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Old 03-18-2007, 05:55 AM   #1
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Default The Most Powerful Diesel Engine in the World

The Most Powerful Diesel Engine in the World!

The Wartsila-Sulzer RTA96-C turbocharged two-stroke diesel engine is the most powerful and most efficient prime-mover in the world today. The Aioi Works of Japan's Diesel United, Ltd built the first engines and is where some of these pictures were taken.

It is available in 6 through 14 cylinder versions, all are inline engines. These engines were designed primarily for very large container ships. Ship owners like a single engine/single propeller design and the new generation of larger container ships needed a bigger engine to propel them.

The cylinder bore is just under 38" and the stroke is just over 98". Each cylinder displaces 111,143 cubic inches (1820 liters) and produces 7780 horsepower. Total displacement comes out to 1,556,002 cubic inches (25,480 liters) for the fourteen cylinder version.
Some facts on the 14 cylinder version:
Total engine weight: 2300 tons (The crankshaft alone weighs 300 tons.)
Length: 89 feet
Height: 44 feet
Maximum power: 108,920 hp at 102 rpm
Maximum torque: 5,608,312 lb/ft at 102rpm

Fuel consumption at maximum power is 0.278 lbs per hp per hour (Brake Specific Fuel Consumption). Fuel consumption at maximum economy is 0.260 lbs/hp/hour. At maximum economy the engine exceeds 50% thermal efficiency. That is, more than 50% of the energy in the fuel in converted to motion.
For comparison, most automotive and small aircraft engines have BSFC figures in the 0.40-0.60 lbs/hp/hr range and 25-30% thermal efficiency range.

Even at its most efficient power setting, the big 14 consumes 1,660 gallons of heavy fuel oil per hour.



Large "slow speed" two-stroke engines are usually designed with a crosshead to absorb the side thrusts of the engine, and due to the extra piston rod being straight, can often get a much longer stroke, allowing for larger compression ratios, as well as the ability to burn heavier and heavier fuels (Marine fuels are often the dregs of what's left over after Refineries are done "cracking" the crude to get the lighter distillates out).

Installing the "thin-shell" bearings. Crank & rod journals are 38" in diameter and 16" wide:

The crank sitting in the block (also known as a "gondola-style" bedplate). This is a 10 cylinder version.
Note the ladder by each crank throw that lead down into the crankcase:

A piston & piston rod assembly. The piston is at the top. The large square plate at the bottom is where the whole assembly attaches to the crosshead:

Pistons

Piston Rods

The "spikes" on the piston rods are hollow tubes that go into the holes you can see on the bottom of the pistons (left picture) and inject oil into the inside of the piston which keeps the top of the piston from overheating. Some high-performance auto engines have a similar feature where an oil squirter nozzle squirts oil onto the bottom of the piston.

The cylinder deck (10 cylinder version). Cylinder liners are die-cast ductile cast iron. Look at the size of those head studs! (tie rods)

The first completed 12 cylinder engine:
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Old 03-18-2007, 06:01 AM   #2
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Emma Maersk
http://en.wikipedia.org/wiki/Emma_M%C3%A6rsk



Emma Mærsk is a container ship owned by the A.P. Moller-Maersk Group. When she was launched, Emma Mærsk became the largest container ship ever built, and as of 2007 the longest ship in use. The largest ship ever built was the supertanker Knock Nevis, but now its serves as a floating storage and offloading unit (FSO). Officially, Emma Mærsk is able to carry around 11,000 TEU in the calculation of the Mærsk company which is about 1,400 more containers than any other ship is capable of carrying.

Capacity

In normal calculation, her cargo capacity is much bigger — between 13,500[3] and 14,500 TEU.[4] The difference between the official and estimated number results from the fact that Mærsk calculates the cargo capacity of a container ship by using the number of containers with a weight of 14 tons that can be carried on a vessel. For the Emma Mærsk, this is 11,000 containers.[5] Other companies calculate the cargo capacity of a ship according to the maximum number of containers that can be put on the ship, independent of the weight of the containers. This number is always greater than the number calculated by the Mærsk company.

Engine and the environment


The Emma Mærsk is powered by a Wärtsilä-Sulzer RTA96-C engine, currently the world's largest single diesel unit, weighing 2,300 tons and capable of 110,000 horsepower. The ship has several features to protect the environment. This includes recycling the exhaust, mixed with fresh air, back into the engine for reuse. This not only increases efficiency by as much as 12% but also reduces engine emissions.[2] Instead of biocides, used by much of the industry to keep barnacles off of the hull, a special silicon-based paint is used.[2] This increases the ships efficiency by decreasing drag while also protecting the ocean from biocides that may leak into the ocean. The silicon paint covering the part of the hull below the waterline is credited for lowering the water drag enough to economize 1200 tonnes of fuel per year.

Specifications

Dimensions
length overall (LOA) = 397 m
beam = 56 m
hull depth = 30 m (deck edge to keel)
draft = 15.5 m
Tonnage
gross = 170,974 bt
net = 55,396 nt
deadweight (DWT) = 156,907 DWT
Power
80,080 kW (109,000 hp) Wärtsilä 14RT-Flex96c plus 40,000 hp from five Caterpillar 8M32
Speed
more than 25.5 knots
Crew
The ship has accommodations for 30 people, though the normal crew is only 13.
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Old 03-18-2007, 10:14 AM   #3
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Interesting stuff. I'm spending my weekend tearing down my son-in-law's Polaris engine. Lots smaller and probably simpler.
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Old 03-18-2007, 02:14 PM   #4
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amazing.love seeing stuff like that
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Old 03-18-2007, 02:38 PM   #5
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Are we going down the bost spotting route???????



Big massive engine though
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Old 03-18-2007, 05:20 PM   #6
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Yea you see these every day on ships

My last ship was built in the '60s and it had an old Sulzer RD engine (the one above is an RTA, the latest in a series). My current one (that I'm currently on as we're moping towards the Suez Canal - I'll try and take pics) has EMD's (Electro-Motive Division, I believe a division of GM), and they're more commonly found in Train Locomotives. I'm currently sailing on a Diesel-Electric

EMD's

One of the original EMD 8-cylinder 567 "U" deck engines is shown on test around 1937. Photo from the "Inside EMD" slide lecture program by Preston Cook.


The following is from a 1938 EMC advertisement.

The GM Diesel is a rugged and compact, uniflow, two-cycle, solid-injection engine. With every down stroke a power stroke, the engine is capable of rapid and smooth acceleration, so very essential in railway service. The cylinders are arranged in two banks forming a 45-deg. Vee and are combined in one unit with the crankcase by welded steel construction, combining light weight and exceptional strength.

Cylinder liners are heat treated cast iron, ground to a mirror finish on the inside. The liners are double-walled with cooling water space between and with transverse air-intake ports opening into an air box which forms a part of the crankcase. Cylinder heads are bolted to the liners independently of the studs which hold the assembly in the blocks.

Pistons are pearlitic malleable iron with the head recessed at the top to form part of the combustion chamber and help create turbulence during fuel injection, deeply ribbed on the underside for strength and to provide additional cooling. Pistons are oil cooled by an oil spray through a separate pump provided for this purpose. Pressure lubrication is supplied to all important points and the oil is properly conditioned by passing through filters and cooler.

Connecting rods are drop forgings of fork and plain rod construction to eliminate cylinder offset and improve bearing conditions. The two-cycle principle permits a simple cap design, allowing removal through the cylinder liners of connecting rods with a large crankpin diameter. The carbon steel crankshaft is drop forged with electro-hardened journals, permitting the use of copper alloy crankpin bearings and special babbitt main bearings. All bearings are precision made, eliminating hand fittings.

The Unit Fuel Injection System employed is a principal and patented feature of GM Diesels. Each cylinder is fitted with an individual injector unit which constitutes an independent and complete injection system operated from the overhead camshaft. Complete and accurate control of the fuel injection, timing, and atomization, combined with complete blower scavenging, result in high efficiency, clear exhaust and smooth operation.
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Old 03-18-2007, 05:37 PM   #7
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Caterpillar, known to most big truck-loving boys as the company that makes huge earth-moving equipment, also makes Marine Diesel Engines (and very good ones, at that). Their engines are on the smaller to medium size ranges (They have yet to produce a huge propeller-moving stud, their engines are more for tug-sized, or if they are on ocean goers..they are used as generators.

1125 HP D399 Caterpillar Engine

S/N 91B01329 1200 rpm Continuous ; Zero Hour Rebuild ; Water Cooled Turbo and Manifold ; Expansion Tank ; Exhaust Elbow ; Air Actuator ; Premium Instrument Panel ; Dyno Tested ; Serviced ; Painted ; has Late Style Block and Serated Rods ;



A Caterpillar natural gas engine at the Distributed Power Generation Research Center - a partnership between Caterpillar, Colorado State University and Woodward Governor to investigate efficient, clean-burning engines that could someday be used to support electrical power grids


Caterpillar introduces C32propulsion engine

Caterpillar Marine Power Systems has announced the C32 marine propulsion engine. Delivering 1,400 bhp (1,045 kW) at 2,300 rpm, it provides quick acceleration and high reserve power, with a relatively small footprint and light weight.

The engine's light weight meets requirements for crew boats and other marine applications where lower weight can be directly translated into fuel savings and increased dollars.

With a high displacement (32.1 liters), the C32 delivers outstanding levels of torque, providing noticeably better acceleration than its predecessors: the Cat C30 and 3412E engines. This fast acceleration is especially well suited for pleasure craft, lobster boats and patrol craft. Other applications include workboats, fishing boats, commercial utility vessels and tugs.

The C32 employs Caterpillar's patented HEUI (Hydraulically actuated, Electronically controlled, Unit Injector) fuel system. The C32 is configured as a V-12, twin turbocharged and aftercooled engine.

Modeled after the durable and reliable Cat 3412 engine, the C32 features a HEUI fuel system that maintains high injection pressures across a broad range of rpms and guarantees maximum fuel efficiency. Fuel consumption at the engine's maximum rated speed is 327 L/hr (86.4 gal/hr).

The C32 is IMO, EPA and EU compliant and features low emissions, with virtually no smoke or soot. The C32 has a flat power curve between its vessel cruising speed of 1,900 rpm and its maximum speed of 2,300 rpm. This power band allows the engine to draw on reserve power for easy acceleration.

Comparing maximum power outputs at 2300 rpm, the C32 delivers 7 percent more power than the C30 and 18 percent more power than the 3412E. Yet, the C32 is similar in size and weight due to its "V" block design, which provides for a compact engine package. Pleasure and selected commercial marine applications benefit from this compact design as well as the engine's power-to-weight ratio of 1.52 kg/mhp (3.4 lb/bhp).

Requiring no sequential turbochargers or high-pressure fuel pumps, the Cat C32 is easier to service and less complex than many alternative engines. Its new Electronic Control Module (ECM) gives the engine superior levels of control, monitoring, and data input and output capabilities. Faster processing capabilities of the ECM allow for the addition of multiple inputs and outputs for future enhancements.

The C32 features a two-piece forged steel piston designed for extended wear and capable of handling engine firing pressures without damage. The engine's crosshatched hardened liners feature longer life due to better oil retention on the liners, and its through hardened crankshafts withstand higher cylinder pressures for longer life.

The engine is available in both keel cooled and heat exchanger cooling options and can be fully integrated with Caterpillar's Engine Vision Display (EVD), Marine Power Display (MPD), Marine Analog Power Display (MAPD) and Multi-Station Control System (MSCS).
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Old 03-18-2007, 05:40 PM   #8
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If anyone has problems with some of the terms listed, just ask! There is no harm in asking, I won't make fun of you, I'll just answer to the best of my knowledge.

If you disagree engines (especially big ones) are sexy and funny...

THRUST

crank THROW

PISTON

piston ROD

cylinder HEAD

camSHAFT

crankSHAFT

PUMP

and finally, the engine cycle:

SUCK, SQUEEZE, BANG, BLOW
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Old 03-18-2007, 06:47 PM   #9
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Having worked on Motorcycle, Automobile and Truck engines I find this fascinating. Thanks for the information.
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Old 03-18-2007, 06:59 PM   #10
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yep, no prob

I just wish I had these pictures I once had with me. My alma mater, The California Maritime Academy, goes on training cruises where we studied and learned to be marine engineers or mates. California State University - Maritime Academy had a partnership with Cal Poly - San Louis Obispo and CSU-Monterey Bay (former for first summer cruise, latter for second cruise), where students at those respective schools could do a "semester at sea" with us, travel to the various ports we go to (we went to a lot of awesome places!), and study at the same time (what else is there to do on a confined ship in the middle of water?). Well its well known most of those that go are girls, so we love it (the maritime schools are predominately male...about 85-95% male). My senior training cruise, there were these girls that were VERY accomodating with some of the guys, and those students also have to observe the ship functions (stand a bridge watch, stand an engine watch). Well these girls in question wore bikinis under their coveralls they were required to wear on the engine watch...and in between the main engines of the Training Ship (T.S. Golden Bear, used to be the USNS Maury, powered by twin Enterprise v16 Medium-Speed 4-stroke engines), they removed their coveralls and posed in their bikinis...

I wish I had those pics..I SO would have posted them. I'll try and find them
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Old 03-18-2007, 07:36 PM   #11
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I think I cought the tail end of a show on Discovery, or TLC about that engine.That thing is HUGE!!

Great thread BD!

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Old 03-18-2007, 08:24 PM   #12
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I love this stuff, thanks
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Old 03-19-2007, 05:27 AM   #13
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Default The Original Reciprocating Engine

As many may or may not know, the first kind of engine used was run on pressurized steam. The culmination of the first style of design was the reciprocating steam engine, many of the marine steam engines were triple-expansion (meaning the steam expanded in 3 seperate stages, often the last expansion the steam had so much volume it had to be split into two seperate piston/cylinders).

A working engine could be seen in the Movie Titanic, which was filmed in the engine room of the SS Jeremiah O'Brien (WWII Liberty Ship).
http://en.wikipedia.org/wiki/Steam_engine

Steam engine in action (animation). Note that movement of the connecting linkage from the centrifugal governor operating the steam throttle is shown for illustrative purpose only, in practice this link only operates when the engine speeds up or slows down.

An animation of a simplified triple-expansion engine.
High-pressure steam (red) enters from the boiler and passes through the engine, exhausting as low-pressure steam (blue) to the condenser.



Built by Collingwood Shipbuilding and Engineering Co. in 1907, this engine is similar to that fitted in the Chesterfield, Grenville and other Upper Lake ships. It differs from the usual marine design in that the piston rod and crosshead are separate. The connecting rod has a wedge-type upper end. Note the thrust block with adjustable collars.

Note how much it looks like some of the diagrams of the diesel engines above

Marine Steam Engines later became Steam Turbines, due to increased power and efficiency

Parsons turbine from the Polish destroyer ORP Wicher in Hel, Poland.

A rotor of a modern steam turbine, used in a power plant
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Old 03-19-2007, 05:49 AM   #14
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MAN Burmeister & Wain


Stationary One-cylinder Single-action Diesel Engine (MAN, Augsburg, 1906, 12 HP) first generation.

Marine Diesel 32/40 Engines (under MAN B&W License)
8CHN32/40 (8L32/40)
Engine type 4 - stroke, in-line, vertical, trunk-piston, non-reversible diesel engine, gas turbo-supercharged and charged air cooling, of gas-tight make and remote automatic control
Rated power, KW:3840
Max. power, KW: 4224
Number of cylinders:8
Cylinder bore, mm :320
Piston stroke, mm :400
Rotational speed, RPM :750
Mean piston speed, m/c: 10,0
Mean effective pressure, bar: 23,9
Compression ratio :13,9
Max. combustion pressure, bar:180
*Specific fuel consumption, g/kW h :186
* Specific oil consumption at burning loss, g/KW h:1,0
Dry weight, t:47
Overhaul period, h. thous. :60-80


MANBWK108ME-C Engine
14 cylinder
bore 108cm.
97,300 kW, over 130,000 hp, urning a propeller of almost 30 feet wide at 94 rpm.


Cylinder showing Piston, Piston Crown, exhaust valve, and injector (Injector is entering cylinder @ an angle)
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Old 03-19-2007, 05:52 AM   #15
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http://peswiki.com/index.php/PowerPediaiesel_engine
Diesel Engine Timeline
  • * 1862 - Nicolaus Otto develops his coal gas engine. Similar to a modern gasoline engine.
  • * 1891 - Herbert Akroyd Stuart, of Bletchley (also home of the world’s first electronic computer) perfects his oil engine, and leases rights to Hornsby of England to build engines. They build the first cold start, compression ignition engines
  • * 1892 - Hornsby engine No. 101 is built and installed in a waterworks. It is now in the MAN truck museum in Northern England.
  • The original patent cover page of Rudolf Diesel for the Diesel-engine
  • Enlarge
  • The original patent cover page of Rudolf Diesel for the Diesel-engine
  • * 1892 - Rudolf Diesel develops his Carnot heat engine type motor which burnt powdered coal dust. He is employed by refrigeration genius Carl Linde, then Munich iron manfacturer MAN AG and later by the Sulzer engine company of Switzerland. He borrows ideas from them and leaves a legacy with all firms.
  • * 1892 - John Froelich builds his oil engine powered farm tractor.
  • * 1894 Witte, Reid, and Fairbanks start building oil engines with a variety of ignition systems.
  • * 1896 - Hornsby builds diesel tractors and railway engines.
  • * 1897 - Winton produces and drives the first US built gas automobile; he later builds diesel plants.
  • * 1898 - Busch installs a Rudolf Diesel type engine in his brewery in St. Louis. It is the first in the United States. Rudolf Diesel perfects his compression start engine, patents and licences it. This engine, pictured above, is in a German museum.
  • * 1899 - Diesel licenses his engine to builders Burmeister & Wain, Krupp and Sulzer who become famous builders.
  • * 1902 - F. Rundlof invents the two stroke crankcase, scavanged hot bulb engine.
  • * 1903 Ship Gjoa transits the ice filled, Northwest Passage, aided with a Dan kerosene engine.
  • * 1904 - French build the first diesel submarine, the Z,
  • * 1908 - Bolinder/Munktell start building two stroke diesel engines.
  • * 1912 - First diesel ship MS Selandia is built. SS Fram, polar explorer Amundsen’s flagship, converted to a AB Atlas diesel.
  • * 1913 - Fairbanks Morse starts building its Y model semi-Diesel. US Navy submarines use NELSECO units.
  • * 1914 - German U-Boats are powered by MAN diesels. War service proves engine's reliability.
  • * 1920s - Fishing fleets convert to oil engines. Atlas-Imperial of Oakland, Union, and Lister diesels appear.
  • * 1924 - First diesel trucks appear.
  • * 1928 - Canadian National Railways employ a diesel shunter in their yards.
  • * 1930s - Clessie Cummins starts with Dutch diesel engines and then builds his own into trucks, and a Duesenberg luxury car at the Daytona speedway.
  • * 1930s - Caterpillar tractor start building diesels for their tractors.
  • * 1934 - General Motors starts a GM diesel research faciility. It builds diesel railroad engines--The Pioneer Zephyr, and goes on to found the General Motors Electro-Motive Division, which becomes important building engines for landing craft and tanks in the Second World War. GM then applies this knowledge to market control with its famous ‘Green Leakers�? for buses, and railroad engines.
  • * 1936 - Mercedes-Benz builds the 260D diesel car. A.T.S.F inaugerates the diesel train Super Chief
  • * 1936 - Airship Hindenburg powered by diesel engines
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Old 03-19-2007, 05:58 AM   #16
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Default Two Stroke Cycle

http://www.dieselduck.ca/machinery_p..._engine.01.htm


Basic drawing showing the steps to the cycle


Remember my first post? The largest engine? Well this is a person inside one of the cylinder liners


Cross section of Engine detailing the parts and their terms


Animation showing the cycle (note the little man showing the size of the engine, and that's actually pretty small, as engines go)

Slower animation of the same as above.
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Last edited by Bilgediver : 03-19-2007 at 06:10 AM.
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Old 03-19-2007, 06:19 AM   #17
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Default 4 Stroke Cycle

What most people think of when someone refers to Gasoline or Diesel Engine is the four stroke cycle. Lovingly referred to as "Suck-Squeeze-Bang-Blow" by Marine Engineering Students (at least those in my classes did, lol)


The 4 "strokes" or steps in the cycle.


Cutaway drawing of a 4 stroke engine detailing parts and pieces


Image showing how a 4 stroke cycle engine could be installed for Marine Propulsion (with the extra option for not only propulsion, but dual-providing electrical power!)



4 Stroke Engines installed on ships and in use.


And an animated GIF showing the cycle in action
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Old 03-19-2007, 08:07 AM   #18
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Some pictures of ships I've been on (some of them include me :P )
http://www.flickr.com/photos/bilgediver/

Changing out piston and cylinder liner (we had to replace the cylinder head, too) while in Djibouti, Africa. This is a picture of me inside the crankcase holding a sledghammer we used to torque down the nut holding the piston rod onto the crosshead (behind me)

An owl that showed up on board the USNS Saturn between Fujairah, UAE and Djibouti, Africa.

Piece of a Screwdriver I found inside the Main Engine Exhaust Passage...just before the turbocharger. This was a 2 foot long screwdriver that was somehow dropped inside #4 Cylinder, causing pretty serious damage...

Picture I took of myself sitting in the Engine Control Room of the USNS Saturn

#5 Main Line Shaft bearing on the USNS Saturn, this Bearing ran hot (about 200 degrees Fahrenheit or so) just before we pulled into Jebel Ali, UAE.

Myself at the Throttle of the USNS Mount Baker (A steam ship) in the Engine Control Room

Air Conditioning Unit Motor Controller that caught fire on the T.S. Golden Bear (Training Ship of the California Maritime Academy), we were all woken up @ 5 AM by the Fire & Emergency Signal...not a good sign

Due to the theme of this thread, I decided only to post pictures I've taken of shipboard engineering machinery (some of which I'm in). I have many other pictures (of Dubai, UAE, for example), that might end up in another thread someday...
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Old 03-19-2007, 11:02 AM   #19
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Great thread Bilgediver!

I love stuffing around with anything with a motor (or a vagina), and i dont get to see any stuff on this sort of a scale.

Very interesting.
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Old 03-19-2007, 01:34 PM   #20
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That's one big engine! Coming from Japan, I can only think they're trying to compensate for something...
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