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Containership Propulsion - beyond Post-Panamax

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

Introduction Engine Programme power. Figure 1 shows the most impor-


Development tant steps taken, and Figure 2 shows the
Containerisation continues to grow as it present MC engine programme.
has done for a long time. While the en- The MC engine programme has now
tire world merchant fleet grew by only been in the market for 18 years, thus It is a well-known fact that the MC en-
1% in 1998, the containership fleet ex- it is a fully mature range of engines gines have sold well throughout their en-
panded by more than 10%, and this covering a unit power span of 2,400 tire lifetime, actually to an extent where
continuous growth has also led to the to more than 93,000 bhp. Through- our engines have become the industry
development of very large containerships. out the years new models have been standard in a very large number of ship
added and existing models upgraded types. The most significant new addition
The term “very large containership” it- both in terms of design features and of engines has been the launch in 1996
self has been constantly redefined over
the last decade.
Mk mep Cm
Ten years ago, a 4,500 teu containership
represented the edge of the available bar m/s
technology whereas today vessels 1981 L35MC introduced
approaching twice that capacity are a 1982 Full L-MC programme 1 15.0 7.2
reality.
1984 L-MC upgraded 2 16.2
Specialists are debating where this 1985 L42MC introduced 2 16.2 7.2
continuous increase in size is going to 1986 K-MC introduced 16.2
stop, and some say that the maximum S-MC introduced 17.0
capacity is likely to be 11,000 teu because
L-MC upgraded 3 16.2 7.6
of Suez regulations on maximum beam
and draught, and the wish for a reason- 1987 S26MC introduced 16.8 8.2
able deadweight/teu ratio. 1988 K-MC-C introduced 16.2 8.0
1991 MC programme upgraded 8.0
As main engine designers, we are obvi-
K and L-MC 5 18.0
ously following the development closely
in order for us to have the optimum main S-MC 6 18.0
engines available for present and future 1992 S26MC and L35MC upgraded 18.5 8.2
container vessels. 1993 S35MC and S90MC introduced
K90MC/MC-C upgraded 6 18.0 8.0
1994 S42MC introduced 6 18.5 8.0
1994 K98MC-C introduced 6 18.2 8.3
1995 K80MC-C upgraded 6 18.0 8.0
1996 L70MC upgraded 6 18.0 8.2
1996 S70MC-C, S60MC-C, S50MC-C 19.0 8.5
and S46MC-C introduced 19.0 8.3
1996 S80MC upgraded 19.0 8.0
1997 L80MC upgraded 6 18.0 8.0
K98MC introduced 6 18.2 8.3
1998 S80MC-C, S90MC-C,
L90MC-C introduced 19.0 8.1
S35MC upgraded 7 19.1 8.2
1999 S42MC upgraded 7 19.5 8.0
mep = mean effective pressure Cm = mean piston speed

Fig. 1: The MC programme development

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

Fig. 2: The 1999 MC engine programme

of the S46-50-60-70MC-C engines Number of engines


Number of engines
and, in 1998, of the S80 – S/L90MC-C
Type On order or delivered In service Type On order or delivered In service
engines.
S90MC-C 5 0 98 20 0
S70MC-C 15 4 Figure 3 shows references for these 90 187 135
S60MC-C 37 12 so-called compact engines and clearly 80 445 394
spells out that they are well accepted 70 724 618
S50MC-C 101 50
by the marine market. 60 1,442 1,284
S46MC-C 34 16
50 1,197 1,018
Total 192 82 In Figure 4 the total MC engine references
46 34 16
Total: 3,146,840 bhp ~ 2,314,501 kW can be seen.
42 204 182
Notable in this respect is also that 35 961 844
Fig. 3: List of reference, S-MC-C, as at 26 171 158
1999.10.01
electronically controlled versions of the
7S60MC-C, designated 7S60ME-C, Total 5,385 4,649
have been chosen as prime movers in Total: 84,198,306 bhp ~61,927,854 kW
a series of VLCCs, with two main engines
in each vessel. Fig. 4: List of reference, all MC types,
as at 1999.10.01

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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

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

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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

Length between LPP 375.0 m


80,000 perpendiculars

60,000 Breadth on BWL 55.0 m


waterline
40,000 Design draught D 13.5 m
3
20,000 Displacement ∇ 175,000 m

Service speed (knots)


0 Propeller(s)
23.0 24.0 25.0 26.0 27.0
As mentioned previously, the capability
of one propeller to absorb the main en-
Fig. 6: Propulsion power for large container vessels 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
The length, breadth and draught of the It may be necessary to have up to 22 container vessels.
ship will have to be increased signifi- containers abreast on the deck in order
cantly in order to accommodate a load to facilitate the mentioned load capa- It may be expected that the propeller
capacity of 12,000 teu. An increase of city and keep the length and draught of will have to be designed to absorb
length, breadth and draught will not the container vessel within reason. The more than 100,000 bhp to make the
only influence the hull design, but will expected dimensions of a 12,000 teu service speed of a 12,000 teu container
also require that harbours and con- container vessel, based on 22 contain- vessel exceed 24.0 knots.
tainer cranes are prepared for the new ers abreast, are shown in the table.
era of container vessels. Propulsion 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
Twin-skeg container vessel propulsion thrust.
55.0 m
Any reduction in propeller efficiency as
a result of a single propeller operating
at high load can open the door for
K98MC K90MC twin-screw container vessels. A vessel
Waterline 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. Outlines with K98MC and K90MC
type engines installed in a twin-skeg
hull are shown in Figure 7.

The future of container vessels with


two propellers will depend on the pos-
sibilities of an appropriate design of the
ship’s hull, and whether the ship’s
Fig. 7: Outlines of K98MC and K90MC engines installed in a twin-skeg hull resistance and the water flow for the

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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

23.0 knots Specified MCR Specified MCR


Margins
86,600 bhp x 104.0 r/min 2 x (39,900 bhp x 94.0 r/min)
The specified Maximum Continuous Appropriate engine: Appropriate engines:
Rating (MCR) of the main engines de- 1 x 11/12K98MC-C 2 x 7K90MC
pends not only on the results obtained
24.0 knots Specified MCR Specified MCR
from the model test/power prediction or
97,500 bhp x 104.0 r/min 2 x (45,200 bhp x 94.0 r/min)
extrapolation of actual trial results, but
also on the margins that the shipyard Appropriate engine: Appropriate engines:
chooses to include in the dimensioning of 1 x 12/14K98MC-C 2 x 8K90MC
the propulsion system. The reasons for,
25.0 knots Specified MCR Specified MCR
and the appropriate size of, sea margin,
109,300 bhp x 104.0 r/min 2 x (50,900 bhp x 94.0 r/min)
engine margin and light running margin
are described in the following. Appropriate engine: Appropriate engines:
1 x 14/16K98MC-C 2 x 9K90MC / 2 x 7K98MC
Sea margin (SM) 26.0 knots Specified MCR Specified MCR
The results from model tests are normally
125,200 bhp x 104.0 r/min 2 x (57,600 bhp x 94.0 r/min)
based on clean hull and calm weather
conditions. Therefore, it is recommend- Appropriate engine: Appropriate engines:
able to add a sea margin to compensate 1 x 16K98MC-C 2 x 10K90MC / 2 x 8K98MC

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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.

Previous Oros geometry


Features:
! High topland
! Oros piston top geometry
! CPR top ring
! Alu-coat piston rings
! Bore cooled, forged piston
of heat resistant steel
! Piston cleaning ring
Improvements:
! Approx. 100 oC 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

Verification:
! Extensive calculations
! Comprehensive tests on K90MC and
K90MC-C
! Service test on K90MC

Fig. 8: Oros combustion chamber geometry

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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

Fig. 9: Oros combustion chamber geometry

K90MC-C New Oros K98MC-C

Relative
heat load

Fig. 10: Heat loads on piston

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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.

12 The results of the NOx measurements


are shown in Figure 11 when using the
10 slide-type fuel valve and, as can be seen,
the IMO NOx compliance is ensured
8 with a good margin for both the slide-type
and the mini-sac fuel valves, which are
6 standard for all large bore MC engines.

4 This new combustion chamber design


has already been introduced on a num-
2 ber of MC engines and is the present
IMO NOx (E3-cycle) = 14.3 g/kWh
standard on all large bore MC/MC-C
0 engines.
0 25 50 75 100
Besides this very important feature, it is
Load (%-MCR) obvious that other well-known design
features have been included, such as
high-topland pistons, which reduces
Fig. 11: NOx emission for slide type fuel valve the thermal load inflicted on the piston
rings by the combustion gases. This
has improved the performance of the
Actual temperature measurements on The reduction in heat load is illustrated piston ring pack significantly, resulting
the piston top are shown in Figure 9. in Figure 10, which compares the heat in higher TBOs (time between overhauls)
A comparison with measurements on a load on a K90MC-C piston of the tradi- for the piston. Tests with high-topland
conventional piston top shows that the tional design with a K98MC-C piston of pistons were started about five years
temperature level has been lowered the new Oros design. ago on an S80MC engine and showed
substantially, by 80-90°C. a significant improvement in the general
combustion chamber condition.

The use of the high topland piston also


means that the mating surfaces between
cylinder liner and cylinder cover has
been lowered, thus reducing the thermal
load on the cylinder liner and improving
the conditions for lubricating it.
! Top piston ring with double-lap S-seal
and 6 Controlled Pressure Relief (CPR)
The piston ring pack features a top
gaps piston ring of the so-called Controlled
!
Pressure Relief (CPR ring) design. This
Even heat distribution on 2nd piston ring
reduces the thermal load on the ring
! 2nd, 3rd and 4th piston rings with oblique pack, as the leak gas flow is divided
cut ring gaps
over the six leakage grooves, Figure
! New piston ring material: RVK-C with 12. The ring height was increased to
Alu-bronze coating ensure the strength of the “finger seal”.
The lower rings are all of the oblique
cut type.
Fig. 12: CPR piston ring

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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.

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-in


coating. The advantage is reduced
Piston cleaning ring Cylinder liner
requirement for running-in time, and
fewer load limitations during running-in
after a piston overhaul. This results in
safer running-in and in cylinder oil con-
sumption savings.

Service experience has shown that the


CPR top ring solves the scuffing also for
the second ring.
Fig. 13: Piston cleaning (PC) ring

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 Cylinder oil
Cylinder
related to these two rings. The main service tank
reason was that the rings lost their
tension relatively quickly due to the Solenoid valve Solenoid valve
thermal load, which resulted in more Lubri- Lubri-
Accumulator
frequent piston overhauls. cator cator
Sensor Sensor
The use of higher 1. and 2. rings gave
a good improvement, and the tendency to
collapsed rings was greatly reduced.
Pump station
with To other
With the introduction of the Mk 5 version stand-by pumps cylinders
of the K80/90MC/MC-C engines, some
cases of scuffing occurred. These were
solved with the introduction of the CPR To other To other
top piston ring with a cermet coating cylinders cylinders
on the running surface.
Tacho Alarm
signal system
A further improvement was obtained by Control unit
Index
introducing the Piston Cleaning (PC) signal
with
Slow-down
ring. The purpose of this ring, shown in back-up system
LCD system
Figure 13, is to control ash and carbon signal
deposits on the piston topland and Indication
thus prevent contact between the operation
panel
cylinder liner and these deposits, which
would remove part of the cylinder oil
from the liner wall. Long-term tests on Fig. 14: Cylinder lubrication with Alpha lubricators

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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.

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