Professional Documents
Culture Documents
Contents Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Programme Development . . . . . . . . . . . . . . . . . . . . . . . . . .
Propulsion Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12,000 teu container vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main engines for a 12,000 teu container vessel . . . . . . . . . . . . . .
Design Aspects of Large MC Engines . . . . . . . . . . . . . . . . . . . . . .
Alpha lubricators and lube oil consumption . . . . . . . . . . . . . . . . .
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Containership Propulsion – beyond Post-Panamax
3
r/min
250 S26MC
210 L35MC
173 S35MC
176 L42MC
136 S42MC
129 S46MC-C
148 L50MC
127 S50MC
127 S50MC-C
123 L60MC
105 S60MC
105 S60MC-C
108 L70MC
91 S70MC
91 S70MC-C
104 K80MC-C
93 L80MC
79 S80MC
76 S80MC-C
104 K90MC-C
94 K90MC
83 L90MC-C
76 S90MC-C
104 K98MC-C
94 K98MC
0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 kW
4
Propulsion Aspects 12K98MC developing 93,360 bhp at The intriguing question in our opinion,
94 r/min, but engines with more cylinders however, is whether single propellers
In 1994 and 1997 we introduced the are feasible. can be designed and built to absorb
K98MC-C and K98MC engines to cater such powers, or whether the tendency
for the power requirements of large 14 and 16-cylinder versions can also would be towards twin propellers/twin
container ships. The main data of these be built, thereby expanding the power engines.
engines are shown in Figure 5. range up to some 125,000 bhp. Such
engines would be available as both tradi- To start from the (maybe) very top of
As mentioned in the introduction, the tional in-line engines and V-type engines. future capacity expectations, we have
future points towards containerships made a feasibility study of the propulsion
even larger than those being considered Although the latter form has not yet machinery for a 12,000 teu container
large today. been realised, we have investigated vessel.
this cylinder configuration in great
Figure 6 is an attempt to quantify the detail, and a large number of patents 12,000 teu container vessel
propulsion power required for such for innovative and exciting inventions
vessels. are pending. Among the advantages A 12,000 teu container vessel will need
offered by the V-type concept, com- other dimensions than have been used
As can be seen, the power requirement pared to the in-line version, are a 15 for the Panamax and Post-Panamax
for the fastest of the 10-12,000 teu per cent weight reduction and a tre- container vessels built in the last few
vessels is beyond what can be covered mendous length saving. decades.
today even by our largest unit, the
K98MC
Power/cylinder 5,720 kW
7,780 bhp
Speed 94 r/min
Mean effective pressure 18.2 bar
Stroke 2,660 mm
Bore 980 mm
Stroke/bore ratio 2.7
Mean piston speed 8.3 m/s
SFOC 126 g/bhph
171 g/kWh
Cylinders 6-12
K98MC-C
Power/cylinder 5,710 kW
7,760 bhp
Speed 104 r/min
Mean effective pressure 18.2 bar
Stroke 2,400 mm
Bore 980 mm
Stroke/bore ratio 2.45
Mean piston speed 8.3 m/s
SFOC 126 g/bhph
171 g/kWh
Cylinders 6-12
5
SMCR (kW)
12,000 TEU
120,000 10,000 TEU
8,000 TEU Length on LWL 385.0 m
6,000 TEU
100,000 4,000 TEU waterline
6
propellers can be kept at levels that for the prevailing weather conditions absorbed power at a given propeller
can match the state-of-the-art for or any increased power requirement speed, is influenced by the advance
single-propeller ships. due to deterioration of hull or propel- speed of the water to the propeller
ler(s). and, subsequently, by the increased
In theory, the open-water propeller effi- resistance of the hull at heavy weather
ciency for a twin-screw installation can The sea margin for Panamax and and/or fouled hull conditions. This phe-
be improved by up to 5%-points when Post-Panamax container vessels has nomenon is also described as a “heavy
using a larger total propeller disc area, been in the range of 20-25% and oc- running propeller”.
fewer blades, etc. This corresponds to casionally up to 30%. The sea margin
an approximately 8% saving in propul- for a 12,000 teu container vessel can It is recommendable during the design
sion power if the resistance of the ship, be kept at this level, since its sensitiv- phase to include a light running margin
wake field and thrust deduction factor ity to changes in weather conditions, (revolution margin) between the theo-
of the twin-skeg hull can be kept at approximate service speed and hull retical propeller curve through the en-
approximately the same level as for an form will be similar to those of the gine’s specified MCR point and the
ordinary hull with one propeller. Panamax and Post-Panamax con- actual layout curve for the propeller at
tainer vessels. calm weather and clean hull conditions.
The available documentation and test
results for container vessels are still Engine operation margin (EM) A light running margin of 5-7% is
scarce, but the information available The Continuous Service Rating (CSR) appropriate for a single-screw con-
from the model tests on VLCC, ULCC, is normally set at 85%-90% of the tainer vessel. The light running margin
Ro-Ro and ferries with twin-skeg hull main engine specified MCR. This for a container vessel with two fixed-pitch
and twin propellers indicates that the corresponds to an engine operation propellers could be increased somewhat
advantage in reduced propulsion power margin of 10-15% of the specified to compensate for the special running
requirement for these types of ship may MCR power. An engine operation mar- conditions when one propeller is blocked
be up to 5-8%. gin is included to provide an additional and the other propeller is in operation.
power margin that can be utilised to
A 12,000 teu container vessel with two catch up with delays in departure etc. Main engines for a 12,000 teu
engines and two propellers, including Moreover, the Specific Fuel Oil Con- container vessel
the necessary auxiliary systems and sumption is approximately 2-3% lower
modification of the hull, will without at 85-90% of specified MCR than at The appropriate choice of main engine
doubt be more expensive in first cost 100% of specified MCR. and expected specified MCR at service
than a single-propeller container vessel. speeds of 23.0, 24.0, 25.0 and 26.0
Therefore, in order for the twin-screw Light running margin (LR) knots are shown in the table below.
container vessel to be an attractive op- The performance of the propeller, i.e.
tion, the increase in first cost must be
compensated by lower operating costs
within a reasonable time frame. Service speed Hull with one propeller Hull with two propellers
7
The expected specified MCR and Design Aspects of Large of the design in order to meet new
engine types for the twin-skeg hull MC Engines demands for reliability and power.
with two propellers are based on the
assumption that the expected advan- As can be seen from the above, the One of the important steps in the
tage in propulsion performance can be main engines relevant for the very large development of the K98 engines has
utilised to its full extent. containerships are the 90 and 98 cm been to secure optimal combustion
bore engines. with low emission parameters without
The service speed and margins should, sacrificing fuel oil consumption and, at
naturally, be adapted so as to utilise The L/K90MC/MC-C were introduced the same time, protecting and con-
the nominal rating of the engines. more than ten years ago, and since trolling the heat-exposed parts in the
then some 180 engines have been combustion chamber.
The propeller speed for hulls with two ordered.
propellers may be further optimised These goals have been achieved by
through detailed investigation of the The K98MC-C and K98MC were intro- virtue of a new combustion chamber,
design of the hull and propellers. duced much later, in 1994 and 1997, called Oros geometry, developed on
and by now 20 engines have been or- the basis of advanced CFD calculations
The comprehensive programme of dered. of various chamber configurations.
90 and 98 cm bore engines from MAN
B&W Diesel offers ship designers the These include 10 x 7K98MC, With the Oros geometry (shown in
possibility of choosing propeller speeds 5 x 10K98MC-C and 5 x 12K98MC-C Figures 8 and 9), we have concentrated
freely within the range of 76.0 r/min for engines. the combustion air around the fuel
the S90MC-C engine type over 83.0 nozzles, and obtained a greater distance
r/min for the L90MC-C engine type and Since the introduction of the MC engines from the nozzles to the piston top. This
94.0 r/min for the K90/98MC engine in 1982, more than 4,600 engines have has resulted in lower heat load on the
types to 104.0 r/min for the K90/98MC-C entered service. During this long period piston top and unchanged heat load
engine types. there has been a continuous updating on the cylinder cover and exhaust valve.
Verification:
! Extensive calculations
! Comprehensive tests on K90MC and
K90MC-C
! Service test on K90MC
8
100% Load Conventional design New Oros design
9 7 7 9
5 5 13 11 1 1 3 11 13
3
3 3 9 7 5 5 7 9
2 2
11 10 8 6 1 6 8 10 11 6
Piston 12 12
14 10 6 10 14
14 4 14 15 16 15
crown 13 4
2
13 16
temperature 17 17
15 15
19 19
Gas side Mean 499 oC , max 509 oC Mean 409 oC , max 421 oC
Cooling oil side Mean 197 oC , max 209 oC Mean 185 oC, max 216 oC
Section Section
M-E M-E
Exhaust valve
temperature K D K D
M E M E
N O H G F N O H G F
Valve seat Mean 439 oC, max 456 oC Mean 448 oC, max 457 oC
Underside Mean 563 oC, max 564 oC Mean 577 oC , max 577 oC
Relative
heat load
9
The mean heat input during combustion
NOx (g/kWh) is reduced by more than 20%, and the
20 local peak heat load is reduced by
25-35%.
18
Exhaust gas emissions tests have been
16 performed with conventional fuel valves,
mini-sac fuel valves and slide-type fuel
14 valves.
10
an S80MC engine since 1994 have
shown positive results, verifying that
“bore polish” may be a decisive factor
in the deterioration of the cylinder
Cylinder cover condition. PC rings are therefore now
Piston - high topland standard on large bore MC engines.
11
The amount of oil injected can be
Cylinder Signal for lubrication controlled according to engine load
lube oil from control unit and raised as required: for example at
Pressure sensor inlet load changes or start/stop.
for
control of lubrication 45 bar
In the event of a malfunctioning solenoid
Outlets valve or transducer, the oil dosage will
for cylinder liner Injection plungers
lube oil points
automatically be increased for the
cylinder in question to the maximum
volume on the other lubricator. If the oil
Solenoid pressure fails, the computer will start a
valve standby pump and close down the faulty
P
A pump. If the computer or position sen-
T A
P sors fail, a back-up computer will take
T
over and ensure sufficient (untimed)
lubrication until the fault has been
corrected.
Spacer The system, fine tuned on MAN B&W’s
for basic setting of Adjusting Actuator
screw piston
4T50MX research engine, has returned
pump stroke
Cylinder lube oil good results on a 7S35MC engine and
outlet has now been in service for more than
one year on a K90MC engine. This sys-
tem has proved high reliability and very
Fig. 15: Cylinder lubricator unit good cylinder condition with unchanged
wear rates with a cylinder oil feed rate
that is lower than our recommendations
with the conventional mechanically
timed lubricator.
Consequently, the design has been modi- The Alpha lubrication system features
fied to a high top ring of the CPR-type, a high-pressure pump and an injector Conclusion
whereas the three lower rings are of the which injects a specific volume of oil
usual ‘low’ type. into each cylinder for every fourth With the new and by now fully tested
revolution, Figure 14. The system is K98 engine, MAN B&W is well prepared
Alpha lubricators and lube oil controlled in such a way that the oil to meet the demand for increasingly
consumption can be introduced to the individual larger main engines for containerships.
cylinder at any piston position but, This engine and other large bore MC
Reduction of the cylinder lube oil consump- preferably, when the piston rings are engines are equipped with the latest
tion represents a significant potential saving adjacent to the lubricating quills. design features known to give high
for engine operators. It is therefore an im- reliability and good operational econ-
portant development target for MAN B&W The computer sending an on/off omy.
to reduce the lube oil dosage without in- signal to a solenoid valve controls
creasing the wear rates or reducing TBOs. the injection function. After a prede-
termined time interval, the computer
Cylinder oil must be injected into the transmits an ‘off’ signal to the sole-
cylinder at the exact position and time noid valve, which shuts off the sys-
that ensures the optimal use of the lube oil. tem pressure and opens the return
Having realised that this is hardly possible oil system. The oil dosage can be
with the conventional, mechanical cylinder changed by adjusting the injection to
lubricators, we have engaged ourselves in e.g. every fifth, sixth, etc. revolution
the development of a computer controlled (or any figure in between, such as
electronic cylinder lubrication system, the “every 4.5 revolution” by alternating
Alpha lubricator, for application on current between injection every fourth and
camshaft controlled engines as well as on every fifth revolution).
computer controlled Intelligent Engines,
see Figure 14.
12