Common Rail - MAN Diesel & Turbo Canada

Common Rail
Medium-speed diesel engines
Less consumption. Less soot. Less NO x .

MAN Diesel & Turbo
The responsible way in leading technology
MAN Diesel & Turbo is the world’s leading designer and manufacturer of low and
medium speed engines – engines from MAN Diesel & Turbo cover an estimated 50%
of the power needed for all world trade. We develop two-stroke and four-stroke
engines, auxi liary engines, turbochargers and propulsion packages that are manufactured
both within the MAN Diesel & Turbo Group and at our licensees.
More than ever before, MAN Diesel & Turbo’s development focus is the environmental
performance of our engines. Using our unrivalled grasp of large engine technology,
we aim to make our engines progressively cleaner, more powerful and more efficient.
Our absolute commitment to reducing emissions while increasing fuel efficiency
and power density starts with our active partnership in the emissions law making
process and ends with the delivery of engines that achieve an ideal synthesis of
prime mover characteristics.
Common Rail – Less consumption. Less soot. Less NO x .
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Injection Technology
Medium-speed four-stroke engines
The coming decades will see a sharp increase in the ecological and economic
demands placed on internal combustion engines. Evidence of this trend is the
yearly tightening of emissions standards worldwide, a development that aims not
only at improving fuel economy but above all at achieving clean combustion that
is low in emissions.
Large reductions in NO X , CO 2 and soot emissions are a
strategic success factor for HFO diesel engines. Special
emphasis is placed on low load operation, where conventional
injection leaves little room for optimisation since
the injection process, controlled by the camshaft, is linked
to the engine speed. Thus, possibilities for designing a
load independent approach to the combustion process
are severely limited.
MAN Diesel & Turbo Common Rail Technology (CR)
severs this link in medium-speed four-stroke engines.
CR permits con tinuous and load-independent control
of injection timing, injection pressure and injection volume.
Thus, CR techno logy achieves the highest levels
of flexibility for all load ranges and yields significantly
better results than any conventional injection system.
MAN Diesel & Turbo now offers a reliable and efficient
CR technology for the wide range of different types of
fuel, also capable to handle residual fuels (HFO).
L 32/44CR
4 Common Rail – Less consumption. Less soot. Less NO x . Common Rail – Less consumption. Less soot. Less NO x .
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MAN Diesel & Turbo CR Technology
Measurably friendly to the environment
General Benefits
Common rail technology
Comparison of engine performance for different
injection systems
MAN Diesel & Turbo Common Rail Technology lowers
the emission rate of soot and NO x at all possible engine
operating points.
CR unit
injector
Soot Emissions
FSN
The graph shown here compares conventional and CR
0.7
0.6
0.5
0.4
0.3
0.2
0.1
injection processes exemplary.
Due to the flexibility of the injection process, NO x emission,
fuel consumption and exhaust opacity can be
improved by varying injection pressure and start of injection.
Even in the commonly problematic low load
range, exhaust opacity can be brought down below
the visibility limit.
high pressure pump
camshaft
0 25 50 75 100
Engine Load (%)
Higher efficiency with flexible injection
Our CR technology is an ideal tool for lowering pollu-
NO x
The old problem with the fixed link between injection
tant emissions and fuel consumption – while giving the
%
pressure and engine speed is well-known. In engines
user the security that this system will continue to meet
104
100
96
92
88
with high effective mean pressure, there is a rapid decline
in injection pressure in the low load range, a phenomenon
that has a negative effect on the air-to-fuel ratio
and on spray atomisation that are key to combustion.
Poor combustion is the consequence.
the demands of the future: today’s diesel engine designs
at MAN Diesel & Turbo already include potential to
meet tomorrow’s requirements.
Retrofit? Retrofit!
CR technology from MAN Diesel & Turbo takes advan-
0 25 50 75 100
The new MAN Diesel & Turbo CR injection technology
tage of a modular high pressure pump system with
Engine Load (%)
permits independent and separate control of injection
multiple lobes on the camshaft. The camshaft drives
pressure and timing. Fuel is fed into the rail (pressure
the high pressure pumps, which are equipped with
SFOC
accumulator) by an electronically controlled high pres-
solenoid operated suction throttle valves for pressure
%
sure pump and stored there for each injection. The
control. This layout – and the modular structure of the
100.5
100.0
99.5
99.0
98.5
98.0
result is improved combustion and lower emissions
with the same or even better fuel economy – strong
advantages, especially in the critical low load range.
Doing more for the environment
The injection flexibility of MAN Diesel & Turbo CR technology
means decidedly lower NO X and CO 2 emissions
units – makes it possible to install MAN Diesel & Turbo
CR technology retrospectively. Thus, many older diesel
engines can still benefit from the new technology: simple,
fast retrofitting and upgrading – for lower emissions with
no loss in output.
0 25 50 75 100
thanks to highly effective combustion.
Engine Load (%)
Conventional Injection
CR Injection
6 Common Rail – Less consumption. Less soot. Less NO x . Common Rail – Less consumption. Less soot. Less NO x .
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Enhancing Reliability
Thinking ahead
MAN Diesel & Turbo CR injection technology is synonymous with reliability – and
reliability begins at the development process.
MAN Diesel & Turbo’s experience in the development and
production of high pressure injection systems has been
consistently advanced and implemented in CR technology.
In addition to theoretical investigations of safety
concept, test operations with HFO on MAN Diesel & Turbo
system test rigs are of central importance and make it
possible to immediately define any preventive measures
required to guard against potential technical problems.
Field tests were conducted, which showed very satisfactory
long-term experience in respect of wear and
component reliability. Consequently, CR technology
from MAN Diesel & Turbo is able to offer excellent reliability
in all operating situations and, from the outset,
brings with it a high degree of maturity.
For example
Should a high pressure pump fail:
MAN Diesel & Turbo CR systems are equipped with
at least two high pressure pumps and the system can
easily be operated with only one high pressure pump.
Should the rail pressure controller fail:
A safety valve with an additional mechanical pressure
control valve ensures the continued operability of the
system.
Should a rail pressure sensor or the speed /
top dead centre sensor malfunction:
Important sensors are redundant to ensure that here,
too, the system will continue to operate.
To protect against fuel escaping from
leaking fuel pipes:
All high pressure lines, rails and high pressure connections
are double wall insulated.
To protect against uncontrolled injections:
Flow limitation valves at each cylinder prevent uninten-
ded injection.
As a matter of principle, MAN Diesel & Turbo has kept
the basic concept of its Common Rail Technology as
simple as possible and has integrated technically proven
components into the design. For example, in keeping
with this philosophy, the design does not use a separate
servo circuit for activating the injection valve. Less
maintenance is one of the benefits. Also, integrated
into the CR technology are well-proven components
with long service experience, such as injection valves
and nozzles. The injection control valves are on the rail
outside of the cylinder head, resulting in greater system
reliability.
8 Common Rail – Less consumption. Less soot. Less NO x . Common Rail – Less consumption. Less soot. Less NO x .
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Mature Technology
Greater reliability and control valves
Introduction of the 32/40CR on the market, followed by 32/44CR respectively
48/60CR, was preceded by years of intensive, practise oriented development at
MAN Diesel & Turbo using the Augsburg test facilities. Subsequent tests performed
in co-operation with a customer yielded such positive results that today,
MAN Diesel & Turbo is able to offer a mature technology that reliably guarantees
an optimum level of performance, environmental compatibility and economy.
Modular pump system for greater reliability
A high pressure rail segment for control valves
MAN Diesel & Turbo engines use either two, three or
four high pressure pumps, depending on the number
of cylinders. The pumps are capable of accumulating
a pressure of up to 1 600 bar in the rail system. This
design offers added machine reliability, because even
if one pump should fail, the engine will continue to be
operable.
Type 48/60CR
Type 32/40CR, 32/44CR
In principle, there are several possible designs for the
fuel accumulator. For example:
• One high pressure rail for the entire engine.
• Independent high pressure rail segments for two or
three cylinders.
• Individual accumulators for each cylinder.
MAN Diesel & Turbo decided on one high pressure rail
segment for two cylinders, as with this design, mediumspeed
four-stroke engines can achieve a maximum
level of pressure stability and operating reliability while
at the same time taking advantage of a simple and
integral structure.
The concept of modular elements has also been implemented
in the rail segment design. The engine types
32/40CR, 32/44CR and 48/60CR use the same base
elements. Only the lengths of the rail units were adjusted.
Common Rail System V32/44CR
Sacos one
The heart of MAN Diesel & Turbo CR injection technology
is the injection module of the SaCoS one (Safety
and Control System on engine). It calculates pressure,
injection timing and injection volume on the basis of
numerous operational parameters recorded by sensors,
such as engine speed, cylinder top dead centre,
load pressure and rail pressure. The calculated current
pulses are then output to the solenoids of the
control valves (rail segment) and suction throttle valve
(high pressure pump).
At precisely the right time, the control valves receive
a pulse that causes the injection valves to open. As
soon as enough fuel has been injected, the valves
close. The injection module is the key to flexible combustion
– and thus to minimizing emissions at a low
level of fuel consumption.
In addition, on both ends of the segment the patented
valve support integrates the control valves with solenoid,
flow limiter and connections for high pressure
Modular rail unit with integrated control valve for different engines
lines.
10 Common Rail – Less consumption. Less soot. Less NO x .
Common Rail – Less consumption. Less soot. Less NO x .
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All data provided in this document is non-binding. This data serves informational purposes only
and is especially not guaranteed in any way. Depending on the subsequent specific individual
projects, the relevant data may be subject to changes and will be assessed and determined
individually for each project. This will depend on the particular characteristics of each individual
project, especially specific site and operational conditions · Copyright © MAN Diesel & Turbo ·
D2366251EN-N4 Printed in Germany KW9-08122
MAN Diesel & Turbo
86224 Augsburg, Germany
Phone +49 821 322-0
Fax +49 821 322-3382
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www.mandieselturbo.com
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