Module 1

Marine Diesel Engine

Development History
 Anna Volkova,
the author of this module,
is fully liable for the content, authenticity and
accuracy of the information
You will be able to:
1. list types of internal combustion engines
2. describe stages of engine development
3. compare types of scrubber systems
Essential сcompetency: explain the necessity of marine diesel engine development

Lesson 1
Internal combustion engines

ENGAGE:

• Discuss the questions.

• What is internal combustion engine?

• Why is it called “internal”?
• What types of engines do you know?
• What do they differ in?
• What is the most common engine type used on board a ship? Why?
• Have you already had your sea practice? What was the engine on board?
• Who was in charge of the main engine?
• Have you participated in any maintenance works related to the ME?
• What, do you think, are the common faults of all ME?

• Match the words with the definitions.

• induction Just before top dead center (TDC) fuel is injected into the
cylinder by the fuel injector. The fuel is "atomized" into tiny
droplets. Because they are very small, these droplets heat up very
quickly and start to burn as the piston passes over TDC. The
expanding gas, from the fuel burning in the oxygen, forces the
piston down the cylinder, turning the crankshaft.
• exhaust The crankshaft is rotating clockwise and the piston is moving
down the cylinder. The inlet valve is open and a fresh charge of
air is being drawn or pushed into the cylinder by the
turbocharger.
• power As the piston approaches the bottom of the cylinder (known as
Bottom Dead Centre or BDC) the exhaust valve starts to open.
As the piston now moves up the cylinder, the hot gases are
 expelled from the cylinder. As the piston approaches TDC again
the inlet valve starts to open and the cycle repeats itself.
• compression The inlet valve has closed and the charge of air is being
compressed by the piston as it moves up the cylinder.

• Label the figure below.

__________________ __________________ __________________ _________________

ACTIVATE I:

• Complete the missing information in the scheme sharing your ideas.

• Name as many as you can remember.

2-STROKE ENGINE PARTS

• Match main components names with their descriptions.

• engine block forged in one piece; counterweights are fitted on every web;
high degree of balancing results in an even and thick oil film
for all bearings
• crankshaft made of tri-metal type with steel back, lead bronze lining and
a soft and thick running layer
• connecting rod hardened for good wear resistance; the set consists of two
directional compression units and one spring-loaded
conformable oil scraper unit; all of them have a wear-resistant
chromium plating
• main bearings has a high and rigid collar to minimise deformations; the
material is a special grey cast iron alloy developed for
excellent wear resistance and high strength; accurate
temperature control is achieved with precisely positioned
longitudinal cooling water bores; to eliminate the risk of bore
polishing, it is equipped with an anti-polishing ring; the
cooling water space between block and itself is sealed off by
double o-rings; in the upper end it is equipped with an anti-
polishing ring to eliminate bore polishing and reduce lube oil
consumption
• big end is of composite design with nodular cast iron skirt and steel
bearings crown; its skirt is pressure lubricated, which ensures a
controlled oil distribution to the cylinder liner under all
operating conditions; oil is fed to cooling gallery in the piston
top through the connecting rod
• cylinder liner designed for easy maintenance with only four hydraulically
tightened studs; no valve cages are used, which results in very
good flow dynamics in the exhaust gas channel; the exhaust
valve seats are water-cooled and all valves are equipped with
valve rotators; the seat faces of the inlet valves are stellite-
plated; in case the engine is specified for MDO operation
only, also the exhaust valves are stellite-plated; engines that
are intended for operation on HFO have nimonic exhaust
valves
• piston can be both tri-metal and bi-metal
• piston rings made of nodular cast iron in one piece for all cylinder
 numbers; the main bearing caps are fixed from below by two
hydraulically tensioned screws, they are guided sideways by
it at the top as well as at the bottom; hydraulically tensioned
horizontal side screws support the main bearing caps
• cylinder head hydraulically tightened; the gudgeon pin bearing is of tri-
metal type; oil is led to the gudgeon pin bearing and to the
piston through a bore in it; made of alloy steel, forged and
machined with round sections; the lower end is split
horizontally to allow removal of piston and itself through the
cylinder liner

• Study the cross-section below. Define the engine type. Remember more of parts names.
 bedplate exhaust port turbo-blower crankshaft

air inlet ports connecting rod A-frame piston rod

exhaust bottom end piston crosshead

manifold bearing

• Study another cross-section. Define the engine type. Remember more of parts names.
 gudgeon pin cylinder head connecting rod
crankcase bottom end bearing cam
cylinder rocker arm water cooling passage
fuel injector exhaust valve piston
crankpin camshaft

• Think over the following.

 DIFFERENCE BETWEEN
2-STROKE ENGINE 4-STROKE ENGINE
Number of revolutions

Maintenance

Speed

Power

Cost

Energy efficiency

Lubrication

Valve operating mechanism

Weight

STUDY:

• Fill in the gaps with the words from the box.

induction exhaust valves piston compression up

piston blower bottom inlet ports variations
down two strokes valve lower four-stroke

The ________________ of power followed by compression are required to complete

one cycle. The events of injection, combustion, expansion and ________________ of the
gases take place in the four-stroke engine, but the exhaust of the burnt gases and the
________________ of air take place at the ________________ of its stroke, this being a
chief difference between the two-stroke cycle and the ________________ cycle.
There are ________________ in two-stroke cycle engines. The most common one is
that it has inlet ports and ________________. The inlet holes or ports are in the
________________ section of the cylinder liner wall. The piston uncovers the inlet ports as
it moves ________________ the cylinder. The ________________ covers the inlet ports as
it moves ________________ the cylinder. This action has the same effect as a
________________ opening and closing. An engine driven scavenge ________________ is
fitted and the incoming air is blown into the cylinder through the ________________ when
they are uncovered by the ________________.

• Complete the sentences.

• The engines can be of __________________________________________________

• One cycle is completed by ______________________________________________
• 4-stroke cycle engine’s operation is ________________________________________
• 2-stroke cycle differs in _________________________________________________
• Upward piston movement _______________________________________________
• Downward piston movement _____________________________________________
• Scavenge blower ______________________________________________________

ACTIVATE II:

• Consider the following and suggest if they are TRUE or FALSE.

• The two-stroke cycle is completed in one revolution of the crankshaft.

• The fresh air in 2-stroke cycle is supplied without being pressurized.
• The air is used to moisturize exhaust gases to let them settle down and to charge the space with
fresh air.
• The ports are opened and closed by the piston sides as it moves.
• The bottom end of the connecting rod is attached to the crosshead bearing.
• There is the valve in the cylinder head for the release of the exhaust gases.
• The incoming air is supplied being de-pressurized.
• Main bearings support the crankshaft within the engine bedplate.
• The entablature consists of the bedplate, house guides and crosshead.
• The main difference between the two cycles is the speed delivered.
• 2-stroke cycle engine loses a lot of power output due to inefficient scavenging.
• 2-stroke cycle engines are normally better choice in terms of weight ratio, since they are lighter
than 4-stroke cycle engines.
• 2-stroke engine requires difficult to handle valve operating mechanism.
• 4-stroke engines operate poorly at high speeds, but consume less lubricating oil.
• 2-stroke engines require regular and accurate maintenance of the reduction gearbox.
• Medium-speed 2-stroke engines deliver approximately 80— 100 rev/min.
• 4-stroke engines operate at medium speed (250 and 750 rev/ min), therefore require the
reduction gearbox when used as the main propulsion.
• 2-stroke engines don’t require any auxiliary blowers due to turbo-charger provides enough air.
• The four-stroke cycle is completed in four revolutions of the crankshaft.
• The inlet and exhaust valves in the 4-stroke engines are housed in the cylinder head and held
shut by springs.
• The piston in 4-stroke engine is joined to the connecting rod by a piston rod.
• The crankshaft in 4-stroke engine is arranged to drive through gears the camshaft, which
operates rocker arms which open the inlet and exhaust valves.
• 4-stroke engine’s supports the camshaft and houses the camshaft bearings.
• The cylinder and cylinder head are arranged with air-cooling passages around them.

• Complete the definitions.

• Crankshaft is a part of a marine engine, which ________________ of a firing cylinder from the
reciprocating piston to the ________________ (or alternator in case of a generator).
• Piston is the lower part of the ________________, seals the cylinder and transmits the gas
pressure to ________________, absorbs heat of combustion, comprises of two pieces:
________________.
• Crosshead piston comprises of ________________ (used in large two stroke engine) which is
connected to crosshead to transfer the ________________ to the engine structure.
• Trunk piston comprises of piston with elongated skirt to ________________ and attached to the
connecting rod by ________________ (used in small 4 stroke marine engines).
• Piston rod helps in transmitting the power produced in the combustion space to
________________ and the running gear of the engine.
• Piston skirt is fitted in both two stroke and four stroke engines. It has different functions for
different engines. In large cross head two stroke engines with uni-flow scavenging these skirts
are short in length and are fitted to act as ________________ and to stabilise
________________ inside the liner.
• In four stroke or trunk piston engines the skirt has arrangement for ________________, which
transmits power from the piston to the gudgeon pin or ________________. As there are no
________________ in four stroke engines, these skirts help in transferring the side thrust
produced from the connecting rod to the liner walls.
• Piston wear ring is a ring made of soft bronze alloy with lead, which is fitted in
________________.
• Connecting rod is a component of a marine engine that ________________ in the engine
block to the crankshaft.
• Crosshead bearing in a large two stroke slow speed engine transfers the power generated in the
combustion chamber to ________________.
• Cylinder liner a hollow cylindrical shell which acts as ________________.
• Cylinder head acts as ________________ thereby providing an enclosed space where the
combustion can take place.
• Reduction gearbox is used to convert ________________ to those required to rotate
the propeller. Gearboxes consist of ________________ on pinions and wheels which
________________ to a driven shaft and reduce speed.
• On two-stroke diesels, electrically-driven auxiliary blowers are usually provided because
________________.
• Camshaft is a shaft fitted with one or more cams and driven by ________________.
• The rocker arm is the part responsible for transmitting ________________ towards the intake
and exhaust valves of the engine.

• Divide into 2 groups. Match the following to get phrases.

GROUP 1

• the main the crankshaft

• the complicated valve at low engine speed
• the cylinders, cylinder heads and the propeller
• cannot provide enough air difference between
• attached to a operating mechanism
• reduction gearbox between it and the scavenge trunking
• revolution of power
• develop twice the crosshead bearing
• forms part of the close the inlet and
• a mechanism to open and inlet and exhaust valves
• rocker arms which open the crankshaft
GROUP 2

• pressurised by a exhaust gases

• inefficient scavenging and other at temperature
• scavenge the propeller speed
• rotary losses
• is fully primed and turbo-blower
• consumes less passages around them
• with a gearbox to provide exhaust gases
• the release of lubricating oil
• water-cooling the crankshaft bearings
• held shut movement of the crankshaft
• supports the cylinders and houses a cylinder head
• at the top by by springs

• Read the text below and complete it with the phrases matched previously.

The two-stroke cycle is completed in two strokes of the piston or one ________________. In
order to operate this cycle, where each event is accomplished in a very short time, the engine
requires a number of special arrangements. First, the fresh air must be forced in under pressure. The
incoming air is used to clean out or ________________ and then to fill or charge the space with
fresh air. Instead of valves, holes, known as 'ports', are used which are opened and closed by the
sides of the piston as it moves. The piston is solidly connected to a piston rod which is
________________ at the other end. The top end of the connecting rod is also joined to the
crosshead bearing.
Ports are arranged in the cylinder liner for air inlet and a valve in the cylinder head enables
________________.
The incoming air is ________________ which is driven by the outgoing exhaust gases. The
crankshaft is supported within the engine bedplate by the main bearings. A-frames are mounted on
the bedplate and house guides in which the crosshead travels up and down. The entablature is
mounted above the frames and is made up of ________________.
________________ the two cycles is the power developed. The two-stroke cycle engine,
with one working or power stroke every revolution, will, theoretically, ________________ of a
four-stroke engine of the same swept volume. ________________, reduce the power advantage.
For a particular engine power, the two-stroke engine will be considerably lighter—an
important consideration for ships. Nor does the two-stroke engine require ________________ of the
four-stroke. The four-stroke engine however can operate efficiently at high speeds which offsets its
power disadvantage; it also ________________.
Each type of engine has its applications which on board ship have resulted in the slow-speed
(i.e. 80— 100 rev/min) main propulsion diesel operating on the two-stroke cycle. At this low-speed
the engine requires no ________________.
The four-stroke engine (usually rotating at medium speed, between 250 and 750 rev/ min) is
used for auxiliaries such as alternators and sometimes for main propulsion ________________ of
between 80 and 100 rev/min.
The reason for circulating fuel in large two-stroke engines is to ensure the system
________________. Oil that has been recirculated in a diesel engine fuel system normally returns to
a buffer/vent/mixing tank. On two-stroke diesels, electrically-driven auxiliary blowers are usually
provided because the exhaust gas-driven turbo-charger ________________. Auxiliary blowers are
internal parts of the main engine.
The four-stroke cycle is completed in four strokes of the piston, or two revolutions of the
crankshaft. In order to operate this cycle the engine requires ________________ exhaust valves.
The engine is made up of a piston which moves up and down in a cylinder which is covered
________________. The fuel injector, through which fuel enters the cylinder, is located in the
cylinder head. The inlet and exhaust valves are also housed in the cylinder head and
________________. The piston is joined to the connecting rod by a gudgeon pin. The bottom end or
big end of the connecting rod is joined to the crankpin which ________________. With this
assembly the linear up-and-down movement of the piston is converted into ________________. The
crankshaft is arranged to drive through gears the camshaft, which either directly or through pushrods
operates ________________. The camshaft is 'timed' to open the valves at the correct point in the
cycle. The crankshaft is surrounded by the crankcase and the engine framework which
________________. The cylinder and cylinder head are arranged with ________________.

• Complete the missing information in the figure below using the prompts.
intake port is combustion transfer port is exhaust valve
covered and chamber covered closed
valve forced
closed
intake valve downstroke piston crankcase
open

valves closed intake valve spark plug exhaust valve

closed open
fuel is spark plug firing piston pushes air-fuel mixture
compressed and out burnt gases is drawn in
ignited
crankshaft explosion forces valves closed connecting rod
 piston down
air-fuel mixture exhaust gases upstroke fuel mixture is
is compressed drawn into
crankcase
valve open transfer port is air fuel mixture burnt fuel is
uncovered and pushed out by
fuel mixture compressed fuel
forced into mixture
cylinder

• Look at the figures and decide the operation of which diesel engine is shown. Prove
your opinion.

• Make up a summary about types of internal combustion engines.

Lesson 2
Otto and Diesel cycles

ENGAGE:
 • Answer the questions.

1. When was ICE invented?

2. Who was the inventor?
3. What do you know about him?
4. Have you heard of other inventors of engines of any types?

• Find out what do the following words have in common.

Otto diesel invention fuel Diesel engine Nikolaus development combustion first Rudolph

• Match the synonyms.

• few set up
• capable exact
• initiate implement
• devise several
• particular trust
• apply able
• rely on design

• Complete the text with some of the words from the previous task or/and add your own
ones.

Ever since its first ________________ in 1912, the internal combustion engine has come to
dominate marine propulsion with only a very ________________ vessels making use of any other
form of motive ________________. ________________ power in the form of turbines is still used
on some new ________________ carriers and it is also employed in some ________________ heat
recovery systems where the heat from an engine and other sources is used to produce steam for
________________.
Most internal combustion engines used by ships are ________________ engines; that does
not mean that they are ________________ of running only on diesel fuel but that they
________________ the Diesel cycle for combustion of the ________________.

ACTIVATE I:

• Comment on the following quote.

• Google for the best synonyms or definitions for the following.

 further
success
series
subsequent
commercial
viability
to be threatened
attempt
vanish
presumably
expire
commit a suicide

• Fill in the gaps with the words from the box below.

ignition compression joined in unsuccessful commercial

successful built efficiency attempts process
common prototype invention interest committing
steam breakdown development set up vanished
expire slow burning

Rudolf Diesel, who is best known for the ________________ of the engine that bears his
name, was born in Paris, France in 1858. His invention came while the ________________ engine
was the predominant power source for large industries. In 1885, Diesel ________________ his first
shop in Paris to begin development of a compression ________________ engine. The process
would last 13 years. In the 1890s, he received a number of patents for his invention of an efficient,
________________, ________________ ignition, internal combustion. From 1893 to 1897, Diesel
further developed his ideas at Maschinenfabrik-Augsburg AG (later Maschinenfabrik-Augsburg-
Nürnberg or MAN).
In addition to MAN, Sulzer Brothers of Switzerland took an early ________________ in
Diesel’s work, buying certain rights to Diesel’s invention in 1893. At MAN in Augsburg,
________________ testing began with a 150 mm bore/400 mm stroke design on August 10, 1893.
While the first engine test was ________________, a series of improvements and subsequent tests
led to a ________________ test on February 17, 1897 when Diesel demonstrated
________________ of 26.2% with the engine.
The first Sulzer-________________ diesel engine was started in June 1898.
________________ of Diesel’s invention needed more time and work to become a
________________ success. Many engineers and developers ________________ the work to
improve the market viability of the idea created by Rudolf Diesel. He, on the other hand, became
somewhat threatened by this ________________ and was not always able to find
________________ language with other engine designers developing his invention.
Diesel’s ________________ of market promotion of the not-yet-ready engine eventually led
into a nervous ________________. In 1913, deeply troubled by criticisms of his role in developing
the engine, he mysteriously ________________ from a ship on a voyage to England, presumably
________________ suicide. After Diesel’s patents started to ________________, a number of other
companies took his invention and developed it further.

• Complete the chart.

 Rudolph Diesel known for,
date of birth, place of birth
1885
1890s
1893-1897
MAN
Sulzer brothers
Prototype testing
First engine test
Following test
1898
Diesel’s worries and
problems
Nervous breakdown
Vanished

STUDY:

• Complete sentences with the words from the box.

considered | ignited | apply | particular | initiating | devised | consume

• Back in the 19th century when internal combustion engines were in the very early stages of
development, two men Nikolaus Otto and Rudolph Diesel ________________ different means
of ________________ combustion of the fuel.
• Otto’s method was to compress the fuel to a ________________ volume and to then
________________ a source of ignition in the form of a spark.
• Diesel’s method was to continue to compress the fuel until it ________________ spontaneously
due to the heat produced by the higher compression used.
• At similar pressures, the Otto engines are ________________ more efficient but because diesel
engines make use of much higher pressures, in practice they are more efficient and
________________ less fuel.

• Mark the statements as FACTS or SOMEBODY’S OPINIONS.

• Nowadays, engines that burn fuel oil mostly rely on the Diesel cycle.
• Dual-fuel engines have not been designed yet, because of difficulties in alternative ignition
source.
• Wartsila has never produced any dual-fuel engines.
• Until 1930s marine diesels were only four-stroke and ran on distillate fuels.
• At present times, most large cargo vessels are equipped with huge two-strokes with their better
weight ratio.
• High-speed diesels are rarely encountered on commercial ships except as generators.

ACTIVATE II:

• In groups, match halves to get sentences.

GROUP 1

• Ever since its first use in 1912, the on diesel fuel but that they rely on the
internal combustion engine has come to Diesel cycle for combustion of the
dominate marine propulsion with fuel.
• Steam power in the form of turbines is to then apply a source of ignition in
still used on some new LNG carriers the form of a spark.
and it is also employed in some waste
• Most internal combustion engines used more efficient but because diesel
by ships are diesel engines; that does engines make use of much higher
not mean that they are capable of pressures, in practice they are more
running only efficient and consume less fuel.
• Back in the 19th century when internal only a very few vessels making use of
combustion engines were in the very any other form of motive power.
early stages of development, two men
Nikolaus Otto
• Otto’s method was to compress the fuel to continue to compress the fuel until
to a particular volume and it ignited spontaneously due to the
heat produced by the higher
compression used.
• Diesel’s method was and Rudolph Diesel devised different
means of initiating combustion of the
fuel.
• At similar pressures, the Otto engines heat recovery systems where the heat
are considered from an engine and other sources is
used to produce steam for electric
generation.

GROUP 2

• Modern oil burning engines by injecting a small quantity of diesel oil

mainly rely on directly into the combustion chambers as
pilot fuel which ignites by compression
ignition as in a conventional diesel engine.
• Wärtsilä dual-fuel engines make after injection.
use of the lean-burn Otto process
in which
• Premixed air-gas mixture in the the Diesel cycle but dual-fuel engines need an
engine combustion chambers alternative ignition source when operating in
and ignition is obtained gas mode.
• By way of contrast, in MAN are regularly used for propulsion in small
Diesel’s high-pressure ME-GI tugs, work boats and ferries.
DF engines
• The gas burns immediately are the engine of choice for most large cargo
vessels.
• As is to be expected both makers are used for most other ship types.
claim advantages for their
 systems and it is for users
• Until the mid-1930s marine gas is admitted into the air inlet channels of
diesels were invariably four- the individual cylinders during the intake
stroke and ran on stroke to give a lean.
• Today the giant two-strokes with distillate rather than residual fuels.
their better power to weight ratio
• Medium speed four-stroke the gas is injected only after the combustion
engines either as propulsion air is compressed, after which it is ignited by
units or powering gensets in a the pilot oil injection.
diesel-electric system
• High-speed diesels are rarely to judge which best suits their own purposes.
encountered on commercial
ships except as generators but

• Complete the chart.

• When have ICE started to

dominate other forms of motive
power?

• Is steam power still in use

nowadays?

• Which ICE are used mostly?

• Are ICE capable of running on

diesel fuel only?

• Which method is applied for

combustion of the fuel?

• Who devised means of initiating

combustion?

• What are two combustion methods

known?
 • Describe Otto’s method.

• Describe Diesel’s method.

• Whose method is more efficient?

• Which cycle do modern engines

rely on?

• Describe Wartsila dual-fuel

engines working operation.

• Describe MAN Diesel’s high-

pressure ME-GI DF engine
working operation.

• What were marine diesels until

mid-1930s?

• What are marine engines today?

Lesson 3
Sabathe and Trinkler cycles

ENGAGE:

• Discuss the questions.

• When was the first use of ICE?
• Are engines capable of running only on diesel fuel?
• What other alternatives to diesel fuel can you suggest?
• Who are inventors of ICE?
• Which ICE is more efficient: Otto’s or Diesel’s? Why?
• Have you ever heard about Sabathe or Trinkler?
• Could you share your ideas on they are famous for?

• Complete the mind map.

• Read the text and title it.

____________________________________________

The dual combustion cycle (also known as the mixed cycle,

Trinkler cycle or Sabathe cycle) is a thermal cycle that is a combination of the Otto cycle and the
Diesel cycle, first introduced by Russian-German engineer Gustav Trinkler, who never claimed to
have developed the cycle though. Heat is added partly at constant volume (isochoric) and partly at
constant pressure (isobaric), the significance of which is that more time is available for the fuel to
completely combust. Because of lagging characteristics of fuel this cycle is invariably used for
Diesel and hot spot ignition engines. It consists of two adiabatic and two constant volume and one
constant pressure processes.
The dual cycle consists of following operations:
• Process 1-2: Isentropic compression
• Process 2-3: Addition of heat at constant volume.
• Process 3-4: Addition of heat at constant pressure.
• Process 4-5: Isentropic expansion.

STUDY I:

• Fill in the definitions using the words from the box.

adiabatic | lagging | to claim | isochoric | isobaric | significance

• ________________ is defined as a process in which no heat transfer takes place.

• ________________ is the act of falling or staying behind.
• In thermodynamics, an ________________ process, also called a constant-volume process,
an isovolumetric process, or an isometric process, is a thermodynamic process during which the
volume of the closed system undergoing such a process remains constant.
• ________________ means to ask for, especially as the right.
• An ________________ process is one that takes place at constant pressure.
• ________________ means having the quality of being "important" — meaningful, essential.

• Complete the sentences with the words from the previous task.

• The ________________ of what was happening was clearer to me than to him.

• ________________ (meaning of the same weight or pressure) may refer to: in thermodynamics,
i.e., one that is carried out at constant pressure.
• A thermodynamic process taking place at constant volume is known as the ________________
process.
• Don't forget ________________ for the travel expenses after you join the vessel.
• An ________________ process is a thermodynamic process which involves the transfer of
energy without transfer of heat or mass to the surrounding.

• Complete the sentences.

1. Sabathe cycle _______________________________________________________________.

2. ________________ engineer Gustav Trinkler _____________________________________.
3. ________________________________________________________ Sabathe/Trinkler cycle.
4. ________________________ lagging characteristics of fuel __________________________.

• Put the operations in correct order.

___ Rejection of heat at constant volume.

___ Isentropic expansion.
___ Addition of heat at constant pressure.
___ Addition of heat at constant volume.
___ Isentropic compression.

ACTIVATE I:

• Study the image below. Consider the following:

EARLY CI engines vs MODERN CI engines

What is the difference?
 • Label the image below, using the prompts from the box.

power stroke constant volume heat addition actual cycle

process
compression process expansion process compression stroke
 intake stroke constant pressure heat addition exhaust stroke
process
constant volume heat rejection process dual cycle

• Complete the text below answering the questions.

The growing demand to reduce engine emissions in recent years has led to interest in engines
fueled by _lng_ (What may engines be fueled by?), which can significantly reduce CO2 emission
(What hazardous emissions’ names can you remember?). This has led to recognition of the
potential for marine engines fueled by natural gas to help reduce marine environmental problems.
To prevent air pollution from ships, regulations covering pollutants such as CO2 and NOx
specified under the 1997 International Maritime Organization (IMO)/MARPOL Convention came
into force in 2005 _Annex 6 (What is the name of the regulation controlling the pollutants
discussed?) ). These regulations were followed in 2011 by the Tier II regulation (What is the
name of the regulation?) (a 15 to 22% reduction on Tier 1), Tier III regulation (What is the
name of the regulation?) (an 80% reduction on Tier 1) to come into force for certain maritime
regions starting from 2016. Similarly, to reduce greenhouse gases (GHGs), ENERGY
EFFICIENCY DESING INDEX (What is the name of the technical measure that deals with
CO2 output?) for CO2 emissions were introduced from 2013. This requires a 10% reduction in
CO2 emissions by 2015 and a 20% reduction by 2020.
The most important plus of fuel conversion to natural gas is that burns cleaner than other
fuels (Why is it so advantageous?). This is in contrast to other technologies, each of which only
works for certain exhaust emissions.

• Study the figures below. Check if you were right completing the previous task.
Consider the questions below.

• What pollutants are being addressed by the regulations? - CO2 . Nox(Nitrogen Oxyde)
Particular matter and Sulpgur
• What do you know about Kyoto Protocol and its goals? Which of the pollutants did it deal with?
The Kyoto Protocol is an international treaty that deals with six main greenhouse gases:
Carbon dioxide (CO2)
Methane (CH4)
Nitrous oxide (N2O)
Hydrofluorocarbons (HFCs)
Perfluorocarbons (PFCs)
Sulfur hexafluoride (SF6)
The main goals of the Kyoto Protocol are:

To control emissions of the main anthropogenigreenhouse gases

• What do you know about EEDI? Which of the pollutants does it deal with?
The Energy Efficiency Design Index (EEDI) is an important technical measure that was
formulated for new ships1. It estimates the amount of CO2 emissions per unit of transport
work . The EEDI deals with carbon dioxide (CO2) emissions
• What regulations address NOx emissions? Have you ever heard of them?
there are several regulations that address Nitrogen Oxides (NOx) emissions: IMO TIER I -II- III and
EPA rules
• What do you know about EPA?
(EPA) is an independent agency of the United States government tasked with environmental
protection matters
• What regulations address sulfur emissions? What are the goals?
The goals of these regulations are to reduce the amount of sulfur emitted, which can lead to
harmful effects on human health and the environment.

• What environmental technologies for marine engines can you name?

Dual-Fuel Marine Engines:
NOx Emission Reduction Technology:
Energy Efficiency Design Index
LNG Fuel for Propulsion:
Sustainable Marine Fuels
Emissions Abatement Equipment:
• Comment on SCR. Which pollutant does it address? What are the drawbacks?
NOx
• Comment on scrubbers. Which of pollutants does it address and to which extent? What are the
drawbacks?
• Comment on EGR. Which of pollutants does it address and to which extent? What are the
drawbacks?
• Comment on emulsion. Which of pollutants does it address? What are the drawbacks?
• Comment on gas engine application. What are the drawbacks? What are the advantages?
• Decide on the best technology. Prove your opinion.

STUDY II:

• Match the words with their definitions.

• 1 redundancy 6 evaporated or boiled LNG vapor

• 2 impact 10 something that is produced in the course of making
another thing
• 3 utilize 8 to replace one with the other
• 4 rig 12 to get something from something else, by using
industrial or chemical processes
• 5 objective 4 installation used in drilling for natural oil and gas
deposits
• 6 boil-off 13 to come into view
• 7 intention 2 a powerful effect that something has on something
• 8 switch 14 to be good enough or have the right qualities to meet the
requirement
• 9 spread 5 an idea or plan of what someone (something) is going to
do
• 10 byproduct 15 safe, protected, shielded, sheltered
• 11 amount 17 amounts that are more than what is needed; extra,
additional
• 12 extraction 1 duplication in mechanical or other equipment so that
operations can continue if one part fails to operate
• 13 appear 16 recommendations, instructions, advice, proposal
• 14 satisfy 3 to use
• 15 secure 11 quantity, total
• 16 guidelines 9 to reach or affect a larger area or more people
• 17 excess 7 purpose, aim, goal

• Complete the sentences below using some of the words from the previous task in a
correct form.

• Vacuum type piston engine _utilized _ coal gas combustion instead of steam.
• Application of ICE strongly ______ after they were invented and continues __to
spread_______ until today.
• After the Second World War there were large ___amount______ of cheap petroleum oil in
regions such as the Middle East.
• Oil ___rigs______ produced a lot of natural gas.
• Natural gas is a _____byproduct____ produced by oil rigs.
• Large amounts of natural gas are being produced by oil rigs in the process of oil
_extraction_______.
• LNG tanker ____boil-off_______ gas is normally used as fuel for ME.
• The reason for gas engines to appear was to burn ___excess____ natural gas.
• Modern dual-fuel engines’ __objective___ is to reduce environmental ___impact.______.
• In order to ___ satisfy____ the market requirement for environmentally-friendly marine engines,
diesel engines may be upgraded to operate on natural gas.
• Today’s DF engines are being built with an _____intention____ to decrease the environmental
impact.
• In case if natural gas engines are used on ships, certain ____secure____ requirements have to be
satisfied in order to ensure safe and smooth operation.
• Technical and manufacturer’s ___guidelines___ must be provided and retained on board.
• DF engines are capable of ___ switching_____ from one fuel to another in case of need.
• 2-stroke DF engines have ___appeared_______ only recently.

ACTIVATE II:

• Decide if the statements below are TRUE or FALSE.

• Gas engine is an innovative technology of the XXI century.

• ICE gained its popularity after the WWII.
• Natural gas is a byproduct of oil extraction.
• Dual-fuel engines are all based on diesel-ignited gas engines that use liquid fuel to ignite the gas
fuel.
• The reason why dual-fuel engines appeared in the market was to limit the liquid fuel
consumption due to its global shortage and high cost.
• Ship technical guidelines provide safety and redundancy requirements which are
recommendatory only and are not mandatory to satisfy.
• First practical DF engines were 4-stroke only.

• Complete and title the text below. Use the words from a) task of the STUDY II section.

____________________________________

Gas engines have a very long history dating back to the invention, just 20 years after James
Watt invented the modern steam engine in 1785, of a vacuum type piston engine that utilize coal gas
combustion instead of steam. This is now recognized as the first-ever internal combustion engine.
Use of internal combustion engines strongly ________________ after the Second World
War when large ________________ of cheap petroleum oil began to be produced in regions such as
the Middle East. To make effective use of the natural gas produced by oil ________________ as a
byproduct of oil ________________, this led to the burning of the gas in diesel engines by mixing it
with the intake air. This was the first example of a dual-fuel engine. Many different types of dual-
fuel engines have been developed since then, many of which have been either diesel-ignited gas
engines that use liquid fuel to ignite the gas fuel, or mixed combustion engines in which LNG tanker
________________ gas or the ________________ natural gas from oil extraction is used together
with another fuel. While these types of dual fuel engines ________________ market requirement
when the ________________ was to utilize ________________ natural gas as a additional fuel,
engines that use natural gas with the ________________ of reducing environmental
________________ must operate by using natural gas as much as possible.
Safety and ________________ requirements specified in ship classifications technical
________________ must be satisfied if natural gas engines are to be used on ships. That is, there is
a need for ________________ provision of backup for the case of gas-fueled operation being lost
due to a problem in the fuel supply system or engine. Dual-fuel engines that are able to
________________ between gas and liquid fuel are recognized as satisfying this requirement.
Such switchable dual-fuel engines were first developed in the late 1990s as four-stroke
engines. Practical two-stroke dual-fuel engines did not ________________ until 2010.

• Comprehension questions.

• Are gas engines considered recent inventions?

• What does gas engine differ from vacuum type piston engine in?
• When and why have ICEs become common to be used?
• What was the point in promoting gas engines development and use?
• Is there just one type of DF engine?
• What do diesel-ignited gas engines differ from mixed combustion engines in?
• Is there any excessive natural gas nowadays?
• Why have gas engines become common to be used nowadays?
• What are certain requirements that have to be satisfied if natural gas engines are to be used?
• Are DF engines capable of switching between fuels?
• When were switchable DF engines developed?
• Which type of engine was first?

Lesson 4
Combustion process

ENGAGE:

• Comment on the following.

ACHIEVING EFFICIENT COMBUSTION:

What is required?

• Answer the questions below. Explain the importance of the following for ensuring
efficient combustion.
• What is known as fuel treatment? How important is it in ensuring efficient combustion?
• Why does fuel temperature matter? How is it connected with volume of emissions produced?
• What happens if there is no sufficient oxygen available? Why is it of importance?
• How does injection timing influence combustion process?
• What is known as atomization? What factors influence its appropriateness?
• What is required for proper penetration of the fuel? Why is it important?
• How can proper air fuel mixing be achieved?
• How do compression pressure and temperature influence combustion process?
• What is necessary to be done to ensure that?

• Give definitions for the following. Google, if necessary.

fuel-to-air ratio (lean/rich)
stoichiometric condition
compression ratio
knocking combustion
misfiring combustion
excess air ratio

ACTIVATE I:

• Watch some videos. Check if you were right.

• Decide if the statements below are TRUE or FALSE. Correct the FALSE ones if you
can.

• There are four elements required for combustion: oxygen, heat, fuel and pressure.
• The fuels used on aboard are liquid hydrocarbon fuels.
• Marine distillate and residual fuels cannot be burnt in the liquid form.
• Residual fuels require no pre-treatment before combustion.
• The fuels must be delivered to the cylinder in a way which generates vapor.
• Combustion oxygen is delivered by the flywheel.
• The amount of air delivered influences the efficiency of combustion.
• The black smoke from the funnel upon starting an engine is an indication of insufficient air is
being supplied.
• Stoichiometric mixture is an ideal ratio of temperature and pressure.
• A spark is an ignition source initiating combustion.
• Diesel engines rely on an external ignition source such as a spark igniter or pilot flame.
• Steam boilers rely on the temperature of the air charge in the cylinder, after compression, being
above the self-ignition temperature of the fuel to provide the ignition source.
• Once ignition takes place, the combustion will be continuous as the main flame vaporizers the
fuel and heats it to above the flash point.
• Flash point is the temperature at which fuel boils.
• Fire point is the temperature at which the fuel will give ff combustible vapors which can be
ignited by an external ignition source in the presence of air.
• The temperature at which a combustible mixture will ignite without an external source of
ignition is known as self-ignition temperature or autoignition temperature or the temperature of
spontaneous combustion.
 • Watch the video. Check if you were right.

• Complete the table below.

Combustion elements oxygen, heat, fuel

Fuels used on board liquid hydrocarbon fuels and LNG

Turbocharger

Black smoke from the Doesn’t enough air

funnel
Stoichiometric Fuel and air
mixture
Ignition sources (3) Compression . ignition spark and flame

DE ignition source Compression

Steam boiler ignition Flame

source
Flash point the lowest temperature at which fuel will start to burn

Fire point the lowest temperature at which the vapor of that fuel will
continue to burn witout ignited sourse
Self-ignition
temperature

• Comprehension questions.

• How many and what elements are required for the combustion process to occur?
• What are the fuels used on board?
• Do marine distillate and residual fuels require any treatment prior to (before) combustion? Why?
• What should be the form of fuels delivered to the cylinder?
• What is the purpose of the fuel system?
• What is the purpose of the turbocharger in combustion process?
• What is the connection between the amount of air delivered and combustion efficiency?
• What does black smoke out of the funnel when engine is started indicate?
• What is known as stoichiometric mixture?
• How is ignition normally achieved in the presence of oxygen and fuel? Name 3 sources.
• What is an ordinary ignition source for diesel engines? What are these engines called?
• What is an ordinary ignition source for steam boilers?
• What makes the combustion process continuous?
• What is known as flash point of a fuel?
• What is known as fire point of a fuel?
• What is known as self-ignition temperature of a fuel? What are other ways it may be called?

STUDY:
 • Match the words with their meanings.

• 1 surface area 7 in the area that is close/near to something

of a cylinder
• 2 penetration 12 open to view, uncovered, being without protection

• 3 swirl plate 9 a lot of tiny drops of water in the air, which make it difficult
to see very far
• 4 break up into 6 spread equally
droplets
• 5 tend to 15 state or condition of confusion, movement,
or agitation; disorder
• 6 even 10 it is obvious that it will happen
distribution
• 7 in the 16 advisable, recommendable
vicinity
• 8 ratio enclosed space in which a very hot fire is made
13
• 9 mist it happens often and is likely to happen again
5
• 10 predictable 1 the total space covered by the flat surfaces of the bases of the
cylinder and its curved surface
• 11 burner tip 14 the maximum area in which something can reach
or detect things
• 12 exposed 11 used to control the injection of fuel into the burner; distribute
the fuel into the airstream to achieve proper mixing
• 13 furnace 2 the distance travelled by the fuel particle inside the
combustion chamber just before burning
• 14 range of 4 the process by which a single mass of fluid breaks into
several smaller fluid masses
• 15 turbulence 8 proportion between two amounts showing the number of
times one value contains or is contained within the other
• 16 desirable 3 adds turbulence, mixing the gas and air to provide a blended
mix to the blower

• Complete the following using the words from the table below.

droplets referred to distribute referred to

desirable combustible surface area evenly
range turbulence achieve ratio

A mixture of fuel and air will only be ________________ if the fuel is vaporized and the
____ratio_____ of fuel to air is within the flammable _____range ____. It is easier to vaporize the
fuel if the ____surface area_____ exposed to the heat source is large compared to the mass of fuel.
It is therefore necessary to break the fuel up into very small ___droplets_____. This process is
___referred to___ as atomization. In a diesel engine, it is ___desirable______ that the whole
volume of the combustion chamber is used. It is therefore necessary to ___distribute____ the fuel
throughout the combustion chamber. This distribution is ____referred to ____ as penetration. The
fuel and air must be mixed so that the fuel and oxygen are ___evenly_____ distributed to ensure that
combustion is as complete as possible. To __achieve____ this, it is necessary to create the correct
mixing conditions, in particular, to control the air movement or __turbulence____.

• Answer the following questions.

• What measures have to be taken to ensure the fuel and air mixture is combustible?
• What makes it easier to vaporize the fuel?
• How much of combustion chamber volume should be used to ensure proper combustion?
• What is the principal difference between atomization and penetration?
• Why is it required to control turbulence and air movement?

• Match the following to get phrases.

• 1 compressed air or steam to 8 atomization to take place

• 2 tend to penetrate further 6 mist
• 3 vaporize in the 9 of the injector
• 4 be predictable if correct 10 scavenge ports
• 5 the distance 12 into turbulent air
• 6 form a 11 very small droplets
• 7 lack of 13 the burnet unit
• 8 generate conditions for 3 hot cylinder
• 9 penetration of fuel 15 in the cylinder
• 10 shape and position of 4 mixing of air and fuel
• 11 the breakup of a liquid fuel into 1 assist the process
• 12 fuel reaching cylinder 7 penetration
• 13 much greater than that 2 than small droplets
• 14 swirl plate of 14 components
• 15 movement of air 16 of the solid liquid stream
• 16 over rich in the vicinity 5 travelled by the fuel

• Listen to the audio and complete the information below using the phrases matched in
the previous task.

Atomization is the term used to describe the breakup of a liquid fuel into very small droplets
which, when mixed with air, generate conditions for mixing of air and fuel . In this state, the
surface area of the fuel is ___ much greater than that _the burnet unit and the fuel will therefore
heat up rapidly and __ vaporize in the hot cylinder ____________ or boiler furnace. The purpose
of the diesel engine fuel injector valve is to form a mist_______________________ as the fuel
enters the combustion chamber. Similarly, a boiler burner tip will help create the conditions for
atomization often using _ compressed air or steam to assist the process
Penetration can be thought of as the distance travelled by the fuel once it enters the combustion
chamber or furnace. Insufficient penetration will lead to the fuel air mixture being over rich in the
vicinity __of the solid liquid stream____________ or burner tip, leading to incomplete
combustion. Excess penetration may lead to tend to penetrate further than small droplets or
furnace walls. Large fuel droplets lack of penetration _________________. Over atomization may
therefore lead to be predictable if correct mixing of air and fuel.
Turbulence is the term used to describe movement of air in the cylinder ______ prior to and
during the combustion process. The movement has to generate conditions for mixing of air and
fuel is to be achieved. Air turbulence is generated in the diesel engine cylinder by the
________________________________ and valves and the shape of the piston crown and other
combustion chamber components. In the boiler furnace, this is achieved by the swirl plate of
components . Correct shape and position of scavenge ports ____ will ensure good distribution
and an even mixture.

ACTIVATE II:

• Complete the information below suggesting your own ideas.

• When the three elements: fuel, oxygen, and heat are present in the right conditions then
combustion_ will occur and __power___ will follow.
• The whole purpose of the combustion process is to convert the __chemical energy______ that
the fuel contains into heat energy which can then be converted into __motion______.
• In the diesel engine the released heat energy from combustion of the fuel, and the associated
pressure rise, act directly on the piston to produce the power to _ make electricity_ and in turn
_operate machinery__ or other equipment.
• In a steam boiler, the released energy is used to generate ___steam___ which is normally used
to _heat fuel
• Stoichiometric mixture is the mixture of _fuel and air___ that would theoretically result in
complete combustion of the fuel.
• The amount can be calculated by considering exactly how much air is required for the
__burning__ of each of the elements within the fuel.
• For the fuels considered, the main elements will be hydrogen, carbon and sulfur____ although
other elements and contaminants are also taken into account.
• In practice, however, the combustion process requires more _oxygen____ than this ideal
minimum.
• In the diesel engine cycle, the short period available for the whole process of fuel injection,
mixing with air, ignition and combustion, means that complete combustion is
________________.
• For the fuel combustion to be as complete as practically possible, _ mixing of fuel and air is
needed.
• Excess air may be as much as _10%___ more than the ideal minimum.
• In a steam boiler furnace, it is easier to mix the fuel and air at entry and a much smaller amount
of __ excess air__ is required.

• Consider the following.

MJ/kg
• What is it?
• What does it measure?
• What elements of marine fuels, to your mind, are the major sources of energy?
• What, do you think, is the energy equivalent of marine fuel?
• What, do you think, is the energy equivalent of hydrogen?
• What, do you think, are the products of combustion of hydrogen?
• Have you heard anything about hydrogen-powered engines?
• Do you think they may substitute conventional diesel engines?
• What, do you think, is the energy equivalent of Sulphur?
• What, do you think, are the products of combustion of Sulphur?
• Do you think the combustion products of Sulphur are environmentally-friendly?
• What is the difference between oxygen and atmospheric air?
• What emissions, do you think, may be considered atmospheric pollutants?
• What do you know about MARPOL Annex VI legislation?
• Do you think complete combustion is possible?
• What are the noncombustible elements that originate from fuel or air supply?

• Watch or listen to the video. Check if you were right.

• Complete the text below.

The heat energy equivalent released during combustion of the hydrogen and carbon in
marine fuel is the _major sourse of energy_ for both the diesel engine and the steam boiler. It is
normally referred to the amount of energy equivalent as the higher or lower value of the heat of
combustion which is measured in __Megajou_______ (MJ/kg). Taking into account the heat energy
required to produce water vapour, gives the lower value of heat of combustion for those substances
where water vapour is a product of combustion. The other elements found in marine fuels have
much lower energy equivalents than __hydrogen and carbon_______. As the concentration of
these other elements increases, the overall heat of combustion of the fuel reduces. Marine fuels
typically have an energy equivalent of between ____39_____ and ______42____ MJ/kg.
Hydrogen has an energy equivalent for the higher value of heat of combustion of
approximately ___142_________ MJ/kg and a lower value of approximately ____121_____ MJ/kg.
The chemical equation for the complete combustion of hydrogen in oxygen shows the products of
combustion are water vapour and heat_________.

Sulphur has an energy equivalent for heat of combustion of approximately ___9___ MJ/kg.
The chemical reaction of Sulphur with an oxidant can produce a number of different oxides of
Sulphur generally referred to as _SOx____. The chemical equation for the complete combustion of
Sulphur in oxygen can be shown in stages and depends on ________________ available. The
products of combustion are ________________.

When combined with water or water vapour, the Sulphur dioxide and Sulphur trioxide can
also form either __sulphurous____. These products contribute to __acid rain______ when present
in exhaust emissions.
 The products of complete combustion for pure hydrocarbon fuels would be only
________________ if the stoichiometric amount of pure oxygen was used.

However, the combustion process is not supplied with oxygen directly, but with
________________ which contains a high proportion of ________________ as well as other trace
elements. Also, marine fuels often contain ___sulphur___ which will burn and produce its own
products of combustion.

Obviously, any other elements that are present in the fuel, and any excess ___lubricating
oil__, will produce other products of combustion. All of these additional products will be emitted to
the atmosphere in the exhaust gas. Some of these emissions are regarded as _atmospheric
pollutant___ which are harmful to the environment and are considered undesirable components of
the exhaust gas. Recent legislation, particularly, the introduction of _MARPOL Annex __ VI,
regulates the permitted levels of these undesirable components in exhaust gas emissions.

The exhaust gas from the diesel engine will contain all of the expected products of
combustion, plus a high amount of the excess air____, which was not used during combustion
process. In addition to those already discussed, there will also be products of
__incomplete__combustion___.

Since complete combustion is __impossible___ to achieve in practice, then combustion of

marine fuel results in the formation of other products of combustion. These will include
___hydrocabron___, ____carbon_____, and ___carbon monoxide______.

There will be incomplete combustion of some of the elements in the fuel resulting in
emission components as shown in the list. Sulphur in the fuel leads to the formation of oxides of
Sulphur referred to as _SOx___. The nitrogen in the combustion air can form a number of different
oxides which are referred to as __NOx____. The NOx and SOx can combine with
___moisture_____________ in the atmosphere to produce __Acids_______ which contribute to
acid rain. Noncombustible elements, such as ___ash___ and ___particulate matter_______,
originating from the fuel or air supply, will pass through the combustion process unchanged or
partly oxidized. All of these will pass out with the exhaust gas and can be ________________.

Lesson 5
Gas/fuel engines

ENGAGE:

• Read and comment on the following.

• Knocking
• Availability of fuel
• Additional plant requirement
• Dual fuels_ engines perform best under moderate to high load.
• Existing engines suffer from major increases in CO and HC emissions.
• Dual fuels___ engines suffer from loss of fuel efficiency at light loads.
• This is because they operate unthrottled, so that the air-fuel mixture becomes leaner as the load
is reduced. As the mixture becomes leaner, combustion eventually degrades, leaving large
amounts of partial reaction products in the exhaust.

What is the list dedicated to? Title it.

What engine category does the list describe?
Do you agree/disagree with the list?
Do you believe the technology has its future in shipping? Comment.
Is the technology being applicable in conventional vehicles?
What advantages of the technology may be considered?

• Watch the video. Answer the questions.

• Which combustion process is utilized by DF engines when operating on gas? – Lean burn
• When does the process of gas and air mixing occur? Before the intake valves
• What is gas and air mixture ignited by? By pilot fuel after compression phase
• How is pilot fuel fed into the cylinder? By common rail system
• When do inlet air valves open?

• Label the image below. Complete its description.

Left: _intake_ stroke

As the piston moves __downwards__, a mixture of _air ___ and _____gas_______ is drawn into
the cylinder. The gas is injected in the inlet channel via a ___spray____.
Middle: ___Compression___ stroke
As the piston moves __upwards_____, the mixture is compressed. The mixture is poor, which
means that __air___ volume is large. Due to this, the mixture does not ___ignited___
spontaneously.
Right: ignition by ___pilot fuel______
Just before the __TDC ___ position of the piston, the fuel is injected into the cylinder under
_pressure__. This ignites immediately causing the __air-and-gas__ mixture to ignite.
ACTIVATE I:

• Consider the following questions.

• What are DF engines’ modes of operation?

• When, do you think, DF engine should run in fuel oil only mode?
• Do you think NG should be pressurized before it is delivered into the cylinder unit?
• What should be the pressure of NG?
• What is used to maintain NG pressurized?
• Do you think NG should be cooled or heated before it is delivered into the cylinder unit? Prove.
• What devices should be used to prevent pressure drops? Solenoid valve
• What can you say about the requirements to gas supply line design?
• Do you think there are any safety devices controlling the process? Warning or shutdown?
• What should be used for lubrication of parts and sealing of gas?
• What would be the result of jammed gas injection valves?
• How, to your mind, the system is protected from undetected pressure drop?
• What would be the result of late ignition while burning gas?
• What would be the result of pilot fuel oil system failure?

• Do the text quiz. Check if you were right.

When engine is well supplied with natural gas, amount of __pilot______ (1) fuel injected is
corresponding to 6% of the total engine load. When gas supply to the engine is constant and limited,
then engine is said to be in “Specified Gas Mode”. Here gas supply is constant, but fuel oil quantity
injected ____ varies____________ (2) to meet changing engine load demand.

In “Fuel Oil Only” mode, gas supply will not be available, and engine runs only on fuel oil.
This mode is used when engine is _unstable____ (3), such as during restricted waters, heavy
weather, manoeuvring, etc.

Natural gas is compressed to about 250-300 bar using a number of _compressors_____ (4),
working in series. Compressed gas is then __pump/cooled____ (5) and led to valve blocks of each
cylinder unit.
Each valve block is fitted with an ______ accumulator/receiver__________ (6) (it has a
capacity to store about 20 times of the amount of gas injected to the unit at full load) for minimizing
pressure ___ drop________ (7) during injection and to monitor pressure drop in case of any
abnormality in the system (such as gas injection valve stuck open).
The gas supply pipe lines are __double____ (8) walled. Compressed air is passed between
the two walls (air seal), which is continuously monitored for any gas __ leakage.____ (9).
Outer wall of the gas pipe is made of stainless steel to withstand very _____low_____ (10)
temperatures, in case of a leakage from inner pipe.
When the flow of compressed air between the gas supply pipe walls fail, the gas supply ___
shutdown____ (11) and the line is purged with inert gas.
 For lubrication of parts and sealing of gas, gas injectors are supplied with _ sealing oil. _
(12). (It is pressurized to about 25-30 bar above gas injection pressure, and is injected and burnt
along with the gas).
Consumption_ (13) of the sealing oil is very low, in the order of 0.13 g/kWh.
The sealing oil system consist of two pumps for _ redundancy_ (14) and a spring loaded
accumulator to maintain the sealing oil pressure, since standby pump takes time to __ • build up
_____ (15) pressure when one pump fails.
When a gas injection valve is stuck open (jammed), then gas pressure drops at the
accumulator in the valve block, resulting in gas system _ shutdown _ (16) and pipe lines are purged
with inert gas.
If the pressure drop is not detected in the above case, then more gas burn, exhaust
temperature rises. This results in gas supply _ shutdown __ (17).
In the case of late ignition while burning gas, there will be rapid pressure ___ rise____ (18)
in the exhaust system, because exhaust gas __ receiver______ (19) is designed to withstand 15 bar
pressure.
Failure of pilot fuel oil system result in combustion __ failure___ (20) of gas, then gas
supply shut down and lines are purged with inert gas.

• • distillate • ignited • pilot

• • varies • same • rises
• • stable • controlled • unstable
• • pumps • compressors • generators
• • cooled • heated • pressurized
• • receiver • accumulator • pump
• • rise • increase • drop
• • double • single • triple
• • sensor • control • leakage
• • low • high • hot
• • slow • restart • shutdown
• • springs • sealing oil • liquid
• • quality • consumption • grade
• • control • error • redundancy
• • open up • reduce • build up
• • slow • shutdown • restart
• • shutdown • slow • error
• • drop • rise • fall
• • control • receiver • boiler
• • failure • improvement • change

• Label the image below using the prompts. Mind, some of the prompts are fake.
 pilot fuel line compressors gas admission valve cylinder unit
exhaust gas receiver inlet channel spark arrester nozzle pipes
gas supply pipe accumulator pilot fuel injection valve block
valve (combined)

• Complete the information below providing your own ideas.

IACS (International Association of Classification Societies) require following safeties in DF

engines:
• use Fuel Oil __ only while starting the engine;
• use __ Fuel Oil __ only during unstable engine conditions, such as _maneuvering___, __poor
weather condition_____, etc.;
• engine should continue to run on ___fuel oil_____ even when gas supply stops;
• crankcase _____relief valve_____ to be fitted in way of each crank throw;
• construction and operation of pressure relief valve of engine units should consider __pressure
drops____ inside the engine and subsequent (following) pressure rise;
• ________________ system of the engine to be independent and not to be mixed with any other
systems;
• air starting line to each unit to be fitted with flame _detector__;
• flame arrester to be fitted at the __beginning___ of the gas supply valve to the units;
• apart from automatic shut down system, gas supply must be able to shut __manualy __ from
engine starting platform or other control stations.

STUDY:

• Match the synonyms.

 • 1 occur 5 get the result, accomplish
• 2 lean 9 include, contain, integrate
• 3 propagate 2 thin, slim, fat-free
• 4 knock 11 arrive at, get to
• 5 achieve 8 uniform, the same
• 6 deviate 3 cover, fill
• 7 spark 4 bang, beat, strike
• 8 homogeneous 10 help, support, develop
• 9 incorporate 14 adapt, change, fix
• 10 promote 1 happen, take place
• 11 reach 7 flicker, flash
• 12 initiate 12 detonate, ignite, launch
• 13 plug 13 begin, start, launch
• 14 adjust 15 produce, generate, increase
• 15 set off 6 differ, vary

• Complete the sentences below using the words from the previous task in the correct
form.

1. High flame temperature promotes the oxidation of the nitrogen.

2. High auto ignition temperature of natural gas means that combustion does not occur simply
by injecting it into the compressed air.
3. Natural gas engines require an ignition source to initiate combustion.
4. Plug or diesel fuel atomization is required by natural gas engines to initiate combustion.
5. Four-stroke engines require pre-mixed incorporation mixture of the fuel and air to be
introduced into the cylinder.
6. The formation of NOx can be reduced by using a pre-mixed fuel-air mixture with a
homogeneous fuel-to-air ratio.
7. In case of gas engines, it is necessary for the ignited flame to propagate through the
unburned fuel mixture until combustion is complete.
8. Because of an increase in load, the unburned fuel mixture may ignite spontaneously before it
is reached by the propagating flame.
9. If spontaneous ignition initiates a chain reaction, this can result in serious damage to the
engine.
10. The type of combustion known as knocking must be avoided in gas engines.
11. If the load changes continuously, there is an increased risk of knocking or misfiring due to
operation deviating from the target excess air ratio.
12. To achieve high output while aiming to keep the excess air ratio in the intermediate zone
between the regions where knocking or misfiring occur, many recent gas engines
incorporate mechanisms for adjusting the excess air ratio in accordance with operating
conditions.

• Complete the sentences below using the words from the table below.

1. It is a difficult job and crew should be paid accordingly.

2. The term electronics generally refers to electrically-induced action.
3. These terms will be used in the manual.
 4. The accident that happened was generally because of human error.
5. CE continuously comes to ECR to do his paperwork.
6. This was not an easy decision; however, a decision was dictated by the duty.
7. The fuel spontaneously ignites because of the high temperature and pressure.
8. There is absolutely no difference!
9. The delay was due to heavy traffic.
10. 2E is careful, whereas the motorman takes risks all the time.
11. The oiler from the Philippines spent simply two years on board.
12. There is one manual in particular that may help you to refresh your knowledge.
13. Never apply water to a burn while the casualty is still in contact with electric current.
14. CE must give clear instructions and standing orders so that everyone understands him.
15. The piston was so hard to overhaul because we have never done that before.
16. in addition to, certificate of competence, officers should get endorsements.

simply spontaneously whereas in particular

due to while generally accordingly
partially throughout so that in addition to
referred to continuously however absolutely

ACTIVATE II:

• Match the following to get phrases.

GROUP 1

• 1 ignition 5 output
• 2 excess 10 combustion
• 3 turbocharger 4 temperature
• 4 lower combustion 8 the engine
• 5 engine 6 mixture
• 6 fuel-air 13 inlet
• 7 known as 2 air ratio
• 8 supplied to 11 ignite
• 9 expected 12 air ratio
• 10 initiating 9 load
• 11 mixture to 10 temperature
• 12 target excess 7 knocking
• 13 air 1 source

GROUP 2

• 1 exhaust 4 load
• 2 engines 9 risk
• 3 propagating 6 air flow
• 4 changes in 14 nitrogen
• 5 compression 13 plug
• 6 intake 2 incorporate mechanisms
• 7 speed of the 8 air
 • 8 compressed 12 mixture
• 9 increased 1 pipe
• 10 unburned 11 reaction
• 11 chain 5 ratio
• 12 leaner 10 fuel mixture
• 13 spark 3 flame
• 14 oxidation of the 7 turbocharger

• Title and complete the texts below using the phrases matched in the previous activity.

________________
Four-stroke diesel engines compress their intake air (or fuel mixture) by a ratio of between
1/14 and 1/16 and this increases the ________________ to between 300 and 350°C. Atomized
diesel fuel is then injected into the compressed air causing it to react immediately with the
surrounding oxygen, ________________. The fuel burns locally, in almost the stoichiometric
condition, and the high flame temperature promotes the ________________ contained in the air.
This is why the NOx levels for diesel combustion are so high.
________________
In the case of a gas engine, the high auto ignition temperature of natural gas means that
combustion does not occur simply by injecting it into the ________________. Accordingly, natural
gas engines require an ________________ to initiate combustion. Generally, a ________________
or diesel fuel atomization is used to achieve this. In the case of a four-stroke engine, a pre-mixed
homogeneous mixture of the fuel and air is introduced into the cylinder. Here, the formation of NOx
can be reduced by using a pre-mixed ________________ with a leaner fuel-to-air ratio (excess air
ratio > 1, meaning more air than is required by the stoichiometric ratio), because it results in a
________________ in the cylinder (see Fig.1).

Figure 1

The way combustion should work in a gas engine is for the ignited flame to propagate
through the ________________ until combustion is complete. However, if the thermal load and
combustion pressure in the cylinder increase for some reason, such as an increase in load, the
unburned fuel mixture may ignite spontaneously before it is reached by the ________________. If
spontaneous ignition sets off a ________________, this can result in serious damage to the engine
due to severe pressure or temperature increases. This type of combustion is ________________, and
it is something absolutely to be avoided in gas engines (see Fig.2).
 Figure 2

Ways of avoiding knocking include reducing the ________________ to reduce the

compressed air temperature, and increasing the excess air ratio as high as possible (using a
________________) to reduce the combustion temperature. However, reducing the temperature by
too much may cause misfiring due to failure of the ________________. And because misfiring may
result in fires due to unburned fuel mixture escaping into the ________________, it is something to
be avoided.
Fig.3 below shows gas engine combustion characteristics, where the horizontal axis
represents the ________________ and the vertical axis represents ________________. Knocking
occurs when output is high in the region where the excess air ratio is around one, whereas the region
in which misfiring occurs is at higher excess air ratios. When developing a gas engine, the
combustion conditions are selected so as to avoid the excess air ratio being in the regions where
knocking or misfiring occur when operating under the ________________. However, when the load
changes continuously, as is the case when used for ship propulsion, there is an ________________
of knocking or misfiring due to operation deviating from the ________________. In particular,
because the inlet air flow depends on the ________________, the engine may fail to operate under
load due to the turbocharger speed being unable to follow quickly to ________________.

Figure 3

To achieve high output while aiming to keep the excess air ratio in the intermediate zone
between the regions where knocking or misfiring occur, many recent gas ________________ for
adjusting the excess air ratio in accordance with operating conditions. Fig.4 below shows one such
mechanism for adjusting the ________________. In addition to the main intake passage, it equips a
bypass that returns some of the intake air to the ________________. A bypass valve in the bypass
closes under full load so that all the air discharged by the turbocharger is ________________, but it
partially opens under partial load by adjusting valve opening angle to maintain the correct intake air
flow to the engine.
 Figure 4

• Define if the statements are TRUE or FALSE. Correct the FALSE ones.

• During compression stroke in 4-stroke DE the air temperature rises to between 300 and 350°C.
• NOx levels for diesel combustion are lower than those for gas combustion.
• In order to initiate combustion, NG engines require a spark plug.
• The reduction in NOx formation in NG engines is achieved by fuel-air mixture with a leaner
fuel-to-air ratio.
• Knocking combustion refers to the chain reaction caused by the spontaneous ignition of the
unburned fuel mixture.
• Flame propagation in NG engines is the proper way to achieve complete combustion and ensure
knocking combustion.
• If the knocking combustion occurred, there is no way to stop it.
• The lower the combustion temperature is, the more efficient the combustion process will be.
• Misfiring may lead to fires due to unburned fuel mixture going into the exhaust pipe.
• Inlet air flow is independent from the speed of the turbocharger.
• Modern NG engines are equipped with a bypass that returns some of the intake air to the
turbocharger inlet to adjust the excess air ratio in accordance with operating conditions and to
prevent knocking or misfiring.
• A bypass valve in the bypass closes under partial load so that all the air discharged by the
turbocharger is supplied to the engine, but it partially opens under full load by adjusting valve
opening angle to maintain the correct intake air flow to the engine.

Lesson 6
DF engines

ENGAGE:

• Comment on the figure below.

 Emissions in mixed Diesel/Gas mode

• During which stroke is the gas fuel supplied?

• What, do you think, the exhaust emissions levels depend on?
• What does the concentration of CO2 depend on?
• Is there any possible way to reduce CO2 in the exhaust gas
• What does the concentration of NOx depend on?
• Is there any possible way to reduce NOx in the exhaust gas?
• What do you know about IMO Tier I, II, III?
• Which emissions do the Tiers address?
• What are the requirements?
• According to Tier III, the proportion of diesel fuel is to be reduced to 2%. Do you think the
conventional nozzles are capable of injecting such a small quantity?
• Which additional device, to your mind, is capable of injecting that small quantity?

• Complete the text below using the most suitable words.

Gas fuel is supplied during the ________________ stroke of a diesel engine, and the exhaust
emissions vary according to the proportions of ________________ fuel and ________________
fuel in the total fuel. Because the concentration of CO 2 in the exhaust gas depends on the
composition of the ________________, it can be reduced by up to about 25% according to the
________________ of diesel fuel and gas fuel. On the other hand, because the concentration of NOx
depends on the combustion ________________, reductions in NOx can only be achieved by
reducing the proportion of ________________ fuel.
While achieving the IMO Tier 3 regulations (80% reduction in ________________) requires
that the proportion of diesel fuel to be reduced to 2%. There are no currently available nozzles that
are able to ________________ the full range of fuel injection quantities, from the amount required
under rated load down to this very ________________ quantity, in a reliable manner (without
variation in the quantity injected for each cycle). To overcome it, adding a small dedicated nozzle
(micro-pilot fuel injector) that supplies ________________ fuel for the ignition when operating on
________________ fuel is necessary.

• Label the figure below suggesting your ideas.

 • Describe the cross-section from the previous activity by completing the information
below.

Here is a cross-section of a ________________ -stroke DF engine. Gas fuel is supplied from

a ________________ in the air intake manifold where it flows into the ________________ as a
mixture with air. Two injectors, one is the ________________ used for diesel mode and another is
the ________________ used for gas mode, are equipped in the cylinder head, the engine can switch
between ________________ mode and ________________ mode freely with certain operating
condition restrictions.

ACTIVATE I:

• Suggest the difference.

4-stroke DF vs. 2-stroke DF

• Label the figure using the prompts below.

 Combustion cycle for 2-stroke DF engine

expansion fuel gas valve compression

mixture scavenging fuel gas
ignition diesel fuel injector pilot fuel injector for ignition

• Define if the statements are TRUE or FALSE. If able, correct the FALSE ones.

• It is not allowed to mix the gas fuel with the intake air, because intake air is used for scavenging
in a 2-stroke engine.
• The diesel fuel is injected into the compressed air, and then ignition is achieved by injecting gas
fuel.
• The micro-pilot fuel injector is used for injecting gas fuel.
• The result of using micro-pilot fuel injector is low level of unburned gas, reduced CO2 emission
and knocking.
• The result of using micro-pilot fuel injector is reduced NOx emission.
• Natural gas is injected into the cylinder in liquid form.
• Natural gas is pressurized in liquid form.

• Read for gist to check if you were right in the previous activity.

Because intake air is used for scavenging in a 2-stroke engine, it is not allowed to mix the
gas fuel with the intake air. Instead, the gas fuel is injected into the compressed air in the same way
as diesel fuel, and then ignition is achieved by injecting fuel via the micro-pilot fuel injector.
Because this results in diffusion combustion, as with diesel fuel, it can reduce CO 2 emissions by
20% or more, with a low level of unburned gas and CO emission and without knocking. However,
the level of NOx emissions is high due to the same reason.
Figure below shows the cylinder cover design for a 2-stroke DF engine. In order to
pressurize gas fuel injected into the compressed air up to 30 MPa, natural gas that has been
pressurized in liquid form is vaporized and then injected into the cylinder. And because there is no
risk of knocking, the switch between diesel fuel and gas fuel can be performed comparatively easily
and quickly.
 One proposal for improving the level of NOx emissions for 2-stroke DF engines is to use a
low-pressure gas fuel injection engine that can operate with a lean pre-mixed fuel mixture despite
being a 2-stroke engine. This involves using a fuel injection timing control method that enables the
time delay of pre-mixing of gas fuel and air during the intake stroke described above that prevents
the fuel-air mixture from coming into direct contact with the exhaust gas. Such an engine is
currently under development with the aim of achieving low-NOx emissions similar to a four-stroke
engine.

• Answer the question and label the figure using the prompts below.

What solution has been mentioned to address the problem of NOx emissions reduction?

Combustion cycle for low-pressure gas injection 2-stroke DF engine

fuel gas valve diesel fuel injector pilot fuel injector for compression
ignition
ignition expansion scavenging fuel injection
fuel gas buffer layer of air between combustion gas and mixture

STUDY:
 • Match the synonyms.

• 1 adjust 6 shake, pulse

• 2 error 10 limit, regulate, fix
• 3 fluctuation 15 arrest, detain, hold back
• 4 sign 11 extra room, gap, possibility
• 5 delay 7 improvement
• 6 vibration 13 salt, caustic soda
• 7 recovery 9 change, passing, shift
• 8 waveform 2 mistake, slip, fault, blunder
• 9 transition 14 category, class, quality, standard
• 10 restrict 3 wavelike motion
• 11 margin 5 stop, cut off, pause
• 12 switchover 1 adapt, change
• 13 alkalis 16 at once, immediately
• 14 grade 12 changeover, shift
• 15 halt 8 movement up, down, back, forth
• 16 instantaneously 4 mark, symbol, indication

• Complete the phrases below using the words from the previous activity.

1. a procedure for transition from diesel mode to gas mode

2. to switch from gas mode to diesel mode by instantaneously shutting off the gas fuel
3. monitoring for signs of knocking or misfiring
4. the vibration is controlled automatically
5. three main error modes in gas mode
6. Knocking can be detected by using a waveform sensor
7. internal cylinder pressure maveform
8. engine automatically adjusts its operation
9. to restrict the ignition timing
10. to sign/halt the knocking
11. engine speed fluctuation
12. misfiring continues for a number of cycles without recovery
13. operating on low grade fuel
14. knocking margin would be reduced
15. build-up of alkalis deposit
16. Restricting the range of fuels that can be used

ACTIVATE II:

• Consider the following.

CHALLENGES FOR DF ENGINES

• Match sentences’ halves to obtain the challenges.

• 1 Because two or more different types 3 the cylinder walls that act as a heat
of fuel are combusted in the same insulator causing the combustion
 cylinder, temperature to increase.
• 2 Whereas lubricants with high base 6 there is a risk for the engine to shut
numbers (30 to 40 mg KOH/g) are down due to knocking when it
used when operating on low grade switches over to this new fuel.
fuel (3.5% sulfur),
• 3 This is why the knocking margin 4 will perform effectively with both
would be reduced in natural gas fuel diesel mode and gas mode.
mode due to the build-up of alkalis
deposit and other combustion deposit
on
• 4 As a result, it can be difficult to 2 lubricants with low base numbers (5
select a lubricant for DF engines that mg KOH/g) are used when operating
on natural gas (0% sulfur).
• 5 Fuel characteristics are 7 restricting the range of fuels that can
be used or limiting output, a
challenge for the future will be to
develop engine technology that can
deal with different fuel
characteristics.
• 6 Ocean-going vessels are supplied 5 a problem specific to DF marine
with fuel at their destinations engines.
(“bunkering”), but because the
characteristics of natural gas differ
depending on where it is produced, if
a vessel takes on fuel with
significantly different characteristics
• 7 Currently though this problem can 1 one of the challenges for DF engines
be overcome using particular is lubrication.
operations such as

• Sum up the challenges.

Lubrication: scope of the problem, errors margin, possible solution

_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Fuel characteristics: scope of the problem, errors margin, possible solution

_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

• Match to get phrases.

 • 1 fuel-air 13 injection
• 2 main 9 sensor
• 3 electromagnetic 10 controller
• 4 engine speed 7 sensor
• 5 cylinder 8 slowly opened
• 6 flow control 4 fluctuation
• 7 gas 5 pressure waveform
• 8 gas valve is 11 or misfiring
• 9 vibration 3 solenoid
• 10 electronic 12 injector
• 11 signs of knocking 2 error modes
• 12 micro-pilot 6 lever
• 13 diesel fuel 1 ratios

• Title and complete the text using the phrases matched previously.

_________________________________________________
Dual-fuel engines use an ___electronic controller_____________ for fuel flow control to enable
switching between diesel mode and gas mode as required. In diesel mode, an actuator mechanically
operates the fuel pump’s __flow control lever__, whereas in gas mode, the timing for opening the
gas valve is controlled electrically with the energizing duration of time for an electromagnetic
solemoid
.
While it is possible to switch from gas mode to diesel mode by instantaneously shutting off
the gas fuel and starting _diesel fuel injection_, switching from diesel mode to gas mode involves
the engine speed control working through a procedure for transitioning from diesel mode to gas
mode as the _gas valve os slowly opened___. This is because of restrictions on the range of the
__fuel air ratio____ that can be used when operating in gas mode, which are dependent on
operation condition such as the load or fuel characteristics, and the switchover is controlled
automatically while monitoring for signs of knocking of misfiring___.
The three ___main error modes in gas mode are knocking, misfiring, and gas leaks.
Knocking can be detected by using a _vibration sensor_ to find changes in combustion vibration or
detected directly from the internal _cylinder pressure waveform_____. If knocking is detected, the
engine automatically adjusts its operation to prevent it. Although the usual practice is to reduce the
maximum pressure in the cylinder by using the micro-pilot injector________ to delay the ignition
timing, if this fails to halt the knocking, the operation automatically switches to diesel mode.
Misfiring can be detected from factors such as the exhaust gas temperature, internal cylinder
pressure waveform, or __engine speed fluctuation _____. If misfiring continues for a number of
cycles without recovery, the operation automatically switches to diesel mode. Gas leaks are detected
with a _gas sensor___. If a gas leak is detected, the gas valve is immediately shut off and the
operation automatically switches to diesel mode.

• Comprehension questions.

• What is the purpose of an electronic controller in DF engines?

• How does an actuator act when operating in diesel mode?
• How is the timing for opening the gas valve controlled when operating in gas mode?
• What is the procedure of switching from gas to diesel mode?
• What is the procedure of switching from diesel to gas mode?
• Why is the procedure of switching from diesel to gas mode complicated?
• What are the three main error modes when operating in gas mode?
• How can knocking be detected?
• What happens upon knocking detection?
• Is anything can be done upon early stage of knocking detection?
• How can misfiring be detected?
• What happens if misfiring continues for a number of cycles?
• How are gas leaks detected?
• What happens upon gas leak detection?

Lesson 7
DF engines. Vol.2

ENGAGE:

• Choose the proper definition. Prove your choice.

DUAL-FUEL ENGINE is…

• a type of internal combustion engine which ignites fuel by injecting it into hot, high-
pressure air in a combustion chamber.
• the diesel engine that can run on both gaseous and liquid fuels.
• any device which can convert heat energy of fuel into mechanical energy.

• Scan the diagram below and comment on it.

Emissions:
Price:
Power:
 • Decipher the following.

GI and LGI

It describes ME features
It is connected to gas-fueled ME
It partially describes state of NG
It describes the injection processes

ACTIVATE I:

• Define if the statements are TRUE or FALSE. Correct the FALSE ones.

• IMO Tier III emission standards deal with SOx emissions produced by fuel oil combustion.
• IMO Tier III NOx emission standards will apply to marine diesel engines installed on new ships
constructed on or after 1 January 2016.
• Natural gas is also defined as “clean gas” because it produces very low/no particulate matter and
none of SOx emissions.
• The ME-GI/ME-LGI engine will fulfil IMO Tier III NOx levels when combined with the
exhaust gas recirculation (EGR) technology.
• In 1987, the first testing of the GI principles was carried out in Japan and Denmark and MAN
Diesel & Turbo introduced their first 2-stroke ME-GI DF engine series in 2011.
• In 2012, MAN Diesel & Turbo decided to expand the engine portfolio and the 2-stroke DF ME-
LGI engine series was introduced in 2013.
• The ME-LGI engine enables the use of more sustainable fuels such as methanol, ethanol and
liquefied petroleum gas (LPG).
• The fuel is injected in a gaseous state in ME-GI and in liquid state in ME-LGI.
• Both ME-GI and ME-LGI engines run on one gas type.

• Study the table below and check if you were right in some of the answers from the previous
activity.
• Watch the video.

• Do the test.

• In the coming years, global shipping will be facing_______.

• liquid fuels • engine breakdowns • tough challenges

• Growing ________ is pushing up liquid fuel prices.

• population • energy demand • gas equipment

• Rising __________ leads to stricter emission regulations, especially in the IMO

emission control areas.

• environmental • fuel prices • qualification demand

awareness

• In the future, ECA areas will be ______exclusively to ships that _____ the IMO Tier III
emission regulation.

• banned, meet • restricted, fulfill • extended, ban

• To meet challenges for tomorrow’s shipping industry, engine manufacturers present new
________ engines.

• zero-emissions • sophisticated • fuel flexible

• The MAN L35/44DF it’s a ____ technology, with two separate _______, makes it run on
any fuel available.
 • dual-fuel, injection • modern, injectors • complicated, pumps
systems

• The MAN L35/44DF is _______ running on HFO, MDO, MGO or gas fuel, like LNG.

• possible to • designed • capable of

• The MAN L35/44DF is based on MAN _______ 32/44CR engine.

• well-proven • medium-speed • four-stroke

• Both engines feature a state-of-the-art CRS with injection pressures of up to _______ bars.

• 160 • 600 • 1600

• In ____, this system and other technologies ___ L35/44DF to fulfill the current emission
regulations IMO Tier II.

• diesel mode, enable • diesel mode, disable • gas mode, check

• To meet even stricter _____ of future regulation IMO Tier III, the L35/44DF can also
______ in gas mode.

• regulations, • emission limits, • recommendations,

breakdown operate operate

• _______ to gas can be done with _________ in engine power.

• keeping, stop • sticking, some loss • switching, no loss

• To ____ the air gas mixture, a small amount of liquid fuel is injected by a separate _______
system.

• ignite, pilot fuel • burn, sparkle • utilize, common rail

• In gas mode, the L35/44DF fully complies with IMO Tier III lowering SOx emission by
_____ and other emissions levels by up to ______ and beyond compared to liquid fuel operation.

• 10%, 100% • 12%, 88% • 20%, 99%

• Over the past years the ______ between liquid and gas fuel has increased steadily and it is
expected to keep growing.

• price difference • level • compromise

• Already now, using natural gas as main fuel, enables ship owners to ____ fuel cost in a
double-digit percentage compared to a _________ diesel engine.
 • cut, old • cut, traditional • save, conventional

• The L35/44DF _______ ship operators to fully harness this potential, plus, the flexibility
________ between fuels at any time for optimum resource utilization.

• allows, switch • stops, flow • allows, --------

• In _______ mode, both gas and diesel supply systems are ______, which lets the engine to
run on multiple ratios of gas and liquid fuels.

• fuel sharing, passive • fuel sharing, active • gas, active

• Fuel sharing mode makes the L35/44DF virtually _ immune _ to variations in gas fuel
quality, allowing it to operate even on gas that would be __ unusable ____ for a conventional gas
engine.

• impossible, too dirty • immune, unusable • the best, treated

• All these makes the L35/44DF the perfect _____ to keep cost of ownership down and give
ship operators the flexibility and _________ they need.

• choice, sustainability • price, tomorrow • option, ban

STUDY:

• Synonym match.

1 challenge 3 limited
• 2 awareness 4 tested
• 3 restricted 7 control
• 4 well-proven 2 distribute
• 5 enable 8 maintain
• 6 loss 1 test
• 7 harness 6 waste
• 8 sustain 10 low-cost
• 9 share 2 understanding
• 10 affordable 5 allow, permit

• Match the following to get phrases.

GROUP 1
• 1 energy 3 mode
• 2 environmental 7 design
• 3 diesel 2 awareness
• 4 pilot 4 fuel system
• 5 price 1 demand
• 6 flexible 5 difference
 • 7 robust 6 switch
• 8 onboard power 8 generation

GROUP 2
• 1 tough 8 mode
• 2 alternative 3 regulations
• 3 emission 2 fuels
• 4 gas 4 mode
• 5 economic 1 challenges
• 6 operating 5 operation
• 7 sustained 7 advantages
• 8 fuel sharing 6 costs

ACTIVATE II:

• Watch the video again.

• Complete the following using some of the phrases matched previously and adding some
more.

In the coming years, global shipping will be facing tough challenges. Growing energy demand is
pushing up liquid fuel prices and the use of alternative fuel becomes ever more attractive. In addition, rising
environmental awareness leads to stricter emission regulations, especially in the IMO emission control
areas. In the future, these areas will be restricted exclusively to ships that fulfill the IMO Tier III emission
regulation.
To meet these challenges for tomorrow’s shipping industry, MAN Diesel and Turbo presents its new
fuel flexible 4-stroke medium-speed engine, that can be used for all applications as a main engine for diesel
mechanic propulsion, for diesel electric propulsion or as an auxiliary engine for onboard power generation.
The MAN L35/44DF it’s a dual-fuel technology, with two separate onboard pewerfull generation,
makes it run on any fuel available. No matter if its liquid fuels such as HFO, MDO and MGO (marine gas oil)
or gaseous fuels, like LNG.
The MAN L35/44DF is based on MAN well-proven 32/44CR engine. Both engines feature a state-of-
the-art CRS with injection pressure of up to 1600 bars. In diesel mode, this system and other technologies
enable L35/44DF to fulfill the current emission regulations IMO Tier II.
To meet even stricter emission limits of future regulation IMO Tier III, the L35/44DF can also
operate in gas mode. Switching to gas can be done in the fly as loads between 15 and 100% with no loss in
performance.To ignite the air gas mixture, a small amount of liquid fuel is injected by a pilot fuel system
In gas mode, the L35/44DF fully complies with IMO Tier III lowering SOx emissions by 20% and other
emissions levels by up to 99% and beyond compared to liquid fuel operation
In addition, using gas as fuel also provides substantial cost savings. Over the past years the price
difference between liquid and gas fuel has increased steadily and it is expected to keep growing.
As fuel makes up the largest partnership expense reducing fuel expenses is the most effective way
to keep costs down. Already now, using natural gas as main fuel, enables ship owners to save fuel cost in a
double-digit percentage compared to a conventional diesel engine.
When looking at onboard power generation, the savings potential become even higher. The
L35/44DF allows ship operators to fully harness this potential, plus, the flexibility between fuels at any time
for optimum resource utilization.
 For robust performance on a wide range of gas qualities, the L35/44DF features a flexible pilot fuel
system. In this mode, both gas and diesel supply systems are active, which lets the engine to run on
multiple ratios of gas and liquid fuels. This makes the L35/44DF virtually immune to variations in fuel
quality, allowing it to operate even on gas that would be unusable for a conventional gas engine.
Its leading position in its class compliance with IMO Tier II and III, without compromise, low
operating cost due to affordable gas fuel, complete environmental sustainability, a design based on proven
engine technology, the ability to upgrade IMO Tier II compliant 32/44 CR engines to do fuel operation
entirely onboard and an increased vessel resale value due to that engine fulfills all regulations for many
years to come.
All these makes the L35/44DF the perfect choice to keep cost of ownership down and give ship
operators the flexibility they need.
With the L35/44DF and a larger one 60DF, MAN Diesel and Turbo offers its customers a complete
range of fuel flexible 4-stroke medium-speed engines that fulfill all economic and environmental
requirements of tomorrow’s shipping industry today.

• Comprehension questions.

1) hat are the tough challenges shipping industry is facing now?

Growing energy demand is pushing up liquid fuel prices and the use of alternative fuel
becomes ever more attractive
2) What are the existing ECAs?
3) What are the discussed ECAs?
4) What regulation the ships intended to operate in ECAs must fulfill?
5) What are the applications the MAN L35/44DF may be used for?
The MAN L35/44DF it’s a dual-fuel technology, with two separate onboard pewerfull
generation, makes it run on any fuel available. No matter if its liquid fuels such as HFO, MDO
and MGO (marine gas oil) or gaseous fuels, like LNG.
6) Which technology is the MAN L35/44DF of?
The MAN L35/44DF is based on MAN well-proven 32/44CR engine. Both engines feature a
state-of-the-art CRS with injection pressure of up to 1600 bars. In diesel mode, this system and
other technologies enable L35/44DF to fulfill the current emission regulations IMO Tier II.
7) What are its specific features?
The MAN L35/44DF it’s a dual-fuel technology, with two separate onboard pewerfull
generation, makes it run on any fuel available.
8) What fuel types the MAN L35/44DF is capable of running on?
HFO, MDO and MGO (marine gas oil) or gaseous fuels, like LNG
9) What is the operating pressure of the MAN L35/44DF common rail system?
1600 bars
10) When operating in diesel does the MAN L35/44DF fulfill all of the regulations?
In diesel mode, this system and other technologies enable L35/44DF to fulfill the current
emission regulations IMO Tier II.
11) How can the MAN L35/44DF fulfill the IMO Tier III requirements?
To meet even stricter emission limits of future regulation IMO Tier III, the L35/44DF can also
operate in gas mode. Switching to gas can be done in the fly as loads between 15 and 100% with
no loss in performance
12) How is the air-gas mixture in gas mode ignited in the MAN L35/44DF?
To ignite the air gas mixture, a small amount of liquid fuel is injected by a pilot fuel system
13) What are the emissions reductions of the MAN L35/44DF when operating in gas mode?
 In gas mode, the L35/44DF fully complies with IMO Tier III lowering SOx emissions by 20%
and other emissions levels by up to 99% and beyond compared to liquid fuel operation
14) What is the main economic advantage of the MAN L35/44DF when compared to a conventional
diesel engine?
using natural gas as main fuel, enables ship owners to save fuel cost in a double-digit percentage
compared to a conventional diesel engine.
15) Besides gas and diesel mode, which another mode the MAN L35/44DF is capable of operating
in?
For robust performance on a wide range of gas qualities, the L35/44DF features a flexible pilot
fuel system.
16) What is the mode operating principle?
In this mode, both gas and diesel supply systems are active, which lets the engine to run on
multiple ratios of gas and liquid fuels. This makes the L35/44DF virtually immune to variations
in fuel quality, allowing it to operate even on gas that would be unusable for a conventional gas
engine
17) Is there a need in exhaust gas after treatment system installment?

• Sum up the information and list the MAN L35/44DF advantages.

_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Lesson 8
Slow steaming

ENGAGE:

• Suggest and define three main companies.

LARGE TWO-STROKE SECTOR FOR MAIN ENGINES MANUFACTURERS

• Discuss the questions.

• Which of the companies has now transferred its business to a new company – Winterthur Gas &
Diesel (Win GD) – initially as a joint venture with China State Shipbuilding Corporation before
disposing of its full stake to its partner?
• Which of the companies has a dominant market share and four out of five engines supplied in
this two-stroke sector are of this manufacturer?
• Which of the companies is considered to be the smallest one in terms of market share of the
three companies?

• Complete the following with the most suitable words.

 With ________________ from its Chinese parent, WGD has ambitions to seriously improve
its market ________________ in the future.
In the medium-speed main engine sector, Wärtsilä has almost ________________ of the
market, MAN Diesel & Turbo around a ________________ with Caterpillar (MaK) leading the rest
of the field. Many more names can be found on ________________ -speed engines which are used
as ________________ mostly by smaller vessels but also as ________________ by all ship types.
Dual-fuel engines have until recently been mostly ________________ strokes but they have
now also made initial references in the ________________ -stroke sector and interest is growing.

• Answer the following.

• What are the WGD plans for the future?

• What do you know about medium-speed main engine sector market share?
• What do you know about high-speed sector market share?
• Is DF engines market sector developing?
• What makes DF engines a point of interest?

STUDY:

• Match the words with the definitions.

• efficiency become greater or more successful than (something or

someone)
• conventional remove or take away (something) from a particular place or
position
• overtake the ratio of the work done or energy developed by a machine,
engine, etc., to the energy supplied to it; usually expressed in
percentage
• contribute following traditional forms
• withdraw give (something) in order to help achieve or provide something

• Put the words in the correct order to create sentences.

• introduction / rail / main / The / controlled / injection / in / development / was / conventional /

the / camshaft / of /common / fuel / place / of / the / and / electronically /.
_____________________________________________________________________________
_____________________________________________________________________________

• controlled / have / Mechanically / withdrawn / sale / engines / not / from / been /.

_____________________________________________________________________________
_____________________________________________________________________________

• popularity / overtaking / controlled / Electronically / controlled / engines / mechanically / now /

are / in / for / orders / new.
_____________________________________________________________________________
_____________________________________________________________________________
• The / of / cylinder / consumption / chamber / fuel / to / redesign / of / also / reduced / combustion
/ the / head / and / contributed / to /.
_____________________________________________________________________________
_____________________________________________________________________________

• was / way / turbocharger / exhaust / efficiency / narrower / improved / by / systems / of /.

_____________________________________________________________________________
_____________________________________________________________________________

ACTIVATE I:

• Choose the most suitable definition.

Energy efficiency…
• means using less energy to provide the same level of energy. It is therefore one method to reduce
greenhouse gas emissions.
• something is more energy efficient if it lasts longer or works better than a traditional version of
the same appliance, but uses the same amount of energy.
• if it delivers the same performance as the traditional version, but uses less energy.

• Discuss the questions.

• What innovative technologies have been implemented into propulsion systems?

• What is an essential difference between conventional and new propulsion systems?
• What steps have been taken towards energy efficiency improvement?
• What nowadays improvements contribute to human labor reduction?
• Do you think DF engines can completely withdraw diesel engines from the market?

• Define if the statements below are FACTS or SOMEBODY’S OPINIONS. Comment on

your idea.

• There is no great demand for greater efficiency as it has been proven that, the more people try to
contribute to energy efficiency, the more they contribute to marine pollution.
• Mechanically controlled engines have been withdrawn from sale by electronically controlled
ones.
• One of the important steps taken towards improving fuel consumption was common rail
application together with electronic injection.
• The re-design of cylinder head and combustion chamber can hardly contribute to reduced fuel
consumption.
• The pioneer in the DF engines was Wartsila, manufacturing engines for use on board LNG
carriers.
• Methanol fuel can’t be the alternative to diesel fuel because of its poor ignition properties.

• Fill in the text with the words from the box.

After a pause towards the end of the last century there have been some major leaps forward
in engine technology because of increasing regulation and ________________ from users for
greater efficiency. Leading the march of developments, was the introduction of the
________________ rail and electronically controlled fuel ________________ in place of the
conventional ________________. Mechanically controlled engines have not been
________________ from sale but electronic versions are now ________________ them in
popularity for new orders.

The degree of additional control and the extended power ________________ allowed by
common rail and electronic injection was first promoted as improving fuel ________________,
allowing different fuel oil ________________ and better part- and low-load running leading to such
engines being described as ‘________________’. At that time, ________________ steaming as an
operating strategy was not even on the radar but electronic engines have since ________________
making it easier to initiate.

Common rail was not the only ________________ taking place in the early 2000s. Evolution
of existing engine types meant significant improvements in power/weight ratios and the
________________ of the cylinder head and combustion chamber also contributed to
________________ fuel consumption. Other changes included improved engineering
________________ allowing for higher cylinder pressure permitted by ________________ strokes
and in some cases a very slightly reduced cylinder ________________. ________________
efficiency was improved by way of narrower exhaust systems. Improvements in ________________
speed engines saw production turning to a more modular system with maximum commonality of
parts across engines with each manufacturers range.

This period also saw the first dual fuel medium-speed engines able to run on either fuel oil or
________________ making their debut. Wärtsilä was the early ________________ in this field with
the engines planned for use in LNG carriers. Today most of the leading engine manufacturers have
________________ dual-fuel versions of some engines into their portfolios although Rolls-Royce
has opted to go with either diesel or pure ________________ versions of its Bergen engine range.
Further developments are ________________ that have seen engines capable of running on LPG,
________________ and liquid gas being produced.

consumption reduced overtaking re-design camshaft

withdrawn turbocharger tolerances bore pioneer
longer injection LNG qualities underway
slow medium development demand incorporated
common range gas methanol smokeless
contributed to

• Comprehension questions.

• Which 20th -21st century leap forward is mentioned in the text?

• What has common rail and electronic injection replaced and why?
• What is meant under ‘improving fuel consumption’? What are the contributors to its
achievement?
• What engine improvements took place in the 21st century?
• How and why was turbocharger efficiency improved?
• What was the need to switch to DF engines manufacture?
• Which company was the early pioneer in DF manufacturing?
ENGAGE II:

• Comment on the image.

What is known as ‘slow steaming’?

• Check the following and suggest what they have in common.

• Watch the video and answer the following questions.

• What happened in 2007 so that MAERSK*9 implemented slow steaming?

• Why, do you think, it was MAERSK which was concerned about the fuel prices?
• What solution to the problem has been found by MAERSK?
• What were the skepticism and resistance all about?
• Which ME parts might get damaged due to slow steaming?
• How may slow steaming endanger crew lives?
• Has MAERSK found the solution to ensure safe slow steaming?
• What was the fuel saving of the trip from Europe to Singapore?
• What was the percentage of CO2 emissions reduction?
• What is the disadvantage of the slow steaming concept?

STUDY II:

• Match the words with their meanings.

• comply with money received for goods, services or

from other sources
• savings result that someone is trying to
achieve
• income create or set up something
(organization)
• establish something which is now present,
available or in operation
 • enable to act in such a way so that to meet
the requirements, standards
• benefit particular action to be performed in
order to achieve particular results
• target make possible for something to
happen
• existing not as good or optimal as possible

• measure money saved by economy and laid

away
• suboptimal improvement in condition or
advantage

• Complete the sentences using the vocabulary units from the previous activity in the
correct form.

• IMO adopted amendments to Annex VI of the MARPOL Convention to reduce the carbon
intensity of ships and include ________________ for energy efficiency and GHG emissions
reduction.
• IMO ________________ ECAs, as an important ________________ to reduce and control SOx,
NOx, and particulate matter (PM) emissions.
• With the establishment of ECAs, ship operators must decide which strategy they should adopt to
________________ ECA regulations.
• Although slow steaming is associated with environmental ________________, the introduction
of slow steaming can increase the round-trip time by 10–20%.
• The introduction of slow steaming can increase the round-trip time by 10–20%, depending on
the sailing route and port times, thus reducing the shipping ________________.
• An increase in transport time due to slow steaming could lead to an increase in the required
number of ships, and in that way the ________________ in fuel consumption and CO2 emission
could decrease significantly.
• Sailing at a speed lower than the ship design speed changes the operating conditions of the
engine that could operate in ________________ conditions.
• Development of technical and operational energy efficiency measures for both new and
________________ ships can be another possible short-term measure.
• LNG fueled ships seem to be technically the most practical alternative to decrease CO 2
emissions in deep-sea shipping since LNG can replace conventional, more-polluting oil-based
fuels, and ________________ almost complete removal of SOx and PM emissions with a
substantial reduction in NOx emissions as well.

ACTIVATE II:

• Match the following to get phrases.

• to minimize fuels
• harmful to sulfur content
• operate in suboptimal trip time
• reduction in operating based fuels
 • carbon-based sea
• DF conditions
• more-polluting oil- and long-term
• older and less gas oil
• low sulfur marine existing ships
• new and matter (PM) emissions
• fuel with lower two-stroke engines
• carried by speed of ships
• short-term, mid-term associated costs
• increase the round- energy efficient
• control SOx, NOx, and particulate the environment

• Read and complete the text with the phrases matched previously.

It should be noted that 16.2% of global GHG emissions are caused by the transport sector
and the reduction in GHG emissions within the transport sector is important. Considering that more
than 80% of the international trade in goods is ________________, maritime transport plays the key
role in international trade and the global economy.
Although during the last decade, the world fleet has become more energy efficient, total
GHG emissions are continuously growing. A large portion in GHG emissions in the maritime sector
comes from container ships, particularly ________________ ones. Bearing in mind that the
container shipping industry is one of the main transport industries in the maritime sector, the GHG
emissions reduction for container ships becomes very important.
It should be noted that most of the world fleet is still powered by ________________
causing the emission of harmful gases.
In June 2021, IMO adopted amendments to Annex VI of the MARPOL Convention to reduce
the carbon intensity of ships and include targets for energy efficiency, to additionally reduce GHG
emissions from ships. In addition to GHG emissions, the maritime transport industry seriously
contributes to the non-GHG emissions, i.e., sulfur dioxides and nitrogen oxides, which are very
________________. IMO has established ECAs, as an important measure to reduce and
________________. With the establishment of ECAs, ship operators must decide whether to
comply with ECA regulations, which strategy they should adopt to comply with ECA regulations,
and establish the ways ________________.
The possible solutions are fuel switching, i.e., using fuel with higher sulfur content when
sailing outside the ECAs, and ________________ inside the ECAs, installment of scrubbers, or
using clean LNG as fuel.
Numerous measures have been proposed by IMO from 2011 onward to reduce CO2
emissions from the maritime transport industry. These measures are categorized as
________________ measures. One of the short-term measures is the ________________ called
slow steaming. The introduction of slow steaming leads to a decrease in fuel consumption and
consequently CO2 emission and is used by almost all global shipping companies.
Although slow steaming is associated with environmental benefits, the introduction of slow
steaming can ________________ by 10–20%, depending on the sailing route and port times, thus
reducing the shipping income. An increase in transport time due to slow steaming could lead to an
increase in the required number of ships, and in that way the savings in fuel consumption and CO 2
emission could decrease significantly.
 It should be noted that sailing at a speed lower than the ship design speed changes the
operating conditions of the engine that could ________________.
Another possible short-term measure is the development of technical and operational energy
efficiency measures for both ________________. LNG fueled ships seem to be technically the most
practical alternative to decrease CO2 emissions in deep-sea shipping since LNG can replace
conventional, ________________, and enable almost complete removal of SO x and PM emissions
with a substantial reduction in NOx emissions as well. While LNG carriers have used LNG as fuel
for a long time, other ship types have recently started to use LNG as fuel. LNG-fueled ships are
powered by ________________, for example, MAN-gas-diesel or Wartsila-DF, where the former
reduces GHGs by 20–24%, NOx by 25–30%, and SOx by 92–97%].
The fuel oil consumption and CO2 emissions for engines powered by low sulfur marine gas
oil and LNG have been analyzed. The reduction in CO2 emission is approximately 31% for a speed
reduction of 13.6% for an engine powered by ________________, and up to 49% for an engine
powered by LNG, in comparison to a ship sailing at the design speed and engine powered by low
sulfur marine gas oil.

• Comprehension questions.

• What is the role of maritime transport in international trade and the global economy?
• Why is the GHG emissions reduction for container ships so important?
• What are the most common fuels used by the world fleet? Why?
• What happened in June, 2021? What are the targets established?
• What is known as ‘ECA’? What are the requirements when sailing in ECAs?
• What solutions have been found to comply with ECA requirements?
• What measures have been proposed by IMO from 2011 onward?
• Which category does ‘slow steaming’ belong to?
• What are the benefits of slow steaming implementation?
• What are the disadvantages of slow steaming implementation?
• Which another short-term measure may be more practical to decrease CO2 emissions?
• What are the benefits of LNG fueled ships?

Lesson 9
Slow steaming. Vol.2

ENGAGE:

• Consider the following.

Beneficiary is a person/a party who/which gains or benefits in some way from something.
 • Consider the following.

Detriment is anything that causes damage or disadvantage.

• Scan the figure below and answer the question.

• What is MCR?
• How many modes of slow steaming can you see in the figure?
• Comment on each of the modes.

• Complete the description of each of modes below and title them.

________________ ________________ ________________

The The Range of main The

________________ ________________ engine load below ________________
and may cut-in the are in service and
________________ periodically for a ________________ ________________
are in service. short time when down to approx. may frequently cut-
Insufficient waste approaching to lower ________________ in to boost poor
heat to operate fresh limit of this load % of load. Till the performance of
________________. range, after the slow steaming era it economiser. Load
Load range below auxiliary boiler is used to be considered range approx.
________________ ________________. as a minimum limit ________________
% of MCR down to Typical load range of continous % of MCR down to
approx. ________________ ________________ ________________
________________ % of MCR. operation for a large % of MCR.
 % of MCR. marine engines.

• Answer the question below labeling the images.

What on board can be affected by slow steaming?

ACTIVATE I:

• Consider the following.

• How, do you think, can ME be affected by slow steaming?

• What does the following formula depict?

CylOil=S%*%MCR*k

• How, to your mind, will change cylinder oil consumption? Will it increase or decrease? Why?
• Study the diagram depicting expected cylinder oil consumption below. Comment on it.
• Now, study the diagrams depicting simulation of cylinder oil dosage and consumption of the
vessel that is employed on a South America – Europe trade with 11800 Nm distance per trip
and total 8 ports, where she spends average 400 hrs. per trip. Comment on them.

• How is cylinder oil dosage and consumption affected by slow steaming?

• Is it the same for cars?

• Complete the information below.

Slow steaming endangers ME operation in the following:

 Cylinder oil overdosing
Consequences:
Surplus oil ______________________________________________________________.
Surplus unburnt oil _______________________________________________________.

Low temperature corrosion

Consequences:
Overcooled area of cylinder liner is __________________________________________.

The main factors triggering low temperature corrosion:

• ________________
• ________________
• ________________
• ________________
How to deal with it on board:
• Increase temperature of cooling water
• Increase temperature of air
 • ________________
• ________________
Fuel valve fouling
According to the figure below, how is fuel valves TBO affected by slow steaming:

What is TBO?

Typical TBO for 2-stroke engines is 16000 rh and for 4-stroke engines is __8000___ rh. Due
to contamination of the nozzle tip _by 4000 to 2st and 1000 to 4st_.
Due to longer time at sea when slow steaming, the overhauling frequency of some machinery
__increases___. It must be taken into account into _maintance plant____.
Also amount of work for crew __ increases ___.

• Consider the following. Share your thoughts on the idea.

Periodical engine’s loading up when slow steaming

Advantages Disadvantages
Cylinder Oil reduced Fuel consumption increased
Less work for crews Thermal shock
 • Match the sentences halves to get information about impact of slow steaming on boiler
plant.

• 1 Due to low velocity of exhaust gas and 3 cuts-in usually below main engine’s
poor atomization as well as combustion load 30 % to 40 % MCR when the
process, economizer is clean.
• 2 Under low ME load, the economizer 6 its additional contamination and
heating consequently much higher fuel
consumption.
• 3 In order to maintain steam 9 below 200-220C the efficiency of
pressure/thermal oil temperature, the dosing plant is disputable.
auxiliary boiler
• 4 The auxiliary boiler cut-in set point 2 capacity becomes insufficient.
reduction
• 5 Dirty economizer brings the auxiliary 0 the most effective in reduction of
boiler to deposits.
• 6 Prolonged auxiliary boilers operation 8 dosing plant is essential.
during sea voyage causes
• 7 High risk of soot ignition can not be 5 cut-in at higher main engine’s load than
40 % MCR.
• 8 Installation and proper functioning of 1 amount of deposits in smoke tubes
soot ignition catalyst increases drastically.
• 9 However, if exhaust gas temperature 7 underestimated in any case.
after turbine drops
• 0 Frequent engine’s loading up and boiler 4 by 1-3 bar may be considered.
water washing is

• Comprehension questions.

• What are the modes of slow steaming operation?

• What on board is affected by slow steaming?
• What is the impact of slow steaming on cylinder oil consumption?
• What are the consequences of cylinder oil overdosing?
• What are the factors contributing to low temperature corrosion?
• What are the recommendations to follow to arrest low temperature?
• What is the impact of slow steaming on fuel valve TBO?
• What are pros and cons of periodical engine’s loading up?
• What is the impact of slow steaming on boiler plant?
• What, do you think, is the effect of slow steaming on fresh water generation process?
• What, do you think, is the effect of slow steaming on sludge system?
• What, do you think, is the effect of slow steaming on ship’s hull?
• What, do you think, is the effect of slow steaming on ship’s crew?

STUDY:

• Match the following with meanings.

• 1 frequency 5 to get closer to something

• 2 impact 13 process of getting faster
• 3 fouling 7 something that is neither large nor small in amount or degree
• 4 cut-in 2 effect or influence that something has on something
• 5 approach 9 enough of something for the purpose
• 6 cut-off 11 something that is extra or more than needed
• 7 moderate 8 to cause to increase, improve
• 8 boost 12 the process of pollution or poisoning
• 9 sufficient 1 number of times something happens over a period of time
• 10 insufficient 15 to make something last longer
• 11 surplus 14 speed
• 12 contamination 3 the formation of biological coating (deposit) on a surface
• 13 acceleration 6 to separate, to stop, to disconnect
• 14 velocity 10 not enough of something for the purpose
• 15 prolong 4 to join in, to blend into, to move into

• Complete the sentences below with the words from the previous activity.

• The auxiliary blowers may cut-in periodically for a short time when approaching to lower limit
of the load range, but after the auxiliary boiler is __ cut off._.
• Due to low ___ velocity___ of exhaust gas and poor atomization as well as combustion process,
amount of deposits in smoke tubes seriously increases.
• Under low main engine load, the economizer heating capacity becomes __ insufficient.____.
In order to maintain steam pressure/thermal oil temperature the auxiliary boiler cut-in
• s..
• Prolong auxiliary boilers operation during sea voyage causes its additional contamination.
• Auxiliary boiler may frequently cut-in to __moderate______ poor performance of economiser.
• The auxiliary blowers may cut-in periodically for a short time when _approaching_____ to
lower limit of the load.
• __Surplus_ oil burns into hard coke resulting in fast abrasive wear down of liner and piston
rings.
• Due to the _ contaminated ___ of the nozzle tip, the fuel valve TBO may be reduced.
• Due to longer time at sea when slow steaming, the overhauling __ frequency_ of some
machinery will increase.
• Periodical engine’s loading up may lead to unexpected machinery failure during _
acceleration._.
• Environment is the beneficiary from the slow steaming in NOx contamination __ reduction due
to low combustion temperature.
• Due to reduced rotation speed, the propeller is more vulnerable (can be easily affected, open to,
sensitive to) to _ fouling._.
• Between reduced speed and deep slow steaming modes, there is a _moderate_ slow steaming
mode.
• There must be ___ surplus___ waste heat to operate fresh water generator.

ACTIVATE II:

• Define the piece of equipment. Answer the questions below.

• What ensures water generation process? Heat

• Is there enough heat from engine when slow steaming to generate water?
• What slow steaming modes affect FWG the worst?
• How is it possible to deal with it on board?
• What are the disadvantages of taking fresh water from shore?
• Do you think the amount of oily deposits related to fuel consumption produced by slow steaming
vessel increase or decrease?
• What is ship’s hull coated with? Antofouling paint
• Do you think antifouling painting is efficient at any engine speed? No. its designed for special
range
• What is the effect of slow steaming on propeller? No. its effected by fouling

• Define if the statements below are TRUE, FALSE or CONTROVERCIAL. Correct the
FALSE ones.

• Most of the ships are manned with a minimum crew, often not more than stated in Minimum
Safe Manning Certificate. True
• Slow steaming doesn’t demand any additional activities from the crew. True
• There are advantages for the crew when the ship is slow steaming.
• Slow steaming became a widely utilized way of cost reduction in shipping and it has been
accepted by major engine builders.
• Vessel operators never understand that additional maintenance requires additional time.
• There are no maintenance procedures which require prolonged berthing or anchorage.
• No additional manpower is required to conduct slow steaming related services together with
standard service and running the ship.
• Prolonged slow steaming without periods with higher load will deteriorate the whole ships
performance and will decrease initial profits.
• The periodical short passages at higher vessel speed should be arranged as frequently as
possible.

Lesson 10
CRS
ENGAGE:

• Comment on the following.

RAIL INJECTION SYSTEM

What is its purpose?
Where is it mounted?
What does it consist of?
Is it commonly used?
Is it easy to maintain?
What is its operating principle?

• Choose the best definition. Prove your choice.

Common rail injection system is –

• uses either air or a liquid to remove the waste heat from an internal combustion engine
• is a direct fuel injection system for diesel engines
• is the process or technique of using a lubricant to reduce friction and/or wear in a contact
between two surfaces
• can be electric, pneumatic or hydraulic; in the case of very large engines, the starter can be
another internal combustion engine

• Look at the scheme and try to explain CRS in work.

 • Discuss the following.

• What was the need to create CRS?

• What is, to your mind, the advantage/disadvantage of this system?
• Why was this system given such a name?

ACTIVATE I:

• Read the text and fill in the empty spaces with words below.

The common rail system, as the name suggest, is a system which is __common__ for every
cylinder or unit of the marine engine. Marine engines of the early times had a fuel system, wherein
each unit had its own ________________ and the oil ________________ was supplied through the
jerk pumps.
However, in common rail system all the cylinders or units are connected to the
________________ and the fuel pressure is ________________ in the rail. The supplied
________________ is thus provided through the rail. A similar type of common rail system is also
there for _servo oil___ system for opening of the exhaust valves.
Speaking about the ________________ system, the common rail system was launched even
before the ________________, but was also not successful because of few ___drawbacks___.
However, because of some latest advancement in technology and electronics, the common rail
system has __gained_ popularity.
The common rail engines are also known as smokeless_ as fuel pressure required for
combustion is same for all _loads or rpm___ of the engine.
The common rail is employed in the following system:
• for __heated_____ fuel oil at a pressure of 1000 bars;
• for servo oil for opening and closing of __exhaust valve___ at a pressure of 200 bars;
• control oil for opening and closing of __valve blocs__ at a pressure of 200 bars;
• _compressed air__ for starting main engine.

accumulated fuel pressure jerk pumps servo oil drawbacks

gained jerk pump valve blocks loads or rpm common
pressure fuel injection heated rail compressed air
 smokeless engines exhaust valves

• Decide if the statements are TRUE or FALSE and correct the FALSE ones.

• CRS is the system that makes the ship more stable.

• Marine engines of the early times had a fuel system wherein each unit had its own jerk pump.
• Most of the cylinders are connected to the rail, leaving those not connected in stand-by mode.
• The fuel pressure is accumulated in the rail and is supplied to the unit by disposable plastic pipe.
• There is no common rail system for servo oil system.
• CRS is not applied on board all ships, even though, it is very successful, because marine
engineers still lack knowledge of how to maintain and overhaul the system.
• Common rail engines generate a lot of smoke causing troubles for shipping companies, which
intend to comply with regulations on GHG emissions.
• Common rail is employed by compressed air for starting main engine system.
• Control oil system for opening and closing of valve blocks is not manufactured in common rail
technology because CRS doesn’t work with oil.
• The fuel pressure required for combustion is different for different loads and rpm of the engine.
• CRS main disadvantage is system’s sensitivity to engine’s load changes.
• CRS was launched even before the jerk pumps, but was not successful because of few
drawbacks.

• Match the following to get phrases.

• 1 access from 4 oil system

• 2 injection 5 sensor
• 3 top dead 6 of the flow
• 4 servo and control 9 remotely
• 5 crank angle 1 the top
• 6 the control 7 hydraulic control
• 7 electro 2 control unit
• 8 fuel 10 cover
• 9 controlled 3 centre
• 10 cylinder 8 oil systems

• 1 engine’s top 9 control

• 2 valve control 5 valve
• 3 high-pressure 7 pressure
• 4 the timing of 4 the opening
• 5 exhaust 1 platform
• 6 to cut off 8 the valve
• 7 accumulated 3 pump
• 8 oil pushes 2 unit
• 9 electronic 6 the signal

• Complete the information below using the phrases matched previously.

High pressure pump

 The common rail system consists of a __high-pressure ________ which can be cam driven
or electrical driven or both. Pressure requirement will be different for different system. For _fuel
oil___ the pressure is as high as 1000 bars, for __ servo and control ______________ the pressure
is about 200 bars.
Rail unit
This is provided after the pumps where the ___accumulated pressure_____ from the pumps
is provided to the rail which supplies it to each unit when required. This is located at the _engines
top platform_______ and just below the _cylnder______. The rail units extend to full length of the
engine. They are enclosed, but have __access from the top______________ for maintenance and
overhauls.

A - fuel oil rail; B - control oil rail; C - servo oil rail; D - injection control unit (ICU); E - valve
control unit (VCU)

Valve block and electronic control system

This is required for _control of the flow________ of the fuel oil, servo oil, control oil and
starting air from the rail to the cylinder. The valve block is operated by the _electronic control____
which operates when it gets a signal indicating that this cylinder is at __top dead centre____ and
fuel has to be injected and decides when exhaust valve__ has to be opened. With the help of
electronics, the injection can be controlled remotely____ from the computer. For e.g., if we want to
cut off fuel to one of the units, then we need ___cut off the signal____ given from the control
system so that the valve will not open.
For the fuel oil system this block is known as ICU (_Injection Control Unit____) and for
exhaust valve it is known as VCU (__Valve Control Unit____). The control system for opening
and closing of ICU and VCU is done by _electro-gydraulic control_____ with which when the
signal for opening is present, the valve for control oil opens and control _oil pushes_ of ICU and
VCU to open. The signal for electronic control is given by __by crank-angle sensor_____ which
senses about each cylinder and sends signal to system which decides whether to open a valve or
close the valve.
The timing of opening _ of the valve can also be controlled by the electronics, which means
that if the signal is given to open the valve early it will open early and vice versa.

STUDY:
 • Complete the definitions from the text.

• CRS HP pump is driven by cam driven or electrical driven or both. _____________

• HP pumps deliver __fuel oil _____________________________________________
• Fuel oil system requires _____ the pressure about 1000 bars.
_______________________________
Servo oil and control oil systems requires _____ the pressure about 200 bars.
• _______________
• Rail unit is located located at the _engines top platform_______ and just below the
_cylnder______. ___
• The purpose of rail unit is ___________________________________________________
• For maintenance purposes, there is ___access from the top __________________
• Valve block is operated by ______electronic control _______________________________
• The purpose of a valve block is for control of the flow________ of the fuel oil, servo oil, control
oil and starting air from the rail to the cylinder._______________________
• Electronic control is activated by __ a signal indicating that this cylinder is at __top dead centre
____________________________________________
• Injection is controlled either __ remotely____ from the computer
• If there is the need to cut off fuel to one of the units _ then we need ___cut off the signal____
given from the control system so that the valve will not open._
• ICU is __ Injection Control Unit ____________________________________________
• VCU is ___ Valve Control Unit ________________________________________________
• Electrohydraulic control is used to open and closу of ICU and VCU
___________________________
• Crank angle sensor is used give signal for electronic
control________________________________________________
• The timing of the opening of the valve __ can also be controlled by the electronics
________________

• Match the sentences’ halves.

Advantages of Common Rail over Conventional Jerk Pump System

• 1 Same injection pressure for engine at 3 cams for each fuel pump are also
all loads or rpm which is not removed.
possible
• 2 Injection timing can be adjusted 6 enabled, which is not there in
during engine running, whereas in traditional system.
• 3 The design of common rail is simple 5 number of pumps and increased
as there are no individual fuel efficient combustion time between
pumps, and overhauls.
• 4 Common rail enables smokeless 2 conventional system, engine has to be
operation whereas in conventional stopped and setting for timing has to
system smokeless be changed.
• 5 Reduced maintenance is required 1 when using jerk pumps, due to the
because of a smaller pumps depend on engine speed.
• 6 With CRS, control of variable 4 operation is possible only during high
 opening of exhaust valve is rpm.

• Complete the following.

CRS advantages
• injection pressure independent from __engine load___________________________
• adjustment of injection timing is possible _to adust when engine
running________________________________
• simplified construction due to absent of jerk pump
________________________________________
• less smoke is produced due to constant pressure (smokeless
operation)_______________________________________
• exhaust valve opening can be _adjusted by
electronic_____________________________________________

ACTIVATE II:

• Label the image below using the prompts.

1 Suction 7 Injector 9 Camshaft 13 Fuel supply

manifold
2 Fuel pump 6 Valve block 10 Timing valve
3 HP collecting 7 Cylinder 11 Accumulator
block
4 HP fuel rail 8 injector 12 Spill valve
 • Google to explain the following.

• to determine the timing

• to release excess pressure – to decrease pressure
• pressure pulse
• operating lever - to operate other devise
• maneuvering lever
• to meet the load demand
• to tend to experience shock - that means that system is sensitive
• to dampen pressure surge – to control pressure
• to suit load change -

• Do the text quiz.

The common rail system has one or more common HP, multiple plunger, fuel pump/pumps.
The fuel is discharged into a manifold called a “_rail___” (1) which is maintained at a very HP.
From this common rail, fuel is supplied to all the fuel ___injectors____ (2) in the various cylinder
units. Between the rail and the injector or injectors for a particular cylinder is a “timing _____ (3)
valve” which determines the timing and amount of fuel delivery. Spill_ (4) valves are connected to
the manifold or rail to release excess pressure and _accumulator__ (5) bottles are included to
reduce pump pressure pulses. The injectors in a common rail system are often referred to as fuel
_valves___ (6).
The timing valve in the common rail system is operated by a cam and a lever_ (7) (see the
figure below). When the timing valve is lifted by the ________________ (8), the lever also is lifted,
thus ensuring that the valve in the timing valve _block_____ (9) allows the HP fuel oil to reach the
fuel injectors. Also, the timing valve operating lever is fixed to a _sliding_ (10) rod. This sliding rod
is fixed with the manoeuvring lever, which governs (controls) the ____amount____________ (11)
of the fuel to be injected into each cylinder unit, meeting the __load___ (12) demands on the engine.

The system has two or more common fuel pumps, which are driven by the __engine __ (13)
itself. They deliver HP fuel oil into one __common_ (14) line. This HP oil in the common rail tends
to __experience__ (15) a pressure surge (shock), when the engine load changes suddenly or
continuously over a period of time. To dampen these pressure ____surges____ (16), an accumulator
_bottle__ (17) is provided on the HP line (common rail).
Also the volume capacity of the HP common rail is __sufficient__ (18) to suit sudden load
changes. When compared with the individual pump engines, these common rail engines do not
require a great deal of concentration at the drive shaft (19). As the fuel pumps supply fuel oil at a
HP, it is ________________ (20) in an accumulator at a pressure of around 400 to 550 atmospheres.
This pressure is sufficiently maintained by the compressed air operated “____spill_____ (21)
valve.” If the pressure in the common rail increases suddenly, the spill __valve__ (22) will open up
and drain the fuel oil to the __service___ (23) tank or the fuel oil drain tank as per the design. Then
the _timing__ (24) valve controls the timing of start/stop of fuel injection.
For the initial start-up of the system, the fuel __priming___ (25) pump is provided, which
can __build-up_ (26) a pressure of about 140 atmospheres. This priming pump is usually
pneumatically (27) driven.
• • pipe • line • 1 rail
• • cylinders • injectors • units
• • timing • spill • relief
• • spill • control • bypass
• • accumulator • cylinder • air
• • valves • lines • levers
• • shaft • lever • rod
• • cam • pressure • force
• • line • interface • block
• • sliding • piston • connecting
• • flow • contamination • amount
• • regulation • load • IMO
• • camshaft • main engine • diesel generator
• • common • specific • separate
• • control • reduce • experience
• • surges • drops • rises
• • block • tank • bottle
• • insufficient • sufficient • limited
• • drive shaft • jerk pump • load surge
• • released • stored • supplied
• • timing • relief • spill
• • lever • valve • block
• • storage • settling • service
• • timing • spill • fuel
• • jerk • supply • priming
• • reduce • build up • drop
• • hydraulically • electrically • pneumatically

• Label the image below.

1 camshaft 5 Fuel priming pump (Its self-priming)

2 Accumulator bottle 6 Spill valve
3 Timing valve 7 Emergency spill valve
4 High pressure pump(Its priming pump)
 • Comprehension questions.

• What is known as ‘CRS’?

• What are the components the system comprises of?
• How many fuel pumps are normally there in a system?
• What are they both driven by? By main engine
• What pressure is required for fuel oil system?
• What are the working pressures of servo oil and control oil system?
• What are the features of rail unit? Where is it located?
• Is there an easy access to the rail unit for maintenance purposes?
• What are the purpose and features of the valve block?
• What is known as ‘ICU’?
• What is known as ‘VCU’?
• What is the purpose of the timing valve in a system?
• What is it operated by?
• What is the connection between timing valve operating lever, sliding rod and maneuvering
lever?
• What is the spill valve fitted in the system for?
• Which component dampens out pressure pulses in a system?
• What is the pressure in the accumulator bottle?
• Which component maintains the required pressure in the accumulator bottle?
• How is system protected from sudden pressure increase?
• What are the purpose and features of fuel priming pump?

Lesson 11
CRS. Vol.2

ENGAGE:

• Watch the animation and answer the following questions.

• Which company is the manufacturer of the CRS in the video?

• What are fuel pumps attached to?
• What do HP lines connect?
• Which device controls the CRS operation?
• How has injection process been characterized?
• What does flexible injection enable?
• How have GHG emissions been reduced?
• What safety features are integrated?
• What are the benefits of CaT CRS application?

• Consider the following.

IMO regulations require reasonable emission reduction and decrease of specific fuel oil
consumption.
Why?

• Study the offer by CaT. Comment on it.

Cat Common Rail offers:

Significant decrease of specific fuel oil consumption:
• for main propulsion engine M32C with Cat CR up to 3% improvement;
• for generating set M32C with Cat CR up to 2% improvement;
• optimized combustion.

Are these improvements important? Are they sufficient enough? Why/why not?

STUDY:

• Match the following with their definitions.

• to sacrifice provide something with a component not fitted

during manufacture
• approach from beginning to end
• to retrofit limited emissions should be kept
• visibility able to be easily modified
• capability a way of dealing with a situation or problem
• throughout make something possible
• flexible a factor involved in a complicated process or
 situation
• reliability state of being able to see or be seen
• multiple power or ability to do something
• complexity numerous and different
• emission sensitive act of giving up something valued for the sake of
something else
• to enable degree to which the result of a measurement can be
depended on to be accurate

• Complete the sentences using the words from the previous activity.

• The engines equipped with CaT CRS demonstrate superior ________________ in heavy fuel
operation and best fuel efficiency in its class.
• By adopting well proven elements of this technology for medium-speed engines, the system
enabled lowest engine emissions with minimum additional ________________.
• Caterpillar decided to adopt a two-step ________________ providing the most effective
solutions with lowest complexity.
• CRS is a very important development in emissions technology being fully
________________ fuel system suitable for HFO, MDO and DO.
• CRs enables invisible smoke under all engine operating conditions offering an effective
technology for ________________ areas.
• CRS purpose is to maintain and improve engine performance by taking advantage of the
________________ and benefits of a fully flexible fuel system.
• When operating at low engine load, CRS guarantees soot emissions to remain below the
________________ limit.
• During normal load operation, NOx emissions can be reduced without ________________
fuel consumption.
• CRS enables vessel operation without visible soot ________________ the whole operating
range.
• CRS is capable of ________________ injection which ________________ optimal
combustion and low emissions at all loads.
• During the development, it was decided to ensure the system can be ________________ to
already existing vessels.

ACTIVATE:

• Match to get phrases.

• without injection
• control fluid pressure
• fuel regulations
• optimal for the injector
• emission combustion
• multiple limit
• environmental visible soot
• injection aspect
• retrofit sensitive
• visibility consumption
 • Fill in empty spaces using phrases matched previously and use correct prepositions.

With Cat CRS, the ________________ is independent from load and speed. For areas that
are especially ________________, soot emissions at low engine load remain well below the
________________. Furthermore, during normal load operation, NOx emissions can be reduced
without sacrificing ________________.
In general, the Cat CRS fuel system enables vessel operation ________________ throughout
the whole operating range.
In addition to that, the fuel system is capable of ________________. Multiple injection
allows ________________ and low emissions at all loads. Characteristic of Cat CRS is the approach
of using the fuel (whether it’s HFO, MDO or diesel oil) as the ________________, thus avoiding
the added complexity of a separate control fluid system.
During the development, the ________________ of the complete system has been
emphasized. As a result, the Cat CR fuel system can be retrofitted to existing M32C engines. This
means increased customer value to reach future ________________.

• Answer the questions below.

• Why has the system been developed?

• What makes it different from conventional system?
• How does multiple injection affect the combustion process?
• What makes the system suitable for operation in emission sensitive areas?
• Is that possible to reduce NOx emissions when operating at normal load?
• Can you remember the factors contributing to NOx formation?
• What does the control fluid system run on?
• Is the system retrofittable?

• Define if the statements are TRUE or FALSE. Correct the FALSE ones.

• The injection pressure is dependent on load and speed.

• Emission sensitive areas require soot emissions at low engine load to remain well below the
visibility limit.
• NOx emissions can only be reduced by sacrificing injection pressure during normal load
operation.
• Throughout the whole operating range, the CaT CRS enables vessel operation without visible
soot emissions.
• Multiple injection allows slow combustion medium emissions at all loads.
• The approach of CaT CRS is to use LNG as the control fluid for the injector.
• CaT CRS is not completely retrofittable, but may be retrofitted to engines built after 2016.
• The system demonstrates superior reliability in all, but heavy fuel operation.
• When running at full load, the smoke will be visible from the funnel.
• Fully flexible fuel injection system enables maximum emissions and poor engine performance.

• Complete the information below with the prepositions.

The main components ______ the Cat Common Rail fuel system are a high pressure (HP)
pump, rail, injector and electronics. Caterpillar’s broad experience ______ electronically controlled
engines, range of product lines and in-house design and analysis expertise allow ______ a unique
system approach. All components are developed ______ Caterpillar design control.
In addition, Caterpillar’s expertise ______ electronics is a major asset to the Cat Common
Rail technology.
Safety considerations and high customer value were the main focus throughout the
development, resulting ______ a state-of-the-art design ______ the following features:
- two high pressure pumps ______ redundancy;
- double-walled lines and rails;
- redundant speed pick-ups;
- pressure sensors;
- a safety gear between pump and engine;
- a pressure relief valve;
- flow limiters.
Two high pressure pumps deliver the required amount ______ fuel ______ the rail and
provide the desired rail pressure in closed loop control. The pump itself is based ______ a proven
design and has been modified ______ HFO operation. By having two pumps ______ all in-line
engines the amount ______ HP connections and components is reduced and thus increases
reliability. The inlet metering control ______ the pump ensures a high pump efficiency.
The double-walled rails are pressurized and act ______ an accumulator, with one rail
segment feeding fuel ______ three injectors, i.e., a nine-cylinder engine has only three rail
segments, an eight-cylinder engine has two rail segments, each feeding four injectors. This layout
reduces the number ______ parts and the number ______ high-pressure connections. Flow limiters
prevent the cylinders ______ over-fueling; a safety valve acts ______ pressure relief ______ case
______ an unwanted over-pressurized rail.
Injector Caterpillar has chosen a simple and robust approach ______ using the actual fuel
______ control fluid, thereby eliminating the need ______ a separate control fluid system. The
injector nozzle is cooled ______ lube oil, a typical feature ______ heavy fuel operation. For the Cat
CR injector, the lube oil circuit has been extended to provide cooling ______ the electrical
components within the injector, thereby increasing the lifetime. The injector design is simple, robust
and compact; the key features are:
- electronically controlled;
- flexible injection timing and duration;
- capability ______ multi shot injections.
The key component is the Caterpillar A4E4 (or ADEM™) Electronic Control Module
(ECM). The ECM acts ______ the brain ______ the Cat Common Rail fuel system. Pioneered
______ Caterpillar 20 years ago, the ADEM™ controller coordinates and enhances fuel delivery, air
supply and other engine functions to maximize overall performance and reduce emissions output.
Having in-house expertise ______ core electronic components and software puts Caterpillar
in a unique position and allows ______ an advantageous systems approach.
Based ______ existing software and engine control strategies, the specific needs ______
heavy fuel burning engines and applications can be easily adopted. Depending ______ engine type,
application and boundary conditions, a tailor-made version allows ______ optimal operation.
The engine protection system operates independently ______ the engine control system and
has its own independent sensor equipment. This ensures that engine operation is monitored
independently ______ other control systems.
The ECM functions can be divided ______ a core system and a performance system.
The core system consists ______ a control device A4E4, one crankshaft speed pick-up, two
camshaft speed pick-ups, two high-pressure sensors, inlet metering valve and injector drivers.
 The performance system ensures optimal engine settings ______ all operating conditions,
using information like exhaust gas temperature, charge air pressure, ambient conditions and lube oil
temperature.

• Complete the chart below answering the questions.

What are the components

of CaT CRS?
What safety devices are
used in the system?
What is HPP purpose?

What type of fuel has the

HPP been modified for?
What is the purpose of the
inlet metering control?
What are HPP key
features?
What is the purpose of the
rail?
How many injectors are
fed by one rail segment?
What is the purpose of the
flow limiter?
What is the purpose of the
safety valves?
Is there a separate control
fluid system?
What do you know about
injector itself?
What is the purpose of the
ECM?
 SPEAKING COMPETENCY DEMONSTRATION
Marine diesel engine development history
List of questions

• 1Comparison of 2-stroke vs 4-stroke engines: maintenance, parts, valve mechanism, energy

efficiency, lubrication, power, cost, weight, etc.
• 2Comparison of Diesel’s and Otto’s engines: energy efficiency, cost, maintenance, common
faults, parts, means of combustion.
• 3Wartsila dual-fuel engine: working operation, energy efficiency, maintenance, common
faults, parts, fuel types.
• 4The dual combustion cycle: operations, peculiarities, application, energy efficiency,
comparison of diesel cycle and dual cycle.
• 5Pollutants: regulations addressing them, abatement technologies.
• 6Gas engines: peculiarities, application, energy efficiency, maintenance, parts, cost.
• 7Combustion process: combustion elements, fuels on board, ignition sources, flashpoint, fire
point, self-ignition temperature, atomization, turbulence, penetration.
• 8Dual-fuel engines: modes of operation, safety devices, maintenance, operational
requirements, emissions, common faults.
• 9Comparison of 2-stroke vs 4-stroke DF engines: combustion cycles, parts, operation,
maintenance, energy efficiency, safety devices, lubrication, power, cost, weight, etc.
• 1ME-GI fuel and ME-LGI fuel types: delivery condition, supply pressure, supply
temperature, fuels characteristics.
• 11MAN L35/44DF: operation, maintenance, fuel types, parts, energy efficiency, advantages,
challenges, compliance.
• 12Energy efficiency: innovative technologies, requirements, compliant engines, future
perspectives.
• 13Slow steaming: modes of operation, application, benefits, challenges, fuel consumption,
emissions.
• 14CRS: operation, maintenance, parts, benefits, challenges, operational characteristics.
• 15Engines with Cat CR: operation, energy efficiency, benefits, challenges, maintenance, fuel
types, parts, safety devices, emissions.