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2 The Test Facility The MAN Diesel & Turbo research centre in Copenhagen was inaugurated in 1992. Its centrepiece is a specially- designed, two-stroke, four-cylinder research engine, which plays an impor- tant role in the development of MAN B&W two-stroke diesel engines. The research engine has logged almost 8,500 hours in operation since 1992 and hosts many, different type tests, from basic research – for example, into materials, tribology, and combustion theory – to testing and verification of engine control systems and type-approval testing (TAT). In recent years, the research engine has also been applied on a large scale for the testing of emission-reduc- ing systems, such as EGR (exhaust gas recirculation) and scrubbers. In 1997, the research centre was ex- panded to include additional test rigs for the simulation of engine sub-com- ponents. The test rigs allow the rapid testing and development of concepts and systems in a safe environment without risking any damage to the engine. This ensures a certain degree of product maturing before installing the systems on, for example, the research engine, thereby saving service time on the engine. More and more test rigs have been added over the years. The research centre was extended once again in 2010 where a third floor with new office facilities, a new engine- control room, and a new emission- measuring room was added. From the offices, the R&D engineers have direct access to the engine-control room. The research engine – 4T50ME-X The research engine has four cylinders of 50-cm bore and a stroke of 2,200 cm, generating 7,080 kW at 123 rev./ min. 7 The 4T50ME-GI Test Engine at MAN Diesel & Turbo’s Copenhagen Test Centre Fig. 1: MAN Diesel & Turbo research centre in Copenhagen Test engine specification – 4T50ME-X Engine type Diesel, two-stroke No. of cylinders 4 Bore 50 mm Stroke 2,200 mm Power 7,080 kW Max. speed 123 rpm Application of the research engine The research engine is utilised for a wide range of research tests. These tests are characterised by the fact that they cannot be carried out elsewhere, for example, on an engine-builder’s testbed or aboard a vessel in service. Furthermore, many tests require highly controlled conditions to ensure a high
eliability while the large volume of data typically acquired from the extensive measuring set-ups make the test centre an eminently suitable test venue. The test centre has also added special adjustment options to ensure valid measurements, for instance, the intake air temperature can be adjusted very precisely, for example, to enable ISO conditions. Other tests involve risks, such as pro- voked breakdowns or the testing of control failures. Fig. 2: Research engine in ME-GI configuration MAN B&W Diesel Other examples of research tests include: Oil-film measurements in bearings testing of piston rings material testing, e.g. for liners SFOC / emission optimisation various combustion studies testing of subcomponents testing of monitoring systems and safety systems, e.g. oil mist detector emission control systems turbochargers engine control systems ECS TAT tests for class societies The test centre engine’s special desig- nation (ME-X) is an indication of its hy- brid engine control design, which, over its lifetime, has frequently changed. Currently, the following configurations are possible: 1. ME: 100% electronically-controlled engine with hydraulically-actuated exhaust valve and fuel injection. 2. ME-B: electronically-controlled engine with hydraulically-actuated fuel injection and simulated mechanically- actuated exhaust valve. 3. ME-GI - ME engine with Gas Injection (see Fig. 2). The 4T50ME-GI Test Engine at MAN Diesel & Turbo’s Copenhagen Test Centre 8
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Page 11 and 12: Gas block ELGI valve Purge & blow-o
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