Edition: October 2003

RT-flex October‘03 / 1 / RB
RT-flex October‘03 / 2 / RB
 RT-flex system

! Introduction
! The Sulzer Common Rail System
! Design Details
! The RT-flex System Benefits
! Service Experience on First Customer Engine
! Redundancy reliability safety
! Overview / status RT-flex (sizes) engines
! Summary

RT-flex October‘03 / 3 / RB
 Introduction Components

Sulzer RTA Sulzer RT-flex

(VEC device) Common Rail

platform
Exh. Valve drive
Fuel pumps
Camshaft WECS-9500
control
Reversing
servomotor
Fuel-linkage
Actuator
VIT device
Start-Air-Distr Supply
unit
Camshaft
drive

RT-flex October‘03 / 4 / RB
 Introduction

Why Common Rail?

" Flexibility in injection and valve operation

" Simplified mechanical system
" Safety through redundancy and simplicity
" Higher efficiency than conventional engines
" Many possibilities to reduce emissions

RT-flex October‘03 / 5 / RB
 Introduction Key Features RT-flex

! Common Rail for fuel and servo oil systems

! Precise volumetric fuel injection control
! Control of individual fuel injection valves
! Ideal for heavy fuel oil: separation of fuel from pilot valves
! Fuel supply pumps based on Sulzer four-stroke injection pumps
! Potential for variable injection rate shaping and free selection of
injection pressure
! Stable pressure level in Common Rail and supply pipes
! All design, development and testing in-house

RT-flex October‘03 / 6 / RB
 Introduction Benefits

! Smokeless operation at all operating speeds (exhaust gas boiler

cleanliness)
! Lower steady running speeds of 10 to 12 % rpm R1
! Reduced part load fuel consumption
! Reduced maintenance requirements by simpler engine setting
! Reduced maintenance cost through precise volumetric fuel
injection control leading to extendable TBO’s
! Higher availability by extended integrated monitoring
! Higher availability by redundancy in pumps, piping and
electronics.

RT-flex October‘03 / 7 / RB
 The Sulzer Common Rail System

RT-flex October‘03 / 8 / RB
 CR System System Arrangement

Easy Access
Rail Unit&
WECS 9500

Redundant
Servo Oil
Supply Lines

Redundant
Fuel Oil
Supply Lines Integrated Automatic
Oil Filter for fine filtration
Fuel Pump of Servo Oil
1000bar
High Efficiency
Supply Unit
Crank Angle Sensor
Servo Oil Pump on Free End Side
200bar

RT-flex October‘03 / 9 / RB
 CR System Fuel System

WECS-9500
WECS-9500
Servo Supply control
control
200 bar

Volumetric
Volumetric
Cylinder
injection
injection
6 5 4 3 2 control
control

Sulzer Common Rail up to ~1000 bar

Fuel
simple
reliable High efficiency
Sulzer Common Rail Pump
flexible

RT-flex October‘03 / 10 / RB
 CR System Exhaust Valve Drive

WECS-9500
WECS-9500
control
control

Cylinder Hydraulic
Hydraulic
6 5 4 3 2 Actuator
actuator

Servo Supply200
Servo Supply 200bar
bar

simple
reliable
flexible Servo oil pump

RT-flex October‘03 / 11 / RB
 CR System System Overview

Exhaust valve WECS 9500 Crank

actuator angle
control
system sensor

Fuel
injectors

50µ
6µ

Exhaust valve
actuating unit

Volumetric fuel
injection control unit

up to ~1000 bar fuel HFO / MDO

200 bar servo oil and control oil

30 bar starting air

RT-flex October‘03 / 12 / RB
 Design Details

RT-flex October‘03 / 13 / RB
 Design Components

Sulzer RT-flex Common Rail

platform
WECS-9500
control

Supply
unit

RT-flex October‘03 / 14 / RB
 Design Supply Unit

! Direct mechanical gear drive

! Generates 1000bar fuel oil

pressure with high efficiency
fuel pumps (jerk type)

! Generates 200bar servo oil

pressure with reversible oil
pumps (axial piston type)

! Pumps’ capacity ensures

redundancy in case of failure

RT-flex October‘03 / 15 / RB
 Design Common Rail

Fuel Rail ! Storage and distribution of fuel

oil up to ~1000 bar and 200bar
servo oil

! Built-in damping of pressure

waves by multiple orifices

! Ensures stable pressure with

simultaneous injection of 3
nozzles at full load
Servo Oil Rail
! No moving parts - no
maintenance required

RT-flex October‘03 / 16 / RB
 Design Injection Control Unit

Volumetric
Injection Control Piston ! Shapes injection pattern

Control oil side ! Enables individual

operation of every single
nozzle

! Ensures precise fuel

amount injected to each
cylinder

! Provides flow out safety

of common rail

HFO side

RT-flex October‘03 / 17 / RB
 Design Valve Actuator

System oil

! Hydraulic piston for valve actuation

! Separates fine filtered servo oil

from standard system oil

! Prevents flow out of servo oil rail

! Prevents dirt from entering fine

filtered oil system

Fine filtered
lubrication oil
RT-flex October‘03 / 18 / RB
 Design Sulzer Rail Valve

! The Sulzer Rail Valve is a bi-stable

valve with switching time of less
than 1 ms

! Used as pilot valve for injection and

exhaust valve actuation

! Switching 200bar 6micron filtered

control oil

! Closed loop control for valve

position

RT-flex October‘03 / 19 / RB
 Design WECS 9500 Functions

WECS 9500
Camshaft Control Security
Substitute
Fuel Inj. Ctrl. Load or Speed Rail Valve Fct.
dependent: Diagnosis
Exh. Valve Ctrl.
Fuel Press Ctrl. Sensor Diagnosis
Start Air Distr.
Servo Oil Ctrl. Value Supervis.

RT-flex October‘03 / 20 / RB
 Design WECS-9500 Common Rail Control

Ship Alarm hardwired RCS backup WECS 9500

System Local Ctrl

hardwired Amplifier ECR

RCS & Safety hardwired Servo Oil WECS
System ASM10 Assistant
(DENIS-9)
hardwired Amplifier
MCM700
4…20mA Fuel
Electronic
Speed 2x CAN Bus

Controller 2x SSI Shaftencoder

CCM10 CCM10 CCM10 CCM10 CCM10 CCM10

Power Supplies 2 x 440VAC

VDM10 VDM10 VDM10 VDM10 VDM10 VDM10

RT-flex October‘03 / 21 / RB
 Design Installation Compatibility

! Engine foundation same as RTA

! Engine overall dimensions same

(except supply unit on A-frame side)

! Engine weight reduced by

approx. 12 tons on 7RT-flex58T-B

! Remote control interface slightly

modified from DENIS 6 to DENIS 9

! Electronic speed controller from

DENIS partner as on RTA

! Additional aux. energy approx.

1.5kW/cyl. for 60cm bore

RT-flex October‘03 / 22 / RB
 The RT-flex System Benefits

RT-flex October‘03 / 23 / RB
 Benefits Flexibility of Fuel Injection Pressure

Sulzer Common Rail System

Injection pressure

System
ecti on
In j
al
en tion
v
Con

25 50 75 100 rpm [%]

Free selectable injection pressure

for low NOx emissions, high efficiency and no smoke at all loads

RT-flex October‘03 / 24 / RB
 Benefits Flexibility of Exhaust Valve Timing

Sulzer Common Rail System

Valve Timing [°CA]

close

Conventional Exhaust Valve Control

open

25 50 75 100 [%] rpm

Free selectable exhaust valve timing

for high efficiency, low NOx level, smokeless operation
Special timing for emergency braking and rapid engine loading possible

RT-flex October‘03 / 25 / RB
 Benefits Standard RT-flex Injection Pattern

Measured Data

Needle lift
! All injection nozzles activated
simultaneously
Cylinder pressure
! High efficiency due to quick ending of
Fuel pressure rail injection

! No significant pressure drop in common

rail during injection

! Small rail pressure fluctuations

Injection pressure

-30° 0° 30° 60°

Crank Angle [deg]

RT-flex October‘03 / 26 / RB
 Benefits Balanced Loads and Temperatures

Measurements on 4 cylinders at 100% load

420

T Exhaust [°C]
400
380
360

5.0
Deviation of injected
fuel quantity [%]

2.5
0.0
-2.5
-5.0
50 Engine combustion cycles 50 Engine combustion cycles
Time Controlled Volumetrically Controlled

RT-flex October‘03 / 27 / RB
 Benefits RT-flex fuel consumption

Typical fuel consumption curve: RTA vs. RT-flex

RTA
[g/kWh]
dBSFC [g/kWh]

Flex
[g/kWh]

PLUS
[g/kWh]

25% 50% 75% 100%

Load [%]

RT-flex October‘03 / 28 / RB
 Benefits Smokeless Mode

Sequential operation of injection nozzles for smokless mode and slow steaming

Sulzer RT-flex Sulzer RT-flex with Common Rail injection

Standard engine
3 nozzles-operation
Alternative 2 nozzle
operation

Alternative 1 nozzle
operation

smokeless operation down to 10 to 12% rpm R1

(12rpm for 6RT-flex58T-B)

RT-flex October‘03 / 29 / RB
 Benefits Smokeless Mode

Sulzer 6RT-flex58T-B MV Gypsum Centennial

Smoke measurement on combinator curve during sea trial
0.50

0.45

0.40 HFO
Filter Smoke Number [ FSN ]

380 cSt
0.35 3% sulphur
0.1% ash
0.30
ON OFF Aux. Blower
0.25

0.20
Smoke visibility limit
0.15
Conventional low speed engine
0.10

0.05
6RT-flex 58T-B with common rail
0.00
0 10 20 30 40 50 60 70 80 90 100
Engine Load [% ]

RT-flex October‘03 / 30 / RB
 Service Experience on First Customer Engine

RT-flex October‘03 / 31 / RB
 Experience General

The “MV Gypsum Centennial”

Gypsum Transportation Ltd.
General Statements:
with Hyundai built 6RT-flex58T-B

! More than 10‘500 running hours

! Running behaviour exceeds all our
expectations for a revolutionary engine
! No real down-time besides 2 hrs
! Operators quickly got acquainted to
the system
! Owners are generaly very satisfied with
engine operation.

RT-flex October‘03 / 32 / RB
 Experience Improvements

Suppy unit
! Fuel pumps (lubr. holes)
! Servo oil collector pipes

Rail unit
! Vibrations on upper platform
! Rail valves improved
! Accessibility of RU

RT-flex control system

! Sensor connections had to be
improved
! VDM improved (thermal sterss)
! Regulating behaviour improved
(at swell and light ship)

RT-flex October‘03 / 33 / RB
 Experience Full Inspection 5300Rhrs

Conventional Parts
! Very good results on liner wear

! Very good result on piston ring wear

! Very good load pattern on

crankshaft gear wheel

! Clean valve seat

! Good injection nozzle shape

RT-flex October‘03 / 34 / RB
 Experience Full Inspection 5300Rhrs

RT-flex Specific Parts

! Very good load pattern on gear wheels of supply
unit
! No wear on fuel cams
! No wear on hydraulic actuator for ExVa
! No wear on crank angle sensor assembly

Injection Control Unit

! No wear on sealing surface of injection control
valve
! No wear on control oil piston
! No wear on injection control valve slide
! No wear on fuel quantity piston
! No change of wear on fuel quantity sensor since
beginning of operation
Shows absolutely same injection pattern as
when tested new

RT-flex October‘03 / 35 / RB
 Experience Summary

Conclusions

! RT-flex system concept works fine

! Some “teething” problems solved

! Our feed-back concept for continuous product improvement paid off

! Crew is operating the engine without assistance since May 2002

! Complete inspection after 5300Rhrs showed very low wear figures on

engine parts incl. RT-flex system

! Some components later adapted according to inspection

RT-flex October‘03 / 36 / RB
 Redundancy reliability safety

RT-flex October‘03 / 37 / RB
 Redundancy RT-flex
RT- flex specific availability (reliability) functions:

Common functions & sensors are redundant:

! Double pipe for Fuel Oil and Servo Oil
! 2 x MCM (one in stand-by modus)
! 2 x Crankangle sensor and 2 x bus / cabling
! Pressure transmitters are double

Fuel and servo oil pumps:

! With one fuel pump out of operation 95% engine load possible
! One servo oil pump out of operation 100% engine load possible

Cylinder related functions are single, if one fails:

! Only single cylinder shut off
! Engine still operative with reduced load

Only one sensor for control & monitoring (EFIC, LP-1, ExVa):

Several emergency modes:

! Fuel pressure ctrl valve
! Open loop control for injection & ExVa

RT-flex October‘03 / 38 / RB
 Redundancy RT-flex

RT-flex specific safety functions:

! Monitored flow out of fuel oil security

! Injection & exhaust valve timing monitoring

! Crank angle (engine position) sensor monitoring

! Security valve in supply unit for fuel system

! Shut down valve in common rail for fuel system

RT-flex October‘03 / 39 / RB
 Overview / Status RT-flex (sizes) engines

RT-flex October‘03 / 40 / RB
 RT-flex engines Size 0, I, II and IV

Size 0: RT-flex50
Size I: RT-flex58T-B
RT-flex60C
Size II: RT-flex68T-B
Size IV: RT-flex84T-D
RT-flex96C
•There will be a complete Sulzer engine program with RT-flex technology
• Introduction sequence according to market request

RT-flex October‘03 / 41 / RB
 Status RT-flex engines
! Flex size I (RT-flex58TB and RT-flex60C):
2 vessels in operation:
Gypsum Centennial 6RTflex58TB, HHI, approx. 10’500 running hours (since December 2001)
Sea lady 6RT-flex58TB, DUL, approx. 300 running hours (since 28th of August 2003)

Sea trial for 1st Agrexco, 7RT-flex60C just ended (10th and 11th of September ‘03)
Sea trial for 1st Chipolbrok 2nd half of September ‘03.
5 engines in operation at the end of 2003, 12 engines in operation end of 2004

! Flex size IV (RT-flex96C):

29 engines on order: 6x 12RT-flex96C at DUL 6x 12RT-flex96C at HSD 4x 8RT-flex96C at HSD
6x 8RT-flex96C at HHI 3x 10RT-flex96C at HSD 4x 7RT-flex96C at HHI
Several “hot projects”
10 engines will have shoptest in 2004 (5 engines in 2005, 7 engines 2006)
1st engine will be 8RT-flex96C at HSD in March ‘04
2nd engine will be 12RT-flex96C at DUL in April ‘04
3 Vessel will be delivered with RT-flex96C engines in 2004, 10 vessels in 2005 and 9 vessels in 2006.

RT-flex October‘03 / 42 / RB
 Summary

RT-flex October‘03 / 43 / RB
 Summary Benefits

! More balanced engine operation

by precise fuel metering
! Reduced maintenance cost owing to better
engine balancing (thermal and mechanical
loads) and extendable times between overhauls

! Reduced maintenance requirements

by simpler engine setting

! Reduced part load fuel consumption

! Flexibility to optimise fuel consumption
at actual service load in compliance with dBSFC [g/kWh]
RTA
[g/kWh]

Flex

IMO NOx limits and different fuel qualities

[g/kWh]

PLUS
[g/kWh]

25% 50% 75% 100%

Load [%]
RT-flex October‘03 / 44 / RB
 Summary Benefits

! Lower steady running speeds of 10 to 12 rpm

0.50

0.45

0.40

0.35

! Smokeless operation 0.30

0.25

throughout entire speed range 0.20

0.15

0.10

0.05

0.00
0 10 20 30 40 50 60 70 80 90 100

! Full electronic control with integrated

monitoring functions and built-in overload
protection
! Built-in redundancy regarding rail pump and
servo oil pump capacities
! Built-in redundancy by double
supply piping, engine master controller,
crank angle sensor and bus system

RT-flex October‘03 / 45 / RB
 ur at tenti on
yo u fo r yo
Than k

RT-flex October‘03 / 46 / RB