Korean Ship Yard Seminar KSYS

August 2015

Small Bore: Latest new engine development, designs and

future technologies

Ole Srensen
Senior Manager
Engineering / Marine Low Speed

MAN Diesel & Turbo < 1 >

Agenda

1 Small bore new engines and latest design information.

2 Cylinder Liner Cold Corrosion, latest engine design

3 FBIV, status and FBIV + TCEV

4 Low sulphur Tier III solutions for small bore engines

MAN Diesel & Turbo < 2 >

Small Bore G engines dot5

G50ME-B9.5
moved to replaced engines

MAN Diesel & Turbo < 3 >

Small Bore S Engines dot5

S50ME-B9.5 exchanged with S50ME-C9.5

S50ME-B9.5 moved to replaced engines
S50ME-C9

MAN Diesel & Turbo < 4 >

 Small Bore engines
New Minimum rpm and MEP Possibilities for dot 5

Engine type rpm Bar

Extended MEP and speed layout
G50ME-C9.5 85->79 16.8->15.8
Introduction of new ECS control strategy - new
G50ME-B9.5 85->79 engine running map
Introduction of modified de-rating concept
S50ME-B9.5/S50ME-C9.5 99->89
S50ME-C8.5 108->102
S46ME-B8.5 110->105
G45ME-C9.5 94->87 16.8->15.8
G40ME-C9.5 106->99 16.8->15.8
S40ME-B9.5 124->111
S35ME-B9.5 142->127
S30ME-B9.5 166->148

Moved to replaced engines

MAN Diesel & Turbo < 5 >

50ME-C9.5 versus 50ME-B9.5

ECS system are quite different from each other.

ME-B Start air and exhaust valves are not fully electronic controlled
For ME-B the control system cannot prevent wrong way starting
For ME-B, Start performance can only be partly affected
For ME-C, Timing of start air valves and exhaust valves are controlled
according to special starting settings, offering full flexibilities for obtaining
good starting performance.
After start , control system automaticalally change timings to SFOC optimization
Improved abilities to perform very heavy running(acceleration)
Improved Start performance
Support for special dot5 running mode.
Improved support of EGR etc.
ME-C control system takes over a range of funtionalities normally handled by
by bridge manouvering system, the interface to these external system is
modified, lead to cost down of the external systems
ME-C necessary in case of GI, GIE, LGIM, LGIP

MAN Diesel & Turbo < 6 >

 LES engine program 2015

S30ME-B9.5
S35ME-B9.5
S40ME-B9.5
G40ME-C9.5
G45ME-C9.5
S46ME-B8.5
S50ME-C8.5
S50ME-C9.5
G50ME-C9.5
MAN Diesel & Turbo < 7 >
 Possibility for Alternative fuels for our
Small Bore Engines.

Our ECS, with the present control system, are not able to support ME-GI
engines with L1 revolution higher than 175 rpm and ME-LGI engines with
L1 revolution higher than 148 rpm.

We are working on a new control system that will support also the required rpm
for the smallest engine, but the timeframe for this is four years from now!

Consequence:
L1 revolution L1 rpm x 1,07 ME-GI max rpm ME-LGI max rpm ME-GI ME-LGI
S30ME-B9.5 195 208,65 175 148 No No
S35ME-B9.5 167 178,69 175 148 Ok No
S40ME-B9.5 146 156,22 175 148 Ok No
G40ME-C9.5 125 133,75 175 148 Ok Ok
G45ME-C9.5 111 118,77 175 148 Ok Ok
S46ME-B8.5 129 138,03 175 148 Ok Ok
S50ME-C8.5 127 135,89 175 148 Ok Ok
S50ME-B9.5 117 125,19 175 148 Ok Ok
G50ME-B/C9.5 100 107 175 148 Ok Ok

For engines with more than 8 cylinder the max. rpm will be reduced.
MAN Diesel & Turbo < 8 >
Agenda

1 Small bore new engines and latest design information

2 Cylinder Liner Cold Corrosion, latest engine design

3 FBIV, status and FBIV + TCEV

4 Low sulphur Tier III solutions for small bore engines

MAN Diesel & Turbo < 9 >

 Cylinder condition design features

S30ME-B S35ME-B S40ME-B G40ME-C G45ME-C S46ME-B S50ME-B/C S50ME-B S50ME-C G50ME-B G50ME-C
MK9.5 Mk9.5 MK9.5 MK9.5 MK9.5 MK8.5 MK8.5 MK9.5 MK9.5 MK9.5 MK9.5

Topland in % 10 7,9 7,9 10 10 8,9 8,9 8 10 6,6 10

~1/2 Lube X X X X X
1/4 Lube X
1/8 Lube X X X X X
Slim Liner X X X X X X
Bore cooled X X X X x
POP V4 X X
POP V5 X X X X
POP V6 X X X X X
RDL X (X) X X X X
LDCL Full X X X X
LDCL Piping X

Moved to replaced engines

MAN Diesel & Turbo < 10 >

 RDL (Rating Dependent Liner)

A new liner is designed for the high Test case

rating (L1 layout).
Focus is in the upper part of the liner.

L1Liner

RDL Liner

MAN Diesel & Turbo < 11 >

Agenda

1 Small bore new engines and latest design information.

2 Cylinder Liner Cold Corrosion, latest engine design

3 FBIV, status and FBIV + TCEV

4 Low sulphur Tier III solutions for small bore engines

MAN Diesel & Turbo < 12 >

Fuel Booster Injection Valve

Next generation ME fuel system is currently being developed.

The basic idea is to further develop the current ME system. The

target for project are the following:

Increase the dynamics/performance of the fuel

injection.
Simplify the system by introducing a unit injector
design.

MAN Diesel & Turbo < 13 >

Fuel Booster Injection Valve

Comparison

Prospective Design Current Design

312 kg 2278 kg

6S50ME-B
MAN Diesel & Turbo < 14 >
 FBIV
Fuel Booster Injection Valve

Slide valve technology Fuel plunger Hydraulic piston Connection to control oil

Suction valve

MAN Diesel & Turbo < 15 >

Service Test of FBIV on
MV Front Mersey 6S50ME-B9.2

Total running hours: 6,500

Excellent condition of components at
first inspection after 534 hours

MAN Diesel & Turbo < 16 >

 FBIV Status

FBIV with FIVA control

Testing in parallel with ELFI controlled FBIV

Testrig with FIVA and 2/3 x BFIV Future ME design

MAN Diesel & Turbo < 17 >

Service Test of:
TCEV (Top Controlled Exhaust Valve) &
FBIV (Fuel Booster Injection Valve)

TCEV & FBIV

vs
Original

Test Cylinder Unit Original Cylinder Unit

with TCEV & FBIV with HCU, Fuel Booster,
& Exhaust Actuator

MAN Diesel & Turbo < 18 >

Service Test of:
TCEV (Top Controlled Exhaust Valve) &
FBIV (Fuel Booster Injection Valve)

TCEV Control
valve

Accumulator

Hydraulic
piston

Air spring

Connection to FBIV

MAN Diesel & Turbo < 19 >

Test at Mitsuis test engine February 2014

MAN Diesel & Turbo < 20 >

Test at Mitsuis test engine October 2014
2nd prototype

MAN Diesel & Turbo < 21 >

 TCEV and FBIV

Service test on 6S50ME-C8 Top Controlled

Test on G95ME-C planned Exhaust Valve
Introduced on G90ME-C10.5 (TCEV)

Fuel Booster
Injection Valves
(FBIV)

MAN Diesel & Turbo JOF-LDF3 3339242.2014.05.02 < 22 >

 Torill Knutsen 6S50ME-C8.1-TII
Service test planned October 2015

TCEV + FBIV will be installed on

cylinder 1 on Starboard engine

MAN Diesel & Turbo < 23 >

 FBIV for Methanol opertion

Hydraulic piston

Suction Valve/purge valve

Fuel plunger

MAN Diesel & Turbo < 24 >

Mitsui Test engine 4S50ME-T
LGI Methanol
Has been operated on Methanol at 100% engine load.
95% methanol and 5% diesel fuel

MAN Diesel & Turbo < 25 >

Agenda

1 Small bore new engines and latest design information.

2 Cylinder Liner Cold Corrosion, latest engine design

4 FBIV, status and FBIV + TCEV

3 Low sulphur Tier III solutions for small bore engines

MAN Diesel & Turbo < 26 >

Emission control areas (ECA)

MAN Diesel & Turbo < 27 >

Choice of technology
Two-Way Approach

Tier III NOx: NOx reduction

with EGR

Low SOx: Low sulphur Exhaust

fuels Gas Scrubbers

MAN Diesel & Turbo < 28 >

IMO Tier III - Low sulphur EGR

Cost down possibilities

MAN Diesel & Turbo < 29 >

IMO Tier III - Low sulphur EGR

EGR version 1+2 EGR version 2.5

MAN Diesel & Turbo < 30 >

IMO Tier III - Low sulphur EGR

MAN Diesel & Turbo < 31 >

IMO Tier III - Low sulphur EGR

1. Siemens EGR5, (7-9 cyl 50,46,45)

MAN Diesel & Turbo < 32 >

IMO Tier III - Low sulphur SCR

SCR (Selective Catalytic Reduction)

MAN Diesel & Turbo < 33 >

IMO Tier III - Low sulphur SCR

MAN Diesel & Turbo < 34 >

IMO Tier III - Low sulphur SCR

MAN Diesel & Turbo < 35 >

Disclaimer

All data provided in this document is non-binding.

This data serves informational purposes only and is especially
not guaranteed in any way. Depending on the subsequent
specific individual projects, the relevant data may be subject
to changes and will be assessed and determined individually
for each project. This will depend on the particular
characteristics of each individual project, especially specific
site and operational conditions.

MAN Diesel & Turbo < 36 >