CIMAC Congress - Schiff & Hafen

CIMAC Congress - Schiff & Hafen CIMAC Congress - Schiff & Hafen

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CIMAC CONGRESS | BERGEN 2010 which take the specific boundary conditions for such applications (e.g. legislative demands, fuel quality and specific operating profile) into account. The future integration of base engine and aftertreatment measures will significantly increase the challenges and effort with regard to system layout as well as calibration. Especially with regard to large ship and locomotive engines the number of hardware variants which can be tested in advance to the final application will be extremely limited. Within this context high-efficient development tools (such as detailed 1D-simulation of the aftertreatment system, detailed characterisation of catalysts on a synthetic gas test bench, assessment of control and sensor concepts based on simulation) as well as high-efficient calibration procedures (such as DoE based calibration or offline calibration of the SCR system) which have been developed for on-road applications, can be used in order to guarantee a reliable system layout and calibration while maintaining short development and engine testing times. Large engine injection systems for future emission legislations C. Kendlbacher, P. Müller, M. Bernhaupt, G. Rehbichler, Robert Bosch AG, Austria Emissions are one of the driving factors in today’s engine development, fuel injection systems as well as exhaust aftertreatment technologies are being developed for large diesel engines. Due to the long life of large diesel engines many of them are upfitted throughout their lives to modern fuel systems to be competitive in the market. Large diesel engines are used in many different industrial applications where they have to comply with various emission regulations (i.e. TIER, EU, IMO) over the next years. Engine internal as well as external modifications (exhaust aftertreatment) are re-quired to meet upcoming emission standards – on the fuel injection side common rail is the best approach to find solutions to this challenge. All of the future fuel injection systems will be based on common rail technology. This is the most complex but also the most flexible fuel injection technology on the market. Individual boundary conditions, engine design constraints and cost drive the type of common rail system which is being applied on a particular engine type and size. Bosch provides all kinds of fuel systems to its customers for small automotive engines to large diesel engines, using many different types of fuels. 15:30 June 14th Room Troldtog (6–2) Product Development, Component & Maintenance Technology – Gas Engines – New Components Port inlet gas admission valves for large gas engines R. Boom, Woodward, Netherlands The paper is about the latest development in port inlet gas admission valves for large gas engines. The Solenoid Operated Gas Admission Valves (SOGAV) has been in the market since the early 1990’s and has gone through a development program to enhance the design to meet the future large gas engine requirements. The development is driven by a demand for higher mass flow rates and reduction of life cycle cost. The new developed generation of SOGAV has a new design to allow higher differential pressure and therefore allows a higher mass flow with the same valve size. The design of the new generation SOGAV has been changed to allow on engine maintenance and reconditioning. This reduces engine downtime and increases availability. The paper will describe design, development and validation testing on the new valve. Also the market trends driving new technologies will be presented. The design of the new valve is based on the existing valve and operational field experiences at numerous different engine types, running at different fuel gases and at different environmental conditions. The paper will give a background on the operational experiences and product improvements. The power demand from gas engines is increasing more and more. This drives a trend towards gas engines with a larger cylinder output and thus requiring a higher mass flow rate of the gas admission valves. Miller valve timing is reducing the amount of time for gas admission and also the requirement for lower caloric fuel gases drive the demand for higher mass flow rates. Maintenance and overhaul of gas admission valves have been a labor intensive activity. Complete valves have to be taken of the engine, with complete disassembling of the electrical connections. Critical stack up tolerances made it difficult to recondition existing valves after several thousand of hours of operation. The design has been changed to accommodate on engine replacement of critical parts. The paper will describe the design of a valve that both can deal with higher differential pressures and also can be maintained much more user friendly at lower operational cost. A new technology electronic ignition which eliminates the limitations of traditional ignition systems J. Lepley, Altronic Inc., USA, K. Brooks, D. Bell, Altronic, LLC, USA Electronic ignition systems remain the standard for internal combustion engines today, in spite of the best efforts of researchers worldwide to find alternatives. The allocation of so much R&D effort to find a replacment for the electronic ignition system is in part driven by a number of limitations in the current electronic ignition systems which have been seen as difficult, if not impossible to overcome. A new approach to electronic ignition will be described and its ability to overcome the various ignition limitations of the past described and demonstrated. The intention of this presentation is to show that in terms of electronic ignition systems ’The best is yet to come’. Development of pre-chamber spark plug for gas engine K. Yamanaka, Denso Corporation, Japan, S. Nishioka, Denso Europe B.V., Netherlands, Y. Shiraga, S. Nakai, Osaka Gas Co., Ltd., Japan Recently, CHP (Combined heat and power) systems are receiving attention because of effect they have on reducing CO 2 emissions. This is especially seen in the increasing number of gas engines used that full into the 5kW (residential use) – 10MW (industrial use) range. Many large gas engines (2MW or above) have prechambers already installed in the combustion chamber. The flame ignition discharged from the prechamber can achieve a high thermal efficiency by creating rapid and stable combustion in a super lean gas mixture area. However, many medium gas engines (2MW or smaller) have open combustion chambers, and the flame kernel is formed by the single spark plug discharge. Therefore the lean gas mixture area is restricted to only the spark plug discharge, and improving thermal efficiency is generally harder than in pre-chamber engines. Therefore, we designed a spark plug with its own pre-chamber (hereinafter PC plug), to achieve improved flame ignition for open-chamber engines similar that of the pre-chamber engine. The goal of this research is to improve thermal efficiency by expanding the lean misfire limit of the openchamber engine by only changing the spark plug and the engine calibration without needing to change the entire ignition system. If this is accomplished, running cost can be reduced without increasing the initial costs. However, the combustion characteristics depend on 34 Ship & Offshore | 2010 | No. 3

Tuesday, 15 June Wednesday, 16 June Thursday, 17 June Monday, 14 June the specifications of the PC plug and the flame ignition mechanism has not been clarified. Hence the purpose of this study is to improve the thermal efficiency of the engine up to the target value after clarifying the specification of the PC plug which up to this point has not yet been specified. • For this purpose, the combustion mechanism of the PC plug was verified using a visible engine and CFD analysis. Based on these test results, prototypes of the PC plugs were made and then combustion period, COV, and thermal efficiency were compared using a supercharged single cylinder engine. • Based on the results, it has been concluded that internal volume, diameter of orifice and sparking position greatly contribute to the combustion characteristics of the engine. The PC plug with the optimum combination of the above mentioned there factors achieved a thermal efficiency value 1% higher than a conventional plug under 1.9Mpa of Pmi. In addition, it enhances lean limit value ramda from 1.8 to 1.85. • Enlarging the internal volume can allow the proper amount of fuel to flow into the prechamber. Reducing diameter of orifice increases the power of the flame jet. An optimized spark position was able to eliminate the influence of the residual gas forecasted by CFD, which ultimatly resulted in high ignitability. • The above results show that the PC plug can be designed to reach the targeted thermal efficiency level in an open-chamber engine. However, because combustion characters differ, the next target is to achieve a wider coverage of engines with minimum changes to the PC plug. The gas engine of the future – Innovative combustion and high compression ratios for highest efficiencies J. Klausner, C. Trapp, H. Schaumberger, M. Haidn, J. Lang, GE Jenbacher GmbH, Austria engine. The present work illustrates a predictive model for cylinder oil stress in low speed two-stroke diesel engines based on the results from several enginetest campaigns. The experimental investigation has been carried out on Wärtsilä large bore marine diesel engines equipped with several lubrication oil systems and on the Bolnes 3(1) DNL 170/600 research engine from Shell Global Solutions (Deutschland) GmbH. Acquired experimental data regarded both cylinder oil sampling techniques, chemical and physical laboratory analysis of the oil samples and optical technique to quantify the amount of oil blown off though the inlet ports from the piston ring pack. Relevant differences in used cylinder lube oil properties between samples gathered with different techniques have been found. The paper will describe these findings and will propose an innovative way of looking at oil stress analysis in two-stroke engines. The piston-running behaviour monitoring of large bore low-speed marine diesel engine at sea by measurement of piston ring oil film thickness and iron content in cylinder drain oil Y. Saito, T. Yamada, IHI Corporation, Japan, K. Moriyama, Diesel United, Ltd., Japan In low speed two stroke diesel engines, the scuffing problem of the cylinder liners and the piston rings is one of the most important subjects in order to secure reliability due to the high cylinder pressure and the low quality fuels in these days. On the other hand, the reduction of cylinder oil feeding rate is required because of the reduction of ship operation cost. Therefore, achieving coexisting of Gas engines are expected to play an increasingly important role within a trend towards decentralized energy supply worldwide. Today’s gas engines have already reached a high level of efficiency thanks to lean burn combustion strategy and Miller/Atkinson valve timing in combination with steadily increasing compression ratios. However, the pressing need to further increase engine efficiency, with the target to maximize the energy harvest from various types of gas, requires further progress. This paper describes a new highpressure turbo charging approach with advanced Miller/Atkinson timing. By increasing the turbo charger efficiency and pressure ratio, the Miller/Atkinson cycle’s potential is more fully exploited than was hitherto possible. The paper describes the modular changes in charging, valve timing, gas exchange, ignition and combustion of the development engines. 15:30 June 14th Room Klokkeklang (4–2) Diesel Engines – Tribology II Cylinder lubrication – understanding oil stress in the low speed two-stroke diesel engine J. Hammett, J. L. Garcia, Shell Global Solutions GmbH, Germany, F. Micali, M. F. Weber, Wärtsilä Switzerland Ltd., Switzerland, A. De Risi, University of Salento, Italy The concept of oil stress in a low speed two-stroke diesel engine has yet to be tackled in the same way or depth as it has been in the four-stroke No. 3 | 2010 | Ship & Offshore 35

Tuesday, 15 June Wednesday, 16 June Thursday, 17 June<br />

Monday, 14 June<br />

the specifications of the PC plug and the flame ignition mechanism<br />

has not been clarified. Hence the purpose of this study is to improve<br />

the thermal efficiency of the engine up to the target value after<br />

clarifying the specification of the PC plug which up to this point has<br />

not yet been specified.<br />

• For this purpose, the combustion mechanism of the PC plug<br />

was verified using a visible engine and CFD analysis.<br />

Based on these test results, prototypes of the PC plugs were made<br />

and then combustion period, COV, and thermal efficiency were<br />

compared using a supercharged single cylinder engine.<br />

• Based on the results, it has been concluded that internal volume,<br />

diameter of orifice and sparking position greatly contribute to the<br />

combustion characteristics of the engine. The PC plug with the<br />

optimum combination of the above mentioned there factors<br />

achieved a thermal efficiency value 1% higher than a conventional<br />

plug under 1.9Mpa of Pmi. In addition, it enhances lean limit value<br />

ramda from 1.8 to 1.85.<br />

• Enlarging the internal volume can allow the proper amount of<br />

fuel to flow into the prechamber. Reducing diameter of orifice<br />

increases the power of the flame jet. An optimized spark position<br />

was able to eliminate the influence of the residual gas forecasted by<br />

CFD, which ultimatly resulted in high ignitability.<br />

• The above results show that the PC plug can be designed to<br />

reach the targeted thermal efficiency level in an open-chamber<br />

engine. However, because combustion characters differ, the next<br />

target is to achieve a wider coverage of engines with minimum<br />

changes to the PC plug.<br />

The gas engine of the future – Innovative<br />

combustion and high compression ratios for<br />

highest efficiencies<br />

J. Klausner, C. Trapp, H. Schaumberger, M. Haidn,<br />

J. Lang, GE Jenbacher GmbH, Austria<br />

engine. The present work illustrates a predictive model for cylinder oil<br />

stress in low speed two-stroke diesel engines based on the results from<br />

several enginetest campaigns. The experimental investigation has been<br />

carried out on Wärtsilä large bore marine diesel engines equipped<br />

with several lubrication oil systems and on the Bolnes 3(1) DNL<br />

170/600 research engine from Shell Global Solutions (Deutschland)<br />

GmbH. Acquired experimental data regarded both cylinder oil<br />

sampling techniques, chemical and physical laboratory analysis of the<br />

oil samples and optical technique to quantify the amount of oil blown<br />

off though the inlet ports from the piston ring pack. Relevant differences<br />

in used cylinder lube oil properties between samples gathered with<br />

different techniques have been found. The paper will describe these<br />

findings and will propose an innovative way of looking at oil stress<br />

analysis in two-stroke engines.<br />

The piston-running behaviour monitoring of<br />

large bore low-speed marine diesel engine<br />

at sea by measurement of piston ring oil<br />

film thickness and iron content in cylinder<br />

drain oil<br />

Y. Saito, T. Yamada, IHI Corporation, Japan,<br />

K. Moriyama, Diesel United, Ltd., Japan<br />

In low speed two stroke diesel engines, the scuffing problem of the<br />

cylinder liners and the piston rings is one of the most important<br />

subjects in order to secure reliability due to the high cylinder pressure<br />

and the low quality fuels in these days. On the other hand, the<br />

reduction of cylinder oil feeding rate is required because of the<br />

reduction of ship operation cost. Therefore, achieving coexisting of<br />

Gas engines are expected to play an increasingly important role<br />

within a trend towards decentralized energy supply worldwide.<br />

Today’s gas engines have already reached a high level of efficiency<br />

thanks to lean burn combustion strategy and Miller/Atkinson valve<br />

timing in combination with steadily increasing compression ratios.<br />

However, the pressing need to further increase engine efficiency,<br />

with the target to maximize the energy harvest from various types of<br />

gas, requires further progress. This paper describes a new highpressure<br />

turbo charging approach with advanced Miller/Atkinson<br />

timing. By increasing the turbo charger efficiency and pressure ratio,<br />

the Miller/Atkinson cycle’s potential is more fully exploited than<br />

was hitherto possible. The paper describes the modular changes in<br />

charging, valve timing, gas exchange, ignition and combustion of<br />

the development engines.<br />

15:30 June 14th Room Klokkeklang<br />

(4–2) Diesel Engines – Tribology II<br />

Cylinder lubrication – understanding oil<br />

stress in the low speed two-stroke diesel<br />

engine<br />

J. Hammett, J. L. Garcia, Shell Global Solutions GmbH,<br />

Germany,<br />

F. Micali, M. F. Weber, Wärtsilä Switzerland Ltd.,<br />

Switzerland,<br />

A. De Risi, University of Salento, Italy<br />

The concept of oil stress in a low speed two-stroke diesel engine has yet<br />

to be tackled in the same way or depth as it has been in the four-stroke<br />

No. 3 | 2010 | Ship & Offshore 35

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