Control system for the world’s most powerful marine engine

Embedded software Environment FPGA development Hardware

SCS has developed a versatile control system for combustion engines for Winterthur Gas & Diesel (WinGD). The new control system makes it possible to control the world's largest dual-fuel marine engine: the "Winterthur Gas & Diesel 12X92DF". Thanks to natural gas operation, the ships save 20%CO2 and more than 90% NOx and particulate matter emissions.

  • Situation

    The combustion of gas and diesel (dual-fuel) in the same engine requires a particularly reliable, dynamic and precise control system. Engine control systems are available "off the shelf" on the market. However, such closed systems limit the ability to innovate and often mean a "vendor lock-in".

  • SCS solution

    The control system is based on modular hardware which, thanks to FPGA technology, allows flexible evaluation of the sensors and precise control of valves and ignition. In addition, a powerful processor enables the development of complex control algorithms and a secure connection to the cloud.

  • Added value

    The control platform allows WinGD simple commissioning, transparent and reliable operation and many expansion options. It therefore forms the basis for future innovations.

Project insights

The CMA CGM Jaques Saade is one of the largest and greenest container ships in the world. Since October 2020, the ship has been powered by the world’s most powerful 12-cylinder dual-fuel marine engine: the 12X92DF from Winterthur Gas & Diesel (WinGD). It must be possible to control 85,000 hp precisely and reliably. SCS has developed a control system for this purpose.

The ship’s engine burns both natural gas (LNG, liquid natural gas) and diesel. By burning natural gas, emissions can be significantly reduced: 20% lessCO2 emissions, 90% less nitrogen oxide (NOx) emissions and virtually no sulphur oxide (SOx) and particulate matter (PM) emissions. The engine makes a significant contribution to reducing greenhouse gas and pollutant emissions in the transport sector. It is also ahead of its time: it already fulfils regulations that will be introduced in the marine sector in the future.

Powered by the world's largest dual-fuel marine engine: the container ship CMA CGM Jaques Saade. Image: Cmacgm13 via Wikimedia
Powered by the world’s most powerful dual-fuel marine engine: the container ship CMA CGM Jaques Saade. Image: Cmacgm13 via Wikimedia
The 12X92DF marine engine weighs 2000 tonnes and is the size of a detached house. Picture: WinGD
The 12X92DF marine engine weighs 2000 tonnes and is the size of a detached house. Picture: WinGD
Natural gas enables CO2 reductions of more than 20 per cent and NOx, SOx and particulate matter reductions of over 90 per cent compared to diesel combustion. Picture: WinGD
Natural gas enables CO2 reductions of more than 20 per cent and NOx, SOx and particulate matter reductions of over 90 per cent compared to diesel combustion. Picture: WinGD

The engine weighs 2000 tonnes and it is absolutely crucial that it can be operated and controlled efficiently and safely at all times. This is only possible with a customised control system. SCS has developed the hardware, FPGA firmware and software for a distributed system. WinGD’s sophisticated control and optimisation algorithms can be calculated in real time on the control system, enabling operation at the optimum operating point at all times.

The control system consists of various modules that can be customised for each motor type. The modules communicate via two redundant Ethernet rings, which ensure reliable communication even if one cylinder fails. In addition to dozens of sensor inputs, each cylinder control unit (CCU) also has powerful control outputs for dynamic control of the electromechanical valves. The gateway control unit (GTU) is equipped with communication interfaces to the Internet, the control bridge and other peripherals, as well as a firewall to ensure cyber security.

After a joint planning phase with WinGD, SCS created the control system in less than 12 months, going through the entire process from specification to completion of the hardware. The focus was always on quality and traceable engineering processes. This also made it possible to obtain the ship classification from Bureau Veritas at the first attempt.

The engine achieves an output of 85,000 hp at 80 revolutions per minute. The valves are controlled with microsecond precision. Picture: WinGD
The engine achieves an output of 85,000 hp at 80 revolutions per minute. The valves are controlled with microsecond precision. Picture: WinGD
The Cylinder Control Unit (CCU) enables local measurements and dynamic control of the engine valves directly on each cylinder. Image: SCS
The Cylinder Control Unit (CCU) enables local measurements and dynamic control of the engine valves directly on each cylinder. Image: SCS
Following successful certification of the control system and extensive sea trials, the first container ship with an SCS control system has just arrived in Europe. Image: geni via Wikimedia

We are delighted that WinGD passed the final tests with the completion of the “gas trial” in October 2020 and that the first of nine planned ships was able to make the crossing to Europe. SCS is already working on further developments in collaboration with WinGD.

Technical details on the engine and control system can be found in the following Winterthur Gas & Diesel publications:

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