Japanese shipyards Service experience ME-GI engines. Service experience ME- LGI engines. Peter Nerenst. Manager LEO. MAN Diesel & Turbo

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Japanese shipyards 2016-09-29 Service experience ME-GI engines.

1 Japanese shipyards Service experience ME-GI engines. Service experience ME- LGI engines. Peter Nerenst. Manager LEO. < 1 >

2 MAN B&W Low Speed Dual Fuel Engines Reference List (Ordered) No. of engines Type Total dual fuel engines including options: 161 engines Mk. 5 S 90 ME-C-GI G 70 ME-C-GI 9.5, L 70 ME-C-GI 8.2 Methane 4 S 70 ME-C-GI 8.2, 7 10 S 50 ME-B-GI / ME-C-GI 9.5, 8.5, G 45 ME-C-GI G 50 ME-B-LGI 9.5 Methanol 3 S 50 ME-B-LGI G 60 ME-C-GIE 9.5 Ethane 3 G 50 ME-C-GIE 9.5 Total power main engine: Total dual fuel engines in service: 2.9 GW 6 engines < 2 >

3 ME-GI and LGI Operation Hours on Dual Fuel Engine type Owner Engine builder Running hours on Dual Fuel 4T50ME-X-GI DRC 473 2S50ME-GI KHI 100 8L70ME-C8.2-GI TOTE 1 Doosan L70ME-C8.2-GI TOTE 2 Doosan 920 5G70ME-C9.2-GI TK 1 HHI-EMD 780 5G70ME-C9.2-GI TK 2 HHI-EMD 480 5G70ME-C9.2-GI TK 3 HHI-EMD 209 5G70ME-C9.5-GI TK 4 HHI-EMD 16 6S50ME-C8.2-GI NavGas 1 HHI-EMD 23 6S50ME-C8.2-GI NavGas 2,3,4 HHI-EMD delivered 8S70ME-C8.2-GI Crowley MES 490 8S70ME-C8.2-GI Crowley MES delivered 8S50ME-C8.2-GI Wallenius NYK KHI delivered 7G70ME-C9.5-GI Elcano 1,2 MES delivered 7G70ME-C9.5-GI Knutsen 1,2 HHI-EMD 380 8S50ME-C8.2-GI Wall., NYK, KHI delivered 7S90ME-C9.5-GI Matson 1, 2 HHI-EMD delivered 5G70ME-C9.2-GI KLC 1,2 Doosan delivered 7S50ME-LGIM MOL 1,2,3 MES delivered 6G50ME-LGIM WL + Marinvest 1,2,3,4 HHI-EMD delivered Nakilat, converted, 2 HHI-EMD delivered Total running hours 5381 More than 5381 hours on gas in service Delivery of Dual Fuel engines has become a daily routine Already 31 engines delivered Note: The GI system has been in service for approx. 20,000 hours on the Chiba Power Plant in Japan. It was a 12K80MC-GI-S version < 3 >

4 Dual Fuel ME-GI Vessels Delivered World's First LNG Powered Containership in Service, 8L70ME-GI Worlds First ME-GI LNG Carrier M/V Creole Spirit, 2 x 5G70ME-GI in DSME < 4 >

ME-GI - Service Experience Operation Hours on Dual Fuel In Service Isla Bella World's First LNG Containership 2 x 8L70ME-GI Engine builder: Doosan Yard: General Dynamics NASSCO Owner: Tote Inc.

5 ME-GI - Service Experience Operation Hours on Dual Fuel In Service Isla Bella World's First LNG Containership 2 x 8L70ME-GI Engine builder: Doosan Yard: General Dynamics NASSCO Owner: Tote Inc. Ship type: Container Capacity/cargo: 3,100 teu Class: ABS Milestones 2012, December: Order signed 2014, June: FAT accepted 2015, July: Mooring trial in diesel mode 2015; August: Sea trial on MDO 2015, October: Official sea trial 2015, November: First vessel in service 2016, January: Successful LNG bunkering Running hours HFO/DO: > 4000 Hereof running hours LNG: > 1800 < 5 >

ME-GI - Service Experience Operation Hours on Dual Fuel In Service M/V Creole Spirit Worlds First ME-GI LNG Carrier 2 x 5G70ME-GI Engine builder: HHI-EMD Yard: DSME Owner: Teekay LNG Partners Ship

6 ME-GI - Service Experience Operation Hours on Dual Fuel In Service M/V Creole Spirit Worlds First ME-GI LNG Carrier 2 x 5G70ME-GI Engine builder: HHI-EMD Yard: DSME Owner: Teekay LNG Partners Ship type: LNG tanker Capacity/cargo: 173,400 cbm Class: ABS Milestones 2012, December: Order signed 2015, January: FAT accepted 2015, October: Sea trial on diesel oil 2015, December: Official gas sea trial 2016, February: Vessel delivery 2016, March: Vessel in service Running hours HFO: > 2 x 2500 Hereof running hours LNG: > 2 x 890 < 6 >

ME-GI - Service Experience Operation Hours on Dual Fuel In Service Rasheeda World's First Conversion 2 x 7S70ME-C to ME-GI Engine builder: Doosan Yard Retrofit yard: NKOM Owner: Nakilat Ship type:

7 ME-GI - Service Experience Operation Hours on Dual Fuel In Service Rasheeda World's First Conversion 2 x 7S70ME-C to ME-GI Engine builder: Doosan Yard Retrofit yard: NKOM Owner: Nakilat Ship type: LNG tanker Capacity/cargo: 266,000 cbm Class: ABS Milestones 2013, December: Turnkey conversion contract signed 2015, April: Ship docking and conversion 2015, May: Sea trial on HFO 2015, September: Initial gas trial performed 2015, November: Official sea trial for both engines 2015, September: Vessel in service Running hours since conversion: > 2 x 6000 Hereof running hours LNG: > 2 x 480 ( Dirt in gas system) < 7 >

8 First succesfully seatrial on Methanol completed Vestfall Larsen The ME-LGI Project Succesfully Completed Seatrial with 6G50ME-LGI Operating on Methanol Worlds First ME-LGI Methanol Carrier M/V LINDANGER Bergen, < 8 >

9 ME-GI-ECS Fuel gas supply system. < 9 >

10 Dual Fuel Injection Control From Gov Index to injection duration and timing < 10 >

11 ME-GI and ME-LGI Gas Technologies The ME-GI Engine is a Diesel-Cycle Combustion Engine Injection and combustion stability on 4T50ME-X: 500 consecutive cycles analysed ME-GI marginally better cycleto-cycle stability < 12 >

12 8L70ME-C8.2-GI-TII, Service hrs Fuel in use Gas or Distillate Deposit control satisfactory, wear very low as Alu-coat still present after 3700 hrs Liner surface very good Sludge residuals in scavenge box is at very low level Deposit control by PC-ring is effective as deposits is not touching the liner < 13 >

13 ME-GI - Service Experience Lubrication System for ME-GI Automated Cylinder Oil Switch (ACOS) system High BN Low BN < 14 >

14 First ACOM prototype Service test Optimal BN < 15 >

15 ME-GI Components < 16 >

16 ME-GI Commissioning Experience Gas channel sensors New type gas channel sensors, atex approved and exchanged on existing vessels in service. < 17 >

17 Failure of ELGI valve. < 18 >

18 ME-GI and ME-LGI Gas Technologies ME-GI Development: GIV Hydraulic Leakage - Cause of Failure < 19 >

19 ME-GI and ME-LGI Gas Technologies ME-GI Development: GIV Hydraulic Leakage - Cause of Failure < 20 >

20 ME-GI and ME-LGI Gas Technologies ME-GI Development: GIV Hydraulic Leakage - Cause of Failure Chamfer made too large, exposing the sealing ring groove. The sealing is extruded out in the gap Latest ver 5 steel seal shows good performance in service. < 21 >

21 Seal oil leak throug Windows and Gas injection valve to gas side and possible transfer to gas silencer. Gas injection valve. Seal oil leak possebility Windows valve. Seal oil leak possebility. Gas silencer on deck < 22 >

Seal oil Scaling resolution and set point adaption To support new types of seal oil systems, which are not completely linear, the scaling output for the seal oil now has 4 points.

22 Seal oil Scaling resolution and set point adaption To support new types of seal oil systems, which are not completely linear, the scaling output for the seal oil now has 4 points. As shown on the graph, this is especially relevant for the ethane (pump + booster), whereas the classic methane seal oil system (350 bar pump). The seal oil pressure controller is activated by setting: SACU Seal Oil Pressure Controller Active. Measured pressure [bar] Methane Ethane Output [ma] This is a rather slow set point adaption, as the seal oil pump is self controlling, working in the same way as self controlling HPS (ME-B). < 23 >

23 ME-GI and ME-LGI Gas Technologies ME-GI Development: Design Updates Service experience Gas injection valve - atomiser < 24 >

$load from pilot valve New atomiser design for reduced heat input Material with increased strength tested Running hours on gas with no fractures: 8L70ME-C-GI: 1000 hours (long version) 7S70ME-C-GI: 2$

24 ME-GI and ME-LGI Gas Technologies ME-GI Development: Gas Atomiser on G70ME-C-GI Development status and results: Cracked gas atomiser on G70ME-C-GI High cyclic thermal load realised Reduced thermal load from pilot valve New atomiser design for reduced heat input Material with increased strength tested Running hours on gas with no fractures: 8L70ME-C-GI: 1000 hours (long version) 7S70ME-C-GI: 2 x 500 hours (long version) 5G70ME-C-GI: 2 x 1000 hours (short version) Extensive follow up on solutions in service < 25 >

25 G70MEC-GI Service Experience: Atomizer layout G70 < 26 >

26 Breakage H.P Pipe 102 and connector. < 27 >

27 Leaking non return valve in gas block < 28 >

28 New design Non return line in Gas block < 29 >

29 N2 Pressure testing New design By drilling a hole into the middle of the End cover it is possible to mount a nonreturn-valve for example a minimess. By drilling holes in the End cover, it is possible to connect this new hole to the gas detection bore. The classification of the modification is similar to the new accumulator in the LPG engine, which is already approved by CLASS < 30 >

30 N2 Pressure testing New design < 31 >

31 Seals for Window valve connector piece damaged. Part nr: Sealing Part nr: Conn piece Part nr: Block < 32 >

Window valve Hydraulic sealing Control oil 0-300 bar, heavy pulsating.

32 Window valve Hydraulic sealing Control oil bar, heavy pulsating. Peak is measured bar Oil SAE30 Temperature C Max gap: 0.173mm radial Sealing oil 350 bar No peak +/- 30 bar Oil SAE30 Temperature C Max gap: 0.173mm radial < 33 >

33 Window valve Hydraulic sealing New sealing ring design and material is introduced Regular inspected are being performed. < 34 >

34 New type seal for hyd connection window valve. < 35 >

35 Crack in accumulator on gas block < 36 >

36 ME-GI and ME-LGI Gas Technologies ME-GI Development: Change-over from Diesel to Gas Change-over from diesel to gas Failing on test bed due to insufficient air venting. Installation of LP booster pump Perfect change over in rough weather condition Manoeuvring in rough weather condition < 37 >

37 ME-GI Commissioning Experience LP oil supply system Booster pump is applied on LP-supply line Pressure is raised to 5 bar, to increase flow and thereby better condition to remove air in the control oil bores < 38 >

38 LPS modification with compensators, accumulator and improved 16 bars pump stuffing box. < 39 >

39 ME-GI and ME-LGI Gas Technologies ME-GI Development: Throttle Valve Mounted on GIV < 40 >

valve: Design used at first GI engines Incidents with

of ELWI valve Root cause is considered to be assembly

40 ME-GI and ME-LGI Gas Technologies ME-GI Development: Throttle Valve Mounted on GIV Initial design of throttle valve: Design used at first GI engines Incidents with broken spring One part of the spring was causing failure of ELWI valve Root cause is considered to be assembly failure; No Loctite was used, plug screw had been loose < 41 >

simple design with no spring is implemented Hard action code 1

41 ME-GI and ME-LGI Gas Technologies ME-GI Development: Throttle Valve Mounted on GIV New design of throttle valve: A more simple design with no spring is implemented Hard action code 1 is used to make sure all valves on all engines are replaced. < 42 >

42 N2 Pressure testing New design Current design: New design: Pressurize entire system Single unit isolation Filling volume: 210 L Filling time: 5 hours Filling volume: 20 L Filling time: 10 min Needs: 600L bottle bank at 200 bar and N2 booster Needs: 50L bottle at 300 bar, a 50L bottle at 400 bar and a N2 compressor Negative feed back both internal and from customer Tested on gas rig in T35 Positive internal feedback < 43 >

43 Bauer type N 2 Compressor < 44 >

44 Manual assembly test 1. Start manual assembly test The manual assembly test has been improved in a number of ways. The major feature is the possibility to close the purge and blow off valve and thereby not pressurize the return pipe. When Pressurize is pressed, buttons will appear on Purge and Blow off valve. To avoid large leaks due to large pressure differences between gas channel and seal oil, the WV will be requested open. The WV open signal will be sent, when the Inlet pressure is above SPCU- 02G25 Min N2 Pressure For Valve Test. < 45 >

45 GI fuel auxiliary equipment Auxiliary equipment for GI/LGI Gas valve train Gas condition from FGSS: Pressure up to 400bar Supercritical state High density and compressible Leak condition: Gas state with cold expansion and short term condensation < 46 >

46 Actions Slow-opening block Slow-opening function will be included in all GVTs and retrofitted on existing. This will minimize high pressure pulses in the systems as well as protect the GVT filter from too high pressure differences when opening for gas to the engine. < 47 >

47 8L70MEC-GI Service Experience Gas Valve Train Strainer The strainer installed in the Gas Valve Train (GVT) are getting blocked within short periods of gas operation Origin of impurities not yet identified Strainer mesh size: 10µm < 48 >

Fine particles from LNG, possibly from perlite insulation, and piston rings on cold

48 Service experience The reason for a filter Due to excessive particles in gas piping after installation: Particles from installation, grinding, slag etc. Fine particles from LNG, possibly from perlite insulation, and piston rings on cold ends or GVT seals - dp measurement for HP filter introduced - Enlarge and strengthen existing HP filter < 49 >

#7 Suction Buffer Vessel and HP pump # 1 strainer

16 Suction Buffer Vessel contaminated with particles of

Particles were seperated in magnetic and non-magnetic

appearing with tempering colors Composition of cleaned

ASTM 304 and 216) together with some (Al, Si, Ca, )

originated from sand/ cement/ perlite or of similar

examined, there were no other particles mixed with

49 #7 Suction Buffer Vessel and HP pump # 1 strainer inspection Suction Buffer Vessel contaminated with particles of diverse appearances: wood, plastic, metal, dust, etc. Particles were seperated in magnetic and non-magnetic The magnetic particles were rinsed and removed from dust and dirt. These particles are mainly in form of machining chips, appearing with tempering colors Composition of cleaned particles (EDS Analysis): Mainly stainless steels (e.g. ASTM 304 and 216) together with some (Al, Si, Ca, ) oxide compounds and brass alloys Oxide compounds can be originated from sand/ cement/ perlite or of similar materials Grit grains from the grit blasting were also examined, there were no other particles mixed with Mixed particles Mixed particles Grit blasting particles For further details see examination report no. N9551A Magnetic particles Non - magnetic particles < 52 >

50 #7 Suction Buffer Vessel and HP pump # 1 strainer inspection HP pump # 1 strainer contaminated in form of accumulated particles combined with dirt and dust High number of various small particles of dust, metal, plastic, etc. among these samples The strainer size for the HP pump # 1 is???tbt For further details see examination report no. N9551A < 53 >

51 Actions Cleaning procedures Flushing/cleaning procedures Production specification Pressure test and cleaning requirements( ), applying to supply pipe systems, has recently been thoroughly updated by LEP. DUN will be issued to stress that it must be possible to access GVT and engine gas connections for the purpose of flushing. For new orders spool pieces will be supplied with the GVT. < 54 >

52 GVT flange connections Double wall pipe installation Spool piece Fix support < 55 >

53 Intelligent Spool Piece The Solution Whenever a pressurization of the divided systems is needed the system is purged and afterwards the block is removed by removing the 6 bolts. The block is then reinstalled upside-down making it impossible for the gas to flow trough the spool piece. < 56 >

54 Actions GVT Commisioning filter/pre-filter Eltronic has developed a larger GVT filter (20 micron) which can be fitted at the inlet of the GVT. This filter can be used during commissioning or fitted permanently as preferred by the customer. < 57 >

55 Actions Specifying gas filter Gas filter in the supply system and bunkering system will be specified. Requirement: A 10 micron filter is required: - In the bunker line ( bunkering filter ) OR - At the suction side of pump ( LP filter ) OR - At the outlet side of vaporizer ( HP filter ) Requirement: Supplier of the FGSS must ensure that particles of more than 10 micron have been removed from the fuel gas at the outlet of the FGSS. LNG Tank FGSS GVT Recommendation: Bunkering filter, minimum in line with SIGTTO Recommendations for the Installation of Cargo Strainers on LNG Carriers ASTM 20 mesh (nominal aperture of 0.84 mm). 20 micron safety filter < 58 >

56 ME-GI and ME-LGI Gas Technologies ME-LGI Methanol - Development Milestones LGI demonstration event at MDT 4T50ME-X TAT at MES 4S50ME-T9 Test at MES 4S50ME-T9 Test at MDT 4T50ME-X Test at HHI 6G50ME-B9.3 Sea trial MNS Taranaki Sun Test at MES 7S50ME-B9.3 Sea trial HMD Lindanger Celebration at MES Sea trial HMD Mari Jone Sea trial HMD Leikanger Sea trial HMD Mari Boyle < 59 >

ME-GI and ME-LGI Gas Technologies ME-LGI Methanol - Service

components in good condition First start up of MeOH operation

57 ME-GI and ME-LGI Gas Technologies ME-LGI Methanol - Service Experience: 6G50ME-B9.3 LGI Service experience: Shop test on 7 engines Currently 300 service hours obtained FBIV works good and hydraulic components in good condition First start up of MeOH operation was carried out by the crew alone Extensive follow-up will be carried out Plunger Atomizer Cut-off shaft < 60 >

58 ME-GI and ME-LGI Gas Technologies ME-LGI Methanol - Service Experience: 6G50ME-B9.3 LGI Challenge: Broken springs in diesel fuel injectors due to high forces during pilot injection when operating on methanol. Countermeasure: Under investigation. Intermediate solution is to run with specified fuel mix using the diesel injection profile instead of pilot profile. < 61 >

3 LGI Challenge: Breaking drain oil pipes on ME-V timing unit on HMD Lindanger

59 ME-GI and ME-LGI Gas Technologies ME-LGI Methanol - Service Experience: 6G50ME-B9.3 LGI Challenge: Breaking drain oil pipes on ME-V timing unit on HMD Lindanger and Mari Jone. Countermeasure: Reduced clearance between timing unit plunger and barrel as well as installation of hydraulic hose instead of steel pipe < 62 >

60 ME-GI and ME-LGI Gas Technologies ME-LGI Methanol - Service Experience: 6G50ME-B9.3 LGI Challenge: Failing HC sensors in cooling sealing oil unit caused by contamination of oil due to overfilling of cooling sealing oil unit. Countermeasure: Ensuring that oil level is not exceeding high level alarm level. Visual inspection will be installed in tank HC sensors moved to a new location away from engine. < 63 >

61 ME-GI and ME-LGI Gas Technologies ME-LGI Methanol - Service Experience: 6G50ME-B9.3 LGI Challenge: Leaking LPS booster pump because of damaged sealing. Countermeasure: Still under investigation, possible reasons: New stuffing box 16 bar < 64 >

62 ME-GI and ME-LGI Gas Technologies ME-LGI Methanol - Service Experience: 6G50ME-B9.3 LGI Challenge: SW challenges observed during operation resulting in false alarms. Countermeasure: New SW version being corrected and introduced. < 65 >

. OBD-system Relevant engine -and alarm data Engine/vessel Performance data MAN B&W - Flame

63 Cylinder Condition & Performance On-Board Diagnostic, OBD / CoCoS Condition Monitoring. Wear data of Liners and Piston rings OBD combines Systems and procedures already established.. OBD-system Relevant engine -and alarm data Engine/vessel Performance data MAN B&W - Flame Marine Drain Oil Analysis Data Fuel oil data. and evaluate, and gives expert knowledge and advice in return < 66 >

Viewing Alarm System Lab Sensors Fuel/Oil Samples Manager / Owner / Consultant OBD XRF,

64 Project: On Board Diagnostic (OBD) On Board Optional On Board Network Diesel & Turbo On Board Management Third party products OBD Cloud Services / VPN CoCoS-EDS / PMI OBD Remote Viewing Alarm System Lab Sensors Fuel/Oil Samples Manager / Owner / Consultant OBD XRF, dotfast,... OBD OBD Data Forms and Reports Jesper Weis Fogh New Design Research & Development 2016_06_08 < 67 >

The ME-LGIM engines For the use of methanol as fuel

International Methanol Conference May 2017 at DTI. Kjeld Aabo Director Customer support MAN Diesel & Turbo Copenhagen, Denmark The ME-LGIM engines For the use of methanol as fuel < 1 > Design and Manufacturing