MAN - Genuine Complete Propulsion Packages - Mari-Tech

MAN - Genuine Complete Propulsion Packages - Mari-Tech

Maritech 2004
Genuine Complete
Propulsion
Packages
by
Mr Lars Fischer
Sales Manager, Propulsion Sales
Locations of MAN B&W Diesel
Great Britain
Paxman
Ruston
Mirrlees Blackstone
Four-stroke engines
•Marine propulsion
•Military marine
•Power generation
•Rail traction
France
Pielstick
Four-stroke engines
•Marine propulsion
•Military marine
•Power generation
•Rail traction
•Service
•Licensor
Stockport
Colchester
Denmark
MAN B&W Diesel A/S
Two-stroke engines
Frederikshavn
•Research and development
•Marine propulsion
•Power generation
Copenhagen
•Service
•Spare parts
Holeby
•Licensor
Rostock
Hamburg
Four-stroke engines
•Complete propulsion package
•GenSets
•Power generation
•Licensor
Paris
Augsburg
Saint-Nazaire
Jouet
Germany
MAN B&W Diesel AG
Four-stroke engines
•Research & development
•Marine propulsion
•Power generation
•Service
•Licensor
The propulsion package traditions
- are based on ten decades of:
4 hp - year 1904
• Craftsmanship
• Experience
• Knowledge
• Research
• Technical innovations
3,700 HP – as of today
The Works
A total of 33,500 m2 :
• Advanced production plant
• Foundry with pattern shop
• Engine test facilities
• Administration and service
”Minor Propulsion”
Part of a Large Product Spectrum
MAN B&W Two-stroke Package
Type of vessel: 1600 TEU Container Vessel
Main engine:
8S50MC-C
12640 kW at 127 rpm
Tunnel gear:
Renk
1800 kWe
CP propeller:
VBS1680
dia. Ø 5700 mm (GL ice E4)
Four-stroke MAN B&W packages
From L21/31 packages
(1,290 kW/engine)
To L58/64 packages
(12,510 kW/engine)
Market trends
•
•
•
•
•
Shipbuilding is moving to countries with low knowledge
Shipyards are out-sourcing project and technical work
Fewer suppliers with more complex product portfolio
More complex requirements to the propulsion plant
Propulsion systems and components are more complex
- All of the above market trends call for genuine complete packages
Trade packages from more locations
Propeller experts
Gear experts
Engine experts
+
+
Control experts
+
80% focused on the shipyard
The genuine package
- All under one roof
MAN B&W Alpha
- during the entire life cycle !
80% focused on the shipowner
The concept of
the genuine propulsion package
The genuine package provides added value to all customers
•
Optimised combination of products and system solutions
•
Optimised quality of products
•
Single source of contact to all experts under one roof
•
One point of responsibility for the complete system
•
One point of service contact during operational lifetime
The 5th product
•Project guides
•Dimension sketches
on discs
•Installation drawings
•Instruction books
•Strenght calculations - ice class
•Special stern tube arrangements
•Whirling calculations
•Torsional vibration calculations
•Axial vibration calculations
•Optimum gear ratios
•PTO/PTI configurations
•Auxiliary propulsion
systems
•Flexstar units
•Ship’s speed prognosis
•Power analysis
•Towing force estimation
•Layout of propellers
•Pressure impulses on hull
•Alignment analysis and
instructions
•Epoxy chock calculations
•Resilient installation
•Highly flexible coupling
•Noise levels
•Ambient conditions
•Ship’s operation profile
•Engine selection
•Jet assist
•Two-stage charge air
cooler
•Layout of piping system
•Back-pressure calculations
•Layout of accessories
•Waste heat recovery
•Alphatronic controls
•Manoeuvring stations
•Operating modes
•Load sharing
•Joystick interfaces
•Alphatronic safety systems
Advantages for the shipyard
Offered by the genuine propulsion package:
No hidden costs, since interfaces and integration matters are solved
Thorough design integration of engine, gearbox, propeller and control
systems leads to minimal installation work on a reduced number of
connecting points
One "Plant Information" package of integrated documentation for the
installation of the entire power train
Shop tests at one location
One batch delivery of all package elements is possible
One team of multi-skilled commissioning engineers for starting up,
quay tests and sea trials
- installation costs may be reduced by up to 10%
Technical clarifications
Total
Freight,
commissioning,
project handling
yard installation
Accessories
CP propeller and
controls
Gearbox
Main engine
Price
Package prices
MAN B&W
Competitor
Advantages for the shipowner
Offered by the genuine propulsion package:
Optimal operating economy is ensured thanks to the optimised layout
of engine, reduction gearbox, propeller and control systems
Operating reliability, durability and predictable service intervals are
assured without compromise, from individually optimised components
Only one type of lube oil needed for engine, reduction gear and
propeller. Simple and reduced on board handling and storage
One integrated package of service documentation, maintenance
programmes and spare parts catalogues
One service organization addressing all propulsion plant support
requirements
Warranties, service agreements etc available for the complete power
train
- total operational economy improved by 2-3 %
Advantages for the shipowner
Confidence in genuine propulsion package:
Technical guarantees
SFOC, bollard pull, propeller efficiency
Product guarantees
General warranties, guaranteed TBO’s, pro rata guarantees
Service agreements
- offering predictable operational costs for the operator
The New Generation of
Propulsion Systems
•
•
•
•
New Generation of Propulsion Engines
Continuous development on Reduction Gearboxes
Continuous development on CP Propellers
New Generation of Remote Control System
Main data - propulsion engines
Designation
Unit
L21/31
L27/38
Bore
Stroke
Stroke/bore
Swept volume/cyl
Cyl nos
Power/cyl
Power range
Speed
SFOC (mcr)
SLOC
Bmep
Mean piston speed
Pmax
mm
mm
ratio
ltr
in line
kW
kW
rev/min
g/kWh
g/kWh
bar
m/s
bar
210
310
1.5 : 1
10.7
6-7-8-9
215
1,290-1,935
1,000
184
0.5-0.8
24.1
10.3
200
270
380
1.4:1
21.8
6-7-8-9
340
2,040-3,060
800
182
0.5-0.8
23.5
10.1
200
The New Concept
Engine L27/38
No cooling water in frame
Separate camshafts
Marine head connecting rod
Noise dampening covers
Oil in sump
Cylinder Unit Concept
• Easy withdrawal of complete cylinder
unit, incl piston and connecting rod.
• Overhaul intervals are 20-25,000 hours.
• Quick and easy ‘pit-stop’ replacement is
possible.
• Professional workshop overhaul ensure
optimal performance and life time.
• Exchange/overhaul contracts are
available.
Cylinder Unit – ’Pit-stop’ Exchange
Dismantling: 2 men – 1 hour
Mounting: 2 men – 1 ½ hour
Alpha Module Reduction Gearbox
Type
AMG28EV
Type
AMG55EV
AMG28EV Gearbox
Lubricating oil
Servo oil – pitch astern
Servo oil – pitch ahead
Clutch oil
VBS Propeller and AMG28EV Gearbox
Propeller for a Chemical Tanker
Engine
Output
Gear
Red. Ratio
PTO/PTI
CPP
Diameter
9L27/38
3060 kW
56VO78
800/144
750 kW
VBS 980
3900 mm
Local Monitoring, Control and Safety
TC
RPM
IL-Bus-ME
PI
PI
Alphacomm
Monitoring
24Vdc
Alphacomm
Safety
24Vdc
(Safety)
Duplicated Net
Engine
RPM
IL-Bus-MGP
STOP
IL-Bus-S
(in Governor)
STOP
START
Components on Engine and Gear
Clutch
In/Out
Ahead/
Astern
PI
PI
Alphacomm
Monitoring
I
Pitch
24Vdc
Alphatronic 2000
Remote control
system
Local monitoring, control
and safety system
The Operator Workstation, Complete
% rpm
Cylinder 1
bar
O
bar
C
O
C
560
530
500
470
440
410
380
350
320
290
260
230
200
2
O
C
560
530
500
470
440
410
380
350
320
290
260
230
200
3
O
C
560
530
500
470
440
410
380
350
320
290
260
230
200
4
O
C
560
530
500
470
440
410
380
350
320
290
260
230
200
5
O
C
560
530
500
470
440
410
380
350
320
290
260
230
200
6
O
C
560
530
500
470
440
410
380
350
320
290
260
230
200
7
O
C
560
530
500
470
440
410
380
350
320
290
260
230
200
8
O
C
560
530
500
470
440
410
380
350
320
290
260
230
200
9
O
Exhaust Gas Temperature
O
bar
Press.
before
Filter
Press.
after
Filter
TC Lub. Oil
Press.
O
bar
6.0
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
C
Temp.
Lubricating Oil
Press.
Temp.
bar
C
560
530
500
470
440
410
380
350
320
290
260
230
200
Press.
Fuel Oil
O
C
Temp.
In
C
Temp.
Out
bar
6.0
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
Press.
O
SHUT DOWN Active
SHUT DOWN Cancelled
Emergency Stop
Overspeed, Engine
Engine Lub. Oil Press. Low
HT Cooling Water Temp. High
HT Cooling Water Press. Low
Gear Lub. Oil Press. Low
Oil Mist in Crank Case
Panel / Lamp
Test
CONTROL POSITION
RUN
STOP
START
LOCAL
REMOTE
bar
40
35
30
25
20
15
10
5
0
Start
Air Press.
% rpm
O
C
bar
O
C
O
C
rpm
% Pitch
%
Ahead
Panel / Lamp
Test
Speed
Start Blocking
Turning Gear
Prop. Pitch not Zero
Propeller Locked
% rpm
Press.
Temp.
Charge Air
Temp.
Out
Safety
RESET
SHUT
DOWN
bar
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
bar
TC Temp.
Out
rpm
C
C
560
530
500
470
440
410
380
350
320
290
260
230
200
LT Cooling Water
HT Cooling Water
CANCEL
SHUT
DOWN
TC Temp.
In
bar
O
C
560 WASTE
BY530 GATE
PASS
500
OPEN
470 OPEN
440
410
BY380 WASTE
PASS
350 GATE
320
290
260
TC Speed
230
200
O
C
Temp.
In
O
rpm
Fuel
Index
Astern
Alphatronic 2000 Control System
Slave Bridge Control Station
Pitch
RPM
Operator
Panel (*)
Pitch
RPM
ES: Emergency Stop
BU: Back-Up Control
Operator
Panel
ES
Slave Bridge Control Station
BU
Operator
Panel (*)
ES
ES
Handles
Interface
Bridge
RPM
Ship’s
Alarm
System
Pitch
Operator
Panel (*)
ES
Start/Stop, Remote/Local
Shaft Generator
/ PMS
(in Governor)
START
STOP
Operator
Panel
(OP-E)
Governor
Speed Set
I
Clutch In/Out, Remote/Local
STOP
Alphacomm
Monitoring
Remote
Control
System
Fuel Index
I
Charge Air Press.
Pitch Set
Operator
Panel
(OP-GP)
Serial
Pitch
Duplicated Network
RPM
Main Bridge Control Station
Alphacomm
Safety
Clutch
In/Out
Ahead/
Astern
Propeller Pitch
Closed Loop
Control Box
Pitch
I
Duplicated
Network
Alphacomm
Monitoring
(ACM-GP)
I
Pitch
Engine Room
Serial
Auxiliary Control
Equipment
Coordinated
Control
System
Alphatronic 2000
Main Bridge Control Station - Standard
U:tok_AT2000_b&ecr_panels_03.03.2000
Integrated Package of Instruction Books
Reference - Example
•
•
Owner has many years of experience with MAN B&W packages
Ordered 6 state-of-the-art chemical tankers in 2001 with complete
MAN B&W Alpha packages
Wappen von Hamburg – 2 x 6L27/38-VBS
April 2004 Market Status
- New Engine Family
L16/24
L16/24
 Introduced
Introduced
 Ordered
Ordered
1995
1995
446
446
L27/38
L27/38
 Introduced
Introduced
 Ordered
Ordered
1998
1998
878
878
L21/31
L21/31
 Introduced
Introduced
 Ordered
Ordered
2001
2001
198
198
Four 1500 TEU container Vessels Highest ice class
8S50MC-C
VBS1680
Tunnelgear PTO
Conclusion
The bottom line of the genuine package is:
A unique propulsion system concept
which offers the best technical and
economical solutions from the first project
ideas to scrap of the vessel.