18

Wrtsil

Wrtsil 2-stroke / Gas Engine /

RT-flex engine conversion to gas

Action

Component and description

Quantity

Existing components to be replaced

Cylinder cover

1 per cylinder

Existing RT-flex parts to be modified

Machining cylinder liner for gas admission valves

(might also need replacement)

1 per cylinder

MDO pump unit for fuel pilot injectors

1 per engine

MDO pipes to fuel pilot injectors

1 system per engine

Pilot fuel injectors

2/3 per cylinder

Pre-chambers

2/3 per cylinder

Waste gate on the turbocharger

1 per engine

By-pass valve on the turbocharger (possibly)

1 per engine

Gas admission valves

2 per cylinder

Servo oil piping to gas admission valves

2 per cylinder

Gas rails (piping)

2 per engine

CCM-20

1 per cylinder

Booster

8 per cylinder

Cylinder pressure sensor

1 per cylinder

Knocking sensor

1 per cylinder

Assembly, relocation of pipes, sensors, small components.

New fuel system related parts

Ignition system

Turbocharging & Scavenge air system parts

Gas admission system components

New automation system related parts

(Installed automation system dependant)

Other

PRELIMINARY
19

Wrtsil

Wrtsil 2-stroke / Gas Engine /