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Content
Abstract........................................................................................................ 5
Introduction.................................................................................................. 6
ME-GI Concept........................................................................................... 10
ME-GI injection system.......................................................................... 11
Sealing oil supply................................................................................... 11
Safety features....................................................................................... 12
High-pressure double-wall piping........................................................... 12
Maintenance of LNG carriers equipped with ME-GI system..................... 13
Engine operating modes........................................................................ 14
Emission control ME-GI engines.......................................................... 15
Efficiency improvement measures during gas operation ......................... 16
Gas Supply Systems .................................................................................. 16
Overall vessel configuration.................................................................... 16
Cryostars solution for ME-GI engines..................................................... 16
EcoRel reliquefaction plant configuration................................................ 16
The high-pressure pump and vaporizer system ...................................... 17
Integration of reliquefaction and fuel gas supply...................................... 17
Experience base.................................................................................... 18
Special benefits..................................................................................... 18
Cryostar system philosophy .................................................................. 18
Overall vessel configuration.................................................................... 19
Fuel gas pressure control....................................................................... 19
System safety........................................................................................ 19
BOG Reliquefaction System from Hamworthy.............................................. 20
LNG high-pressure liquid pump system.................................................. 21
Laby-GI Compressor from Burckhardt Compression................................. 22
Design concept..................................................................................... 22
Laby-GI key components.................................................................... 22
Fuel gas compressor engineering........................................................... 22
Compressor safety................................................................................. 24
Control requirements for the fuel gas system ......................................... 24
Power saving mode............................................................................... 24
Simulation and test................................................................................ 25
Reliquefaction system and Laby-GI compressor integration ................... 25
TGEs Cascade Reliquefaction System ....................................................... 26
Sub-conclusions.................................................................................... 26
ME-GI for Container Ships, Tankers and Bulk Carriers................................. 27
Abstract
2015.
maintenance costs.
Reliquefaction*
Oxidiser
LNG
HP Compressor
II
Oxidiser
LNG
III
Reliquefaction*
Cryogenic
HP Pump
CNG
HP Compressor
HP Vaporiser
300 bar and 45
Introduction
reality worldwide.
tional scenarios.
Fig. 2: New TOTE container vessel powered by MAN B&W dual fuel ME-GI
at different locations.
application.
ties.
LNG
GAS
BOG
4-6 bar
DF Gensets
BCA Laby GI Compressor
BOG
oped and designed the ME-GI gas supply system in detail, using the Laby GI
compressor. In 2009, Burckhardt Com-
pression got the first order for a LabyGI compressor, a full scale demonstra-
ME-GI
BOG
LNG Cargo
Tanks
Fig. 4: ME-GI engine with Laby-GI compressor system (reliquefaction unit not shown)
GCU
BOG Heater
N2
Cold BOG
Warm BOG
Condensate
Vent gas
ponents.
Hamworthy and MDT have worked
BOG Compressor
BOG Desuperheater
N2 Heat Exchanger
Cold Box
Reliquefaction
N2 C ompander
LNG Flash
Drum
LNG Return
Pump
LNG Vaporiser
ME-GI Engine
ties in France.
GI engine.
ME-GI Concept
this installation.
ate on gas.
Inert gas system that enables purging of the gas system on the engine
cargo vessels.
New units:
being burned.
tasks:
injection valves
system.
50 bar higher).
structure.
be detected by HC sensors.
Cylinder cover
Connection to the
ventilated pipe system
Gas fuel supply
consists of:
Time
Gas
Press
Gas Block
Window Valve
Under normal operation, where no malfunctioning of the fuel oil valve is found,
the fuel gas valve is opened at the correct crank angle position, and gas is
injected. The gas is supplied directly
Valve Closed
ELWI
Purge
Safety features
ELGI
Window valve
Gas outlet
the HC sensors.
The engine gas pipes are designed for
a 50% higher pressure than the normal working pressure, and they are
Hydraulically actuated
purge/blow-off valve
Gas areas
Ventilation air channel
Ventilation system
Cylinder no. 4
GPSU
Fuel
Valve
Fuel
Valve
Fuel
Valve
Fuel
Valve
Gas
Valve
Gas
Valve
Gas
Valve
Gas
Valve
FS
6303
Cylinder no. 1
V3 V4
6302
FS
Silencer
6312
V3 V4
ACCU
V5
GPCU
FS
ACCU
V5
XT
6332
GPSU
needs.
Sets.
fuel-oil-only mode
Gas modes:
Fig. 12: Fuel type modes for the ME-GI engines for LNG carriers
also an option.
fuel-oil-only mode
type engine
Load 100%
g/kWh
Load 100%
g/kWh
mode.
CO2
577
CO2
446
O2 (%)
1359
O2 (%)
1340
CO
0.64
CO
0.79
NOx
11.58
NOx
8.76
HC
0.19
HC
0.39
SOx
10.96
SOx
0.88
PM (mg/m3)
0.54
PM (mg/m3)
0.34
Fig. 13
of the tanks.
gines
hull configuration.
ration
solution.
Results
SFOC reduces 1-3%
NOx margin is still available
8.00
6.00
4.00
2.00
0.00
-2.00
-4.00
-6.00
-8.00
-10.00
-12.00
25.00
Diesel reference
Gas reference
Gas NOx tuning
20
30
40
50
60
70
Diesel reference
Gas reference
Gas NOx tuning
20.00
NOx (g/kWh)
SFOC/NOx tuning
NOx margin in gas mode
SFOC reduction potential
Design limits maintained
SFOC (g/kWh)
80
90
100
15.00
10.00
5.00
0.00
20
30
40
50
60
70
80
90
100
EcoRel-S
BOG
Compressor
N2
Cold BOG
Warm BOG
Condensate
BOG
Intercooler
BOG
Desuperheater
N2 Counter Current
Exchanger
BOG
Condenser
N2 Compander
Tank 5
Tank 4
Tank 3
Tank 2
Tank 1
izer system
requirements.
A typical skid is fitted with three pumping chambers to smooth out the flow.
In addition, a pulsation damper is fitted
to avoid any issues with downstream
pulsation in the fuel gas lines. Simple
control loops are used to maintain a
constant fuel gas pressure irrespective
of the flow.
Integration of reliquefaction and fuel
gas supply
Cryostar has designed a simple interface between the two systems to allow
simple operation of the fuel gas supply,
either by reliquefaction or independently
if required. The liquid supply to the HP
Reliquefaction Plant
GCU
BOG
Condenser
N2 cooling system
Flash
tank
HP
pump
Vaporiser
Engines
Vent
mast
whenever
advanta-
economically
EcoRel
geous
operations.
System safety
plications.
Because the pump is controlled by a
control valve
Reliquefaction Plant
BOG to tank
BOG condensate
LNG
Flash
PC
PC
LC
IP pump
PC
PC
Engine
LNG return
pump
LNG
M
M
Start up bypassline
LNG
Liquid to
tank
application
of
conventional
Fig. 19: Process description of LNG reliquefaction system (Mark III, 3rd generation)
system
BOG compression.
160C.
gine load.
Fig. 20: Process integration between the LNG reliquefaction system and fuel gas supply system for dual fuel ME-GI engine
Optimiser (1)
Fig. 21: High-pressure gas supply system from Hamworthy, including 2 x LNG pumps and a vaporiser (size 7 x 3 x 2 m)
Design concept
in this field.
applications.
e1
stag
not
led
coo
5
e 4/
stag e
lub
e1
stag
not
led
coo
e2
stag
e 3 cooled
g
a
t
s
led
coo
analysis of thermal stresses and pulsation and vibration issues of the compressor and its related equipment, e.g. gas
piping, pulsation vessels, gas coolers,
etc.
heat barrier
1st stage
ballancing weights
on cross-head
Vent
1st stage
PCV 03
2nd stage
3rd stage
PCV 04
4th stage
5th stage
TCV 01
Legend
PCV01
TCV 02
P
PCV 02
To GCu / Reliquefaction
Prange :
3.5 to
6.5 bar
Trange : -4.5 to +4.5 C
Compressor safety
of the compressor.
resulting in a higher-than-acceptable
sive loading.
and, furthermore, by certification societies like DNV, ABS and Lloyds Register.
Design Point
100%
Min injection
pressure
cept.
Valve Unloading 50%
& Recycle 4/5th stage
The primary function of the compressor control system is to ensure that the
required discharge pressure is always
available to match the demand of the
Max injection
pressure
main propulsion diesel engines. In doing so, the control system must be able
to adequately handle the gas supply
variables, such as tank pressure, BOG
rate (laden and ballast voyage), gas
composition and gas suction tempera50%
ture.
100%
Laby-GI
BOG
the entire fuel gas system, was successfully tested in a combined process
ME-GI
Stage 1-2
Stage 3-5
Stage 1-3
VENT
Nitrogen loop
thy Gas Systems have developed a solution that integrates the Laby-GI compressor in the Mark III reliquefaction
Expander
LNG
TGEs cascade type reliquefaction system for LNG BOG on LNG carriers has
been developed in cooperation with
4.500
4.000
3.500
2.500
configurations:
2.000
1.500
0%
10%
20%
30%
40%
50%
60%
70%
80%
trogen cycle
90% 100%
Engine Load
Fig. 26: Comparison between existing plants using full reliquefaction with high-pressure pump fuel gas
system, excess gas reliquefaction with a nitrogen cycle, or excess gas reliquefaction by way of the cascade technology.
system.
phase transition
Sub-conclusions
one compressor
stages.
The energy efficient mass flow control
concept of the Laby-GI has been
adapted to the combined duty of ethylene and BOG compression. The bal-
Fig. 27: Cascade reliquefaction plant for LNG carriers developed by TGE and Burckhardt Compression.
(FSRU) in 2009.
Concluding Remarks
available and have now also been tested and are on order. The first 70-bore
plant is recommended.
included in the high-pressure pipe volume. The heliflow heat exchanger, also
ships.
less than 0.5% reduction of the efficiency of the ME-GI engine compared with
an ME-C type engine.
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. CopyrightMAN Diesel & Turbo.
5510-0063-06ppr Aug 2014 Printed in Denmark