S40ME-B

Teknik og Tema 23. januar 2008

Agenda:
10.00 – 10.30: 1. Design Koncept v/OZS
10.30 – 10.45: 2. Software Koncept v/KEJ
10.45 – 11.00: 3. Verifikation af design v/LRJ
11.00 – 11.10: Pause
11.10 – 11.30: 4. Produktion og komponent inspektion v/OEG
11.30 – 11.45: 5. Strukturmålinger v/HRA
11.45 – 12.00: 6. Motor performance v/VJ

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 1

Teknik og Tema 22/1-2008

ECS Differences between ME and ME-B

• The ECS Development
• The ECS Control Functionality
• The ECS Commissioning Functionality

FOCUS on:
• ‘added value’ functionalities
• limit redundancy to class requirements

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 2

The worst case scenario

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 3

The ME-B ECS Development

Significant differences compared to ME:

• We had ME ECS feedback & experience
• Classification societies already knew ME
• ME-B ECS had strong ambassadors in T41
• BES was actually used as platform
• A solid pre-analysis had been made
• ME-B ECS was developed in a LDE Project
• planning and risk handling
• strong relations to internal ‘customers’
• SW production bottlenecks were eliminated
ME-B ECS was developed in 5 man years.
Calendar time 1½ years.

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 4

ME-B ECS Functionality (the easy part)

The ECS will provide the following main functionalities:

 Control of ELFI valves.
 Control of Alpha Lubricators
 Control of Engine Speed (Governor)
 Interface to Hydraulic Power Supply (HPS)
 ‘MCC style’ interface to Remote Control Systems
 Main Operating Panel for SW download, status display, engine adjustments etc.

Refe
2006-12-22
4T50ME-X: Step-profiles 100% load, fuel-pump pressure

Step
MAN B&W Diesel A/S 2006-12-21 21:27

1000

900

800

700

600

bar abs
500

400

300

200

100

0
170 180 190 200 210
deg a BDC

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 5

ME-B ECS Functionality (the hard part)

The following ME ECS functionality is not a part of first ME-B release:

 Control of auxiliary blowers

 Finish with engine/stand by status display/handling

 ‘Start Blocked’ status display/handling
 Exhaust Valve Control
 Start air control
 Load program, barred speed ranges and similar speed set modifications
 Power management interface
 HPS control (pump start/stop, swash plate control, inlet pressure supervision)
 Support of CW and BR valves.

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 6

ME-B ECS Functionality (the tricky part)
On Bridge
Bridge Panel

CCU
In Engine Control Room

MOP B MOP A ECR PANEL

 Control of ELFI’s & Lubricator’s

 Speed Governor
 Local/Remote Selection
EICU

In Engine Room/On Engine

ESC
ESC

CCU 1 CCU ½n EICU

 HPS ‘Control’ & Supervision
HCU  Cylinder Lube Feedrate
 Engine Running Mode (VIT)
Pressure

Pressure
Booster

Booster
Pressure

Pressure
Booster

Booster

 ECR/Bridge Selection
ALS ALS ALS ALS
ELFI ELFI ELFI ELFI

HCU (cyl 1+2) HCU (cyl m+n)

HPS MOP
M PUMP 1

M PUMP 2
Pressure

 Daily User Interface

Control

HPS

MPC - Multi Purpose Controller

 ECS Alarm Handling
 SW/Parameter Backup
EICU - Engine Interface Control Unit (MPC)
CCU - Cylinder Control Unit (MPC)
MOP - Main Operating Panel
CRANKSHAFT
HPS - Hydraulic Power Supply

 Service/Commissioning Facilities
POSITION
CPS - Crankshaft Position Sensors
SENSORS - CPS
LOP - Local Operating Panel
ALS - Alpha Lubricator System

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 7

 ME-B ECS MPC Requirements

Number of MPC’s MPC’s MPC’s

Cylinders ME-C ME-B Reduction

6 13 4 9 (69%)
7 14 5 9 (64%)
8 15 5 10 (66%)
9 16 6 10 (63%)
 6S50ME-C 13 MPCs
10 17 6 11 (65%)
11 18 7 11 (61%)
 6S50ME-B 4 MPCs 12 19 7 12 (63%)

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 8

ME-B ECS Commisioning

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 9

ME-B ECS Commisioning

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 10

ME-B ECS Commisioning

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 11

 ME-B
Mechanical/Hydraulic Diagram

HCU

HPS

BOLL filter

ME-B ECS KEJ/LDE2 2200/OZS/20061122 © MAN Diesel A/S 12

 ME-B
Mechanical/Hydraulic Concept
Dual cylinder Camshaft driven
HPS
HCU Pressure boosters exhaust actuators

ELFI Light camshaft

Hydraulic oil rail Valves

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 13

 ME-B Hydraulic Power Supply (HPS)

Electric motor

Safety block

Hydraulic pump

Hydraulic oil 300 bar

Lube oil inlet

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 14
 ME-B Hydraulic Cylinder Unit (HCU)

Pressure booster
Alpha lubricator
with ACC

Accumulator

ELFI valve
Distributor block

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 15

ELFI for ME-B

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 16

 Alpha Lubricator for ME-B

Inductive proximity switch

for feed-back signal Signal for lubrication
for control of from controller
piston movement

Actuator piston

A:Level sensor

Outlets
for cylinder liner Injection plungers
lube oil injectors

B:Flow sensor
Spacer
for basic setting
of pump stroke Drain oil
outlet 200-300 bar
Cylinder
system oil
Stroke adjusting screw lube oil supply
inlet

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 17

Crankshaft Position Sensing System

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 18

Crankshaft Position Sensing System

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 19

Crankshaft Position Sensing System

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 20

Pneumatic system

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 21

Engine Side Console

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 22

Main Operating Panel (MOP)

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 23

Service Facilities via MOP

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 24

Strategy for Test

Test after each process step, with focus on possible errors

introduced by this step.
Software development
 Module Test: Automatic, PC, Developers
 Subsystem Test: Automatic, PC DSE, Developers
 System Test (carried out by a test team)
 Divided into Functionality Groups
 Office Hardware Test Setup
 Test engine 4T50MX
Production
 Component test
 Shop test
 Quay test and Sea trial
ME-B ECS KEJ/LDE2 © MAN Diesel A/S 25
Official Tests

Development
 Component – Type Approval
 ECS – TAT
Production
 Component test
 Official shop test
 Official Quay test and Sea trial

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 26

ME-B Engine Concept

Approval Procedure for the ME-B concept:

Engine: ME-B system:
Design assessment according to IACS
unified rule M44 for each engine type
Type test running for each engine type
Type approved MAN B&W engines
Different MC/MC-C engine types
Design concept approval
Detailed design approval
Function test on running engine
Type approved ECS for ME-B concept,
including the pertaining safety system

60 50 46 40 35 ME-B ECS

S35ME-B
Type approved
Other types MAN B&W ME-B
engines
S60ME-B

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 27

Official Shop Test
Normal shop test program, including
following ME-B specific points

1. Confirm adjustment of hydraulic

pressure safety valve.
2. Manual running of HPS
3. Test of cylinder lubrication level sensor
(slow down) *.

*) If actual plant fitted with lube oil flow sensor this test is omitted.
ME-B ECS KEJ/LDE2 © MAN Diesel A/S 29
 Special electronic components of
the ME-B ECS

Component Approval / environmental test

MPC: Multi Purpose Controller Same as ME-ECS A503355-1
MOP: Main Operating Panel Same as ME-ECS Type approved PC
• Control Network PCI Board (mounted Same as ME-ECS A503355-1
in MOP)
• Keyboard Same as ME-ECS Test pending
• Trackball Same as ME-ECS A503355-1
ELFI valve
• Parker proportional - directional Variant of control valve for (A503355-1)
control valve, variant for ME-B ELFI ME-ECS FIVA
• FIVA/ELFI position sensor Same as ME-ECS A503355-1
Encoder for crankshaft position Same as ME-ECS E502069-1
Marker sensor for crankshaft position Same as ME-ECS E500330-1
TSA: Tacho Signal Amplifier Same as ME-ECS E500957-1
E500330-1
HPS pressure control valve Component for ME-B ECS Type approval handled by
manufacturer Bosch-Rexroth
ME cylinder lubricator (Alpha lubricator) Same components as K251260-2
stand-alone Alpha lubricator

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 31

 Components in last
environmental test

Designation Manufacturer/ Type System

supplier
Exhaust valve position Pepperl+Fuchs 8-22M64-I-Y192253 ME-ECS
sensor
Exhaust valve/Fuel Pepperl+Fuchs 8-22M64-I-Y192252 ME-ECS
booster position sensor
Control valve for ELFI Parker Hannifin D1FPE50FB9NS00XG030 ME-B-ECS
FIVA position sensor Nabtesco DL940-223E ME-ECS, ME-B-ECS
Incremental Encoder Leine & Linde 1) 830900001 ME-ECS, ME-B-ECS,
PMI online
Keyboard Dekorsy DS DS102W ME-ECS, ME-B-ECS
Keyboard
Keyboard Unotron/CASP S5000K-B ME-ECS, ME-B-ECS
Elec.
Trackball CASP Electronic TB-102U ME-ECS, ME-B-ECS
Incremental Encoder BEI Ideacod Type 2 Stand-alone Alphalub,
2 output PMI offline, (PMI online)
Incremental Encoder BEI Ideacod Type 3 Stand-alone Alphalub,
1 output PMI offline, (PMI online)
Incremental Encoder Hengstler Type RI 58 Stand-alone Alphalub

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 32

 MAN Diesel designed
ME components: Status

MPC: 3 manufacturers in volume production (1 Denmark, 2 Japan)

2 manufacturers in pre-production state (1 Denmark, 1 Korea)

Control Network PCI Board (mounted in MOP):

1 manufacturer in volume production (Denmark)
FIVA / hyd. amplifiers:
1 manufacturer in volume production (Denmark)
2 manufacturers in pre-production state / 1 interested
(2 Japan / 1 Korea)

Tacho signal amplifier:

1 manufacturer in volume production (Denmark)

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 33

Third party ME components: Status

MOP: Various PCs type-approved by manufacturers

Keyboard: 1 type approved, 2 alternatives in test
Trackball: 1 type approved, 1 alternative in test
FIVA: 2 designs in production: CW and MAN-FIVA
2 designs to come: Variant of MAN-FIVA and Bosch-Rexroth
ME-B ELFI: 1 design in production: MAN-ELFI
3 alternative designs under investigation.
Tacho: tooth-wheel on fly-wheel + sensors
1 encoder design approved (Thalheim)
1 encoder design in test and approval process
Exh. Valve/fuel booster sensors:
1 design in volume production (Denmark)
1 design in production ramp-up (Germany)
2 manufacturers in prototype development
(1 Japan / 1 Korea)
Swash plate / prop.valve signal conditioning amp.s:
1 design in volume production (Denmark)
Alternative solution under investigation

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 34

Relation between products - and
components type approvals

ME-ECS
type certificate
Components
ME-B-ECS type approved
type certificate by MAN Diesel,
type certificate
AlphaLub
type certificate
Components
type approved
4-stroke by
systems manufacturers
type certificate

Other products
type certificates

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 35

TAT of software
ECS failure handling

1. Failing ELFI valve

2. EICU unit failing
3. One CCU unit failing
4. One network failing
5. One power supply unit failing
6. One tacho system failing
7. One stop signal failing
8. Active control station failing
9. Slow Down - Lubricator failure
10.Slow Down - Cylinder lube oil flow failure
11.Main operation panel failing
12.Earth failure

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 36

TAT of software
Demonstration of ECS facilities

1. Engine adjustment of
a. Pmax
b. MIP balance
c. Chief limit
d. Hydraulic pressure
2. Service facilities at MOP
3. IMO data / parameter check sum
4. Parameter set dump
5. Exchange of MPC

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 37

Changes to Programme for TAT

 Point 4.2 is made on net A (J65) instead of net B (J66)

 Demonstration of ECS facilities – reversing added

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 38

TAT on 4T50MX

 For the test of the ME-B control system, a complete ME-B installation
has been made on 4T50MX. This includes the electronic and
pneumatic systems, sensors, actuators and hydraulic power supply
according to the ME-B design description. As a consequence, all
control functions are identical to a ME-B production engine.
 However, as our test engine has been operated as a ME engine for a
long period, the test engine uses no camshaft for exhaust valve
activation. On a ME-B production engine the exhaust valves will be
activated by a camshaft. For ME-B tests we therefore use the ME
control system to activate the exhaust valves. The required oil flow
for the ME exhaust valve activations, is delivered by the ME hydraulic
power supply.
 As on a ME-B production engine, the ME-B hydraulic power supply
supplies the flow for the fuel and cylinder lubrication injections, and it
does the actual pressure control.

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 39

 TAT on 4T50MX (Hydraulic Setup)

Installation allows for pressure level up to 250bar

ME-B HPS the controls pressure.

ME-B delivers flow eq. to fuel injection.

ME start up pumps
are kept stopped

ME swashplate pumps are locked equivalent

to exhaust valve consumption (30% swash deflection)
ME-B ECS KEJ/LDE2 © MAN Diesel A/S 40
TAT on 4T50MX

1. Mounting of the ECS controllers

a. The EICU and the 2 CCU’s are mounted in a large cabinet on the
wall behind the engine.
c. Also one extra CCU - N is mounted here for simulating a higher
number of cylinders (not used for the TAT).
2. Standard FPP control setup with minor deviations
a. No Remote Control System
b. External slow down logic not available, TAT test just generate the
slow down request.

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 41

Research Center with test engine
4T50ME-X

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 42

ME-B ECS KEJ/LDE2 © MAN Diesel A/S 43