Module 1

Marine Diesel Engine

Development History
 Anna Volkova,
the author of this module,
is fully liable for the content, authenticity and
accuracy of the information
You will be able to:
1. list types of internal combustion engines
2. describe stages of engine development
3. compare types of scrubber systems
Essential сcompetency: explain the necessity of marine diesel engine development

Lesson 1
Internal combustion engines

ENGAGE:

a) Discuss the questions.

 What is internal combustion engine?

 Why is it called “internal”?
 What types of engines do you know?
 What do they differ in?
 What is the most common engine type used on board a ship? Why?
 Have you already had your sea practice? What was the engine on board?
 Who was in charge of the main engine?
 Have you participated in any maintenance works related to the ME?
 What, do you think, are the common faults of all ME?

b) Match the words with the definitions.

1. induction Just before top dead center (TDC) fuel is injected into the
cylinder by the fuel injector. The fuel is "atomized" into tiny
droplets. Because they are very small, these droplets heat up very
quickly and start to burn as the piston passes over TDC. The
expanding gas, from the fuel burning in the oxygen, forces the
piston down the cylinder, turning the crankshaft.
2. exhaust The crankshaft is rotating clockwise and the piston is moving
down the cylinder. The inlet valve is open and a fresh charge of
air is being drawn or pushed into the cylinder by the
turbocharger.
 3. power As the piston approaches the bottom of the cylinder (known as
Bottom Dead Centre or BDC) the exhaust valve starts to open.
As the piston now moves up the cylinder, the hot gases are
expelled from the cylinder. As the piston approaches TDC again
the inlet valve starts to open and the cycle repeats itself.

4. compression The inlet valve has closed and the charge of air is being
compressed by the piston as it moves up the cylinder.

c) Label the figure below.

__________________ __________________ __________________ _________________

ACTIVATE I:

a) Complete the missing information in the scheme sharing your ideas.

b) Name as many as you can remember.

2-STROKE ENGINE PARTS

c) Match main components names with their descriptions.

1. engine block forged in one piece; counterweights are fitted on every web;
high degree of balancing results in an even and thick oil film
for all bearings
2. crankshaft made of tri-metal type with steel back, lead bronze lining and
a soft and thick running layer
3. connecting rod hardened for good wear resistance; the set consists of two
directional compression units and one spring-loaded
conformable oil scraper unit; all of them have a wear-resistant
chromium plating
4. main bearings has a high and rigid collar to minimise deformations; the
material is a special grey cast iron alloy developed for
excellent wear resistance and high strength; accurate
temperature control is achieved with precisely positioned
longitudinal cooling water bores; to eliminate the risk of bore
polishing, it is equipped with an anti-polishing ring; the
cooling water space between block and itself is sealed off by
double o-rings; in the upper end it is equipped with an anti-
polishing ring to eliminate bore polishing and reduce lube oil
consumption
5. big end is of composite design with nodular cast iron skirt and steel
bearings crown; its skirt is pressure lubricated, which ensures a
controlled oil distribution to the cylinder liner under all
operating conditions; oil is fed to cooling gallery in the piston
top through the connecting rod
6. cylinder liner designed for easy maintenance with only four hydraulically
tightened studs; no valve cages are used, which results in very
good flow dynamics in the exhaust gas channel; the exhaust
valve seats are water-cooled and all valves are equipped with
valve rotators; the seat faces of the inlet valves are stellite-
plated; in case the engine is specified for MDO operation
only, also the exhaust valves are stellite-plated; engines that
are intended for operation on HFO have nimonic exhaust
valves
7. piston can be both tri-metal and bi-metal
8. piston rings made of nodular cast iron in one piece for all cylinder
 numbers; the main bearing caps are fixed from below by two
hydraulically tensioned screws, they are guided sideways by
it at the top as well as at the bottom; hydraulically tensioned
horizontal side screws support the main bearing caps
9. cylinder head hydraulically tightened; the gudgeon pin bearing is of tri-
metal type; oil is led to the gudgeon pin bearing and to the
piston through a bore in it; made of alloy steel, forged and
machined with round sections; the lower end is split
horizontally to allow removal of piston and itself through the
cylinder liner

d) Study the cross-section below. Define the engine type. Remember more of parts
names.

bedplate exhaust port turbo-blower crankshaft

 air inlet ports connecting rod A-frame piston rod

exhaust bottom end piston crosshead

manifold bearing

e) Study another cross-section. Define the engine type. Remember more of parts
names.

gudgeon pin cylinder head connecting rod

 crankcase bottom end bearing cam
cylinder rocker arm water cooling passage
fuel injector exhaust valve piston
crankpin camshaft

f) Think over the following.

DIFFERENCE BETWEEN
2-STROKE ENGINE 4-STROKE ENGINE
Number of revolutions

Maintenance

Speed

Power

Cost

Energy efficiency

Lubrication

Valve operating mechanism

Weight

STUDY:

a) Fill in the gaps with the words from the box.

induction exhaust valves piston compression up

piston blower bottom inlet ports variations
down two strokes valve lower four-stroke

The ________________ of power followed by compression are required to

complete one cycle. The events of injection, combustion, expansion and
________________ of the gases take place in the four-stroke engine, but the exhaust of
the burnt gases and the ________________ of air take place at the ________________ of
its stroke, this being a chief difference between the two-stroke cycle and the
________________ cycle.
There are ________________ in two-stroke cycle engines. The most common one
is that it has inlet ports and ________________. The inlet holes or ports are in the
________________ section of the cylinder liner wall. The piston uncovers the inlet ports
as it moves ________________ the cylinder. The ________________ covers the inlet
ports as it moves ________________ the cylinder. This action has the same effect as a
________________ opening and closing. An engine driven scavenge ________________
is fitted and the incoming air is blown into the cylinder through the ________________
when they are uncovered by the ________________.
 b) Complete the sentences.

1. The engines can be of __________________________________________________

2. One cycle is completed by ______________________________________________
3. 4-stroke cycle engine’s operation is ________________________________________
4. 2-stroke cycle differs in _________________________________________________
5. Upward piston movement _______________________________________________
6. Downward piston movement _____________________________________________
7. Scavenge blower ______________________________________________________

ACTIVATE II:

a) Consider the following and suggest if they are TRUE or FALSE.

1) The two-stroke cycle is completed in one revolution of the crankshaft.

2) The fresh air in 2-stroke cycle is supplied without being pressurized.
3) The air is used to moisturize exhaust gases to let them settle down and to charge the space
with fresh air.
4) The ports are opened and closed by the piston sides as it moves.
5) The bottom end of the connecting rod is attached to the crosshead bearing.
6) There is the valve in the cylinder head for the release of the exhaust gases.
7) The incoming air is supplied being de-pressurized.
8) Main bearings support the crankshaft within the engine bedplate.
9) The entablature consists of the bedplate, house guides and crosshead.
10) The main difference between the two cycles is the speed delivered.
11) 2-stroke cycle engine loses a lot of power output due to inefficient scavenging.
12) 2-stroke cycle engines are normally better choice in terms of weight ratio, since they are
lighter than 4-stroke cycle engines.
13) 2-stroke engine requires difficult to handle valve operating mechanism.
14) 4-stroke engines operate poorly at high speeds, but consume less lubricating oil.
15) 2-stroke engines require regular and accurate maintenance of the reduction gearbox.
16) Medium-speed 2-stroke engines deliver approximately 80— 100 rev/min.
17) 4-stroke engines operate at medium speed (250 and 750 rev/ min), therefore require the
reduction gearbox when used as the main propulsion.
18) 2-stroke engines don’t require any auxiliary blowers due to turbo-charger provides enough
air.
19) The four-stroke cycle is completed in four revolutions of the crankshaft.
20) The inlet and exhaust valves in the 4-stroke engines are housed in the cylinder head and held
shut by springs.
21) The piston in 4-stroke engine is joined to the connecting rod by a piston rod.
22) The crankshaft in 4-stroke engine is arranged to drive through gears the camshaft, which
operates rocker arms which open the inlet and exhaust valves.
23) 4-stroke engine’s supports the camshaft and houses the camshaft bearings.
24) The cylinder and cylinder head are arranged with air-cooling passages around them.

b) Complete the definitions.

1) Crankshaft is a part of a marine engine, which ________________ of a firing cylinder from

the reciprocating piston to the ________________ (or alternator in case of a generator).
2) Piston is the lower part of the ________________, seals the cylinder and transmits the gas
pressure to ________________, absorbs heat of combustion, comprises of two pieces:
________________.
3) Crosshead piston comprises of ________________ (used in large two stroke engine) which
is connected to crosshead to transfer the ________________ to the engine structure.
4) Trunk piston comprises of piston with elongated skirt to ________________ and attached to
the connecting rod by ________________ (used in small 4 stroke marine engines).
5) Piston rod helps in transmitting the power produced in the combustion space to
________________ and the running gear of the engine.
6) Piston skirt is fitted in both two stroke and four stroke engines. It has different functions for
different engines. In large cross head two stroke engines with uni-flow scavenging these
skirts are short in length and are fitted to act as ________________ and to stabilise
________________ inside the liner.
7) In four stroke or trunk piston engines the skirt has arrangement for ________________,
which transmits power from the piston to the gudgeon pin or ________________. As there
are no ________________ in four stroke engines, these skirts help in transferring the side
thrust produced from the connecting rod to the liner walls.
8) Piston wear ring is a ring made of soft bronze alloy with lead, which is fitted in
________________.
9) Connecting rod is a component of a marine engine that ________________ in the engine
block to the crankshaft.
10) Crosshead bearing in a large two stroke slow speed engine transfers the power generated in
the combustion chamber to ________________.
11) Cylinder liner a hollow cylindrical shell which acts as ________________.
12) Cylinder head acts as ________________ thereby providing an enclosed space where the
combustion can take place.
13) Reduction gearbox is used to convert ________________ to those required to rotate
the propeller. Gearboxes consist of ________________ on pinions and wheels which
________________ to a driven shaft and reduce speed.
14) On two-stroke diesels, electrically-driven auxiliary blowers are usually provided because
________________.
15) Camshaft is a shaft fitted with one or more cams and driven by ________________.
16) The rocker arm is the part responsible for transmitting ________________ towards the
intake and exhaust valves of the engine.

c) Divide into 2 groups. Match the following to get phrases.

GROUP 1

1. the main the crankshaft

2. the complicated valve at low engine speed
3. the cylinders, cylinder heads and the propeller
4. cannot provide enough air difference between
5. attached to a operating mechanism
6. reduction gearbox between it and the scavenge trunking
7. revolution of power
8. develop twice the crosshead bearing
9. forms part of the close the inlet and
10. a mechanism to open and inlet and exhaust valves
11. rocker arms which open the crankshaft

GROUP 2

1. pressurised by a exhaust gases

2. inefficient scavenging and other at temperature
 3. scavenge the propeller speed
4. rotary losses
5. is fully primed and turbo-blower
6. consumes less passages around them
7. with a gearbox to provide exhaust gases
8. the release of lubricating oil
9. water-cooling the crankshaft bearings
10. held shut movement of the crankshaft
11. supports the cylinders and houses a cylinder head
12. at the top by by springs

d) Read the text below and complete it with the phrases matched previously.

The two-stroke cycle is completed in two strokes of the piston or one

________________. In order to operate this cycle, where each event is accomplished in a very
short time, the engine requires a number of special arrangements. First, the fresh air must be
forced in under pressure. The incoming air is used to clean out or ________________ and then
to fill or charge the space with fresh air. Instead of valves, holes, known as 'ports', are used
which are opened and closed by the sides of the piston as it moves. The piston is solidly
connected to a piston rod which is ________________ at the other end. The top end of the
connecting rod is also joined to the crosshead bearing.
Ports are arranged in the cylinder liner for air inlet and a valve in the cylinder head
enables ________________.
The incoming air is ________________ which is driven by the outgoing exhaust gases.
The crankshaft is supported within the engine bedplate by the main bearings. A-frames are
mounted on the bedplate and house guides in which the crosshead travels up and down. The
entablature is mounted above the frames and is made up of ________________.
________________ the two cycles is the power developed. The two-stroke cycle engine,
with one working or power stroke every revolution, will, theoretically, ________________ of a
four-stroke engine of the same swept volume. ________________, reduce the power advantage.
For a particular engine power, the two-stroke engine will be considerably lighter—an
important consideration for ships. Nor does the two-stroke engine require ________________ of
the four-stroke. The four-stroke engine however can operate efficiently at high speeds which
offsets its power disadvantage; it also ________________.
Each type of engine has its applications which on board ship have resulted in the slow-
speed (i.e. 80— 100 rev/min) main propulsion diesel operating on the two-stroke cycle. At this
low-speed the engine requires no ________________.
The four-stroke engine (usually rotating at medium speed, between 250 and 750 rev/ min)
is used for auxiliaries such as alternators and sometimes for main propulsion ________________
of between 80 and 100 rev/min.
The reason for circulating fuel in large two-stroke engines is to ensure the system
________________. Oil that has been recirculated in a diesel engine fuel system normally
returns to a buffer/vent/mixing tank. On two-stroke diesels, electrically-driven auxiliary blowers
are usually provided because the exhaust gas-driven turbo-charger ________________.
Auxiliary blowers are internal parts of the main engine.
The four-stroke cycle is completed in four strokes of the piston, or two revolutions of the
crankshaft. In order to operate this cycle the engine requires ________________ exhaust valves.
The engine is made up of a piston which moves up and down in a cylinder which is
covered ________________. The fuel injector, through which fuel enters the cylinder, is located
in the cylinder head. The inlet and exhaust valves are also housed in the cylinder head and
________________. The piston is joined to the connecting rod by a gudgeon pin. The bottom
end or big end of the connecting rod is joined to the crankpin which ________________. With
this assembly the linear up-and-down movement of the piston is converted into
________________. The crankshaft is arranged to drive through gears the camshaft, which
either directly or through pushrods operates ________________. The camshaft is 'timed' to open
the valves at the correct point in the cycle. The crankshaft is surrounded by the crankcase and the
engine framework which ________________. The cylinder and cylinder head are arranged with
________________.

e) Complete the missing information in the figure below using the prompts.

intake port is combustion transfer port is exhaust valve

covered and chamber covered closed
valve forced
closed
 intake valve downstroke piston crankcase
open

valves closed intake valve spark plug exhaust valve

closed open

fuel is spark plug firing piston pushes air-fuel mixture

compressed and out burnt gases is drawn in
ignited

crankshaft explosion forces valves closed connecting rod

piston down

air-fuel mixture exhaust gases upstroke fuel mixture is

is compressed drawn into
crankcase

valve open transfer port is air fuel mixture burnt fuel is

uncovered and pushed out by
fuel mixture compressed fuel
forced into mixture
cylinder

f) Look at the figures and decide the operation of which diesel engine is shown. Prove
your opinion.

g) Make up a summary about types of internal combustion engines.

 Lesson 2
Otto and Diesel cycles

ENGAGE:

a) Answer the questions.

1. When was ICE invented?

2. Who was the inventor?
3. What do you know about him?
4. Have you heard of other inventors of engines of any types?

b) Find out what do the following words have in common.

Otto diesel invention fuel Diesel engine Nikolaus development combustion first Rudolph

c) Match the synonyms.

1. few set up
2. capable exact
3. initiate implement
4. devise several
5. particular trust
6. apply able
7. rely on design

d) Complete the text with some of the words from the previous task or/and add your
own ones.

Ever since its first ________________ in 1912, the internal combustion engine has come
to dominate marine propulsion with only a very ________________ vessels making use of any
other form of motive ________________. ________________ power in the form of turbines is
still used on some new ________________ carriers and it is also employed in some
________________ heat recovery systems where the heat from an engine and other sources is
used to produce steam for ________________.
Most internal combustion engines used by ships are ________________ engines; that
does not mean that they are ________________ of running only on diesel fuel but that they
________________ the Diesel cycle for combustion of the ________________.

ACTIVATE I:
 a) Comment on the following quote.

b) Google for the best synonyms or definitions for the following.

further
success
series
subsequent
commercial
viability
to be threatened
attempt
vanish
presumably
expire
commit a suicide

c) Fill in the gaps with the words from the box below.

ignition compression joined in unsuccessful commercial

successful built efficiency attempts process
common prototype invention interest committing
steam breakdown development set up vanished
expire slow burning

Rudolf Diesel, who is best known for the ________________ of the engine that bears his
name, was born in Paris, France in 1858. His invention came while the ________________
engine was the predominant power source for large industries. In 1885, Diesel
________________ his first shop in Paris to begin development of a compression
________________ engine. The process would last 13 years. In the 1890s, he received a number
of patents for his invention of an efficient, ________________, ________________ ignition,
internal combustion. From 1893 to 1897, Diesel further developed his ideas at Maschinenfabrik-
Augsburg AG (later Maschinenfabrik-Augsburg-Nürnberg or MAN).
In addition to MAN, Sulzer Brothers of Switzerland took an early ________________ in
Diesel’s work, buying certain rights to Diesel’s invention in 1893. At MAN in Augsburg,
________________ testing began with a 150 mm bore/400 mm stroke design on August 10,
1893. While the first engine test was ________________, a series of improvements and
subsequent tests led to a ________________ test on February 17, 1897 when Diesel
demonstrated ________________ of 26.2% with the engine.
The first Sulzer-________________ diesel engine was started in June 1898.
________________ of Diesel’s invention needed more time and work to become a
________________ success. Many engineers and developers ________________ the work to
improve the market viability of the idea created by Rudolf Diesel. He, on the other hand, became
somewhat threatened by this ________________ and was not always able to find
________________ language with other engine designers developing his invention.
Diesel’s ________________ of market promotion of the not-yet-ready engine eventually
led into a nervous ________________. In 1913, deeply troubled by criticisms of his role in
developing the engine, he mysteriously ________________ from a ship on a voyage to England,
presumably ________________ suicide. After Diesel’s patents started to ________________, a
number of other companies took his invention and developed it further.

d) Complete the chart.

Rudolph Diesel known for,

date of birth, place of birth
1885

1890s

1893-1897

MAN

Sulzer brothers

Prototype testing

First engine test

Following test

1898

Diesel’s worries and

problems
Nervous breakdown

Vanished

STUDY:

a) Complete sentences with the words from the box.

considered | ignited | apply | particular | initiating | devised | consume

1) Back in the 19th century when internal combustion engines were in the very early stages of
development, two men Nikolaus Otto and Rudolph Diesel ________________ different
means of ________________ combustion of the fuel.
2) Otto’s method was to compress the fuel to a ________________ volume and to then
________________ a source of ignition in the form of a spark.
3) Diesel’s method was to continue to compress the fuel until it ________________
spontaneously due to the heat produced by the higher compression used.
4) At similar pressures, the Otto engines are ________________ more efficient but because
diesel engines make use of much higher pressures, in practice they are more efficient and
________________ less fuel.

b) Mark the statements as FACTS or SOMEBODY’S OPINIONS.

 Nowadays, engines that burn fuel oil mostly rely on the Diesel cycle.
 Dual-fuel engines have not been designed yet, because of difficulties in alternative ignition
source.
 Wartsila has never produced any dual-fuel engines.
 Until 1930s marine diesels were only four-stroke and ran on distillate fuels.
 At present times, most large cargo vessels are equipped with huge two-strokes with their
better weight ratio.
 High-speed diesels are rarely encountered on commercial ships except as generators.

ACTIVATE II:

a) In groups, match halves to get sentences.

GROUP 1

1. Ever since its first use in 1912, the on diesel fuel but that they rely on the
internal combustion engine has come to Diesel cycle for combustion of the
dominate marine propulsion with fuel.

2. Steam power in the form of turbines is to then apply a source of ignition in

still used on some new LNG carriers the form of a spark.
and it is also employed in some waste

3. Most internal combustion engines used
by ships are diesel engines; that does
not mean that they are capable of
running only
4. Back in the 19th century when internal
combustion engines were in the very
early stages of development, two men
Nikolaus Otto
5. Otto’s method was to compress the fuel
to a particular volume and
6. Diesel’s method was
more efficient but because diesel
engines make use of much higher
pressures, in practice they are more
efficient and consume less fuel.
only a very few vessels making use of
any other form of motive power.
to continue to compress the fuel until
it ignited spontaneously due to the
heat produced by the higher
compression used.
and Rudolph Diesel devised different
means of initiating combustion of the
fuel.

7. At similar pressures, the Otto engines heat recovery systems where the heat
are considered from an engine and other sources is
used to produce steam for electric
generation.

GROUP 2
1. Modern oil burning engines by injecting a small quantity of diesel oil
mainly rely on directly into the combustion chambers as
pilot fuel which ignites by compression
ignition as in a conventional diesel engine.
2. Wärtsilä dual-fuel engines make after injection.
use of the lean-burn Otto process
in which

3. Premixed air-gas mixture in the the Diesel cycle but dual-fuel engines need an
engine combustion chambers alternative ignition source when operating in
and ignition is obtained gas mode.

4. By way of contrast, in MAN are regularly used for propulsion in small

Diesel’s high-pressure ME-GI tugs, work boats and ferries.
DF engines

5. The gas burns immediately are the engine of choice for most large cargo
vessels.

6. As is to be expected both makers are used for most other ship types.
claim advantages for their
systems and it is for users

7. Until the mid-1930s marine gas is admitted into the air inlet channels of
diesels were invariably four- the individual cylinders during the intake
stroke and ran on stroke to give a lean.

8. Today the giant two-strokes with distillate rather than residual fuels.
their better power to weight ratio

9. Medium speed four-stroke the gas is injected only after the combustion
engines either as propulsion air is compressed, after which it is ignited by
units or powering gensets in a the pilot oil injection.
diesel-electric system
10. High-speed diesels are rarely to judge which best suits their own purposes.
encountered on commercial
ships except as generators but

b) Complete the chart.

1. When have ICE started to

dominate other forms of motive
power?

2. Is steam power still in use

nowadays?
3. Which ICE are used mostly?

4. Are ICE capable of running on

diesel fuel only?

5. Which method is applied for

combustion of the fuel?

6. Who devised means of initiating

combustion?

7. What are two combustion methods

known?

8. Describe Otto’s method.

9. Describe Diesel’s method.

10. Whose method is more efficient?

11. Which cycle do modern engines

rely on?

12. Describe Wartsila dual-fuel

engines working operation.

13. Describe MAN Diesel’s high-

pressure ME-GI DF engine
working operation.
14. What were marine diesels until
mid-1930s?

15. What are marine engines today?

Lesson 3
Sabathe and Trinkler cycles

ENGAGE:

a) Discuss the questions.

 When was the first use of ICE?

 Are engines capable of running only on diesel fuel?
 What other alternatives to diesel fuel can you suggest?
 Who are inventors of ICE?
 Which ICE is more efficient: Otto’s or Diesel’s? Why?
 Have you ever heard about Sabathe or Trinkler?
 Could you share your ideas on they are famous for?

b) Complete the mind map.

c) Read the text and title it.

____________________________________________

The dual combustion cycle (also known as the mixed cycle, Trinkler cycle or Sabathe
cycle) is a thermal cycle that is a combination of the Otto cycle and the Diesel cycle, first
introduced by Russian-German engineer Gustav Trinkler, who never claimed to have developed
the cycle though. Heat is added partly at constant volume (isochoric) and partly at constant
pressure (isobaric), the significance of which is that more time is available for the fuel to
completely combust. Because of lagging characteristics of fuel this cycle is invariably used for
Diesel and hot spot ignition engines. It consists of two adiabatic and two constant volume and
one constant pressure processes.
The dual cycle consists of following operations:
 Process 1-2: Isentropic compression
 Process 2-3: Addition of heat at constant volume.
 Process 3-4: Addition of heat at constant pressure.
 Process 4-5: Isentropic expansion.

STUDY I:

a) Fill in the definitions using the words from the box.

adiabatic | lagging | to claim | isochoric | isobaric | significance

1. ________________ is defined as a process in which no heat transfer takes place.

2. ________________ is the act of falling or staying behind.
3. In thermodynamics, an ________________ process, also called a constant-volume
process, an isovolumetric process, or an isometric process, is a thermodynamic process during
which the volume of the closed system undergoing such a process remains constant.
4. ________________ means to ask for, especially as the right.
5. An ________________ process is one that takes place at constant pressure.
6. ________________ means having the quality of being "important" — meaningful,
essential.

b) Complete the sentences with the words from the previous task.

 The ________________ of what was happening was clearer to me than to him.

 ________________ (meaning of the same weight or pressure) may refer to: in
thermodynamics, i.e., one that is carried out at constant pressure.
 A thermodynamic process taking place at constant volume is known as the
________________ process.
 Don't forget ________________ for the travel expenses after you join the vessel.
 An ________________ process is a thermodynamic process which involves the transfer of
energy without transfer of heat or mass to the surrounding.

c) Complete the sentences.

1. Sabathe cycle _______________________________________________________________.

2. ________________ engineer Gustav Trinkler _____________________________________.
3. ________________________________________________________ Sabathe/Trinkler cycle.
4. ________________________ lagging characteristics of fuel __________________________.

d) Put the operations in correct order.

___ Rejection of heat at constant volume.

___ Isentropic expansion.
___ Addition of heat at constant pressure.
___ Addition of heat at constant volume.
___ Isentropic compression.

ACTIVATE I:

a) Study the image below. Consider the following:

EARLY CI engines vs MODERN CI engines

What is the difference?
 b) Label the image below, using the prompts from the box.

power stroke constant volume heat addition actual cycle

process
compression process expansion process compression stroke

intake stroke constant pressure heat addition exhaust stroke

process
constant volume heat rejection process dual cycle

c) Complete the text below answering the questions.

The growing demand to reduce engine emissions in recent years has led to interest in
engines fueled by ________________ (What may engines be fueled by?), which can
significantly reduce ________________ (What hazardous emissions’ names can you
remember?). This has led to recognition of the potential for marine engines fueled by natural
gas to help reduce marine environmental problems.
To prevent air pollution from ships, regulations covering pollutants such as
________________ (What are the 2 pollutants that are considered the most dangerous?)
specified under the 1997 International Maritime Organization (IMO)/MARPOL Convention
came into force in 2005 (________________ (What is the name of the regulation controlling
the pollutants discussed?) ). These regulations were followed in 2011 by the
________________ (What is the name of the regulation?) (a 15 to 22% reduction on Tier 1),
________________ (What is the name of the regulation?) (an 80% reduction on Tier 1) to
come into force for certain maritime regions starting from 2016. Similarly, to reduce greenhouse
gases (GHGs), ________________ (What is the name of the technical measure that deals
with CO2 output?) for CO2 emissions were introduced from 2013. This requires a 10%
reduction in CO2 emissions by 2015 and a 20% reduction by 2020.
The most important plus of fuel conversion to natural gas is that ________________
(Why is it so advantageous?). This is in contrast to other technologies, each of which only
works for certain exhaust emissions.

d) Study the figures below. Check if you were right completing the previous task.
Consider the questions below.

1) What pollutants are being addressed by the regulations?

2) What do you know about Kyoto Protocol and its goals? Which of the pollutants did it deal
with?
3) What do you know about EEDI? Which of the pollutants does it deal with?
4) What regulations address NOx emissions? Have you ever heard of them?
5) What do you know about EPA?
6) What regulations address sulfur emissions? What are the goals?

7) What environmental technologies for marine engines can you name?

8) Comment on SCR. Which pollutant does it address? What are the drawbacks?
9) Comment on scrubbers. Which of pollutants does it address and to which extent? What are
the drawbacks?
10) Comment on EGR. Which of pollutants does it address and to which extent? What are the
drawbacks?
11) Comment on emulsion. Which of pollutants does it address? What are the drawbacks?
12) Comment on gas engine application. What are the drawbacks? What are the advantages?
13) Decide on the best technology. Prove your opinion.

STUDY II:

a) Match the words with their definitions.

1. redundancy evaporated or boiled LNG vapor

2. impact something that is produced in the course of making

another thing
3. utilize to replace one with the other

4. rig to get something from something else, by using industrial

or chemical processes
5. objective installation used in drilling for natural oil and gas
deposits
6. boil-off to come into view

7. intention a powerful effect that something has on something

8. switch to be good enough or have the right qualities to meet the

requirement
9. spread an idea or plan of what someone (something) is going to
do
10. byproduct safe, protected, shielded, sheltered

11. amount amounts that are more than what is needed; extra,
 additional
12. extraction duplication in mechanical or other equipment so that
operations can continue if one part fails to operate
13. appear recommendations, instructions, advice, proposal

14. satisfy to use

15. secure quantity, total

16. guidelines to reach or affect a larger area or more people

17. excess purpose, aim, goal

b) Complete the sentences below using some of the words from the previous task in a
correct form.

 Vacuum type piston engine ________________ coal gas combustion instead of steam.
 Application of ICE strongly ________________ after they were invented and continues
________________ until today.
 After the Second World War there were large ________________ of cheap petroleum oil in
regions such as the Middle East.
 Oil ________________ produced a lot of natural gas.
 Natural gas is a ________________ produced by oil rigs.
 Large amounts of natural gas are being produced by oil rigs in the process of oil
________________.
 LNG tanker ________________ gas is normally used as fuel for ME.
 The reason for gas engines to appear was to burn ________________ natural gas.
 Modern dual-fuel engines’ ________________ is to reduce environmental
________________.
 In order to ________________ the market requirement for environmentally-friendly marine
engines, diesel engines may be upgraded to operate on natural gas.
 Today’s DF engines are being built with an ________________ to decrease the
environmental impact.
 In case if natural gas engines are used on ships, certain ________________ requirements
have to be satisfied in order to ensure safe and smooth operation.
 Technical and manufacturer’s ________________ must be provided and retained on board.
 DF engines are capable of ________________ from one fuel to another in case of need.
 2-stroke DF engines have ________________ only recently.

ACTIVATE II:

a) Decide if the statements below are TRUE or FALSE.

1) Gas engine is an innovative technology of the XXI century.

2) ICE gained its popularity after the WWII.
3) Natural gas is a byproduct of oil extraction.
4) Dual-fuel engines are all based on diesel-ignited gas engines that use liquid fuel to ignite the
gas fuel.
5) The reason why dual-fuel engines appeared in the market was to limit the liquid fuel
consumption due to its global shortage and high cost.
6) Ship technical guidelines provide safety and redundancy requirements which are
recommendatory only and are not mandatory to satisfy.
7) First practical DF engines were 4-stroke only.

b) Complete and title the text below. Use the words from a) task of the STUDY II
section.

____________________________________

Gas engines have a very long history dating back to the invention, just 20 years after
James Watt invented the modern steam engine in 1785, of a vacuum type piston engine that
________________ coal gas combustion instead of steam. This is now recognized as the first-
ever internal combustion engine.
Use of internal combustion engines strongly ________________ after the Second World
War when large ________________ of cheap petroleum oil began to be produced in regions
such as the Middle East. To make effective use of the natural gas produced by oil
________________ as a byproduct of oil ________________, this led to the burning of the gas
in diesel engines by mixing it with the intake air. This was the first example of a dual-fuel
engine. Many different types of dual-fuel engines have been developed since then, many of
which have been either diesel-ignited gas engines that use liquid fuel to ignite the gas fuel, or
mixed combustion engines in which LNG tanker ________________ gas or the
________________ natural gas from oil extraction is used together with another fuel. While
these types of dual fuel engines ________________ market requirement when the
________________ was to utilize ________________ natural gas as a additional fuel, engines
that use natural gas with the ________________ of reducing environmental ________________
must operate by using natural gas as much as possible.
Safety and ________________ requirements specified in ship classifications technical
________________ must be satisfied if natural gas engines are to be used on ships. That is, there
is a need for ________________ provision of backup for the case of gas-fueled operation being
lost due to a problem in the fuel supply system or engine. Dual-fuel engines that are able to
________________ between gas and liquid fuel are recognized as satisfying this requirement.
Such switchable dual-fuel engines were first developed in the late 1990s as four-stroke
engines. Practical two-stroke dual-fuel engines did not ________________ until 2010.

c) Comprehension questions.

1) Are gas engines considered recent inventions?

2) What does gas engine differ from vacuum type piston engine in?
3) When and why have ICEs become common to be used?
4) What was the point in promoting gas engines development and use?
5) Is there just one type of DF engine?
6) What do diesel-ignited gas engines differ from mixed combustion engines in?
7) Is there any excessive natural gas nowadays?
8) Why have gas engines become common to be used nowadays?
9) What are certain requirements that have to be satisfied if natural gas engines are to be used?
10) Are DF engines capable of switching between fuels?
11) When were switchable DF engines developed?
12) Which type of engine was first?

Lesson 4
 Combustion process

ENGAGE:

a) Comment on the following.

ACHIEVING EFFICIENT COMBUSTION:

What is required?

b) Answer the questions below. Explain the importance of the following for ensuring
efficient combustion.

 What is known as fuel treatment? How important is it in ensuring efficient combustion?

 Why does fuel temperature matter? How is it connected with volume of emissions produced?
 What happens if there is no sufficient oxygen available? Why is it of importance?
 How does injection timing influence combustion process?
 What is known as atomization? What factors influence its appropriateness?
 What is required for proper penetration of the fuel? Why is it important?
 How can proper air fuel mixing be achieved?
 How do compression pressure and temperature influence combustion process?
 What is necessary to be done to ensure that?

c) Give definitions for the following. Google, if necessary.

fuel-to-air ratio (lean/rich)

stoichiometric condition
compression ratio
knocking combustion
misfiring combustion
excess air ratio

ACTIVATE I:

a) Watch some videos. Check if you were right.

b) Decide if the statements below are TRUE or FALSE. Correct the FALSE ones if you
can.

1) There are four elements required for combustion: oxygen, heat, fuel and pressure.
2) The fuels used on aboard are liquid hydrocarbon fuels.
3) Marine distillate and residual fuels cannot be burnt in the liquid form.
4) Residual fuels require no pre-treatment before combustion.
5) The fuels must be delivered to the cylinder in a way which generates vapor.
6) Combustion oxygen is delivered by the flywheel.
7) The amount of air delivered influences the efficiency of combustion.
8) The black smoke from the funnel upon starting an engine is an indication of insufficient air is
being supplied.
9) Stoichiometric mixture is an ideal ratio of temperature and pressure.
10) A spark is an ignition source initiating combustion.
11) Diesel engines rely on an external ignition source such as a spark igniter or pilot flame.
12) Steam boilers rely on the temperature of the air charge in the cylinder, after compression,
being above the self-ignition temperature of the fuel to provide the ignition source.
13) Once ignition takes place, the combustion will be continuous as the main flame vaporizers
the fuel and heats it to above the flash point.
14) Flash point is the temperature at which fuel boils.
15) Fire point is the temperature at which the fuel will give ff combustible vapors which can be
ignited by an external ignition source in the presence of air.
16) The temperature at which a combustible mixture will ignite without an external source of
ignition is known as self-ignition temperature or autoignition temperature or the temperature
of spontaneous combustion.

c) Watch the video. Check if you were right.

d) Complete the table below.

Combustion elements

Fuels used on board

Turbocharger

Black smoke from the

funnel
Stoichiometric
mixture
Ignition sources (3)

DE ignition source

Steam boiler ignition

source
Flash point

Fire point

Self-ignition
temperature

e) Comprehension questions.

1) How many and what elements are required for the combustion process to occur?
2) What are the fuels used on board?
3) Do marine distillate and residual fuels require any treatment prior to (before) combustion?
Why?
4) What should be the form of fuels delivered to the cylinder?
5) What is the purpose of the fuel system?
6) What is the purpose of the turbocharger in combustion process?
7) What is the connection between the amount of air delivered and combustion efficiency?
8) What does black smoke out of the funnel when engine is started indicate?
9) What is known as stoichiometric mixture?
10) How is ignition normally achieved in the presence of oxygen and fuel? Name 3 sources.
11) What is an ordinary ignition source for diesel engines? What are these engines called?
12) What is an ordinary ignition source for steam boilers?
13) What makes the combustion process continuous?
14) What is known as flash point of a fuel?
15) What is known as fire point of a fuel?
16) What is known as self-ignition temperature of a fuel? What are other ways it may be called?

STUDY:

a) Match the words with their meanings.

1. surface area in the area that is close/near to something

of a cylinder
2. penetration open to view, uncovered, being without protection

3. swirl plate a lot of tiny drops of water in the air, which make it difficult to see
very far
4. break up into spread equally
droplets
5. tend to state or condition of confusion, movement, or agitation; disorder

6. even it is obvious that it will happen

distribution
7. in the vicinity advisable, recommendable

8. ratio enclosed space in which a very hot fire is made

9. mist it happens often and is likely to happen again

10. predictable the total space covered by the flat surfaces of the bases of the
cylinder and its curved surface
11. burner tip the maximum area in which something can reach or detect things

12. exposed used to control the injection of fuel into the burner; distribute the
fuel into the airstream to achieve proper mixing
13. furnace the distance travelled by the fuel particle inside the combustion
chamber just before burning
14. range of the process by which a single mass of fluid breaks into several
smaller fluid masses
15. turbulence proportion between two amounts showing the number of times
one value contains or is contained within the other
16. desirable adds turbulence, mixing the gas and air to provide a blended mix
to the blower

b) Complete the following using the words from the table below.

droplets referred to distribute referred to

desirable combustible surface area evenly
range turbulence achieve ratio

A mixture of fuel and air will only be ________________ if the fuel is vaporized and the
________________ of fuel to air is within the flammable ________________. It is easier to
vaporize the fuel if the ________________ exposed to the heat source is large compared to the
mass of fuel. It is therefore necessary to break the fuel up into very small ________________.
This process is ________________ as atomization. In a diesel engine, it is ________________
that the whole volume of the combustion chamber is used. It is therefore necessary to
________________ the fuel throughout the combustion chamber. This distribution is
________________ as penetration. The fuel and air must be mixed so that the fuel and oxygen
are ________________ distributed to ensure that combustion is as complete as possible. To
________________ this, it is necessary to create the correct mixing conditions, in particular, to
control the air movement or ________________.

c) Answer the following questions.

 What measures have to be taken to ensure the fuel and air mixture is combustible?
 What makes it easier to vaporize the fuel?
 How much of combustion chamber volume should be used to ensure proper combustion?
 What is the principal difference between atomization and penetration?
 Why is it required to control turbulence and air movement?

d) Match the following to get phrases.

1. compressed air or steam to atomization to take place

2. tend to penetrate further mist
3. vaporize in the of the injector
4. be predictable if correct scavenge ports
5. the distance into turbulent air
6. form a very small droplets
7. lack of the burnet unit
8. generate conditions for hot cylinder
9. penetration of fuel in the cylinder
10. shape and position of mixing of air and fuel
11. the breakup of a liquid fuel into assist the process
12. fuel reaching cylinder penetration
13. much greater than that than small droplets
14. swirl plate of components
15. movement of air of the solid liquid stream
16. over rich in the vicinity travelled by the fuel

e) Listen to the audio and complete the information below using the phrases matched
in the previous task.

Atomization is the term used to describe ________________________________ which,

when mixed with air, ________________________________. In this state, the surface area of
the fuel is ________________________________ and the fuel will therefore heat up rapidly
and ________________________________ or boiler furnace. The purpose of the diesel engine
fuel injector valve is to ________________________________ as the fuel enters the combustion
chamber. Similarly, a boiler burner tip will help create the conditions for atomization often using
________________________________.
Penetration can be thought of as ________________________________ once it enters
the combustion chamber or furnace. Insufficient penetration will lead to the fuel air mixture
being ________________________________ or burner tip, leading to incomplete combustion.
Excess penetration may lead to ________________________________ or furnace walls. Large
fuel droplets ________________________________. Over atomization may therefore lead to
________________________________.
Turbulence is the term used to describe ________________________________ prior to
and during the combustion process. The movement has to
________________________________ is to be achieved. Air turbulence is generated in the
diesel engine cylinder by the ________________________________ and valves and the shape
of the piston crown and other combustion chamber components. In the boiler furnace, this is
achieved by the ________________________________. Correct
________________________________ will ensure good distribution and an even mixture.

ACTIVATE II:

a) Complete the information below suggesting your own ideas.

1) When the three elements: ________________ are present in the right conditions then
________________ will occur and ________________ will follow.
2) The whole purpose of the combustion process is to convert the ________________ that the
fuel contains into heat energy which can then be converted into ________________.
3) In the diesel engine the released heat energy from combustion of the fuel, and the associated
pressure rise, act directly on the piston to produce the power to ________________ and in
turn ________________ or other equipment.
4) In a steam boiler, the released energy is used to generate ________________ which is
normally used to ________________.
5) Stoichiometric mixture is the mixture of ________________ that would theoretically result
in complete combustion of the fuel.
6) The amount can be calculated by considering exactly how much air is required for the
________________ of each of the elements within the fuel.
7) For the fuels considered, the main elements will be hydrogen, carbon and
________________ although other elements and contaminants are also taken into account.
8) In practice, however, the combustion process requires more ________________ than this
ideal minimum.
9) In the diesel engine cycle, the short period available for the whole process of fuel injection,
mixing with air, ignition and combustion, means that complete combustion is
________________.
10) For the fuel combustion to be as complete as practically possible, ________________ is
needed.
11) Excess air may be as much as ________________ more than the ideal minimum.
12) In a steam boiler furnace, it is easier to mix the fuel and air at entry and a much smaller
amount of ________________ is required.

b) Consider the following.

MJ/kg
 What is it?
 What does it measure?
 What elements of marine fuels, to your mind, are the major sources of energy?
 What, do you think, is the energy equivalent of marine fuel?
 What, do you think, is the energy equivalent of hydrogen?
 What, do you think, are the products of combustion of hydrogen?
 Have you heard anything about hydrogen-powered engines?
 Do you think they may substitute conventional diesel engines?
 What, do you think, is the energy equivalent of Sulphur?
 What, do you think, are the products of combustion of Sulphur?
 Do you think the combustion products of Sulphur are environmentally-friendly?
 What is the difference between oxygen and atmospheric air?
 What emissions, do you think, may be considered atmospheric pollutants?
 What do you know about MARPOL Annex VI legislation?
 Do you think complete combustion is possible?
 What are the noncombustible elements that originate from fuel or air supply?

c) Watch or listen to the video. Check if you were right.

d) Complete the text below.

The heat energy equivalent released during combustion of the hydrogen and carbon in
marine fuel is the ________________ for both the diesel engine and the steam boiler. It is
normally referred to the amount of energy equivalent as the higher or lower value of the heat of
combustion which is measured in ________________ (MJ/kg). Taking into account the heat
energy required to produce water vapour, gives the lower value of heat of combustion for those
substances where water vapour is a product of combustion. The other elements found in marine
fuels have much lower energy equivalents than ________________. As the concentration of
these other elements increases, the overall heat of combustion of the fuel reduces. Marine fuels
typically have an energy equivalent of between ________________ and ________________
MJ/kg.
Hydrogen has an energy equivalent for the higher value of heat of combustion of
approximately ________________ MJ/kg and a lower value of approximately
________________ MJ/kg. The chemical equation for the complete combustion of hydrogen in
oxygen shows the products of combustion are ________________.

Sulphur has an energy equivalent for heat of combustion of approximately

________________ MJ/kg. The chemical reaction of Sulphur with an oxidant can produce a
number of different oxides of Sulphur generally referred to as ________________. The chemical
equation for the complete combustion of Sulphur in oxygen can be shown in stages and depends
on ________________ available. The products of combustion are ________________.

When combined with water or water vapour, the Sulphur dioxide and Sulphur trioxide
can also form either ________________. These products contribute to ________________ when
present in exhaust emissions.
 The products of complete combustion for pure hydrocarbon fuels would be only
________________ if the stoichiometric amount of pure oxygen was used.

However, the combustion process is not supplied with oxygen directly, but with
________________ which contains a high proportion of ________________ as well as other
trace elements. Also, marine fuels often contain ________________ which will burn and
produce its own products of combustion.

Obviously, any other elements that are present in the fuel, and any excess
________________, will produce other products of combustion. All of these additional products
will be emitted to the atmosphere in the exhaust gas. Some of these emissions are regarded as
________________ which are harmful to the environment and are considered undesirable
components of the exhaust gas. Recent legislation, particularly, the introduction of
________________ VI, regulates the permitted levels of these undesirable components in
exhaust gas emissions.

The exhaust gas from the diesel engine will contain all of the expected products of
combustion, plus a high amount of the ________________, which was not used during
combustion process. In addition to those already discussed, there will also be products of
________________.
 Since complete combustion is ________________ to achieve in practice, then
combustion of marine fuel results in the formation of other products of combustion. These will
include ________________, ________________, and ________________.

There will be incomplete combustion of some of the elements in the fuel resulting in
emission components as shown in the list. Sulphur in the fuel leads to the formation of oxides of
Sulphur referred to as ________________. The nitrogen in the combustion air can form a
number of different oxides which are referred to as ________________. The NOx and SOx can
combine with ________________ in the atmosphere to produce ________________ which
contribute to acid rain. Noncombustible elements, such as ________________ and
________________, originating from the fuel or air supply, will pass through the combustion
process unchanged or partly oxidized. All of these will pass out with the exhaust gas and can be
________________.

Lesson 5
Gas/fuel engines

ENGAGE:

a) Read and comment on the following.

 Knocking
 Availability of fuel
 Additional plant requirement
 ________________ engines perform best under moderate to high load.
 Existing engines suffer from major increases in CO and HC emissions.
 ________________ engines suffer from loss of fuel efficiency at light loads.
 This is because they operate unthrottled, so that the air-fuel mixture becomes leaner as the
load is reduced. As the mixture becomes leaner, combustion eventually degrades, leaving
large amounts of partial reaction products in the exhaust.

What is the list dedicated to? Title it.

What engine category does the list describe?
Do you agree/disagree with the list?
Do you believe the technology has its future in shipping? Comment.
Is the technology being applicable in conventional vehicles?
What advantages of the technology may be considered?

b) Watch the video. Answer the questions.

 Which combustion process is utilized by DF engines when operating on gas?

 When does the process of gas and air mixing occur?
 What is gas and air mixture ignited by?
 How is pilot fuel fed into the cylinder?
 When do inlet air valves open?

c) Label the image below. Complete its description.

Left: ________________ stroke

As the piston moves ________________, a mixture of ________________ and
________________ is drawn into the cylinder. The gas is injected in the inlet channel via a
________________.
Middle: ________________ stroke
As the piston moves ________________, the mixture is compressed. The mixture is poor, which
means that ________________ volume is large. Due to this, the mixture does not
________________ spontaneously.
Right: ignition by ________________
Just before the ________________ position of the piston, the fuel is injected into the cylinder
under ________________. This ignites immediately causing the ________________ mixture to
ignite.

ACTIVATE I:

a) Consider the following questions.

 What are DF engines’ modes of operation?
 When, do you think, DF engine should run in fuel oil only mode?
 Do you think NG should be pressurized before it is delivered into the cylinder unit?
 What should be the pressure of NG?
 What is used to maintain NG pressurized?
 Do you think NG should be cooled or heated before it is delivered into the cylinder unit?
Prove.
 What devices should be used to prevent pressure drops?
 What can you say about the requirements to gas supply line design?
 Do you think there are any safety devices controlling the process? Warning or shutdown?
 What should be used for lubrication of parts and sealing of gas?
 What would be the result of jammed gas injection valves?
 How, to your mind, the system is protected from undetected pressure drop?
 What would be the result of late ignition while burning gas?
 What would be the result of pilot fuel oil system failure?

b) Do the text quiz. Check if you were right.

When engine is well supplied with natural gas, amount of ________________ (1) fuel
injected is corresponding to 6% of the total engine load. When gas supply to the engine is
constant and limited, then engine is said to be in “Specified Gas Mode”. Here gas supply is
constant, but fuel oil quantity injected ________________ (2) to meet changing engine load
demand.
In “Fuel Oil Only” mode, gas supply will not be available, and engine runs only on fuel
oil. This mode is used when engine is ________________ (3), such as during restricted waters,
heavy weather, manoeuvring, etc.
Natural gas is compressed to about 250-300 bar using a number of ________________
(4), working in series. Compressed gas is then ________________ (5) and led to valve blocks of
each cylinder unit.
Each valve block is fitted with an ________________ (6) (it has a capacity to store about
20 times of the amount of gas injected to the unit at full load) for minimizing pressure
________________ (7) during injection and to monitor pressure drop in case of any abnormality
in the system (such as gas injection valve stuck open).
The gas supply pipe lines are ________________ (8) walled. Compressed air is passed
between the two walls (air seal), which is continuously monitored for any gas
________________ (9).
Outer wall of the gas pipe is made of stainless steel to withstand very ________________
(10) temperatures, in case of a leakage from inner pipe.
When the flow of compressed air between the gas supply pipe walls fail, the gas supply
________________ (11) and the line is purged with inert gas.
For lubrication of parts and sealing of gas, gas injectors are supplied with
________________ (12). (It is pressurized to about 25-30 bar above gas injection pressure, and
is injected and burnt along with the gas).
________________ (13) of the sealing oil is very low, in the order of 0.13 g/kWh.
The sealing oil system consist of two pumps for ________________ (14) and a spring
loaded accumulator to maintain the sealing oil pressure, since standby pump takes time to
________________ (15) pressure when one pump fails.
When a gas injection valve is stuck open (jammed), then gas pressure drops at the
accumulator in the valve block, resulting in gas system ________________ (16) and pipe lines
are purged with inert gas.
 If the pressure drop is not detected in the above case, then more gas burn, exhaust
temperature rises. This results in gas supply ________________ (17).
In the case of late ignition while burning gas, there will be rapid pressure
________________ (18) in the exhaust system, because exhaust gas ________________ (19) is
designed to withstand 15 bar pressure.
Failure of pilot fuel oil system result in combustion ________________ (20) of gas, then
gas supply shut down and lines are purged with inert gas.

1. a) distillate b) ignited c) pilot

2. a) varies b) same c) rises
3. a) stable b) controlled c) unstable
4. a) pumps b) compressors c) generators
5. a) cooled b) heated c) pressurized
6. a) receiver b) accumulator c) pump
7. a) rise b) increase c) drop
8. a) double b) single c) triple
9. a) sensor b) control c) leakage
10. a) low b) high c) hot
11. a) slow b) restart c) shutdown
12. a) springs b) sealing oil c) liquid
13. a) quality b) consumption c) grade
14. a) control b) error c) redundancy
15. a) open up b) reduce c) build up
16. a) slow b) shutdown c) restart
17. a) shutdown b) slow c) error
18. a) drop b) rise c) fall
19. a) control b) receiver c) boiler
20. a) failure b) improvement c) change

c) Label the image below using the prompts. Mind, some of the prompts are fake.
pilot fuel line compressors gas admission valve cylinder unit

exhaust gas receiver inlet channel spark arrester nozzle pipes

gas supply pipe accumulator pilot fuel injection valve block

valve (combined)

d) Complete the information below providing your own ideas.

IACS (International Association of Classification Societies) require following safeties in

DF engines:
— use ________________ only while starting the engine;
— use ________________ only during unstable engine conditions, such as ________________,
________________, etc.;
— engine should continue to run on ________________ even when gas supply stops;
— crankcase ________________ to be fitted in way of each crank throw;
— construction and operation of pressure relief valve of engine units should consider
________________ inside the engine and subsequent (following) pressure rise;
— ________________ system of the engine to be independent and not to be mixed with any
other systems;
— air starting line to each unit to be fitted with flame ________________;
— flame arrester to be fitted at the ________________ of the gas supply valve to the units;
— apart from automatic shut down system, gas supply must be able to shut ________________
from engine starting platform or other control stations.

STUDY:

e) Match the synonyms.

1. occur get the result, accomplish

2. lean include, contain, integrate
3. propagate thin, slim, fat-free
4. knock arrive at, get to
5. achieve uniform, the same
6. deviate cover, fill
7. spark bang, beat, strike
8. homogeneous help, support, develop
9. incorporate adapt, change, fix
10. promote happen, take place
11. reach flicker, flash
12. initiate detonate, ignite, launch
13. plug begin, start, launch
14. adjust produce, generate, increase
15. set off differ, vary

f) Complete the sentences below using the words from the previous task in the correct
form.

1. High flame temperature ________________ the oxidation of the nitrogen.

2. High auto ignition temperature of natural gas means that combustion does not
________________ simply by injecting it into the compressed air.
3. Natural gas engines require an ignition source to ________________ combustion.
4. ________________ or diesel fuel atomization is required by natural gas engines to initiate
combustion.
5. Four-stroke engines require pre-mixed ________________ mixture of the fuel and air to be
introduced into the cylinder.
6. The formation of NOx can be reduced by using a pre-mixed fuel-air mixture with a
________________ fuel-to-air ratio.
7. In case of gas engines, it is necessary for the ignited flame to ________________ through the
unburned fuel mixture until combustion is complete.
8. Because of an increase in load, the unburned fuel mixture may ignite spontaneously before it
is ________________ by the propagating flame.
9. If spontaneous ignition ________________ a chain reaction, this can result in serious
damage to the engine.
10. The type of combustion known as ________________ must be avoided in gas engines.
11. If the load changes continuously, there is an increased risk of knocking or misfiring due to
operation ________________ from the target excess air ratio.
12. To ________________ high output while aiming to keep the excess air ratio in the
intermediate zone between the regions where knocking or misfiring occur, many recent gas
engines ________________ mechanisms for ________________ the excess air ratio in
accordance with operating conditions.

g) Complete the sentences below using the words from the table below.

1) It is a difficult job and crew should be paid ________________.

2) The term electronics ________________ electrically-induced action.
3) These terms will be used ________________ the manual.
4) The accident that happened was ________________ because of human error.
5) CE ________________ comes to ECR to do his paperwork.
6) This was not an easy decision, ________________, a decision was dictated by the duty.
7) The fuel ________________ ignites because of the high temperature and pressure.
8) There is ________________ no difference!
9) The delay was ________________ heavy traffic.
10) 2E is careful, ________________ motorman takes risks all the time.
11) The oiler from the Philippines spent ________________ two years on board.
12) There is one manual ________________ that may help you to refresh your knowledge.
13) Never apply water to a burn ________________ the casualty is still in contact with electric
current.
14) CE must give clear instructions and standing orders ________________ everyone
understands him.
15) The piston was so hard to overhaul ________________ because we have never done that
before.
16) ________________ certificate of competence, officers should get endorsements.

simply spontaneously whereas in particular

due to while generally accordingly
partially throughout so that in addition to
referred to continuously however absolutely

ACTIVATE II:

a) Match the following to get phrases.

GROUP 1
 1. ignition output
2. excess combustion
3. turbocharger temperature
4. lower combustion the engine
5. engine mixture
6. fuel-air inlet
7. known as air ratio
8. supplied to ignite
9. expected air ratio
10. initiating load
11. mixture to temperature
12. target excess knocking
13. air source

GROUP 2

1. exhaust load
2. engines risk
3. propagating air flow
4. changes in nitrogen
5. compression plug
6. intake incorporate mechanisms
7. speed of the air
8. compressed mixture
9. increased pipe
10. unburned reaction
11. chain ratio
12. leaner fuel mixture
13. spark flame
14. oxidation of the turbocharger

b) Title and complete the texts below using the phrases matched in the previous
activity.

________________
Four-stroke diesel engines compress their intake air (or fuel mixture) by a ratio of
between 1/14 and 1/16 and this increases the ________________ to between 300 and 350°C.
Atomized diesel fuel is then injected into the compressed air causing it to react immediately with
the surrounding oxygen, ________________. The fuel burns locally, in almost the stoichiometric
condition, and the high flame temperature promotes the ________________ contained in the air.
This is why the NOx levels for diesel combustion are so high.
________________
In the case of a gas engine, the high auto ignition temperature of natural gas means that
combustion does not occur simply by injecting it into the ________________. Accordingly,
natural gas engines require an ________________ to initiate combustion. Generally, a
________________ or diesel fuel atomization is used to achieve this. In the case of a four-stroke
engine, a pre-mixed homogeneous mixture of the fuel and air is introduced into the cylinder.
Here, the formation of NOx can be reduced by using a pre-mixed ________________ with a
leaner fuel-to-air ratio (excess air ratio > 1, meaning more air than is required by the
stoichiometric ratio), because it results in a ________________ in the cylinder (see Fig.1).
 Figure 1

The way combustion should work in a gas engine is for the ignited flame to propagate
through the ________________ until combustion is complete. However, if the thermal load and
combustion pressure in the cylinder increase for some reason, such as an increase in load, the
unburned fuel mixture may ignite spontaneously before it is reached by the ________________.
If spontaneous ignition sets off a ________________, this can result in serious damage to the
engine due to severe pressure or temperature increases. This type of combustion is
________________, and it is something absolutely to be avoided in gas engines (see Fig.2).

Figure 2

Ways of avoiding knocking include reducing the ________________ to reduce the

compressed air temperature, and increasing the excess air ratio as high as possible (using a
________________) to reduce the combustion temperature. However, reducing the temperature
by too much may cause misfiring due to failure of the ________________. And because
misfiring may result in fires due to unburned fuel mixture escaping into the ________________,
it is something to be avoided.
Fig.3 below shows gas engine combustion characteristics, where the horizontal axis
represents the ________________ and the vertical axis represents ________________.
Knocking occurs when output is high in the region where the excess air ratio is around one,
whereas the region in which misfiring occurs is at higher excess air ratios. When developing a
gas engine, the combustion conditions are selected so as to avoid the excess air ratio being in the
regions where knocking or misfiring occur when operating under the ________________.
However, when the load changes continuously, as is the case when used for ship propulsion,
there is an ________________ of knocking or misfiring due to operation deviating from the
________________. In particular, because the inlet air flow depends on the ________________,
the engine may fail to operate under load due to the turbocharger speed being unable to follow
quickly to ________________.
 Figure 3

To achieve high output while aiming to keep the excess air ratio in the intermediate zone
between the regions where knocking or misfiring occur, many recent gas ________________
for adjusting the excess air ratio in accordance with operating conditions. Fig.4 below shows one
such mechanism for adjusting the ________________. In addition to the main intake passage, it
equips a bypass that returns some of the intake air to the ________________. A bypass valve in
the bypass closes under full load so that all the air discharged by the turbocharger is
________________, but it partially opens under partial load by adjusting valve opening angle to
maintain the correct intake air flow to the engine.

Figure 4

c) Define if the statements are TRUE or FALSE. Correct the FALSE ones.

1) During compression stroke in 4-stroke DE the air temperature rises to between 300 and
350°C.
2) NOx levels for diesel combustion are lower than those for gas combustion.
3) In order to initiate combustion, NG engines require a spark plug.
4) The reduction in NOx formation in NG engines is achieved by fuel-air mixture with a leaner
fuel-to-air ratio.
5) Knocking combustion refers to the chain reaction caused by the spontaneous ignition of the
unburned fuel mixture.
6) Flame propagation in NG engines is the proper way to achieve complete combustion and
ensure knocking combustion.
7) If the knocking combustion occurred, there is no way to stop it.
8) The lower the combustion temperature is, the more efficient the combustion process will be.
9) Misfiring may lead to fires due to unburned fuel mixture going into the exhaust pipe.
10) Inlet air flow is independent from the speed of the turbocharger.
11) Modern NG engines are equipped with a bypass that returns some of the intake air to the
turbocharger inlet to adjust the excess air ratio in accordance with operating conditions and
to prevent knocking or misfiring.
12) A bypass valve in the bypass closes under partial load so that all the air discharged by the
turbocharger is supplied to the engine, but it partially opens under full load by adjusting
valve opening angle to maintain the correct intake air flow to the engine.

Lesson 6
DF engines

ENGAGE:

a) Comment on the figure below.

Emissions in mixed Diesel/Gas mode

 During which stroke is the gas fuel supplied?

 What, do you think, the exhaust emissions levels depend on?
 What does the concentration of CO2 depend on?
 Is there any possible way to reduce CO2 in the exhaust gas
 What does the concentration of NOx depend on?
 Is there any possible way to reduce NOx in the exhaust gas?
 What do you know about IMO Tier I, II, III?
 Which emissions do the Tiers address?
 What are the requirements?
 According to Tier III, the proportion of diesel fuel is to be reduced to 2%. Do you think the
conventional nozzles are capable of injecting such a small quantity?
 Which additional device, to your mind, is capable of injecting that small quantity?

b) Complete the text below using the most suitable words.

Gas fuel is supplied during the ________________ stroke of a diesel engine, and the
exhaust emissions vary according to the proportions of ________________ fuel and
________________ fuel in the total fuel. Because the concentration of CO 2 in the exhaust gas
depends on the composition of the ________________, it can be reduced by up to about 25%
according to the ________________ of diesel fuel and gas fuel. On the other hand, because the
concentration of NOx depends on the combustion ________________, reductions in NOx can
only be achieved by reducing the proportion of ________________ fuel.
 While achieving the IMO Tier 3 regulations (80% reduction in ________________)
requires that the proportion of diesel fuel to be reduced to 2%. There are no currently available
nozzles that are able to ________________ the full range of fuel injection quantities, from the
amount required under rated load down to this very ________________ quantity, in a reliable
manner (without variation in the quantity injected for each cycle). To overcome it, adding a
small dedicated nozzle (micro-pilot fuel injector) that supplies ________________ fuel for the
ignition when operating on ________________ fuel is necessary.

c) Label the figure below suggesting your ideas.

d) Describe the cross-section from the previous activity by completing the information
below.

Here is a cross-section of a ________________ -stroke DF engine. Gas fuel is supplied

from a ________________ in the air intake manifold where it flows into the ________________
as a mixture with air. Two injectors, one is the ________________ used for diesel mode and
another is the ________________ used for gas mode, are equipped in the cylinder head, the
engine can switch between ________________ mode and ________________ mode freely with
certain operating condition restrictions.

ACTIVATE I:

a) Suggest the difference.

4-stroke DF vs. 2-stroke DF

b) Label the figure using the prompts below.

 Combustion cycle for 2-stroke DF engine

expansion fuel gas valve compression

mixture scavenging fuel gas
ignition diesel fuel injector pilot fuel injector for ignition

c) Define if the statements are TRUE or FALSE. If able, correct the FALSE ones.

1) It is not allowed to mix the gas fuel with the intake air, because intake air is used for
scavenging in a 2-stroke engine.
2) The diesel fuel is injected into the compressed air, and then ignition is achieved by injecting
gas fuel.
3) The micro-pilot fuel injector is used for injecting gas fuel.
4) The result of using micro-pilot fuel injector is low level of unburned gas, reduced CO2
emission and knocking.
5) The result of using micro-pilot fuel injector is reduced NOx emission.
6) Natural gas is injected into the cylinder in liquid form.
7) Natural gas is pressurized in liquid form.

d) Read for gist to check if you were right in the previous activity.

Because intake air is used for scavenging in a 2-stroke engine, it is not allowed to mix the
gas fuel with the intake air. Instead, the gas fuel is injected into the compressed air in the same
way as diesel fuel, and then ignition is achieved by injecting fuel via the micro-pilot fuel
injector. Because this results in diffusion combustion, as with diesel fuel, it can reduce
CO2 emissions by 20% or more, with a low level of unburned gas and CO emission and without
knocking. However, the level of NOx emissions is high due to the same reason.
Figure below shows the cylinder cover design for a 2-stroke DF engine. In order to
pressurize gas fuel injected into the compressed air up to 30 MPa, natural gas that has been
pressurized in liquid form is vaporized and then injected into the cylinder. And because there is
no risk of knocking, the switch between diesel fuel and gas fuel can be performed comparatively
easily and quickly.
 One proposal for improving the level of NOx emissions for 2-stroke DF engines is to use
a low-pressure gas fuel injection engine that can operate with a lean pre-mixed fuel mixture
despite being a 2-stroke engine. This involves using a fuel injection timing control method that
enables the time delay of pre-mixing of gas fuel and air during the intake stroke described above
that prevents the fuel-air mixture from coming into direct contact with the exhaust gas. Such an
engine is currently under development with the aim of achieving low-NOx emissions similar to a
four-stroke engine.

e) Answer the question and label the figure using the prompts below.

What solution has been mentioned to address the problem of NOx emissions reduction?

Combustion cycle for low-pressure gas injection 2-stroke DF engine

fuel gas valve diesel fuel injector pilot fuel injector for compression
ignition
ignition expansion scavenging fuel injection

fuel gas buffer layer of air between combustion gas and mixture

STUDY:

a) Match the synonyms.

 1. adjust shake, pulse
2. error limit, regulate, fix
3. fluctuation arrest, detain, hold back
4. sign extra room, gap, possibility
5. delay improvement
6. vibration salt, caustic soda
7. recovery change, passing, shift
8. waveform mistake, slip, fault, blunder
9. transition category, class, quality, standard
10. restrict wavelike motion
11. margin stop, cut off, pause
12. switchover adapt, change
13. alkalis at once, immediately
14. grade changeover, shift
15. halt movement up, down, back, forth
16. instantaneously mark, symbol, indication

b) Complete the phrases below using the words from the previous activity.

— a procedure for ________________ from diesel mode to gas mode

— to switch from gas mode to diesel mode by ________________ shutting off the gas fuel
— monitoring for ________________ of knocking or misfiring
— the ________________ is controlled automatically
— three main ________________ modes in gas mode
— Knocking can be detected by using a ________________ sensor
— internal cylinder pressure ________________
— engine automatically ________________ its operation
— to ________________ the ignition timing
— to ________________ the knocking
— engine speed ________________
— misfiring continues for a number of cycles without ________________
— operating on low ________________ fuel
— knocking ________________ would be reduced
— build-up of ________________ deposit
— ________________ the range of fuels that can be used

ACTIVATE II:

a) Consider the following.

CHALLENGES FOR DF ENGINES

b) Match sentences’ halves to obtain the challenges.

1. Because two or more different types of the cylinder walls that act as a heat
fuel are combusted in the same insulator causing the combustion
cylinder, temperature to increase.
 2. Whereas lubricants with high base there is a risk for the engine to shut
numbers (30 to 40 mg KOH/g) are down due to knocking when it
used when operating on low grade fuel switches over to this new fuel.
(3.5% sulfur),

3. This is why the knocking margin will perform effectively with both
would be reduced in natural gas fuel diesel mode and gas mode.
mode due to the build-up of alkalis
deposit and other combustion deposit
on

4. As a result, it can be difficult to select lubricants with low base numbers (5

a lubricant for DF engines that mg KOH/g) are used when operating
on natural gas (0% sulfur).

5. Fuel characteristics are restricting the range of fuels that can

be used or limiting output, a challenge
for the future will be to develop
engine technology that can deal with
different fuel characteristics.

6. Ocean-going vessels are supplied with a problem specific to DF marine

fuel at their destinations engines.
(“bunkering”), but because the
characteristics of natural gas differ
depending on where it is produced, if a
vessel takes on fuel with significantly
different characteristics
7. Currently though this problem can be one of the challenges for DF engines
overcome using particular operations is lubrication.
such as

c) Sum up the challenges.

Lubrication: scope of the problem, errors margin, possible solution

_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
Fuel characteristics: scope of the problem, errors margin, possible solution
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

d) Match to get phrases.

1. fuel-air injection
2. main sensor
3. electromagnetic controller
4. engine speed sensor
5. cylinder slowly opened
6. flow control fluctuation
7. gas pressure waveform
8. gas valve is or misfiring
9. vibration solenoid
10. electronic injector
11. signs of knocking error modes
12. micro-pilot lever
13. diesel fuel ratios

e) Title and complete the text using the phrases matched previously.

_________________________________________________

Dual-fuel engines use an ________________ for fuel flow control to enable switching
between diesel mode and gas mode as required. In diesel mode, an actuator mechanically
operates the fuel pump’s ________________, whereas in gas mode, the timing for opening the
gas valve is controlled electrically with the energizing duration of time for an
________________.
While it is possible to switch from gas mode to diesel mode by instantaneously shutting
off the gas fuel and starting ________________, switching from diesel mode to gas mode
involves the engine speed control working through a procedure for transitioning from diesel
mode to gas mode as the ________________. This is because of restrictions on the range of the
________________ that can be used when operating in gas mode, which are dependent on
operation condition such as the load or fuel characteristics, and the switchover is controlled
automatically while monitoring for ________________.
The three ________________ in gas mode are knocking, misfiring, and gas leaks.
Knocking can be detected by using a ________________ to find changes in combustion
vibration or detected directly from the internal ________________. If knocking is detected, the
engine automatically adjusts its operation to prevent it. Although the usual practice is to reduce
the maximum pressure in the cylinder by using the ________________ to delay the ignition
timing, if this fails to halt the knocking, the operation automatically switches to diesel mode.
Misfiring can be detected from factors such as the exhaust gas temperature, internal
cylinder pressure waveform, or ________________. If misfiring continues for a number of
cycles without recovery, the operation automatically switches to diesel mode. Gas leaks are
detected with a ________________. If a gas leak is detected, the gas valve is immediately shut
off and the operation automatically switches to diesel mode.

f) Comprehension questions.
1) What is the purpose of an electronic controller in DF engines?
2) How does an actuator act when operating in diesel mode?
3) How is the timing for opening the gas valve controlled when operating in gas mode?
4) What is the procedure of switching from gas to diesel mode?
5) What is the procedure of switching from diesel to gas mode?
6) Why is the procedure of switching from diesel to gas mode complicated?
7) What are the three main error modes when operating in gas mode?
8) How can knocking be detected?
9) What happens upon knocking detection?
10) Is anything can be done upon early stage of knocking detection?
11) How can misfiring be detected?
12) What happens if misfiring continues for a number of cycles?
13) How are gas leaks detected?
14) What happens upon gas leak detection?

Lesson 7
DF engines. Vol.2

ENGAGE:

a) Choose the proper definition. Prove your choice.

DUAL-FUEL ENGINE is…

 a type of internal combustion engine which ignites fuel by injecting it into hot,
high-pressure air in a combustion chamber.
 the diesel engine that can run on both gaseous and liquid fuels.
 any device which can convert heat energy of fuel into mechanical energy.

b) Scan the diagram below and comment on it.

Emissions:
Price:
Power:
 c) Decipher the following.

GI and LGI

It describes ME features
It is connected to gas-fueled ME
It partially describes state of NG
It describes the injection processes

ACTIVATE I:

a) Define if the statements are TRUE or FALSE. Correct the FALSE ones.

 IMO Tier III emission standards deal with SOx emissions produced by fuel oil combustion.
 IMO Tier III NOx emission standards will apply to marine diesel engines installed on new
ships constructed on or after 1 January 2016.
 Natural gas is also defined as “clean gas” because it produces very low/no particulate matter
and none of SOx emissions.
 The ME-GI/ME-LGI engine will fulfil IMO Tier III NOx levels when combined with the
exhaust gas recirculation (EGR) technology.
 In 1987, the first testing of the GI principles was carried out in Japan and Denmark and
MAN Diesel & Turbo introduced their first 2-stroke ME-GI DF engine series in 2011.
 In 2012, MAN Diesel & Turbo decided to expand the engine portfolio and the 2-stroke DF
ME-LGI engine series was introduced in 2013.
 The ME-LGI engine enables the use of more sustainable fuels such as methanol, ethanol and
liquefied petroleum gas (LPG).
 The fuel is injected in a gaseous state in ME-GI and in liquid state in ME-LGI.
 Both ME-GI and ME-LGI engines run on one gas type.

b) Study the table below and check if you were right in some of the answers from the
previous activity.
c) Watch the video.

d) Do the test.

1. In the coming years, global shipping will be facing_______.

a) liquid fuels b) engine breakdowns c) tough challenges

2. Growing ________ is pushing up liquid fuel prices.

a) population b) energy demand c) gas equipment

3. Rising __________ leads to stricter emission regulations, especially in the IMO

emission control areas.

a) environmental b) fuel prices c) qualification demand

awareness

4. In the future, ECA areas will be ______exclusively to ships that _____ the IMO Tier III
emission regulation.

a) banned, meet b) restricted, fulfill c) extended, ban

5. To meet challenges for tomorrow’s shipping industry, engine manufacturers present new
________ engines.

a) zero-emissions b) sophisticated c) fuel flexible

6. The MAN L35/44DF it’s a ____ technology, with two separate _______, makes it run on
any fuel available.

a) dual-fuel, injection b) modern, injectors c) complicated, pumps

systems
7. The MAN L35/44DF is _______ running on HFO, MDO, MGO or gas fuel, like LNG.

a) possible to b) designed c) capable of

8. The MAN L35/44DF is based on MAN _______ 32/44CR engine.

a) well-proven b) medium-speed c) four-stroke

9. Both engines feature a state-of-the-art CRS with injection pressures of up to _______

bars.

a) 160 b) 600 c) 1600

10. In ____, this system and other technologies ___ L35/44DF to fulfill the current emission
regulations IMO Tier II.

a) diesel mode, enable b) diesel mode, disable c) gas mode, check

11. To meet even stricter _____ of future regulation IMO Tier III, the L35/44DF can also
______ in gas mode.

a) regulations, b) emission limits, c) recommendations,

breakdown operate operate

12. _______ to gas can be done with _________ in engine power.

a) keeping, stop b) sticking, some loss c) switching, no loss

13. To ____ the air gas mixture, a small amount of liquid fuel is injected by a separate
_______ system.

a) ignite, pilot fuel b) burn, sparkle c) utilize, common rail

14. In gas mode, the L35/44DF fully complies with IMO Tier III lowering SOx emission by
_____ and other emissions levels by up to ______ and beyond compared to liquid fuel operation.

a) 10%, 100% b) 12%, 88% c) 20%, 99%

15. Over the past years the ______ between liquid and gas fuel has increased steadily and it
is expected to keep growing.

a) price difference b) level c) compromise

16. Already now, using natural gas as main fuel, enables ship owners to ____ fuel cost in a
double-digit percentage compared to a _________ diesel engine.

a) cut, old b) cut, traditional c) save, conventional

17. The L35/44DF _______ ship operators to fully harness this potential, plus, the flexibility
________ between fuels at any time for optimum resource utilization.
 a) allows, switch b) stops, flow c) allows, --------

18. In _______ mode, both gas and diesel supply systems are ______, which lets the engine
to run on multiple ratios of gas and liquid fuels.

a) fuel sharing, passive b) fuel sharing, active c) gas, active

19. Fuel sharing mode makes the L35/44DF virtually _____ to variations in gas fuel quality,
allowing it to operate even on gas that would be ________ for a conventional gas engine.

a) impossible, too dirty b) immune, unusable c) the best, treated

20. All these makes the L35/44DF the perfect _____ to keep cost of ownership down and
give ship operators the flexibility and _________ they need.

a) choice, sustainability b) price, tomorrow c) option, ban

STUDY:

a) Synonym match.

1. challenge limited
2. awareness tested
3. restricted control
4. well-proven distribute
5. enable maintain
6. loss test
7. harness waste
8. sustain low-cost
9. share understanding
10. affordable allow, permit

b) Match the following to get phrases.

GROUP 1
1. energy mode
2. environmental design
3. diesel awareness
4. pilot fuel system
5. price demand
6. flexible difference
7. robust switch
8. onboard power generation

GROUP 2
1. tough mode
2. alternative regulations
3. emission fuels
4. gas mode
5. economic challenges
6. operating operation
 7. sustained advantages
8. fuel sharing costs

ACTIVATE II:

a) Watch the video again.

b) Complete the following using some of the phrases matched previously and adding
some more.

In the coming years, global shipping will be facing ________________. Growing

________________ is pushing up liquid fuel prices and the use of ________________ becomes
ever more attractive. In addition, rising ________________ leads to stricter ________________,
especially in the IMO emission control areas. In the future, these areas will be restricted
exclusively to ships that fulfill the IMO Tier III emission regulation.
To meet these challenges for tomorrow’s shipping industry, MAN Diesel and Turbo
presents its new ________________ 4-stroke medium-speed engine, that can be used for all
applications as a main engine for diesel mechanic propulsion, for diesel electric propulsion or as
an auxiliary engine for ________________.
The MAN L35/44DF it’s a dual-fuel technology, with two separate ________________,
makes it run on any fuel available. No matter if its ________________, such as HFO, MDO and
MGO (marine gas oil) or ________________, like LNG.
The MAN L35/44DF is based on MAN well-proven 32/44CR engine. Both engines
feature a state-of-the-art CRS with ________________ of up to 1600 bars. In diesel mode, this
system and other technologies enable L35/44DF to fulfill the current emission regulations IMO
Tier II.
To meet even stricter ________________ of future regulation IMO Tier III, the
L35/44DF can also operate in ________________. Switching to gas can be done in the fly as
loads between 15 and 100% with ________________. To ignite the air gas mixture, a small
amount of liquid fuel is injected by a ________________.
In gas mode, the L35/44DF fully complies with IMO Tier III lowering
________________ by 20% and other emissions levels by up to 99% and beyond compared to
________________.
In addition, using gas as fuel also provides substantial ________________. Over the past
years the price difference between liquid and gas fuel has increased steadily and it is expected to
________________.
As fuel makes up the largest partnership ________________, reducing fuel expenses is
the most effective way to keep ________________. Already now, using natural gas as main fuel,
enables ship owners to save fuel cost in a double-digit percentage compared to a
________________.
When looking at ________________, the savings potential become even higher. The
L35/44DF allows ship operators to fully harness this potential, plus, the ________________
between fuels at any time for optimum ________________.
For ________________ on a wide range of gas qualities, the L35/44DF features a
________________. In this mode, both gas and diesel supply systems are active, which lets the
engine to run on ________________ of gas and liquid fuels. This makes the L35/44DF virtually
immune to variations in ________________, allowing it to operate even on gas that would be
unusable for a conventional gas engine.
Its ________________ in its class compliance with IMO Tier II and III, without
________________, low operating cost due to affordable gas fuel, complete
________________, a ________________ based on proven engine technology, the ability to
upgrade IMO Tier II compliant 32/44 CR engines to do fuel operation entirely onboard and an
increased vessel resale value due to that engine fulfills all regulations for many years to come.
All these makes the L35/44DF the perfect choice to keep cost of ownership down and
give ship operators the ________________ they need.
With the L35/44DF and a larger one 60DF, MAN Diesel and Turbo offers its customers a
complete range of fuel flexible 4-stroke medium-speed engines that fulfill all economic and
________________ of tomorrow’s shipping industry today.

c) Comprehension questions.

1) What are the tough challenges shipping industry is facing now?

2) What are the existing ECAs?
3) What are the discussed ECAs?
4) What regulation the ships intended to operate in ECAs must fulfill?
5) What are the applications the MAN L35/44DF may be used for?
6) Which technology is the MAN L35/44DF of?
7) What are its specific features?
8) What fuel types the MAN L35/44DF is capable of running on?
9) What is the operating pressure of the MAN L35/44DF common rail system?
10) When operating in diesel does the MAN L35/44DF fulfill all of the regulations?
11) How can the MAN L35/44DF fulfill the IMO Tier III requirements?
12) How is the air-gas mixture in gas mode ignited in the MAN L35/44DF?
13) What are the emissions reductions of the MAN L35/44DF when operating in gas mode?
14) What is the main economic advantage of the MAN L35/44DF when compared to a
conventional diesel engine?
15) Besides gas and diesel mode, which another mode the MAN L35/44DF is capable of
operating in?
16) What is the mode operating principle?
17) Is there a need in exhaust gas after treatment system installment?

d) Sum up the information and list the MAN L35/44DF advantages.

_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Lesson 8
Slow steaming

ENGAGE:

a) Suggest and define three main companies.

LARGE TWO-STROKE SECTOR FOR MAIN ENGINES MANUFACTURERS

b) Discuss the questions.

 Which of the companies has now transferred its business to a new company – Winterthur Gas
& Diesel (Win GD) – initially as a joint venture with China State Shipbuilding Corporation
before disposing of its full stake to its partner?
 Which of the companies has a dominant market share and four out of five engines supplied in
this two-stroke sector are of this manufacturer?
 Which of the companies is considered to be the smallest one in terms of market share of the
three companies?

c) Complete the following with the most suitable words.

With ________________ from its Chinese parent, WGD has ambitions to seriously
improve its market ________________ in the future.
In the medium-speed main engine sector, Wärtsilä has almost ________________ of the
market, MAN Diesel & Turbo around a ________________ with Caterpillar (MaK) leading the
rest of the field. Many more names can be found on ________________ -speed engines which
are used as ________________ mostly by smaller vessels but also as ________________ by all
ship types.
Dual-fuel engines have until recently been mostly ________________ strokes but they
have now also made initial references in the ________________ -stroke sector and interest is
growing.

d) Answer the following.

 What are the WGD plans for the future?

 What do you know about medium-speed main engine sector market share?
 What do you know about high-speed sector market share?
 Is DF engines market sector developing?
 What makes DF engines a point of interest?

STUDY:

a) Match the words with the definitions.

1. efficiency become greater or more successful than (something or

someone)

2. conventional remove or take away (something) from a particular place or

position

3. overtake the ratio of the work done or energy developed by a machine,

engine, etc., to the energy supplied to it; usually expressed in
percentage
4. contribute following traditional forms

5. withdraw give (something) in order to help achieve or provide something

b) Put the words in the correct order to create sentences.

1) introduction / rail / main / The / controlled / injection / in / development / was /
conventional / the / camshaft / of /common / fuel / place / of / the / and / electronically /.
_____________________________________________________________________________
_____________________________________________________________________________

2) controlled / have / Mechanically / withdrawn / sale / engines / not / from / been /.

_____________________________________________________________________________
_____________________________________________________________________________

3) popularity / overtaking / controlled / Electronically / controlled / engines / mechanically /

now / are / in / for / orders / new.
_____________________________________________________________________________
_____________________________________________________________________________

4) The / of / cylinder / consumption / chamber / fuel / to / re-design / of / also / reduced /

combustion / the / head / and / contributed / to /.
_____________________________________________________________________________
_____________________________________________________________________________

5) was / way / turbocharger / exhaust / efficiency / narrower / improved / by / systems / of /.

_____________________________________________________________________________
_____________________________________________________________________________

ACTIVATE I:

a) Choose the most suitable definition.

Energy efficiency…
 means using less energy to provide the same level of energy. It is therefore one method to
reduce greenhouse gas emissions.
 something is more energy efficient if it lasts longer or works better than a traditional version
of the same appliance, but uses the same amount of energy.
 if it delivers the same performance as the traditional version, but uses less energy.

b) Discuss the questions.

 What innovative technologies have been implemented into propulsion systems?

 What is an essential difference between conventional and new propulsion systems?
 What steps have been taken towards energy efficiency improvement?
 What nowadays improvements contribute to human labor reduction?
 Do you think DF engines can completely withdraw diesel engines from the market?

c) Define if the statements below are FACTS or SOMEBODY’S OPINIONS.

Comment on your idea.

 There is no great demand for greater efficiency as it has been proven that, the more people
try to contribute to energy efficiency, the more they contribute to marine pollution.
 Mechanically controlled engines have been withdrawn from sale by electronically controlled
ones.
 One of the important steps taken towards improving fuel consumption was common rail
application together with electronic injection.
 The re-design of cylinder head and combustion chamber can hardly contribute to reduced
fuel consumption.
 The pioneer in the DF engines was Wartsila, manufacturing engines for use on board LNG
carriers.
 Methanol fuel can’t be the alternative to diesel fuel because of its poor ignition properties.

d) Fill in the text with the words from the box.

After a pause towards the end of the last century there have been some major leaps
forward in engine technology because of increasing regulation and ________________ from
users for greater efficiency. Leading the march of developments, was the introduction of the
________________ rail and electronically controlled fuel ________________ in place of the
conventional ________________. Mechanically controlled engines have not been
________________ from sale but electronic versions are now ________________ them in
popularity for new orders.
The degree of additional control and the extended power ________________ allowed by
common rail and electronic injection was first promoted as improving fuel ________________,
allowing different fuel oil ________________ and better part- and low-load running leading to
such engines being described as ‘________________’. At that time, ________________
steaming as an operating strategy was not even on the radar but electronic engines have since
________________ making it easier to initiate.
Common rail was not the only ________________ taking place in the early 2000s.
Evolution of existing engine types meant significant improvements in power/weight ratios and
the ________________ of the cylinder head and combustion chamber also contributed to
________________ fuel consumption. Other changes included improved engineering
________________ allowing for higher cylinder pressure permitted by ________________
strokes and in some cases a very slightly reduced cylinder ________________.
________________ efficiency was improved by way of narrower exhaust systems.
Improvements in ________________ speed engines saw production turning to a more modular
system with maximum commonality of parts across engines with each manufacturers range.
This period also saw the first dual fuel medium-speed engines able to run on either fuel
oil or ________________ making their debut. Wärtsilä was the early ________________ in this
field with the engines planned for use in LNG carriers. Today most of the leading engine
manufacturers have ________________ dual-fuel versions of some engines into their portfolios
although Rolls-Royce has opted to go with either diesel or pure ________________ versions of
its Bergen engine range. Further developments are ________________ that have seen engines
capable of running on LPG, ________________ and liquid gas being produced.

consumption reduced overtaking re-design camshaft

withdrawn turbocharger tolerances bore pioneer
longer injection LNG qualities underway
slow medium development demand incorporated
common range gas methanol smokeless
contributed to

e) Comprehension questions.

 Which 20th -21st century leap forward is mentioned in the text?

 What has common rail and electronic injection replaced and why?
 What is meant under ‘improving fuel consumption’? What are the contributors to its
achievement?
 What engine improvements took place in the 21st century?
 How and why was turbocharger efficiency improved?
 What was the need to switch to DF engines manufacture?
 Which company was the early pioneer in DF manufacturing?

ENGAGE II:

a) Comment on the image.

What is known as ‘slow steaming’?

b) Check the following and suggest what they have in common.

IMO Tier II, III

Energy
GHG emissions
efficiency

Decarbonization Paris Agreement

Fuel
Slow steaming
consumption

c) Watch the video and answer the following questions.

1) What happened in 2007 so that MAERSK implemented slow steaming?

2) Why, do you think, it was MAERSK which was concerned about the fuel prices?
3) What solution to the problem has been found by MAERSK?
4) What were the skepticism and resistance all about?
5) Which ME parts might get damaged due to slow steaming?
6) How may slow steaming endanger crew lives?
7) Has MAERSK found the solution to ensure safe slow steaming?
8) What was the fuel saving of the trip from Europe to Singapore?
9) What was the percentage of CO2 emissions reduction?
10) What is the disadvantage of the slow steaming concept?

STUDY II:

a) Match the words with their meanings.

1. comply with money received for goods, services or

from other sources
2. savings result that someone is trying to
achieve
3. income create or set up something
(organization)
4. establish something which is now present,
available or in operation
5. enable to act in such a way so that to meet
the requirements, standards
6. benefit particular action to be performed in
order to achieve particular results
7. target make possible for something to
happen
8. existing not as good or optimal as possible

9. measure money saved by economy and laid

away
10. suboptimal improvement in condition or
advantage

b) Complete the sentences using the vocabulary units from the previous activity in the
correct form.

 IMO adopted amendments to Annex VI of the MARPOL Convention to reduce the carbon
intensity of ships and include ________________ for energy efficiency and GHG emissions
reduction.
 IMO ________________ ECAs, as an important ________________ to reduce and control
SOx, NOx, and particulate matter (PM) emissions.
 With the establishment of ECAs, ship operators must decide which strategy they should
adopt to ________________ ECA regulations.
 Although slow steaming is associated with environmental ________________, the
introduction of slow steaming can increase the round-trip time by 10–20%.
 The introduction of slow steaming can increase the round-trip time by 10–20%, depending
on the sailing route and port times, thus reducing the shipping ________________.
 An increase in transport time due to slow steaming could lead to an increase in the required
number of ships, and in that way the ________________ in fuel consumption and CO2
emission could decrease significantly.
 Sailing at a speed lower than the ship design speed changes the operating conditions of the
engine that could operate in ________________ conditions.
 Development of technical and operational energy efficiency measures for both new and
________________ ships can be another possible short-term measure.
 LNG fueled ships seem to be technically the most practical alternative to decrease CO 2
emissions in deep-sea shipping since LNG can replace conventional, more-polluting oil-
based fuels, and ________________ almost complete removal of SOx and PM emissions
with a substantial reduction in NOx emissions as well.

ACTIVATE II:

a) Match the following to get phrases.

1. to minimize fuels
2. harmful to sulfur content
3. operate in suboptimal trip time
4. reduction in operating based fuels
5. carbon-based sea
6. DF conditions
7. more-polluting oil- and long-term
8. older and less gas oil
9. low sulfur marine existing ships
10. new and matter (PM) emissions
11. fuel with lower two-stroke engines
12. carried by speed of ships
13. short-term, mid-term associated costs
14. increase the round- energy efficient
15. control SOx, NOx, and particulate the environment

b) Read and complete the text with the phrases matched previously.

It should be noted that 16.2% of global GHG emissions are caused by the transport sector
and the reduction in GHG emissions within the transport sector is important. Considering that
more than 80% of the international trade in goods is ________________, maritime transport
plays the key role in international trade and the global economy.
Although during the last decade, the world fleet has become more energy efficient, total
GHG emissions are continuously growing. A large portion in GHG emissions in the maritime
sector comes from container ships, particularly ________________ ones. Bearing in mind that
the container shipping industry is one of the main transport industries in the maritime sector, the
GHG emissions reduction for container ships becomes very important.
It should be noted that most of the world fleet is still powered by ________________
causing the emission of harmful gases.
In June 2021, IMO adopted amendments to Annex VI of the MARPOL Convention to
reduce the carbon intensity of ships and include targets for energy efficiency, to additionally
reduce GHG emissions from ships. In addition to GHG emissions, the maritime transport
industry seriously contributes to the non-GHG emissions, i.e., sulfur dioxides and nitrogen
oxides, which are very ________________. IMO has established ECAs, as an important measure
to reduce and ________________. With the establishment of ECAs, ship operators must decide
whether to comply with ECA regulations, which strategy they should adopt to comply with ECA
regulations, and establish the ways ________________.
The possible solutions are fuel switching, i.e., using fuel with higher sulfur content when
sailing outside the ECAs, and ________________ inside the ECAs, installment of scrubbers, or
using clean LNG as fuel.
Numerous measures have been proposed by IMO from 2011 onward to reduce CO 2
emissions from the maritime transport industry. These measures are categorized as
________________ measures. One of the short-term measures is the ________________ called
slow steaming. The introduction of slow steaming leads to a decrease in fuel consumption and
consequently CO2 emission and is used by almost all global shipping companies.
Although slow steaming is associated with environmental benefits, the introduction of
slow steaming can ________________ by 10–20%, depending on the sailing route and port
times, thus reducing the shipping income. An increase in transport time due to slow steaming
could lead to an increase in the required number of ships, and in that way the savings in fuel
consumption and CO2 emission could decrease significantly.
It should be noted that sailing at a speed lower than the ship design speed changes the
operating conditions of the engine that could ________________.
Another possible short-term measure is the development of technical and operational
energy efficiency measures for both ________________. LNG fueled ships seem to be
technically the most practical alternative to decrease CO 2 emissions in deep-sea shipping since
LNG can replace conventional, ________________, and enable almost complete removal of
SOx and PM emissions with a substantial reduction in NOx emissions as well. While LNG
carriers have used LNG as fuel for a long time, other ship types have recently started to use LNG
as fuel. LNG-fueled ships are powered by ________________, for example, MAN-gas-diesel or
Wartsila-DF, where the former reduces GHGs by 20–24%, NOx by 25–30%, and SOx by 92–
97%].
The fuel oil consumption and CO2 emissions for engines powered by low sulfur marine
gas oil and LNG have been analyzed. The reduction in CO2 emission is approximately 31% for a
speed reduction of 13.6% for an engine powered by ________________, and up to 49% for an
engine powered by LNG, in comparison to a ship sailing at the design speed and engine powered
by low sulfur marine gas oil.

c) Comprehension questions.

1) What is the role of maritime transport in international trade and the global economy?
2) Why is the GHG emissions reduction for container ships so important?
3) What are the most common fuels used by the world fleet? Why?
4) What happened in June, 2021? What are the targets established?
5) What is known as ‘ECA’? What are the requirements when sailing in ECAs?
6) What solutions have been found to comply with ECA requirements?
7) What measures have been proposed by IMO from 2011 onward?
8) Which category does ‘slow steaming’ belong to?
9) What are the benefits of slow steaming implementation?
10) What are the disadvantages of slow steaming implementation?
11) Which another short-term measure may be more practical to decrease CO2 emissions?
12) What are the benefits of LNG fueled ships?

Lesson 9
Slow steaming. Vol.2

ENGAGE:

a) Consider the following.

 ?
Charterer
?

?
Technical operator
?

?
Slow steaming beneficiaries

Ship's crew ?

?
?

?
Environment
?

Beneficiary is a person/a party who/which gains or benefits in some way from something.

b) Consider the following.

?
Charterer
?

?
Technical operator
?

?
Slow steaming due detriments

Ship's crew ?

?
?

?
Environment
?

Detriment is anything that causes damage or disadvantage.

c) Scan the figure below and answer the question.

 What is MCR?
 How many modes of slow steaming can you see in the figure?
 Comment on each of the modes.

d) Complete the description of each of modes below and title them.

________________ ________________ ________________

The The Range of main The

________________ ________________ engine load below ________________
and may cut-in the are in service and
________________ periodically for a ________________ ________________
are in service. short time when down to approx. may frequently cut-
Insufficient waste approaching to lower ________________ in to boost poor
heat to operate fresh limit of this load % of load. Till the performance of
________________. range, after the slow steaming era it economiser. Load
Load range below auxiliary boiler is used to be considered range approx.
________________ ________________. as a minimum limit ________________
% of MCR down to Typical load range of continous % of MCR down to
approx. ________________ ________________ ________________
________________ % of MCR. operation for a large % of MCR.
% of MCR. marine engines.

e) Answer the question below labeling the images.

What on board can be affected by slow steaming?

ACTIVATE I:

a) Consider the following.

1) How, do you think, can ME be affected by slow steaming?

2) What does the following formula depict?

CylOil=S%*%MCR*k

3) How, to your mind, will change cylinder oil consumption? Will it increase or decrease?
Why?
4) Study the diagram depicting expected cylinder oil consumption below. Comment on it.
 5) Now, study the diagrams depicting simulation of cylinder oil dosage and consumption of
the vessel that is employed on a South America – Europe trade with 11800 Nm distance
per trip and total 8 ports, where she spends average 400 hrs. per trip. Comment on them.

6) How is cylinder oil dosage and consumption affected by slow steaming?

7) Is it the same for cars?

b) Complete the information below.

Slow steaming endangers ME operation in the following:

Cylinder oil overdosing

Consequences:
Surplus oil ______________________________________________________________.
Surplus unburnt oil _______________________________________________________.

Low temperature corrosion

Consequences:
Overcooled area of cylinder liner is __________________________________________.
The main factors triggering low temperature corrosion:
 ________________
 ________________
 ________________
 ________________
How to deal with it on board:

 ________________
 ________________
 ________________
 ________________
Fuel valve fouling
According to the figure below, how is fuel valves TBO affected by slow steaming:
 What is TBO?

Typical TBO for 2-stroke engines is ________________ rh and for 4-stroke engines is
________________ rh. Due to contamination of the nozzle tip ________________.
Due to longer time at sea when slow steaming, the overhauling frequency of some
machinery ________________. It must be taken into account into ________________.
Also amount of work for crew ________________.

c) Consider the following. Share your thoughts on the idea.

Periodical engine’s loading up when slow steaming

Advantages Disadvantages

d) Match the sentences halves to get information about impact of slow steaming on
boiler plant.

1. Due to low velocity of exhaust gas and cuts-in usually below main engine’s
poor atomization as well as combustion load 30 % to 40 % MCR when the
process, economizer is clean.
2. Under low ME load, the economizer its additional contamination and
heating consequently much higher fuel
consumption.
3. In order to maintain steam below 200-2200C the efficiency of
pressure/thermal oil temperature, the dosing plant is disputable.
auxiliary boiler
4. The auxiliary boiler cut-in set point capacity becomes insufficient.
reduction

5. Dirty economizer brings the auxiliary the most effective in reduction of

boiler to deposits.
6. Prolonged auxiliary boilers operation dosing plant is essential.
during sea voyage causes

7. High risk of soot ignition can not be cut-in at higher main engine’s load than
40 % MCR.

8. Installation and proper functioning of amount of deposits in smoke tubes

soot ignition catalyst increases drastically.

9. However, if exhaust gas temperature underestimated in any case.

after turbine drops

10. Frequent engine’s loading up and boiler by 1-3 bar may be considered.
water washing is

e) Comprehension questions.

1) What are the modes of slow steaming operation?

2) What on board is affected by slow steaming?
3) What is the impact of slow steaming on cylinder oil consumption?
4) What are the consequences of cylinder oil overdosing?
5) What are the factors contributing to low temperature corrosion?
6) What are the recommendations to follow to arrest low temperature?
7) What is the impact of slow steaming on fuel valve TBO?
8) What are pros and cons of periodical engine’s loading up?
9) What is the impact of slow steaming on boiler plant?
10) What, do you think, is the effect of slow steaming on fresh water generation process?
11) What, do you think, is the effect of slow steaming on sludge system?
12) What, do you think, is the effect of slow steaming on ship’s hull?
13) What, do you think, is the effect of slow steaming on ship’s crew?

STUDY:

a) Match the following with meanings.

1. frequency to get closer to something

2. impact process of getting faster
3. fouling something that is neither large nor small in amount or degree
4. cut-in effect or influence that something has on something
5. approach enough of something for the purpose
6. cut-off something that is extra or more than needed
7. moderate to cause to increase, improve
8. boost the process of pollution or poisoning
9. sufficient number of times something happens over a period of time
10. insufficient to make something last longer
11. surplus speed
12. contamination the formation of biological coating (deposit) on a surface
13. acceleration to separate, to stop, to disconnect
14. velocity not enough of something for the purpose
15. prolong to join in, to blend into, to move into
 b) Complete the sentences below with the words from the previous activity.

1) The auxiliary blowers may cut-in periodically for a short time when approaching to lower
limit of the load range, but after the auxiliary boiler is ________________.
2) Due to low ________________ of exhaust gas and poor atomization as well as combustion
process, amount of deposits in smoke tubes seriously increases.
3) Under low main engine load, the economizer heating capacity becomes ________________.
4) In order to maintain steam pressure/thermal oil temperature the auxiliary boiler
________________.
5) ________________ auxiliary boilers operation during sea voyage causes its additional
contamination.
6) Auxiliary boiler may frequently cut-in to ________________ poor performance of
economiser.
7) The auxiliary blowers may cut-in periodically for a short time when ________________ to
lower limit of the load.
8) ________________ oil burns into hard coke resulting in fast abrasive wear down of liner and
piston rings.
9) Due to the ________________ of the nozzle tip, the fuel valve TBO may be reduced.
10) Due to longer time at sea when slow steaming, the overhauling ________________ of some
machinery will increase.
11) Periodical engine’s loading up may lead to unexpected machinery failure during
________________.
12) Environment is the beneficiary from the slow steaming in NOx ________________
reduction due to low combustion temperature.
13) Due to reduced rotation speed, the propeller is more vulnerable (can be easily affected, open
to, sensitive to) to ________________.
14) Between reduced speed and deep slow steaming modes, there is a ________________ slow
steaming mode.
15) There must be ________________ waste heat to operate fresh water generator.

ACTIVATE II:

a) Define the piece of equipment. Answer the questions below.

 What ensures water generation process?

 Is there enough heat from engine when slow steaming to generate water?
 What slow steaming modes affect FWG the worst?
 How is it possible to deal with it on board?
 What are the disadvantages of taking fresh water from shore?
 Do you think the amount of oily deposits related to fuel consumption produced by slow
steaming vessel increase or decrease?
 What is ship’s hull coated with?
 Do you think antifouling painting is efficient at any engine speed?
 What is the effect of slow steaming on propeller?

b) Define if the statements below are TRUE, FALSE or CONTROVERCIAL. Correct

the FALSE ones.

 Most of the ships are manned with a minimum crew, often not more than stated in Minimum
Safe Manning Certificate.
 Slow steaming doesn’t demand any additional activities from the crew.
 There are advantages for the crew when the ship is slow steaming.
 Slow steaming became a widely utilized way of cost reduction in shipping and it has been
accepted by major engine builders.
 Vessel operators never understand that additional maintenance requires additional time.
 There are no maintenance procedures which require prolonged berthing or anchorage.
 No additional manpower is required to conduct slow steaming related services together with
standard service and running the ship.
 Prolonged slow steaming without periods with higher load will deteriorate the whole ships
performance and will decrease initial profits.
 The periodical short passages at higher vessel speed should be arranged as frequently as
possible.

Lesson 10
CRS

ENGAGE:

a) Comment on the following.

RAIL INJECTION SYSTEM

What is its purpose?
Where is it mounted?
What does it consist of?
Is it commonly used?
Is it easy to maintain?
What is its operating principle?

b) Choose the best definition. Prove your choice.

Common rail injection system is –

 uses either air or a liquid to remove the waste heat from an internal combustion engine
 is a direct fuel injection system for diesel engines
 is the process or technique of using a lubricant to reduce friction and/or wear in a contact
between two surfaces
 can be electric, pneumatic or hydraulic; in the case of very large engines, the starter can be
another internal combustion engine

c) Look at the scheme and try to explain CRS in work.

d) Discuss the following.

 What was the need to create CRS?

 What is, to your mind, the advantage/disadvantage of this system?
 Why was this system given such a name?

ACTIVATE I:

a) Read the text and fill in the empty spaces with words below.

The common rail system, as the name suggest, is a system which is ________________
for every cylinder or unit of the marine engine. Marine engines of the early times had a fuel
system, wherein each unit had its own ________________ and the oil ________________ was
supplied through the jerk pumps.
However, in common rail system all the cylinders or units are connected to the
________________ and the fuel pressure is ________________ in the rail. The supplied
________________ is thus provided through the rail. A similar type of common rail system is
also there for ________________ system for opening of the exhaust valves.
Speaking about the ________________ system, the common rail system was launched
even before the ________________, but was also not successful because of few
________________. However, because of some latest advancement in technology and
electronics, the common rail system has ________________ popularity.
The common rail engines are also known as ________________ as fuel pressure required
for combustion is same for all ________________ of the engine.
The common rail is employed in the following system:
— for ________________ fuel oil at a pressure of 1000 bars;
— for servo oil for opening and closing of ________________ at a pressure of 200 bars;
— control oil for opening and closing of ________________ at a pressure of 200 bars;
— ________________ for starting main engine.
accumulated fuel pressure jerk pumps servo oil drawbacks
gained jerk pump valve blocks loads or rpm common
pressure fuel injection heated rail compressed air
smokeless engines exhaust valves

b) Decide if the statements are TRUE or FALSE and correct the FALSE ones.

1) CRS is the system that makes the ship more stable.

2) Marine engines of the early times had a fuel system wherein each unit had its own jerk pump.
3) Most of the cylinders are connected to the rail, leaving those not connected in stand-by mode.
4) The fuel pressure is accumulated in the rail and is supplied to the unit by disposable plastic
pipe.
5) There is no common rail system for servo oil system.
6) CRS is not applied on board all ships, even though, it is very successful, because marine
engineers still lack knowledge of how to maintain and overhaul the system.
7) Common rail engines generate a lot of smoke causing troubles for shipping companies,
which intend to comply with regulations on GHG emissions.
8) Common rail is employed by compressed air for starting main engine system.
9) Control oil system for opening and closing of valve blocks is not manufactured in common
rail technology because CRS doesn’t work with oil.
10) The fuel pressure required for combustion is different for different loads and rpm of the
engine.
11) CRS main disadvantage is system’s sensitivity to engine’s load changes.
12) CRS was launched even before the jerk pumps, but was not successful because of few
drawbacks.

c) Match the following to get phrases.

1. access from oil system

2. injection sensor
3. top dead of the flow
4. servo and control remotely
5. crank angle the top
6. the control hydraulic control
7. electro control unit
8. fuel cover
9. controlled centre
10. cylinder oil systems

1. engine’s top control

2. valve control valve
3. high-pressure pressure
4. the timing of the opening
5. exhaust platform
6. to cut off the valve
7. accumulated pump
8. oil pushes unit
9. electronic the signal

d) Complete the information below using the phrases matched previously.

 High pressure pump
The common rail system consists of a ________________ which can be cam driven or
electrical driven or both. Pressure requirement will be different for different system. For
________________ the pressure is as high as 1000 bars, for ________________ the pressure is
about 200 bars.
Rail unit
This is provided after the pumps where the ________________ from the pumps is
provided to the rail which supplies it to each unit when required. This is located at the
________________ and just below the ________________. The rail units extend to full length
of the engine. They are enclosed, but have ________________ for maintenance and overhauls.

A - fuel oil rail; B - control oil rail; C - servo oil rail; D - injection control unit (ICU); E - valve
control unit (VCU)

Valve block and electronic control system

This is required for ________________ of the fuel oil, servo oil, control oil and starting
air from the rail to the cylinder. The valve block is operated by the ________________ which
operates when it gets a signal indicating that this cylinder is at ________________ and fuel has
to be injected and decides when ________________ has to be opened. With the help of
electronics, the injection can be ________________ from the computer. For e.g., if we want to
cut off fuel to one of the units, then we need ________________ given from the control system
so that the valve will not open.
For the fuel oil system this block is known as ICU (________________) and for exhaust
valve it is known as VCU (________________). The control system for opening and closing of
ICU and VCU is done by ________________ with which when the signal for opening is present,
the valve for control oil opens and control ________________ of ICU and VCU to open. The
signal for electronic control is given by ________________ which senses about each cylinder
and sends signal to system which decides whether to open a valve or close the valve.
________________ of the valve can also be controlled by the electronics, which means
that if the signal is given to open the valve early it will open early and vice versa.

STUDY:

a) Complete the definitions from the text.

1) CRS HP pump is driven ____________________________________________________

2) HP pumps deliver _________________________________________________________
3) Fuel oil system requires ____________________________________________________
4) Servo oil and control oil systems requires ______________________________________
5) Rail unit is located _________________________________________________________
6) The purpose of rail unit is ___________________________________________________
7) For maintenance purposes, there is ____________________________________________
8) Valve block is operated by __________________________________________________
9) The purpose of a valve block is _______________________________________________
10) Electronic control is activated by ______________________________________________
11) Injection is controlled either _________________________________________________
12) If there is the need to cut off fuel to one of the units _______________________________
13) ICU is ___________________________________________________________________
14) VCU is ___________________________________________________________________
15) Electrohydraulic control is used to _____________________________________________
16) Crank angle sensor is used to _________________________________________________
17) The timing of the opening of the valve __________________________________________

b) Match the sentences’ halves.

Advantages of Common Rail over Conventional Jerk Pump System

1. Same injection pressure for engine at cams for each fuel pump are also
all loads or rpm which is not possible removed.

2. Injection timing can be adjusted enabled, which is not there in

during engine running, whereas in traditional system.

3. The design of common rail is simple number of pumps and increased

as there are no individual fuel pumps, efficient combustion time between
and overhauls.
4. Common rail enables smokeless conventional system, engine has to be
operation whereas in conventional stopped and setting for timing has to be
system smokeless changed.
5. Reduced maintenance is required when using jerk pumps, due to the
because of a smaller pumps depend on engine speed.

6. With CRS, control of variable opening operation is possible only during high
of exhaust valve is rpm.

c) Complete the following.

CRS advantages
— injection pressure independent from __________________________________________
— adjustment of injection timing is possible ______________________________________
— simplified construction due to _______________________________________________
— less smoke is produced due to _______________________________________________
— exhaust valve opening can be _______________________________________________

ACTIVATE II:

a) Label the image below using the prompts.

 Suction Injector Camshaft Fuel supply
manifold
Fuel pump Valve block Timing valve
HP collecting Cylinder Accumulator
block
HP fuel rail injector Spill valve

b) Google to explain the following.

 to determine the timing

 to release excess pressure
 pressure pulse
 operating lever
 maneuvering lever
 to meet the load demand
 to tend to experience shock
 to dampen pressure surge
 to suit load change

c) Do the text quiz.

 The common rail system has one or more common HP, multiple plunger, fuel
pump/pumps. The fuel is discharged into a manifold called a “________________” (1) which is
maintained at a very HP. From this common rail, fuel is supplied to all the fuel
________________ (2) in the various cylinder units. Between the rail and the injector or
injectors for a particular cylinder is a “________________ (3) valve” which determines the
timing and amount of fuel delivery. ________________ (4) valves are connected to the manifold
or rail to release excess pressure and ________________ (5) bottles are included to reduce pump
pressure pulses. The injectors in a common rail system are often referred to as fuel
________________ (6).
The timing valve in the common rail system is operated by a cam and a
________________ (7) (see the figure below). When the timing valve is lifted by the
________________ (8), the lever also is lifted, thus ensuring that the valve in the timing valve
________________ (9) allows the HP fuel oil to reach the fuel injectors. Also, the timing valve
operating lever is fixed to a ________________ (10) rod. This sliding rod is fixed with the
manoeuvring lever, which governs (controls) the ________________ (11) of the fuel to be
injected into each cylinder unit, meeting the ________________ (12) demands on the engine.

The system has two or more common fuel pumps, which are driven by the
________________ (13) itself. They deliver HP fuel oil into one ________________ (14) line.
This HP oil in the common rail tends to ________________ (15) a pressure surge (shock), when
the engine load changes suddenly or continuously over a period of time. To dampen these
pressure ________________ (16), an accumulator ________________ (17) is provided on the
HP line (common rail).
Also the volume capacity of the HP common rail is ________________ (18) to suit
sudden load changes. When compared with the individual pump engines, these common rail
engines do not require a great deal of concentration at the ________________ (19). As the fuel
pumps supply fuel oil at a HP, it is ________________ (20) in an accumulator at a pressure of
around 400 to 550 atmospheres. This pressure is sufficiently maintained by the compressed air
operated “________________ (21) valve.” If the pressure in the common rail increases
suddenly, the spill ________________ (22) will open up and drain the fuel oil to the
________________ (23) tank or the fuel oil drain tank as per the design. Then the
________________ (24) valve controls the timing of start/stop of fuel injection.
For the initial start-up of the system, the fuel ________________ (25) pump is provided,
which can ________________ (26) a pressure of about 140 atmospheres. This priming pump is
usually ________________ (27) driven.

1. a) pipe b) line c) rail

2. a) cylinders b) injectors c) units
3. a) timing b) spill c) relief
4. a) spill b) control c) bypass
5. a) accumulator b) cylinder c) air
6. a) valves b) lines c) levers
7. a) shaft b) lever c) rod
8. a) cam b) pressure c) force
9. a) line b) interface c) block
10. a) sliding b) piston c) connecting
11. a) flow b) contamination c) amount
12. a) regulation b) load c) IMO
13. a) camshaft b) main engine c) diesel generator
14. a) common b) specific c) separate
15. a) control b) reduce c) experience
16. a) surges b) drops c) rises
17. a) block b) tank c) bottle
18. a) insufficient b) sufficient c) limited
19. a) drive shaft b) jerk pump c) load surge
20. a) released b) stored c) supplied
21. a) timing b) relief c) spill
22. a) lever b) valve c) block
23. a) storage b) settling c) service
24. a) timing b) spill c) fuel
25. a) jerk b) supply c) priming
26. a) reduce b) build up c) drop
27. a) hydraulically b) electrically c) pneumatically

d) Label the image below.

1 5
2 6
3 7
4
 e) Comprehension questions.

1) What is known as ‘CRS’?

2) What are the components the system comprises of?
3) How many fuel pumps are normally there in a system?
4) What are they both driven by?
5) What pressure is required for fuel oil system?
6) What are the working pressures of servo oil and control oil system?
7) What are the features of rail unit? Where is it located?
8) Is there an easy access to the rail unit for maintenance purposes?
9) What are the purpose and features of the valve block?
10) What is known as ‘ICU’?
11) What is known as ‘VCU’?
12) What is the purpose of the timing valve in a system?
13) What is it operated by?
14) What is the connection between timing valve operating lever, sliding rod and maneuvering
lever?
15) What is the spill valve fitted in the system for?
16) Which component dampens out pressure pulses in a system?
17) What is the pressure in the accumulator bottle?
18) Which component maintains the required pressure in the accumulator bottle?
19) How is system protected from sudden pressure increase?
20) What are the purpose and features of fuel priming pump?
 Lesson 11
CRS. Vol.2

ENGAGE:

a) Watch the animation and answer the following questions.

1) Which company is the manufacturer of the CRS in the video?

2) What are fuel pumps attached to?
3) What do HP lines connect?
4) Which device controls the CRS operation?
5) How has injection process been characterized?
6) What does flexible injection enable?
7) How have GHG emissions been reduced?
8) What safety features are integrated?
9) What are the benefits of CaT CRS application?

b) Consider the following.

IMO regulations require reasonable emission reduction and decrease of specific fuel oil
consumption.
Why?

c) Study the offer by CaT. Comment on it.

Cat Common Rail offers:

Significant decrease of specific fuel oil consumption:
 for main propulsion engine M32C with Cat CR up to 3% improvement;
 for generating set M32C with Cat CR up to 2% improvement;
 optimized combustion.

Are these improvements important? Are they sufficient enough? Why/why not?

STUDY:

a) Match the following with their definitions.

1. to sacrifice provide something with a component not fitted

during manufacture
2. approach from beginning to end

3. to retrofit limited emissions should be kept

4. visibility able to be easily modified

5. capability a way of dealing with a situation or problem

6. throughout make something possible

7. flexible a factor involved in a complicated process or

situation
8. reliability state of being able to see or be seen

9. multiple power or ability to do something

10. complexity numerous and different

11. emission sensitive act of giving up something valued for the sake of
something else
12. to enable degree to which the result of a measurement can be
depended on to be accurate

b) Complete the sentences using the words from the previous activity.

1) The engines equipped with CaT CRS demonstrate superior ________________ in heavy
fuel operation and best fuel efficiency in its class.
2) By adopting well proven elements of this technology for medium-speed engines, the
system enabled lowest engine emissions with minimum additional ________________.
3) Caterpillar decided to adopt a two-step ________________ providing the most effective
solutions with lowest complexity.
4) CRS is a very important development in emissions technology being fully
________________ fuel system suitable for HFO, MDO and DO.
5) CRs enables invisible smoke under all engine operating conditions offering an effective
technology for ________________ areas.
6) CRS purpose is to maintain and improve engine performance by taking advantage of the
________________ and benefits of a fully flexible fuel system.
7) When operating at low engine load, CRS guarantees soot emissions to remain below the
________________ limit.
8) During normal load operation, NOx emissions can be reduced without
________________ fuel consumption.
9) CRS enables vessel operation without visible soot ________________ the whole
operating range.
10) CRS is capable of ________________ injection which ________________ optimal
combustion and low emissions at all loads.
11) During the development, it was decided to ensure the system can be ________________
to already existing vessels.

ACTIVATE:

a) Match to get phrases.

1. without injection
2. control fluid pressure
3. fuel regulations
4. optimal for the injector
5. emission combustion
6. multiple limit
7. environmental visible soot
8. injection aspect
9. retrofit sensitive
10. visibility consumption
 b) Fill in empty spaces using phrases matched previously and use correct
prepositions.

With Cat CRS, the ________________ is independent from load and speed. For areas
that are especially ________________, soot emissions at low engine load remain well below the
________________. Furthermore, during normal load operation, NOx emissions can be reduced
without sacrificing ________________.
In general, the Cat CRS fuel system enables vessel operation ________________
throughout the whole operating range.
In addition to that, the fuel system is capable of ________________. Multiple injection
allows ________________ and low emissions at all loads. Characteristic of Cat CRS is the
approach of using the fuel (whether it’s HFO, MDO or diesel oil) as the ________________,
thus avoiding the added complexity of a separate control fluid system.
During the development, the ________________ of the complete system has been
emphasized. As a result, the Cat CR fuel system can be retrofitted to existing M32C engines.
This means increased customer value to reach future ________________.

c) Answer the questions below.

 Why has the system been developed?

 What makes it different from conventional system?
 How does multiple injection affect the combustion process?
 What makes the system suitable for operation in emission sensitive areas?
 Is that possible to reduce NOx emissions when operating at normal load?
 Can you remember the factors contributing to NOx formation?
 What does the control fluid system run on?
 Is the system retrofittable?

d) Define if the statements are TRUE or FALSE. Correct the FALSE ones.

 The injection pressure is dependent on load and speed.

 Emission sensitive areas require soot emissions at low engine load to remain well below the
visibility limit.
 NOx emissions can only be reduced by sacrificing injection pressure during normal load
operation.
 Throughout the whole operating range, the CaT CRS enables vessel operation without visible
soot emissions.
 Multiple injection allows slow combustion medium emissions at all loads.
 The approach of CaT CRS is to use LNG as the control fluid for the injector.
 CaT CRS is not completely retrofittable, but may be retrofitted to engines built after 2016.
 The system demonstrates superior reliability in all, but heavy fuel operation.
 When running at full load, the smoke will be visible from the funnel.
 Fully flexible fuel injection system enables maximum emissions and poor engine
performance.

e) Complete the information below with the prepositions.

The main components ______ the Cat Common Rail fuel system are a high pressure (HP)
pump, rail, injector and electronics. Caterpillar’s broad experience ______ electronically
controlled engines, range of product lines and in-house design and analysis expertise allow
______ a unique system approach. All components are developed ______ Caterpillar design
control.
 In addition, Caterpillar’s expertise ______ electronics is a major asset to the Cat
Common Rail technology.
Safety considerations and high customer value were the main focus throughout the
development, resulting ______ a state-of-the-art design ______ the following features:
- two high pressure pumps ______ redundancy;
- double-walled lines and rails;
- redundant speed pick-ups;
- pressure sensors;
- a safety gear between pump and engine;
- a pressure relief valve;
- flow limiters.
Two high pressure pumps deliver the required amount ______ fuel ______ the rail and
provide the desired rail pressure in closed loop control. The pump itself is based ______ a
proven design and has been modified ______ HFO operation. By having two pumps ______ all
in-line engines the amount ______ HP connections and components is reduced and thus
increases reliability. The inlet metering control ______ the pump ensures a high pump
efficiency.
The double-walled rails are pressurized and act ______ an accumulator, with one rail
segment feeding fuel ______ three injectors, i.e., a nine-cylinder engine has only three rail
segments, an eight-cylinder engine has two rail segments, each feeding four injectors. This
layout reduces the number ______ parts and the number ______ high-pressure connections.
Flow limiters prevent the cylinders ______ over-fueling; a safety valve acts ______ pressure
relief ______ case ______ an unwanted over-pressurized rail.
Injector Caterpillar has chosen a simple and robust approach ______ using the actual fuel
______ control fluid, thereby eliminating the need ______ a separate control fluid system. The
injector nozzle is cooled ______ lube oil, a typical feature ______ heavy fuel operation. For the
Cat CR injector, the lube oil circuit has been extended to provide cooling ______ the electrical
components within the injector, thereby increasing the lifetime. The injector design is simple,
robust and compact; the key features are:
- electronically controlled;
- flexible injection timing and duration;
- capability ______ multi shot injections.
The key component is the Caterpillar A4E4 (or ADEM™) Electronic Control Module
(ECM). The ECM acts ______ the brain ______ the Cat Common Rail fuel system. Pioneered
______ Caterpillar 20 years ago, the ADEM™ controller coordinates and enhances fuel delivery,
air supply and other engine functions to maximize overall performance and reduce emissions
output.
Having in-house expertise ______ core electronic components and software puts
Caterpillar in a unique position and allows ______ an advantageous systems approach.
Based ______ existing software and engine control strategies, the specific needs ______
heavy fuel burning engines and applications can be easily adopted. Depending ______ engine
type, application and boundary conditions, a tailor-made version allows ______ optimal
operation.
The engine protection system operates independently ______ the engine control system
and has its own independent sensor equipment. This ensures that engine operation is monitored
independently ______ other control systems.
The ECM functions can be divided ______ a core system and a performance system.
The core system consists ______ a control device A4E4, one crankshaft speed pick-up,
two camshaft speed pick-ups, two high-pressure sensors, inlet metering valve and injector
drivers.
 The performance system ensures optimal engine settings ______ all operating conditions,
using information like exhaust gas temperature, charge air pressure, ambient conditions and lube
oil temperature.

f) Complete the chart below answering the questions.

What are the components

of CaT CRS?
What safety devices are
used in the system?
What is HPP purpose?

What type of fuel has the

HPP been modified for?
What is the purpose of the
inlet metering control?
What are HPP key
features?
What is the purpose of the
rail?
How many injectors are
fed by one rail segment?
What is the purpose of the
flow limiter?
What is the purpose of the
safety valves?
Is there a separate control
fluid system?
What do you know about
injector itself?
What is the purpose of the
ECM?
 SPEAKING COMPETENCY DEMONSTRATION
Marine diesel engine development history
List of questions

1. Comparison of 2-stroke vs 4-stroke engines: maintenance, parts, valve mechanism,

energy efficiency, lubrication, power, cost, weight, etc.
2. Comparison of Diesel’s and Otto’s engines: energy efficiency, cost, maintenance,
common faults, parts, means of combustion.
3. Wartsila dual-fuel engine: working operation, energy efficiency, maintenance, common
faults, parts, fuel types.
4. The dual combustion cycle: operations, peculiarities, application, energy efficiency,
comparison of diesel cycle and dual cycle.
5. Pollutants: regulations addressing them, abatement technologies.
6. Gas engines: peculiarities, application, energy efficiency, maintenance, parts, cost.
7. Combustion process: combustion elements, fuels on board, ignition sources, flashpoint,
fire point, self-ignition temperature, atomization, turbulence, penetration.
8. Dual-fuel engines: modes of operation, safety devices, maintenance, operational
requirements, emissions, common faults.
9. Comparison of 2-stroke vs 4-stroke DF engines: combustion cycles, parts, operation,
maintenance, energy efficiency, safety devices, lubrication, power, cost, weight, etc.
10. ME-GI fuel and ME-LGI fuel types: delivery condition, supply pressure, supply
temperature, fuels characteristics.
11. MAN L35/44DF: operation, maintenance, fuel types, parts, energy efficiency,
advantages, challenges, compliance.
12. Energy efficiency: innovative technologies, requirements, compliant engines, future
perspectives.
13. Slow steaming: modes of operation, application, benefits, challenges, fuel consumption,
emissions.
14. CRS: operation, maintenance, parts, benefits, challenges, operational characteristics.
15. Engines with Cat CR: operation, energy efficiency, benefits, challenges, maintenance,
fuel types, parts, safety devices, emissions.