A Technical Customer Magazine of MAN Diesel & Turbo 3/2015

Traditional dhows at anchor in Doha, Qatar, home to Nakilat

(picture used under Creative Commons licence, StellarD,Wikipedia)

The World’s First MAN MAN Alpha FP Kappel

Design Launches
B&W ME-GI in Service 58,500-dwt Bulker into
Retrofit milestone: successful ME-GI gas injection
project for Nakilat’s ‘Rasheeda’ Fuel-Saving Future
Nakilat, in association with Qatari Nakilat’s Rasheeda built in 2010 Serv, said: “This is a fantastic mile- Fixed pitch propeller delivers excel- completed its own sea trials.
LNG producers Qatargas and Ras- is a 266,000 m3 LNG carrier with stone in our company’s history. It lent results in service. Lemissoler reports that the Kap-
Gas Company Limited and engine two MAN B&W S70ME-C HFO- is a lighthouse project, and there pel propeller offers significant fuel
manufacturer MAN Diesel & Turbo, burning engines, which have been has been a remarkable partner- One of the first bulk carrier applica- savings compared to conventional
recently celebrated the success of converted to the dual-fuel ME-GI ship and cooperation through this tions of MAN Diesel & Turbo’s new propellers and, together with the
the ME-GI project. concept. The shipyard operator historic conversion. Our ME-GI or- MAN Alpha Kappel FP propeller new vessels’ design and lines as
Nakilat-Keppel Offshore & Marine der book now stands at 140 orders took place off the coast of China well as the silyl acrylate antifoul-
The project involved retrofitting (N-KOM) carried out the ship’s – for different vessel sizes and ap- recently when the ‘Elsabeth C’, a ing paint, contributed to the fa-
chartered Q-Max vessel, Rashee- conversion at its Erhama bin Jaber plications, which we see as a com- 58,500-dwt Supramax bulk carrier vourable results from the first two
da, with a gas-burning M-Type Al Jalahma Shipyard facilities in the pelling case for our technology to owned by Frontmarine Co. Ltd – an vessels’ sea trials. It reports that
Electronically Controlled – Gas In- major Qatari port of Ras Laffan In- be designated the industry stand- affiliated and managed company of both vessels consumed an aver-
jection (ME-GI) System, which has dustrial City. ard.” Lemissoler Navigation Co. Ltd., the age 23 mtns per day at a speed
now been successfully commis- The project collaborators, in- Nakilat Managing Director Eng. Cypriot ship management group – of some 14.2 knots in ballast con-
sioned. cluding MAN PrimeServ, installed Abdullah Al-Sulaiti, said, “The suc- successfully completed its sea tri- ditions during the trials. The Elsa-
The Qatari-owned Q-Max vessel the ME-GI system on the vessel cess of the ME-GI project is the als. The newbuilding is the first in a beth C also performed a success-
is the world’s first low-speed ma- at the Erhama bin Jaber Al Jalah- culmination of years of coopera- series of eight sister-ships, all fea- ful crash-stop test that was notable
rine diesel engine to be converted ma shipyard in Qatar in June 2015. tion with Qatargas, RasGas and turing single MAN B&W 5S60ME- for its lack of noise and vibration.
to use LNG as a fuel. The retro- The partner for the ME-GI fuel sup- MAN Diesel & Turbo as turnkey C8.2 engines with an SMCR 8050 Thomas Leander, Head of Pro-
fit modification meets the current ply system is TGE. project manager. In late 2013, Na- kW @ 89 rpm. The Elsabeth C’s pulsion – PrimeServ Four-Stroke –
known and future stated global Christian Ludwig, Head of Ret- kilat worked with our charterers... sister ship, ‘Mirela’, the second in Denmark, said:...
emissions regulations. rofit and Upgrades, MAN Prime-  Continued on page 2 the series, has since successfully  Continued on page 2

World-First Dual-Fuel Popularity of 32/44CR Condition-Based Main- Record-Breaking Engine

Conversion Announced Engine Confirmed tenance for TCA and TCR Leaves Test Bed in Korea
Four-stroke MAN engine Influx of orders in fishing Turbochargers MAN B&W-branded
on container ship segment New concept introduced engine’s market début

> Page 3 > Pages 4-5 > Pages 6-7 > Page 9
PAGE 2 DIESELFACTS 3/2015

The World’s First MAN B&W ME-GI in Service MAN Alpha FP Kappel Design
Continued from front page MAN Diesel & Turbo sees sig-
...to implement a pilot conversion nificant opportunities arising for
on Q-Max Rasheeda, the first ret- gas-fuelled tonnage as fuel prices
rofit ME-GI project ever to be im- rise and modern exhaust-emission
plemented in the marine industry. limits tighten. Indeed, research in-
This is a milestone moment for all dicates that the ME-GI engine de-
involved parties.” livers significant reductions in CO2,
MAN Diesel & Turbo reports NO X and SOx emissions. Further-
that the vessel’s ME-GI units have more, the ME-GI engine’s negligi-
displayed a seamless change be- ble methane slip makes it the most
tween fuel-oil and gas operation – environmentally friendly technol-
a key characteristic of the ME-GI ogy available. As such, the ME-GI
technology. engine represents a highly efficient,
The Qatar fleet comprises 14 Q- flexible, propulsion-plant solution.
Max and 31 Q-Flex LNG carriers, An ME-LGI counterpart that
all using dual MAN Diesel Turbo’s uses LPG, methanol and other liq-
S70-ME-C low-speed diesel en- uid gasses is also available and
gines for propulsion. has already been ordered.

The ME-GI engine About Nakilat

The ME-GI engine represents the Nakilat is a Qatari LNG transport
culmination of many years of work, company providing an essential
and gives ship owners and oper- transportation link in the State of
ators the option of utilising fuel or Qatar’s LNG supply chain. Its LNG A closer view of the 6.8 metre Kappel FP propeller fitted with ‘propeller hub cap fins’
gas depending on relative price shipping fleet is the largest in the
and availability, as well as environ- world, comprising 63 LNG vessels.
mental considerations. The ME-GI Nakilat also manages and oper- Continued from front page sel types. In doing so, MAN Diesel The Elsabeth C and Mirela were
uses high-pressure gas injection, ates four large LPG carriers via two “A key point during the design & Turbo has managed to ensure constructed by New Times Ship-
allowing it to maintain the numer- strategic joint ventures: N-KOM stage was to address the prob- a significantly safer and more reli- building Co. Ltd, Jiangsu, China
ous positive attributes of MAN and NDSQ. Nakilat operates the lem experienced by similar ves- able course of operation, while at and were scheduled for delivery in
B&W low-speed engines, which ship repair and construction facili- sels that encounter an overly-small the same time improving the ves- September 2015. The remaining
have made them the default choice ties at Erhama Bin Jaber Al Jalah- light running margin (LRM). There- sel’s efficiency and manoeuvrabil- sisters are scheduled for delivery
of the maritime community. The ma Shipyard in Ras Laffan Indus- fore, MAN Diesel & Turbo recently ity during its entire lifetime.” over the following 12 months. This
ME-GI is not affected by the mul- trial City. Nakilat also offers a full introduced new light running mar- The MAN Alpha Kappel propeller series of vessels was specifically
tiple deratings, fuel-quality adjust- range of marine support services gins for all FP propellers and two- optimisation has been carried out designed to have the largest carry-
ments or large methane-slip issues, to all those vessels operating in stroke engines of 4-10%. Further- based on the stern and wake field ing capacity and greatest efficien-
which have been seen with other Qatari waters. more, the propeller layout for these for the newly designed 58,500-dwt cy of any vessel within the 190-me-
dual-fuel solutions. 58,500-dwt vessels is 3-4% higher vessel, with a 58,500-dwt stock tre LOA range.
than normally applied to these ves- propeller.

About Lemissoler
Over the years Lemissol-
er has become a diversi-
fied shipping group with
activities in the business
fields of liner shipping,
ship owning and ship
management. The group
is based in Limassol, Cy-
prus and is represented
globally through a broad
network of offices.

The Elsabeth C and Mirela newbuildings

Japan’s First ME-GI

Successfully Passes FAT
The FAT (Factory Acceptance Test) auxiliary engines for each vessel, for environmentally responsible
of the first ME-GI engine in Japan in early-2014. shipping.
recently took place at the Tamano The ConRo ships – with con- Crowley selected the high-
Works of Mitsui Engineering & Ship- tainer Lift-On/Lift-Off (LO/LO) and pressure, Diesel-cycle ME-GI en-
building Co., Ltd. (MES). Roll-On/Roll-Off (RO/RO) – will be gines due to their high efficiency
named ‘El Coquí’ and ‘Taíno’, and and power concentration. The
Overseen by the DNV GL classi- are scheduled for delivery in the ME-GI’s ability to avoid derating,
fication society, the engine is the second and fourth quarters of and its negligible methane slip,
first of two 8S70ME-C8.2-GI units 2017, respectively. also contributed to its selection.
for delivery to VT Halter Marine of The vessels will be two of the Crowley reports that the new-
Mississippi, USA for installation world’s first LNG-powered Con- buildings will reduce the amount
aboard two 2,400-teu ConRo Ro ships, designed to travel at of CO2 emissions attributable to
ships for Crowley Maritime Cor- speeds up to 22 knots, and carry each container by some 38%.
poration, USA. various sized containers, along Also, the ships will meet or ex-
with hundreds of vehicles in en- ceed all regulatory requirements
The Crowley order closed, weather-tight car decking. and have the CLEAN notation,
Crowley, the marine solutions, Crowley states that the vessels which requires limitation of opera-
transportation and logistics com- will offer customers fast ocean- tional emissions and discharges,
pany, ordered the ME-GI engines, transit times and, being powered as well as the Green Passport,
along with 3 × MAN 9L28/32DF by LNG, will set a new standard both issued by DNV GL.
DIESELFACTS 3/2015 PAGE 3

World-First, Dual-Fuel Container

Ship Conversion Announced
Four-stroke MAN engine to be converted to dual-fuel operation
Wessels Reederei, the German ship- adopt our dual-fuel technology.” vices as well as the development respect, the Wes Amelie has 23 up projects to be easily implement-
ping company, has signed a contract Wessels has earlier stated that costs, reducing significantly the sister ships, 16 of them structurally ed. This ship therefore facilitates a
with MAN Diesel & Turbo at the Euro- the project will promote the de- costs for follow-up projects. In this identical, which would allow follow- multiplier effect, with multiple, oth-
port exhibition for maritime technol- mand for LNG as a fuel within the er ‘conversion-capable’ vessels
ogy to retrofit the 8L48/60B main en- maritime industry where Wessels also found around the European
gine of its 1,000-teu container ship Reederei GM, Christian Hoepfner, continent.
‘Wes Amelie’ to dual-fuel operation. said: “With each rebuild, we are
creating an increasing demand for About Wessels Reederei
The vessel will be the first of its kind LNG as a clean fuel. Only in this With a current fleet of 43 ships,
worldwide to be converted to an way – and not only through ap- Wessels Reederei is one of the
LNG-capable propulsion system. peals – can the development of an largest managers of coastal ves-
Through running on LNG, the LNG infrastructure continue to gain sels with 33 coasters, four con-
Wes Amelie will drastically reduce momentum.” tainer and six multipurpose vessels
emissions of sulphur oxide by over Due to the long delivery time of in its fleet portfolio. The company
99%, nitrogen oxide by approxi- LNG tanks, the engine retrofit will employs a staff of 45 at its Haren/
mately 90%, and carbon dioxide commence in Q4 2016. Full op- Ems headquarters.
by up to 20%. erational usage of LNG as fuel is The optimisation of fuel con-
Dr. Thomas Spindler, Head of planned for early December, 2016. sumption and pollutant emission
Upgrades & Retrofits – MAN Prime- has always been an integral com-
Serv Four-Stroke – MAN Diesel & Multiplier effect ponent of its business philosophy.
Turbo, said: “We are very excited The Wes Amelie is a modern feed- Initiatives range from the establish-
about the signing of this contract er-vessel that was launched in ment of emissions optimisation
and view its potential for broader 2011 and operates in the North Pictured at the signing at Europort were (front, left to right) Dr Thomas Spindler measures, software implementa-
adoption within the maritime sec- and Baltic Seas. When selecting (Head of Upgrades & Retrofits, MAN PrimeServ Four-Stroke) and Christian tion to increase energy efficiency
tor as significant. We enjoy an ex- a suitable vessel for conversion, Hoepfner (Wessels Reederei GM); (back, left to right) Marcel Lodder (Project and the development of alternative
Engineer, Upgrade & Retrofit, MAN PrimeServ), Stefan Eefting (Vice President,
cellent cooperation with Wessels special attention was paid to the MAN PrimeServ), Rainer Runde (Project Manager, Wessels Reederei), and Gerd
propulsion systems.
and commend their willingness to scalability of the engineering ser- Wessels (Managing Partner – Wessels Reederei)

The ‘Wes Carina’, a sister ship to the ‘Wes Amelie’ (picture courtesy Wessels)
PAGE 4 DIESELFACTS 3/2015

New Order Confirms the

Popularity of the 32/44CR Engine
Complete propulsion package drives influx of orders in fishing segment
Voyager Fishing Company, Ltd., one of the most powerful pelagic- Atlantic in an area known for its Beneficial propulsion to 60 Hz). This, in turn, provides
based in Kilkeel, Northern Ireland, fishing vessels in the world with a challenging weather, a primary optimisation the highest efficiency in all opera-
has ordered a new trawler/purse bollard pull of more than 120 tons reason behind the owner ordering The two-speed RENK gearbox of- tion modes, ensuring a reduction
seiner, designed by Salt Ship Design and commented on its very high such a powerful engine. fers both economic and environ- in fuel consumption of up to 20%,
in Norway and to be built at Karstens- efficiency when comparing the bol- The Voyager will replace the mental benefits, particularly for depending on the vessel’s opera-
ens Skipsværft in Skagen, Denmark. lard pull with the size/power of the existing 75.6-metre vessel of the fishing vessels and other vessels tion profile.
engine. same name that Karstensens built having a multiple operational pro- Furthermore, cavitation and
The newbuilding will be powered Carstens continued: “The en- in 2010, and represents the largest file or reduced transit speed. noise are reduced when operat-
by a propulsion package compris- gine has gained a good foothold vessel built at the shipyard to date. As a result of the vessel’s float- ing at low propeller rpm, which
ing an MAN 12V32/44CR main en- in the market for its flexibility, low Upon completion, the 86.4-metre ing frequency system (from 50 to improves the vessel’s fishing ca-
gine, a 4,400-mm ø MAN Alpha levels of noise/vibration, reduced fishing vessel will have a loading 60 Hz), the propulsion system is pabilities.
VBS 1100 propeller, a two-speed smoke during engine start and capacity of more than 3,200 m3. also able to operate in ‘shaft alter-
RENK Type RSVL1000 gearbox, operation, and is already building Notably, when comparing the two nator mode’ with reduced engine Boost injection
and an Alphatronic AT3000 remote a reputation as an excellent work- vessels, the newer model’s larger, and propeller speed in both steps. The MAN 32/44CR engine also
control system. Vessel delivery is horse.” He concluded: “We are optimised propeller has meant that With this part-load optimisation boasts of a special, patented
scheduled for August 2017. also very pleased with how well the shipowner has been able to feature, offering up to 16.7% low- feature for common-rail engines,
Frederik Carstens, Head of the common-rail system has per- employ a smaller engine, despite er engine/propeller speed in both called boost injection. SaCoSone,
Sales, Offshore/Fishing, MAN Die- formed in this key segment.” the larger size of the newbuilding. steps, the fuel consumption is fur- the engine’s safety and control
sel & Turbo, said: “Fishing is an im- MAN Diesel & Turbo reports that ther reduced. system, is able to detect a load in-
portant segment for the 32/44CR A powerful engine the Voyager order is just the latest in The gear box features two gear- crease at an early stage and im-
engine. A key reason behind the MAN Diesel & Turbo reports a string of orders the company has ratio settings, which facilitate a re- prove the load response of the en-
demand for the engine is that MAN that this order is its first for a landed in the fishing segment for duced propeller speed at an opti- gine significantly by activation of a
Diesel & Turbo offers complete 12V32/44CR type with a power the 32/44CR engine. These include mal engine speed. This allows the boost injection in the common-rail
propulsion-package solutions that rating of 7,200 kW, making it the orders for European tuna boats, electric power generation for the control.
– in terms of SFOC – are optimised hitherto most powerful model the and North American and Scan- PTO on the gearbox to remain un- If an engine detects a sudden
from start to finish.” company has delivered to the pe- dinavian trawlers, of which two of interrupted in both trawling and load increase, it changes the in-
Director Tage Rishøj, Karstens- lagic fishery market. The new Voy- the latter have been delivered by transit modes in combination with jection timing and increases the
ens, stated that Voyager will be ager will catch fish in the North Karstensens already this year. the floating frequency (from 50 rail pressure by about 200 bar.

Graphical rendering of the new ‘Voyager’

DIESELFACTS 3/2015 PAGE 5

Chinese CMP
Renews Four-Stroke
Licence Agreement
At a signing ceremony in Anqing, CMP today one of MAN Diesel
Anhui province on 8 October & Turbo’s major licensees glob-
2015, CSSC Marine Power Co., Ltd. ally for such engines, and the
(CMP) renewed its contract with largest producer of MAN four-
MAN Diesel & Turbo for another 10 stroke engines in China.”
years of production of four-stroke Ulrich Vögtle – Vice President
medium speed engines. CMP is an and Head of Large Bore Four-
engine-manufacturing division of Stroke Licensing – said: “We
the Chinese State Shipbuilding view our relationship with CSSC
Corporation (CSSC), one of the as pivotal to our success in giv-
largest Chinese shipbuilders. ing Chinese customers access
Library photo of the MAN 12V32/44CR engine ordered for the Voyager newbuilding to our technology. Accordingly,
The new agreement marks the we are very happy and proud
This change leads to higher engine Principal details – Voyager renewal and continuation of a today to be able to officially an-
torque, a reduced speed-drop, a Length overall (m) 86.4 cooperation that first started in nounce the continuation of our
short recovery time, and no addi- the 1980s. excellent business relationship
Breadth (m) 17.8
tional air consumption. Mr. Zhang Haisen, Chairman for the next decade.”
Depth (m) 10.3 To date, CMP has deliv-
of CSSC Marine Power Co., Ltd.
Alphatronic 3000 control system Main engine 1 × MAN 12V32/44CR (7,200 kW) - said: “The extension of the four- ered 5,000 units of MAN four-
The propulsion control system Propeller plant ø (mm) 4,400 stroke licence agreement be- stroke diesel engines, equiva-
specified for the Voyager is MAN Shaft alternator (kW) 3,500 tween CMP and MAN Diesel & lent to 4,700,000 kW. CMP also
Diesel & Turbo’s new and ad- Turbo is a tribute to the very first holds a licence agreement for
Thrusters (kW) 1 × 1,400
vanced Alphatronic 3000 genera- licence we bonded 35 years two-stroke MAN B&W engines,
tion. The installation will be config- Gearbox Two-speed RENK – Type RSVL1000 ago. Furthermore, the com- which it too renewed for a dec-
ured for complete control station Propeller 4.4-m MAN Alpha propeller, incl. AHT nozzle prehensive cooperation scope ade at a ceremony in Beijing
set-ups at the main bridge, the AT3000 remote control system with refers not only to four-stroke earlier this year.
starboard and port indoor bridge Control system two-speed gear selection diesel engines, but also to two-
wings, aft bridge and the engine Source: MAN Diesel & Turbo stroke low speed engines, CPP About CSSC/CMP
control room. As a special feature propellers, turbochargers, and Headquartered in Beijing,
for optimised operational economy, SCR systems. CSSC values CSSC handles shipbuilding
the control system is specified with and in full operation. fuel-consumption savings and low- MAN Diesel & Turbo as its pre- activities in the east and south
two-speed gear selection – in ad- er exhaust-gas emissions. The fine mium partner, and sincerely ex- of China and consists of vari-
dition to the load control for floating An optimised aft-ship solution tuning of the final propeller-blade pects to continue this important ous ship yards, equipment
frequency operation. The high-efficiency (Alpha High design has been based on a care- business partnership to another manufacturers, research insti-
The MAN Alpha remote con- Thrust) AHT propeller nozzle has ful assessment of the Voyager’s 35-year milestone.” tutes and shipbuilding-related
trol system AT3000 is highly user- been specified in this case for predicted operational power/ Klaus Engberg – Senior Vice companies. Some of the best-
friendly and intuitive with the ability ‘headbox’ mounting. The optimi- speed/duration profiles, while tak- President and Head of Two- known shipbuilders in China,
to switch between the two speeds sation and integration of the large ing onto consideration the com- Stroke Licensing –said: “We such as Jiangnan Shipyard and
ensuring that the vessel always op- propeller and nozzle into the ves- promises involved in finding the have enjoyed a long, close co- Hudong-Zhonghua Shipbuild-
erates with the highest possible ef- sel’s aft-ship design was carried perfect design solution for, for ex- operation with CSSC/CMP that ing, are currently owned by
ficiency. MAN handles all interfac- out in close cooperation with Salt ample, high-speed steaming and stretches all the way back to CSSC.
es to clutch control, PMS, etc. Ship Design. maximum pulling power efficiency 1980, and over the years CMP Zhenjiang Marine Diesel
Additionally, the propeller speed A propeller- and propulsion-op- at trawling speed with suppression has produced a broad range of (ZJMD), CMP’s predecessor,
change is performed automatically timised aft-ship solution delivers of cavitation and noise. MAN four-stroke engines, but was founded in 1976 and
with the shaft alternator engaged energy optimisation, resulting in also small two-stroke engines.” signed a 15-year medium-
Engberg continued: “Especially speed licensing agreement with
over the last decade, our two MAN Diesel & Turbo on 13 May
companies have intensified their 1980. This was subsequently
technical cooperation, making extended in 1995 and 2005.

MAN Diesel & Turbo attendees at the ceremony included Klaus Eng-
berg – Senior Vice President and Head of Two-Stroke Licensing, Ulrich
Vögtle – Vice President and Head of Large Bore Four-Stroke Licensing, Dr
Manfred Biedermann – Head of MAN Diesel & Turbo, China, and Dai Jun –
Library photo of the 4,400-mm ø MAN Alpha VBS 1100 propeller, the associated rudder bulb, and the high-efficiency
Head of Licensing Support, China
(Alpha High Thrust) AHT propeller nozzle
PAGE 6 DIESELFACTS 3/2015

Condition-Based Maintenance
for TCA and TCR Turbochargers
Kemal Oguz Coban – of the Product Line Turbochargers Division – MAN Diesel & Turbo,
introduces a new concept
As 75% of the total output of contem- hauls. Figures 4 and 5 are taken
porary diesel engines is solely at- from the service reports for two
tributable to the turbochargers, their different TCR22s aboard different
downtime greatly endangers the tankers after 26,000 and 24,000
operational availability of the plant/ hours, respectively.
vessel.
CBM for Compressor Wheels
Moreover, they are – in general – In MAN Diesel & Turbo project
one of the most critical compo- guides, the expected lifetime of
nents of an engine as they are sub- TCA compressor wheels are stated
ject to both extreme temperatures as 80,000 operating hours. How-
and revolutions, which makes their ever, experience shows that the
production, as well as the produc- actual lifetime of the compressor
tion of turbocharger spare-parts, wheel mostly depends on operat-
very expensive. Accordingly, en- ing cycles, with operating temper-
suring their safe operation and reg- atures being of particular impor-
ular maintenance is of great impor- tance. Lifetime evaluation is based
tance for shipowners. on the relation between electrical
Having been introduced in the Figure 1: Bearings from a TCA66 turbocharger pictured aboard a bulk carrier after 28,000 running hours conductivity and material hard-
early 2000s, MAN’s latest turbo- ness. However, measuring mate-
charger series – the TCA and TCR bly of the filter silencer and insert Therefore, effective cleaning is par- There are many good examples of rial hardness can lead to damage,
series – have been very well re- piece, a task easily performed by ticularly necessary as prescribed in nozzle rings that have not required particularly on an aluminum alloy
ceived by the market as they are on-board crew over roughly 2-3 the respective instruction manuals. replacement during major over- as very high forces are brought to
both still able to cope with the re- hours. In comparison, the TCR
quirements of the entire MAN en- series requires no intermediate in-
gine portfolio despite the many spection. Accordingly, to all intents
changes in market demands and and purposes, both turbocharger
new regulations. This positive mar- series can operate normally be-
ket reception has not only yielded tween consecutive dry-dock visits.
more than 7,000 TCR references Expected bearings lifetime for the
and some 6,500 for the TCA, but TCA and TCR series are, respec-
has also culminated in millions of tively, 50,000 and 30,000 hours.
running hours that have delivered Service experience with both se-
valuable service experience. This, ries has, until now, shown that the
in turn, has led to MAN developing bearings can be used up to a sec-
a number of service solutions for ond major overhaul, provided that
customers, one of which is called internal lubrication is normal and
‘Condition-Based Maintenance’ rotor balance is maintained. During Figure 2: Axial Bearings on a TCR22-21 turbocharger pictured aboard a tanker after 26,000 running hours
(CBM). major overhauls, the wear limits for
axial and radial bearings are meas-
The CBM concept ured and evaluated regarding con-
In brief, CBM can be described as tinued use until the following, major
the replacement of parts only when overhaul. Figures 1 and 2 belong
absolutely necessary. During over- to the recent service reports for a
hauls, all turbocharger parts are in- TCA66 and for a TCR22 after a first
spected and evaluated according major overhaul and illustrate the
to pre-defined MAN PrimeServ cri- condition of different bearings that
teria. If evaluated as being within were evaluated as acceptable for
the prescribed limits, the parts are continued use.
deemed as fit to use until the next
overhaul provided that operating CBM for nozzle rings:
instructions are strictly adhered to. In MAN Diesel & Turbo’s project
guides, the expected lifetime of
CBM for bearings TCA and TCR nozzle rings are stat- Figure 3: Nozzle rings on no. 1 and 2 TCA77s after 57,000 running hours
Since 2009 and the introduction ed as 40,000 and 30,000 hours,
of new lubrication-tank and axial respectively. During inspections,
bearing designs, more than 2,000 the TCAs are specifically checked
TCAs have entered service with, for cracks. Critical types of crack
notably, no reported failures to are described in more detail in
date. As a result, the previously pre- MAN Diesel & Turbo’s customer
scribed, intermediate, axial-bear- information letter – PCI338. In Fig-
ing inspections for both two- and ure 3, the condition of the nozzle
four-stroke engines were revoked rings from a TCA77 aboard a con-
in April 2014 (as announced by tainer ship after 57,000 hours can
customer letter CUS333). The cur- be observed.
rent, intermediate inspection for The wear on TCR nozzle rings
the TCA series just recommends compared to TCA units tends to be
a visual check of the compressor higher owing to the way the vanes
wheel for possible blade damage; are exposed to exhaust gases
this entails the simple disassem- and the duration of the exposure. Figures 4 and 5: TCR22 nozzle rings pictured after 26,000 and 24,000 hours
DIESELFACTS 3/2015 PAGE 7

bear on a very small area, which the results compared to the pro- pelled to replace parts due to the
can potentially cause tiny cracks. duction values. If the values are scope of an overhaul or based
Instead, MAN uses an electrical within the designated limits, the purely on the age of parts. Moreo-
conductivity test where the com- compressor wheel is evaluated as ver, parts are replaced only when
pressor wheels are evaluated by suitable for continued operation necessary and there is no ‘service
their “International Annealed Cop- until the next overhaul as long as kit’ concept where every compo-
per Standard”, known as ‘% IACS’, individual operating instructions nent is renewed regardless of con-
that is, the electrical conductiv- are strictly adhered to. To date, no dition. In addition, MAN Diesel &
ity for metals and alloys relative TCA compressor wheel has been Turbo offers owners several types
to a standard, annealed, copper opened for a third major overhaul of maintenance contract, depend-
conductor. During the production but precedence exists in the form ing on their requirements and
phase and upon the finalisation of of the ample service experience budget, where their fleet is under
each compressor wheel, its elec- that exists for the previous-gen- continuous surveillance. So far,
trical conductivity is measured at eration NA series. Figures 8 and nearly 1,500 MAN turbochargers
several designated points and reg- 9 are from the service report for are covered by such contracts.
istered in a database, see Figures an NA57/T turbocharger aboard a Correct spare-parts handling and
6 and 7. containership after 107,000 oper- effective maintenance planning
During an overhaul, this test is ating hours. play a major role for owners in their
offered to shipowners as an op- budget planning for plants. Thanks
tion, especially when the expected Conclusion to the CBM concept for TCA and
lifetime of a compressor wheel is The examples we have covered in TCR turbochargers, shipowners
close or already reached. In such this article clearly show that the can enjoy significant savings by
a case, the same points as were CBM concept delivers potentially maintaining equipment at the opti- Figure 6: Basics of the electric conductivity test where a potentiometric method
measured in production are meas- significant savings to shipowners mal time. with electrodes is employed that creates an electric field that causes electrons
ured by service engineers and that are not automatically com- to drift towards the positive terminal

Figures 8 and 9: Measuring Points on an NA57/T compressor wheel Figure 7: Example of measurement points on a compressor wheel

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PAGE 8 DIESELFACTS 3/2015

MAN PrimeServ Welcomes

New Member to Prestigious Club
MAN Diesel & Turbo’s service wing owner of a memorial plaque boast-
recently welcomed a new member ing of its fine achievement. In gen-
to its noteworthy ‘100,000 Operating eral, the 32/40 engine has a power
Hours Club’. output from 3 - 9,000 kW, and is
characterised by low wear-rates
The happy party was Mastermind and long maintenance intervals.
Shipmanagement Ltd. of Cyprus The Mastermind Group is princi-
who received the award for an pally a ship-owning company but
MAN 9L32/40 engine that serves its ship-management division
as main driver aboard the ‘Ema- technically manages a fleet of
nuel 49’, a multipurpose tween- more than 16 vessels, which con-
decker that has sailed the high sists of dry bulk, break-bulk and
seas since 1997 with special break multipurpose vessels. The Master-
bulk and heavy lift cargoes. mind Group was a launching part-
Originally built at MAN Diesel & ner of MAN Diesel & Turbo’s 6S40
Turbo’s Augsburg works in south- ME-B engine and is a keen pro-
ern Germany, Emanuel 49’s four- moter of the EMC (Engine Manage-
stroke engine is now the proud ment) concept.

(From left) Mastermind’s Technical Manager – Andreas Potamitis – and Manag-

ing Director, Captain Eugen-Henning Adami, pictured receiving their memorial
plaque from Hans Odgaard, Managing Director, Man Diesel & Turbo, Cyprus The Emanuel 49 (picture courtesy Mastermind)

and has made numerous signifi- est tanker fleet for the China Mer-

AMCL Signs Turbocharger cant and innovative contributions

to the development of Chinese
shipping industries around the
chants Group in all aspects cov-
ering ship management,
commercial operations, corpo-

Premium Maintenance Contract world.

Today, AMCL is one of the lead-
ing ship management companies
rate and accounting services as
well as new building supervision,
while retaining a high degree of
in Hong Kong, operating the larg- cost efficiency.
The Turbocharger unit of MAN Accordingly, MAN PrimeServ MAN PrimeServ Turbocharg-
PrimeServ, MAN Diesel & Turbo’s Turbocharger – in coordination er monitors and administrates
service division, recently signed with the MAN PrimeServ network upcoming maintenance inter-
a Premium Turbocharger Mainte- – will coordinate and plan all up- vals
nance Contract with AMCL - Asso- coming scheduled maintenance Fixed prices for turbocharger
ciated Maritime Company (HKG) Ltd. intervals for AMCL’s turbocharg- services and spare parts
ers, including the timely delivery Turbocharger operational
The contract initially covers ap- of necessary spare parts. data constantly updated in-
proximately 36 turbochargers, cluding the complete mainte-
installed aboard various ves- Premium Maintenance Con- nance history
sels from the AMCL fleet operat- tracts Open access to mainte-
ing worldwide. The turbocharger With a Premium Maintenance nance documentation, elec-
types covered by the contract Contract, MAN Diesel & Turbo tronic spare-parts catalogues
are essentially TCA axial types handles all scheduled mainte- and service reports through
for main engines, and NR radial nance planning for the customer PrimeServ’s customer in-
types for auxiliary engines. six to seven months prior to an tranet.
MAN PrimeServ reports that its upcoming turbocharger service.
global network of service centres The customer simply confirms the About AMCL
is well-placed to serve AMCL’s upcoming service by email. Such AMCL is a ship management
trading routes. Under the terms contracts entail several, other company that is historically
of the agreement, PrimeServ will benefits: linked with the Tung Group. Dur- Pictured at the contract signing (from left) Eric Siu - Spare Parts Sales
provide all relevant services as Timely spare-parts planning ing its long history, the Group was Manager – MAN PrimeServ – HKG; Wu Jianyi General Manager Tech. Dept.
part of a complete maintenance that enables higher price flex- among the first in pioneering Very AMCL; Peter Dittrich – Head of Contract Management – MAN PrimeServ
Turbocharger, Ryan Soong - Spare Parts Sales Manager – MAN PrimeServ –
package. ibility Large Crude Carriers (VLCCs) HKG
DIESELFACTS 3/2015 PAGE 9

Alternate view of the 11G95ME-C9.5 engine during its shop test in Korea (courtesy Doosan)

Record-Breaking MAN B&W

Engine Leaves Test Bed in Korea
Largest and most powerful MAN gine, with a bore of 950 mm and a
B&W-branded engine ever built ap- stroke of 3,460 mm, provides 6,870
proaches market début. kW/cylinder at 80 rpm and 21 bar
MEP (in L1) and supplements the
Propulsion
Doosan Engine has reported that successful S90ME-C9/10 engine
SMCR power
the initial start of an MAN B&W types by allowing the engine to be
kW
11G95ME-C9.5 two-stroke engine further de-rated thanks to the larg-
took place during October 2015 at er cylinder bore and/or fewer cylin- 90,000
its works in Korea – a successful ders to be installed.
shop-test subsequently followed. MAN Diesel & Turbo’s G-type 80,000
Rated at 103,000 horsepower, programme entered the market in S90ME-C10
the engine is the largest and most October 2010. The ‘G’ prefix be- 70,000 G95ME-C9
S90ME-C9
powerful engine from the MAN fore an engine means it has a de-
60,000
Diesel & Turbo portfolio ever de- sign that follows the principles of
signed and built. MAN Diesel & Turbo’s large-bore,
50,000
The engine is the first in a series Mark 9 engine series with an ultra-
of six, bound for six 19,160-teu long stroke that reduces engine
40,000
container ships ordered by Medi- speed, thereby paving the way for
terranean Shipping Company S.A. ship designs with unprecedented 30,000
(MSC), one of the world’s largest high-efficiency.
shipping lines. G-type engines’ longer stroke 20,000
MAN Diesel & Turbo reports results in a lower rpm for the en-
that it currently has orders for 28 gine driving the propeller. This low- 10,000
× 11G95ME-C9.5 units, all for ves- er optimum engine speed allows
60 70 80 90 100 r/min
sels serving the international con- the use of a larger propeller and is,
Engine/propeller speed at SMCR
tainer trade. ultimately, significantly more effi-
The introduction of the G95ME- cient in terms of engine propulsion.
C9 was an important addition to Together with an optimised engine
MAN Diesel & Turbo’s G-engine design, this reduces fuel consump-
programme. The G95ME-C9 en- tion and CO2 emissions. The G95ME-C9 engine supplements the successful S90ME-C9/10 engine types
PAGE 10 DIESELFACTS 3/2015

PrimeServ Clinches Large Retrofit

Contract with Florida-Based Client
Major cruise line gets new turbochargers; installation during regular sailing schedule
MAN PrimeServ has won the con- PrimeServ Diesel, said: “This tur- spective. In the end it’s an invest- vative in the world. Thus we are reputation; our customers always
tract from Royal Caribbean Cruises bocharger upgrade will not only ment in sustainability.” always eager to explore new solu- expect the best vacation experi-
Ltd. (RCCL) to retrofit the turbo- boost engine performance but Gregory Purdy, Senior Vice Pres- tions to increase their performance. ence. To meet and even exceed
chargers aboard four cruise liners also extend engine life and sup- ident, Marine Operations, Royal We put high expectations in this this expectation we need reliable
from its fleet. port the entire operation both from Caribbean International, said: “Our turbocharger upgrade.” partners with focus on sustain-
a technical as well as a cost per- ships are the best and most inno- “Our fleet has an outstanding ability” underlined William Baum-
The contract covers the retrofit of gartner, SVP Global Marine Oper-
a total of 30 turbochargers aboard ations at RCCL.
four vessels – two operated by Wayne Jones was equally con-
Royal Caribbean International, fident: “RCCL’s vision is exactly
and two operated by Pullmantur, what we strive to achieve: to ex-
a wholly-owned RCCL subsidiary, ceed our customer’s expectations
along with attachment kits and and this is exactly what we hope
technical support. The vessels are for in this project!”
called ‘Grandeur of the Seas’ and Installation of the first retrofit will
‘Enchantment of the Seas’, are both take place aboard Enchantment of
equipped with 4 × 12V48/60 MAN the Seas in December 2015 dur-
engines, and will be retrofitted with ing its regular sailing schedule be-
16 × TCA55 turbochargers. Simi- tween Florida and the Bahamas.
larly, the cruise vessels ‘Horizon’ Each installation will take approxi-
and ‘Zenith’ – both equipped with mately 10 days per engine.
2 × 9L40/54B and 5 × 6L40/54B The project has been and will be
engines – will also be retrofitted handled from MAN PrimeServ Tur-
with 4 × NA40/S and 10 × NA34/S bocharger HQ in Augsburg, in
turbochargers. Pictured at the signing of the turbocharger contract (from right to left): Gregory M. Purdy (SVP, Marine Operations, Royal close collaboration with the local
Speaking at RCCL headquar- Caribbean International), Wayne Jones (SVP MAN PrimeServ), Carlos Pedercini (VP, Marine Operations & Global Nautical MAN PrimeServ Diesel team in
ters in Miami, Wayne Jones, Senior Services, Royal Caribbean International), Michael Kontny (Director Sales, MAN PrimeServ), Evangelos P. Sampanidis (As- Fort Lauderdale (USA).
sociate VP, Fleet Management, Celebrity), Leonidas Lavdas (Fleet Director, Celebrity), Kimmo Heikkila (Director, Power-
Vice President and Head of MAN plant & Technical Systems) , Stiliyan Dimov (Manager, Global Marine Operations)

Dredging Specialist Selects MAN Power

MAN Diesel & Turbo propulsion pack- Green credentials Propellers and aft-ship details box-mounted AHT nozzles. A high – should such a scenario arise.
ages ordered for two dredger new- Special attention was paid to the The MAN Alpha propeller and aft- degree of service friendliness is
buildings. energy-efficiency of the vessels. ship package supply for each Van ensured since the propeller-hub Propulsion control
The design includes several as- Oord vessel consists of a complete mechanism can be inspected and The twin-screw Alphatronic 3000
Van Oord, the leading dredging pects which result in substantial twin-screw propeller, nozzle and dismantled from aft. Additionally, system will control the two propul-
and marine contractor based in reductions in fuel consumption shaft system, including Alphatronic by means of intermediate plates sion lines with engine, reduction
Rotterdam, has placed an order for and consequently a fall in CO 2 3000 propulsion controls. between propeller blade flanges gear and CP propeller via main-
two trailing-suction hopper dredg- emissions. The vessels will be The CP propellers are driven via and propeller blades, the propel- bridge control stations, engine-room
ers. Each vessel will feature a com- equipped with innovative and sus- shaft lines. Each shaft includes ler blades are predisposed to un- control stations and an interface to
plete MAN Diesel & Turbo propul- tainable systems and will both ob- a disc brake and locking system. derwater replacement – in this joystick control for dynamic-posi-
sion package with: tain a Green Passport and Clean The ducted propellers are head- way avoiding the need for docking tioning requirements.
MAN 6L48/60CR engines Ship Notation.
RENK gearboxes with PTO
MAN Alpha CP Propeller sys- The 48/60CR engine
tems The 48/60CR engine type is one of
AHT (Alpha High Thrust) Pro- the most successful engine types
peller nozzles used in dredging application. Cur-
MAN Alpha AT3000 propul- rently, MAN Diesel & Turbo has 14
sion-control systems. such engines on order for instal-
The vessels will be constructed at lation aboard cutter- and hopper-
CNN LaNaval Shipyard in Sestao, dredger newbuildings for cus-
Spain with delivery dates sched- tomers in Benelux and China. All
uled for 2017. The order is part of engines will be built at MAN’s main
Van Oord’s continuous investment facility in Augsburg, Germany.
programme. The engines are equipped with
The new dredgers will have a key, in-house-developed technol-
hopper capacity of approximately ogies to optimise their economic
17,000 m3, a length of 158 metres and ecological performance, in-
and a width of 36 metres. They will cluding:
also be equipped with two suc- high-efficiency, TCA-type, ex-
tion pipes with submerged e-driv- haust-gas turbochargers
en dredge pumps, two shore-dis- advanced, electronic fuel-in-
charge dredge pumps, six bottom jection system
doors and a total installed power of electronic hardware and soft-
23,680 kW. The newbuildings will ware for engine control, moni-
each have accommodation for 38 toring and diagnosis, SaCoSone Graphical representation of the new hopper-suction dredger (courtesy Van Oord)
persons. and CoCoS EDS.
DIESELFACTS 3/2015 PAGE 11

MAN Engines Ordered for World’s

Largest Cutter-Suction Dredger

Graphical rendering of the Jan De Nul Group newbuilding ‘JDN8069’ that, upon completion, will become the largest
cutter-suction dredger in the world (picture courtesy Jan De Nul Group)

Jan De Nul Group, the leading dredg- Group knows MAN very well and hopper-dredger newbuildings for Jan De Nul Group Order – Principal Engine Data
ing specialist, is set to further ex- much of its fleet features our en- customers in Benelux and China. Total installed power (kW) 40,975
pand its modern fleet with a self- gines. This new vessel represents All engines will be built at MAN’s 16,800 (14V48/60CR)
propelled, cutter-suction dredger to a significant development within main facility in Augsburg, Germany. Individual engine output (kWmech) 10,800 (9L48/60CR)
be built at Croatian shipyard, Uljanik the dredger segment in that, up to The 48/60CR engines are Engine fuel HFO/MDO/ MGO
Brodogradiliste in Pula. now, the largest installed power on equipped with key, in-house-de-
Cutter power (kW) 8,500
similar vessels was approximately veloped technologies to optimise
The vessel, currently designat- 27-28 MW, a figure the new vessel their economic and ecological per- Pump power (kW) 3 × 8,500
ed ‘JDN8069’, will feature 1 × easily surpasses. I’m confident this formance, including: Length o.a. (m) 151.3
MAN 14V48/60CR + 2 × MAN order will help Jan De Nul Group high-efficiency, TCA-type, ex- Width (m) 36.0
9L48/60CR engines as well as 3 maintain its strong presence in the haust-gas turbochargers
Draught (m) 5.8
× step-up, RENK Rheine gearbox- dredger market.” advanced, electronic fuel-in-
Speed (kn) 12.0
es for a diesel-electric plant. RENK jection systems
will also deliver the gearboxes for Popular dredging choice electronic hardware and soft- Suction pipe (mm) 1 × 1,100
the cutter-head drive as well as for The MAN L/V 48/60CR engine ware for engine control, moni- Dredging depth (m) 45.0
the dredger and booster pumps. type is one of the most successful toring and diagnosis in the form Source: Jan De Nul
Upon completion, the vessel will engine types used in dredging ap- of MAN Diesel & Turbo’s propri-
be the largest of its type in the plications. Among the 56 such en- etary SaCoSone system. proximately 50% more powerful skilled employees and the world’s
world. gines MAN Diesel & Turbo current- than the Luxembourg outfit’s own most modern fleet, Jan De Nul
Lex Nijsen – Vice President and ly has on order for various marine The new vessel will be able to ‘J.F.J. De Nul’, currently the largest Group is a leading expert in dredg-
Head of Four-Stroke Marine – MAN applications, 14 alone are bound boast of over 40,000 kW total die- cutter-suction dredger in the world. ing and marine construction activi-
Diesel & Turbo, said: “Jan De Nul for installation aboard cutter- and sel installed power, making it ap- JDN8069 is due for delivery at the ties, as well as in specialised ser-
beginning of 2017 and will operate vices for the offshore industry of oil,
globally. gas and renewable energy. These
core marine activities are further
About Jan De Nul Group enhanced by Jan De Nul Group’s
People and global expertise. These in-house civil and environmental
are the corner stones of Jan De capabilities offering clients a com-
Nul Group’s success. Thanks to its plete package solution.

Side profile of the dredger newbuilding (picture courtesy Jan De Nul Group)
Library photo of the MAN 48/60CR engine
 DIESELFACTS 3/2015

MAN Diesel & Turbo library photo of the MAN 32/44CR engine

MAN 32/44CR Gets EPA Certification

Common-rail unit declared ready for the vital US market
MAN Diesel & Turbo has announced stroke, marine-engine strategy for nal emissions tier for Category 3 gine to power a newbuilding trawl- sistently proven their reliability and
that the MAN 32/44 Common Rail the US market. The engine family (≥ 30L/cyl displacement) engines, er for Fishermen’s Finest, the U.S. durability within the fishing industry.
engine family (rated power: 3,600 has been certified US EPA Tier 2 and is similar to US EPA Tier 4 for fishing company. This order was
– 12,000 kW) has received US EPA for Category 3 engines and builds Category 1 and 2 (< 30 L/cyl dis- significant in that it represented a 32/44CR characteristics
Certification, a requirement for all the foundation for us to introduce placement) engines. breakthrough for the CR engine in MAN common-rail engines are
engines installed aboard US-flagged our US EPA Tier 3 for Category 3 The US EPA certification pro- the important, US domestic-fishing among the most technological-
vessels. product in 2016. This will allow US cess was initiated in response to segment. ly advanced in its portfolio with a
customers to benefit from the high demand from the American fishing MAN’s CR engines are marked segment-leading SFOC that sig-
Chuck Griffith, Sales Manag- power output and low fuel-con- industry. MDT has already received by their excellent fuel efficiency nificantly lowers emissions of soot
er, MAN Diesel & Turbo, North sumption of our medium-speed, several orders within the United and low operating costs. Since and NO X over its complete oper-
America, said: “This certification common-rail engines.” States for the engine, including being introduced in Europe eight ating range. The company’s CR
is a significant step in our four- US EPA Tier 3 is currently the fi- that for an MAN 8L32/44CR en- years ago, the engines have con- engines have already established
a solid presence in several marine
segments globally.
Specifically, the MAN 32/44CR
is characterised by:
common-rail technology fea-
turing optimised NOX vs. SFOC
trade-off at every load point, in-
dependent of rpm
a high power output: 600 kW/
cyl for diesel-electric set-ups
and CPPs; 510 kW/cyl for FPPs
and dredgers
low fuel-consumption of 172.4
g/kW-hr for diesel-electric and
CPP set-ups, and the use of
high-efficiency turbochargers.
MAN 32/44CR engines are suita-
ble for a variety of applications in-
cluding fishing, ATBs (Articulated
Tug Barges), anchor handlers, off-
The US EPA certification: (top) 2015 Model Year, Certificate of Conformity with the Clean Air Act; (bottom) Office of Transportation and Air Quality, shore construction vessels, dredg-
Engine International Air Pollution Prevention Certificate ers and drill ships.

For further information

MAN Diesel & Turbo See DieselFacts online with video clips: Publisher: All data provided in this document is non-binding. This data serves informational purpo-
ses only and is especially not guaranteed in any way. Depending on the subsequent spe-
dieselfacts@mandieselturbo.com www.mandieselturbo.com/dieselfacts Peter Dan Petersen,
cific individual projects, the relevant data may be subject to changes and will be assessed
www.mandieselturbo.com or download the app to your tablet or MAN Diesel & Turbo and determined individually for each project. This will depend on the particular characteri-
stics of each individual project, especially specific site and operational conditions.
smartphone.