Wärtsilä Ship Power Piero Zoglia. Gas Storage and supply systems /Piero Zoglia

Transcription

1 Gas Storage and supply systems Wärtsilä Ship Power Piero Zoglia 1 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

2 Gas Storage and supply systems Welcome on board Viking Grace! Piero Zoglia, Fuel Gas Handling Sales Support engineer 2 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

3 Gas Storage and supply systems 1. Introduction 2. Gas storage systems 3. Supply systems 4. LNGPac working principles 5. LNGPac alternatives 6. ISO container 7. Gas system on board Viking Grace 8. Conclusions 3 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

4 INTRODUCTION 1. Introduction: LNG as fuel Challenges: Rules and requirements; Space optimization; Hazardous zones; Integration on board; Availability of LNG. 4 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

5 INTRODUCTION 1. Introduction: LNG as fuel BUT The technology is proven, it is time for growth.. Technology is proven; Emerging LNG bunkering; Normally no increased safety Risks with LNG; Need for qualified and experienced business partners. 5 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

6 Gas Storage and supply systems Vessel application Operational profile Consumer type(s) Installed power Sailing area Range Ambient conditions Accelerations & loads Position of tank(s) Bunkering time Secondary systems Tank shape Hazardous zones 6 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

7 GAS STORAGE SYSTEMS 7 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

8 Gas Storage systems 1. Gas storage systems Membrane IMO Type A -B B IMO Type C 8 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

9 Gas Storage and and supply supply systems systems Type C tanks: Key parameters: Process system Cost Weight Holding time 9 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

10 Gas Storage and and supply supply systems systems Process system: Pump configuration To Gas Valve Units lower design pressure; Both 2-st and 4-st DF engines (low pressure) x Rotating equipment x Higher maintenance cost x System less reliable Pressure build up configuration PBE To Gas Valve Units MGE No rotating equipment Self regulating system Reliable system low maintenance cost x Higher design pressure x Only 4-st DF low pressure engines 10 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

11 TANK DESIGN Tank Type Comparison Double-Walled Fuel Storage Tank Single-Walled Fuel Storage Tank Tank design pressure bar, pressure built-up system (pump configuration is also possible) 4.0 to 6.0bar, pump configuration Volume-Weight ratio - + Theoretical holding time + - Cost of the tank - + Cost of the installation?? Tank design life Vessel life time, 25 years Vessel life time, 25 years Volume range m3 (geometric) m3 (geometric) 11 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

12 Gas Storage systems 1. Gas storage systems- Type C tanks Double walled tank Single walled tank Designed as a unit! No LNG is led out of the system during normal operation, LNG runs in DW pipes through the ship to the process equipment 12 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

13 SUPPLY SYSTEMS 13 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

14 Bunkering Truck to ship ~40 m3/h Stationary tank to ship ~ 500 m3/h Ship to ship ~ m3/h Courtesy of AGA 14 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

15 Bunkering Following equality must apply for bunkering,, + > Inerting procedure! Pre cooling of bunkering lines! The higher the difference between feeding pressure and p 2 the higher the volume flow is. TANK PRESSURE (pg) Pmax Pmin BOTTOM FILLING LINE TOP FILLING (SPRAY) LINE 15 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

16 Bunkering of Bit Viking 430m3/h Engines running on gas Flaring Vapour return Bunker 2h Pressure increase 20 min 16 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

17 LNGPAC WORKING PRINCIPLES 17 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

18 LNGPac Simplified P&ID 18 Wärtsilä Gas Storage and supply systems /Piero Zoglia September18, 2013

19 Bunkering procedure Bunkering Station 1. Check that on board bunkering line is inerted and cooled down 2. Collapse the gas pressure in the tank 3. Open the main filling line 4. Close the filling line valves 5. Inert the piping with N 2 To engines Bar(g) Time Glycol/water mixture 19 Wärtsilä Gas Storage and supply systems /Piero Zoglia September18, 2013

20 Tank pressure increase Bunkering Station 1. Open pressure control valve 2. LNG flow by the hydrostatic pressure into the vaporizer 3. LNG is vaporized and gas is returned to the tank To engines PBE Bar(g) Time Glycol/water mixture 20 Wärtsilä Gas Storage and supply systems /Piero Zoglia September18, 2013

21 Normal operation Bunkering Station 1. The master gas valve is opened (pneumatic actuated valve with manual override) 2. LNG is forced by the tank pressure through the product evaporator and instantly evaporated. Gas flows to the GVU Master Gas Valve Product evaporator Glycol/water mixture M1 G1 M2 21 Wärtsilä Gas Storage and supply systems /Piero Zoglia September18, 2013

22 TANK DESIGN LNGPac solutions Horizontal LNPac Vertical LNGPac Containerized LNG system 22 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

23 LNGPac Solutions- ISO LNGPac ISO is a modularized and flexible system for storage and preparation of LNG as fuel for ships utilizing LNG fuel tank containers of standard frame sizes. The LNG fuel tank containers can be transported and refilled on land, thus eliminating the requirement of a LNG bunkering facility nearby. The LNG fuel tank containers can be changed quickly if filled containers are available at port. Engineering and feasibility study done with Germanischer Lloyd for conversion of a RoRo to gas with LNGPac ISO as gas supply system 23 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

24 LNGPac Solutions- ISO The LNGPac ISO system shall be installed on open deck in naturally ventilated spaces. It consists of the following modules: Evaporator skid Preparation of the LNG (evaporation and heating) to meet the gas requirements to the engine LNG fuel tank containers (40 ft) Standard ISO frame dimensions Automation Complete automation and safety system for the gas supply system Gas to GVU(s) Docking station Docking skid with flexible hoses and cables Glycol-water skid (option) Supplies glycol-water to the evaporator skid for evaporation and heating of the LNG/gas. Uses LT-water as heating media Vent mast Common outlets from safety relief/vent valves in the docking station and the evaporator skid shall be connected to a vent mast. 24 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

25 ON BOARD VIKING GRACE 25 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

26 Gas System on board Viking Grace LNGPac - LNG storage Wärtsilä LNGPac : 2 x 200 cbm Pre-cooled bunkering lines Harbour time 1 h Operation in gas mode Simultaneous bunkering Cold Recovery system Bunkering Station(s) below tank(s) Classified by: Bunker station Engine room 26 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

27 Gas Storage and supply systems Bunker Station Lower than the tank Auxiliary equipment Room: cold recovery Operation mode during bunkering Maximum Bunkering flexibility Gas feed interconnection Classified by: 27 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

28 HVAC Cold Recovery To/from HVAC To/from LTwater system To engines +25 LNG -135 at 5 bar 28 Wärtsilä Gas Storage and supply systems /Piero Zoglia

29 Viking Grace Wärtsilä scope of supply 4 Main engines W8L50DF, each rpm 2 x 200 m 3 LNGPac 4 x Gas Valve Units (GVU-ED ) 2 shaft lines with 5 bladed Built-Up fixed pitch propellers 2 bow thrusters 2300 kw, 1 stern thruster 1500 kw Compact Silencer system Classified by: 29 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

30 CONCLUSIONS 30 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

31 Conclusions LNG is ready to take the sea Wartsila offers a complete solution for LNG fuelled ships From fuel system to rudder Single supplier for the most essential equipment on board of the vessel Dual-Fuel concept, a solution for every vessel application redundancy as standard Optimized fuel economy and emission reduction Total mechanical, process & automation system interfacing Global sales & service network, 24/7 Wärtsilä LNGPac In house expertise & design Safety first approach meeting high standards of the oil & gas industry Entirely pre-assembled and tested system Various tank design (horizontal / vertical / container) Standardized process operation, with full flexibility on tank sizing Low/high pressure systems Competitive Capex and Opex System certified by classification societies 31 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

32 Thank you! 32 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

33 Gas Storage systems Double-Walled Fuel Storage Tank Inner tank: IMO type C tank design. Class acceptance of bottom pipe connection Outer tank: function of secondary barrier, creating a double containment system Perlite / Vacuum insulation or optional Multi Layer Insulation (MLI) / Vacuum Inner/outer vessels manufactured in austenitic stainless steel or 9% Ni steel Tank Saddles & Tank Connection Space directly attached to the outer tank Inner tank Outer tank LNGPac Annular space, Perlite / Vacuum insulation Tank Connection Space 33 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

34 Gas Storage systems Single-Walled Fuel Storage Tank IMO type C tank design. All pipe connections above maximum liquid level Tank material: austenitic stainless steel or 9% Ni steel Polyurethane insulation Galvanized sheet steel cladding / protection of insulation for below deck arrangements Glassfiber Reinforced Polyester (GRP) or Stainless Steel (SS316) cladding / weather protection for above deck arrangements Tank Saddles to be mounted at yard during installation Tank Connection Space separated from Tank Dome on top of Tank for all tank pipe connections Dome Polyurethane insulation LNGPac IMO type C tank Galvanized sheet steel, GRP or SS316 cladding Tank Connection Space 34 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

35 Gas Storage systems Membrane IMO Type A/B IMO Type C Construction Operating pressure Non-self-supporting tanks which consist on a thin layer (membrane) supported through insulation by the adjacent hull structure. Hull shaped, model tested tank design, requiring, refined analytical tools and analysis methods to determine stress levels, fatigue life and crack propagation characteristics. Pressure vessels. These are tanks meeting IGC code 1) pressure vessels criteria (accepting overpressure). < 0.7 bar < 0.7bar <10.0bar (IGF code) >10.0bar (IGC code) Shape Prismatic optimum space utilization Prismatic optimum space utilization Cylindrical consuming more space Secondary barrier Yes Yes, for type A Partly for type B No, for single shell if all penetrations above liquid level. Yes (double-walled), if bottom penetration 35 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

36 Benefits and disadvantages Single walled Double walled Benefits Disadvantages Benefits Disadvantages Price Lower Holding time Long Holding time Price Simple structural construction Easier pipes connections Higher diameters and volume can be achieved Bottom penetration is not accepted w/o a secondary barrier Lifetime of PUR insulation System is not compact, more challenging installation on board Penetrations are not enclosed in a secondary barrier, not suitable for below deck installations Bottom penetration is allowed pressure build up system Long lifetime Fire protection Compact system, easier installation on board All penetrations and connections are enclosed in a secondary barrier, suitable for installation below deck More complex structural construction Movement of pipes in the annular space Limitation in diameter of outer shell, suitable only for volumes below 700 cbm September18, Gas Storage and supply systems /Piero Zoglia

37 TANK DESIGN Tank Type Comparison Double-Walled Fuel Storage Tank Single-Walled Fuel Storage Tank Tank design complexity HIGH, advanced supports between inner and outer tank, full pipe stress analyses of piping in annular space, special bottom pipe/valve arrangement MEDIUM, saddle construction, special transport saddle Tank design life Vessel life time, 25 years Vessel life time, 25 years Volume efficiency of type C tank HIGHER than S-W tank, small annular space through perlite/vacuum insulation SMALLER than D-W tank, thicker insulation, as polyurethane is having less good insulation value Volume range m3 (geometric) m3 (geometric) Volume-Weight ratio LOW, double containment system, especially combination of large diameters, small volume and high design pressure BETTER than S-W tanks, especially for large tank diameter/volumes in combination with 9% Ni Steel Tank shape HORIZONTAL & VERTICAL HORIZONTAL, BILOBE 37 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

38 TANK DESIGN Tank Type Comparison Theoretical holding time Tank design pressure for Wartsila 4-stroke DF main engine and 4- stroke DF auxiliary engines Tank design pressure for Wartsila 2-stroke DF main engine and 4- stroke DF auxiliary engines Tank pipe connections Double-Walled Fuel Storage Tank HIGH, IGF compliant, excellent insulation medium, for smaller tank diameters more critical bar, pressure built-up system, no rotating equipment, possible to consume gas from gas cushion 6.0bar, external canned fuel transfer pumps, mounted in tank connection space, possible to consume gas for 4-S engines from gas DISHED END, one side only, thermal expansion loops in annular space Single-Walled Fuel Storage Tank MEDIUM, IGF compliant, for larger tank diameters large volume/surface ratio with high cold duty compensating disadvantages of insulation type 6.0bar, submerged or dome mounted deepwell fuel transfer pump, possible to consume gas from gas cushion 6.0bar, submerged or dome mounted deepwell fuel transfer pump, possible to consume gas for 4-S engines from gas DOME, always on top of the tank, requires more height 38 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

39 ACTUAL Projected LNG LNG main Bunkering production demand locations (2020) Europe: 2 m mt Japan/Korea 0,4 m mt Huston N.America: 1,2 m mt Antwerp Middle East: 0,5 m mt Jubail Singapore Shanghai China: 0,5 m mt Main Type of Transport Seaway transport S.America: 0,35 m mt S.E. Asia: 0,6 m mt Australia: 0,15 m mt Pipeline Transport Data Source: Clarkson & Industry Sources 39 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

40 LNGPac Solutions- ISO Hazardous zone 0 Hazardous zone 1 Hazardous zone 2 No air inlets to safe areas 1.5 m 1.5 m 3 m Connections Valve box PBE box Inner tank Outer tank To be confirmed by class 40 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

41 LNGPac Solutions- ISO The LNG fuel tank containers are connected to the on board gas system in a docking station Modularized skid design Number of slots, i.e. how many simultaneously connected LNG fuel tank containers is determined according to the required LNG capacity. To be installed on open deck with drip trays and LNG spray protection Connections LNG to evaporator skid To vent mast Heating media in & out Nitrogen Pneumatic air Cables for control and monitoring Equipment Flexible hoses with dry disconnect couplings Cable connections to LNG fuel tank containers Process valves, safety & vent valves Docking panels Instrumentation 41 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

42 LNGPac Solutions- ISO The evaporator skid is used for evaporating and heating of the LNG. Installed on open deck To be mounted on a drip tray To be installed in a naturally ventilated shelter for LNG spray protection and weather protection Equipment Evaporators Process valves Master gas valve Safety relief valves Instrumentation Connections LNG from docking station Gas to GVUs/engines Vent to vent mast Heating media in & out Nitrogen for purging of piping Pneumatic air to actuators 42 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia

43 LNGPac Solutions- ISO The glycol-water (GW) skid extracts heat from the engine LT-water circuit for evaporating and heating of the LNG A mixture of glycol and water is used as heating media and supplied to the evaporator skid The GW skid shall preferably be installed in the engine room Flange connections GW to/from evaporator skid LT- water in & out Equipment Redundant GW pumps GW/LT heat exchangers Process valves Instrumentation 43 Wärtsilä September18, 2013 Gas Storage and supply systems /Piero Zoglia