Different ideas

Different applications

The choice,
Vee or Line
medium speed
power generating sets ?

December 2013.
 Line or Vee?????

Advantages ??
Disadvantages ???:

The choice, is simple, see the explanation as

follows in four sectors;
- Production
- Transportation
- Operation availability
- Maintenance

And then, politics, and /or

commercial thinking!
 Line or Vee, production

- Production
Block casting,

A line engine
block is easier
and cheaper to
produce.

Less mistakes
In the casting
Foundery, own production

• Highly experienced foundry,

established 1898

• Modern design with ProEngineer

• Engine blocks, cylinder heads,

flywheels, cooling water rings and
charge air housings made of high
quality nodular cast iron

• Environmentally friendly due to 95%

recycling of 20,000 t quarzsand a
year

• High flexibility due to own design,

research and manufacturing
 Line or Vee production

- Production
Block casting,
Vee blocks are
complicated
castings,
where easy
centerline
deformations
are not
detected
if
 Line or Vee production

Block casting, Vee blocks

have
problems
with thermal
expansion.

The large
heavy
center is
sensitive for
thermal
stress.
It’s a chunk
of cast iron.
Line or Vee production

Thermal expansion,
complicated,

Not only CM, all

Vee blocks
expand in three
dimensional
directions.

Cracks will be a
result.
Special in the
center.
 Line or Vee production

Competition, MAN, see the difference in the

scavenging air channel !!.
Vee engine inlet duct,

The Vee engine has its

V form in the center
used as the charge air
duct. This is where dust
is collected easy and it
where most blocks crack
after 150,000 hrs.

This is a MCM 12 cyl

Line or Vee production

Thermal expansion, Linear,

Line
blocks
expand in
linear
directions.

Thermal
expansion
is not
causing
stress.
Vee engine inlet duct,

The line engine

has a more
accessible duct at
the side,
inspections are
easy!!

This is a Loulo 8
cylinder
 Line or Vee production

Vee engines, use

the same
crankshaft as in
line engines,

So line engine
crankshafts are
loaded 50%,
compared with the
– Vee engines.

So are the bearings!

 Line or Vee production.

Vee engines,
have two big
end bearings
on one crank,
if it means
more difficult
installation
and higher
bearing load
– per cm2
 Line or Vee production.

Two big
end
bearings
on one
crank, is
double
trouble!

–
 Line or Vee production

One big
end
bearing on
one crank,
is a lot
more safe
over
300,000
engine
– hours
Less
pressure
per sq cm2
 Line or Vee floorspace

Building.
Less floor space for a 16CM32,
compared to two 8CM 32.
Measurements block :
16 cyl gen set is;
Long; 12 meter, Wide; 4 meter

8CM32 block is;

Long; 10,6 meter, Wide; 3,5 meter

Hart line distance 5 for line, 6 meter for

vee engines.
 Line or Vee floorspace

Floor space for a 40 MW power plant

with six sets 16CM32,
compared to twelve sets 8CM32.

The 16CM sets require 504 m2

The 8CM sets require 680 m2.
 Line or Vee transport

Transport is more simple,

a line engine has a better stability.
The base is as wide as the “ shoulder”.

A line engine 8CM32 is 2,490 mm

A Vee engine 16CM32 is 2,960 mm

( a 40 ft container is 2,440 mm wide)

–
Transport medium speed set
 Line or Vee transport

Transport weights.
Type Output Genset weight Gen set: pure engine weight Engine only:

m tons/ 1000 kg kg/ekw kg/ekw

6CM25 1.780 ekW 43 mTon 24,2 kg/ekW 19 mTon 10,7 kg/ekW
8CM25 2.300 ekW 49 mTon 21,3 kg/ekW 25 mTon 10,9 kg/ekW
9CM25 2.590 ekW 53 mTon 20,5 kg/ekW 28 mTon 10,8 kg/ekW

6CM32 2.760 ekW 65 mTon 23,6 kg/ekW 34 mTon 12,3 kg/ekW

8CM32 3.680 ekW 83 mTon 22,6 kg/ekW 44 mTon 12,0 kg/ekW
9CM32 4.140 ekW 96 mTon 23,2 kg/ekW 48 mTon 11,6 kg/ekW
12CM32 5.520 ekW 121 mTon 21,9 kg/ekW 65 mTon 11,8 kg/ekW
16CM32 7.360 ekW 145 mTon 19,7 kg/ekW 82 mTon 11,1 kg/ekW

– 6CM43 5.240 ekW 144 mTon 27,5 kg/ekW 82 mTon 15,6 kg/ekW
8CM43 6.980 ekW 187 mTon 26,8 kg/ekW 114 mTon 16,3 kg/ekW
9CM43 7.860 ekW 206 mTon 26,2 kg/ekW 123 mTon 15,6 kg/ekW
12CM43 10.475 ekW 274 mTon 26,2 kg/ekW 162 mTon 15,5 kg/ekW
16CM43 13.970 ekW 335 mTon 24,0 kg/ekW 215 mTon 15,4 kg/ekW
 Line or Vee transport

Transport weights.

Two engines 8CM32 are 44 mTons each

A single 16CM32 is 82 mtons.

Its cheaper to transport two 8CM32 sets,

compared with one 16CM 32.

Two Loulo sets to Dakar, 57,000 Euro (7&8)

Two MCM sets to Nouakchott 105,000 Euro
( both heavy lift vessels)
A 16CM32 would have been 132,000 Euro.
Line or Vee transport
 Line or Vee Operation availability;

Unscheduled stops are in 95% forced

due to cylinder related problems.

An 8 cyl line engine has a change of

( 8/100% =) 8 %

An 16 cyl Vee, has 16% change to make

a forced stop,

Or, the changes that a 16 Vee engine

has to stop are double if compared to an
8 cylinder.
 Line or Vee Operation availability;

Maintenance periods,
average over 40,000 hrs,
Duration, average 60 hrs per cylinder.
An 8CM32 is 240 hrs /year down
A 16CM 32 is 420 hrs/ year down

Availability of the 8 cyl engine is 94,5%

Availability of the 16 cyl engine is 89%

( 1-(60*8/8760)) = 94,5%

Or, the 8CM is 240 hrs per year more on

line
That’s 10 full days!!!!!. More productive!!
 Line or Vee Operation availability;

Availability, Spinning reserve!!

Four sets 16CM32 > 7,200 ekW each

Running at 90% load, = 25,920 ekW plant.

Each set has 90% - 110% in spinning

reserve, or, 1,440 kWe. per set

One set trips ; = – 6,480 ekW to cover!!

Three poor sets, in 110%,
will only be able to supply 23,760 ekW
So the whole plant trips.
 Line or Vee Operation availability;
Availability, Spinning reserve!!

Eight sets 8CM32 > 3,600 ekW each

Running at 90% load, = 25,920 ekW plant.

Each set has 90% - 110% in spinning

reserve, or, 720 ekW.

One set trip; = – 3,240 ekW loss

Seven sets left over,
These sets can supply 27,720 ekW,
Sets only have to go to 103% to keep the
plant running.
 Line or Vee Operation availability;
10% utility rule,
in Larger utilities, this is even below 5%.

In a stable power plant distribution system

( a grid) it is advised to keep the maximum
unit output below 10% of the total installed
power in the whole system.

This means that in a 100 MW grid, the

maximum unit power can be 10 MW only

And in a 40 MW grid, only 4 MW per set.

Wärtsilä is not applying this system.

 Line or Vee, consultants:
N+1 or N+2
This is often a request from consultants.
First N + 1.
Say a 40 MW power plant is required.
Wärtsilä will offer five sets of 8 MW, the 18V32,
plus the extra 1 set, so 6 sets in total.
This is 108 cylinders at 750 revs.

If we offer N+1, with the 9 cyl CM32,

This is a 4 MW unit, we have 10 +1 sets.
This is 99 cylinders, at 600 revs.

What’s a better choice?

Vee @ 750 revs, or Line @ 600 revs?
 Line or Vee, consultants:
N+2,

Say a 40 MW power plant is required.

Wärtsilä will offer five sets of 8 MW, the 18V32,
plus the extra 2 sets, so 7 sets in total.
This is 126 cylinders at 750 revs.

If we offer N+2, with the 9 cyl CM32,

This is a 4 MW unit, we have 10 +2 sets.
This is 108 cylinders, at 600 revs.

What’s a better choice? 750 revs, or 600 revs?

 Line or Vee, consultants:
N + high speed, is a better option

N sets are the high investment.

To have a high investment set, standing idle, is too
expensive.
Medium speed sets are not build for stand-by.
Starting up of a medium speed set is 45 Minutes,
load taking, another hour if warming up is properly
done.

High speed sets can start immediately and take

load in 20 seconds,
 Line or Vee Operation availability;

Reliability,

Same story as availability

With a 16 or 18 cylinder, the large number

of cylinders nearly doubles the change on
forced stops, if compared with a 8 or a 9
cylinder engine
 Line or Vee, Maintenance???

Vee
engines,
To remove
a simple
cylinder
head,
there are
special
tools
– required,
image the
struggle
 Line or Vee maintenance???

Line
engine,
here you
see the
straight
lifting
sling,
simple,
one hook
– only.
 Line or Vee maintenance???

Vee engines,
have liners
under an angle,
so all lifting
requires special
tools and
attention.
See the struggle
–
 Line or Vee maintenance???

Vee engines,
Need more
muscles in
elbow, stomach
and knees to
lift the cylinder-
heads, cooling
ring, Pistons
and liners,
– Lifting and
lowering under
an angle, see
the struggle
 Line or Vee, maintenance???

See the
efforts to get
a simple
piston back
into the liner.
Think of all
the possible
damage what
can happen in
Africa!!
–
Maintenance problems with Vee
Charge aircoolers
Charge aircoolers
are difficult to
remove as they are
to be removed
forward, due to the
two exhaust lines.
They are as well
pretty big and
difficult to handle.
Its a struggle !!
Aircooler removal can be very easy!!

Line engines,
The charge air cooler is
removed from the side,
No struggle with overhead
crane and extra blocks,
Vee engine accessibility!

Cylinder
heads are
difficult
to access
from both
sides,
more
labour
hours
required.
How deep can you sink?

Overhaul of an
engine like this is
a criminal act.

Dust gets in every

where.
Parts get lost,

Real work hrs per

day stopped is 6
out of 24
All 12 cyl heads removed

This way
of
overhaul
creates
extra work
How to handle sensitive parts??

Fuel pumps,
laying in the
dust,

and how to
keep the
control???
How to create a mess??

Workshop is
full!!

What a
mess !!
How to create a mess??

See how
parts are
handled. !!
Overhaul and inspection!!

Work like
this has to
be done on
all parts, ,
during this
work no
electricity
production.

A waste of
time
Overhaul and inspection!!

Same here,
all this
inspection is
time consuming,

This particular
overhaul took 10
full weeks.
 Financial,

Financial, investments generator sets,

Medium speed sets, 750 revs, will cost

1300 $/ ekW installed, on light fuels, if
running on heavy fuels, its 20% more,
1,600 US$ /ekW.

Medium speed sets, 600 revs, will cost

1600 $/ ekW installed, on light fuels, if
running
– on heavy fuels, its 15% more,
1,800 US$ /ekW

These are APS prices!!

 Financial, a line engine is
a lower investment!
,
Financial, re-calculated
Line 600 revs versus Vee at 750 revs.

Medium speed sets, 600 revs,

Power is linear with revs.
600 > 750 = 1,25 factor.

If we take the 1,800 US$/ekW installed for

our line CM32,

Compared with line engines, 750 revs,

The Vee’s from Wartsila, MAN and MaK
Our price is 0,8 ( 600/750) = 1,440 US$ /ekW
 Line or Vee, applications
generator sets,

Several questions for different applications.

-Investment restrictions?
-Stand-by, prime power or baseload?
-Expansions expected?
- Expected lifetime in years?
- Expected running hours per year?
- Starting response time required?
-Transport and construction limits
-Production cost per ekW?

-Total Cost of Ownership?????

-Over how many years?????
 Financial, a line engine is a
priced higher, by CPGS
- CPGS is having a commercial pricing
system for the engines purchased from
Kiel Engine Center. (KEC)

- One ex Marine sales, person, in the CAT

organisation has confirmed that KEC is
having lower prices for line engines
compared to Vee engines.
- Simple reasons;
- Lower production cost due to faster and
simpler assembly
- Higher turnover in line engines for
Marine applications.
 Financial, why Vee engines
by CPGS
- CPGS is having a Wärtsilä mentality and is
trying to copy the Wärtsilä style of doing
business.

- Wärtsilä is always promoting Vee engines for

power plants, as these guys are aiming at 100 >
200 MW power plants and trying to beat gas
turbine plants.
- The Vee engine has the largest output and less
units are used for plants above 60 MW.
- Wärtsilä has based its engineering and
purchasing on Vee engines, this to limit the
variations possible.
 Financial, why Vee engines
by CPGS
- Why was and is Wärtsilä promoting Vee engines?
- History, Wärtsilä shipyard went bankrupt in 1982,
- The engine factory was kept alive and had a
restart, these guys saw the market for power
generation with their Vaasa W32, their only
product.
- There was already a market with the Mirllees
Blacksmoke, the Stork Werkspoor etc, all larger
bore sets.
- The 12 MW SWD TM620, only line was a popular
engine for power generation.
- As well Sulzer’s low- & medium speed.
- Plus the low speed B&W’s, the MAN’s and the
Mitsui’s and other Japanese marine sets.
- ,
 Political, Wärtsilä & CPGS.

- F.e, the 12 bMW, 9TM620, did 11 eMW in land

based power.

- Wärtsilä had to compete only the Vasa W32 sets.

- They started to compete the low and medium
speed sets. This with their lower priced 750 revs
sets. They where successful!

- The cutting edge was their standard power plant,

every section was engineered on low purchase,
low installation work and spare part sales after
the warranty period.
- So Wärtsilä successfully pushed the low- and
medium speed line engines out of the market.
- ,
 Political, Wärtsilä & CPGS.

- Another negative, or positive effect;

- Vee engines have more often damages, and
consume more parts.
- Wärtsilä promoted V engines as this increased
the turnover in parts.
- Same with CPGS, i guess, more parts
consumption after the warranty period is cash$$

- Ship owners are longer in the business and more

focused on 25 year Total Cost of Ownership.

- That’s’ why ship owners go for line engines.

 - Line versus Vee
financial, SFC

Fuel consumption,

My real question mark with the information

from CPGS is the given fuel consumptions.

Ignition and combustion periods and stroke

have an important influence on the SFC.

This is not reflected in the CM engine

information.
 - Line versus Vee
financial, on SFC:
- Fuel consumption,

Combustion period
for a line engine:
600 revs = 0,03333 seconds

For a Vee engine

750 revs – 0,026777 seconds

Difference is 20 more time for the

combustion in a line engine!!!

CPGS is having commercial reasons

to keep the SFC at the same level.
 MaK Long-Stroke
Engines • Technical Data

Advantages of the long-stroke engine

• Maximum operational reliability
• Maximum economy
• Low fuel consumption
• Low lubricating oil consumption
• Long maintenance intervals and com-
ponent lifetime
• Heavy fuel compatibility
• Robust and simple
• Reduction in the numer of components
• Highly maintenance-friendly
• Environmentally-friendly due to low NOx
and CO2 emissions
• Easy installation
 MaK Long-Stroke
Engines • Technical Data
Engine Type M 20 M 25 IM 32 C VM 32 C IM 43 C VM 43 C
Number of Cylinder 6, 8, 9 6, 8, 9 6, 8, 9 12, 16 6, 7, 8, 9 12, 16
Bore [mm] 200 255 320 320 430 430
Stroke [mm] 300 400 480 420 610 610
Stroke/Bore Ratio 1,5 1,57 1,5 1,31 1,42 1,42
Cylinder Rating 170-190 300-330 380-500 480-500 900-1000 900-1000*
[kW]
Speed [min-1] 900-1000 720-750 600 720-750 500-514 500-514
Mean Piston Speed 9,0-10,0 9,6-10,0 9,6 10,1-10,5 10,2-10,5 10,2-10,5
[m/s]
BMBP [bar] 24,1-24,2 24,2-25,8 24,9 23,7 23,7-27,1 23,7-27,1
Power Range [kW] 1020-1710 1800-2970 2880-4500 5760-8000 5400-9000 10800-16000*

SFOC**[g/kWh] 186-190 182-184 178 180 176-178 176-178

100 % MCR
SLOC [g/kW] 0,6 0,6 0,6 0,6 0,6 0,6
tol. + 0,3 g/kWh
 MaK Long-Stroke
Engines • Technical Data

MaK / CPGS has now the new 12 & 16 CM32

As well the long stroke concept.
Important issue is the mean average piston speed.
The new 12/16CM32 have a new long stroke, 460 mm
( it was 420 mm)
This results (@750 revs) in 11,5 meter/ sec.
The line CM32, (@600 revs) with a stroke of 480 mm
Has an average piston speed of 9,6 m/sec.

This is 17% higher average piston speed.

Needless to say that the SFC will be a lot higher.
Spare part consumption will be significant higher.
 Line or vee, pure commercial?.

Commercial thinking is to see what the

competition is doing and make sure the
competition is beaten in area’s where they can
be beaten.
Do not try to beat Wärtsilä and MAN on price.

Due to KEC & CPGS double digits profits and

our margins as dealer, we will never be able to
beat the competition on price
So we have to win the Consultant first with our
better technical proposal.
 Line or vee, pure commercial?.

After winning the Consultant, we have to

convince the Owner that our proposal is
technical better, has a better efficiency and a
better availability.

Our offers with line engines are to be

considered as technical superior and we shall
make sure our technical proposal is different
and better.
 Line or vee, pure commercial?.

Convince the new Owner, and its Consultant,

that our idea with line engines is a better
option.

Special in remote African area’s for Island

operated power plants,
Special when working with African labour and
doubtful technical knowledge.

Line engines keep operation and maintenance

as simple as possible.
 Last but not least

Shipping,
the most common engines are line engines.
QE2'S POWER PLANT IS DIESEL ELECTRIC, a system
chosen for its inherent reliability and flexibility. In 1986/87,
in an operation costing £100m, nine medium speed MAN
L58/64 nine cylinder turbo charged diesel engines were
fitted, in place of the aging and fuel thirsty steam plant. The
diesel engines drive C.E.C. generators, and each develop
10.5 MW of electrical power at 10,000 volts.
Each engine weighs approximately 120 tons.
This is a double busbar system.
Last but not least

Marine,
philosophy,
Line engines
where possible

5,000 mtons
Crane vessel.
Has 9 sets 9
cyl W32
Wartsila’s
 Warning !

.
This presentation is a science of
vague assumptions based on
debatable figures from inconclusive
instruments performed with equipment
of problematic accuracy by a person
of doubtful reliability and questionable
mentality!
 Thanks

Hope it is clear
why Line engines
are the ultimate
choice for African
projects

Wish you all the

luck in the future.
Hans