Electronically Controlled engine ME vs.

RTF

07.11.14 C/S Team

Electronically Controlled Engine

INDEX
1. Engine reference for ME vs. RTF 2. Design comparison 1) General Overview 2) Hydraulic Cylinder Unit for ME 3) Common Rail System for RT-flex 4) Hydraulic Power Supply Unit 3. Service experience

Engine reference for ME vs. RT-Flex engines

Sept. 2007 ME K98ME-C In-Service S60ME-C L/S70ME-C K98ME-C At shipyard S60ME-C L/S70ME-C K98ME-C Manufacturing till 2009 S60ME-C L/S70ME-C 7 5 10 2 33 26 6 57 RTF96C RTF84T/D RTF68TB RTF96C RTF84T/D RTF68TB RTF96C RTF84T/D RTF84C RT-Flex 35 6 2 8 2 52 8 6
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Electronically Controlled Engine

INDEX
1. Engine reference for ME vs. RTF 2. Design comparison 1) General Overview 2) Hydraulic Cylinder Unit for ME 3) Common Rail System for RT-flex 4) Hydraulic Power Supply Unit 3. Service experience

General Overview

General overview
Main design difference
. . . . Combined pressure generation and injection rate shape control One complete electro-mechanical hydraulic pump system per cylinder Common rail vs. fuel is brought to high pressure at every cylinder station Single injection nozzle operation vs. no single injection nozzle

RT-flex engine

800 - 950 bar ME engine

150 - 200 bar

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General overview

Under-slug receiver is WCHs standard for all new RT-flex96C/RTA96C engines

Advantages
Increased margin against water carry over Simple welded construction Easy assembly Gallery arrangement for easy cooler dismantling Cooler arrangement for easy and efficient cleaning

Hydraulic Cylinder Unit for ME

FIVA Valve FIVA Valve

Stop Running
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Hydraulic Cylinder Unit for ME

Hydraulic Cylinder Unit
The HCU, one per cylinder, consists of a support console on which a distributor block is mounted. The distributor block is fitted with a number of accumulators to ensure that the necessary hydraulic oil peak flow is available for the Electronic Fuel Injection(ELFI) and the Electronic exhaust Valve Activation(ELVA) systems.

Suction valve

High pressure pipe Fuel pump Fuel oil inlet 8 bar Membrane accumulator

Slide Fuel valve

Fuel pump plunger Hydraulic piston ELFI Proportional valve

High pressure hydraulic oil - inlet

Common Rail System for RT-Flex

Fuel System

Common Rail System for RT-Flex

Exhaust Valve Drive

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Hydraulic Power Supply Unit

Hydraulic power supply unit for ME(200 bar)

Supply unit for RT-flex(200, 1000 bar)

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Hydraulic Power Supply Unit

The purpose of the HPS units is to deliver the necessary high pressure hydraulic oil flow to the systems(ELFI & ELVA, hydraulic actuator) at the required 200 bar and/or 1000 bar, during start-up as well as in normal service.

Distribution block
Fuel pump Housing

Accumulator with pipe(1000 bar) Servo oil pump Gear wheel (200bar)

Servo oil pump (200bar)

Camshaft assy

Gear wheel(Z= 69)

Gear wheel Pinion (Z=24) (Z=131)

Supply Unit

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Fuel oil Injection Control

Fuel oil pressure booster with ELFI for ME (Elec. Fuel Injection)

Suction valve Fuel pump plunger Hydraulic piston ELFI Proportional valve

High pressure pipe Slide Fuel valve Fuel pump Fuel oil inlet 8 bar Membrane accumulator

High pressure hydraulic oil - inlet

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Fuel oil Injection Control

Fuel oil injection control valve with fuel valve for RT-flex (Elec. Fuel Injection) Shapes injection pattern Enables individual operation of every single nozzle Ensures precise fuel amount injected to each cylinder
Volumetric Injection control valve Fuel oil side Oil flow quantity sensor Control oil side

Rail valve

Common rail
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Electronically Controlled Engine

INDEX
1. Engine reference for ME vs. RTF 2. Design comparison 1) General Overview 2) Hydraulic Cylinder Unit for ME 3) Common Rail System for RT-flex 4) Hydraulic Power Supply Unit 3. Service experience

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Flex components Main issue 1. Fuel quantity sensor failure

-. Reason
1) Distance sleeve loosening 2) Plug / connector wear

-. Countermeasure
1) Distance sleeve : Gluing method change from thread fitting to welding 2) Plug / connector : Material change from Aluminium to steel
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Flex components Main issue 2. Rail valve failure

-. Reason
1) Quality check 2) Switching time 3) Magnetic properties

-. Countermeasure
1) Quality check : Function and quality check strengthened since May. 2005 2) Switching time : Introduction of small clearance (RV2 as latest design) 3) Magnetic properties : Additional specification for magnetic properties
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Flex components Main issue 3. Connection piece crack

-. Reason
1) Material and hardening process

-. Countermeasure
1) Material and hardening process : S45C + Induction hardening has been changed to SKD61 + Nitriding

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Flex components Main issue 4. Rail unit Control oil pipe broken

-. Reason
1) Vibration and/or misalignment

-. Countermeasure
1) Material was changed to flexible hose

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Flex components Main issue 5. Protective tube crack of Fuel oil HP pipe

-. Reason
1) Vibration and metal contact between pipe and pipe clamp

-. Countermeasure
1) Material of pipe clamp was changed to SPCE(DC04) with hardness

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ME components Main issue 1. Damage on accumulator of HCU

-. Reason
1) Incorrect charging of Nitrogen 2) Incorrect type of screw and improper tightening

-. Countermeasure
1) Reducing the charging pressure (From 104Bar to 95Bar at 20 Deg) 2) Replace all screw with 8.8 screw and tightening procedure.
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ME components Main issue 2. Leakage from coupling of HCU block

-. Reason
1) Poor quality of minimess valve

-. Countermeasure
1) Replaced all minimess valve with improved one

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ME components Main issue 3. Wear marks on actuator piston of Alpha lubricator

Steel shim

-. Reason
1) Abnormal movement of spring 2) Poor workmanship for assembly

-. Countermeasure
1) Installed steel shims 2) Replace O-ring
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ME components Main issue 4. Double-wall piping; oil leak from sealing ring

-. Reason
1) Unsuccessful choice of sealing rings

-. Countermeasure
1) New type of sealing rings introduced on engine size 80 bore and up

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ME components Main issue 5. Exhaust valve feedback sensor

-. Reason
1) Sensor damaged due to hydraulic pressure

-. Countermeasure
1) New sensor design with reinforced sensor head introduced

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Electronically Controlled engine ME vs. RT-Flex

THANKS FOR YOUR ATTENTION

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