ENGINEERING AND TECHNICAL CHALLENGES IN LNG CONVERSIONS. 1 Wärtsilä

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1 ENGINEERING AND TECHNICAL CHALLENGES IN LNG CONVERSIONS 1 Wärtsilä

2 Content Introduction Principles of Gas fuelled vessels Gas storage onboard ships Classification society requirements Bunkering of LNG LNG conversion Tank location Modification to the existing vessel Gas engine conversions Case: The Bit Viking conversion Bunkering of the Bit Viking Conclusion 2 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

3 10 years of LNG operation 10 years of LNG operation ceremony at Nor-Shipping in Oslo 10 years of LNG operation ceremony at Nor-Shipping in Oslo 3 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

4 Viking Energy: 10 years of LNG operation Viking Energy, information: Delivered 2003 Speed 17,2 knots LNG tank 220 m 3 4 x Wärtsilä 6L32DF gensets Power 4 x 2020 kw Total 8080 kw 4 Wärtsilä 29 September 2009

5 Principles of Gas fuelled vessels 5 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

6 Gas storage on ships Membrane IMO Type A - B IMO Type C 6 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

7 Classification society requirements IMO Resolution MSC.285(86) Interim Guidelines on Safety for Natural Gas- Fuelled Engine Installations in Ships (Adopted on 1 June 2009) DRAFT INTERNATIONAL CODE OF SAFETY FOR SHIPS USING GASES OR OTHER LOW FLASHPOINT FUELS (IGF CODE) IMO IGC Code - International Code for the Construction and Equipment of Ships Carrying Liquefied Gases in Bulk Classification society rules 7 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

8 Cooling and Bunkering Truck to ship Stationary tank to ship Ship to ship 8 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

9 LNG conversion Tank location Modifications to the existing vessel 9 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

10 LNG piping Prefabricated pipe sections 10 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

11 DF conversion Parts which will be exchanged Connecting rods (upper part) Pistons & piston rings Cylinder liner & antipolishing ring Cylinder heads Dualneedle injection valve Control system UNIC Turbochargers modified for DF operation Camshaft pieces for DF Miller valve timing 3rd IMarEST Ship Propulsion Systems Conference

12 DF conversion Components added on the engine Exhaust gas waste gate Gas rail pipe Gas admission valves Pilot fuel system: - Pilot fuel oil filter - Common rail piping - Pilot fuel oil pump 12 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

13 Case: Bit Viking conversion 25,000 dwt Twin Screw Chemical Tanker Built by Shanghai Edward Shipbuilding 2007 Class = GL ME 2 x W6L46B / 5850 kw AE 2 x W8L20 / 1360 kw On a charter for Statoil along the Norwegian coastline 2 x W6L50DF / 5700 kw Autonomy = 12 days operating on ~80% load 2 x 500 m 3 LNG tanks 13 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

14 Bit Viking conversion Bunker stations Tank room and aux room LNG tanks 14 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference November

15 Bit Viking conversion Pipes Supports Insulation Foundation steelwork Access gangways Cabling 15 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

16 Failure Mode Effect Analysis result Additional instruments added to ensure detection of hazards which could lead to large spill of LNG During bunkering and after bunkering single valve failure was recognized as critical Temperature sensors in LNGPac gas mast detect possible leak and performs necessary shutdown. 16 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

17 Transportation Road and barge transportation 17 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

18 Lifting operation at yard Conversion work lasted 10 weeks from the arrival at dock to handing over the vessel to the owner after successful first bunkering and gas trials 18 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

19 Engine conversion Engine conversion was completed in 4 weeks 19 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

20 GVU in enclosure 20 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

21 Cooling and Bunkering Risk analysis review and full scale LNG bunkering from Risavika terminal Courtesy of Skangass 21 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

22 Bunkering of Bit 430m 3 /h Engines running on gas Flaring Vapour return Bunker 2h Pressure increase 20 min 22 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

23 Operating hours Operating hours Gas Diesel 0 24/10/2011 7/1/ /3/2012 5/6/ /8/2012 2/11/2012 Superior gas availability: ~99% Diesel running hours due to start and stop in diesel mode (crew preference) Vessel has frequent port calls, median time in diesel 10 min/day at idling load 23 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

24 Meeting Tier III and the Energy Efficiency Design Index LNG bunkered during one year 4700 ton Carbon contents in fuel estimated as follow: HFO: 85%-w, LNG: 75% Bit Viking saving in annual CO 2 production 4500 ton CO UK average CO 2 emissions for new cars 138,1g/km Savings correspond to 32,5 million km:s driven In addition to savings above: No MDO used in boiler for HFO bunker heating 24 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

25 GRIEG: Case study LNG as fuel Source: 25 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

26 Many different firsts First Dual-Fuel engine marine conversion First Dual-Fuel engine in Mechanical drive application First Gas Valve Unit in enclosure First LNGPac delivered by Wärtsilä First Dual-Fuel single main engine approval LNGPac L N G LNGPac L N G 26 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

27 Conclusions Technically possible Complete gas propulsion train Engineering in an early stage paves the way forward Risks can be managed Classification society rules and risk analysis First LNG conversion Largest LNG tanks: 2 x 500m 3 Fastest bunkering: 430 m 3 /h DF- Mechanical in the North Atlantic Superior gas availability: ~99% 27 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

28 IN DETAIL 01/2012 Read more in: IN DETAIL 01/2012 LNG conversions for marine installations 28 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

29 Thank you 29 Wärtsilä 3rd IMarEST Ship Propulsion Systems Conference

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