Auxiliary engine developments

Marine diesel engine specialists Wärtsilä and MAN B&W share a common goal in many respects. One such example is the intention to significantly increasing the time between overhauls (TBO) on their marine auxiliary engines

MAN B&W says that for any engine, the time between overhaul (TBO) is a constant focus for the designer and for the operator. The operator seeks the longest possible intervals, with respect to the initial investment and without having to spend too much on the daily service costs. Also, the engine designer seeks to obtain the longest possible overhaul intervals, with respect to market competition, design tools, procurement and manufacturing costs.

Wärtsilä offers the shipowner three types of auxiliary engine, the Wärtsilä 20, Wärtsilä 26 and Wärtsilä 32, for marine generating sets with electrical outputs of 495 to 8,640kWe. The Wärtsilä 20 has cylinder configurations of four, five, six eight and nine cylinders in-line, while the Wärtsilä 26 and 32 are both offered with six, eight and nine cylinders in-line and 12, 16 and 18 cylinders Vee-form. All are turbocharged four-stroke type built for reliable heavy-duty operation on the same heavy fuel oils as in the main engines.

MAN B&W has sold more than 100 L21/31s since the first L21/31 GenSet was installed onboard the Princess of Scandinavia. This set has now passed its 10,000 hours of service with a positive service record. The L21/31 is the third of the new generation of GenSets from Holeby. The first, the L16/24, was introduced in 1996, and the next, the L27/38, was introduced in 1999. The L27/38 has been particularly popular in the container ship market, and the sales record is approaching the 1,000 engine mark.

Wärtsilä Corporation has also been strong in this market and has manufactured its 2,000th Wärtsilä 20 diesel engine in its ten year production run and service experience has confirmed its ability to achieve long times between overhauls. The engine manufacturer says that up to 24,000 hours operation between overhauls are achieved on light fuel oils.

The 2000th engine is one of three nine-cylinder engines being supplied as complete diesel generating sets for a 2500 TEU container ship being built at the German shipyard Aker MTW Werft GmbH in Wismar for the German shipowner Reederei Nord Klaus E. Oldendorff GmbH. This is one of 16 container ships of the same class from Aker MTW for various owners, for which Wärtsilä has also supplied Sulzer 7RTA72U-B main engines but with various configurations of Wärtsilä 20 generating sets according to the shipowners? requirements.

MAN B&W has also achieved an important milestone working with CP Ships (UK) Limited when its MAN B&W Holeby L28/32H GenSet reached its 24,000 hours operating interval and the owner is now heading for 30,000 hours before the main overhaul.

The company opened up the No. 3 auxiliary engine on Canmar Courage, which is seven years old and has run 24,441 hours since new without being opened up. The Canmar vessels are each powered by one six cylinder and two nine cylinder sets. We took a look at one unit to gauge if we could extend the running hours to 30 000, when I believe the main bearings should be inspected, says Paul Siddons, technical director of CP Ships. He explains that the fuel used is 380 cSt and is quality controlled through full analysis before it is put to the engine. Also the lube oil is analysed every three months and frequently separated and always maintained within specification.

The next stage is 27,000 If the pulled cylinder unit looks good at 27 000 hrs, then Siddons says he will be confident in continuing the operation to 30 000 hrs, where a complete overhaul will be carried out, which is expected to take place at the end of the year.

This means that CP Ships plans to continue with these ships for 10 years and 30,000 hours. This is possible with the ships? load pattern ? where one of the three3 GenSets onboard is normally sufficient powerwise for the ships hotel load and the reefer containers. Consequently, the GenSets are loaded at approx. 75-80% of MCR. Two of the GenSets are continuously running on 380 cSt HFO, whereas the third standby set is held on MDO. The third GenSet is only in operation for the additional bow thrusters power during harbour manoeuvring.

In order to even out the operating hours on all three sets, the power tasks for the GenSets are changed and turned around for each vessels? round-trip.

Common?rail fuel injection

The leading development for Wärtsilä auxiliary engines in recent years is common-rail fuel injection and has been coming into service with a growing number of Wärtsilä engines during 2003. Although the majority of these are ships? main engines, with the largest installation being four Wärtsilä 16V46 engines with a combined output of 67.6 MW in the new passenger liner Queen Mary 2 being delivered in December 2003, there are also a significant number of Wärtsilä common-rail engines in marine auxiliary applications.

At present, only the Wärtsilä 32 engines are available for marine auxiliary applications with common-rail fuel injection. Their lack of visible smoke makes them particularly beneficial in port when engines might be lightly loaded supplying power for lighting, air conditioning and other hotel systems, as well as some engine-room ancillary services.

The first application of Wärtsilä 32 engines with common-rail injection is for powering generating sets engines in large container liners. The first such engine entered service in March 2003 in the containership Axel Maersk, built at Odense Steel Shipyard A/S in Lind?, Denmark, for AP M?ller. Similar plant has been on the Anna Maersk, Arnold Maersk and Arthur Maersk.

Each of these ships actually has four diesel generating sets, three with Wärtsilä 8L32 engines and one with a Wärtsilä 6L32 engine. One of the eight-cylinder auxiliary engines is equipped with common-rail fuel injection. The Wärtsilä 8L32 sets each give an electrical output of 3460 kW at 720 rpm, and the Wärtsilä 6L32 set 2590 kW at the same speed.

Model Cylinders Ouput range (kW) ABC Anglo Belgian Corporation NV. www.abcdiesel.be DX L3,6,8 138-750 Allen, Rolls Royce Diesel Business, www2rolls-royce.com 2000 L4,6,8,9 704-1584 3000 V12,16 1584-4160 4000 L6,8,9,V12,16 1970-5255 5000 L6,8,V12,14,16 3150-8400 Moteurs Baudouin, www.moteurs-baudouin.fr VTI V12 317-604 R 124 SR L6 294-375 M26 L6,V8,12 177-957 BERGEN Rolls-Royce Marine ASA. www2rolls-royce.com K L6,8,9,V12,16,18 885-3975 C25 L5,6,8,,9 1100-2700 BRG L6,8,9,V12, 2545-5300 B32 L6,8,9,V12 2880-6000 CALLESEN DIESEL Heinrich Callesen AS. www.cat-engines.com 425 L3,4 132-177 427 L3,4,5,6,8 254 CATERPILLAR Inc. www.cat-engines.com 3400 L6,V8,12 228-620 3500 V8,12,16 588-1901 3600 L6,V8,12,16 1730-5420 CUMMINS Engine Company Ltd. www.cummins.com/marine NT855 L6 280-395 VTA28-M V12 458-608 KTA19/M L6 336-507 KTA38/M V12 746-1007 KTA50/M V16 880-1291 QSK60 V16 1563-1901 DAEWOO Heavy Industries Ltd. www.dhiltd.co.kr V158TI V8 302-353 V180TI V10 357-441 V222TI V12 446-530 DAIHATSU DIESEL Mfg. Co. Ltd. www.dhtd.co.jp/index.html DC-17 L5,6 480-610 6DL-16 L6 440 6DL-19 L6 353-551 DK-20 L3,5,6,8 480-1280 DK-26 L5,6 1280-1600 DK-28 L6,8,16 1900-5000 DK-32 L6,8,12 2208-4413 DK-36 L6,8,12 3310-6325 DETRIOT DIESEL Corporation. www.detroitdiesel.com Series 60, 14L L6 298-410 DEUTZ AG www.deutz.de FM 1015 V6,8 210-554 616 V8,12,16 384-864 620 V8,12,16 834-1819 628 L6,8,9,V12,16 1230-3600 EMD Electro-Motive Division, General Motors Corporation www.gmed.com 645 E6 V8,12,16 785-1565 645 F7B V8,12,16,20 1265-2985 645 EB V8,12,16,20 1184-2960 710 V8,12,16,20 1500-3730 GE DIESEL General Electric Company, www.ge.com/transportation 7FDM V8,12,16 1268-2984 FDL V8,12,16 1488-2976 GRENAA Motorfabrik A/S. www.grmo.dk FS24 L3,6 318-728 GUASCOR S.A. www.guascor.com E318 V12 352-569 F180 L6 248-419 F240 L8 369-455 F360 V12 566-698 F480 V16 783-908 SF L6,8,V12,16 260-1229 HANSHIN Diesel Works, www.sphere.ne.jp/hanshin-d/engine 6L24GSH L6 478 6LU24 L6 621 6LUD24 L6 660 LH26 L6 882 LH26/A L6 1029 LC26 L6 625 6LU26 L6 738 8MX28 L6 2427 6MUH28 L6 1691 6MX28 L6 1839 LH28 L6 1029 6LUN28 L6 1176 L/C/H/Z28L L6 1176-1471 LH30L L6 1323 LH31 L6 1323 LH32L L6 1471 LH34LA L6 1618 LA34 L6 1765-1838 6LU35 L6 1471 6LUD35 L6 1470 LH36L/LA L6 1765-2206 6EL38 L6 2058 6LUS40 L6 2794 6LU40 L6 2059 6LUS40 L6 2202 6EL40 L6 2430 LH41L/LA L6 2427-2647 6LF46/A L6 2647-2942 LH46L/LA L6 2942-3309 6LF50/A L6 2942-3309 6LF54/A L6 3677-4045 6LF58/A L6 4413-4633 HEDEMORA DIESEL AB www.hedemoradiesel.se VA V6,8,12,16,18 550-1650 VB V6,8,12,16,18 700-2100 HIMSEN Hyundai Heavy Industries www.hhi.co.kr H21/32 L5,6,7,8,9 800-1800 H25/33 L5,6,7,8,9 1450-2610 ISOTTA FRASCHINI SpA. www.isottafraschini.it 1300 L6,V8,12 219-673 1700 V8,12,16 698-1730 IVECO Aifo SpA, www.aifo.com 8281/8291 V8,12 206-883 IZAR Propulsion Y Energia Motores, www.enbazan.es BRAVO V12,16,18 4500-7200 KELVIN Diesels PLC. www.britishpolarengines.co.uk KEL140-6M L6 354 TBSC8 L8 399 KEL170-6M L6 560 KOMATSU Diesel Company Ltd. www.komatsu.co.jp/product/compocat/ 117 L6 349 122 L6 405-463 125 L6 368-410 132 L6 423-514 137 L6 500-566 140 L6,V12 421-955 170 L6 669-735 LUGGER Alaska Diesel Electric Co Ltd, www.northern-lights.com SA6D140-1 L6 373-522 SA6D170-A-1 L6 522-671 MAK Catapillar Motoren GmbH & Co KG. www.mak.de M20 L6,8,9 970-1450 MAKITA Corporation, www.netwave.or.jp/~makita/ M30M L6 1103 L30M L6 1342-1492 M31M L6 1342-1492 L31M L6 1342-1492 M32M L6 1342-1492 M33M L6 1492-1715 LS33L L6 1119-1471 LS35L L6 1268-1692 LS38L L6 1566-2059 LS42L L6 1902-2500 MAN NUTZFAHRZEUGE AG, www.man-nutzfahrzeuge.de 2866 L6,V8,10,12 250-809 2876 L6 515 MAN B&W Diesel AG, www.manbw.com 16/24 L5,6,7,8,9 475-855 21/31 L5,6,7,8,9 905-1840 23/30H L5,6,7,8 615-1215 27/38 L5,6,7,8,9 1425-2735 28/32H L5,6,7,8,9 1000-1880 32/40 L6,7,8,9,V12,14,16,18 2750-8380 VP185 12,18 1402-3120 RK215 RK6,8,12,16 745-2760 RKG RK6,8,12,16 1030-2880 RK270GS RK6,8,12,16 950-3425 RK270 RK6,8,12,16,20 1420-6000 RK280 RK12,16,20 3715-8640 MIRRLEES BLACKSTONE www.manbwltd.com See MAN B&W MITSUBISHI Heavy Industries Ltd. www.mhi.co.jp/index.html SA L6,V12 405-858 SN V12 589-689 SR L6,V12,16 340-2300 6SGACE-1 L6,V12 660 MTU Motoren-und Turbinen-Union, www.mtu-friedrichafen.com/mtu/e/index.html 183 TE52 V8,12,16 300-550 2000 M40A/B V12,16 575-930 2000 M50A/B V12,16 498-800 396 TE54 V8,12,16 680-1580 4000 M40A/B V8,12,16 880-2080 4000 M50A/B V8,12,16 760-1840 NIIGATA Engineering Co Ltd, http//nigata-eng.co.jp 22HLX L6 810 28HLX L8 3000 34HLX V18 9990 PAXMAN www.manbwltd.com See MAN B&W PERVOMAISKDIESEL Pervomaiskdieselmash JSS. www.biz.mk.ua 8DFG 25/34 L8 320-600 ROTARY POWER International Inc. www.rotarypowerinternational.com 580 W2,4,6 ROTORS 723-2207 RUSTON See MAN B&W Diesel SCANIA Industrial & Marine Engines,www.scania.com DC9 L6 228-291 DC12 L6 273-405 SEMT PIELSTICK S.A. www.pielstick.com PA6B V12,16,20 3900-6900 PA6BSTC V12,16,20 4860-8100 PC2.6B V12,14,16,20 9000-15000 PC4.2B V10,12,16,18,20 13250-26500 SKL DIESEL Motoren-und Systemtechnik AG. www.skl-magdeburg.de 18/16 L6,8 525-2800 26/20 L6,8 530-883 29/24 L6,8 1320-2350 SULZER Wartsila Corporation. Marine Marketing & Sales, www.wartsila.com See Wartsila VOLVO PENTA AB, www.penta.volvo.se TAMD165A/C L6 240-407 D25A MS/MT L6 340-602 D30A MS/MT L6 300-602 D34A MS/MT V12 550-728 D49A MS/MT V12 730-1539 D65A MS/MT V16 1100-1539 D95A MS V16 1000-1489 WARTSILA Corporation. Marine Engines, www.wartsila.com 20 L4-,5,6,8,9 520-1620 26 L6,8,9,V12,16,187 1860-5850 32 L6,8,9,V12,16,18 2700-9000 YANMAR DIESEL Engine Co Ltd. www.yanmar.co.jp LAK V12,16 809-1214 LAA V12 736-831 LAH3 L6 456-515 KYM L6 478 6NY16/16A L6 331-559 6AY L6 555 6RY17 L6 736 ZVEZDA Production Association. www.zvezda.spb.ru M503A R7 2425 M520 R7 3600 M532/A R7 1765-1985 DRA534 R7 2426