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Introduction i.e. injection start, injection quantity The tests showed also at a high
and injection pressure, the realisation engine speed of 1200 rpm very good
The Diesel engine is and will, also in of pilot and post injection. As the engine performance.
the future, be one of the most eco- already existing engine series is to be
nomic possibilities for converting equipped with CR, the system had to Furthermore extensive simulation
chemical fuel energy into mechanical be designed in order to permit were done to compare the hydraulic
energy. This applies both to the mounting on the engine without behaviour of different fuel injection
automotive range and the propulsion constructive interventions. Due to this systems. At figure 1 a conventional
of large vessels or power plant requirement, the mechatronic compo- injection system is compared to two
generators. In order to make use of nents could not be accommodated in different kind of CR systems. With the
the Diesel engine’s economy also in the cylinder head. As our engines are lift controlled system the rail pressure
the future, it will, with regard to heavy fuel oil compatible, the fuel- continuously is located at the needle
environmental aspects, become more relevant conditions, such as abrasive seat, with the advantage of fast
and more important to prevent visible and corrosive constituents and high response behaviour. Such kind of
and, in particular, pollutant compo- temperature, must be fulfilled with the systems are mainly applied at high
nents from being contained in the utmost reliability and the usual speed Diesel engines in the truck or
exhaust gas. Already at an early maintenance intervals. automotive market at engine speeds
stage, MAN B&W attached great up to 5000 rpm. At another variant of
importance to this requirement , With regard to the success of a new CR systems the needle lift is control-
carried out corresponding develop- development, it is of fundamental led by pressure increase like at a
ment work and launched exhaust gas importance that the courses are conventional system. The pressure
optimised engines [1]. Following the already correctly set during the exists only during the injection period
philosophy of environment-friendly development phase. For this reason, at the needle seat, which is an
engine development, CR will, as a the different system possibilities, important safety factor for the applica-
next step, be introduced for MAN including one and two-circuit sys- tion at medium speed diesel engines.
B&W engines. tems, were tested in pre-studies on
an L 16/24 engine [1]. In this connec- With further matching of the geometry
Due to an electronic control system’s tion, it was very soon evident that the of the throttles inside the control and
degrees of freedom, CR now offers final development solution could only injection valve it is possible to adjust
engine developers a considerably be a one-circuit system as it proved also a very high pressure inside the
wider spectrum of injection curve that the requirement for a variable sac hole of the injection nozzle (figure
design, i.e. total combustion will design of the injection curve can, 2). This potential of the pressure
prevent harmful constituents from system-dependent, not be achieved controlled CR system gives the
being produced in the exhaust gas. with a two-circuit system. freedom for best matching results at
When taking all possibilities of com- engine operation values.
bustion process design into consid-
eration, one must be fully aware of the Pre-studies
fact that the injection system and, System description
particularly, CR, is one of the most For safeguarding the long term
important components of an engine technology planning of MAN B&W ’s The MAN B&W CR injection system
and that the engine is no longer CR concept different pre-studies were is designed for the use of heavy
functional if the injection system fails. done. At the experimental tests with fuel oil with viscosities of up to 700
The development of CR focused, in the single circuit system investigations cSt at 50°C. These fuels have to be
addition to functionality and represen- were done with regard to the materi- preheated to a temperature of up to
tation of the degrees of freedom, als and the necessary production 150°C in order to reach a suitable
particularly on its reliability. methods of the control valves. injection viscosity. Another problem
Furthermore the CR system for basic with heavy fuel in electronic controlled
In order to take a decisive develop- developments at the engine L16/24 injection systems is the high content
ment step forward in engine technol- was modified with an separate control of abrasive particles and aggressive
ogy with the help of CR, relevant valve at the rail to pre-test a hydraulic components in these fuels. All parts
development targets were precisely concept as it is described below, that control the injection therefore
fixed. Optimum combustion requires, where no mechatronic components have to work under the conditions
in addition to the degrees of freedom, are installed in the cylinder head. of high temperature, high viscosity,
1
highly abrasive particles and aggres-
sive components.
2
an improved utilisation of the available
space on the engine, which results in
advantages during assembly and
spare parts storing.
3
limit value, the piston will be pressed
to a sealing seat at the outlet side at
the end of the stroke and will thus
avoid permanent injection at the injec-
tor.
The high-pressure pipes and accumu- Fig. 6: Positions of control valve during injection
lator units are designed with double
walls in order to prevent fuel from part of the injection system is heated of the high-pressure pumps (4),
penetrating to the outside in the case by means of circulating hot heavy via the pump accumulator (6),
of leakage or break of connections. fuel oil. For this purpose, the flushing through the accumulator units (7)
In this case, the operating personnel valve (15), located at the end of the and the open scavenging valve (15).
will be warned by means of the float last accumulator unit connected in After sufficient heating of the injec-
lever switch. series, will be opened pneumatically. tion system, the scavenging valve is
The heavy fuel oil will now be pumped closed and the engine started.
The fuel supply system is provided back into the fuel tank from the low-
with a heavy fuel oil preheating sys- pressure fuel pump (1), through The scavenging valve serves also
tem. For start-up of the cold engine the throttle valves (2) and the suction for pressure relief of the high-pres-
with heavy fuel oil, the high-pressure valves (3), through the pump chamber sure part of the injection system in
4
the case of emergency stop, mainte-
nance, repair work and regular engine
stop.
5
sure control valve Æ Emergency
operation possible in the case of a
rail pressure control failure.
• 2 Rail pressure sensors and 2
speed /TDC pick ups Æ Continued
operation in the case of a sensor or
pick up failure.
6
Development results
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Figure 11 shows one of these test rigs
with the CR injection system 32/40
installed.
The optimization of the CR injection Fig. 12: Matching of the rate of injection
system at the injection test rigs shall
be demonstrated at a few examples:
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mized by CFD calculations and the
modified parts were tested again.
The picture on the right side shows
the same area after appr. 2500 h
and demonstrates the significant
improvement.
Enigine results
Demands on exhaust gas emis- Fig. 14: Thermal load of high pressure pump
sions of medium-speed Diesel
engines
The 32/40 engine is used as main and Fig. 15: Optimized design of control valve Fig. 16: Optimized design of control valve
auxiliary marine engine, in stationary after few thousand operating hours without cavitation and wear marks
power generation plants as well as
for special applications, e.g., in the When the engine is operated on requirements: e.g. smoke reduction
offshore range. The engine is gener- heavy fuel oil of medium quality, the at low load and NOX reduction at
ally loaded at a constantly rated fuel is heated to a supply temperature medium, resp. full load [3]. Figure 17
engine speed of 750, resp. 720 rpm. of approx. 150°C in order to reach a shows, based on the example of an
In individual cases it can, however, fuel viscosity of 12 cSt upstream of injection pressure variation at 100%
also be operated in the so-called the engine. engine load and an injection pressure
combinator or propeller mode within of 1000 resp. 1400 bar, how smoke
a speed range of between 450 and As injection pressure and start-up and NOX emissions as well as the heat
750 rpm. In these operating modes, are freely selectable at any load point release can be influenced by injection
the engine is increasingly loaded within the engine characteristic map, pressure variations. In both cases, the
at rising engine speeds. the engine is, depending on the load, exhaust gas at the funnel is invisible.
able to cope with quite a variety of
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Injection pressure and injection start
variations were carried out at all load
points within the engine character-
istic field and evaluated in the trade
off smoke emissions, SFOC (specific
fuel oil consumption) and NOX emis-
sion. In addition, modifications of the
injection rate curve were examined
and the injection nozzle configuration
varied. As matters stand at present,
the following intermediate results can
be stated.
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main injection, the MAN B&W patent-
ed “boost injection”, means that the
fuel is injected considerably later (ap-
prox. 50° crank angle after the main
injection). In addition, a considerably
larger amount of fuel is injected in the
case of boost injection. This very late
post injection results in an increase of
energy supply at the exhaust gas tur-
bine and, therefore, the air mass flow
rate in the compressor increases. This
is requested, in particular for dynamic
engine operation, when load is applied
with increased tendency of smoke
emissions due to insufficient combus-
tion air. Figure 19 shows the increase
in the charge air pressure, measured
10 seconds after load application due
to the connected boost injection. In
this connection, a short-term increase Fig.19: Improved dynamic engine behaviour with post injection
in the fuel consumption is accepted.
Additional equipments for dynamic has considerable scope for further mit Common Rail Einspritzsystem“, 5.
engine operation, as presently used, development, securing today’s and Dresdner Motorenkolloquium, 5. und
can be avoided in the future. future customer requirements. 6. Juni 2003, pp 78
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