Du Sulzer RT Flex English

DU-WRTSIL RT-flex Engine
April 2006
DIESEL UNITED, LTD.
RT-flex
Customer / File.PPT / 1 / Date
RT-flex Engine
Concept of RT-flex Engine
High economy
Low specific fuel consumption
Low maintenance cost
High operational flexibility
Lower minimum revolution
Good slow steaming capability
Smooth engine starting
Smooth and immediate reversing
action
Operation
Engine operation is same as
conventional engines
RT-flex
Customer day / File.PPT / 2 / Date
RT-flex Engine
Concept of RT-flex Engine
High reliability and safety
Redundancy in main components
Extended integrated monitoring
Gentle to environment
Smokeless operation at all load
Maintenance
No adjustment of fuel oil pump
RT-flex
RT-flex Engine
Characteristic of
RT-flex Engine
Electronically
controlled
Fuel Injection
Exhaust Valve Drive
Starting Air

Common Rail Technology
Flexible and optimum engine

tuning is available
RT-flex
Improvement of fuel
consumption
Clean environment
Sulzer Common Rail System
RT-flex
Components
RTA
(VEC device)
Exh. Valve drive
Fuel pumps
Camshaft
Reversing servomotor
RT-flex
Common Rail
WECS-9520
Control
Fuel linkage
VIT device
Start - Air Distr.
Camshaft drive
RT-flex
Supply unit
Common Rail System
Fuel System
WECS-9520
WECS-9500
Control
control
Control
Oil
Servo Supply
200 bar
Cylinder
Cylinder
4
Volumetric
Volumetric
Injection
injection
Control
control
Sulzer Fuel Rail ~1000 bar

9Each fuel valve on each cyl. can
be controlled individually.
simple
Fuel
Fuel
Flexible Injection timing, Injection

High efficiency
reliable
High efficiency
quantity
Sulzer Common Rail Pump

flexible
9High fuel injection pressure can be Sulzer common Rail Pump
kept at all operation range.

High thermal efficiency
RT-flex
Common Rail System
Exhaust Valve Drive

WECS-9520
WECS-9500
control
Control
System oil
Cylinder
Cylinder
4
Hydraulic
Hydraulic
actuator
Servo oil
Supply
200 bar
Servo
rail 200
bar
9Exhaust valve open / close timing can

be simple
controlled at all operation range.
reliable
9Optimum compression pressure can be

Servo
pump
Servo
oil oil
pump
achieved at allflexible
operation range.
RT-flex
Benefits
Flexibility of Fuel Injection Pressure
Fuel Injection Pressure of Common Rail System
Injection Pressure
Conventional injection system
25
Free selection of
injection pressure
RT-flex
50
75
100Load [%]
Low fuel consumption
Low Nox
Smokeless operation
Steady running at low load
Benefits
Flexibility of Exhaust Valve Timing

Exhaust Valve Timing of Sulzer Common Rail System
Valve Timing [CA]
close
Conventional Exhaust Valve Control

open
25
Free selection of
exhaust valve timing
RT-flex
50
75
100 [%] rpm
Low fuel consumption

Low Nox
Smokeless operation
Steady running at low load
Benefits
Sequential Operation
Sequential Operation of Injection Nozzle
(Smokeless operation and slow steaming)
Sequential Operation
Reduce number of injection valve to increase injection quantity of one
injection valve at low load.Improvement of injection spray
Standard injection pattern

2 nozzle operation
Low load :
1 nozzle operation
Smokeless operation down to 10-12 rpm R1

RT-flex
(13rpm for 6RT-flex50)
Merit of RT-flex Engine
RT-flex
Flexible Operation
High fuel injection pressure
Optimized exhaust valve timing
Sequential injection nozzle operation
Lower minimum revolution10-12 rpm R1(6RT-flex5013rpm)

Good slow steaming capability without any countermeasure, by
improvement of fuel injection.
Smooth and immediate reversing action due to no mechanical
reversing device.
Flexible operation can be possible
especially in harbor.
RT-flex
Easy Maintenance
Simpler engine setting.

(injection / exhaust valve timing)
In case of trouble, control module can
simply be exchanged.
RT-flex
Easy Operation
RT-flex58TB
Control console in
control room
Same arrangement
as console for
conventional engine
RT-flex
Easy Operation
Engine side operation stand (RT-flex)
Engine side operation stand (RTA)
Control panel (without handle)
Operation by control handle
RT-flex
High Reliability and Redundancy DesignTest

1. In-house test for flex parts.
Function test of fuel injection system and
exhaust valve drive system.
Endurance test of Sulzer rail valve by
300,000,000 switching.
2. Built-in redundancy regarding fuel pump and servo
oil pump capacities
Multiple pumps are installed on the engine.
RT-flex
High Reliability and Redundancy Doubled Main Parts
Doubled common functions and sensors to ensure higher

reliability
Fuel oil and servo oil piping
Crank angle sensor, exhaust valve stroke sensor,
pressure transmitter
Communication cable
Main power supply unit
RT-flex
High Reliability and Redundancy Monitoring Function
Monitoring of engine condition by sensors

Sulzer rail valve operation
Injection timing and quantity from injection control unit
Exhaust valve open / close timing
Crank angle sensor monitoring
Fuel oil and servo oil pressure monitoring
RT-flex
Gentle to Environment
Smokeless
Smoke
Result
SmokeMeasurement
measurement result
12RT-flex96C
Smoke [ %, 3L ]
Smoke
25
12RT- flex96C
20
12RTA96C Conventional
15
Diesel Oil operation
SmokeVisibility
Visibility Limit
Smoke
Limit
10
5
0
0
10
20
30
High injection pressure
40 50 60 70
Engine Load (%)
Optimized exhaust valve timing

Sequential injection nozzle operation
RT-flex
80
90
100 110
Load(%)
Improvement of fuel injection

Smokeless operation at all
operation range
Gentle to Environment
Emission
Exhaust
GasEmission
Emission
Measurement Result
Exhaust
measurement
6RT- flex58T- B
CO2 (%)
6RT- flex58T- B
6RTA58T
CO2 Concentration
6
5
4
3
0
CO (ppm)
60
25
50
CO Concentration
50
40
30
20
HC (ppm)
600
RT-flex
400
200
0
HC Concentration
75
100
Clean in Environment
RT-flex
For Future Requirement
Service Experience
First flex Engine in the world

6RT-flex58T-B
Since September 2001
RT-flex
Experience
General Statements:
l
l
l
l
More than 8000 running hours

Running behaviour exceeds all
our expectations for a
revolutionary engine
No real down-time besides 2hrs
Operators quickly got
acquainted to the system
Several non-concept troubles
solved
WCH Sales Kit 03May / 38 / RB
General
Experience
l Lubrication of rail pumps failed
F Rail pumps replaced with correctly
machined ones plus design changed
> solved
l Servo oil connecting pipes to collector
block cracked
F Connecting pipes replaced by flexible
hoses > solved
Supply Unit
Experience
l Vibrations on upper platform
F Modified design for new engines
> solved
l Rail valve connections broken

F Better quality assurance and slight
modification on connectors
> solved
l Insufficient accessibility of rail unit
casing internals
F Accessibility vastly improved by new
design
> solved
Rail Unit
Experience
l Malfunction of some sensors
F Sensors were defective or showed bad
wiring
> solved
l Valve drive module failures
F new print set-up for lower thermal

stress of components
> solved
VDMPCB
l Regulating behaviour unsuitable for
large swell and light ship

F Software control loops modified for
compatibility
> solved
RT-flex Control System
Experience
Conventional Parts
Very good results on liner wear
Very good result on piston ring wear
Very good load pattern on crankshaft

gear wheel
Clean valve seat
Good injection nozzle shape
Full Inspection 5300Rhrs
Experience
RT-flex Specific Parts

Very good load pattern on gear wheels of supply
unit
No wear on fuel cams
No wear on hydraulic actuator for ExVa
No wear on crank angle sensor assembly
Electrically driven hydraulic pumps have been

modified (couplings, vibs)
Emergency pressure regulating valve has been

modified (tightness)
Experience
RT-flex Injection Control Unit

Shows absolutely same injection pattern as when tested new
No wear on sealing surface of injection

control valve
No wear on control oil piston
No wear on injection control valve slide
Experience
RT-flex Injection Control Unit
No wear on fuel quantity piston
No change of wear on fuel quantity

sensor since beginning of operation
Experience
Fault History
Shutdowns: 2
10
8
6
4
2
0
18 Sep 2001 Sea trials completed
12
Sept
15 Nov 2001 Start of delivery voyage
Faults 14
New faults
Repeated faults
Nov
2001
Jan
Mar
May
Jul
Sep
Nov
2002
Note that faults are only recorded from start of delivery voyage
Repeated faults are owing to time taken to develop final solutions
Jan
Experience
Summary
Conclusions
l RT-flex system concept works fine
flex
l Some teething problems solved
l Our feed-back concept for continuous product improvement paid off
l Crew is operating the engine without assistance since May 2002

20025Wartsila
l Complete inspection after 5300Rhrs showed very low wear figures on
engine parts incl. RT-flex system
5300hrsRT-flex
l Some components later adapted according to inspection
Service Experience M/T SEA LADY 6RT-flex58T-B

First RT-flex Engine at DIESEL UNITED
Eng. Type 6RT-flex 58T-B
MCR 12,000kW x 103min-1
Vessel name SEA LADY

Afra max tanker
In Service August 28 2003
Total running hour 9,700 hrs
September 2005
RT-flex
Service Experience M/T SEA LADY 6RT-flex58T-B
RT-flex
Total run hour9,700 Hr

September 2005
Cyl. Oil feed rate1.36 g/kWhr

85%Load
Some initial problems were

solved.
Operators quickly got

acquainted to the flex system.
Now the engine runs without
problem.
Service Experience
Inspection Result
2,737Hr
Conventional Parts
Piston ring / Cylinder linerVery good condition
Crank shaft gearVery good condition
Sludge accumulation in piston under side on flex
engine compared with conventional engines :
Clear, Excellent (Ship crews evaluation)
Extension of maintenance interval
2,737Hr
2,737Hr
RT-flex
Service Experience
Conclusion
RT-flex system concept works fine.
Some teething problems were experienced and
solved. Necessary feed-back for improvement were
carried out.
Operators quickly got acquainted to the flex system
and operate the engine without problem.
Overhaul inspection result of flex parts shows very
good condition.
Sludge accumulation in piston under side is clean
& excellent.
RT-flex
Service Experience
Voice of chief engineer

At June 3 2005
We are satisfied with the flex engine. Basically better
than conventional engines.
Smokeless operation at starting and shifting
slow halfspeed.
Easy handling. Electric module exchange work
requires only 15 minutes.
Simple setting of fuel injection timing.
Smooth and immediate reversing operation.
RT-flex
Improvement of Main Parts Reliability

z Main Bearing
Optimized design by Elasto Hydro Dynamic.

Application of back relief and lemon shape.
z Guide Shoe
Optimized design consideration of deformation by FEM.
Increased contact area between guide rail and guide shoe
at BDC.
z Piston Ring / Cyl. Liner
Application of Tribo-pack.
z Stuffing Box
Application of BICO-type Stuffing box.
RT-flex
RT-flex Conclusion
z High Reliability and Reduced Running Costs
z
Image1 : Is running cost of RT-flex higher?

Running cost of RT-flex decreases.
Saving fuel oil consumption.
Reducing maintenance hours.
Extension TBO and simple structure.
Image2 : Is operation of RT-flex difficult?
Easy operation of RT-flex.
Operations can quickly get acquainted to flex system and operate the engine.
Easy trouble shooting of WECS system.
z
Image3 : Is reliability of RT-flex lower?
Higher reliability of flex system was proved by good service experience more
than 70,000 hours.
RT-flex
Higher reliability of RT-flex compared with conventional

mechanical engines.

Du Sulzer RT Flex English

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Du Sulzer RT Flex English

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DU-WRTSIL RT-flex Engine

Flexible and optimum engine

Sulzer Common Rail System

Common Rail System

Sulzer Fuel Rail ~1000 bar

Flexible Injection timing, Injection

Sulzer Common Rail Pump

kept at all operation range.

Common Rail System

Exhaust Valve Drive

9Exhaust valve open / close timing can

9Optimum compression pressure can be

Flexibility of Fuel Injection Pressure

Fuel Injection Pressure of Common Rail System

Sulzer Common Rail System

Conventional injection system

Flexibility of Exhaust Valve Timing

Valve Timing [CA]

Sulzer Common Rail System

Conventional Exhaust Valve Control

100 [%] rpm

Low fuel consumption

Standard injection pattern

Smokeless operation down to 10-12 rpm R1

(13rpm for 6RT-flex50)

Merit of RT-flex Engine

Lower minimum revolution10-12 rpm R1(6RT-flex5013rpm)

Simpler engine setting.

Engine side operation stand (RTA)

Control panel (without handle)

Operation by control handle

High Reliability and Redundancy DesignTest

High Reliability and Redundancy Doubled Main Parts

Doubled common functions and sensors to ensure higher

High Reliability and Redundancy Monitoring Function

Monitoring of engine condition by sensors

Diesel Oil operation

High injection pressure

Optimized exhaust valve timing

Improvement of fuel injection

For Future Requirement

First flex Engine in the world

More than 8000 running hours

WCH Sales Kit 03May / 38 / RB

l Servo oil connecting pipes to collector

WCH Sales Kit 03May / 39 / RB

l Rail valve connections broken

l Insufficient accessibility of rail unit

WCH Sales Kit 03May / 40 / RB

l Valve drive module failures

F new print set-up for lower thermal

l Regulating behaviour unsuitable for

large swell and light ship

WCH Sales Kit 03May / 41 / RB

RT-flex Control System

Very good result on piston ring wear

Very good load pattern on crankshaft

Clean valve seat

Good injection nozzle shape

WCH Sales Kit 03May / 42 / RB

Full Inspection 5300Rhrs

Full Inspection 5300Rhrs

RT-flex Specific Parts