Cylinder Generel For Hand-Out

Cylinder Condition.
MAN B&W Diesel
Is there a PROBLEM!!!!
© MAN B&W Diesel <1>

Cylinder Condition
MAN B&W Diesel
Why bother about the cylinder condition ?
K90MC-C, 15,000 h. K90MC-C, 1.775 h.

Cylinder Condition
MAN B&W Diesel
Bad Good
7S80MC 12K90MC-C
Running hours: 5,098 Running hours: 12,045
Cylinder Condition
MAN B&W Diesel
This is a piston crown with piston ring remainings 7S42MC

Cylinder ConditionWear of
MAN B&W Diesel
Piston Groove
S35MC
24,101 hours
without overhaul
That is at least
some hours too
much!

Cylinder Condition
MAN B&W Diesel
Economy Reliability
•Lube oil cost •Predictable
overhauling
•Wear rates, spare part
intervals
consumption
•Overhaul in due
•Overhauling intervals
time
labour cost.
Cylinder Condition.
MAN B&W Diesel

MAN B&W Diesel
Cylinder Oil

Cylinder Condition.
MAN B&W Diesel

Cylinder Condition.
MAN B&W Diesel
Aresting Screw.
Level Alarm
Adjusting Screw.
Common adj.
Handel.
Operational
Alarms.
Alarm Unit.
Position for
Plungers.
© MAN B&W Diesel < 10 >

Cylinder Condition.
MAN B&W Diesel

Cylinder Condition.
MAN B&W Diesel
Qopt = QN x 0,α% x 0,β%
How to use the Engine

Specification and the α = 85%
Service letter –
SL.
β = 90%

Cylinder Condition.
MAN B&W Diesel
Qopt = QN x 0,α%
α = 85%
How to use the Engine

Specification and the
Service letter –
SL.

Cylinder Condition.
MAN B&W Diesel

Cylinder Condition.
MAN B&W Diesel

Cylinder Condition.
MAN B&W Diesel

Cylinder Condition.
MAN B&W Diesel

Cylinder Condition.
MAN B&W Diesel

Cylinder Condition.
MAN B&W Diesel

Cylinder Condition.
MAN B&W Diesel

Cylinder Condition.
MAN B&W Diesel

MAN B&W Diesel
Cylinder Condition
Economy Reliability
Influencing factors
•Lube oil dosage
•Lube oil quality
•Combustion room design
•Engine load
© MAN B&W Diesel

•Maintenance level < 22 >
84
MAN B&W Diesel
© MAN B&W Diesel

T2
BF
spec. consump. g/bhph at MCR
18
0
0
0.2
0.4
0.6
0.8
1
1.2
8.
42 5
V ba
T2 r
BF
90 0.
8. 26
5
ba
K8 r
4E 0.
F 39
9.
5
ba
K9 r
8F 0.
F 24
10
ba
L9
0G r
F 0.
11 21
.6
ba
K/
L4 r
5G 0.
K/ F 35
L9 12
0G ba
FC r
A 0.
12 45
K/ .9
L4 ba
5G r
FC 0.
A 35
13
ba
K/ r
L-
G 0.
K/
L/ B 45
S- 15
M ba
C r
M
K
K/ I-II 0.
L- I1 5
M 7
C ba
M
Cylinder Condition
K r
V
Cylinder oil feed rate in the period 1965 to 2000
-V 0.
S- I1 6
M 8
C ba
M r
K
V
-V 1
I1
8
K/ ba
L- r
M
C, 1.
ne 2
w
SL
S-
M
C, 0.
ne 9
w
SL
1.
1
< 23 >
Cylinder Condition
MAN B&W Diesel
New Cylinder Lubrication guidelines.
Basic setting (ref. to K and L/MC : 0.9 g/bhph

MCR load): SMC/C : 1.1 g/bhph
Minimum feed rate (ref. to L and KMC/C : 0.60 g/bhph

MCR load): SMC/C : 0.70 g/bhph
Maximum
recommendable feed rate L and KMC/C : 1.35 g/bhph
during normal operation SMC/C : 1.65 g/bhph
(ref. to MCR).

Cylinder Condition.
MAN B&W Diesel
1Bhph = 0,7355kwh
1kwh = 1,3596Bhph
Ex: 1,7g/kwh = 1,25g/Bhph or
1,25g/Bhph = 1,7g/kwh
That is:
1,7/1.3596 = 1,2500(1,25)
1,25/0,7355 = 1,6995(1,7)
MAN B&W Diesel
© MAN B&W Diesel

84
VT Spec. consump. g/bhph at MCR
2B
F 18
42 0
0
1
0.2
0.4
0.6
0.8
1.2
8.
VT
2B 5
ba
F 90 r
8. 0.
5 26
K8 ba
4E r
F 0.
9. 39
5
K9 ba
8F r
F 0.
L9 10 24
0G ba
F r
11 0.
K/ .6 21
L4 ba
5G r
K/
L9 F 0.
0G 12 35
FC ba
A r
K/ 12 0.
L4 .9 45
5G ba
FC r
A 0.
13 35
K/ ba
K/
L/
L-
G r
S- B 0.
M 15 45
C
M ba
K/
L- K r
M I-I
C II 0.
5
M 17
K ba
S- V- r
M
Period 1965 to 2005?
VI
C 18 0.
6
M
K ba
V- r
VI
18 1
K/
L- ba
M r
C
,S 1.
L 2
S- 38
M 5
C
,S 0.
L 9
N K/
L
38
5
ea
rf Al
ut ph 1.
u a 1
Cylinder Oil Feed Rate in the
re lu
S- b
Al
ph
N a
ea lu
rf b
ut
u re 0.
go 8
Fu al
t ur
a 0.
6
go
al
0.
39
< 26 >
Cylinder Condition
MAN B&W Diesel

Cylinder Condition
MAN B&W Diesel

Cylinder Condition
MAN B&W Diesel

Cylinder Condition
MAN B&W Diesel
12K90MC Mark VI

Design and Experience
MAN B&W Diesel
7S80MC
M/T Vanadis
Cylinder unit No.4
Piston with CPR top ring

after 17,296 running hours
without overhaul
CPR = Controlled Pressure Relief Exhaust side

Cylinder Condition
MAN B&W Diesel
Economy Reliability
Influencing factors
•Lube oil dosage
•Lube oil quality
•Combustion room design
•Engine load
•Maintenance level
MAN B&W Diesel
Engine Development
Mean effective pressure 22 bar 4T50MX
20
18
16
14 MC engines
12
0
1975 1980 1985 1990 1995 2000 Year
4T50MX
Combustion pressure 160 bar
140
120
100 MC engines (S26MC: 170 bar)
80
60
1975 1980 1985 1990 1995 2000 Year
4T50MX
Stroke/bore ratio 4.5 Stroke/bore
4
3.5
3
2.5 MC engines
2
1975 1980 1985 1990 1995 2000 2005 Year

Cylinder Liners
MAN B&W Diesel
Original design
50MC/MC-C:
Expected lifetime 60,000 hours
46MC/MC-C, 42MC, 35MC:

26MC:

Cylinder Liners, 50 MC/MC-C,
MAN B&W Diesel
46 MC/MC-C, 42 MC, 35 MC, 26 MC
MBD-C produced liners

Always produced to the latest design.
Produced with wave-cut and semi-honed
surfaces.
MBD-C supply
• Ensures correct liner material for the original
piston ring pack.
• Ensures correct port height.
• Ensures correct angles and number of
lubricating holes.

Cylinder Liners
MAN B&W Diesel
MBD-C produced liners

All types with wave cut and semi-honed surfaces.
Cast-in in cooling pipes with oval cross-section and
one bend.
MBD-C supply Oval pipes
• Ensures correct liner material for the original

piston ring pack.
• Ensures correct port height.
• Ensures correct angle and number of lubricating
holes.

Cylinder Condition.
MAN B&W Diesel

Cylinder Liner
MAN B&W Diesel
Cylinder liner for S70MC-C
The number of cooling bores has been increased from 24 to 30

MAN B&W Diesel
Cylinder Condition
Combustion
Room Design

Cylinder Condition
MAN B&W Diesel Combustion Room Design

Cylinder Condition
MAN B&W Diesel
Combustion Room
Design history

Upper side of Piston Rings.
MAN B&W Diesel

Alu-Coated Piston Ring
MAN B&W Diesel
Genuine spare parts A-A

Alu-Coat
Developed at our
Research Centre
• Reduced running-in
time by more than 50% A A
• Thus saving cylinder oil
• Thickness: about 0.3 mm

Service Experience
MAN B&W Diesel
Piston ring lower

side armouring,
new standard:
Hard-chrome

Cylinder Condition
MAN B&W Diesel
Controlled pressure relief (CPR) piston ring

F F
F F
F F
F
A
© MAN B&W Diesel

Piston Ring,
80 MC/MC-C – 26 MC
MAN B&W Diesel
MBD-C supply
Always supplied according to latest design.
Upper ring : Height reduced by 0.1mm. (Reduced
risk of sticking).
Position of relief grooves has been modified
(grooves moved away from the stress area).
Ensures the correct ring configuration.
Ensures the correct ring material for the original
cylinder liner.
*CPR ring ensures :

• Improved pressure drop across the ring pack.
• Reduced heat load on second piston ring.
• Longer lifetime of ring pack.

MAN B&W Diesel
Orginal CL Groove Locations
Predominant breakage location

Piston Rings
MAN B&W Diesel
Broken K98 piston ring,

original type
Piston crown on K98MC-C

Broken top ring, 2nd and 3rd
ring collapsed

Typical Breakage of CPR
MAN B&W Diesel
Top Piston Ring in CL Groove

Cylinder Condition
MAN B&W Diesel
Controlled pressure relief piston ring (CPR)

90 and 98 bore engines
F
F F
F
A F
3 mm
6S90MC Engine –
MAN B&W Diesel Inspection after 8267 Hours
CPR Piston Ring

Combustion Chamber Layout
MAN B&W Diesel
Ring pack
1st ring: Type: RVK-C, CPR

with Alu-Coat
High
2nd ring: Type: RM5, oblique cut
with Alu-Coat
Low
3rd ring: Type: RM5, oblique cut
with Alu-Coat
Low
4th ring: Type: RM5, oblique cut
with Alu-Coat
Low
High topland piston crown

1st piston ring with increased height
Copper band on piston skirt

Cylinder Condition
MAN B&W Diesel
“Borepolish” from topland

© MAN B&W Diesel
deposits. < 53 >
Cylinder Condition
MAN B&W Diesel
“Borepolish” from topland

deposits.

Cylinder Liner /
MAN B&W Diesel
Piston Cleaning Ring
Cylinder cover
Piston – high topland
Piston cleaning ring Cylinder liner

Oros Piston and Piston Ring
MAN B&W Diesel
Ring pack
1st ring: Type: CPR

with Alu-Coat
High
2nd ring: Type: RM5, oblique cut

with Alu-Coat
Low
3rd ring: Type: RM5, oblique cut
with Alu-Coat
Low
4th ring: Type: RM5, oblique cut
with Alu-Coat
Low

Cylinder Condition
MAN B&W Diesel

Previous and OROS
Combustion Chamber
MAN B&W Diesel
Narrow combustion Large combustion

volume volume
© MAN B&W Diesel

Maximum Measured Combustion
MAN B&W Diesel Chamber Temperatures
436 639 567 394

392 379
465
185 198
225 196
Left: Previous chamber with M6-33 atomizer

Right: Oros chamber with 0.88 atomizer
© MAN B&W Diesel

Cylinder Condition K98MC-C
MAN B&W Diesel
The very first

K98MC engine
has now run
24,088 hours
It has not yet been
necessary to
overhaul piston
nos. 1, 3 and 4
7K98MC
Cylinder no 4,
24,088 hours without overhaul
Piston Rings and Cylinder Liners
70 to 26 cm Bores
MAN B&W Diesel
Standard Standard
Ring No. 1 CPR, high RVK-C Alu-coating
Ring No. 2 Low, left cut RM5 Alu-coating
Ring No. 3 Low, right cut RM5 Alu-coating
Ring No. 4 Low, left cut RM5 Alu-coating
Piston ring Cylinder liner

C8 PVA
MAN B&W standard
RM4 Tarkalloy C/A piston rings and their
RVK-(C) compatibility
with different kinds
Uballoy Tarkalloy C of cylinder liner
RM5 Tarkalloy materials
Other combinations of piston ring/cylinder liner materials can lead

to increased wear of either the piston rings or the cylinder liners

Piston Rings and Cylinder Liners
80 to 98 cm Bores
MAN B&W Diesel
MAN B&W standard piston rings and their compatibility

with different kinds of cylinder liner materials
Ring No. 1 CPR, high RVK-C with Alu-coating
Ring No. 2 Low, left cut RM5 with Alu-coating
Ring No. 3 Low, right cut RM5 with Alu-coating Standard
Ring No. 4 Low, left cut RM5 with Alu-coating
Piston ring Cylinder liner

C8 PVA
RM4 Tarkalloy C/A
RVK-(C)
Uballoy Tarkalloy C
RM5 Tarkalloy
Other combinations of piston ring/cylinder liner materials can lead

to increased wear of either the piston rings or the cylinder liners

Piston Ring –
Cylinder Liner Compatibility
MAN B&W Diesel
Daros Nippon Riken Properties Cylinder liner material
RM 5 Uballoy Rik 45 Grey cast iron Tarkalloy
RM 5 NPR Uballoy S Rik 47 Copper-molybdenum alloyed,flake Tarkalloy

graphite Tarkalloy-C
RM 4 Vanadium and copper molybdenum PVA

alloyed, flake graphite *(Tarkalloy C)
RVK-C Tarkalloy G Rik 29 Alloyed high strength CV graphite iron Tarkalloy C/A
RVK/pm 14 Base material RKV with ceramic coating All

on the running surface
RVK-C Tarkalloy G Rik 29V Alloyed high strength CV graphite iron with Tarkalloy C/A
wear reducing carbides
RVK-C/Alu-bronze Tarkalloy G/ Alu- Rik29V/ Alu- Alloyed high strength CV graphite iron,with All
bronze bronze wear reducing coating
CV : Compact vermicular iron RM4 piston rings have in special

cases been used successfully in
According to design info of 20030624 No 056524 DAROS PISTON RING MATERIALS :
tarkalloy C-Va cylinder liners.
• RVK – C (January 2003) substitutes all previous editions for RVK/RVK-C specifications
• RM 4 replaces previous material C8
• RM 5 replces the previous material Uballoy

The MC Programme
MAN B&W Diesel

Design Piston Rod Stuffing Box
MAN B&W Diesel
Scraper ring Original standard New standard

Sealing
ring
Sealing ring Sealing ring

Stuffing
box drain
Stuffing
box drain
Sraper Scraper
ring ring
No relief
Lamella groove
Return oil
Back up to crankcase
spring
Relief groove Base ring SL Modification of
Relief groove
stuffing box
SL 02-408

Cylinder Condition.
MAN B&W Diesel
BN Level Consideration:
The increase in BN can influence the ability of the oil to reject
water.
It will then be difficult for the centrifuge to remove water, which
may thus accumulate in the system lube oil.
Water together with Ca can then form
Calsium Hydrogen/Carbonate
This will build up a deposit of Laquer in the bearings.
An other effect is an increased sludge formation when water is

present.
System Oil Contamination
MAN B&W Diesel
K90MC-C
Scavenge box.
Not unusal
appearence

”Clover-leafing”
MAN B&W Diesel

S70MC Cold Corrosion on
Liner - Clover Leafing
MAN B&W Diesel
Cylinder oil
Inlet
No wear
Corroded area
No ring contact

Cylinder Liner and
MAN B&W Diesel
Cylinder Frame
A: Previous design
Cold corrosion on cylinder
liners has been experienced
in some cases
B: New design
Cylinder liner
Using an uncooled cylinder
Frame, the temperature on the Cylinder
running surface has been frame uncooled
increased in the lower part of
the cylinder liner by about 60°C
Good experience
The general cylinder condition
is improved
A B

Cylinder Liner and Frame
Configuration
MAN B&W Diesel
S-MC S-MC-C
Cylinder liner:
Low position of mating surface cylinder
cover/cylinder liner
Slim cylinder liner
Straightforward cooling jacket
Cylinder frame:
Smaller and lighter
Uncooled and straightforward design

6S90MC Inspection after 8267 Hours
MAN B&W Diesel
Piston Rings
© MAN B&W Diesel

6S90MC Engine –
MAN B&W Diesel
Inspection after 8267 Hours

Alpha System
MAN B&W Diesel
CPS
Control box Engine load
Load changes
Tank
Pressure switch
Control Valve
Cylinder
Pump
station
Lubricators
Pressure control unit

Economy
MAN B&W Diesel
Operating cost 7S80MC Mk VI. Cylinder oil versus maintenance cost

Oil dosage
7S80MC Mk VI 1.2 g/bhph 1.4 g/bhph 0.8 g/bhph

36,540 % % %
Cyl oil per year (tons) 285 333 190

Yearly cylinder oil expens. (us $) 438,480 90 511,560 94 292,320 79
Asumed liner wear rate (mm/1000) 0.08 0.06 0.12

Max wear 0.6% (mm) 5 5 5
Life time of liners (Year) 9 12 6

Yearly cyl liner expens . (us $) 25,490 5 19,117 4 38,235 10
Labor price per piston overhaul $ 3,000 3,000 3,000

Asumed T. B. O. (hours) 12,000 24,000 8,000
Labor price per year $ 11,375 2 5,688 1 17,063 5

Price piston rings, o-rings etc. per overhaul $ 2,466 2,466 2,466
Price piston rings, o-rings etc. per year $ 9,351 2 4,675 1 14,026 4
Piston crown ($) 4,675 1 2,338 0 7,013 2
Total expence per year (us $) 489,371 100 543,378 100 368,657 100

Alpha Lubricator System
MAN B&W Diesel
Signal for lubrication

Inductive feed-back from control unit
sensor for control of
Alpha lubricator piston movement
Solenoid valve - deactivated
Injection plungers
Solenoid
valve
Spacer Adjusting screw Actuator piston Cylinder lube Cylinder

for basic setting oil outlet lube oil inlet
of pump stroke

Alpha Lubricator System
MAN B&W Diesel
Signal for lubrication

Inductive feed-back from control unit
sensor for control of
piston movement
Alpha lubricator
Solenoid valve - activated
Injection plungers
Solenoid valve
Cylinder lube Cylinder

oil outlet lube oil inlet
Spacer
for basic setting Adjusting screw Actuator piston
of pump stroke

Timing of cylinder oil injection
MAN B&W Diesel
Pressure bar
Injection pressure
25 Alpha lubricator
20
Pressure Drop over the Rings
15
Injection pressure
mechanical lubricator
10
Oil quill pressure

5
0
0 10 20 30 40 50 60 70 80 90 ms Time
Injection nozzle
MAN B&W Diesel
Cylinder liner
Injection nozzle
with non-return
valve

Alpha Lubricator on S50MC-C
MAN B&W Diesel

MAN B&W Diesel
Alpha Lub on new S50MC-C

MAN B&W Diesel

6S90MC Engine –
MAN B&W Diesel
Inspection after 8267 Hours
Scavenging Air Reciever

Lubricator Systems, Status
MAN B&W Diesel
10K90MC-C Mk 6 retrofitted with Alpha lubricator April 2000 at

16,500 engine hours. The condition now at 22,082 engine
hours after running 0.57 g/bhph:
© MAN B&W Diesel

Cylinder Condition
MAN B&W Diesel
Example of very low

lubrication (0.43 g/bhph) with
Alpha Lubricator system
10K90MC-C retrofitted with Alpha

Lubricators at 16,500 h:
Cylinder 3 at 27,682 hours without
overhaul, the last 5000 h with a
cylinder lube oil feed rate of
0.43/bhph

Scuffed Liner and Piston Ring
Surfaces
MAN B&W Diesel

Cylinder Condition, abrasive wear
CAT-Fines
MAN B&W Diesel

Cylinder Condition, abrasive wear
CAT-Fines
MAN B&W Diesel

Scuffing!!
MAN B&W Diesel

Scuffing!!
MAN B&W Diesel

Alpha ACC
MAN B&W Diesel
Alpha ACC,
Alpha
Adaptive
Cylinder oil
Control

Cylinder lubrication, latest news
MAN B&W Diesel
Guiding Cylinder Oil Feed rates

Status S/L/K-MC/MC-C/ME/ME-C, Mk 6 and newer engines with Alpha Lubricators and ACC-mode
Standard BN70 Cylinder oil BN40 Cylinder oil

0.26 - 0.34 g/kWh x S% 0.26 - 0.34 g/kWh x 7/4 x S%
Basic setting
0.19 - 0.25 g/bhph x S% 0.19 - 0.25 g/bhph x 7/4 x S%
0.60 - 0.70 g/kWh

Minimum feed rate
0.45 - 0.50 g/bhph
Maximum feed rate 1.7 g/kWh

during normal service 1.25 g/bhph
Proportional to engine load
Part-load control
Below 25% load, proportional to MEP (Mean Effective Pressure)
First 5 hours: 1.7 g/kWh
Alu-coat piston
From 5 to 250 hours: 1.5 g/kWh
rings:
Feed From 250 to 500 hours: 1.2 g/kWh
Running-in rate: Non-coated or First 15 hours: 1.7 g/kWh
new -or hard-coated From 15 to 250 hours: 1.5 g/kWh
reconditione rings: From 250 to 500 hours: 1.2 g/kWh
d liners and
new piston Alu-coat piston
rings Stepwise increase to max. load over 5 hours
rings:
Engine
loading: Non-coated or
hard-coated Stepwise increase to max. load over 15 hours
rings:
Alu-coat piston rings: No load restrictions
Running-in new rings in
Non-coated or hard-coated rings: Stepwise load increase to max.
already run-in and well
load over 5 hours.
running liners:
Feed rate: Basic setting +25% for 24 hrs.
© MAN B&W Diesel Copenhagen June 2005 H. Rolsted 2300 < 92 >
MAN B&W Diesel
Cylinder Lubrication Status
Alpha ACC (Adaptable Cylinder oil Control)

”Alpha Sulphur handle” Cylinder lubrication control
M/T Astro Cygnus, 6S90MC-C:
Cylinder oil dosage proportional to the fuel oil sulphur according

to formula: Dosage = S% * 0.22g/bhph, with a minimum of 0.44
g/bhph (below 2.4% sulphur), i.e. similar dosage as the test on
K90MC
Part load control proportional with the engine load
Test started 8 February 2002 at 3.366 engine hours

Cylinder lubrication, latest news
MAN B&W Diesel
Status
SULPHUR
30.00%
27.09%
25.00%
% 22.39% 22.02%
o
20.00%
f
D
e
l 15.00%
i
v 11.97%
e
r
10.00%
i
e 7.68%
s
5.00% 3.79%
3.03%
1.39%
0.46% 0.19%
0.00%
<0.50 0.50 - 0.99 1.00 - 1.49 1.50 - 1.99 2.00 - 2.49 2.50 - 2.99 3.00 - 3.49 3.50 - 3.99 4.00 - 4.49 4.50 - 4.99
Sulphur Content
Source: DNV
© MAN B&W Diesel Copenhagen June 2005 H. Rolsted 2300 < 94 >
Alpha ACC
MAN B&W Diesel
Specific
0 100% Svovl % %
Sulphur
dosage
HMI
setting
% g/bhph
Engine speed 1 0.50 77
The ”Sulphur Algorithm” 0 100%

1.1
1.2
0.50
0.50
77
77
1.3 0.50 77
Fuel index 1.4 0.50 77
1.5 0.50 77
1.6 0.50 77
0 100% 1.7 0.50 77
1.8 0.50 77
Oil pressure 1.9 0.50 77
2 0.50 77
2.1 0.53 81
o 2.2 0.55 85
C rpm
2.3 0.58 88
2.4 0.60 92
deg % 2.5 0.63 96
2.6 0.65 100
2.7 0.68 104
min bar 2.8 0.70 108
Oil pressure 2.9 0.73 112
low 3 0.75 115
3.1 0.78 119
Index failure 3.2 0.80 123
3.3 0.83 127
Mark/trig 3.4 0.85 131
failure 3.5 0.88 135
Feedback 3.6 0.90 138
failure 3.7 0.93 142
3.8 0.95 146
Common 3.9 0.98 150
alarm 4 1.00 154
4.1 1.03 158
4.2 1.05 162
4.3 1.08 165
4.4 1.10 169
4.5 1.13 173
4.6 1.15 177
4.7 1.18 181
4.8 1.20 185
4.9 1.23 188
5 1.25 192

Alpha ACC
MAN B&W Diesel
Cylinder oil dosage (g/bhph)

1.25
1.00
Optimised (reduced) side and
top-clearances introduced
based on good experience
0.75
with the MC-Compact
engines
Optimal ‘lemon-shape’
will give a minimum oil film
0.50
thickness increase of 30-40%
0.25
Sulphur %
0 0 1 2 3 4 5

Cylinder Condition
MAN B&W Diesel
Condition After 17 Hours on Low-Sulphur

Distillate Fuel with BN70 Commercial Lube Oil

Scuffing of Cylinder Liner
MAN B&W Diesel
Design and Experience
Scuffing

MAN B&W Diesel
Duel Lube Solution
BN70 BN40
C y l. 1
C y l. 2
C y l. 3
C y l. 4
© MAN B&W Diesel
Retrofit Alpha
MAN B&W Diesel
1. Pump station
2. Alpha Lubricator
3. Conventional
lubricator
4. T-piece
5. ALCU (Computer)
6. Non-return valves

Alpha Lubricator (Retrofit)
MAN B&W Diesel
Engine type: 11K90MC-C

Layout point: SMCR 72,930 BHP
Load point: NCR = 75,0 % of SMCR 54,698 BHP
Fuel oil sulfur content 3%
Cylinder lubrication oil consumption with mechanical lubricators: 1.00 g/BHPh
Cylinder lubrication oil consumption with Alpha lubricators: 0.75 g/BHPh
Running hours per year: 7,000 hours
Lubrication oil price: 1,001 UDS/ton
Lub. oil consumption with mechaniacl lubricators 464,054 kg
Lub. oil consumption with Alpha lubricators 287,162 kg
Saving in cyl. lub. oil consumption 176,892 kg
Saving in USD 177,146 USD
Price for Alpha lubricator system 162,300 USD
Price for supervision during installation 16,500 USD
Price for fitter assistance 24,900 USD
Total price for Alpha lubricator system 203,700 USD
Pay back time 1,15 years

MAN B&W Diesel

MAN B&W Diesel

MAN B&W Diesel

MAN B&W Diesel
Incremental encoder Trigger signal

1024 trigger pulser per marker
Int 0
Marker signal
Int 1
Int 2
Int 3
MCU
Marker 1
TDC 1
Marker 2
TDC 2
BCU
Standard tacho system.

Retrofit Alpha
MAN B&W Diesel
Angle encoder

MAN B&W Diesel

MAN B&W Diesel

MAN B&W Diesel

MAN B&W Diesel

MAN B&W Diesel

S70MC-C Cooling Jacket and
Cylinder Liner
MAN B&W Diesel

MAN B&W Diesel

MAN B&W Diesel

MAN B&W Diesel
Hardware Environmental Test (according to E10):

Performed by Delta Electronics, Hørsholm.
• Power supply variations and failure

• Insulation resistance and high voltage
• Conducted low frequency interference
• Conducted radio frequency interference
• Electrical fast transients (burst)
• Electrostatic Discharges
• Radiated radio frequency interference
• Surge transients
• Conducted emission
• Radiated emission
• Dry heat
• Low temperature (cold)
• Damp heat (cyclic)
• Vibration (resonance search and endurance)
MAN B&W Diesel
Lube oil dosage control:

Basic principle: Intermittent lubrication
The number of engine revolutions per injection controls the amount of oil
injected.
Amount of oil injected is dependent on MEP which is calculated from fuel index
and engine rpm: The lower MEP, the fewer injections.
Normal situation (basic rate):

• Injection rate per cylinder: 1:4rpm (100% MEP)
100% extra lubrication:

• Injection rate per cylinder: 1:2rpm (at 100% MEP)
Minimum injection rate: 1:10rpm

12K98MC-C with Alpha
MAN B&W Diesel Lubricator
© MAN B&W Diesel

MAN B&W Diesel
Pump station

MAN B&W Diesel
MAN B&W has the MANPOWER
L/8294-1.0/0199

MAN B&W Diesel A/S
MAN B&W Diesel
Thank you for

your attention!

Cylinder Generel For Hand-Out

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Cylinder Generel For Hand-Out

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Cylinder Condition.

MAN B&W Diesel

© MAN B&W Diesel <1>

Why bother about the cylinder condition ?

K90MC-C, 15,000 h. K90MC-C, 1.775 h.

This is a piston crown with piston ring remainings 7S42MC

© MAN B&W Diesel <4>

© MAN B&W Diesel <5>

Why bother about the cylinder condition ?

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Qopt = QN x 0,α% x 0,β%

How to use the Engine

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How to use the Engine

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Basic setting (ref. to K and L/MC : 0.9 g/bhph

Minimum feed rate (ref. to L and KMC/C : 0.60 g/bhph

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Cylinder unit No.4

Piston with CPR top ring

CPR = Controlled Pressure Relief Exhaust side

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Why bother about the cylinder condition ?

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46MC/MC-C, 42MC, 35MC:

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MBD-C produced liners

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MBD-C produced liners

MBD-C supply Oval pipes

• Ensures correct liner material for the original

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Cylinder liner for S70MC-C

The number of cooling bores has been increased from 24 to 30

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Genuine spare parts A-A

• Thus saving cylinder oil

• Thickness: about 0.3 mm

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High topland piston crown