18 Service Experience Me Gi Engines

Korean Shipyard seminar 2016-08-30
Service experience ME-GI engines.
Service experience ME- LGI engines.
Peter Nerenst.
Manager LEO.
MAN Diesel & Turbo < 1 >

MAN B&W Low Speed Dual Fuel Engines
Reference List (Ordered)
No. of
Type Mk.
engines
5 S 90 ME-C-GI 10.5
118 G 70 ME-C-GI 9.5 , 9.2
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, 8.2
2 G 45 ME-C-GI 9.5
6 G 50 ME-B-LGI 9.5
Methanol
3 S 50 ME-B-LGI 9.3
5 G 60 ME-C-GIE 9.5
Ethane
3 G 50 ME-C-GIE 9.5
Total dual fuel engines including options: 161 engines
Total power main engine: 2.9 GW
Total dual fuel engines in service: 6 engines

ME-GI and LGI
Operation Hours on Dual Fuel
Engine
Engine type Owner Running hours on Dual Fuel
builder
4T50ME-X-GI DRC 473 Delivery of Dual
2S50ME-GI KHI 100 Fuel engines has
8L70ME-C8.2-GI TOTE 1 Doosan 1890
8L70ME-C8.2-GI TOTE 2 Doosan 920 become a daily
5G70ME-C9.2-GI
5G70ME-C9.2-GI
TK 1
TK 2
HHI-EMD
HHI-EMD
780
480
routine
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 Already 31
7G70ME-C9.5-GI Elcano 1,2 MES delivered
engines
7G70ME-C9.5-GI Knutsen 1,2 HHI-EMD 380
8S50ME-C8.2-GI Wall., NYK, KHI delivered 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 Note: The GI system
Total running hours 5381 has been in service for
approx. 20,000 hours on
the Chiba Power Plant
in Japan. It was a
More than 5381 hours on gas in service 12K80MC-GI-S version

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
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
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

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)

ME-GI-ECS Fuel gas supply system.

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

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 cycle-

to-cycle stability

8L70ME-C8.2-GI-TII, Service hrs.
3685. Fuel in use Gas or Distillate
Deposit control satisfactory, wear very low

as Alu-coat still present after 3700 hrs
Liner surface
very good
Deposit control by PC-ring is

Sludge residuals in effective as deposits is not
scavenge box is at touching the liner
very low level

Lubrication System for ME-GI
Automated Cylinder Oil Switch (ACOS)

system
High Low
BN BN

First ACOM prototype Service test
Optimal BN

ME-GI Components

ME-GI Commissioning Experience
Gas channel sensors
New type gas channel sensors, atex approved and exchanged on

existing vessels in service.

Failure of ELGI valve.

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.

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

Seal oil
Scaling resolution and set point adaption
To support new types of seal 600

oil systems, which are not
Measured pressure [bar]

500
completely linear, the scaling
output for the seal oil now
400
has 4 points.
300
As shown on the graph, this
is especially relevant for the 200
ethane (pump + booster), Methane
100
whereas the classic Ethane
methane seal oil system 0
(350 bar pump). 0 5 10 15 20 25
Output [mA]
The seal oil pressure
controller is activated by
setting: SACU1-010113
Seal Oil Pressure Controller
Active.
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).

ME-GI Development: Design Updates
Service experience
Gas injection valve - atomiser

G70MEC-GI Service Experience:
Atomizer layout
G70

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

Breakage H.P Pipe 102 and connector.

Leaking non return valve in gas block

New design Non return line in Gas
block

N2 Pressure testing
New design
By drilling a hole into the

middle of the End cover it is
possible to mount a non-
return-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

N2 Pressure testing
New design

Seals for Window valve connector piece
damaged.
Part nr: Sealing 5562740-8

Part nr: Conn piece 5592691-7
Part nr: Block 5615022-9

Window valve
Hydraulic sealing
Control oil
0-300 bar, heavy pulsating.
Peak is measured 600-700 bar
Oil SAE30
Temperature 50-80 C
Max gap: 0.173mm radial
Sealing oil
350 bar
No peak +/- 30 bar
Oil SAE30
Temperature 50-80 C
Max gap: 0.173mm radial

Window valve
Hydraulic sealing
New sealing ring design and material is introduced

Regular inspected are being performed.

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

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

LPS modification with compensators , accumulator
and improved 16 bars pump stuffing box.

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

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.

Bauer type N 2 Compressor

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

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.

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: 10m

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

#6 GVT trouble shooting - Particles in gas block
16th of November 2015
Gas Block contaminated in form of a high number of

different small particles in a dark accumulated substance
Black particles).
Composition of contamination (EDS Analysis):
The dark substance is rich in flourine
Mainly composed of different oxide compounds , sulphates and
stainless steels
Combination of oxides resembles Perlite material and/or
concrete
CU, Cr and Mo among other elements also detected
Barium sulphate particles also detected , they could originate
from the oil and gas production.
For further details see examination report no. N9551
a) Flaky particle in gas block b) Particles in gas block

#7 Suction Buffer Vessel and HP pump # 1 strainer inspection
02.01.16
Suction Buffer Vessel contaminated with particles of

diverse appearances: wood, plastic, metal, dust, etc.
Particles were seperated in magnetic and non-magnetic

02.01.16
Mixed particles
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 Mixed particles Grit blasting particles
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
For further details see examination report no. N9551A

Magnetic particles Non - magnetic particles

02.01.16
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

Actions
Cleaning procedures
Flushing/cleaning procedures
Production specification Pressure test and cleaning

requirements(0743759-4), 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.

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.

GVT flange connections
Double wall pipe installation
Spool
piece
Fix
support
Actions
Specifying gas filter
Gas filter in the supply system and bunkering system will be specified.
Requirement: Requirement:
A 10 micron filter is required: Supplier of the FGSS must ensure that
- In the bunker line (bunkering filter) OR particles of more than 10 micron have been
- At the suction side of pump (LP filter) OR removed from the fuel gas at the outlet of the
- At the outlet side of vaporizer (HP filter) FGSS.
LNG Tank FGSS GVT
Recommendation: 20 micron safety filter

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).

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,

ME-LGI Methanol - Development Milestones
TAT at MES 4S50ME-T9

LGI demonstration event
at MDT 4T50ME-X
Test at MES 4S50ME-T9
Sea trial MNS Taranaki Sun

Test at MDT 4T50ME-X Test at HHI 6G50ME-B9.3
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
2015 2016

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 Plunger Cut-off shaft
the crew alone
Extensive follow-up will be
carried out
Atomizer

Challenge: Countermeasure:
Breaking drain oil pipes on ME-V timing unit Reduced clearance between timing unit
on HMD Lindanger and Mari Jone. plunger and barrel as well as installation of
hydraulic hose instead of steel pipe

Too many false alarms without reason in the Skip automatic supervision on each cylinder
drain steel blocks by Baumer sensor (yellow) and make procedure for manual detection in
case of leakage to outer pipe.
Quick fix - replaced

by dummy plug
In later ECS
software release,
these alarms will
be deleted.

Failing HC sensors in cooling sealing oil unit Ensuring that oil level is not exceeding high
caused by contamination of oil due to level alarm level.
overfilling of cooling sealing oil unit. Visual inspection will be installed in tank
HC sensors moved to a new location
away from engine.

Leaking LPS booster pump because of Still under investigation, possible reasons:
damaged sealing. New stuffing box 16 bar

Broken springs in diesel fuel injectors due to Under investigation.
high forces during pilot injection when Intermediate solution is to run with
operating on methanol. specified fuel mix using the diesel
injection profile instead of pilot profile.

SW challenges observed during operation New SW version being corrected and
resulting in false alarms. introduced.

Cylinder Condition & Performance
On-Board Diagnostic, OBD / CoCoS
OBD combines Systems and

procedures already established ..
Condition Monitoring.
Wear data of Liners and Relevant engine -and
Piston rings OBD-system alarm data
Engine/vessel
Performance
data
Drain Oil
MAN B&W - Flame Marine Analysis Data
. and evaluate, and gives

Fuel oil data
expert knowledge and advice in return

Project: On Board Diagnostic (OBD)
On Board
Optional On Board Network
Diesel & Turbo

On Board
Third party products Management
Email / VPN OBD Cloud Services
CoCoS-EDS / PMI OBD
Remote Viewing
Alarm System
Lab
Sensors
Fuel/Oil Samples
Manager / Owner / Consultant

XRF, dotFast, ... OBD OBD
OBD
Data Forms
and Reports
MAN Diesel & Turbo Jesper Weis Fogh New Design Research & Development 2016_06_08 < 62 >

18 Service Experience Me Gi Engines

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Korean Shipyard seminar 2016-08-30

Service experience ME-GI engines.

Service experience ME- LGI engines.

MAN Diesel & Turbo < 1 >

Total power main engine: 2.9 GW

Total dual fuel engines in service: 6 engines

MAN Diesel & Turbo < 3 >

World's First LNG Powered

Worlds First ME-GI LNG Carrier

M/V Creole Spirit

MAN Diesel & Turbo < 6 >

MAN Diesel & Turbo < 7 >

MAN Diesel & Turbo < 8 >

MAN Diesel & Turbo < 9 >

Injection and combustion

ME-GI marginally better cycle-

MAN Diesel & Turbo < 11 >

Deposit control satisfactory, wear very low

Deposit control by PC-ring is

MAN Diesel & Turbo < 12 >

Automated Cylinder Oil Switch (ACOS)

MAN Diesel & Turbo < 13 >

MAN Diesel & Turbo < 14 >

MAN Diesel & Turbo < 15 >

New type gas channel sensors, atex approved and exchanged on

MAN Diesel & Turbo < 16 >

MAN Diesel & Turbo < 17 >

MAN Diesel & Turbo < 18 >

MAN Diesel & Turbo < 19 >

Chamfer made too large,

Latest ver 5 steel seal

MAN Diesel & Turbo < 20 >

Gas injection valve.

MAN Diesel & Turbo < 21 >

To support new types of seal 600

Measured pressure [bar]

This is a rather slow set

MAN Diesel & Turbo < 22 >

MAN Diesel & Turbo < 23 >

MAN Diesel & Turbo < 24 >

Development status and results:

MAN Diesel & Turbo < 25 >

MAN Diesel & Turbo < 26 >

MAN Diesel & Turbo < 27 >

MAN Diesel & Turbo < 28 >

By drilling a hole into the

By drilling holes in the End

The classification of the

MAN Diesel & Turbo < 29 >

MAN Diesel & Turbo < 30 >

Part nr: Sealing 5562740-8

MAN Diesel & Turbo < 31 >

MAN Diesel & Turbo < 32 >

New sealing ring design and material is introduced

MAN Diesel & Turbo < 33 >

Change-over from diesel to gas

MAN Diesel & Turbo < 34 >

Booster pump is applied on LP-supply line

MAN Diesel & Turbo < 35 >

MAN Diesel & Turbo < 36 >

Current design: New design:

Pressurize entire system Single unit isolation

Filling volume: 210 L Filling volume: 20 L

Filling time: 5 hours Filling time: 10 min