Propulsion Large Containership

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    Contents

    Containership Propulsion - beyond Post-Panamax

    P a g e

    Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Engine Programme Development . . . . . . . . . . . . . . . . . . . . . . . . . .

    Propulsion Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    12,000 teu co ntainer vess el . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    P ropeller(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Main engines for a 12,000 teu conta iner vess el . . . . . . . . . . . . . .

    Design Aspects of Large MC Engines . . . . . . . . . . . . . . . . . . . . . .

    Alpha lubrica tors a nd lube oil co nsumption . . . . . . . . . . . . . . . . .

    Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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    Introduction

    C ontainerisation continues to grow as it

    has done for a long time. While the en-

    tire world merchant fleet grew by only

    1% in 1998, the containership fleet ex-

    panded by more than 10% , and this

    continuous growth has also led to the

    development of verylarge containerships.

    The term very large containership it-

    self has been constantly redefined over

    the last decade.

    Tenyears ago, a 4,500 teu containership

    represented the edge of the available

    technology whereas today vessels

    approaching twice that capacityare a

    reality.

    Specialists are debating where this

    continuous increase in size is going to

    stop, and some say that the maximum

    capacity is likelyto be 11,000 teu because

    of Suez regulations on maximum beam

    and draught, and the wish for a reason-able deadweight/teu ratio.

    As main engine designers, we are obvi-

    ously following the development closely

    in order for us to have the optimum main

    engines available for present and future

    container vessels.

    Engine ProgrammeDevelopment

    The M C engine programme has now

    been in the market for 18 years, thus

    it is a fully mature range of engines

    covering a unit power span of 2,400

    to more than 93,000 bhp. T hrough-

    out the years new models have been

    added and existing models upgraded

    both in terms of design features and

    power. Figure 1 shows the most impor-

    tant steps taken, and Figure 2 shows the

    present M C engine programme.

    It is a well-known fact that the M C en-

    gines have sold well throughout their en-

    tire lifetime, actually to an extent where

    our engines have become the industry

    standard in a very large number of ship

    types. T he most significant new addition

    of engines has been the launch in 1996

    3

    Containership Propulsion beyond Post-Panamax

    1981 L35M C introduced

    1982 Full L-M C programme

    1984 L-M C upgraded

    1985 L42M C introduced

    1986 K -M C introduced

    S-M C introduced

    L-M C upgraded

    1987 S26M C introduced

    1988 K -M C -C introduced

    1991 M C programme upgraded

    K and L-M C

    S-M C

    1992 S26M C and L35M C upgraded

    1993 S35M C and S90M C introduced

    K 90M C/M C -C upgraded

    1994 S42M C introduced

    1994 K 98M C-C introduced

    1995 K 80M C-C upgraded

    1996 L70M C upgraded1996 S70M C -C , S60M C -C , S50M C -C

    and S46M C -C introduced

    1996 S80M C upgraded

    1997 L80M C upgraded

    K 98M C introduced

    1998 S80M C -C , S90M C -C ,

    L90M C -C introduced

    S35M C upgraded

    1999 S42M C upgraded

    mep = mean effective pressure C m = mean piston speed

    M k mep Cm

    bar m/s

    7.2

    7.2

    7.6

    8.2

    8.0

    8.0

    8.2

    8.0

    8.0

    8.3

    8.0

    8.28.5

    8.3

    8.0

    8.0

    8.3

    8.1

    8.2

    8.0

    1 15.0

    2 16.2

    2 16.2

    16.2

    17.0

    3 16.2

    16.8

    16.2

    5 18.0

    6 18.0

    18.5

    6 18.0

    6 18.5

    6 18.2

    6 18.0

    6 18.019.0

    19.0

    19.0

    6 18.0

    6 18.2

    19.0

    7 19.1

    7 19.5

    Fig. 1: The MC p rogramme development

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    of the S46-50-60-70M C -C engines

    and, in 1998, of the S80 S/L90M C -Cengines.

    Figure 3 shows references for these

    so-called compact engines and clearly

    spells out that they are well accepted

    by the marine market.

    In Figure 4 the total M C engine references

    can be seen.

    Notable in this respect is also that

    electronically controlled versions of the

    7S60M C -C , designated 7S60M E-C ,have been chosen as prime movers in

    a series of VLC Cs, withtwo main engines

    in each vessel.

    4

    250

    210

    173

    S26M C

    L35M C

    S35M C

    L42M C176

    136

    129

    S42M C

    S46M C -C

    L50M C148

    S50M C127

    S50M C -C127L60M C123

    S60MC105

    S60M C -C105

    108

    91 S70M C

    91 S70M C -C

    93 L80M C

    104 K 80M C -C

    79

    76

    S80MC

    S80M C -C

    104 K 90M C -C

    K90M C

    S90M C -C

    L90M C -C

    94

    76

    83

    104

    94

    0 10,000 20,000 30,000 40,000 50,000 60,000 70,000

    r/min

    kW

    L70M C

    K 98MC -C

    K98M C

    Fig. 2: The 1999 MC engine programme

    Number of engines

    Total: 84,198,306 bhp ~61,927,854 kWTotal

    Type

    98

    90

    80

    70

    60

    50

    46

    42

    35

    26

    O n order or delivered In service

    0

    187 135

    445 394

    724 618

    1,442 1,284

    1,197 1,018

    34 16

    204 182

    961 844

    171 158

    5,385 4,649

    20

    Fig. 4: List of reference, all MC types,

    as at 1999.10.01

    Number of engines

    Total: 3,146,840 bhp ~ 2,314,501 kW

    5 0

    15

    37 12

    101 50

    34 16

    Total 192 82

    Type

    S90M C -C

    S70M C -C

    S60M C -C

    S50M C -C

    S46M C -C

    O n order or delivered In service

    4

    Fig. 3: List of reference, S-MC-C, as at

    1999.10.01

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    Propulsion Aspects

    In 1994 and 1997 we introduced the

    K 98M C-C and K 98M C engines to cater

    for the power requirements of large

    container ships. T he main data of these

    engines are shown in Figure 5.

    As mentioned in the introduction, the

    future points towards containerships

    even larger than those being considered

    large today.

    Figure 6 is an attempt to quantify the

    propulsion power required for such

    vessels.

    As can be seen, the power requirement

    for the fastest of the 10-12,000 teu

    vessels is beyond what can be covered

    today even by our largest unit, the

    12K98M C developing 93,360 bhp at

    94 r/min, but engineswith more cylinders

    are feasible.

    14 and 16-cylinder versions can also

    be built, thereby expanding the power

    range up to some 125,000 bhp. Such

    engineswould be available as both tradi-

    tional in-line engines and V-type engines.

    Although the latter form has not yet

    been realised, we have investigated

    this cylinder configuration in greatdetail, and a large number of patents

    for innovative and exciting inventions

    are pending. Among the advantages

    offered by the V-type concept, com-

    pared to the in-line version, are a 15

    per cent weight reduction and a tre-

    mendous length saving.

    T he intriguing question in our opinion,

    however, is whether single propellers

    can be designed and built to absorb

    such powers, or whether the tendency

    would be towardstwin propellers/twin

    engines.

    To start from the (maybe) very top of

    future capacity expectations, we have

    made a feasibilitystudyof the propulsion

    machinery for a 12,000 teu container

    vessel.

    12,000 teu container vessel

    A 12,000 teu container vessel will need

    other dimensions than have been used

    for the Panamax and Post-Panamax

    container vessels built in the last few

    decades.

    5

    K98MCPower/cylinder

    Speed

    M ean effective pressure

    Stroke

    Bore

    Stroke/bore ratio

    M ean piston speed

    SFOC

    C ylinders

    K98MC-CPower/cylinder

    Speed

    M ean effective pressure

    Stroke

    Bore

    Stroke/bore ratio

    M ean piston speed

    SFOC

    C ylinders

    5,720 kW

    7,780 bhp94 r/min

    18.2 bar

    2,660 mm

    980 mm

    2.7

    8.3 m/s

    126 g/bhph

    171 g/kWh

    6-12

    5,710 kW

    7,760 bhp

    104 r/min

    18.2 bar

    2,400 mm

    980 mm

    2.45

    8.3 m/s

    126 g/bhph

    171 g/kWh

    6-12

    Fig. 5: K98MC/MC-C, cross section and main data

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    The length, breadth and draught of the

    ship will have to be increased signifi-cantly in order to accommodate a load

    capacity of 12,000 teu. An increase of

    length, breadth and draught will not

    only influence the hull design, but will

    also require that harbours and con-

    tainer cranes are prepared for the new

    era of container vessels.

    It may be necessary to have up to 22

    containers abreast on the deck in orderto facilitate the mentioned load capa-

    city and keep the length and draught of

    the container vessel within reason. The

    expected dimensions of a 12,000 teu

    container vessel, based on 22 contain-

    ers abreast, are shown in the table.

    Length on

    waterline

    LWL 385.0 m

    Length between

    perpendiculars

    LPP 375.0 m

    Breadth on

    waterline

    BWL 55.0 m

    Design draught D 13.5 m

    Displacement 175,000 m3

    Propeller(s)

    As mentioned previously, the capability

    of one propeller to absorb the main en-

    gine power, and generate the required

    propulsion thrust at a reasonable effi-

    ciency, will be an important issue when

    discussing the propulsion of very large

    container vessels.

    It may be expected that the propeller

    will have to be designed to absorb

    more than 100,000 bhp to make the

    servicespeed of a 12,000 teu container

    vessel exceed 24.0 knots.

    P ropulsion power of this magnitude

    on a single shaft has not so far been

    used on commercial vessels, and will

    necessitate an appropriate fixed-pitch

    propeller design that can deliver the

    propulsion thrust.

    Any reduction in propeller efficiency as

    a result of a single propeller operating

    at high load can open the door for

    twin-screw container vessels. A vessel

    equipped with two propellers should

    preferably be designed as a twin-skeg

    hull, since this solution will provide the

    best overall propulsion efficiency ac-

    cording to available theory on the sub-

    ject. O utlines with K98M C and K 90M C

    type engines installed in a twin-skeg

    hull are shown in Figure 7.

    The future of container vessels withtwo propellers will depend on the pos-

    sibilities of an appropriate design of the

    ships hull, and whether the ships

    resistance and the water flow for the

    6

    Service speed (knots)0

    20,000

    40,000

    60,000

    80,000

    100,000

    120,000

    23.0 24.0 25.0 26.0 27.0

    SMC R (kW)12,000 T EU10,000 T EU

    8,000 TEU6,000 TEU4,000 TEU

    Fig. 6 : Propu lsion power fo r large container vessels

    K90M C

    55.0 m

    K98M C

    Twin-skeg c onta iner vess el

    Waterline

    Fig. 7: Out lines of K98MC and K90MC engines installed in a twin-skeg hull

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    propellers can be kept at levels that

    can match the state-of-the-art for

    single-propeller ships.

    In theory, the open-water propeller effi-

    ciency for a twin-screw installation can

    be improved by up to 5% -points when

    using a larger total propeller disc area,

    fewer blades, etc. T his corresponds to

    an approximately 8% saving in propul-

    sion power if the resistance of the ship,

    wake field and thrust deduction factor

    of the twin-skeg hull can be kept atapproximately the same level as for an

    ordinary hull with one propeller.

    The available documentation and test

    results for container vessels are still

    scarce, but the information available

    from the model tests on VLC C , U LC C ,

    R o-Ro and ferries with twin-skeg hull

    and twin propellers indicates that the

    advantage in reduced propulsion power

    requirement for these types of ship may

    be up to 5-8% .

    A 12,000 teu container vessel with two

    engines and two propellers, including

    the necessary auxiliary systems and

    modification of the hull, will without

    doubt be more expensive in first cost

    than a single-propeller container vessel.

    Therefore, in order for the twin-screw

    container vessel to be an attractive op-

    tion, the increase in first cost must be

    compensated by lower operating costs

    within a reasonable time frame.

    Margins

    The specified M aximum C ontinuous

    R ating (M C R ) of the main engines de-

    pends not only on the results obtained

    from the model test/power prediction or

    extrapolation of actual trial results, but

    also on the margins that the shipyard

    choosesto include in the dimensioning of

    the propulsion system. The reasons for,

    and the appropriate size of, sea margin,

    engine margin and light running margin

    are described in the following.

    Sea margin (SM)The results from modeltestsare normallybased on clean hull and calm weather

    conditions. Therefore, it is recommend-

    able to add a sea margin to compensate

    for the prevailing weather conditions

    or any increased power requirement

    due to deterioration of hull or propel-

    ler(s).

    The sea margin for Panamax and

    Post-Panamax container vessels has

    been in the range of 20-25% and oc-

    casionally up to 30% . T he sea margin

    for a 12,000 teu container vessel can

    be kept at this level, since its sensitiv-

    ity to changes in weather conditions,

    approximate service speed and hullform will be similar to those of the

    Panamax and Post-Panamax con-

    tainer vessels.

    Engine op erat ion m a rgin (EM)The Continuous Service Rating (C SR )

    is normally set at 85% -90% of the

    main engine specified M C R . T his

    corresponds to an engine operation

    margin of 10-15% of the specified

    M C R power. An engine operation mar-

    gin is included to provide an additional

    power margin that can be utilised tocatch up with delays in departure etc.

    M oreover, the Specific Fuel O il Con-

    sumption is approximately 2-3% lower

    at 85-90% of specified M C R than at

    100% of specified M C R .

    Light running margin (LR)The performance of the propeller, i.e.

    absorbed power at a given propeller

    speed, is influenced by the advance

    speed of the water to the propeller

    and, subsequently, by the increased

    resistance of the hull at heavy weather

    and/or fouled hull conditions. T his phe-

    nomenon is also described as a heavy

    running propeller.

    It is recommendable during the design

    phase to include a light running margin

    (revolution margin) between the theo-

    retical propeller curve through the en-gines specified M C R point and the

    actual layout curve for the propeller at

    calm weather and clean hull conditions.

    A light running margin of 5-7% is

    appropriate for a single-screw con-

    tainer vessel. The light running margin

    for a container vesselwith two fixed-pitch

    propellerscould be increased somewhat

    to compensate for the special running

    conditionswhenonepropeller is blocked

    and the otherpropeller is in operation.

    Main engines for a 12,000 teucontainer vessel

    The appropriate choice of main engine

    and expected specified M C R at service

    speeds of 23.0, 24.0, 25.0 and 26.0

    knots are shown in the table below.

    7

    Service speed Hull with one propeller Hull with two propellers

    23.0 knots Specified M C R

    86,600 bhp x 104.0 r/minAppropriate engine:

    1 x 11/12K 98M C -C

    Specified M C R

    2 x (39,900 bhp x 94.0 r/min)Appropriate engines:

    2 x 7K90M C

    24.0 knots Specified M C R

    97,500 bhp x 104.0 r/min

    Appropriate engine:

    1 x 12/14K 98M C -C

    Specified M C R

    2 x (45,200 bhp x 94.0 r/min)

    Appropriate engines:

    2 x 8K90M C

    25.0 knots Specified M C R

    109,300 bhp x 104.0 r/min

    Appropriate engine:

    1 x 14/16K 98M C -C

    Specified M C R

    2 x (50,900 bhp x 94.0 r/min)

    Appropriate engines:

    2 x 9K90M C / 2 x 7K 98M C

    26.0 knots Specified M C R

    125,200 bhp x 104.0 r/min

    Appropriate engine:

    1 x 16K 98M C -C

    Specified M C R

    2 x (57,600 bhp x 94.0 r/min)

    Appropriate engines:

    2 x 10K 90M C / 2 x 8K 98M C

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    The expected specified M C R and

    engine types for the twin-skeg hull

    with two propellers are based on the

    assumption that the expected advan-

    tage in propulsion performance can be

    utilised to its full extent.

    The service speed and margins should,

    naturally, be adapted so as to utilise

    the nominal rating of the engines.

    The propeller speed for hulls with two

    propellers may be further optimisedthrough detailed investigation of the

    design of the hull and propellers.

    The comprehensive programme of

    90 and 98 cm bore engines from M AN

    B& W Diesel offers ship designers the

    possibility of choosing propeller speeds

    freely within the range of 76.0 r/min for

    the S90M C -C engine type over 83.0

    r/min for the L90M C -C engine type and

    94.0 r/min for the K 90/98M C engine

    types to 104.0 r/min for the K 90/98MC-C

    engine types.

    Design Aspects of LargeMC Engines

    As can be seen from the above, the

    main engines relevant for the very large

    containerships are the 90 and 98 cm

    bore engines.

    The L/K 90M C /M C -C were introduced

    more than ten years ago, and since

    then some 180 engines have been

    ordered.

    The K 98M C -C and K 98M C were intro-

    duced much later, in 1994 and 1997,

    and by now 20 engines have been or-

    dered.

    These include 10 x 7K98M C ,

    5 x 10K98M C -C and 5 x 12K98M C -C

    engines.

    Since the introduction of the M C engines

    in 1982, more than 4,600 engines have

    entered service. During this long period

    there has been a continuous updating

    of the design in order to meet new

    demands for reliability and power.

    O ne of the important steps in the

    development of the K98 engines has

    been to secure optimal combustion

    with low emission parameters without

    sacrificing fuel oil consumption and, at

    the same time, protecting and con-

    trolling the heat-exposed parts in the

    combustion chamber.

    These goals have been achieved byvirtue of a new combustion chamber,

    called O ros geometry, developed on

    the basis of advanced C FD calculations

    of various chamber configurations.

    With the O ros geometry (shown in

    Figures 8 and 9), we have concentrated

    the combustion air around the fuel

    nozzles, and obtained a greater distance

    from the nozzles to the piston top. This

    has resulted in lowerheat load on the

    piston top and unchanged heat load

    on the cylinder cover and exhaust valve.

    8

    Features:

    H igh topland

    O ros piston top geometry

    C PR top ring

    Alu-coat piston rings

    Bore cooled, forged piston

    of heat resistant steel

    P iston cleaning ring

    Verification:

    Extensive calculations

    C omprehensive tests on K 90M C and

    K 90M C-C

    Service test on K 90M C

    Improvements:

    Approx. 100 C lower temperature

    on top compared to former type piston

    Elimination of Inconel coating on piston top

    Increased chrome layer thickness in bottom

    of ring grooves

    Anti-erosion bushing in oil outlet in piston

    rod foot

    o

    P revious Oros g eometry

    Fig. 8: Oros combustion chamber geometry

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    9

    New Oros K98MC-CK90MC-C

    Fig. 10: Heat loads on p iston

    100% Load

    G as side M ean 499 , max 509 M ean 409 , max 421C ooling oil side M ean 197 , max 209 M ean 185 , max 216

    Valve seat M ean 439 , max 456 M ean 448 , max 457

    Underside M ean 563 , max 564 M ean 577 , max 577

    Piston

    crown

    temperature

    Exhaust valve

    temperature

    SectionM-E

    E

    FHON

    M

    G

    DK

    E

    FHON

    M

    G

    SectionM-E

    DK

    C onventional design New O ros design

    9 9

    19

    17

    15

    13 11

    9 7 5

    3 1 1

    3

    5 7 9

    1 1 1 3

    15

    17

    19

    16

    14 10 6

    1014

    16

    57

    5 7

    11

    13

    15

    1

    2

    3 3

    4 4

    810

    12

    1413

    15

    11 6 68 10

    12

    14

    2 2

    6

    oC

    oC

    oC

    oC

    o

    CoC

    o

    CoC

    oC

    oC

    oC

    oC

    oC

    oC

    oC

    oC

    Fig. 9: Oros combustion chamber geometry

    Relativeheat load

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    Actual temperature measurements on

    the piston top are shown in Figure 9.

    A comparison with measurements on a

    conventional piston top shows that the

    temperature level has been lowered

    substantially, by 80-90C .

    The reduction in heat load is illustrated

    in Figure 10, which compares the heat

    load on a K90M C -C piston of the tradi-

    tional design with a K 98M C -C piston of

    the new O ros design.

    The mean heat input during combustion

    is reduced by more than 20% , and the

    local peak heat load is reduced by

    25-35% .

    Exhaust gas emissions tests have been

    performed with conventional fuel valves,

    mini-sac fuel valves and slide-type fuel

    valves.

    The results of the NO x measurements

    are shown in Figure 11 when using the

    slide-type fuelvalve and, as can be seen,the IM O NO x compliance is ensured

    with a good margin for both the slide-type

    and the mini-sac fuelvalves, which are

    standard for all large bore M C engines.

    This new combustion chamber design

    has already been introduced on a num-

    ber of M C engines and is the present

    standard on all large bore M C /M C -C

    engines.

    Besides this very important feature, it is

    obvious that other well-known designfeatures have been included, such as

    high-topland pistons, which reduces

    the thermal load inflicted on the piston

    rings by the combustion gases. T his

    has improved the performance of the

    piston ring pack significantly, resulting

    in higherTBO s (time between overhauls)

    for the piston. Tests with high-topland

    pistons were started about five years

    ago on an S80M C engine and showed

    a significant improvement in the general

    combustion chamber condition.

    The use of the high topland piston alsomeans that the mating surfaces between

    cylinder liner and cylinder cover has

    been lowered, thusreducing the thermal

    load on the cylinder liner and improving

    the conditions for lubricating it.

    The piston ring pack features a top

    piston ring of the so-called Controlled

    Pressure Relief (C PR ring) design. This

    reduces the thermal load on the ring

    pack, as the leak gas flow is divided

    over the six leakage grooves, Figure

    12. T he ring height was increased toensure the strength of the finger seal.

    The lower rings are all of the oblique

    cut type.

    10

    Top piston ring with double-lap S-seal

    and 6 C ontrolled Pressure Relief (C PR )

    gaps

    Even heat distribution on 2nd piston ring

    2nd, 3rd and 4th piston rings with oblique

    cut ring gaps

    New piston ring material: R VK -C with

    A lu-bronze coating

    Fig. 12 : CPR piston ring

    NO x (g/kWh)

    20

    10

    8

    6

    4

    2

    50 75

    0

    18

    100

    16

    12

    14

    0 25

    Load (% -M CR )

    IMO NO x (E3-cycle) = 14.3 g/kWh

    Fig. 11 : NOxemission fo r slide type fuel valve

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    Initially, the height of both the top ring

    and the second ring was increased

    because cases with too short time

    between overhauls were found to be

    related to these two rings. The main

    reason was that the rings lost their

    tension relatively quickly due to the

    thermal load, which resulted in more

    frequent piston overhauls.

    The use of higher 1. and 2. rings gave

    a good improvement, and the tendencyto

    collapsed rings wasgreatlyreduced.

    With the introduction of the M k 5 version

    of the K 80/90M C /M C -C engines, some

    cases of scuffing occurred. These were

    solved with the introduction of the CPR

    top piston ring with a cermet coating

    on the running surface.

    A further improvement was obtained by

    introducing the P iston C leaning (P C )

    ring. T he purpose of this ring, shown in

    Figure 13, is to control ash and carbon

    deposits on the piston topland and

    thus prevent contact between thecylinder liner and these deposits, which

    would remove part of the cylinder oil

    from the liner wall. Long-term tests on

    an S80M C engine since 1994 have

    shown positive results, verifying that

    bore polishmay be a decisive factor

    in the deterioration of the cylinder

    condition. PC rings are therefore now

    standard on large bore M C engines.

    In connection with the introduction of

    the Piston Cleaning ring, the ring pack

    was modified to include Alu-coat on all

    rings.

    The Alu-coat is applied as a running-incoating. T he advantage is reduced

    requirement for running-in time, and

    fewer load limitations during running-in

    after a piston overhaul. T his results in

    safer running-in and in cylinder oil con-

    sumption savings.

    Service experience has shown that the

    C PR top ring solves the scuffing also for

    the second ring.

    11

    C ylinder

    Lubri-

    cator

    Lubri-

    catorAccumulator

    Solenoid valve Solenoid valve

    Sensor Sensor

    C ylinder oil

    service tank

    Pump station

    with

    stand-by pumps

    To other

    cylinders

    To other

    cylinders

    To other

    cylinders

    Tachosignal

    Indexsignal

    LCDsignal

    Indication

    operationpanel

    Alarmsystem

    Slow-downsystem

    Control unitwith

    back-up system

    Fig. 14: Cylinder lubrication with Alpha lubricators

    Piston - high topland

    Piston cleaning ring C ylinder liner

    C ylinder cover

    Fig. 13: Piston cleaning (PC) ring

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    C onsequently, the design has been modi-

    fied to a high top ring of the C PR-type,

    whereas the three lower rings are of the

    usual low type.

    Alphalubricatorsandlubeoilconsumption

    Reduction of the cylinder lube oilconsump-

    tion represents a significant potential saving

    for engine operators. It is therefore an im-portant development target for M AN B& W

    to reduce the lube oildosage without in-

    creasing the wear ratesor reducing TBO s.

    C ylinder oil must be injected into the

    cylinder at the exact position and time

    that ensuresthe optimaluse of the lube oil.

    Having realised that this is hardly possible

    with the conventional, mechanical cylinder

    lubricators, we have engaged ourselves in

    the development of a computer controlled

    electronic cylinder lubrication system, the

    Alpha lubricator, for application on currentcamshaft controlled engines as well as on

    computer controlled Intelligent Engines,

    see Figure 14.

    The Alpha lubrication system features

    a high-pressure pump and an injector

    which injects a specific volume of oil

    into each cylinder for every fourth

    revolution, Figure 14. The system is

    controlled in such a way that the oil

    can be introduced to the individual

    cylinder at any piston position but,

    preferably, when the piston rings are

    adjacent to the lubricating quills.

    The computer sending an on/off

    signal to a solenoid valve controls

    the injection function. After a prede-

    termined time interval, the computer

    transmits an off signal to the sole-

    noid valve, which shuts off the sys-

    tem pressure and opens the return

    oil system. The oil dosage can be

    changed by adjusting the injection to

    e.g. every fifth, sixth, etc. revolution

    (or anyfigure in between, such as

    every 4.5 revolutionby alternating

    between injection every fourth andevery fifth revolution).

    The amount of oil injected can be

    controlled according to engine load

    and raised as required: for example at

    load changes or start/stop.

    In the event of a malfunctioning solenoid

    valve or transducer, the oil dosage will

    automatically be increased for the

    cylinder in question to the maximum

    volume on the other lubricator. If the oil

    pressure fails, the computer will start a

    standbypump and close down the faulty

    pump. If the computer or position sen-sors fail, a back-up computer will take

    over and ensure sufficient (untimed)

    lubrication until the fault has been

    corrected.

    The system, fine tuned on M AN B& Ws

    4T50M X research engine, has returned

    good results on a 7S35M C engine and

    has now been in service for more than

    one year on a K90M C engine. This sys-

    tem has proved high reliability and very

    good cylinder condition with unchanged

    wear rates with a cylinder oil feed ratethat is lower than our recommendations

    with the conventional mechanically

    timed lubricator.

    Conclusion

    With the new and by now fully tested

    K 98 engine, M AN B& W iswell prepared

    to meet the demand for increasingly

    larger main engines for containerships.

    This engine and other large bore M C

    engines are equipped with the latest

    design features known to give high

    reliability and good operational econ-omy.

    12

    Pressure sensor

    for

    control of lubrication

    C ylinder

    lube oil

    inlet

    45 bar

    C ylinder lube oil

    outlet

    O utlets

    for cylinder liner

    lube oil points

    Signal for lubrication

    from control unit

    Spacer

    for basic setting of

    pump stroke

    Solenoid

    valveP

    A

    T

    Adjusting

    screw

    Actuator

    piston

    Injection plungers

    A TP

    Fig. 15: Cylinder lubricator unit