title of presentation - · pdf fileman diesel & turbo jna/lde 2012.06.14 1 me-gi 2012 man...
TRANSCRIPT
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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
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2MAN Diesel & Turbo JNA/LDE 2012.06.14
• 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
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3MAN Diesel & Turbo JNA/LDE 2012.06.14
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:
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4MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI Development
ME-GI concept: Combustion Principles
Diesel process:
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5MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI Development
ME-GI concept: Combustion Principles
Diesel process:
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6MAN Diesel & Turbo JNA/LDE 2012.06.14
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.
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7MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI gas injection
LNG
tank
Hydraulic oil
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8MAN Diesel & Turbo JNA/LDE 2012.06.14
Inert gas system
- for purging of gas pipes
LNG
tank
Inert gas
system
Hydraulic oil
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9MAN Diesel & Turbo JNA/LDE 2012.06.14
Double pipes
and ventilation system
LNG
tank
Inert gas
system
Hydraulic oil
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10MAN Diesel & Turbo JNA/LDE 2012.06.14
Sealing oil system
LNG
tank
Inert gas
system
Hydraulic oil
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11MAN Diesel & Turbo JNA/LDE 2012.06.14
Hydraulic activation of blow-of and
purge valves
LNG
tank
Inert gas
system
Hydraulic oil
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12MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI
overview
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13MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI
Gas control block
ELWI
ELGI
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14MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI
Gas Injection System
Gas injection valve Connection flanges
Blow-off valve
Purge valve
Connection block
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15MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI
Gas control block
Material S45R (393 kg)
H=396.5mm ;W=505mm; D=340
Acc. volumen for 20 gas injections.
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16MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI
DSME FGS System Layout
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17MAN Diesel & Turbo JNA/LDE 2012.06.14
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
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18MAN Diesel & Turbo JNA/LDE 2012.06.14
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
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19MAN Diesel & Turbo JNA/LDE 2012.06.14
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
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20MAN Diesel & Turbo JNA/LDE 2012.06.14
Controllers of the system
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21MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI GMOP
Main dashboard display
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22MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI GMOP
Gas supply overview
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23MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI GMOP
Double pipe ventilation system
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24MAN Diesel & Turbo JNA/LDE 2012.06.14
ME-GI GMOP
Hydraulic- and Seal oil display
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25MAN Diesel & Turbo JNA/LDE 2012.06.14
Gas injection - safety
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26MAN Diesel & Turbo JNA/LDE 2012.06.14
<
ME-GI
Gas Injection Control
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27MAN Diesel & Turbo JNA/LDE 2012.06.14
<
ME-GI
Gas Injection Control Step 1
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28MAN Diesel & Turbo JNA/LDE 2012.06.14
<
ME-GI
Gas Injection Control Step 2
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29MAN Diesel & Turbo JNA/LDE 2012.06.14
<
ME-GI
Gas Injection Control Step 3
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30MAN Diesel & Turbo JNA/LDE 2012.06.14
<
ME-GI
Gas Injection Control Step 4
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31MAN Diesel & Turbo JNA/LDE 2012.06.14
Gas injection - safety
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32MAN Diesel & Turbo JNA/LDE 2012.06.14
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
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33MAN Diesel & Turbo JNA/LDE 2012.06.14
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
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34MAN Diesel & Turbo JNA/LDE 2012.06.14
Combustion 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:
Cylinder pressure monitoring:
Compression pressure monitoring
Maximum pressure monitoring
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35MAN Diesel & Turbo JNA/LDE 2012.06.14
Combustion 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
Fast integrated supervision:
Cylinder pressure monitoring:
Compression pressure monitoring
Maximum pressure monitoring
Expansion pressure monitoring:
Σ Pafter TDC – Σ Pbefore TDC
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36MAN Diesel & Turbo JNA/LDE 2012.06.14
Expansion pressure monitoring,
50% load, missing pilot oil injection
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37MAN Diesel & Turbo JNA/LDE 2012.06.14
Expansion pressure monitoring, - Missing pilot oil injection & cyl. lube Oil
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38MAN Diesel & Turbo JNA/LDE 2012.06.14
Expansion pressure monitoring,
25% load, missing pilot oil injection
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39MAN Diesel & Turbo JNA/LDE 2012.06.14
Expansion pressure monitoring,
25% load, missing pilot oil injection
Expansion calculation
over 100 revolutions
Misfiring
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40MAN Diesel & Turbo JNA/LDE 2012.06.14
Expansion pressure monitoring,
5% Pilot injection combustion detection
Cylinder pressure
if no combustion
Cylinder pressure
at 5% pilot injection
and no gas
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41MAN Diesel & Turbo JNA/LDE 2012.06.14
Expansion pressure monitoring,
5% Pilot injection combustion detection
Misfiring
detection limit
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42MAN Diesel & Turbo JNA/LDE 2012.06.14
GI valve and Window-valve
leakage detection
LNG
tank
Inert gas
system
Hydraulic oil
Gas channel
pressure
sensor
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43MAN Diesel & Turbo JNA/LDE 2012.06.14
GI valve and Window-valve
leakage detection methods, principle
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44MAN Diesel & Turbo JNA/LDE 2012.06.14
Window-valve leakage
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45MAN Diesel & Turbo JNA/LDE 2012.06.14
Gas injection valve leakage
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46MAN Diesel & Turbo JNA/LDE 2012.06.14
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
Gas shut down or gas stop
Engine changes to fuel mode
Continuous operation without loss of power
Result of single failure
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47MAN Diesel & Turbo JNA/LDE 2012.06.14
Port to port operation
Speed reduction => Windmilling
Stop => Windmilling
Reversing
Low load sailing
RPM
Fuel index
Scavenging air press.
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48MAN Diesel & Turbo JNA/LDE 2012.06.14
Gas stand-by
Hydraulic oil
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49MAN Diesel & Turbo JNA/LDE 2012.06.14
Port to port operation
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
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50MAN Diesel & Turbo JNA/LDE 2012.06.14
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
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51MAN Diesel & Turbo JNA/LDE 2012.06.14
Port to Port Operation
Change over to gas operation
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52MAN Diesel & Turbo JNA/LDE 2012.06.14
Port to Port Operation
- Mixed mode
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53MAN Diesel & Turbo JNA/LDE 2012.06.14
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
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54MAN Diesel & Turbo JNA/LDE 2012.06.14
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
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55MAN Diesel & Turbo JNA/LDE 2012.06.14
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
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56MAN Diesel & Turbo JNA/LDE 2012.06.14
Change-over from gas to fuel oil during
load variations
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57MAN Diesel & Turbo JNA/LDE 2012.06.14
Change-over from fuel oil to gas during
load variations
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58MAN Diesel & Turbo JNA/LDE 2012.06.14
Gas return system
- to minimize methane slip
LNG
tank
Inert gas
system
Hydraulic oil
Gas
return
tank
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59MAN Diesel & Turbo JNA/LDE 2012.06.14
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
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60MAN Diesel & Turbo JNA/LDE 2012.06.14
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.
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61MAN Diesel & Turbo JNA/LDE 2012.06.14
• 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
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62MAN Diesel & Turbo JNA/LDE 2012.06.14
<
ME-GI Engine Control System
System test, automated test system
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63MAN Diesel & Turbo JNA/LDE 2012.06.14
<
ME-GI Engine Control System
System test, automated test system
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64MAN Diesel & Turbo JNA/LDE 2012.06.14
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!