Pounder's Marine Diesel Engines and Gas Turbines Ninth edition Edited by Doug Woodyard AMSTERDAM· BOSTON· HEIDELBERG· LONDON· NEW YORK OXFORD • PARIS· SAN DIEGO· SAN FRANCISCO· SINGAPORE SYDNEY· TOKYO ELSEVIER Butterworth-Heinemann is an imprint of Elsevier
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Pounder's Marine Diesel Engines and Gas Turbines Ninth edition
Edited by
Doug Woodyard
AMSTERDAM· BOSTON· HEIDELBERG· LONDON· NEW YORK
OXFORD • PARIS· SAN DIEGO· SAN FRANCISCO· SINGAPORE
SYDNEY· TOKYO ELSEVIER Butterworth-Heinemann is an imprint of Elsevier
Contents
Preface ............................................................................................................. vii Introduction ..................................................................................................... ix
1 Theory and General Principles ............................................................ 1
2 Dual-Fuel and Gas Engines ................................................................ 41
3 Exhaust Emissions and Control ......................................................... 61
4 Fuels and Lubes: Chemistry and Treatment ..................................... 87
ABC see Anglo Belgian Corporation Abrasive impurities in heavy fuel, 92 ACERT technology in Caterpillar high-speed
engines, 769 Acid stress, 127 Active mountings, 25-6 ADD see Advanced Diesel Engine
Development Company ADD30V Engine, 513-16 ADEC see Advanced Diesel Engine Control ADEMill:
Caterpillar control system, 768-9 EUI system for fuel injection, 543-4, 567
Admiralty Constant and engine performance, 150
Advanced Diesel Engine Control (ADEC), 801 Advanced Diesel Engine Development (ADD)
Company, 513-16 AFR see air-fuel ratio Afrika,x After top dead centre (AFDC), 3, 8-9 Air filtration for gas turbines, 839-40 Air manifold, MAN Diesel V28/33D engines,
608 Air-fuel ratio (AFR), 201, 858 Aircraft jet engines and gas turbines, 840-3 Akasaka Diesel low speed four-stroke piston
engines, 759, 761 Alcap system for cleaning fuel oils, 106-7,
109-10 Alfa Laval Alcap system, 106-7, 109-10 Alignment of large bore engines, 309
Index
Alkalinity reserve see base nnmber AlIen (Rolls-Royce) engines, 525-9 Alpha adaptive cylinder (AAC) oil control, 315 Alpha cylinder lubricator unit, 132-4 Alpha Diesel (MAN Diesel), 531-5 Alston Engines, 603 Aluminium alloy, 817 American Bureau of Shipping, 116 AMOS, UK XTS-W bearing wear sensor, 871-2 Amot speed monitor for VS 12 engine, 529 Anglo-Belgian Corporation (ABC), medium-
performance, 150 APR see anti-polishing ring Ash content of fuel oils, 97 Asphaltene content of fuel oils, 98 Asphaltenes stress, 127 Astern running and engine performance, 154-7 AIDC see after top dead centre Atmospheric distillation, 88 ATR see automatic flexible rating Automatic flexible rating (ATR), 370 Automation and Wiirtsilii medium-speed 64
type engine, 712 Automotive-derived high-speed engines:
Scania, 825-6 Volvo Penta, 826-7
Auxiliary blowers: Burmeister & Wain L-GB engines, 473 MAN B&W ME engines, 360
Auxiliary power generation, 162-3 Axial vibrations, 33-6
,,'I,
875
876 Index
B Backbone for MaK M32 engine, 552 Balancing, 18-19 Base number (BN), 119, 129-32, 134-5, 141 Bazan Motores, Spain, 537, 540 BBC see Brown Boveri BDC see bottom dead centre Bearing Overheating Monitoring System
Cantieri Navali Riuniti, xi Carbon dioxide (C02) emissions:
dual-fuel engines, 41 engine thermal efficiency, 287 exhaust gas emissions, 63-4 medium-speed engines, 517 Miller cycle, 189 two-stage turbocharging, 191
Carbon monoxide (CO), 63, 76, 86 Carbon-cutting see anti-polishing CASS see combustion air saturation system Cat Data link, 768 Catalytic cracking, 88-9 Caterpillar:
high-speed engines, 766-71 3500 series, 767-8 ACERT technology, 769 ADEM III control system, 544, 768-9 high-displacement, 766
Caterpillar Common Rail (CCR) fuel injection system, 565-8
Caterpillar Marine Power Systems, 257 CBM Management tool, 430-1 CCR see Caterpillar Common Rail CCU see cylinder control unit Centinel oil management system, 771 Centrifugal separators for fuel oils, 110-12 Cermet (ceramic metal) coatings, 350 Cetane number for fuel oils, 96 CFD see computational fluid dynamics
Charge air humidification, 73-4 Charge coolers for MAN Diesel V28/33D
engines, 608-9 Chevron Global Lubricants, 129 Chevron Marine Combustion Improver, 104-5 Chrome ceramic piston rings, 424 Churchill, Winston, ix CIT see controllable injection timing CL see controlled leakage Clean design for Bergen (Rolls-Royce) B32-40
engine, 622 Cleaning of fuel oils, 106 Cloud point of fuel oils, 98 CMCR see contract maximum continuous
rating CNG see compressed natural gas CO see carbon monoxide CO2 see carbon dioxide Coalescer for air filtration, 839 CoCoS computerized surveillance system, 781 CODAG see combined diesel engine and gas
turbine Code of Practice for Atmospheric Oil Mist
Detectors, 866 CODEG see combined diesel and gas turbine
electric CODOG see combined diesel or gas turbine
propulsion COGAG see combined gas turbine and gas
turbine COGES see combined-cycle gas turbine and
steam turbine electric Coking and lubricating oil for gas turbines,
838-9 Cold filter plugging point (CFPP), 105 Combined diesel and gas turbine (CODAG)
propulsion, 85, 172, 830-1 Combined diesel and gas turbine electric
(CODEG) propulsion, 830 Combined diesel or gas turbine (CODOG)
propulsion, 830 Combined gas turbine and gas turbine
(COGAG) propulsion, 830 Combined-cycle gas turbine and steam turbine
electric (COGES) propulsion, 832-3 Combustion air saturation system (CASS), 73 Combustion chambers:
Alpha (Diesel) 28/32A medium-speed engines, 533
Doxford low-speed engines, 479-80 large bore engines, 309-14 MAN B&W B7W ME engines, 358 MAN Diesel 48/60B engines, 595
Cylinder units: Bergen (Rolls-Royce) engines B32-40, 623 concept in four-stroke engines, 509 MAN (Holeby) L16/24 series, 781-3 Wlirtsila high speed engines W200 series, 821
Cylinders: condition in B&W engines, 327-8 covers for MC engines, 294 cut-out system for B&W engines, 334-5 Doxford low-speed engines, 482-4 frames for MC engines, 294 jacket water cooling system for RTA84T
engine, 408, 412 jackets for Sulzer RL engines, 444 pressure measuring system, 344 technology in medium-speed engines, 517 wear and lubricating oils, 121-3
Daihatsu single pipe (DSP), 718 Daring, 856 Data collector in CBM Management tool, 430 DDC see Detroit Diesel Corporation Delphi Bryce fuel injection systems, 249-50,
252-3,253-4,254-5
Derating of engine performance, 147 Det Norske Veritas Petroleum Services (DNV),
96,116-17,865,868 Detroit Diesel Corporation (DDC), 764, 795 Deutz engines:
628 series, 545 high-speed, 772-3 TBD 645 series engine, 546
DF see duel-fuel
DICARE system support (MaK engines), 569 Diesel combined Cycle, xxvi-xxvii Diesel, Rudolf, xvii, 1 Diesel-- electric drives, 166--71, 171-2 Diesel-mechanical drives, 161-6, 171-2 DIMOS system support (MaK engines), 569 Direct injection systems, 236-8 Direct water injection (DWl), 72-3, 76 DLE see dry-Iow emissions DNV see Det Norske Veritas Dorthe Maersk, 192 Doxford low-speed engines, 475-6, 476--191
Dry-Iow emissions (DLE) technology, 838 DSP see Daihatsu single pipe Dual-fuel (DF) engines, 41-60
gas engines, 51-2 gas-diesel engines, 51 injection systems, 248 MAN 51/60DF engine, 48-51 performance gas injection engine, 56-9 Wartsilli 50DF engine, 45-8
DWl see direct water injection
E East Asiatic Company ix-x Eavestone, xiv EC see exhaust closure ECC see 'eco cylinder controller' ECL see electronically controlled cylinder
lubrication 'Eco cylinder controller' (ECC), 384 'Eco main controller' (EMC), 384 Eco-engine (UBC series), 379-85 ECS see electronic control system ECD see engine control module; engine control
unit
, I I
EEC see electronic engine controller Efficiency of engines, 4-5 EGR see exhaust gas recirculation EIAPP see Engine International Air Pollution
Electronic gas injection (ELGI), 54-5 Electronic high-pressure cylinder lubricator for
large bore engines, 314-15 Electronic unit injection (EUI), 543-4 Electronically controlled cylinder lubrication
(ECL),384 Electronics and common rail fuel injection, 567 ELGI see electronic gas injection EMC see 'eco main controller' EMD see Electro-Motive Division Emissions see exhaust emissions Energol CLO 50M 70BN lubricant, 120 Engine blocks:
maximum rating, 144-6 mean effective pressure, 147-8 power build-up, 152-3 propellers
law, 148-9 performance, 150-2 slip, 148, 150
trailing/locking of propellers, 153-4 Engine Vision System (EVS) Enginerooms and safety, 865-74 Ensel engine selection program, 392 Environment:
gas turbines, 830 issues, xx-xxi legislation and lubricating oils, 118 performance of RT-flex electronic engines,
436 EUI see electronic unit injection European Union and greenhouse gases, 63 EVC see exhaust valve closure EVO see exhaust valve opening EVS see Engine Vision System Exhaust and air intake, 3600 series engines,
Expert system in CBM Management tool, 430 Explosions:
crankcases, 866-72, 872-4 relief valves for VS12 engine, 529
External unbalanced moments and vibrations, 29
ExxonMobil Marine Fuels, 101-2
F FADEC see full authority digital engine control Fast ferry propulsion, 767-8, 813 Father-and-son layout, 165-6,830 FCC see fluid catalytic cracking FCT see flexible camshaft technology Finnjet, 829 Fiona, ix First-order moments, 29-31 Flash point of fuel oils, 99, 135 Flexibility and gas turbine propulsion, 830
Flexible camshaft technology (FCT), 560, 563-4
Flexible manufacturing systems (FMS), 764 Fluid Analytical Consultancy Services (FACS),
142 Fluid catalytic cracking (FCC), 87, 89 FMS see flexible manufacturing systems Four-stroke engines:
Hoerbiger explosion relief valves, 872-4 Horsepower, 10-11 Hot Combustion process, xxvi-xxvii H.S. Denision, 847 HT see high temperature Humid air motor (HAM), 73 Hydrocarbons (HC), 61-3, 76-7, 78, 82-3, 86
IACS see International Association of Classification Societies
IC see inlet closure ICR see intercooled recuperated IF30 grade fuel, 818, 843, 845 !FEP see integrated full electric propulsion !MO see International Maritime Organization Impulse method for turbochargers, 183 InFi see intelligent fuel injection Injection and combustion, 235-8 Injectors for fuel injection, 238-40, 567 Inlet closure (IC), 10 Inlettemperature for Siemens GT35 gas
InVA see intelligent valve actuation Invisible smoke (IS), 596-7 IS see invisible smoke ISO 8178, emission regulations, 82-3 ISO 8217, fuel standard for marine
NA series, 212-14, 217-19 NR series, 212-14 TCA series, 214-20, 221 TCR series, 220-1 turbo compound systems, 231
vibrations, 27-8 volatile organic compounds, 56
MAN (Holeby) high-speed engines, 775-83 L16/24 genset series, 775-8, 778-83
MAN low-speed KSZ series engines structure, 496-8
Manoeuvring system (without bridge control) for L-GB engines, 472
Marine Spey SMlC combustor, 858 Marioff Oy company, 73 Marpol 73/78 regulation for marine pollution,
137 Maschinefabrik Augsburg Nurnberg see MAN Materials for MaK M32 engine, 555 Maximum continuous rating (MCR), 143,391 Maximum rating and engine performance,
144-6 MCR see maximum continuous rating
i I
888 Index
MCRS see modular common rail fuel system MCS see monitoring and control system MCD see main control unit MDEC (MTU Diesel Control Unit), 790 Mean effective pressure and engine
Modular system for MaK M32 engine, 553 Moment compensators for Burmeister & Wain
L-GB engines, 471 Monitoring and control system (MCS) Monte Penedo, xiii-xiv Mountings, active, 25-6 MPC turbocharging system, 647 MTU Diesel Control Unit (MDEC), 790 MTU Friedrichshafen:
active mountings, 25 common rail system, 257-63 fuel injection systems
Nodes and vibration, 14-16 Nohab medium-speed engines, 736-7 Noise:
engines, 19-21 gas turbines, 830 low-speed engines, 272
Northrop Grumman, USA, 854 NOx see nitrogen oxides NR series (turbochargers), 212-14
o Oil mist detection (OMD), 335, 865-6, 867-9,
871,872 Oil stress, 127-8 OMD see oil mist detection Oranje, xv Oros combustion chambers, 309-11, 327,
350-2 Otto working principle, 56 Overcritical running and torsional vibrations,
38-9 Overspeed protection on Allen (Rolls-Royce)
VS12 engine, 529
p Particulate matter (PM), 63 Particulates, soot and smoke, 81--6 Passenger ferries, gas turbines, 829 Paulstra active mountings, 25 Paxman (MAN Diesel):
high speed engines, VP185 type, 806-12 high-speed engines, 806-12
PC see piston cleaning PDM see Pulse Width Modulation Peak firing pressure in high-speed engines,
765-6 Performance of engines, 143-57 Performance gas injection (PFI) engine, 56-9 Petit Pierre, xi PFI see performance gas injection Pipework in MaK M43C engine, 562
MAN Diesel 48/60B engines, 596 L27/38 and L21131 engines, 599-600 L32/40 engines, 591 L58/64 engines, 574-6 V28/33D engines, 608
MAN (Holeby) high-speed engines L16/24 series, 779
MAN KSV series, 500-2 mean speed, 12-13 MTU series 4000 engine, 799 ring packs, 311-13, 359 rod glands, 428-9 Ruston (MAN Diesel) engines, 630-1, 633 Semt-Pielstick (MAN Diesel Group)
engines, 640-3, 647 SKL VDS 29/24AL engine, 739 speed in high-speed engines, 765 speed in Semt-Pielstick PA6B STC engine,
Wartsila (Sulzer) RTA84T engine, 405 see also rotating piston
Plant configurations for gas turbines, 830-4 Plant selection, 159-72 Plunger seizures, Sulzer (Wartsila) ZA40/
engines, 658-9 PM see particulate matter Podded propulsors, 170-1 Post weld-heat treatment (PW-HT), 349 Pour point of fuel oils, 99 Power:
build-up and engine performance, 152-3 Semt-Pielstick
/ PA6B STC engine, 816 PC2-6B engine, 639
turbines for MC engines, 297-80 Power related unbalance (PRU), 32 Power take ins (PTIs), 229, 298 Power take offs (PTOs), 26, 34-5, 36, 162,
165,297 Practical cycles, 2-3 Pressure:
ratings for engines, xxvii testing fuel valves in B&W engines, 333-4
Pressure charging: charge air cooling, 178-9 scavenging, 179-80 turbochargers, 173-233
Preussen, xix, 192 Propellers:
engine performance, 150-2 law and engine performance, 148-9 slip and engine performance, 148, 150
Propulsion: fast ferry, 767-8, 813 gas turbines, 829-34 intercooled recuperated cycle, 835-6, 857-8,
860 PTIs see power take in; power take ins PTOs see power take offs Pulse converter method for turbochargers,
183 Pulse jet cylinder lubrication, 427-8 Pulse Width Modulation (PDM) drive, 166 Pump/pipe injector v. unit injector for fuel
injection, 249-52
Pump/pipe injectors for fuel injection, 252-3 Pumps for fuel injection, 242-5
Q Quantum System Electronics, 771 Queen Elizabeth, 2, ix Queen Mary, 2, 85, 832 Quiet engine rooms, 21--4
R Rail in common rail fuel injection, 567 RCS see remote control system Refinery processes, 87-9 Reina Del Pacifico, 867 Reliability, gas turbines, 830 Relief valves for crankcase explosions, 872--4 REMIND software for centrifugal separators,
111 Remote control system (RCS), 790 Retrofits of turbochargers, 228-9 Reversing mechanism:
Burmeister & Wain L-GB engines, 471 MAN B& W MC engines, 297 Wartsila (Sulzer) RTA84T engine, 405
Schwitzer turbochargers, 811-12 SCR see selective catalytic reduction SECAs see sulphur emission control areas Second-order moments, 31-3 Secundus, xiv Sediment content offuel oils, 98 Selandia, ix-x, xiii Selection of engines, 159-72 Selective catalytic reduction (SCR):
carbon monoxide, 86 environmental issues, xx exhaust emissions, 77-81
Sequentially turbocharged (STC), 604 Service propulsion (SP) point, 292 Shaft generators for MC engines, 297 SHC see synthesized hydrocarbon Shell Alexia X OIL, 119 Siemens:
gas turbines, 843-7 GT35 (SGT-500) engine, 843-6
Signal processing unit (SPU), 869-70 Single pipe exhaust (Spex) in Wiirtsilii engines,
SMU see smart drive unit Societe des Etudes de Machines Therrniques
seeSEMT 'Soft blast' cleaning for Siemens GT35 gas
turbine engine, 846 SOLAS regulations (safety), International
Maritime Organization, 865, 867 SP see service propulsion SPC see spill port closure Specific fuel oil consumption, 144-5 Specific gravity offuel oils, 99-100 Spex see single pipe exhaust
Spill port closure (SPC), 245 SPU see signal processing unit SRB see sulphate-reducing bacteria SSV see start-up and safety valve Start-up and safety valve (SSV), 267 Starting air system:
Burmeister & Wain L-GB engine, 473-4 MAN B&W low-speed ME engines, 345 MAN Diesel V28/33D engines, 609
Starting in Allen (Rolls Royce) VS12 engine, 528-9
STC see sequential turbocharging system; sequentially turbocharged
Stena HSS 1500-class ferry, 830, 840 Stop-Choc active mountings, 25 Storage of heavy fuel oils, 89-90 Stork-Werkspoor Diesel (SWD):
T TBN see total base number TBO see time-between-overhaul TDC see top dead centre TDC, fuel injection, 822 Theoretical heat cycle, 1-2,2-3 Thermal cracking, 88 Thermal efficiency of engines, 6-7, 287 Thermal load in MaK M32 engine, 555 Thermal stress, 127 Thermodynamic conditions, MaK M32 engine,
551 Thrust bearings for Burmeister & Wain L-GB
engines, 465 Time-between-overhaul (TBO):
condition-based maintenance, 430 Doxford RL-type engines, 448 large bore cylinder liners, 425 piston rod glands, 428-9 Tribopack,423-5 Wiirtsila (Sulzer)
RT-flex engines, 432 RTA96C engines, 415-16
Timing for fuel injection, 245-6 Tin- aluminium (Sn40Al) alloy in main
bearings, 308-9 Toiler, xii Top dead centre (TDC), 2, 7, 19,42,59 Topham, Nick, 127 Torque, 11-12 Torsional vibrations, 36-9 Total base number (TBN), 101, 118, 119-20 Trailing/locking of propellers, 153-4 Trends for fuel injection, 247-9 TriboPack:
MAN (Holeby) L16124 series, 780 MAN KSZ series engines, 500-3 medium-speed engines, 508 Miller cycle, 188-9 Miller system for Niigata 32FX engine, 804 Mitsubishi Heavy Industries, 222-7 MTU 1163 series engines, 788 4000 series, engine, 800 8000 series engines, 790, 795 NA Series, 212-14, 217-19 Napier,210-12 noise, 21 Paxman (MAN Diesel) VP185 engine,
Ulstein Group, 615 Undercritical running and torsional vibrations,
38 Unified reqnirements (UR) and safety in engine
rooms, 867-8 Uniflow scavenging, 361, 387 Uniformity in fuel injection, 246-7 Union Steamship Company, xv Unit injector v. pump/pipe injector for fuel
injection, 249-52 Unit injectors, fuel injection, 250-2
V Vacuum distillation, 88 Valve inlet timing (VIT) in Sulzer (WiirtsiHi)
ZA40S engine, 660 Valves:
3600 series engines, 539 L-GB engines, 468 MAN Diesel V28/33D engines, 608 Nimonic, 527, 542
VAN see variable area nozzles Vanadium and corrosion by fuel oils, 92 Vandal, xi Vane separator for air filtration, 839-40 Variable area nozzles (VAN), 858-9 Variable compression ratio (VCR), 278 Variable exhaust valve closing (VEC), 274,
VIC see variable inlet valve closure Viscosity, fuel oils, 95-6, 135, 845 Viscosity index (VI), 109 Viscous damping, 412 VlT see variable injection timing
Viton O-rings for VS12 engine, 525-7 VLCC see ver:y large container carriers VMT see Variable Multi-Pulse VOCs see volatile organic compounds Volatile organic compounds (VOCs), 56 Volvo Penta automotive-derived high-speed
engines, 826-7 VRT see variable radial turbine (VRT) VTA see variable turbine area VTG see variable turbine geometr:y VTR-type turbochargers, 192-8 Vulcanus, xii
w WacoReG see water-cooled residual gas WfutsiHi:
7RTA52U two-stroke engine, 81 32DF engine, 44-5 50DF engine, 45-8 cleaning of fuel oils, 107-9 common rail injection systems, 257,
264-8 DF four-stroke engines, 42-4 direct fuel injection, xx direct water injection, 71-2 EnviroEngine concept, 83-4 exhaust emissions, 85-6 high-speed engines, 764, 818-15
RTAseries, 387-90, 392-5, 395-7,401-5 RTA68T-B,414 RTA84C, 414-19 RTA84T series, 405-10, 410-13 RTA96C,414-19,419-23 Sulzer RL-type, 440-9 Tribopack for extended TBO, 423-5 see also Sulzer (Wfutsilii)
Waspaloy Inconel 718 alloy for exhaust valves,
805 Waste heat recover:y (WHR), 287 Water in fuel oil, 90, 98, 135 Water-cooled residual gas (WACoReG), 76 WAVE engine performance simulation, 522-3 WECS see Wfutsilii Engine Control System Weight of Semt-Pielstick PA6B STC engine,
817-18
896 Index
Wetpac H system for Wiirtsilii, 73 WHR see waste heat recovery Wichmann WX28 two-stroke medium-speed
engines, 747-50 Wide operating speed range (WOSR), 769 Woodward Governor see Delphi Bryce Working cycles, 7-9
WOSR (wide operating speed range) technology in Caterpillar engines, 769