GAS CONVERSIONS

Gain fuel flexibility, high efficiency and

environmental compliance with a dual fuel (DF) conversion

1 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Conversion benefits – environmental aspects

Low NOx emissions

Low SOx emissions
Low particulate emissions
Low CO2 emissions due to high efficiency
Lubricating oil change interval prolonged

2 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Conversion benefits – state-of-the-art technology

Same concept as new factory engines

Latest technology
control systems & software
engine main components
gas/fuel injection system
Engine running hour reset to zero after conversion

3 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Conversion benefits – prolonged maintenance intervals

Gas is a pure fuel

Maintenance cost of plant decreases
Component lifetime extended
Oil change interval is prolonged

4 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Conversion benefits – fuel operational aspects

Fuel flexibility
Possibility to operate on LFO, HFO and Natural Gas
Dual fuel or even Tri-fuel capability
Instant switch-over from one fuel to another
Instant switch-over from gas to LFO operation at full load

5 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Gas conversion – advantages

Fuel flexibility Cleaner exhaust

(lower costs) gas emissions
(and lower fees)

New/latest technology
(cost-effective solutions)

6 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Fast track to reduced operating costs and lower emissions

Example: 2x18V32DF = 3 months

UPGRADED
OLD PLANT
PLANT
Conversion

Fuel costs Fuel costs

7 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Reference list – new gas engines

Application Wärtsilä 34SG Wärtsilä 32DF Wärtsilä 50DF

Power plant 415 engines 39 engines 32 engines

2,946 MW 220 MW 521 MW
Ship power 13 engines 96 engines
928 MW

Application Wärtsilä 32GD Wärtsilä 46GD

Power plant 54 engines 15 engines
308 MW 232 MW

Ship power 39 engines 12 engines

193 MW 65 MW

8 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Reference list –gas engine conversions Status 10 November 2007

Project Name Country Year Conversion type Status

Tintrofa Portugal 2004 1 x 12V32 HFO 12V34SG Ready
Almeida Portugal 2004 1 x 12V32 HFO  12V32DFc Ready
Tearfil Portugal 2005 1 x 12V32 HFO  12V32DFc Ready
Century Power Pakistan 2005 3 x 12V32 HFO  12V32DFc Ready
Denizli Turkey 2006 1 x 16V46 HFO  16V50DF Ready
Cerestar German 2006 1 x 16V46 HFO  16V50DF Ready
Batamindo I Indonesia 2005 5 x 18V32 HFO  18V32DFc Ready
Batamindo II Indonesia 2006 7 x 18V32 HFO  18V32DFc Ready
Batamindo III Indonesia 2007 4 x 18V32 HFO  18V32DFc Ready
Arenko Turkey 2006 2 x 18V32 HFO  18V34SG Ready
Cresent Textile Mills Pakistan 2007 1 x 16V32 HFO  16V32DFc Ready
Bilag India 2007 1 x 18V32 HFO  18V32DFc Will start 10/07
Lucky Cement Pakistan 2008 7 x 18V32 HFO  18V32DFc Under work
Lucky Cement Pakistan 2009 3 x 12V46 HFO  12V50DF Sold

9 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 The Batamindo Plant, Indonesia

16 18V32 HFO  16 18V32DFc

10 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Before conversion…

11 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 …after conversion
Exhaust gas
ventilation piping

Gas piping

WECS system

Exhaust gas
ventilation fan

Starting air supply line

Starting motors

12 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Which type of conversion is the most suitable?

Step 1: Gas conversion or not?

INFRASTRUCTURAL / ECONOMICAL / ENVIRONMENTAL
• Gas is available / increasing availability?
• Competitive price?
• Subsidised investment?
• Emission requirements?

Step 2: Type of gas? Step 3: Type of conversion

TECHNICAL
TECHNICAL
Stable gas supply?
Decide type of
Gas quality?
conversion
Gas supply pressure?

13 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Gas engine conversion – performance data

32DFc 32DF 32GD 34SG 46GD 50DF

350 350 375 345 975 950
Engine shaft power kW/cylinder
335 335 370 330 975 950
Electrical efficiency % 40.5 42.5 41.8 44.3 42.8 44.9

Heat rate at kJ/kWh 8,890 8,470 8,610 8,130 8,400 8,020

Lube oil consumption g/kWh 0.6 0.4 0.6 0.4 0.8 0.8

Natural gas amount % 99 99 95 100 95 99

Pilot fuel (LFO)
% 1 1 5 – 5 1
amount 1)
Back-up fuel % 100 100 100 – 100 100

NOx (as NO2) vol-ppm 90 90 970 90 970 90

Heat rate and efficiency at generator terminals, including engine driven pumps, ISO 3046 conditions and LHV, tolerances 0 %.
1)
Wärtsilä 32GD and 46GD engines can use both LFO/HFO as pilot fuel

14 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Gas engine conversion – portfolio

GD (Gas Diesel) SG (Lean Burn) DF or DFc (Dual Fuel)

Fuels Natural gas, HFO/LFO, Crude Oil Natural gas Natural gas, HFO/LFO

Wärtsilä Vasa 4R, 6R, 9R, 12V, 16V and 18 V cylinder 12V and 18V cylinder 6R, 12V, 16V and 18V
32 LFO/HFO configurations configurations cylinder configurations
engines
Wärtsilä 32 (Wärtsilä 34SG)
LFO/HFO 12V, 16V, 18V and 20V
engines cylinder configurations

Wärtsilä 46 (Wärtsilä 46GD) N/A (Wärtsilä 50DF)

LFO/HFO 6L, 9L, 12V, 16V and 18V 6L, 9L, 12V, 16V and 18V
engines cylinder configurations cylinder configurations

15 © Wärtsilä 15.02.2007 Service Sales Support -JAI

 Gas engine conversion – characteristics

GD (Gas Diesel) SG (Lean Burn) DF or DFc* (Dual Fuel)

Fuels Natural gas, HFO/LFO Natural gas Natural gas, HFO/LFO

Engine process Diesel process Otto process Otto process when running
Ignited with LFO pilot fuel Spark ignited in natural gas mode. Ignited
with LFO pilot fuel. Diesel
process when running on
HFO/LFO.

Required gas Compressors needed (min. suction ~ 5 bar ~ 5 bar

pressure pressure 5 bar) or „off the well gas‟. Feed
pressure (after compressors) min 350 bar

Characteristics GD is suitable for „non-stable‟, medium Stable gas supply Fuel switching between gas
quality gas supply. required and diesel operating mode
Fuel sharing is possible possible.

* DFc is a “light” version of the DF conversion. Pistons, liners, camshafts are retained.
However, on LN engines these are replaced as well.

16 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Gas engine conversion – characteristics
GD (Gas Diesel)
High pressure gas engine (> 350
bar). Injects both gas and liquid
fuel through the injection valve.
17 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398
SG (Spark Ignited Gas)
Low pressure gas engine (~ 5 bar)
using a pre chamber with spark plug
for ignition.
Main gas admission valves used for
gas injection to main chamber and
pre-chamber controlled gas valves
for pre-chamber gas.
DF (Dual Fuel)
Low pressure gas engine (~ 5 bar)
using a twin injection valve for pilot
fuel and back-up fuel injection.
Gas admission valve used for gas
injection.
 DF conversion technology – fuel system

Combined fuel
injection valve Main gas valve
High pressure lines The engines can be started
Pilot fuel (LFO) pump either in gas mode or in
diesel mode. In gas mode
the engine is started only
with LFO pilot fuel injection,
when combustion is
stabilized in every cylinder,
Pilot fuel injection valve
gas admission is activated.
Fuel (LFO) injection pump
(Back-up fuel system)

18 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion – gas mode operation

EX IN

Compression
Air & Gas intake Ignition by pilot fuel
of Air & Gas

19 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion – back-up fuel mode operation

EX IN

Air intake Compression of air Injection of diesel fuel

20 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion – operating modes (fuel flexibility)

Diesel mode Gas mode

GAS TO DIESEL TRANSFER (full load)

DIESEL TO GAS TRANSFER (lower load)

Load %

• Works as an ordinary • Automatic and instant

diesel engine transfer to diesel operation
• Pilot fuel injection in in alarm situations
operation • Transfer to diesel
• Transfer to gas operation operation at any load
at lower load

21 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion – scope

Project planning Equipment Training and support

UPGRADED
OLD PLANT
PLANT
Conversion

• Supervision, installation and commissioning, start-up, project

management, documentation, engineering... ( full EPC )
• Parts needed for conversion ( engine parts + auxiliary parts and
modifications )

22 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion – scope

ENGINE CONVERSION
• Fuel system/Gas supply system
• Engine components
• Engine control and automation systems (UNIC-C3)
PLANT CONVERSION
• Plant systems
• Cabinets
• Operation stations

23 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion, 4 18V32DF power plant

Gas regulating units

Gas piping

24 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion, 4 18V32DF power plant

Explosion protection vent

Exhaust piping

25 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion, 4 18V32DF power plant

Gas meter

26 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion

CONVERSION CONCEPT
• Same engine components as new
factory built DF engines.
• Well proven and reliable ported gas
injection with pilot fuel oil concept.
• Same operating safety concept as for
new power plants.
• Latest engine control and automation
system (same as new power plants)
• Conversion time approximately
40 days per engine

27 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion

ENGINE PERFORMANCE DATA

• Running on low pressure (<5 bar),
99% natural gas (1% LFO pilot fuel)
• Ignition by pilot fuel in gas mode
• NOx emissions 90 ppm at 15 % O2, dry
• Derating of engine power in accordance
with new factory engines.

28 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion

• Cylinder head and cylinder head components

• Pistons and piston ring sets
• Cylinder Liners
• Connecting rods (upper part and shims)
• Camshaft pieces (miller timing)
• Turbochargers (re-matching)
• Air driven starting motors
• Exhaust gas wastegate ( air/fuel ratio control )
• Gas fuel system
• Pilot fuel system
• Engine control system

29 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion – gas components on the engine

Dual-needle
Gas admission
injection
valves
valve

Pilot fuel pump

30 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion – mechanical components on the engine

Turbochargers
Cylinder
modified for DF
heads
operation

Cylinder liner
Exhaust gas
with anti-
waste gate
polishing ring

Pistons; two Camshaft

compression pieces for DF
rings, Miller valve
one oil ring timing

Three piece Turbine-type

“Marine”- type pneumatic
connecting rod starting motors

31 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion – schematic view of UNIC-C3

• Start and stop control

• Run control
• Engine load & speed
control
• Air-fuel ratio control
• Combustion control
• Monitoring and safety
system handling
• Communication with
external systems

32 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 DF conversion – gas regulating unit

33 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Budgetary Offer DF Conversion

• DF conversion of the power plant (8 x W18V46) Budgetary Price

28,966,300.00 EUR.
• EPC type of scope:
• Gas system including gas regulating unit (engine specific) from inlet
flange on the unit up to and including the engine
• Automation and low voltage system modifications required for
converting plant and engine for dual fuel operation
• Man power for auxiliary works (mechanical & electrical) and engine
conversion works

34 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 Budgetary Offer GD Conversion

• GD conversion of the power plant (8 x W18V46) Budgetary Price of

17,974,000.00 EUR
• Limited EPC type of scope which basically means all engineering,
material and works inside the power house:
• Gas system including valve skid (engine specific) from inlet flange of
the skid up to and including the engine (also including safety venting).
• Automation and low voltage system modifications required for
converting engine and delivered auxiliaries for dual fuel operation
• Man power for auxiliary works (mechanical & electrical) and engine
conversion works for supplied equipment
• The two extension engines are only GD prepared engines which means
the engine block and cylinder head has preparations (drillings) ready for
GD equipment. This means we anyhow need to deliver all the same GD
equipment to these extension engines as for the other six existing HFO
engines.

35 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398

 THANK YOU!

36 © Wärtsilä WFI0032_DF_conversion_presentation.ppt / Dan Pettersson, Jens Norrgård, DocumentID: DBAA290398