The Bergen B-gas engine

...the powerful worker for a cleaner planet

© 2006 Rolls-Royce.

The information in this document is the property of Rolls-Royce plc and may not be copied,
communicated to a third party, or used for any purpose other than that for which it is supplied, without the
express written consent of Rolls-Royce plc. Rolls-Royce Marine AS, Engines - Bergen
PO Box 924, N-5808 Bergen, Norway.
While this information is given in good faith based upon the latest information available to
Rolls-Royce plc, no warranty or representation is given concerning such information, which must not Telephone: +47 55 53 60 00
be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of Fax: +47 55 53 61 04
its subsidiary or associated companies.
E-mail: bergen.sales@rolls-royce.com
MR205-01/06-5M

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 N o r t h e r n Eu ro p e
De n m a rk
Rolls-Royce Marine AS
Høgevej 19, DK-6705 Esbjerg Ø
Tel +45 75 14 15 22
Fax +45 75 14 20 66
Fr a n ce
Rolls-Royce Marine
4, Place des Etats-Unis
Silic 261, 94578 Rungis Cedex
Tel +33 1468 62811
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T he N e t h e r l a n d s
R o b u s t , h a r d wo r k i n g a n d h i g h l y e f f i c i e n t , t h e B e e p l ay s a n i nv a l u a b l e r o l e Rolls-Royce Marine Benelux b.v
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N o r wa y
Rolls-Royce Marine AS, Engines – Bergen
PO Box 924, N-5808 Bergen, Norway
Tel: +47 55 53 60 00
...the powerful worker for a cleaner planet Fax: +47 55 53 61 04
S o u t h e r n Eu ro p e A s i a Pa c i f i c A m e r ic a s
Italy A u s t ra l i a B ra z i l
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U n i ted Kingdom
Rolls-Royce Power Engineering plc
Sandland Court, Pilgrim Centre,
For more than two decades we have developed, manufactured and installed more than 350 Rolls-Royce lean burn gas engines for Brickhill Drive, Bedford, MK41 7PZ,UK
Tel +44 (0)1234 251 101
industrial power stations and municipal applications. Our engines are at the forefront of technology and quality. Fax +44 (0)1234 211 074

Rolls-Royce Power Engineering plc

Rolls-Royce lean-burn gas engine research started in 1984. Crossley Works, Pottery Lane
Openshaw, Manchester M11 2DP
The first Rolls-Royce gas engine was handed over to the customer in 1991 and millions of operating hours have Tel +44 (0)161 223 1353
Fax +44 (0)161 223 1738
been logged since then.

The B-diesel engine was launched in the late 1980s and several hundred engines are operating worldwide.

B-gas engine research and development has involved comprehensive tests and studies on technology
demonstrator engines to establish our new technology.

Since the launch in October 2003, the B-gas engine has been sold to all our core markets.

B-gas

K-gas B-diesel

Combining
experience and
technology

Proven gas engine technology Proven strength in extreme

environment
 ...the world’s most powerful gas engine*
Development
The design philosophy for the
B-gas engine has been driven by
stringent requirements for lower
exhaust emissions, highest possible
electrical and heat recovery
efficiency, extreme reliability and
high and dependable power suited
to today’s and tomorrow’s
applications.
Gas engine power range
The new B-gas engine is the
natural extension of our very
successful K-gas engine range.
Building on the latest B-diesel
hardware, specifically re-designed
and modified for the requirements
of the gas engine market, and
incorporating the best of the K-gas
combustion and governing
technology, we have created the
new B-gas engine.
This sets new standards both in
power and efficiency in the 720 –
750 rpm class. Key features are the
enlarged cylinder volume and
optimised combustion technology,
which ensure class-leading
performance without over-
stressing the engine – in spite of
gas quality and cooling limitations
in the markets.
*Medium-speed, spark-ignited
 ...protecting the world’s environment
Lean-burn technology
Rolls-Royce was one of the pioneers in
developing the modern lean-burn
gas engine concept, and this has
been carried even further for the
new B-gas.
A lean-burn gas engine is an
“Otto-cycle” engine with mixture
compression and external ignition.
By suitable development of a
strong ignition source, the pre-
chamber and the gas-air mixture in
the cylinder can be leaned out,
giving much improved engine
performance.
Efficiency is increased, emissions
are reduced, particularly those of
NOx, and the specific power of the
engine can be significantly
increased because the knock limit is
extended.
Fast and complete combustion...
... is always the aim, the difference is
how it is achieved.
The turbocharger supplies
combustion air via the intercooler
and the charge air manifold to the
individual cylinders.
A timed mechanical gas valve
injects gas into the inlet air stream.
The special inlet port design and
the engine control system ensures
a homogeneous and lean mixture
of air and gas. During compression,
the lean mixture in the cylinder is
partially pushed into the pre-
chamber, where it mixes with pure
gas to form a rich mixture that
easily ignites by the spark plug.
Fast and complete combustion of
the main mixture in the cylinder is
ensured by a powerful ignition
discharge from the pre-chamber
and an optimised combustion
chamber layout.
Advanced electronic engine
control system ensures that
operating parameters of the engine
are adjusted and optimised in
relation to each other.
The system sets the optimum main
and pre-chamber gas pressures,
the air-fuel-ratio, the fuel rack
position, the ignition timing and
the air throttle position.
 ...world class technology
High technology, low risk
Simple, quick and reliable
control
Based on our well proven K–gas
Gas Engine Controller, which
combines mechanically operated
gas valves, air flow control directly
by the variable turbocharger
geometry and a limited number of
electronics, including cylinder
selective knock and ignition
control. This control concept
ensures a particularly good
transient load response as well as
very good part-load performance,
which is very important in island
mode operation.
The class leader...
Superior combustion system ...in low emissions ...in cylinder power ...in efficiency
Long experience with lean-burn The specific power of gas engines The combination of large
The B-gas engine gives
gas engines as well as is limited by gas and operating components running at low rpm
exceptionally low emissions of
comprehensive research constraints, so a large volume is together with optimised
NOx, CO and UHC combined,
programmes have resulted in the needed to achieve a high cylinder combustion and turbocharger
which is a tribute to its efficient
refined combustion system which output, and with 350 x 400mm the technology ensure the best
combustion technology.
is the key element behind the B-gas is the leader in its class. efficiency.
superior performance of the B–gas
...in exhaust heat
engine. Important details include
The combination of a good
the special inlet port arrangement,
combustion system that requires
flame deck layout, piston bowl
less air dilution and the variable
shape etc. in combination with our
geometry of the turbocharger
well known pre-chamber
results in more recoverable exhaust
technology, which ensure quick
heat.
and complete combustion under
...in unit output
all operating conditions.
The B-gas engine gives the widest
Mechanically robust design
power range in the 720 – 750 rpm
Based on a state-of-the-art diesel
class.
design with an excellent reliability
record, which include advanced
features such as nodular cast iron
structure, 6 studs per cylinder
head, strong backed cylinder head
and liner, latest bearing and valve
materials.
 ...a world of difference

Coeffective
Cost nt rol systechnology
te m s The B-gas engine

E x h a u s t s ys t em Tu r b o c h a rg e r s
Single pipe MPC type optimised for high efficiency and reliable The engine is equipped with two turbochargers, mounted back-to-back
operation. with one exhaust outlet, which have variable turbine geometry (VTG) for
ease and precision of air flow control. This gives a simple and very
G a s a d m i s s i o n a n d g ov e r n i n g efficient system, which easily adjusts to changing operating or ambient
The combination of a separate admission valve and an adjustable flow conditions.
control valve, ensure quick governing response and easy cylinder
balancing. Cy l i n d e r h e a d
Development from the very successful diesel design, by specially modified
Ch a rge air rece i ve r new ports, gas admission valves, special firing pressure indicators,
The generous charge air receiver gives low pressure losses, dampens out modified cooling bore layout as well as a different flame deck machining.
pressure fluctuations and ensures good and equal air supply to each
cylinder. P r e-c o m b u s t i o n c h a m b e r
The small pre-combustion chamber of special heat-resistant steel is
I g n i t i o n a n d co nt ro l s centrally located in the cylinder and optimised to give even and rapid
The ignition system is of the latest solid-state type, with individual timing distribution of ignition energy to the complete combustion space.
and diagnosis for each cylinder as well as adjustable energy level.
The ignition system is linked to a knock-detection system, which Cy l i n d e r l i n e r
monitors and adjusts each cylinder individually. This is a development of the latest diesel engine design, optimised in
terms of material, wall thickness and cooling bore layout for gas operation.
Ca m s h a f t
The camshaft is a simple and reliable design with individual cams shrunk P i s ton and ru n n i n g - g e a r
on to a precision ground and segmented shaft. Cams can be changed This is a well-proven steel-aluminium composite design with a special gas
individually. engine combustion bowl with focus on good cooling. Piston rings as well
as the cuff ring are also special developments for gas operation.
Cr a n k s h a f t The connecting rod is identical to the very successful diesel engine design.
The crankshaft is a single forging of specially alloyed steel and is identical
to the diesel engine design, complying with all marine classification rules.
The timing gear drive is at the flywheel end.
M a i n technic a l d at a
E ngine bloc k Bore 350 mm
This is an advanced mono-block structure, high precision cast in nodular Stroke 400 mm
iron for maximum strength and ease of repair and contains charge air, Cylinder swept volume 38,48 dm3
cooling water and lube oil and drain channels. Cylinder configuration 12, 16 & 20 cylinders
Speed 720-750 1/min
 ...serving the world
Contfriendliness
Service r o l s ys t e m s
Particularly robust, simple
and straightforward design
with a proven reliability
record and is easy to maintain.
Limited number of service
parts and items.
Good accessibility through
ample space, large covers
and doors.
Service work based on a
limited number of hydraulic
tools, which are particularly
safe and easy to use.
Regular maintenance checks
are reduced to a minimum
and grouped in a few defined
service stops, in order to
enhance running time and
thus the availability of the
engine.
The use of a component
exchange system rather than
detail repair, reduces down-
time and improves quality of
work.
Well-established and
experienced service network
with a comprehensive field of
services, including efficiency
and emission tune-ups and
re-calibration.
Service concept
The Rolls-Royce service and
support concept has been
developed to ensure complete life-
cycle support for your engine and
equipment. Our role is to make the
engine and plant profitable and to
protect your investment through
our dedicated global network.
We know by experience that
lifelong support of your
investment means minimum
downtime and low life-cycle costs.
We provide services to optimise
the B-gas engine during its
lifetime.
These include high accessibility to
original spare parts, regular on-site
inspections, technical support and
computer-based personnel training
programmes.
The importance of effective and
easy servicing has always been
highly rated among our customers.
That is why we provide technical
support and field service by expert
personnel worldwide.
By using our service network,
customers benefit from:
Long Term Service Agreements
including guaranteed
availability
Safe running
Quality parts
Technical customer support
Time and cost efficient
solutions
Warranty
Upgrading / modifications
24 hour support availability
 ... world-class performance

The profitable solution Total capability...

Long overhaul ...in gas engine applications ...in meeting the needs of the . . . i n l e a n - b u rn gas engines
intervals
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Test our capability in your next project

 ...the powerful worker for a cleaner planet

Installed power

In 2002 the Tørring cogeneration
plant in Denmark became the focus
of a major upgrade to meet both
future environmental needs and
demand for extra heat.
The relationship between Tørring
and Rolls-Royce goes back to 1993
and the installation of the site’s
first K-gas engine. This long
co-operation has led to the
agreement for the delivery of the
new B-gas engine at the plant.
delivery in August, the first
B-gas engine was installed
in the new facility where it has
operated since October 2003.
The heat produced is used as the
base load for the Tørring
community district-heating
network.
Tariff structure requirements mean
heat is stored in a huge
accumulator tank during high
tariff hours and the engine is
stopped during low tariff hours.
The new plant operates some
4,300 hours per year.

The previous K-gas engine has

been removed and the existing
plant modified to handle the bigger
unit. After assembly, test and