MAN B&W Diesel, Company Presentation

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel
2005.05.01 4140/PWN <1>

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN <2>

The Founding of the Company

MAN B&W Diesel

In 1843 Hans Heinrich Baumgarten establishes a

mechanical workshop in Copenhagen

In 1846 a partnership is established with

Carl Christian Burmeister and they
establish a company named
”Baumgarten & Burmeister”
The activities include a mechanical
workshop and a foundry
In 1854 a shipyard is established
In 1861 Hans Heinrich Baumgarten
retires from the company

William Wain joins the company in 1865, and the

name of the company is changed to Burmeister
& Wain (B&W)

© MAN B&W Diesel 2005.05.01 4140/PWN <4>

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 History
MAN B&W Diesel

C. C. Burmeister W. Wain

© MAN B&W Diesel 2005.05.01 4140/PWN <5>

The First B&W Diesel Engine

MAN B&W Diesel

The first B&W four-

stroke diesel engine
was delivered in 1904

Engine No. 1
Type: 140
Customer: N. Larsen,
Carriage Manufacturer,
Frederiksberg, Denmark

© MAN B&W Diesel 2005.05.01 4140/PWN <6>

The First Diesel Engine

for Ocean-going Ship Propulsion
MAN B&W Diesel

M/S Selandia, delivered to the Danish East Asiatic Company in 1912,

is the world’s first ocean-going diesel motor ship.

Type: DM 8150-X (2 x 8 cylinder engines)

Power: 2,500 IHP total
Ship’s speed: 11 knots

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 The World’s First Turbocharged
Two-stroke Diesel Engine
MAN B&W Diesel

M/S Dorthe Mærsk, delivered to

the Danish company A. P.
Møller by Odense Steel
Shipyard in 1952, is the first
ship to be powered by a
turbocharged two-stroke diesel
engine

Engine type: 674VTBF-160

Power: 7,500 BHP @ 115 r/min

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Engine Development 1952 - 1980

MAN B&W Diesel

1952: The world’s first turbocharged two-stroke engine

Type: 674VTBF-160 – Power: 7,500 BHP
(Introduced on M/S Dorthe Mærsk)
1967: Introduction of the K-EF range of engines, as well as the
large K98FF type (3,800 BHP/cyl. @ 103 RPM)
1973: Delivery of the first K-GF engine
1976: The first to introduce modern long stroke diesel engines
Type: L-GF, with a stroke-bore ratio of 2.5:1
1978: The first with constant pressure turbo charging of modern
uniflow scavenged diesel engines
1979: The first to test a rotating air-spring on exhaust valves in
service
1980: The first to introduce layout flexibility, as well as a specific
fuel oil consumption below 140 g/BHPh – Type: L-GFCA

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Diesel Chronicle
MAN B&W Diesel

1933 The first to introduce uniflow on a two-stroke engine

1952 The first to introduce turbocharging on two-stroke slow speed
diesel engines
1978 The first with constant pressure turbocharging of modern
uniflow engines
1981 The first to demonstrate engine efficiency of more than 50%
corresponding to specific fuel oil consumption figures below
125 g/BHPh
1994 The first to introduce an engine with power above 90,000 bhp
1996 The first to introduce a new generation of compact engines
1998 The first to introduce the Environmentally Friendly prop. system
2000 The first to put an electronically controlled engine into service

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 The History of MAN B&W Diesel
MAN B&W Diesel

In 1758 Eisenhütte St. Antony is established in Oberhausen

In 1840 Sander'sche Maschinen Fabrik is established in Augsburg

In 1843 Baumgarten establishes a workshop in Copenhagen

Gutehoffnungshütte Burmeister & Wain M.A.N.

Actienverein (GHH) (1865) Maschinenfabrik
is established in B&W Motor A/S Augsburg-Nürnberg
1873 (1974) (1908)

In 1921 GHH In 1979/80 B&W Motor A/S is taken over by

acquired a majority M.A.N., and M.A.N. B&W Diesel A/S is
in M.A.N. established

In 1986 M.A.N. was merged into GHH and renamed MAN AG

The divisions were hived off to form individual public limited companies

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MAN B&W Diesel A/S

A Historical Overview Since 1843
MAN B&W Diesel

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 13 >

The MAN Group - 2005

MAN B&W Diesel

61,259 employees
Turnover € 14,9 billion
PBT € 453 million

Industrial Services

Commercial Printing Machines Diesel Engines Turbo Machines Further Industrial Industrial Services Financial Services
Vehicles Holding*
MAN MAN Roland MAN MAN RENK MAN Ferrostaal AG MAN Financial
Nutzfahrzeuge AG Druckmaschinen B&W Diesel AG Turbomaschinen AG Aktiengesellshaft Services GmbH
AG MAN
Technologie AG
MAN DWE GmbH
Schwäbische
Hüttenwerke GmbH

Turnover € 7,4 billion Turnover € 1,6 billion Turnover € 1,4 billion Turnover € 0,7 billion Turnover € 3,2 billion

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 MAN B&W Diesel Group
MAN B&W Diesel

MAN Aktiengesellschaft München

100%

67% 100% 100%

S.E.M.T. Pielstick MAN B&W Diesel Ltd MAN B&W Diesel AG MAN B&W Diesel A/S
France England Germany Denmark

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Locations of MAN B&W Diesel

MAN B&W Diesel

Great Britain Denmark

Paxman MAN B&W Diesel A/S
Ruston 2.349 employees
Mirrlees Blackstone Frederikshavn Two-stroke engines
683 employees • Research and development
Four-stroke engines • Marine propulsion
• Marine propulsion Copenhagen • Power generation
• Military marine • Service
Holeby
• Power generation Rostock • Spare parts
• Rail traction Stockport • Licensor
Hamburg
Four-stroke engines
Colchester • Complete propulsion package
France • GenSets
Pielstick • Power generation
723 employees • Licensor
Four-stroke engines
Paris Germany
• Marine propulsion Augsburg MAN B&W Diesel AG
• Military marine
Saint-Nazaire 2.719 employees
• Power generation
Jouet Four-stroke engines
• Rail traction
• Service • Research & development
• Licensor • Marine propulsion
• Power generation
• Service
• Licensor

As at 31 March 2005
Total 6.474
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Worldwide Service Network

MAN B&W Diesel

Service Centres 20
AuthorisednRepair Shops 55
Licensees 15

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 Two-Stroke Licensees
MAN B&W Diesel

China Croatia Japan

HHM 1980 Uljanik 1954 Mitsui 1926
DMD 1980 Split 1984 • Makita 1981
YMD 1989 Hitachi 1951
Kawasaki 1981

Korea Poland Russia

Hyundai 1976 Cegielski 1959 Bryansk 1959
Doosan 1983
STX 1984

Spain Vietnam
IZAR – Manises 1941 Vinashin 2004

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Two-stroke Licensees
MAN B&W Diesel

As at August 2004

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MAN B&W Diesel

MAN B&W DIESEL

COPENHAGEN MAIN OFFICE

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 MAN B&W Diesel A/S, Copenhagen
MAN B&W Diesel

Main Office
Warehouse

Production of
Key Components

Factory
Administration
R&D Centre

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MAN B&W Diesel A/S, Copenhagen

MAN B&W Diesel

R&D Centre
Production of
Key Components
Factory
Administration

Warehouse

Main Office

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MAN B&W Diesel A/S, Research Centre

MAN B&W Diesel

ME Simulator
Classroom

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 Research engine 4T50ME-
4T50ME-X
MAN B&W Diesel

Engine type 4T50MX

Initial engine output 10,200 BHP
Engine speed 123 r/min
Cylinder diameter 500 mm
Piston stroke 2200 mm
Stroke to bore ratio 4.4 : 1
Firing pressure 180 bar
Mean effective pressure
Mean piston speed 9 m/s

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MAN B&W Diesel A/S, Frederikshavn

MAN B&W Diesel

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MAN B&W Diesel A/S, Holeby

MAN B&W Diesel

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 MAN B&W Diesel

12K98MC 12K98ME-C

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MAN B&W Diesel

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12K98MC
MAN B&W Diesel

Bore: 0.98 meter

Stroke: 2.66 meter
Speed: 94 rpm
Output: 93,360 Bhp
68,640 kW
Piston speed: 8.3 m/sec

Consumption per day: Height: 15 m.

Fuel oil 303 tons
Sulphur (3.5%) 10
tons Cyl. lube oil 2.0
tons Air
15,000 tons
Weight: 2,200 tons

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 MAN B&W Diesel
12K98MC

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6S35MC and 10K98MC-C on Testbed

MAN B&W Diesel

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12K98MC-C on Test bed

MAN B&W Diesel

As at January 2000
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MC Bedplate
MAN B&W Diesel

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Design Bedplate
MAN B&W Diesel

Features: K90MC, K90MC-C

ƒ Well defined and rigid main bearing housing
for thin shell main bearings
ƒ Transfer of forces to holding-down bolts and
cylinder cover through simple structure and
high quality double butt welds
Improvements:
ƒ Simple steel castings without holes for stay
bolt, giving better casting quality
K98MC-C, K98MC, S90MC-C
ƒ Stay bolts attached to top of bedplate, thus L90MC-C, S80MC-C
reducing deformation of bearing housing and
eliminating fretting in bearing saddle
ƒ Easier maintenance of holding-down bolts.
Verification:
ƒ Extensive calculation
ƒ Service experience from a large number
of S-MC-C "compact" engines
ƒ 6 years service on 4T50MX

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 Installation Aspects
MAN B&W Diesel

Side chocks, modified design

Previous design New design

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MAN B&W Diesel

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MAN B&W Diesel

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 MAN B&W Diesel

L60MC-C Bedplate
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MAN B&W Diesel

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Installation Aspects
MAN B&W Diesel

End chocks
Cast iron
end chock liner

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MAN B&W Diesel

L60MC-C Crankshaft.
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MAN B&W Diesel

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K98FF (1966) Versus K98MC (1999)

MAN B&W Diesel

2800 kW per cylinder 5720 kW per cylinder

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MAN B&W Diesel

L60MC-C Landing Crankshaft in Bedplate

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MAN B&W Diesel

L60MC-C Crankshaft in Bedplate

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Earthing Device
MAN B&W Diesel

Spark erosion in main bearings

Bronze: Propeller = +

Potential difference
< 50 mV
V
Main bearing

Current Earthing device

Steel: Hull
=÷ Intermediate shaft
Propeller shaft

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MAN B&W Diesel

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MAN B&W Diesel

L60MC-C A-Frame
Mounted on Bedplate.
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 Design Features
MAN B&W Diesel

Crosshead Latest design Traditional design

• Telescopic pipe mounted in wide guide shoes

• No need to dismantle the telescopic pipe at overhaul of piston
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 MAN B&W Diesel

L60MC-C Frame Box Exhaust Side.

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 Crankcase relief valve
MAN B&W Diesel

Test equipment for

Relief Valves

ONLY
Hoerbiger type EVN
and
Mt Halla type HCSG-N

Approved by MAN B&W

© MAN B&W Diesel 2005.05.01 4140/PWN < 133 >

Crankcase relief valve

MAN B&W Diesel

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Crankcase relief valve

MAN B&W Diesel

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 Crankcase relief valve
MAN B&W Diesel

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Crankcase Explosion
MAN B&W Diesel

Cases of explosions where the cause is known

Year Cause of Explosion Cause of Failure

1995 Bearing in PTO gearbox

1996 Inlet pipe for piston cooling oil falling off Incorrect tightening
1997 Incorrect spring mounted in piston rod stuffing box Unauthorised spare part
1997 Piston rod interference with cylinder frame
1999 Weight on chain tightener falling off Incorrect tightening
1999 Fire outside the engine
2000 Main bearing
2000 Camshaft bearing
2000 Incorrect shaft in camshaft drive Unauthorised spare part
2001 Crankcase failure
2001 Piston crown failure
2001 Main bearing
2001 Crankpin bearing
2002 Inlet pipe for piston cooling oil falling off Incorrect tightening

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Deformation of Flame Arrester

MAN B&W Diesel

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 Simplification of Cylinder Frame
MAN B&W Diesel

Previous design New design

Cooling
water
inlet

Cooling
water
inlet

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Cylinder Liner and Frame Configuration

MAN B&W Diesel

S-MC S-MC-C

Cylinder liner:
ƒ Low position of mating surface cylinder
cover/cylinder liner
ƒ Slim cylinder liner
ƒ Straightforward cooling jacket

Cylinder frame:
ƒ Smaller and lighter
ƒ Uncooled and straightforward design

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S70MC-C versus S70ME-C

Cylinder Frame
MAN B&W Diesel

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Vibration Aspects
MAN B&W Diesel

General terms
Internal forces
Piston

Crosshead

α
T

N
P S
S

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L60MC-C Camshaft

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MAN B&W Diesel

L60MC-C Top Cover for Camshaft Housing

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The New S-MC-C Engines

MAN B&W Diesel

Camshaft arrangement for MC-C

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Alpha Lubricator System

MAN B&W Diesel

Signal for lubrication

Alpha lubricator Inductive feedback
from control unit
sensor for control of
piston movement

Outlets for
cylinder liner
lub. oil Injection plungers
injectors

Solenoid
valve
T

Spacer Adjusting screw Actuator piston Cylinder Cylinder

for basic setting Lub. oil outlet lube oil inlet
of pump stroke

© MAN B&W Diesel < 173 >

Alpha Lubricator System

MAN B&W Diesel

Alpha lubricator Inductive feed-back

Signal for lubrication
from control unit
Solenoid valve - activated sensor for control of
piston movement

Outlets for
cylinder liner
lub. oil Injection plungers
injectors

Solenoid valve

Cylinder Cylinder
lube
lube oil inlet
Spacer oil outlet
for basic setting Adjusting screw Actuator piston
of pump stroke

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 Alpha lubricator
Nordic Brasilia – 6S70MC-E
MAN B&W Diesel

Lubricators

Intermediate
box with
feedback
indication

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MAN B&W Diesel

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Alpha Lubricator System

MAN B&W Diesel

Pump Station

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 Cylinder Liners
MAN B&W Diesel

Injection nozzle

Injection nozzle
with non-return Cylinder liner
valve

© MAN B&W Diesel < 178 >

Cylinder Condition
MAN B&W Diesel

Timing of cylinder oil injection

25 Injection pressure
Pressure bar Alpha lubricator

20

15

10

Oil quill pressure Injection pressure

5 mechanical lubricator

0
0 10 20 30 40 50 60 70 80 90 ms Time
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Combustion Chamber Design

S-MC-C and S50MC
MAN B&W Diesel

S-MC-C S-MC
ƒ Piston with high top land
Cylindrical top land

ƒ Piston ring further

away from combustion
space
Top land

ƒ Lower mating surface

between cylinder cover
and cylinder liner
Mating
ƒ First piston ring special surface
patented CPR ring

ƒ PC ring

ƒ Bronze band

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 K90MC-C Design
MAN B&W Diesel

Combustion chamber

Features:
• High top land Previous New
• Oros shape of piston top
• CPR top piston ring
• Alu-coat piston rings
• Bore cooled, forged piston of heat resistant steel
• Piston cleaning ring

Improvements:
• Approx. 100 °C lower temperature on top compared
with 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

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Combustion Chamber Layout

MAN B&W Diesel

Combustion chamber engines – Piston rings

• High 1st piston ring to accommodate CPR

design
• Optimal pressure drop over the upper piston
ring reduces the heat load on the second
piston ring significantly
• All piston rings Alu-coat

Good performance of the piston

ring pack means high reliability of
the combustion chamber
components and the cylinder
condition

Controlled Pressure Relief (CPR) gaps

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MAN B&W Diesel Service

MAN B&W Diesel

Genuine spare parts

Piston ring with controlled pressure

relief (CPR piston ring)

• Reduced differential pressure on

piston ring No. 2

• Reduced temperature on
piston ring No. 2

© MAN B&W Diesel 2005.05.01 4140/PWN < 187 >

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 Piston Ring CPR Alu Coat
MAN B&W Diesel

Pressure relieved
0,25 mm Wiew from E
E F

F-F
Alu coat
D

D A

© MAN B&W Diesel 2005.05.01 4140/PWN < 188 >

Cylinder Condition
MAN B&W Diesel

Controlled pressure relief piston ring (CPR)

90 and 98 bore engines

F F
F
F F
A
3 mm

© MAN B&W Diesel 2005.05.01 4140/PWN < 189 >

MAN B&W Diesel Alu-Coated Piston Ring

Genuine spare parts

A-A
Developed at our Alu-Coat
Research Centre

• Reduced running-in
time by more than 50%
A A
• Thus saving cylinder oil

• Thickness: about 0.3 mm

© MAN B&W Diesel 2005.05.01 4140/PWN < 190 >

47
 MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 191 >

Alu-coated Piston Ring

MAN B&W Diesel

Ring pack 1st ring: Type: CPR

with Alu-Coat
High

2nd ring: Type: RM5,

oblique cut
with Alu-Coat
Low

3rd ring: Type: RM5,

oblique cut
with Alu-Coat
Low

4th ring: Type: RM5,

oblique cut
with Alu-Coat
Low

High topland piston crown

1st piston ring with increased height
Copper band on piston skirt

© MAN B&W Diesel 2005.05.01 4140/PWN < 192 >

K90MC-C Design
MAN B&W Diesel

Combustion chamber
Previous New
Features:
• High topland
• Oros shape of piston top
• CPR top piston ring
• Alu-coat piston rings
• Bore cooled, forged piston of heat resistant steel
• Piston cleaning ring

Improvements:
• Approx. 100 °C lower temperature on top compared
with 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

© MAN B&W Diesel 2005.05.01 4140/PWN < 193 >

48
 Production
MAN B&W Diesel

Piston and piston rings

Oros Piston

ALU Coated
Piston Rings

© MAN B&W Diesel 2005.05.01 4140/PWN < 194 >

Combustion Chamber Layout

MAN B&W Diesel

Piston – high top land

Cylinder cover

Piston – high top land

Cylinder liner

Piston cleaning ring

© MAN B&W Diesel 2005.05.01 4140/PWN < 195 >

“Bore polish” from topland deposits.

MAN B&W Diesel

• Example of heavy deposits

on the piston topland, being
polished from rubbing
against the liner running
surface

© MAN B&W Diesel 2005.05.01 4140/PWN < 196 >

49
 “Bore polish” from topland deposits.
MAN B&W Diesel

Example of,
polished liner
surface, from
heavy
deposits on
the piston
topland,
rubbing
against the
liner surface.

© MAN B&W Diesel 2005.05.01 4140/PWN < 197 >

Piston Rod and Stuffing Box

for S-MC-C
MAN B&W Diesel

• Hardened piston rod

• Higher scraper ring tension
• Reduced piston rod drain oil amount

© MAN B&W Diesel 2005.05.01 4140/PWN < 198 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 199 >

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 MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 200 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 202 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 203 >

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 MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 204 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 205 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 206 >

52
 MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 207 >

MAN B&W Diesel

Piston for
puncture valve
Puncture valve
high pressure
Drain Fuel pump top cover
High
pressure Suction valve
fuel to
fuel valve

Fuel pump barrel

Fuel pump housing

Fuel pump plunger

Fuel inlet

Lube hole

High pressure fuel Drain

Low pressure fuel
Atmospheric air

© MAN B&W Diesel 2005.05.01 4140/PWN < 208 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 209 >

53
 MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 211 >

Fuel Valve
MAN B&W Diesel

Circulation Start of opening

Fuel oil inlet
injection
Fuel oil outlet
circulation

Open Closed Closed

© MAN B&W Diesel 2005.05.01 4140/PWN < 212 >

Performance
MAN B&W Diesel

Fuel Valves

Conventional fuel valve Mini-sac valve Slide-type fuel valve

Sac volume 1690 mm3 Sac 520 mm3 Sac volume 0 mm3

© MAN B&W Diesel 2005.05.01 4140/PWN < 213 >

54
 Slide-type Fuel Valve
MAN B&W Diesel

Now used
as standard

Possibility for
retrofit

Conventional fuel valve Slide-type fuel valve

Sac volume 1690 mm3 Sac volume 0 mm3

© MAN B&W Diesel 2005.05.01 4140/PWN < 214 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 215 >

Fuel Valve, Spring Housing

MAN B&W Diesel

Malfunction due to incorrect tightening

Tightening torque for engines up to 70MC = 60Nm

For large bore above 70MC = 65Nm
SL 94-316

© MAN B&W Diesel 2005.05.01 4140/PWN < 216 >

55
 MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 217 >

6L80MC
MAN B&W Diesel

Damaged Piston Crown

Reason: Fuel valves in bad condition

© MAN B&W Diesel 2005.05.01 4140/PWN < 218 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 219 >

56
 MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 220 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 221 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 222 >

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 MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 223 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 224 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 225 >

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 MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 226 >

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 227 >

“Finish with Engine”

MAN B&W Diesel

© MAN B&W Diesel 2005.05.01 4140/PWN < 228 >

59