MAN B&W Diesel A/S

The Electronically Controlled

ME Engine

2002.05.24 - (2440/PCS)

Development History
Software audit

Approval test of Electronic Control System Quay trial Sea trial Inspection 8020 hours
2002.05.24 (2440/PCS)

ME Engine Programme

2002.05.24

(2440/PCS)

MC versus ME Engine plus the ME Engine Control System

MC Engine

ME Engine

2002.05.24

(2440/PCS)

The difference

2002.05.24

(2440/PCS)

Removed from the MC

Chain drive for camshaft Camshaft with fuel cams and exhaust cams Fuel pump actuating gear Conventional fuel injection pumps Exhaust valve actuating gear and roller guides Engine driven starting air distributor Electronic governor with actuator Regulating shaft Engine-side control console Mechanical cylinder lubricators
2002.05.24 (2440/PCS)

Added to make it an ME
Hydraulic power supply unit Hydraulic cylinder unit Engine Control System Crankshaft position sensing and tacho system Electronically controlled starting air valves Integrated electronic control of auxiliary blowers Integrated electronic governor functions Electronically controlled Alpha Lubricators Local Operating Panel

2002.05.24

(2440/PCS)

ME-C Engines
Reduction of weight for ME-C compared to MC-C 6S70MC-C: 555 ton

Calculated reduction 25 ton 6S70ME-C: 530 ton

Approximately 5% reduction

Mechanical Hydraulic System

Hydraulic Cylinder Unit

Hydraulic Power Supply

Mechanical Hydraulic System

Hydraulic Cylinder Unit

Safety and accumulator block Engine driven pumps Electrically driven pumps Filter Hydraulic Power Supply

Mechanical Hydraulic System Hydraulic Power Supply

(2440/PCS)

Hydraulic Power Supply

(HPS)
4T50ME-X; Pumps at fore end

Pumps and pump gear drive

MC
2002.05.24 (2440/PCS)

ME

7S50ME-C

ME-C Engines Hydraulic Oil Loop

Fuel oil pump Fuel 10 bar Hydraulic cylinder unit Alpha lubricator ELFI ELVA Exhaust valve actuator

200 bar

CCU Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. 5 Cyl. 6

Fine aut. filter

Safety and accumulator blok

Main lube pump Piston cooling + bearings Return to sump

From sump Engine driven hydraulic pumps EL. driven hydraulic pumps

L/73273-7.0/0902

(2600/RL)

7S50ME-C Engine Outline

L/73146-8.0/0802

(2220/TOV)

S50ME-C Overview
Location of gearbox for the 3 hydraulic pumps.

Port side

Starboard side

(2200/OZS)

S50ME-C Main inner parts

Output wheel.. Intermediate wheel Connected wheels. Gearwheel on crankshaft.
Double row of teeth

Removable distance piece

Total ratio: 12:1

(2200/OZS)

Two-Stroke Medium Bore ME Engine, Design Concept

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

Filter station Step-up Gear Hydraulic pumps 2. Order Moment Compensator shaft Tightening of Guideway arrangement

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

Guideway Arrangement
Chain wheel

Studs for hydraulic tightening

Balancer weigths

(2600/KNB)

Available Engine Power on the Propeller Curve: 7S50ME-C

% 100 90 80 70 60 50 40 30 20 10
Number of 56% pumps in use. 56% Hydraulic 56% pump index.

110 100

110 100

With cylinder cut-outs: 2 cylinders cut 1 cylinder cut 22 0 57

54% 54% 54% 83% 83% 81% 81% 100% 100% 100%

X%

Engine driven pump

(2440/PCS)

Example: 7S50ME-C with 3 engine driven pumps

Available Engine Power on the Propeller Curve: 12K98ME-C

% 100 90 80 70 60 50 40 30 20 10
66% Number of pumps in use. 66% Hydraulic pump index. 66% 100%

110 100

110 100 With cylinder cut-outs: 2 cylinders cut 1 cylinder cut 45 25 12

63% 63% 63% 100% 99% 99% 100% 95% 95% 100% 100% 100% 100% 100% 100% 100%

X%

Engine driven pump

(2440/PCS)

Example: 12K98ME-C with 4 engine driven pumps

Mechanical Hydraulic System

Hydraulic Cylinder Unit Fuel pump Exhaust valve actuator ELVA valve

ELFI valve Distributor block

Hydraulic Power Supply

Mechanical Hydraulic System

Hydraulic Cylinder Unit Fuel pump

Exhaust valve actuator ELFI valve

ELVA valve

Distributor block

Hydraulic Cylinder Unit (HCU)

Fuel injection Valve actuation

ELFI Proportional Valve

ELVA On/Off Valve Fuel Pump Exhaust Valve Actuator

Accumulator
2002.05.05 (2440/PCS)

Distribution Block

Two-Stroke Medium Bore ME Engine, Design Concept

Fuel Pump S60ME-C.
Topcover

Plunger

Position sensor (1 per pump)

Umbrella

Main Hydraulic Piston

Fuel Pump Housing

2600/KNB

August 2002.

Two-Stroke Medium Bore ME Engine, Design Concept

Exhaust Actuator S60ME-C.
Top cover Minimesh Actuator house Drain hole Actuator Piston Exhaust Valve

Actuator Piston Main hydraulic 1. Step 2.Step

2600/KNB

August 2002.

S50ME-C

MS.12 Exhaust valve

Sealing oil control unit Inductive sensor

S50ME-C

MS.12 Exhaust valve

Sealing oil control unit Self-adjusting Damper piston Hydraulic nut/ measuring cone

Standard: SNCrW rolled seat Option: Nimonic 80A Contactless sensor with integrated electronics

Damper Bushing with new sealing system

W-seat

S50ME-C cylinder frame

Camshaft housing closed by casting used as drain compartment. Intermediate piece with aft-most pair of staybolts.

Hydraulic Cylinder Unit

Hydraulic Cylinder Unit (complete)

Hydraulic Cylinder Units mounted on common base plate.

Hydraulic Exhaust Actuator (ELVA)

Hydraulic exhaust actuator is handled as one unit. Easy mounting/dismounting on hydraulic cylinder unit. Sealings in accordance with Solas classification rules.

Two-Stroke Medium Bore ME Engine, Design Concept

Common Beam for mounting of HCU for 6S70ME-C.

Face for HCU.

The Beam is to mounted on top of extended brackets for ordinary gallery for 6S70MC-C.

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

HCU for S70ME-C mounted on Common Beam (seen from Fore).
Fuel Pump Topcover Fuel pump Housing ElFI Valve Common Oil supply for HCU from HPS (Double Wall Pipe) Drain oil Collector is common for the entire row of HCU. Drain pipe from collector to crankcase or lub. oil tank

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

Hydraulic Cylinder Units for a 6S70ME-C.

(2600/KNB)

Mechanical Hydraulic System Hydraulic Cylinder Unit

(2440/PCS)

Engine Control System

Bridge

Engine Control Room

Engine Room/On Engine

(2440/PCS)

Engine Control System

Bridge

Main Operating Panel

Engine Control Room

Control Network

Controller

Engine Room/On Engine

(2440/PCS)

Engine Control System

Bridge

Main Operating Panel

Engine Control Room

Control Network

Controller

Engine Room/On Engine

(2440/PCS)

Engine Control System

Bridge

Main Operating Panel

Engine Control Room

Controller

Interface

Engine
Controller Control Network

Controller

Controller

Auxiliaries
(2440/PCS)

Cylinders

Engine Room/On Engine

Engine Control System

Bridge

Main Operating Panel

Engine Control Room

Controller

Controller

Interface

Interface

Engine
Controller

Engine
Controller Control Network

Controller

Controller

Auxiliaries
(2440/PCS)

Cylinders

Engine Room/On Engine

Engine Control System

Bridge

Main Operating Panel

Engine Control Room

Controller

Controller

Interface

Interface

Engine
Controller

Engine
Controller Control Network

Controller

Controller

Auxiliaries
(2440/PCS)

Cylinders

Engine Room/On Engine

Engine Control System

Bridge

Main Operating Panel

Engine Control Room

Controller

Controller

Interface

Interface

Engine
Controller

Engine
Controller Control Network

Cylinders
Controller Controller

Auxiliaries
(2440/PCS)

Engine Room/On Engine

Engine Control System

Bridge

Main Operating Panel

BACK-UP FOR MOP Control Room Panel PC

Engine Control Room

Controller

Controller

Interface

Interface

Engine
Controller

Engine
Controller Control Network

Cylinders
Controller Controller

Auxiliaries
(2440/PCS)

Engine Room/On Engine

Engine Control System

Bridge Panel

Bridge

Main Operating Panel

BACK-UP FOR MOP Control Room Panel PC

Engine Control Room

Controller

Controller

Interface

Interface

Engine
Controller

Engine
Controller Control Network

Cylinders
Controller Controller

Auxiliaries
(2440/PCS)

Engine Room/On Engine

Engine Control System

Bridge Panel

Bridge

Main Operating Panel

BACK-UP FOR MOP Control Room Panel PC

Engine Control Room

EICU A

EICU B

Engine Interface Control Unit A and B

Engine Control Unit A and B

ECU A ECU B Control Network

Cylinders Control Unit 1 per cylinder

ACU CCU

Auxiliaries Control Unit 1, 2 and 3

(2440/PCS)

Engine Room/On Engine

Engine Control System

Bridge Panel

Bridge

Main Operating Panel

BACK-UP FOR MOP Control Room Panel PC

Engine Control Room

EICU A

EICU B

Engine Interface Control Unit A and B

Local Operation Panel ECU B Control Network

Engine Control Unit A and B

ECU A

Cylinders Control Unit 1 per cylinder

ACU CCU

Auxiliaries Control Unit 1, 2 and 3

(2440/PCS)

Engine Room/On Engine

Engine Control System

Bridge Panel

Bridge

Main Operating Panel

BACK-UP FOR MOP Control Room Panel PC

Engine Control Room

Multi-Purpose Multi-Purpose Controller LOP

MPC MPC

Local Operation Panel Control Network

MPC MPC

MPC

MPC

Engine Room/On Engine

(2440/PCS)

Configuration of Control System

(2440/PCS)

Combustion pressure sensor

Hydraulic Cylinder Unit External sensor Indicator valve (sketch) Internal sensor with holder

Combustion pressure sensor

Pretension parts

Pressure sensor Holder for sensor (preliminary design)

Basic Electronic System (BES)

The aim has been to have a general platform and framework of validated and well-proven hardware and software components allowing for application oriented development. Systems should be built using a minimum number of identical BES hardware components as building blocks. The system should cater for, the development of, a number of more or less well-defined applications over the coming years.

2002.05.24

(2440/PCS)

Basic Electronic System Hardware

The hardware of the Basic Electronic System currently consists of three main components:
The Multi-Purpose Controller The Main Operating Panel The Control Network.

Four secondary Basic Electronic System hardware components are also available:

2002.05.24

Control Network converter/repeater/isolator/hub Tacho Signal Amplifier Amplifier for ELFI valve Amplifier for pump control.
(2440/PCS)

Multi-Purpose Controller Mk 2

(2440/PCS)

Multi-Purpose Controllers Mk I and Mk II

Mk I

Mk II

(2440/PCS)

Multi-Purpose Controller
Other Computer Equipment

Power

Power

B
Serial Communication Service Channel

A B Network

Multi-Purpose Controller Complex Controller

Output
A ct s -2 0m

Input
io m et er -2 0m (0 )4
X

en t

0V

on ta

0V

00

(2440/PCS)

Ta ch o

PT 1

(0 )4

+/ -1

+/ -1

Po t

Basic Electronic System Multi-Purpose Controller Software

Power Power Other Computer Equipment

A
Alarm handling

B
Serial Protocole Service Terminal

Multi-Purpose Controller

Variable Variabel handling

Parameter handling

Application Functionality

Control Network protocol protocole (Services)

Sensor-Actuator API

(2440/PCS)

Network

System Clock

A B

Main Operating Panel

(2440/PCS)

Basic Electronic System Main Operating Panel Software

Main Operating Panel

SW configuration display

Detailed alarm info

Control Network protocole protocol (services)

Input / output check and test

Load of Load of Multi-Purpose Complex Controller Controllers

Application SW back-up

Parameter back-up

(2440/PCS)

Network

Graphic Application Pictures

Alarm Handling - Alarm list - Event list - Cut-out lists

A B

Local Operating Panel (LOP)

(2440/PCS)

7S50ME-C Engine Control Box

L/73148-1.0/0802

(2220/TOV)

7S50ME-C Engine Control Box

L/73149-3.0/0802

(2220/TOV)

Process Flexibility Control Modes

Cylinder pressure

Start opening exhaust valve Stop injection Length injection Shape of injection Length of open exhaust valve

Exhaust valve area Scavenging port area

Start injection

Fuel pump pressure

Closing exhaust valve

Injection Shaping
1 3 Test rig measurements showing four possibilities of fuel injection pattern.
1: Typical Pump Injection 2: Typical Common Rail 3: Special 4: Special

Each example shows fuel injection pressure at the fuel valve and the corresponding fuel valve spindle lift curve.

2002.05.05

(2440/PCS)

Fuel Injection Pressure ME versus MC

Bar abs

MC

ME

Engine load %

2002.05.05

(2440/PCS)

Fuel Injection Pressure

2002.05.05

(2440/PCS)

Flexibility of the ME Concept

Change NOx in % 140 130 120 110 100 90 80 70 60 50 40 6 5 4 3 2 1 0 -1 -2 -3 -4 -5

NOx

ME-C MC-C

g/kWh

SFOC

30

50

70 90 Engine load in %

110

130

L/74336-7.0/0502

(2430/NK)

Odfjell - M/T Bow Cecil 37,000 dwt Chemical Carrier

Confirmation Test

Main Engine: 6L60MC 6L60ME

Confirmation Test aboard Bow Cecil Total - 2002.07.01 - 8020 hours

with electronically controlled engine
2002.07.01 (2440/PCS)

M/T Bow Cecil: Hydraulic Cylinder Unit

ME fuel pump

Standard fuel pump

2002.05.24

(2440/PCS)

6L60MC/ME - M/T Bow Cecil

Arrangement of HPS at the fore end of the engine Arrangement of HCUs for the ELFI and ELVA System

Engine Room of M/T Bow Cecil

6L60MC/ME cam engine

6L60MC/ME cam-less engine

Tacho System on M/T Bow Cecil

Semicircular wheel marking precisely half the circumference Tacho gearwheel 360 teeth

Tacho sensors

Turning wheel

Before rebuilding

Tacho System on M/T Bow Cecil

After rebuilding

Engine Room of M/T Bow Cecil

2002.05.24

(2440/PCS)

Hydraulic Cylinder Unit (HCU)

Fuel Pump Accumulators Exhaust Valve Actuator

Inspection onboard onboard Bow Cecil after after 4137 running hours as ME engine

ELFI Proportional Valve

ELVA On/Off Valve

2002.05.24

(2440/PCS)

Exhaust Valve Actuator

Inspection onboard Bow Cecil after 4137 running hours as ME engine

2002.05.24

(2440/PCS)

Exhaust Valve Actuator

Inspection onboard onboard Bow Cecil after 4137 running hours as ME engine

2002.05.24

(2440/PCS)

Fuel Pump Plunger and Actuator Piston

Inspection onboard Bow Cecil after 4137 running hours as ME engine

2002.05.24

(2440/PCS)

Fuel Pump Actuator Piston

Inspection onboard Bow Cecil after 4137 running hours as ME engine

2002.05.05

(2440/PCS)

Distribution Block

Pitting

Inspection onboard Bow Cecil after 4137 running hours as ME engine

ELFI and ELVA Valves

Inspection onboard Bow Cecil after 4137 running hours as ME engine

Multi-Purpose Controller - ECU

Inspection onboard onboard Bow Cecil after after 4137 running hours as ME engine

2002.05.24

(2440/PCS)

Main Operating Panel in ECR - HMI

Interview with the daily operators - finger touch to trackball -

Inspection onboard Bow Cecil after 4137 running hours as ME engine

Main Operating Panel - HMI

2002.05.24

(2440/PCS)

Service Experience
Tacho system, mechanical: More rigid suspension of the sensors as well as relocation of same for better acces for adjustments of the sensors introduced. Tacho system, software: at second failure of a tacho set, shift of tacho set was not always performed. Software bug in the low level failure-handling algorithm found and corrected. A small number of bad electrical connections resulting in various alarms has occurred. At all instances the redundancies in the system has secured the engine availability. CCU changed by the crew while engine was still running. After 4000 hours in service all moving mechanical parts in the hydraulic system showed excellent surfaces. After 4000 hours in service two places with pitting was found on top of the distribution block below the fuel pump actuator piston house. This design will be modified. ELFI valve changed. Tacho sensor drowned by salt water.
2002.05.05 (2440/PCS)

ME Compensators Concept
Linear Force Compensator LinComp Rotating Force Compensator RotComp

Steering gear room

2002.05.24

(2440/PCS)

Prototype and Model of RotComp

2002.05.24

(2440/PCS)

Alpha Lubricator System

Cylinder oil service tank Cylinder liner Cylinder liner

Lubricator

Lubricator

Lubricator

Solenoid valve 200 bar system oil Hydraulic cylinder unit

Solenoid valve Hydraulic cylinder unit To other cylinders

Lube oil pipes Electrical connections Multi Purpose Controller Multi Purpose Controller

L/74177-3.0/0402

(2200/OZS)

Lubricator

Feedback sensor

Feedback sensor

Feedback sensor

Alpha Lubricator System

(2600/KNB)

Orders and Projects for ME Engines

Orders
1* 7S50ME-C 2 + 2 * 7S60ME-C 2* 6S60ME-C 2 + (1) * 6S70ME-C Odfjell 37.000 dwt Stena 316.000 dwt Viken Viken 150.000 dwt Chemical Carrier Crud Oil Tanker Aframax Tanker Suezmax Tanker Alpha Diesel HHI HSD HSD

Total 9 + (1) covering ME engine bore range from 50 to 70 bore

Projects
2* 7K98ME-C* 2* 6S50ME-C 2 + 2 * 5S80ME-C 6S70ME-C 1* 7S60ME-C* 1* 5S60ME-C* 1* 6S70ME-C* 6S60ME-C 7S50ME-C
2002.08.16 (2440/PCS)

Wulff ? Stena Stena Norgas Carriers Andromeda ALPHA Tanker

Container P.C. Tanker Tanker Tanker Tanker Tanker

HSD/Gdynia Hitachi HHI HHI Kina/Korea Korea Korea Japan Japan

* Originally MC-C

MAN B&W Diesel A/S

2002.05.24

(2440/PCS)

Advantages of the ME Engine

Reduced fuel consumption: fuel injection characteristics can be optimised at a large number of load conditions constant pmax in the upper load range can be achieved by a combination of fuel injection timing and variation of the compression ratio (the latter by variation of the closing of the exhaust valve). Due to this, the max. pressure can be kept constant over a wider load range without overloading the engine, leading to SFOC reductions at part load on-line monitoring of the cylinder process can ensures that the load distribution among the cylinders and the individual cylinders firing pressure can be kept up to as new standard, maintaining the as new performance over the lifetime of the engine the engines crash stop and reverse running performance can be improved because the timing of exhaust valves and fuel injection can be optimal for these situations too engine braking may be obtained, reducing the stopping distance of the vessel
1 of 3

Operational safety and flexibility:

Advantages of the ME Engine

Operational safety and flexibility - continued: faster acceleration of the engine because the scavenge air pressure can be increased faster than normal by opening the exhaust valve earlier during acceleration dead slow running, slow steaming, is improved significantly: the minimum RPM is significantly lower than for a conventional engine, dead slow running is much more regular and combustion is improved due to the electronic control of fuel injection. Minimum RPM of 12 rpm has been measured for a 6L60MC engine in service the engine control system includes our on-line OPS-feature: Overload Protection System, which ensures that the engine complies with the load-diagram and is not overloaded (as is often seen in shallow waters and with heavy propeller operation)

2 of 3

Advantages of the ME Engine

Flexibility regarding exhaust gas emissions: the engine can change over to different low emission modes where its NOx exhaust emission can be reduced below the IMO limits if desirable due to local emission regulations. Thus the vessels may sail with lower exhaust gas emission within the special areas where this may be required (or be feasible due to special harbour fee schemes) without having negative effects on SFOC outside such special areas mode for smokeless slow steaming can be made available adaptation to different fuels adaptation to different operation mode computer controlled cylinder lubricator with intermittent lubrication, enables a reduction in lube oil dosage. less weight: approximate 3 tons per cylinder for a 60-bore engine

Others:

3 of 3

Montageramme til sensorbeslag

Montering af segmenter

Triggersegment

Placering af sensorboxe

7S50ME-C High Pressure Pipe

High Pressure pipe from accumulator block to hydraulic cylinder units.

L/73145-6.0/0802

(2220/TOV)

S50ME-C Main outer parts

Gearbox. Hydraulic pumps.. Inspection covers. Base between gearbox and bedplate.

(2200/OZS)

Hydraulic Cylinder Unit

Hydraulic Exhaust Actuator (ELVA) Cover for return oil pipe Return oil stand pipe ELFI valve ELVA valve Plug valve

Hydraulic Cylinder Unit

Fuel Pump (ELFI) Connecting flange Hydraulic accumulator

Two-Stroke Medium Bore ME Engine, Design Concept

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

Hydraulic Power Supply with integrated 2. Order Momment Compensator. Chaindrive from Crankshaft to stepup gear. Chaindrive is adjusted by means of a guideway arrangement. The guideway arrangement as well as the tensioning of the chain is carried-out by means of hydraulic jacks.

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

Accumulator bloc Filter station Main pipe for lub. oil Hydraulic pumps Step-up gear 2. Order Moment Compensator shaft Tightening of Guideway arrangement Turning wheel Crankshaft

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

Hydraulic Cylinder Unit Distributor Block.
Exhaust Valve Actuator high pressure supply

Fuel Pump high pressure supply

Main Hydraulic Pressure

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

Distributor Block Comparison S70 vs. S60ME-C

S70ME-C
Weigth: 777kg

S60ME-C
Weigth: 555kg

(2600/KNB)

Two-Stroke Medium Bore ME Engine, Design Concept

Cylinder Frame for S70ME-C without integrated housing for camshaft.

(2600/KNB)

S50ME-C Fuel pump ELFI

Suction valve Fuel oil inlet Feed-back sensor

Distributor Block

2200/OZS/20020813

Bores in Distributor Block

2200/OZS/20020813

Bores in Distributor Block.

2200/OZS/20020813

Hydraulic Exhaust Actuator (ELVA)

Oil cylinder top piece Piston step 2
(2 test pistons tenifer)

(KPF) (SNitr)
(S34Cr1)

Oil cylinder middle piece Piston step 1 Minimess (x2) Kantseal Oil cylinder bottom piece Kantseal (x2)

(KP) (SNitr)

(SNitr)

Hydraulic Exhaust Actuator (ELVA)

Mounting on distributor block.