Kawasaki Green Gas Engine

The World Best Performance Electrical Efficiency

March 2015

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

1
Who we are our roots
Contents

1902
Outline of Kawasaki
Gas Engine Design and Performance
Application

Dry dock
Maintenance
Feature of Gas Engine Plant
Reference

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

2
 Net Sales Business Segment
(Year ended March 31,2014)

Ship & Offshore

Others Stracture
9.9% 5.8%
Precision Rolling Stock
Machinery 10.6%
8.8%

\1,385
Aerospace
billion
20.2%

Motorcycle &
Engine Plant &
23.2% Infrastructure Gas Turbines &
Engineering Machinery
7.4% 13.6%

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

3
 Kawasaki Heavy Industries, Ltd.

Kawasaki Heavy Industries, Ltd.

Ships & Offshore

Structure Company

Rolling Stock Gas Turbine

Company Division

Aerospace Machinery
Company Division

Gas Turbine & Kawasaki Gas Turbine

Machinery Company Europe GmbH (Germany)

Plant Infrastructure Kawasaki Gas Turbines

Company Americas (USA)

Motorcycle & Kawasaki Gas Turbine

Engine Company Asia (Malaysia)

Precision Machinery
Company

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

4
 Company Organization

Gas Turbine & Machinery Company

Gas Turbine Division Machinery Division Energy Solution

Division
Akashi Works Kobe Works

L20A Gas Turbine Diesel

Standby Steam Turbine /TRT Centrifugal Compressor /

Generator Set Offshore compression module

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

5
Who we are our roots
Contents

1902
Outline of Kawasaki
Gas Engine Design and Performance
Application

Dry dock
Maintenance
Feature of Gas Engine Plant
Reference

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

6
 Engine Models

High Efficiency and Environmental Performance

Model KG-12 KG-18 KG-12-V KG-18-V

Cylinder Bore x
300 x 480
Stroke(mm)
50Hz/
750rpm
5,200 7,800 5,200 7,800
Output
(kW) 60Hz/
720rpm
5,000 7,500 5,000 7,500

Heat Rate(kJ//kWh) 7,423 7,347

Electrical
Efficiency (%) 48.5 49.0
NOx(ppm)[O2=0%] 200 or Less(at O2=0%) 57 or Less(at O2=15%) Equivalent

Operating Range 30~100% Load

By-Pass Valve Type Variable Nozzle Type

Turbocharger
Control System

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

7
 KG-12/18 Green Gas Engine

KG-18
Dimension
13m5.4m3.2m
(LHW)
Engine
Weight(Dry) 133 ton
Generator
Electrical
75007800kW
Output

Spring Damper

KG-12
Dimension
11.2m5m3.2m
(LHW)
Engine
Weight(Dry) 102 ton

Electrical Generator
50005200kW
Output

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

8
 Features and Benefits

Main Features

Highest Electrical Efficiency 49%

Excellent Partial Load Performance

Wide Continues Operating Range

Less Impact by Ambient Conditions

Quick Start-UpIn 10minutes to 100% Load

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

9
 Features and Benefits

Highest Electrical Minimized Fuel Cost

Efficiency 49% High Environmental
Lower NOx Emission Performance
50
Electrical Efficiency (%)

48
Green
Gas Engine

46

44
Competitor
0 60 120 180
NOx at 15%O2(ppm)
2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved
10
 Features and Benefits

High Partial Load Performance

Wide Continues Operating Flexible Operation
Range 30~100%

50
Electrical Efficiency (%)

40

30

20

10

0
30 40 50 60 70 80 90 100
Load(%)
2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved
11
 Features and Benefits

Less Impact Stable Output in Hot Climates

by Ambient Conditions /at High Altitudes

Intake Air Temperature vs Load Altitude vs Load

Gas Turbine Green Gas Engine Gas Turbine Green Gas Engine

110 110

100 100
Output(%)

Output(%)
90 90

80 80

70 70

60 60
15 20 25 30 35 40 45 50 0 500 1000 1500 2000 2500
Intake Air Temperature () Altitude (m)

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

12
 Features and Benefits

In 10 minutes to 100%
Quick Start-Up Full Load from Start Order
[% ]

Start Preparation
100
100
Auto
Load or Rotation Speed [%]

80 synchronization
80

60
60
Rated Load

40
40

Load Up
20
20

00
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Time [min]
[]

Rotation Speed
Load

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

13
Who we are our roots
Contents

1902
Outline of Kawasaki
Gas Engine Design and Performance
Application

Dry dock
Maintenance
Feature of Gas Engine Plant
Reference

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

14
 Application of Heat Recovery

Typical Application for Steam/Hot Water/Chilled Water Demand

Exhaust Steam 15%

Example1 Exhaust Gas Gas Boiler

ElectricitySteam
Natural Total Efficiency
Hot Water gas
Electricity
77
49%

Heat Hot Water

HT Cooling Water
Exchanger 13%

Hot
Exhaust Gas Water Boiler
Example2
Total Efficiency
ElectricityHot Water Natural Electricity 81
gas 49%

Heat Hot Water

HT Cooling Water Exchanger
32%

Exhaust Chilled Water

Example3 Exhaust Gas Chiller
Gas Boiler 15%

Electricity Chilled Water Total Efficiency

Natural
Electricity 77
gas
49%
1090USRT
Heat Chilled Water
HT Cooling Water Chiller
Exchanger 7.4%

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

15
Who we are our roots
Contents

1902
Outline of Kawasaki
Gas Engine Design and Performance
Application

Dry dock
Maintenance
Benefits of Gas Engine Plant
Reference

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

16
 Maintenance Schedule

Level A B C D E F
Interval
(Running hours)
2,000 6,000 12,000 24,000 48,000 96,000

Scheduled
KG-12 1 1 9 12 14 14
outage
KG-18 1 1 12 14 17 17

A Replacement of spark plugs

B Replacement of non-return valves + Level A
Replacement of cylinder covers, piston rings, air starter and
C
inspections* for others + Level B
Replacement of crankpin bearings, main bearings,
D
turbocharger bearings and inspections* for others + Level C
Refurbishment of flexible coupling and inspections* for others
E
+ Level D
Refurbishment of flexible coupling and inspections* for others
F
+ Level E

* Check with Cleaning

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved
17
Who we are our roots
Contents

1902
Outline of Kawasaki
Gas Engine Design and Performance
Application

Dry dock
Maintenance
Feature of Gas Engine Plant
Reference

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

18
 Plant Feature

General Operation Continuity

Required Load In
Fuel Investment On failure
Conventional Turbine water Category Maintenance
Much
NG Natural Gas

Petroleum
P Base or or

50% 50%
Biomass

Per every 4 yrs

GTCC Sufficient

NG
Base
or or
Middle
P 25% 25%

Per every 1 yr
Multiple Gas engine Units Few

100% 100%
Base
NG Middle or or
Peak
93% 93%

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

19
 Position of Gas Engine

Flexible

Petroleum Fuel Peak

- GT Open Cycle

Gas Firing
- GT Combined Cycle
- Boiler / Steam Turbine
Middle

Fossil - Boiler Steam Turbine

Flexibility
Nuclear Base
Hydraulic
Renewable
0 6 12 18 24 Inflexible
Typical Daily Power Demand & Power Source

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

20
 50MW Gas Engine Plant Typical Layout

122m
400
82.5m
103-4

Lubrication Oil Tank

Urea Tank Yard

Transformer with
106m
350

270-5
Switchgear 82.5m

8 (7+1) Units
Engine Generator with
Transformer Yard Radiator and SCR

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

21
Who we are our roots
Contents

1902
Outline of Kawasaki
Gas Engine Design and Performance
Application

Dry dock
Maintenance
Feature of Gas Engine Plant
Reference

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

22
 Reference List

Number of Total Supply Record

Domestic Unit: 69 Units
Market Number of Unit: 75 Units
Total
Capacity: Total Capacity: 567.8MW
524.1MW

As of March 2015

Number of
Overseas Unit: 6 Units
Market Total Capacity:
43.7MW

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

23
 110MW Gas Engine Power Plant

Nihon Techno
Sodegaura Green Power Plant
Model KG-18-V
Output 7,800kW
Unit 14
Total Output 109.2MW
August
Operation Start
2012
Engine Building

60m

High Voltage
Switch Yard

Radiator
200m

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

24
 KOBE Power Center

Power Center #1

Model KG-12-V

Output 5.0MW

Operation Start May 2010

Power Center #3

Model KG-18-V

Output 7.5MW

Operation Start July 2013

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

25
 Singapore LNG Corporation

Model KG-18-V
Output 7,800kW
Unit 2
Total Output 15.6MW
Under
Operation Start
Construction

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

26
 2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved
27
 Features

Pre Combustion Chamber

Achieved stable combustion using fluid
analysis etc.

Ignition plug is applied

Solenoid Valve
Fuel Gas
Main Combustion Chamber
Solenoid
Lean combustion Valve Ignition Plug
Pre Combustion
Optimized main combustion shape using Non-return Chamber
fluid analysis etc. Valve

Exhaust
Individual Cylinder Control Gas
Intake Air

Ignition timing and gas amount are Pressure sensor

controlled by the analysis of each cylinder

Press
Main
Independent Fuel Supply Clank Combustion
Piston Chamber
Fuel gas is supplied separately to main
combustion and pre combustion chamber
using different solenoid valve Connecting Rod

Optimized injection timing and amount

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

28
 Individual Control System

Main Control Unit

Ignition Air Fuel

Gas Valve Knocking
Timing Ratio
Control Detection
Control Control

Gas Valve Exhaust Gas Variable Nozzle

Spark Plug

Pressure sensor Air

Blower Turbine
Generator Main Engine
Turbo Charger
2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved
29
 Development Focus Points

Focus points for high performance and their realization

1. Optimization of operating point

2. Good combustion
3. Reliable ignition

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

30
 Optimized Operation

Ignition Timing
High
Advanced
Knocking Misfiring

Retard

Efficiency

Optimized
Operation

Low
Low Air Fuel Ratio High
Rich Fuel Density Lean

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

31
 Ignition Timing Control

Optimized Ignition Timing

Ignition
Ignition
by Knocking Timing
TimingControl
Detection Control
System

Ignition Timing Control

Knocking
KnockingDetection
DetectionUnit
Unit
Plug
Plug
Plug

Knocking Detection Unit

Measure
Measure Analyse
Measure Analyse
Analyze
Judge
Judge
Judge


explosion Sensor
Sensor
Sensor

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

32
 Flat Characteristics by Multiple Units

50
45
40 Gas Engine x 14 units
Efficiency [%]

35
30
40MW GTx3 units
25
20
15
10
Operation Unit Control (100MW Plant)
5
0
0 10 20 30 40 50 60 70 80 90 100

50
45
40 GGE x 14 units
Efficiency [%]

35
30
40MW GTx3 units
25
20
15
10
5
All Units Control (100MW Plant)
0
0 10 20 30 40 50 60 70 80 90 100

Power Output [MW]

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

33
 Typical Application (1) Cooling Tower
Type1 : Electric Power Only

0.45MPa
Silencer
320 Fuel Gas Flow Regulator

7800kW

Stack
25
Air Filter
88.6

115ton/h
59.3

72.0

38.5 60
43.2
67.1

Fuel Gas
Lube oil
HT Cooling Water
LT Cooling Water
115ton/h Exhaust Gas
32
Cooling Tower
2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved
34
 Typical Application (1) Radiator
Type1 : Electric Power Only

0.45MPa
Silencer
320 Fuel Gas Flow Regulator

7800kW

Stack
25
Air Filter
88.6

115ton/h
88.6

72.0
Radiator 72.0

38.6 60

43.4 67.1

38.6 Fuel Gas

Lube oil
HT Cooling Water
LT Cooling Water
32 115ton/h Exhaust Gas

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

35
 Typical Application (2) Cooling Tower
Type2 : Low Pressure Steam & Hot Water Demand
Steam Supply
0.78MPa 0.45MPa
Silencer
G/3.3ton/h
320 Fuel Gas Flow Regulator
156
7800kW
Stack Waste Heat
Air Filter
Recovery
Steam Boiler 25
Water Supply
60 88.6 88.6
115ton/h
72.0 72.0
Hot Water
Demand

(Option) 59.3

38.5 60

67.1
Hot Water
Demand
(Option)
Fuel Gas
Lube oil
HT Cooling Water
LT Cooling Water
32 115ton/h Exhaust Gas
Heat Recovery
Cooling Tower
2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved
36
 Typical Application (2) Radiator
Type2 : Low Pressure Steam & Hot Water Demand
Steam Supply
0.78MPa 0.45MPa
Silencer
G/3.3ton/h 320 Fuel Gas Flow Regulator
156
7800kW
Stack Waste Heat
Recovery Air Filter
Steam Boiler 25
Water Supply
88.6 115ton/h 88.6
60
72.0 (88.6 )
(88.6 ) 72.0
Hot Water
Demand
(Option) (72.0)
Radiator
38.6 60

67.1

43.4 Fuel Gas

Lube oil
HT Cooling Water
LT Cooling Water
115ton/h Exhaust Gas
32 Heat Recovery

2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved

37
 Typical Application (3) Cooling Tower
Type3 : Chiller
Chiller
0.45MPa
850USRT Steam Silencer
0.78MPaG 320 Fuel Gas Flow Regulator
156 3.3ton/h
7800kW
Waste Heat
60 Air Filter
Recovery
Stack Steam Boiler 25
88.6 88.6
115ton/h
Water Supply
72.0 72.0

59.3

38.5 60

67.1

Fuel Gas
Lube oil
HT Cooling Water
LT Cooling Water
32 115ton/h Exhaust Gas
Heat Recovery
Cooling Tower
2013 Kawasaki Heavy Industries, Ltd. All Rights Reserved
38