Rev.

DOOSAN RETROFIT SERVICE

Part Sales & Technical Service Team

 Retrofit Service Items

1 Alpha Lubricator System

2 DOOSAN BWM System

3 DOOSAN WIO System

4 Temperature Monitoring System

5 Turbo-charger Cut out System

6 Approved Method Files

1
ADAPTIVE CYLINDER OIL CONTROL SYSTEM

The Ultimate Lubrication System

2
Contents

1. What is Alpha Lubricator ?

2. Layout

3. Main components

4. How to retrofit ?

5. Benefits of Alpha Lubricator

6. Reference list

3
1. What is Alpha Lubricator ?

High pressure injection directly into the piston ring pack

Very Precise Injection Timing ( Electronically )

Optimal Utilization of the Oil with minimum of loss

Very Easy and Precise control of the feed rate

Pre-lubrication of the cylinder before start of the engine

4
1. What is Alpha Lubricator ?

Mechanical Type VS Alpha Lubricator

Description Mechanical Type Alpha Lubricator

1.2 g/kwh (K/L)

Feed Rate S % x 0.26 g/kwh
1.5 g/kwh (S)
Oil Consumption RPM dependent LOAD dependent
Pump Stroke Injection Frequency
Adjustment of Feed Rate
(Adjusting Bolt) (in HMI)
Pump Stroke Adjustable Fixed
Injection Frequency 1 / 1 revolution ( fixed ) Adjustable
Injection Pump Pressure 4 5 bar 40 50 bar
Oil Actuating Power Camshaft Rotation Booster Oil Pressure
Operating Method Mechanic Electronic

5
2. Layout
1) System layout

6
2. Layout
2) System connection PUMP ALCU HMI
STATION

PUMP STATION TANK

Build up oil pressure(40-50 bar)

LUBRICATOR UNIT
Oil Injection

ALCU 24V DC

(Alpha Lubricator Cont. Unit) 220 V

Master Control Unit 440 V,
3 ph
Back Up Control Unit

HMI PANEL
(Human Machine Interface)
Remote Control & Display

LOAD TRANSMITTER
ANGLE ENCODER LUBRICATOR
LOAD ANGLE
BACK UP TRIGGER
BACK UP
TRANSMITTER ENCODER TRIGGER
SYSTEM
Piping System
CYLINDER
Electrical Connection 7
3. Main components
1) PUMP STATION AND STARTER PANEL

Build up oil pressure (40-50 bar)

Consist of two pumps, Heater, Filters, Suction
Tank and Pressure/Temperature sensor.
One pump is for Stand-by

Cylinder Lube Oil Pressure Cylinder Lube Oil Temperature

Normal service Value 40-50 bar Normal Service Value 30-60 C

Alarm min. 35 bar Alarm max 70C

Alarm max. 60 bar

8
3. Main components
2) LUBRICATOR UNITS

Oil Injection
- One Lubricator for below 60 bore Engines, Two Lubricators for 70 98 bore
Engines
- Consist of inlet nitrogen accumulator ( 25-30 bar ) and outlet
accumulator (1.5bar )

9
3. Main components
3) ALCU & LOAD TRANSMITTER

ALCU
- Master Control Unit (MCU)
- Switch Board Unit (SBU)
- Backup Control Unit (BCU)

LOAD TRANSMITTER
- Calibration with Engine load
- FUEL INDEX MCU

10
3. Main components
4) ANGLE ENCODER & PICK UP UNIT

ANGLE ENCODER
- Installed at Crankshaft Fore End
- TDC & Trigger signal MCU

PICK UP UNIT
- Installed at Turning Wheel
- Consist of two pick-up sensors
- TDC signal MCU & BCU

11
3. Main components
5) HMI & UPS PANEL

Control & Display Interface

- Adjustment of Feed Rate
- Display of Engine Speed,
Fuel Index, Oil Pressure,
Oil Temperature and Alarm

UPS Panel
- Uninterruptible Power
Supply for Alpha System

12
4. How to retrofit ?

MODIFICATION PARTS FOR ALPHA

1) CYLINDER LINER
in case of previous design
- Drilling of Oil Hole ( 4 -> 9 )
- Grinding Oil Groove

2) NON RETURN VALVE

- Adoption of New Non Return Valve

13
4. How to retrofit ?

1) CYLINDER LINER

14
4. How to retrofit ?

1) CYLINDER LINER

Modification of Lub. Quill

- Drilling and Grinding

15
4. How to retrofit ?

2) NON RETURN VALVE

16
 4. How to retrofit ?

MODIFICATION TIME CHART

WORKING DAY
PROCEDURE
1 2 3 4 5 6 7

Cyl. Cover Dismounting & Assembly

Cyl. Liner Modified Lub. Oil Pocket

Replaced Non-return Valve

Electric Cabling

Booster Pump Unit

Piping & Lub. Unit

Control Unit
Installation of
Alpha HMI Panel
Component
Angle Encoder

Back up Trigger

Flushing & Cleaning

Supervision Commisioning of System

REMARK 8 WORKING PEOPLE

17
5. Benefits of Alpha Lubricator

1) Saving Cost
Specification 6S50MC-C 7S60MC 7S80MC 12K90MC

Kw 9,488 14,313 25,485 54,898

Layout SMCR
BHP 12,900 19,460 34,650 74,640

Kw 8,065 12,166 21,662 46,663

Load point
(=85% SMCR) 10,965 16,541 29,453 63,444
BHP

Fuel oil sulphur content % 3.00 3.00 3.00 3.00

g/Kwh 1.50 1.50 1.50 1.20

Mech. Lubricator
g/BHPh 1.10 1.10 1.10 0.90
Feed rate
g/Kwh 0.78 0.78 0.78 0.78
Alpha with ACC
g/BHPh 0.57 0.57 0.57 0.57

Running Hours/Year Hour 7,500 7,500 7,500 7,500

Cylinder Lub. Oil price $/ton 1,700 1,700 1,700 1,700

Saving for Year $/year 74,096 111,776 199,025 266,941

18
5. Benefits of Alpha Lubricator

2) Cylinder Liner Condition

ENGINE : DOOSAN-MAN B&W 12K90MC OWNER : A.P.MOLLER

DEL. DATE : 2000.09.25
TEST DATE : 2001.12.08 ( at 8390 Running Hour )

12K90MC, 3th April 2002 at

10,543 engine hours and
2153 operating hours at
Alpha ACC = S% * 0.25 g/bhph

19
5. Benefits of Alpha Lubricator

3) Cylinder Liner Wear Down 12K90MC-C

901,40

901,20
Max Liner Diameter (mm)

901,00

900,80

900,60

900,40

900,20

900,00

899,80
0 5000 10000 15000 20000 25000

0.05 / 1000 Hours (mm) Cyl No. 1A Cyl No. 2A Cyl No. 3A Engine Hours
Cyl No. 4A Cyl No. 6A Cyl No. 8A Cyl No. 9A
Cyl No. 1A Cyl No. 9A Cyl No. 10A Cyl No. 1A
Cyl No. 6A Cyl No. 7A Cyl No. 10A Cyl No. 12A

Average Wear down rate of Alpha Lubricator : 0.05 mm / 1000 Hours

Average Wear down rate of Mechanical Lubricator : 0.10 mm / 1000 Hours
20
6. Reference List

Reference List of Alpha for Doosan Engine

As of MARCH 2010
RETROFIT WORK
ENG.TYPE (INCLUDING MATERIAL SUPPLY TOTAL
MATERIAL)
46MC/MC-C 3 3
50MC/MC-C 44 16 60
60MC/MC-C 22 19 41

70MC/MC-C 15 15

80MC/MC-C 13 13
90MC/MC-C 16 16
98MC/MC-C 3 3
TOTAL 116 35 151

21
BEARING WARNING AND CONTROL SYSTEM

An Ultimate Solution for the Bearing Safety

22
Contents

1. What is BWACS ?

2. Layout

3. Main components

4. System function

5. Specification

6. How to retrofit ?

23
1. What is BWACS ?

1) Introduction

MAN Diesel have adopted Bearing Wear Monitoring (BWM) system as standard
equipment for new vessel contracts signed after 1st March 2008.

BWACS, which is a BWM (Bearing Wear Monitoring) System, is specially developed

by Doosan as a engine builder and fully approved by MAN Diesel and classes.

By introducing BWACS, severe bearing damage resulting in consequential damage

to the crankshaft, bedplate and crossheads can be avoided, and long and costly
repair time can be minimised.

When installed, open-up inspections on a routine basis can be omitted or decreased

in frequency.

24
 1. What is BWACS ?

1) Introduction

Bearing damages

Solution !

Open-up inspection is a main fact of bearing damage.

25
1. What is BWACS ?

2) Working principle
The principle of BWACS is to measure the change of BDC (Bottom Dead Center) level
relative to engine structure.
Measure how far the crosshead guide shoe comes down at BDC position of each cylinder.

Key Features
High accurate system of 10m degrees.
Simple and compact components.
User-friendly monitoring program.

Crosshead bearing

Crankpin bearing

Main bearing

26
2. Layout
1) System configuration

Main units for BWACS

SCU (Signal Capture Unit)
SAU (Signal Analysis Unit)
DMU (Data Monitoring Unit)
UPS
Power supply

SCU is consisted of two proximity sensors, a temperature sensor and a control module.
It can measure bearing wear value and send the measured data to SAU.

SAU analyzes the measured data and then send the analyzed data to DMU shows
operators the result of wear value and wear trend.

DMU displays real time wear value and trend graph.

UPS and Power supply unit supply the electric power to SCU, SAU and DMU.

27
2. Layout
2) System configuration diagram

..
SCU SCU SCU SCU
Inside of Engine

SAU UPS Power supply

Inside of Console at ECR

: Signal Flow
DMU : Power Flow
Mount of Console at ECR

28
2. Layout
3) Mechanical installation diagram
ENGINE INSIDE

1 2 3 4 5 6

Guide shoe
SCU

Cable Gland
Engine Wall
Power Supply & Communication Line

ENGINE OUTSIDE ENGINE CONTROL ROOM

DMU

JUNCTION Power Cable

BOX RS485 Cable

RS485 Cable UPS POWER SUPPLY

SAU
220V AC

24V DC

29
To AMS
2. Layout
4) System connection diagram

30
3. Main components
1) SCU (Signal Capture Unit)

Installed inside of each all cylinders in engine

Measure crosshead level at BDC
Provide self diagnostic function using internal temp sensor
Two proximity sensors and one temperature sensor
Easy installation and maintenance

31
3. Main components
2) SAU (Signal Analysis Unit)

Installed inside console of ECR (Engine Control Room)

Communicate with SCUs to analyze the measured data
Provide an early bearing warning, alarm and slowdown
Possible to connect up to 20 SCUs by one unit

3) DMU (Data Monitoring Unit)

Mounted in ECR console

Real time monitoring
Display wear trend and system status
Touch screen PC with UPS

32
4. System function
1) Wear value and deviation monitoring
B-WACS shows the Filtered wear value from two sensors of all cylinders in real time
wear values are displayed as graphs.
Sensor Deviation shows designated the difference between the individual sensor and the
average of all sensors.

33
4. System function
2) Wear trend monitoring
BWACS is to show trend of wear value in real time, short term and long term.
Real Time : It shows the filtered values for the period, which is between 50 sec to 10 min.
Short term : It continuously displays the filtered values for the latest 24 hours.
Long term : It shows average, maximum, and minimum of Filtered Wear Value at the
interval of 6 hours. It is possible to set up monitoring time.

34
4. System function
3) Alarm list 4) Alarm limits
Alarm list contains all Alarms happening Standard alarm limits presented by MAN Diesel.
after the start of the B-WACS system. The limits are changeable as needed.

Description Wear Value

Alarm limit, filtered sensor value 0.5 mm

Alarm limit, sensor deviation 0.4 mm

Alarm limit. cylinder deviation 0.3 mm

Slow down limit, filtered sensor value 0.7 mm

Slow down limit, sensor deviation 0.5 mm

Pre warning limit, sensor deviation 0.25 mm

35
 5. Specification
1.SCU
1) Proximity Sensor
- Input Voltage : 10 - 30V DC
- Current Consumption : 4 - 20 mA
- Sensing Range : 1 - 7 mm
- Accuracy : 10
- Housing Material : Chrome-plated brass
- Operating Temperature : 25 - 70
2) Control module
- Input Voltage : 15 V to 34 V DC
- Current Consumption @24V : 150mA average
- Operating Temperature : -20 top 70
2.SAU
- Input Voltage : 15 V to 34 V dc
- Current Consumption @24V : 150mA average
- Internal Nonvolatile Memory : 16GBytes
- Operating Temperature : -20 top 70
3.DMU
- Input Voltage : DC 24V +15%/-20%
- Power Consumption : 30W
- Touch Screen : Analogue Resistive 8.4, 800 x 600
- IP Rating : IP60
- Vibration : 0.7g
- Operating Temperature : 0C to + 60C / 32F to 140F
4.UPS
- Input Voltage : 24VDC
- Output Voltage : 24VDC
- Power : 1150VA/770Watt
- Interface : USB, Serial Port
5. Power supply
- Input Voltage : 100 240VAC
- Input fuse : 6.3A
- Input frequency : 45 65 Hz
- Output Voltage : 24VDC
36
6. How to retrofit?

1) Installation of SM (Sensing Module)

SCU

37
6. How to retrofit?
2) Fixation of cable

Engine inside

Engine outside
38
 6. How to retrofit?

3) Tuning of gap between sensor and crosshead 4) Installation of SAU

5) Installation of DMU

4mm shim for tuning

39
6. How to retrofit?

SAU
DMU

ECR

Liner Engine side

Junction Box
Crosshead
SCU

#1 #2 #3 #4 #5

40
 6. How to retrofit?

MODIFICATION TIME CHART

Retrofit Schedule for BWM System ( Below 8 cyl')

WORKING DAY
PROCEDURE
1 2 3 4 5 6

Electric Cabling

Signal Capture Unit

UPS & Power Supply

Installation of
BWM Signal Analysis Unit
Component
Data Monitoring Unit

Cleaning

Supervision Commisioning of System

REMARK 5 WORKING PEOPLE

41
 6. How to retrofit?

MODIFICATION TIME CHART

Retrofit Schedule for BWM System ( Over 9 cyl')

WORKING DAY
PROCEDURE
1 2 3 4 5 6

Electric Cabling

Signal Capture Unit

UPS & Power Supply

Installation of
BWM Signal Analysis Unit
Component
Data Monitoring Unit

Cleaning

Supervision Commisioning of System

REMARK 7 WORKING PEOPLE

42
OIL WARNING AND CONTROL SYSTEM

The Best Solution for Water in Oil Monitoring

43
Contents

1.What is OWACS ?

2.Layout

3.Main components

4.System function

5.Specification

6.How to retrofit ?

7.Scope of supply

44
1. What is OWACS ?

1) Background
Water in oil is a major contributor to a poor bearing
condition, and worst for crosshead bearings having
a lead-based overlayer featuring a nickel interlayer.
The rapid wear from corrosion due to water in
lubricating oil can lead to scuffing between the pin
and the nickel-interlayer, which can lead to steel to
steel contact in a matter of hours.

These problems can be prevented by OWACS.

Bearing Metal Worn Out

45
1. What is OWACS ?

2) Introduction of OWACS
OWACS is a WIO (water in oil) system for measuring water contents in the lubricating oil,
which is designed by Doosan Engine as engine builder and approved by MAN Diesel and
classes.

Key Features
Measurement of Water Activity and
Sensor unit temperature.
Three relay for alarm output.
Built in modbus protocol RS485-based.
Save log data (Max30years).
Fully integrating with BWACS (option).

Control unit

46
2. Layout
1) System layout
Engine side Engine control room

Terminal Block in
Main L.O Inlet Pipe
console

Controller Junction Box

DMU

Water Sensor

Alram Monitoring system

47
2. Layout
2) System interconnection

Engine side Engine control room

RS485
Twisted pair
Multicore screened
Multicore
12 twisted 12 twisted DMU
pair screened pair screened

Controller Box Junction Box Terminal Block

1X1 Ships
screened per Alarm
sensor Monitoring
Multicore
System
Sensor 6 twisted
pair screened
Main L.O Inlet Pipe

48
3. Main components
1) Sensor unit
Sensor unit is attached at main inlet pipe and measures
water content in lubricating oil by humidity sensor.
High accuracy (including nonlinearity, 0.02[aw])
Maximum Operating Pressure: 10bar
Housing: Stainless Steel

2) Control unit
Installed on engine for analysing of data from sensor unit.
Displays measured data and setting parameters
Supports serial communication [Modbus/RTU]
Supply three types of outputs
(RS485, Analog signal and digital relay signal)

49
 3. Main components
2) Control unit

Humidity range : 0 ~1 Water Activity (aw)

1X1 screened per sensor

1
Accuracy : +0.02 ~ -0.02
WIO Sensor

2
3
4 Operating voltage : 18 ~ 36VDC
5
6 Relay output : 0.5A, 250VAC
7
Digital output : RS485
0VDC Analog output : 4 ~ 20mA
24VDC

S.G.S.G.

TRX+
TRX-
Analog Out -
Analog READY

0VDC

24VDC

TRX-
TRX+
NO1.

(Modbus
RS485
READY

NO2.
Out
READY

NO2.

NO1.

(Modbus
RS485
READY
+ (Current)

HH HH
H ALARM

Interface
H ALARM

ALARM

RTU/ASCII)
Interface
ALARM

RTU/ASCII)

Alarm Monitoring System

Multicore 12 twisted pair screened
50
3. Main components
3) DMU (Data Monitoring Unit)

Mounted in ECR console

Real time oil condition monitoring
Display oil condition trend
Touch screen PC with UPS
Data Monitoring Unit is an option item !

4) Software program
Software program for Personal Computer
DMU can be substituted by this software program.

51
 4. System function

1) Water activity and temperature monitoring 2) History function

OWACS shows the water activity and Water activity and temperature data can be
lub oil temperature in real time. stored at flash memory which is loaded
inside on the period set by users.

52
 5. Specification

1.Water activity 5.General

- Measuring range : 0 ~ 1 aw - Supply voltage : 15 ~ 32V DC
- Accuracy : 0.02 aw, 3.0 aw (0.90 aw) - Current consumption : 12 ~ 24 V DC
- Response time with stainless steel filter at 20 C : 10min in still oil - Pressure range for tight probe : 0.01 ~ 20bar
- Cable grand : M24 (Aluminum)

2.Temperature
- Working range : -50 ~ 200 C
- Temperature sensor element : PT100 ohm (Tolerance class A)
- Accuracy : 0.2 C

3.Transmission Outputs
- Analogue outputs
Y2 : T(-50 ~ 250), 4 ~ 20mA, Load resistance 500 ohm
Y3 : aw(0.00 ~ 1.00), 4 ~ 20mA, Load resistance 500 ohm

4.Relay Outputs
- Three freely selectable relay outputs : three a contact
(normal state : 0.7aw, alarm state : 0.8aw, fault state : 1.0aw)

53
6. How to retrofit?

1) Installation of Control unit

When installing diesel engine for a ship, install it by using L-bracket and vibration proof pad.

Vibration proof pad

L-Bracket

54
6. How to retrofit?

2) Installation of Sensor unit

When installed Sensor unit at oil pipe, it is recommended to install within 45 vertically.
Basically the sensing part of sensor unit should be sunk in the lubricating oil.

RECOMMENDED MOUNTING
POSITION RANGE

Main LO inlet pipe

Sensor unit

Main LO inlet pipe

55
 6. How to retrofit?

MODIFICATION TIME CHART

Retrofit Schedule for WIO System

WORKING DAY
PROCEDURE
1 2 3 4

Electric Cabling

Installation of Controller
WIO
Component Sensing Module

Supervision Commisioning of System

REMARK 2 WORKING PEOPLE

56
7. Scope of supply

1) Package 1 (Full package)

Doosan delivers material, installation work and commissioning.
AMS interface is optional.
DMU is an option item.

2) Package 2 (Material package)

Doosan delivers below items.
A. Material
B. Quick installation guide
C. Software for personal computer
DMU is an option item.

57
7. Scope of supply

2) Package 2 (Material package)

Material list
NO. ITEM SPEC QUANTITY
SENSOR
1 SENSOR & CONTROLLER SET 1SET
CONTROLLER
2 CABLE 7 X 2 X 0.75 (RADOX MFH-S, TP) 100M
3 FLAT BAR 25W X 3T X 1000L 5EA
4 CABLE WITH BUCKLE A-W20 X 250 50EA
5 CABLE TIE A-140 50EA
6 VIBRATION RUBBER A=11, B=30, L=15 5EA
7 L-BRACKET 40 X 40 X 30 X 0.5 5EA
8 FERRULES 1SET = 50EA 1SET
9 HEX.SOCKET BOLT for CONTROL BOX M5 X 50 (SIZE .) 10EA
10 SOFTWARE PROGRAM FOR PERSONAL COMPUTER 1SET
11 DATA MONITORING UNIT OPTION ITEM 1EA

58
TEMPERATURE MONITORING SYSTEM

The Best Solution for Temperature Monitoring

59
Contents

1.Why Bearing Temperature Monitoring?

2.What is DOOSAN Bearing Temperature Monitoring?

3.Why Liner wall Temp Monitoring?

4.What is DOOSAN Liner wall Temp Monitoring?

5.Our Temperature Monitoring Solution

60
1. Why Bearing Temperature Monitoring?

1) In 2-stroke engine, approx. 10% of all damages reported to classification

societies related to bearings.

It may result in repair periods counted in weeks or even months!

With crankshaft related failures, which can result in notations in the class book,
influence the market value of the vessel negatively!

61
1. Why Bearing Temperature Monitoring?

2) In most cases of oil mist detection, the slow down will be triggered too late to avoid
harm to the bearing journal.

( oC )
BTM VS OMD
Main Bearing
Abstracts from report made by
Temperature
D.Paro, G. Liljenfeldt, T. Blomberg,
400
Wrtsil

300

200 Oil Mist

Alarm from temperature sensor Alarm from oil mist

100
Cutting the oil supply

1 2 3 4 5 ( Min )

Oil Mist Detection can not protect engine components from damages!

62
1. Why Bearing Temperature Monitoring?

3) Why DOOSAN temperature monitoring?

Offers real time temperature monitoring.

Can be integrated into any existing alarm and monitoring system.

Fast & reliable response from high quality sensors gives a higher level or safety.

63
 2. What is DOOSAN Bearing Temperature Monitoring?
1) Sensing points

Cross head bearing sensing

position

Main bearing sensing points

Crank pin bearing sensing position

64
2. What is DOOSAN Bearing Temperature Monitoring?

2) What is DOOSAN bearing temperature monitoring ?

Oil supply is the transmitter of bearing temperature to a temp sensor.
Sensor type : Main bearing ( Pt 100 )
Crank pin bearing ( Pt 100 )
Cross head bearing ( Base Pt 100 , Optional wireless sensor )

Alarm Monitoring System

Cross head

Crank pin

Intermediate
Box

Main BRG

65
2. What is DOOSAN Bearing Temperature Monitoring?
3) Main bearing temperature monitoring

66
2. What is DOOSAN Bearing Temperature Monitoring?
4) Crank pin bearing temperature monitoring

Crank pin side ENG wall

Sensing element : PT100

67
2. What is DOOSAN Bearing Temperature Monitoring?
5) Cross head bearing temperature monitoring
We can install two kinds of sensor at cross head bearing position.

Sensor Type : PT100 Sensor Type : Wireless

68
3. Why Liner Wall Temp Monitoring ?

1) In 2-stroke engine, approx. 6% of all damages reported to classification

societies related to cylinder liners.

Main engine damage claim 1998-2004

Total cost : USD 69.8 million

21% Various
4% Piston, Piston rod
5% Camshaft, Coupling
5% Fuel Pump, Gear
10% Journal, Bearing
5% Enablature, Stay bolts
6% Cylinder Liner
20% Crankshaft Con. Rod
24% Turbo Charger

Source : The Swedish Club Highlights, September 2005, Main engine damage.

69
3. Why Liner Wall Temp Monitoring ?

2) Why liner wall temp monitoring ?

Most 2-stroke engine cylinder liners have 2 holes predrilled for this system

Following symptoms can be monitored by liner wall temp system!

Insufficient cooling and lubrication.

Blow by on some of the piston rings.

Abnormal combustion condition.

70
4. What is DOOSAN liner wall temp monitoring ?

1) What is DOOSAN liner wall temp monitoring ?

Measuring the temperature in the upper part of the cylinder 5~6mm from the
inner surface.
Alarm, Slow down can be set on the AMS system.
Components
Sensor spec.
Type : Thermocouple
Ambient temp : 0 ~ 70c
Circuit current : 4 ~ 20 mA
Accuracy : 0.75 %
Converter
Measuring range : 0 ~ 600 c
Power source : DC 24V
Temperature sensor

71
4. What is DOOSAN liner wall temp monitoring ?

2) Install position

Inside

Alarm Monitoring System

Converter box

sensor

72
5. Our temperature monitoring system solution !
SYSTEM LAY OUT

Liner wall

Converter box

X-head bearing Alarm monitoring system

Intermediate box

Crank pin bearing

Main bearing

73
TURBOCHARGER CUT OUT SYSTEM

Reducing Fuel oil consumption & Exhaust emissions

74
Contents

1. Why Turbocharger cut out ?

2. Benefits

3. Concept of Turbocharger cut out

4. How to retrofit ?

5. Approval of document after Turbocharger cut out

6. Service Experience

75
1. Why Turbocharger cut out ?

1) Purpose of T/C Cut out system

Reduce fuel oil consumption

Reduce exhaust emission

Optimize cargo capacity in fleet

Due to the current economical crisis, it is noticed that some ship-owners, have large
container vessels, are considering operating their vessels with slow speed in order to
reduce main-engine fuel consumption.

To meet this growing demand, turbocharger cut out system has been introduced to
Improve engine performance during low-load operation.

76
1. Why Turbocharger cut out ?

2) Relations between Ship speed and Power

Relative
Relative propulsion
propulsion power
power needed
needed
%
120

110

100 Fig.1 shows the relation between power

90 25 knots refer to 100% and speed for a typical modern large post
relative propulsion power
80 panamax container vessel.
70

60
According to Fig.1 reducing the ship speed
50
by e.g. 4knots reduces the power requirement
to some 50%.
40

30
18 19 20 21 22 23 24 25 26 knot
Ship speed
Ship speed

Fig.1

77
1. Why Turbocharger cut out ?

3) Technical considerations of ship power reduction !

Operating at low speed in the 30-50% load area can create problems.

Depositing of soot particles in exhaust gas boiler

Build up of soot in turbocharger
Frequently cut in/out of auxiliary blowers
Increased heat load on components

78
 2. Benefits

1) Benefits of T/C Cut out

Turbocharger cut out will improve scavenge air pressure during low load operation
Improve specific fuel oil consumption
Reduce the heat load on engine components

2) Compare with other methods

Method Advantage Disadvantage

1. Choose a less powerful engine Cheaper initial investment Limits speed for entire ship life

2. Derate a new engine Significant SFOC reduction Typically limits speed for entire ship
life

3. Increase scavenge air Improve SFOC and reduce heat load on Major modification with regard to
pressure at low load components in the 30-50% load area IMO regulations
(Method of TC CUT OUT)

79
2. Benefits

Fig. 2 SFOC versus Engine load

Engines with four turbochargers and one turbocharger cut-out enables

operation at loads from 20% to 70% MCR :

Approx. 5g/kwh reduction of SFOC and 0.33bar increase in scavenge air

pressure at 50% power. (1 T/C cut-out of 4 T/Cs)
Approx. 3g/kwh reduction of SFOC and 0.40bar increase in scavenge air
pressure at 75% power. (1 T/C cut-out of 4 T/Cs)

80
2. Benefits

Fig. 2 SFOC versus Engine load

Engines with four turbochargers and one turbocharger cut-out enables

operation at loads from 10% to 35% MCR :

An SFOC reduction of 1 to 3g/kwh in the power range of 25 to 35% can be

expected.

81
3. Concept of Turbocharger cut out

Manual swing gate valve

Case of operation :
Possible to switch between slow and high speed
by manual valve operation

Treatment of rotor shaft :

Remain unchanged
Sealing air line of T/C should be modified
Caution :
It is necessary to supply lub oil for cooling of
journal part of rotor (T-side).
Supplying sealing air from turbocharger in
Fig. 4 T/C Cut out swing gate valve operation is required.

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3. Concept of Turbocharger cut out

Treatment of each flange

Exhaust gas receiver Gas inlet Swing Gate valve

Air outlet Swing Gate valve

Gas outlet No change

Treatment LO inlet No change

of
each flange
LO outlet No change

Air vent No change

Cooler Cooler Cooler
Scavenging air receiver Necessary to be supplied
Sealing air
By T/C modification

83
4. How to retrofit ? (Swing gate Valves)

1) Install swing gate valve at turbine side.

84
4. How to retrofit ? (Swing gate Valves)

2) Install swing gate valve at compressor side.

85
4. How to retrofit ? (Swing gate Valves)

3) Install control panel and modify main air valve

86
 4. How to retrofit ? (Swing gate Valves)

4) Install and modify T/C sealing air line

Fig. 5 Modify oil labyrinth

Fig. 6 Modify supporter

In case of MHI turbocharger

87
4. How to retrofit ? (Swing gate Valves)

5) Install indicator panel

88
5. Approval of document before T/C Cut out

1) In case of turbocharger cut off, it is considered as a major conversion in

accordance with Reg.13(2)(a) of MARPOL Annex .

2) Therefore the engine shall be carried out NOx emission test to ensure that
it still complies with the NOx emission limits contained in Reg.13 of MARPOL
Annex .

3) But if your engines are meet the following conditions, NOx emission test can
be omitted by common documentation.
Engine type is K98ME/ME-C, K98MC/MC-C
Three or four T/C
Only one T/C is cut out
Exhaust valve timing & Fuel injection timing is unchanged

89
6. Service Experience
Installed swing gate valve
- Engine : Doosan MAN-B&W 12K98MC-C (T/C type : MET83MA x 4 sets)
- Test date : 2010.12.20 ( Sea trial )

[Normal mode] [T/C Cut Out Mode]

15.86g/kwh reduction of SFOC at 50% load Reduction 4,085

ton/year
* Need to go further for long term measurements * Yearly operating hours: 7,000 hrs

90
6. Service Experience

Reference List of T/C cut out

As of MARCH 2012

ENG.TYPE T/C type Owner TOTAL

12K98ME-C MET83 x 4sets CSCL 2

12K98MC-C MET83 x 4sets CSCL 4
10K98MC-C MET83 x 3sets PIL 1

8K90MC-C MET66 x 3sets PIL 8

8K90MC-C TCA77 x 3set PIL 7

TOTAL 116 35 22

91
Approved Method File for Pre-2000 engines

The Best Solution for the Pre-2000 engines

92
Contents

1. Approved Method Files for MAN Engines

2. NOx Technical Code 2008

3. Benefits

93
1. Approved Method File for MAN Engines
AMF

Approved Document in compliance with Tier I NOx limit for

Pre-2000 engines

NOx (g/kwh)

NOx Limit Regulation

17.0

14.3
Pre-2000 Tier I Nox
Engines Tier II Nox
Tech Code
Tech Code
3.4 1997
2008
Tier III

1990 2000 2011 2016

AMF for MAN Engines consists of

- Slide Fuel Valve with low-NOx nozzle
- Engine Performance Adjustment
2. Nox Technical Code 2008
AMF

The revised MARPOL Annex VI and NOx Technical Code 2008

Enter force on 1 July 2010.

The Engines should comply with IMO Tier I NOx limit.

- Marine Diesel Engines

- Installed on a Ship Constructed, 1 JAN 1990 ~ 1 JAN 2000
- Power output of more than 5,000 kW
- Cylinder displacement at or above 90 liters

Application (for example : 7S70MC)

1st Vessel Last Vessel

Date of approval 1 years 5 years

Lead time Depending on certificate renewal date

(renewal survey)

5th. Oct. 2010 6th. Oct. 2011 6th. Oct. 2016

3. Benefits
AMF

Clean Gas Way

Compliance of
Regulation

Lower
NOx
Less emission
Smoke
Reducing
SFOC
Contact Point

Part Sales & Technical Service Team

Kim, yunki
General manager
Tel: 82-55-260-6530
E-mail: yunki1.kim@doosan.com

Park, dong gyu

Tel : 82-55-260-6137
E-mail : donggyu1.park@doosan.com

Cho, doo hyeong

Tel : 82-55-260-6138
E-mail : doohyeong.cho@doosan.com

www.doosanengine.com

97
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