bÇáíáçåW=gìåÉ=OMMQ=EÑçê=pÉêîáÅÉ=p~äÉëF

RT-flex March `04 / 1 / RB

RT-flex March `04 / 2 / RB
 RT-flex system
z Introduction
z The Sulzer Common Rail System
z Design Details
z The RT-flex System Benefits
z Service Experience on First Customer Engine
z RT-flex sizes / engine introduction
z Redundancy reliability safety
z Summary

RT-flex March `04 / 3 / RB

 Introduction Components

Sulzer RTA Sulzer RT-flex

(VEC device) Common Rail

platform
Exh. Valve drive
Fuel pumps
Camshaft WECS-9520
control
Reversing
servomotor
Fuel-linkage
Actuator
VIT device
Start-Air-Distr Supply
unit
Camshaft
drive

RT-flex March `04 / 4 / RB

 Introduction

Why Common Rail?

¾ Flexibility in injection and valve operation

¾ Simplified mechanical system
¾ Safety through redundancy and simplicity
¾ Higher efficiency than conventional engines
¾ Many possibilities to reduce emissions

RT-flex March `04 / 5 / RB

 Introduction Key Features RT-flex

z Common Rail for fuel and servo oil system

z Precise volumetric fuel injection control
z Control of individual fuel injection valves
z Ideal for heavy fuel oil: separation of fuel from pilot valves
z Fuel supply pumps based on Sulzer four-stroke injection pumps
z Potential for variable injection rate shaping and free selection of
injection pressure
z Stable pressure level in Common Rail and supply pipes
z All design, development and testing in-house

RT-flex March `04 / 6 / RB

 Introduction Benefits

z Smokeless operation at all operating speeds (exhaust gas boiler

cleanliness)
z Lower steady running speeds of 10 to 12 % rpm R1
z Reduced part load fuel consumption
z Reduced maintenance requirements by simpler engine setting
z Reduced maintenance cost through precise volumetric fuel
injection control leading to extendable TBO’s
z Higher availability by extended integrated monitoring
z Higher availability by redundancy in pumps, piping and
electronics.

RT-flex March `04 / 7 / RB

 The Sulzer Common Rail System

RT-flex March `04 / 8 / RB

 CR System System Arrangement

Easy Access
Rail Unit&
WECS 9520

Redundant
Servo Oil
Supply Lines

Redundant
Fuel Oil
Supply Lines Integrated Automatic
Oil Filter for fine filtration
Fuel Pump 1000bar of Servo Oil

High Efficiency
Supply Unit
Crank Angle Sensor
Servo Oil Pump 200bar on Free End Side

RT-flex March `04 / 9 / RB

 CR System Fuel System

WECS-9520
WECS-9500
Servo Supply control
control
200 bar

Volumetric
Volumetric
Cylinder
injection
injection
6 5 4 3 2 control
control

Sulzer Common Rail up to ~1000 bar

Fuel
simple
reliable High efficiency
Sulzer Common Rail Pump
flexible

RT-flex March `04 / 10 / RB

 CR System Exhaust Valve Drive

WECS-9520
WECS-9500
control
control

Cylinder Hydraulic
Hydraulic
6 5 4 3 2 Actuator
actuator

Servo Supply200
Servo Supply 200bar
bar

simple
reliable
flexible Servo oil pump

RT-flex March `04 / 11 / RB

 CR System System Overview

Exhaust valve WECS 9520 Crank

actuator angle
control
system sensor

Fuel
injectors

50µ
6µ

Exhaust valve
actuating unit

Volumetric fuel
injection control unit

up to ~1000 bar fuel HFO / MDO

200 bar servo oil and control oil

30 bar starting air

RT-flex March `04 / 12 / RB

 Design Details

RT-flex March `04 / 13 / RB

 Design Components

Sulzer RT-flex Common Rail

platform
WECS-9520
control

Supply
unit

RT-flex March `04 / 14 / RB

 Design Supply Unit

z Direct mechanical gear drive

z Generates 1000bar fuel oil

pressure with high efficiency
fuel pumps (jerk type)

z Generates 200bar servo oil

pressure with reversible oil
pumps (axial piston type)

z Pumps’ capacity ensures

redundancy in case of failure

RT-flex March `04 / 15 / RB

 Design Common Rail

Fuel Rail z Storage and distribution of fuel

oil up to ~1000 bar and 200bar
servo oil

z Built-in damping of pressure

waves by multiple orifices

z Ensures stable pressure with

simultaneous injection of 3
nozzles at full load
Servo Oil Rail
z No moving parts - no
maintenance required

RT-flex March `04 / 16 / RB

 Design Injection Control Unit

Volumetric
Injection Control Piston
z Shapes injection
pattern
Control oil side z Enables individual
operation of every
single nozzle

z Ensures precise fuel

amount injected to each
cylinder

z Provides flow out safety

of common rail

HFO side
RT-flex March `04 / 17 / RB
 Design Valve Actuator

System oil

z Hydraulic piston for valve actuation

z Separates fine filtered servo oil from

standard system oil

z Prevents flow out of servo oil rail

z Prevents dirt from entering fine filtered

oil system
Fine filtered
lubrication oil
RT-flex March `04 / 18 / RB
 Design Sulzer Rail Valve

z The Sulzer Rail Valve is a bi-stable

valve with switching time of less
than 1 ms

z Used as pilot valve for injection and

exhaust valve actuation

z Switching 200bar 6micron filtered

control oil

z Closed loop control for valve

position

RT-flex March `04 / 19 / RB

 Design WECS 9520 Functions

WECS 9520
Camshaft Control Security
Substitute
Fuel Inj. Ctrl. Load or Speed Rail Valve Fct.
dependent: Diagnosis
Exh. Valve Ctrl.
Fuel Press Ctrl. Sensor Diagnosis
Start Air Distr.
Servo Oil Ctrl. Value Supervis.

RT-flex March `04 / 20 / RB

 tb`pJVROM=`çããçå=o~áä=`çåíêçä=

RCS backup WECS-9520

Local Ctrl
CAN Bus

ECR
Service Amplifier
bVM
CAN Bus

c`jJOM
WECS
Interface, Servo Oil
Assistant
IMO tuning
hardwired Amplifier
Fuel
Ship Alarm 3x CAN Bus
System 2x SSI Shaftencoder

O=ñ=QQMs^`
RCS & Safety bVRKN bVRKO bVRKP bVRKQ bVRKR bVRKS bVRKT
System Power
c`jJOM

c`jJOM

c`jJOM

c`jJOM

c`jJOM

c`jJOM

c`jJOM
(DENIS-9) Supplies

Electronic
Speed
Controller

RT-flex March `04 / 21 / RB

jçÇìä=c`jJOM=

RT-flex March `04 / 22 / RB

 Design Installation Compatibility

z Engine foundation same as RTA

z Engine overall dimensions same

(except supply unit on A-frame side)

z Engine weight reduced by

approx. 12 tons on 7RT-flex58T-B

z Remote control interface slightly

modified from DENIS 6 to DENIS 9

z Electronic speed controller from

DENIS partner as on RTA

z Additional aux. energy approx.

1.5kW/cyl. for 60cm bore

RT-flex March `04 / 23 / RB

 The RT-flex System Benefits

RT-flex March `04 / 24 / RB

 Benefits Flexibility of Fuel Injection Pressure

Injection pressure Sulzer Common Rail System

S y stem
ec ti on
n j
al I
e n tion
v
Co n

25 50 75 100 rpm [%]

Free selectable injection pressure

for low NOx emissions, high efficiency and no smoke at all loads

RT-flex March `04 / 25 / RB

 Benefits Flexibility of Exhaust Valve Timing

Valve Timing [°CA] Sulzer Common Rail System

close

Conventional Exhaust Valve Control

open

25 50 75 100 [%] rpm

Free selectable exhaust valve timing

for high efficiency, low NOx level, smokeless operation
Special timing for emergency braking and rapid engine loading possible

RT-flex March `04 / 26 / RB

 Benefits Standard RT-flex Injection Pattern

Measured Data

Needle lift
z All injection nozzles activated
simultaneously
Cylinder pressure
z High efficiency due to quick ending of
Fuel pressure rail injection

z No significant pressure drop in common

rail during injection

z Small rail pressure fluctuations

Injection pressure

-30° 0° 30° 60°

Crank Angle [deg]

RT-flex March `04 / 27 / RB

 Benefits Wide Variety of Possible Injection Patterns

===mêÉJáåàÉÅíáçå================qêáéäÉ=áåàÉÅíáçå=========pÉèìÉåíá~ä=áåàÉÅíáçå

Needle lift

Injection pressure Cylinder pressure Fuel pressure rail

NOx Emission Reduction Possibilities

by Simple Software Tuning

RT-flex March `04 / 28 / RB

 Benefits Balanced Loads and Temperatures

Measurements on 4 cylinders at 100% load

420

T Exhaust [°C]
400
380
360
Deviation of injected

5.0
fuel quantity [%]

2.5
0.0
-2.5
-5.0
50 Engine combustion cycles 50 Engine combustion cycles
Time Controlled Volumetrically Controlled

RT-flex March `04 / 29 / RB

 Benefits RT-flex fuel consumption

Typical fuel consumption curve: RTA vs. RT-flex

RTA
[g/kWh]
dBSFC [g/kWh]

Flex
Standard-tuning
[g/kWh]

PLUS
Delta-tuning
[g/kWh]

25% 50% 75% 100%

Load [%]

RT-flex March `04 / 30 / RB

 Benefits RT-flex fuel consumption

Fuel consumption curve: RT-flex Standard vs Delta-tuning

RT-flex March `04 / 31 / RB

 Benefits Smokeless Mode

Sequential operation of injection nozzles for smokless mode and slow steaming

Sulzer RT-flex Sulzer RT-flex with Common Rail injection

Standard engine
3 nozzles-operation Alternative 2 nozzle
operation

Alternative 1 nozzle
operation

smokeless operation down to 10 to 12% rpm R1

(12rpm for 6RT-flex58T-B)

RT-flex March `04 / 32 / RB

 Benefits Smokeless Mode

Sulzer 6RT-flex58T-B MV Gypsum Centennial

Smoke measurement on combinator curve during sea trial
0.50

0.45

0.40 HFO
Filter Smoke Number [ FSN ]

380 cSt
0.35 3% sulphur
0.1% ash
0.30
ON OFF Aux. Blower
0.25

0.20
Smoke visibility limit
0.15
Conventional low speed engine
0.10

0.05
6RT-flex 58T-B with common rail
0.00
0 10 20 30 40 50 60 70 80 90 100
Engine Load [% ]

RT-flex March `04 / 33 / RB

 Service Experience on First Customer Engine

RT-flex March `04 / 34 / RB

 Experience General

The “MV Gypsum Centennial”

Gypsum Transportation Ltd.
General Statements:
with Hyundai built 6RT-flex58T-B

z More than 14’000 running hours

z Running behaviour exceeds all our
expectations for a revolutionary engine
z No real down-time besides 2 hrs
z Operators quickly got acquainted to
the system
z Owners are generally very satisfied
with engine operation.

RT-flex March `04 / 35 / RB

 Experience Improvements
Supply unit
z Fuel pumps (lubr. holes)
z Servo oil collector pipes

Rail unit
z Vibrations on upper platform
z Rail valves improved
z Accessibility of RU

RT-flex control system

z Sensor connections had to be
improved
z VDM improved (thermal stress)
z Regulating behaviour improved
(at swell and light ship)

RT-flex March `04 / 36 / RB

 Experience Full Inspection 5300Rhrs

Conventional Parts
z Very good results on liner wear

z Very good result on piston ring wear

z Very good load pattern on crankshaft

gear wheel

z Clean valve seat

z Good injection nozzle shape

RT-flex March `04 / 37 / RB

 Experience Full Inspection 5300Rhrs

RT-flex Specific Parts

z Very good load pattern on gear wheels of
supply unit
z No wear on fuel cams
z No wear on hydraulic actuator for ExVa
z No wear on crank angle sensor assembly

Injection Control Unit

z No wear on sealing surface of injection
control valve
z No wear on control oil piston
z No wear on injection control valve slide
z No wear on fuel quantity piston
z No change of wear on fuel quantity sensor
since beginning of operation
Shows absolutely same injection
pattern as when tested new
RT-flex March `04 / 38 / RB
 Experience Summary

Conclusions

z RT-flex system concept works fine

z Some “teething” problems solved

z Our feed-back concept for continuous product improvement paid off

z Crew is operating the engine without assistance since May 2002

z Complete inspection after 5300 running hours showed very low wear
figures on engine parts incl. RT-flex system
z Some components later adapted according to inspection

RT-flex March `04 / 39 / RB

 RT-flex sizes / engine introduction

RT-flex March `04 / 40 / RB

 RT-flex engines Size 0, I, II and IV

Size 0: RT-flex50
Size I: RT-flex58T-B
RT-flex60C
Size II: RT-flex68T-B
Size IV: RT-flex84T-D
RT-flex96C

RT-flex March `04 / 41 / RB

 RT-flex engines Introduction Sequence

n There will be a complete Sulzer engine program with

RT-flex technology

n Introduction sequence according to market request

(RT-flex84T-D, RT-flex68T-B, ….)
n Development and drawings will be prepared
according marked request

RT-flex March `04 / 42 / RB

 Redundancy reliability safety

RT-flex March `04 / 43 / RB

 Redundancy RT-flex96C

Fuel pumps Question:

At which engine load can the
12RT-flex96C be operated
with one or more fuel pumps
cut out and with one or more
servo oil pumps cut out.

Redundancy:
At the supply unit from the
12RT-flex96C 8 fuel pumps
are installed and 6 servo oil
pumps (please see also
the supply unit drawing).

Maximum loads for 12RT-flex96C engine with disabled fuel and

servo-oil pumps

Fuel Pumps in operation (ø 42mm) 8 7 6

Servo oil pumps % Load Possible 110 94 74

Servo-Oil Pumps in operation 6 5 Test

% Load Possible >>100 >100
RT-flex March `04 / 44 / RB
 Redundancy RT-flex96C
RT- flex specific availability (reliability) functions:
z redundancy regarding pump capacities
z Fuel pumps
z Servo oil pumps

z common functions & sensors are redundant

z double pipe
z 2 x Crankangle sensor
z 2 x bus / cabling

z cylinder related functions are single, if one fails

z only single cylinder shut off
z engine still operative with reduced load

z several emergency modes

z fuel pressure ctrl valve
z open loop control for injection & ExVa

RT-flex March `04 / 45 / RB

 Summary

RT-flex March `04 / 46 / RB

 Summary Benefits

z More balanced engine operation

by precise fuel metering
z Reduced maintenance cost owing to better
engine balancing (thermal and mechanical
loads) and extendable times between overhauls

z Reduced maintenance requirements

by simpler engine setting

z Reduced part load fuel consumption

z Flexibility to optimise fuel consumption
at actual service load in compliance with RTA
[g/kWh]

dBSFC [g/kWh]
Flex
[g/kWh]

IMO NOx limits and different fuel qualities PLUS

[g/kWh]

25% 50% 75% 100%

Load [%]
RT-flex March `04 / 47 / RB
 Summary Benefits

z Lower steady running speeds of 10 to 12% rpm of R1

0.50

0.45

0.40

0.35

z Smokeless operation 0.30

0.25

throughout entire speed range 0.20

0.15

0.10

0.05

0.00
0 10 20 30 40 50 60 70 80 90 100

z Full electronic control with integrated

monitoring functions and built-in overload
protection
z Built-in redundancy regarding rail pump and
servo oil pump capacities
z Built-in redundancy by double
supply piping, engine master controller,
crank angle sensor and bus system

RT-flex March `04 / 48 / RB