WÄRTSILÄ 32GD

GAS-DIESELS FOR OIL FIELD POWER PRODUCTION

AND MECHANICAL DRIVE APPLICATIONS
 GAS FROM THE WELL – USE IT, SHARE IT.

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 Wärtsilä gas-diesel technology is the solution for the power
generating needs of the oil and gas industry. Thanks to the
unique pilot fuel injection method for initiating combustion,
associated gas can be used for power generation at the oil
field. And if the supply of gas varies in quantity and quality,
the answer is fuel sharing – the Wärtsilä innovation that
revolutionizes the concept of fuel flexibility. What was once
considered an expense, is now an asset.

Gas-diesel (GD) technology was introduced in 1987 with the

DON’T FLARE IT. Wärtsilä 32GD, the first gas engine in the Wärtsilä portfolio. This
technology was mainly used in offshore applications, although it
also found applications in the power plant sector. GD technology
makes it possible to run a power plant on either associated
gas or crude oil, giving the operator fuel versatility and security
against gas supply disturbances. The system accommodates
variations in gas quality.
Gas-diesels use the diesel combustion cycle in both gas and
liquid fuel operation, which gives them the characteristics of a
diesel engine with uncompromised output and derating. In the
gas mode, a small amount of pilot fuel oil injection is used to
initiate combustion.

The optimized dual-fuel injection system contributes to complete

combustion of all fuels over the entire load range.

Gas fuel

Liquid fuel

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 Diesel Gas
share % share %
0 100
GD operation
10 90
20 80
30 70
40 60
50 50
Fuel Sharing Fuel Sharing
60 40
70 30
80 20
Transfer window
90 10
100 0 Fuel oil operation
0 10 20 30 40 50 60 70 80 90 100
Engine load%

Fuel sharing window

WHEN THE GAS SUPPLY VARIES, GO FOR FUEL SHARING!

Fuel sharing enables the use of GD
technology even when the gas supply is not
constant or the quality of the gas varies.
Fuel sharing optimizes power production at
the oil field in all situations.
The fuel sharing system allows the engine
to run on gas and liquid fuel in different
proportions, in order to optimize plant operation
according to the availability of the fuels. For
example, if with the gas available only 30% of
the rated output can be achieved, the engine
will use fuel oil for the remaining 70%. The
operator can freely change the setpoint of the
fuel share, and the control system will ensure
that the actual operating point is within the
specified operating windows. Of course, the
operator has the choice of running the engine
in conventional GD or fuel oil operation mode
as well.
FUEL OIL OPERATION
Fuel oil operation is based on the use of
normal fuel oil injection pumps and the system
operates just like any diesel engine. The engine
can run on crude oil, light fuel oil or heavy fuel
oil as the main and pilot injection fuel, without
any changes to the fuel injection system. Fuel
oil operation is available within the full load
range from zero to the rated load of the engine.
GD OPERATION
GD is the original gas-diesel operation mode,
where gas is the main source of energy,
pilot fuel oil injection of approximately 5% is
used to ignite the combustion. GD operation
is available at any point between 30%
and 100% of rated load and the plant can
transfer to and from GD operation within this
same range.
FUEL SHARING OPERATION
The fuel sharing option is available between
35% and 87.5% of rated load. The fuel share
setpoint can be adjusted on-line from WOIS
(Wärtsilä Operators Interface System). The
operator may, for example, want to run with
35% gas at full engine load, so he gives a
35% setpoint and selects fuel sharing mode.
If at any time the engine load is too low
to achieve the selected setpoint, the control
system will automatically adjust the setpoint
to the minimum or maximum limit. The
operator may also change the setpoint at any
time during operation.

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Fuel sharing technology

FUEL SHARING CONTROL SYSTEM

The fuel sharing system is essentially a
combination of the GD engine and a new
control system and control principle. The
system controls both gas and oil injection
simultaneously and allows both to be used
within the allowed operating window limits.
The new control system is integrated into
the programmable logic control (PLC) of the
Wärtsilä extended level automation system
using the WOIS platform.
Since the control system is now integrated
into the Wärtsilä standard extended
level automation system, gas conversion
applications or future gas conversions are now
much more attractive than with the original GD
system.

The main advantages of the fuel sharing

system are:
•• Flexible operation with variable proportions
of gas and oil
•• Flexibility in fuel oils, for example LFO, HFO
and crude oil can be used as main and pilot
fuel
•• The system can operate on low methane
number gas
•• The system can use both low and high heat
value gas
CONVERSION OF EXISTING ENGINES
If conditions at the field change and it becomes
more economical to use gas as the main fuel
for field energy production, Wärtsilä Vasa
32LN engines can be converted to gas-diesel
operation.

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 Wärtsilä supplies complete power generating KHULNA (TIGER 1 AND TIGER 3)
solutions, based on compact modular Location: Bangladesh
Engines: 19 x Wärtsilä 18V32LN (GD)
components. Engines, alternators, control
Output 110 MW
systems. Even housing structures can be Delivered: 1997
included. Complete with engine auxiliary
equipment, fire fighting systems, maintenance
provisions, monitoring, ventilation etc.

All this from one supplier who takes complete

responsibility for your installation – throughout
its lifetime! With more than 1000 MW dual-fuel
power installed throughout the world, Wärtsilä
is the partner you can rely on.

THE PROOF IS OUT THERE.

PETROPRODUCTION SEQOYA
In 2002 Wärtsilä was contacted by Dygoil, an
Ecuador-based company, with a specification
that called for true fuel sharing capability
for an oil field power supply system. Dygoil
needed a power plant that could run on both
associated gas and crude oil because the gas
supply was not stable and gas availability was
declining over time as the watercut increased.
Wärtsilä took up the challenge and developed
the fuel sharing system for the 2 x Wärtsilä
16V32GD project. The plant was handed over
for commercial operation in March 2004.

VESSLEFRIKK
Norwegian Statoil decided to convert two of
the platform’s eight installed Wärtsilä Vasa
12V32 diesel gensets from Marine Diesel
Oil (MDO) to associated gas. The engines
were initially designed for easy conversion.
In close cooperation with Statoil, the Wärtsilä
team carried out the conversion as well as a
total upgrade to the latest technology. And a
complete rebuilding of two other engines that
had been in operation for ten years. The entire
project was carried out in just three months
on board Veslefrikk platform in the North Sea,
without disturbing oil production.

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 WÄRTSILÄ 32GD MAIN TECHNICAL DATA

Power production
SANAA Cylinder bore 320 mm
Location: Yemen
Piston stroke 400 mm
Engines: 3 x Wärtsilä 18V32GD
Rated speed 750/720 rpm
Output: 15.5 MW
Delivered: 2006 BMEP 2.09/2.10 MPa
Cylinder output 420/405 kW

Technical data 50 Hz/750 rpm Unit 16V32GD 20V32GD

Power, electrical kW 6505 8148
Heat rate kJ/kWh 8200 (7843)* 8181 (7813)*
Electrical efficiency % 43.9 (45.9)* 44.0 (46.0)*
Technical data 60 Hz/720rpm
Power, electrical kW 6273 7857
Heat rate kJ/kWh 8200 (7843)* 8181 (7813)*
Electrical efficiency % 43.9 (45.9)* 44.0 (46.0)*
Dimensions and dry weight with generating set
Length mm 11303 12890
Width mm 3300 3300
Height mm 4472 4243
Weight tonne 120 132
Heat rate and electrical efficiency at generator terminals, including engine-driven pumps, ISO 3046 conditions and
LHV > 36 MJ/m3. Tolerance 5%. Power factor 0.8. Gas pressure at engine inlet 350 bar.
*in liquid mode.

Mechanical drive
Cylinder bore 320 mm
Piston stroke 400 mm
Speed range 600 -750 rpm
BMEP 2.09 MPa
Cylinder output 420 kW

Technical data 750 rpm 6L32GD 8L32GD 9L32GD

Shaft power kW 2520 3360 3780
Shaft power hp 3378 4504 5067
Heat rate kJ/kWh 7912 (7580)* 7912 (7580)* 7912 (7580)*
Shaft efficiency % 45.5 (47.5)* 45.5 (47.5)* 45.5 (47.5)*

Dimensions and dry weight

Length mm 5297 6245 7116
Width mm 2300 2300 2300
Height mm 3421 3450 3571
Weight tonne 30 42 44

Technical data 750 rpm 12V32GD 16V32GD 18V32GD 20V32GD

Shaft power kW 5040 6720 7560 8400
Shaft power hp 6757 9009 10135 11261
Heat rate kJ/kWh 7912 (7580)* 7912 (7580)* 7912 (7580)* 7912 (7580)*
Shaft efficiency % 45.5 (47.5)* 45.5 (47.5)* 45.5 (47.5)* 45.5 (47.5)*

Dimensions and dry weight

Length mm 6837 8206 8766 9276
Width mm 2870 3296 3296 3233
Height mm 3595 3595 3595 4139
Weight tonne 54 63 70 89
Technical data is based on mechanical output at shaft, including engine-driven pumps, ISO conditions and LHV >
36 HJ/m3. Tolerance 5%. Gas pressure at engine inlet 350 bar. * In liquid mode.

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 01.2009 / Bock´s Office / Arkmedia
Wärtsilä enhances the business of its customers by providing them
with complete lifecycle power solutions. When creating better and
environmentally compatible technologies, Wärtsilä focuses on the
marine and energy markets with products and solutions as well as
services. Through innovative products and services, Wärtsilä sets out
to be the most valued business partner of all its customers. This is
achieved by the dedication of close to 19,000 professionals manning
160 locations in 70 countries around the world. Wärtsilä is listed on
the Nordic Exchange in Helsinki, Finland.

WÄRTSILÄ® is a registered trademark. Copyright © 2009 Wärtsilä Corporation.