Caterpillar Marine - Marine Engines Caterpillar

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FCT is a robust solution based on a mechanical lever shaft that automatically influences both injection timing and inlet valve processes. The engine load required for activating the lever can be flexibly adjusted according to the operator’s requirements. In any case, visible smoke is eliminated at partial load and performance (load response behaviour) is enhanced, while the IMO I standards are complied with at all load points. Invisible smoke is a clear advantage for all ships and boats. A low smoke level for vessels operating is increasingly required by the regulatory authorities in emissionsensitive areas. About 20 MaK engines equipped with FCT in the M 32 C and M 43 C series have been sold for cruise ships and ferries to date. Caterpillar Common Rail (CCR) FCT meets current market requirements. However, further smoke reduction at partial load will be required in future. The mechanical basis of this technology meanwhile offers only limited scope for improvement. “On the other hand, Caterpillar Common Rail clearly points the way to complying with future regulations,” explains Frank Starke. “CCR is also based on the ACERT system and represents a totally flexible fuel system offering sufficient potential for meeting even stricter smoke reduction requirements (about 28 50% below FCT).” And CCR uses injection maps, a technology for the fine tuning of the injection parameters for every single engine operation point. Starke: “Injection mapping not only guarantees optimal injection pressure with given load but also makes it possible to reduce soot and NOx emissions.” Smoke emissions at low engine load remain well below the visibility limit for particularly emission-sensitive areas. Moreover, even when the engine is started there is no visible soot, which is a great advantage, particularly in the cruise business. CCR generally permits ship operation without visible soot throughout the operating range. Moreover, fuel consumption during operation at normal load can be reduced without having to make compromises on NOx emissions. CCR is suitable for operation with HFO (Heavy Fuel Oil), MDO (Marine Diesel Oil) and DO (Diesel Oil). And, most importantly, the system can be retrofitted. CCR – an integrated system Rail segment with three injector and assembled at the engine Caterpillar’s comprehensive experience with electronically controlled engines, wide product range and design expertise enable it to adopt a unique system approach. The main components of the Caterpillar Common Rail fuel system – high-pressure pump, rail, injection system and electronic control – were developed under Caterpillar’s design leadership, so that it includes the expertise with electronic controls available in the company as a keynote of CCR technology. n High-pressure pumps Two highpressure pumps deliver the required amount of fuel to the rail and ensure the necessary rail pressure in a closed loop. The pumps are based on a proven design, but have been modified for HFO oil operation. As there are only two pumps (for series engines), the number of high-pressure connections and components is reduced while also ensuring adequate redundancy. The suction control ensures high pump efficiency. n Rail The double-walled rails are pressurized and serve as accumulator. One rail segment supplies fuel to several injectors, so that a 9-cylinder engine for example has three rail segments each supplying three injectors, while an eight-cylinder engine has two rail segments each feeding four injectors. This design reduces the number of components and highpressure connections required. Flow limiters prevent the cylinders from being oversupplied with fuel, a safety valve ensuring pressure relief if there is excessive pressure in the rail. A scav-
enging circuit makes it possible to keep the entire fuel system (high- and low-pressure system) in a pre-heated condition and ensures reliable HFO operation. n Injectors Caterpillar opted for a simple, robust, compact approach by using the fuel itself for controlling the injectors, thereby obviating the need for a separate control fluid. The cooling of the injection nozzle by means of lube oil is another typical characteristic of HFO operation. For CCR the lube oil circuit has meanwhile been expanded to cool the electrical components within the injector and thus increase service life. The injection process is electronically controlled and permits flexible timing from the beginning Injector including the capability for multiple injection. The injection profile and the shaping of the injection process were optimised using the combustion modelling available with the Caterpillar CAT-3D software, as well as comprehensive engine testing. n Electronics The key component of the CCR system is the proprietary electronic ADEM control module. The ADEM control system, pioneered by Caterpillar as a trail-blazing innovation almost 20 years ago, controls fuel delivery, air supply and other basic engine processes, thereby achieving an optimal balance between performance and emissions. The tailor-made software for MaK engines with CCR is based on Caterpillar's wealth of experience gained with the existing ADEM software and various engine control strategies and also takes into consideration the specific requirements of HFO operation with medium-speed engines. The functions of ADEM can be basically subdivided into a core system and a performance system. The core system comprises the actual control unit, a crankshaft speed pickup, two camshaft speed pickups, two high-pressure sensors, two intake throttles and the injectors. The performance system ensures an optimal setting of the engine under all operating conditions using information such as exhaust gas temperature, charge air pressure, ambient conditions and lube oil temperature. Safety and reliability – a matter of course The focus was on safety and reliability during the entire development process. Ulrich Hopmann, Engineering Supervisor CCR, Caterpillar Motoren GmbH & Co. KG (Kiel, Germany), points out in this connection that “CCR offers a state-of-the-art design by ensuring engine operation with proven technology (ADEM control unit), specific innovations (injectors) and redundant components (high-pressure pumps, double-walled lines and rails, speed pickups, pressure sensors).” A safety gear between pumps and engine, a pressure relief valve and flow limiters between rail and injectors further enhance the operating reliability of the CCR system. CCR – the ultimate solution Dr. Udo Schlemmer-Kelling, Manager Research, Caterpillar Motoren GmbH & Co. KG (Kiel, Germany), describes the current CCR technology for mediumspeed engines as the result of a long successful period of basic research and comprehensive pre-field testing. “A common rail solution for MaK engines was tested as early as 1988, and socalled unit pumps with electronically controlled solenoid valves were developed in 1995,” recalls Schlemmer-Kelling. The first MaK common rail concept was formulated at the dawn of the new millennium and finally led to the official launch of CCR at SMM 2006. Dr. Frank Starke: “Another important lesson that we have meanwhile learned is the retrofit aspect, which makes it possible to install the entire system in any existing MaK M 32 C engine already in operation.“ New Technology Thanks to the closed loop, the electronically controlled injection system provides long-term stable operation and emission values compared with mechanical solutions. Moreover, the injection mapping has the potential to respond to the wear and tear of an older engine by using modified control parameters, which are implemented during regular engine maintenance. “CCR combined with FCTcontrolled valve activation offers an almost unlimited degree of freedom for engine optimisation and control,“ concludes Frank Starke. A Caterpillar Common Rail CCR is the result of extensive research into system stability and service life with HFO operation and a prudent assessment of the experience gained in the field with competing solutions. It combines innovative technology with a level of reliability that is unprecedented for the sector. The MaK 6 M 32 CCR marine engine presented at SMM 2006 opens up a new chapter in the long Cat and MaK success story. And we are only at the beginning of an exciting development: starting with MaK M 32 series, CCR will be provided in future for the entire range of medium-speed MaK engines, with the M 20 C, M 25, M 32 C and M 43 C. Initial customer responses to the official launch of CCR have been very encouraging. According to Jaime Tetrault, Manager Europe Africa Middle East Marine, Caterpillar Marine Power Systems, Hamburg, Germany, CCR technology is now also being considered for cruise ships operating in emission-sensitive areas and cargo vessels with gensets running continuously during loading and unloading routines in port: “Caterpillar Marine Power Systems is confident of being able to conclude further contracts for MaK engines based on CCR.” High performance, low fuel consumption and minimised emissions are thus no longer mutually exclusive parameters. With Caterpillar Common Rail, MaK marine engines have certainly taken a great step forward! 29
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