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Dual Fuel Development of small bore Medium Speed Engine Bore 23 & 28 DF

Global Organisation BU-L Seminar 2013. Dual Fuel Development of small bore Medium Speed Engine Bore 23 & 28 DF . Finn Fjeldhøj Small Bore Four-stroke Engineering . Dual fuel Project. Business case Executive Summary.

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Dual Fuel Development of small bore Medium Speed Engine Bore 23 & 28 DF

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  1. Global Organisation BU-L Seminar 2013 • Dual Fuel Development of small bore Medium Speed Engine • Bore 23 & 28 DF Finn FjeldhøjSmall Bore Four-stroke Engineering

  2. Dual fuel Project

  3. Business caseExecutive Summary Dual fuel power technology is becoming increasingly important as emission legislation is tightening and oil prices are rising. We need to have a dual fuel solution for the market in order to sustain and increase our revenue on small bore Medium Speed GenSets. A retrofit model with development and production in co-operation with Licensees is by far the most profitable solution and gives early access to the global market within the Marine, Stationary and Aftersales segments. We need to move now in order to access the increasing DF market in due time. It is required by the fast moving market, expansion of the gas infrastructure and the head start of our competitors. - Otherwise we will be left behind -

  4. Competitor LandscapeMain competitors By retrofit and modification of existing Small Bore Medium Speed GenSets we will cover a significant part of our competitors’ power range * Under development (Pilot Engine MaK M32DF: 2015) ** Rumor: Cat/MaK plans Small Bore DF engine in the range up to 3 MW *** V28/32S Retrofit to meet the demand from existing power plants

  5. MarketForecast Marine Auxiliary DF/HFO Forecast MDT Dual Fuel Auxiliary Market • Forecast Assumptions: • MDT market size only possible if we can offer Dual Fuel technology to the market within a year • MDT market share calculated from MDT target of 40% in 2021 • Penetration of Marine Dual Fuel Technology is based on experience from previous new technology penetration into market • Dual fuel proportion based on Dual Fuel propulsion in all LNG carriers and 45% of the annual global delivered fleet in 2021 • Forecast of the Marine Auxiliary Market by Dept. LB-CPH

  6. Benefits DF Retrofit and Modification of Existing engines • Able to offer and sell retrofit DF packages for 28/32 and 23/30 within ½ year • Able to offer complete DF energy systems within one year • Stepping stone to meet 40% market share target • Access to market via Licensees • Reactivation of 28/32 Power Plant HFO engines (e.g. India) • Increased co-operation and knowledge sharing within the Business Units • To get a DF solution which covers all market segments: • Retrofit (PrimeServ) • New building auxiliary engines (BU-L / Licensees) • New building diesel electric propulsion (BU-M) • New sales stationary GenSets (BU-P)

  7. Development of Small Bore Medium Speed DF GenSets Marine GenSets Gas/fuel ratio 70/30 HFO Engine L23/30H L28/32H L28/32 DF-R L23/30 DF-R DF Retrofit Power Range 0.54 – 1.1 MW 0.9 – 1.7 MW Q1 2013 Q1 2013 Sales Release Q1 2014 Q1 2014 First Delivery Q1 2014 Q1 2015 Q1 2015 Q1 2014 L23/30 DF L28/32 DF Final DF Power Range 0.62 – 1.2 MW 1.0 – 1.8 MW Gas/fuel ratio 90/10 Q1 2014 Sales Release Q1 2014 Q1 2013 Q1 2015 First Delivery Q1 2015 Q1 2014

  8. Development of Small Bore Medium Speed DF GenSets Power Generation HFO Engine V28/32S V28/32H Gas/fuel ratio 70/30 V28/32S DF-R V28/32H DF-R DF Retrofit Power Range 2.3 – 3.55 MW 2.1 – 3.35 MW Sales Release Q1 2013 Q1 2014 First Delivery Q1 2014 Q1 2015 Final DF V28/32S DF Power Range 2.4 – 3.60 MW Gas/fuel ratio 90/10 Sales Release Q1 2014 First Delivery Q1 2015

  9. Small Bore DFKey Performance Indicator

  10. Roles LE-HOL • Project Management • Engineering • Liaison • Sourcing • Test Preparation • Installation • Safety Concept Licensee • Engineering • Testing • Production Experience • Gas Retrofit Experience • Safety Concept • Gas Injection Design • Control System Engineering EE LE-CPH • Gas Expertise • Test Planning • Plant Equipment PrimeServ • Sales • Promotion Material • Customer Contact and Contract Power BU-M BU-L

  11. 23/30DF and 28/32 DFOngoing design work DF Kick-off and Work packages defined First DF retrofit design spec. DF retrofit concept First V28/32DF injection layout Pipe and assembling design First casting of injection module Control hardware and software

  12. Gas / fuel ratio

  13. Dual Fuel engine – Tote projectGas / Fuel ratio

  14. Dual fuel engine HFO / gas engine dilemma A dual fuel retrofit engine is not a TIER III gas engine

  15. DesignExample L28/32 Engine Data performance • Actual engine output as HFO/MDO engine: • 220 kW/cyl • Future engine output (dual fuel mode): • 200 kW/cyl @ 720 rpm (BMEP= 16 bar) • With gas - MN > 80 - Tbef. eng. < 45 °C The dual fuel technology includes: • Add-on gas injection equipment to standard 28/32 engine • Exchange of major engine components • Adaptation of plant equipment (gas ramp) • Adaptation of engine and plant control system • FAT at dual fuel operation

  16. 28/32 DF Gas pipe area INLET Exhaust EXHAUST Inlet

  17. 28/32 DF 28/32 DF Gas pipe

  18. 28/32DF 28/32DF casting piece and gas injection valve

  19. 28/32 DF Pressure measuring cock

  20. 28/32 DF Water pipe

  21. 28/32 DF Expansion bellows

  22. 28/32 DF Assembly

  23. L/V 28/32 & L23/30 DF-Conversion New turbo matching Installation of charge air bypass Installation of safety head Installation of knocking control sensors Installation of new cool.w. pipe Installation of sogav, gas train Installation of casted piece between sogav and cyl. cover. (see next slide) Add of stop for governor not to exceed 20% load on diesel Exchange of valve/valve seat Exchange of piston ring packet Exchange + adding of explosion valvesif necessary Re-calc. of vibration damper Re-machining of engine frame, e.g. bypass • Adding of control and measuring points • Modification and add of extra actuators • … • Test and follow up + troubleshooting • Adaption of insulation and covering • Installation of gas pipe arrangements • Installation of gas zero pressure regulators • Installation of gas train

  24. DesignGas conversion kit additional components • The conversion of plant includes: • Gas line and gas valve units • Air fuel ratio controller • Double wall, crankcase and exhaust ventilation • Pressure relieve valves on exhaust manifold • Automation panels • Gas detector unit • Knocking system and sensors

  25. DesignEngineering gas line typical arrangement vents vents Power Pressure Speed Engine controller Engine controller Valves Gas feeding 4-6 Bar Filter ( option ) (Gas Valves Unit) Engine

  26. Control SystemGeneral Overview

  27. EnvironmentSafety concept The safety of the installation is guided by our Safety Concept which describes the safety philosophy of MAN Diesel & Turbo’s dual fuel engine and the necessary safety installation and the engine room arrangements. The safety concept of MAN Diesel & Turbo’s DF engines is designed to operate on gas with the same safety level as using diesel oil as the main fuel. The concept is based on an early detection of critical situations which are related to the different system components of the gas supply, the combustion and the exhaust system.

  28. BenefitsCost Saving Environmentally friendly: • 4-stroke DF engines can meet Emissions legislations & NOx rules without exhaust gas treatment. • No additional measures to reach NOx and SOx limits. Reduced PM and CO2 emissions. • Green image of LNG engine systems due to a reduction of visible smoke. • Carbon credits possible. Low investment cost: 100 to 140 €/kW • Modifications limited to the bone. • Simple proven and reliable solution design based on field experiences. • Return on investment in few months. • Extending the life cycle of older engines. Less operation cost: • The main fuel is natural gas for which the cost is lower than the price of HFO in many areas of the world. Maintenance cost reduced: • Engine is cleaner while running in gas mode compared to HFO mode. • The maintenance interval is extended.

  29. Dual Fuel engineCo-development with licensees Time pressure from licensees and sales High interest for co-development We are preparing a Gas Engine plan based on L23/30H engine for applying a project imbursed by the Ministry of Industry and Information Technology of the people's Republic of China.   Best Regards/Shi Naixiang / RongAn Thank you very much for your visit, according our conversation, we reached a lot of common ground, especially in the development of new engine and dual-fuel engine. CME has been in operation and the Yangtze river ship customers began to exchange, because of the government preferential policies, they are very interested in working with our company for reconstruction the ship to running dual-fuel engine. Best Regards BaoDongming / ZJCME We are requested to confirm the below. • Possibility of conversion of 8L28/32 to DF engine by MDT • Similar size (1.5MW~2.0MW) of genset model which can be delivered by 1st half of 2013 • Best Regards • Seung-Suk MDT-Korea (On behalf of STX) All engines shall be of Dual Fuel LNG Type ! Are you able to you deliver 28/32 DF GenSet in time ? Mit freundlichen Grüßen / Best regards Manfred Hohlweg

  30. Disclaimer

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