Beruflich Dokumente
Kultur Dokumente
According to “The 35th Issue of Production Trends of Marine Engine in Each Country” issued by Japan
Marine Equipment Association in August, 2010, the total amount of ships (over 100GT) newly
constructed in the whole world in 2009 was 3,554 ships in number and 77,072,507 GT in gross tonnage.
The number increased by 312 ships and the gross tonnage increased by 9,382,684 GT from the
respective figures of the previous year.
If the above amount is examined by each country, the new tonnage built in Japan was 18,972,278 GT,
which increased by 316,126 GT (1.7 %) from 18,656,152 GT of the previous year and occupied 24.6 %
(27.6 % in the previous year) in the total new tonnage constructed in the world. The tonnage newly built
in Korea was 28,848,797 GT which increased by 2,470,189 GT (9.4%) from 26,378,608 GT in the
previous year and occupied 37.4 % (39.0 % in the previous year) in the total tonnage newly built in the
world. Korea was followed by China which ranked 2nd place and newly constructed 21,969,189 GT.
Japan ranked 3rd place. These 3 countries were followed by Germany which constructed 780,809 GT,
and further followed by Rumania, Italy, Turkey, Formosa, Croatia and Poland in order of description.
(Table 2.1-1)
If the above amount is categorized by a type of ship (over 1,000GT), the oil tankers were 371 ships or
21,453,980 GT, which increased by 44.2 % in GT in comparison with the gross tonnage of the previous
year. The bulk carriers were 535 ships or 22,691,944 GT which increased by 74.4 % in GT. The general
cargo ships were 463 ship or 7,369,832 GT which decreased by 3.3 %, the container ships were 270 ships
or 11,474,651 GT which decreased by 29.3 %, the liquefied gas carrier and chemical tankers were 497
ships or 11,786,280 GT which decreased by 17.5 % and the fishing ships were 15 ships or 31,734 GT
which increased by 22.5 %. (Table 2.1-2)
The merchant ships of more than 2,000DWT newly built in 2009 in the world were 2,272 ships in
number or 113,131,225DWT, which respectively increased by 221 ships in number and by
23,536,275DWT in tonnage from the previous year. Looking at the actual construction result of these
ships by every kind of main engine, the diesel ships were 2,260 ships or 112,194,807DWT, which
increased by 230 ships in number or by 24,264,687DWT in tonnage from the previous year. Also, the
average tonnage equipped with diesel engine among the merchant ships of more than 2,000DWT newly
built within 2009 was 49,644DWT which increased by 6,328DWT from the previous year. However, the
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output of main engine per ship was 12,356kW which deceased by 744kW from the previous year.
The diesel main engines installed on board the merchant ships of more than 2,000 DWT in newly
completed in the world in 2009 were 2,869 units or 27,925,251kW. In comparison with the respective
figures of the previous year, the number increased by 619 units and the output increased by 1,331,240
kW.
If the above results are classified by each country which produced the main engine, Korea produced 585
units or 10,599,882 kW, which increased by 58 units in number and decreased by 206,546 kW in output
(98.1 % against the figure of the previous year) respectively from the previous year, and its production
share was 38.0 % in output which was the first place in the world. The next place was occupied by China
which produced 913 units or 7,185,962 kW that respectively increased by 223 units in number or by
1,316,862 kW (122.4 % against the figure of the previous year) in output, and its production share was
25.7 %. The above two countries were followed by Japan which produced 477 units and 5,297,146 kW
(95.0 % against the figure of the previous year) and ranked 3rd place. The above 3 countries occupied
82.7 % of the total world production. Further, Germany ranked 4th place followed by Rumania occupied
5th place. (Table2.1-3) The actual production results of 2 stroke engines in 2009 were 1,425 units or
22,025,949 kW (97.1 % against the figure of the previous year), and also, the production results of 4
stroke engines were 1,436 units or 5,869,864 kW (134.0 % against the figure of the previous year).
As regards 2 stroke engines among these engines, MAN-B&W was 1,238 units or 18,440,385 kW, which
respectively increased by 128 units in number or 1,088,096 kW in output (106.3 % against the figure of
the previous year), and its share was 83.7 % that was the increase of 7.2 point in comparison with the
point of the previous year.
Wartsila was 94 units or 2,757,804 kW which decreased by 28 units in number or by 1,608,576 kW in
output respectively from the figures of the previous year. Its share was 12.5 % which decreased by 6.7
point from the previous year. Mitsubishi UE was 93 units or 827,760 kW, which decreased by 12 units in
number or by 143,278 kW in output respectively from the figures of the previous year. Its share was
3.8 % which decreased by 0.5 point from the previous year. (Table 2.1-4)
As for 4 stroke engine, the first place was occupied by Wartsila the production result of which was 285
units or 1,884,728 kW that increased by 84 units in number or by 168,845 kW in output, and its share
was 32.1 %.
Wartsila was followed by MAK as 2nd ranking the production result of which was 255 units or 1,140,752
kW that increased by 28 units or by 8,580 kW respectively from the figures of the previous year. The
share of MAK was 19.4 %. The 3rd place was occupied by MAN which produced 175 units or 1,024,747
kW. Further, MAN was followed by Caterpillar, Bergen and Chinese STD Type I in order of description.
(table 2.1-5)
Table 2.1-2 Newly built tonnage of each country categorized by types of ship (2009)
Oil tankers Bulk carriers General cargo ships Container Vessels
Country
ships GT ships GT ships GT ships GT
1 South Korea 120 9,661,361 53 4,115,186 11 528,742 108 6,539,042
2 China 143 6,916,293 250 9,187,072 177 1,758,181 86 2,166,799
3 Japan 85 4,647,994 190 8,426,238 95 2,854,835 26 1,124,253
4 Germany 2 29,994 2 40,468 12 336,689 18 311,272
5 Italy 0 0 0 0 9 536,645 0 0
6 Turkey 1 1,539 1 10,000 10 45,259 3 28,167
7 Taiwan 0 0 0 0 0 0 11 472,202
8 Poland 0 0 0 0 14 181,781 3 84,687
Others 20 196,799 39 912,980 135 1,127,700 15 748,229
Total 371 21,453,980 535 22,691,944 463 7,369,832 270 11,474,651
Liquefied gas carriers,
Chemical tankers
Fishing boats Others Total
Country
ships GT ships GT ships GT ships GT
1 South Korea 213 7,544,590 0 0 12 457,763 517 28,846,684
2 China 106 1,448,627 0 0 178 431,937 940 21,908,909
3 Japan 79 1,858,887 0 0 7 17,070 482 18,929,277
4 Germany 2 27,757 1 1,981 9 32,119 46 780,280
5 Italy 1 3,836 0 0 4 10,424 14 550,905
6 Turkey 64 369,700 1 2,751 10 40,217 90 497,633
7 Taiwan 0 0 2 2,200 0 0 13 474,402
8 Poland 1 7,833 0 0 13 76,265 31 350,566
Others 31 525,050 11 24,802 209 854,622 460 4,390,182
Total 497 11,786,280 15 31,734 442 1,920,417 2,593 76,728,838
Table 2.1-3 Diesel engine production results of each country (completed in 2009)
Production Previous year Fraction Share
Country
Units Output(kW) Units Output(kW) (%) (%)
1 South Korea 585 10,599,882 527 10,806,428 98.1 38.0
2 China 913 7,185,962 690 5,869,100 122.4 25.7
3 Japan 477 5,297,146 480 5,576,084 95.0 19.0
4 Germany 58 527,624 86 1,026,003 51.4 1.9
5 Rumania 92 516,450 24 295,757 174.6 1.8
6 Italy 45 421,277 44 655,549 64.3 1.5
7 Taiwan 10 353,647 1.3
8 Turkey 103 343,156 98 378,214 90.7 1.2
9 Philippines 16 309,097 16 178,382 173.3 1.1
10 Poland 53 299,867 23 259,228 115.7 1.1
Others 517 2,071,143 262 1,549,266 133.7 7.4
Total 2,869 27,925,251 2,250 26,594,011 105.0 100.0
Table 2.1-4 Diesel engine production results of each brand (in 2009) 2-stroke engines
Production Previous year Fraction Share
Brand
Units Output(kW) Output(kW) (%) (%)
MAN-B&W 1,238 18,440,385 17,352,289 6.3 83.7
SULZER 94 2,757,804 4,366,380 -36.8 12.5
Mitsubishi UE 93 827,760 971,038 -14.8 3.8
Total 1,425 22,025,949 22,689,707 -2.9 100.0
Table 2.1-5 Diesel engine production results of each brand (in 2009) 4-stroke engines
Production Previous year Fraction Share
Brand
Units Output(kW) Output(kW) (%) (%)
WARTSILA 285 1,884,728 1,715,883 9.8 32.1
MAK 255 1,140,752 1,132,172 0.8 19.4
MAN 175 1,024,747 703,544 45.7 17.5
CATERPILLAR 205 514,689 12,925 3882.1 8.8
BERGEN 100 432,497 0 7.4
CHINEESE STD.TYPE 105 196,879 196,084 0.4 3.4
YANMAR 75 172,506 139,758 23.4 2.9
DAIHATSU 54 131,699 168,674 -21.9 2.2
CUMMINS 58 84,190 16,110 422.6 1.4
HANSHIN 33 83,373 115,353 -27.7 1.4
Others 91 203,804 179,244 13.7 3.5
Total 1436 5,869,864 4,379,747 34.0 100.0
This diesel test engine is 2 cycle electronically controlled engine having 50cm of cylinder diameter which
is same in size as the actual engine, and therefore, the test can be conducted under the same conditions
as the actual engine. It started the first running in July, 2010, and the performance in fully loaded
conditions was verified in the end of August. Since then, the change test of electronic control to reduce
NOx and water emulsified fuel test etc. have been carried out. In addition to the NOx reduction
apparatus originally developed, the verification of engine performance and characteristic of exhaust gas
will be further conducted with the verification of the performance of NOx reduction apparatus and the
development of environmental measures will be prompted.
On the other hand, as the joint development works with Kawasaki Kisen Kaisha Ltd., KHI installed the
water emulsified fuel supply system originally developed for the newbuilding bulk carrier of 58,000
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DWT and carried out the sea trials during the period between December, 2010 and January, 2011. From
now on KHI will carry out the long term onboard operation test and they will pursue that the water
emulsified fuel technology will be practically used as one of efficient technologies to clear the 3rd
regulation of IMO.
(2) The remarkable engine produced in 2010;
In 2010, KHI produced a port sided type engine (port design) 7L70ME-C8 in which the right and left are
arranged conversely against the arrangement of ordinary engine. In case of the main engine of the ship
equipped with single engine and single propeller, the exhaust manifold is usually arranged on starboard
side of ship, however, it is arranged on portside of ship in case of this engine. This ship is a RO/RO ship
and has been built in special consideration of client’s desire that the ship’s exhaust system should be
arranged on portside which is most remote from wharf upon berthing of the ship. Also, the technology
called TES (Thermal Efficiency System) was adopted for this engine. This is the system that the exhaust
gas needed for turbo-charging is controlled under the application of the highly efficient turbochargers
and the surplus exhaust gas by-passes the turbochargers and the said gas is led to exhaust pipe of hull
to recover the exhaust heat in order that the heat efficiency of whole ship can be elevated. The opening
motion of the by-pass valve is automatically controlled by ECS (Engine Control System) of main engine
in compliance with the operation conditions. The appearance of this engine is shown in Fig. 2.2-3.
Heavy Industries, Ltd. The production number in 2010 is 22 units, and 30 units have been so far
produced since the operation of the first unit started in February, 2009, and further, 18 units have been
under operation. 9 units out of the above are equipped with electronically controlled lubrication system
(ECL timing lubrication system). This system makes it possible to substantially reduce the consumption
of cylinder oil by the most suited lubrication timing by the use of electronic control.
UEC45LSE type engine has been developed as a substitute engine for UEC52LA type engine, and the
length over all is about 19 % shorter than 6UEC52LA and it enables the increase of cargo space. Further,
the weight of engine has been lightened about 18 % (195ton / 6 cylinder engine), and therefore, mono
block forwarding and mono block installation have become more easy. If the engine is evaluated from
structural point of view, the number of fastening bolt for cylinder cover and exhaust gas valve casing has
been reduced in comparison with the conventional kinds of engine. Also, it has been made pipe-less by
processing the oil passage within cam shaft casing in which the piping such as supply pipe of exhaust
valve hydraulic oil and lubrication pipe of cam shaft bearing etc. are arranged. These devices contribute
to the reduction of man hours of maintenance works. The cam shaft casing is solidly structured in
engine frame made from cast iron, and so, the structure has become compact.
As for the production numbers of LA/LS type engine, each one unit of UEC45/52/60LA has been
produced, and the production of LA/LS type engine is planned to be discontinued at the end of 2010. In
the matter of the total production number of LA/LS type engine, 45LA type is 151 units, 52LA/LS type is
284 units and 60LA/LS type is 144 units. The core of engine production will be LSII type and LSE type
from now on.
(2) The production results in 2010;
The production results of Kobe Diesel in 2010 are described in table 2.2-3 .
consideration of countermeasure against the 3rd regulation to be applied in 2016, and therefore, this is
really the environmental diesel engine of next generation type that excels in economical performance.
(b) DU developed the timing cylinder lubricating system of electronic type DU-TLS (DU-Timing
Lubricating System) for low speed 2 stroke marine main engine.
This lubricating system is the system in which the lubricating pump is hydraulically driven instead of
conventional mechanical driving and the suitable and proper quantity of lubrication becomes possible at
the fixed timing of crank angle, and this system is effective in enabling the improvement of sliding
condition of ring / liner and the reduction of cylinder oil consumption. (Refer to Fig. 2.2-9 & Fig. 2.2-10)
The shop test completed without problem in July, 2010 and the mechanical lubricating system of
RTA48T engine installed on the existing ship was replaced by DU-TSL, and then, the field test started
in March, 2011 and the system and engine have been under operation in good condition up to the
present.
(c) DU has endeavored to make better piston ring with a view to improving the seizure resistance and
abrasion resistance upon decrease of lubrication ratio, and as a result, in cooperation with IHI they were
successful in the development of the new spray-coated ring of next generation which is more superior in
seizure resistance and abrasion resistance to the existing spray-coated ring presently used by DU. This
new spray-coated ring was tested at shop at the same time together with the test of new lubricating
system (DU-TLS) and satisfactory result was obtained. After the affirmation of the above result, they
have started the field test on the aforesaid engine from March, 2011.
(2) The production results in 2010;
The production results of marine engine of DU in 2010 are as per Table 2.2-9. Among 26 units of 2 cycle
engine produced by DU, flex engine is 21 units and more than 80 % is occupied by electronically
controlled engine.
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In 2010, Hitachi Zosen completed demonstration tests on single cylinder engine and then they installed
SCR apparatus on the multi-cylinder engine as the next step. Fig. 2.2-14 shows the appearance of the
multi-cylinder engine on which SCR apparatus has been installed.
From the beginning of 2011, they have carried out the onshore demonstration test on the multi-cylinder
engine, and then, they now plan to install it on the actual ship to conduct the demonstration test on
the ship actually in operation from the 2nd half of 2011.
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The electronically controlled engines produced in 2010 are 9 units in total consisting of MAN B&W type
and Wartsila type, and the total of units has gradually increased. Also, the number of units produced in
a year was most after the production works was transferred to Ariake.
of IMO.
Makita has newly adopted COL (Controlled Oil Level) for the seal device of exhaust valve and the
improvement of seal performance has been pursued.
50cm of bore as the major kinds of engine produced by MES and it is the most modern type 2 cycle
electronically controlled engine of 4 cylinders, on which the various kind of test can be conducted under
the same conditions as the actual engine.
After the installation of test engine, the necessary performance of engine has been verified by starting
and test running. Further, by the use of this test engine, they will advance from now on the development
and optimization of THS (Turbo Hydraulic System) and EGS (Exhaust Gas Separation System) that are
their original technologies of reduction of fuel consumption, and SCR and EGR (Exhaust Gas
Recirculation) that are the environmentally-friendly technologies.
VLCC and VLOC. And they fixed the most optimum specifications for VLOC of 225,000 ~ 330,000 dwt
class and VLCC of 300,000 dwt class on the basis of the results of thorough market research, and they
fed back the know-how and field data accumulated throughout the experiences of past UE engines and
applied at the same time the most update energy-saving and environmentally-friendly technologies and
the improvement of maintenance performance, and as a result, MHI has been able to produce the
realizable specifications of engine. Further, by application of the UE electronically controlled engine
UEC-Eco having the excellent actual operation results, this engine has enabled the establishment of low
fuel consumption in which MHI surpasses other competitors even in case of application of the 2nd
regulation of IMO-NOx, and this engine will satisfactorily respond to the market needs as the engine
that will have further advanced the special features of UE engine well received by the clients, such as
high reliability, highly economical performance and highly environmental adaptability.
Also, the electronically controlled engine UEC Eco-Engine has been accumulating the satisfactory
operation results during more than 5 years, since the first unit of this engine went into operation in June,
2005 as the main engine of car carrier, and the necessary inspections were respectively carried out
during the 1st dock in February, 2008 and during the 2nd dock in June, 2010, and the engine has been
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(b) RT engine: The electronically controlled engine RT-flex96C which has a number of the actual results
as the main engine of large container ship has been under continuous construction.
of the Miller cycle system for which Miller type cam and high pressure ratio turbocharger are combined.
2) In relation to the use of heavy oil of low quality, Yanmar has been successful in the substantial
extension of maintenance interval and life of parts by application of stain control technology of the inside
of combustion chamber and by adoption of the application that is resistant to stain.
3) Yanmar has secured the enough maintenance space by optimization of arrangement of fitting
machinery of engine and developed the structure which assembling and decomposition are easy.
4) With the application of high output・modularization of parts, and re-examination of structure etc.
Yanmar has reduced the weight of engine by about 10 % in comparison with the conventional types of
their engines and reduced the space for the engine installation by about 17 % and expanded the freedom
of layout in engine room.
5) They have adopted PF type fuel injection pump in which pump itself and driving part are separately
structured, and at the same time, they painted special carbon coating on plunger by which the
adaptability to low sulfur fuel could be improved.
6) They reduced the use of the environmentally hazardous substances by the standard application of
mercury-less digital exhaust thermometer that excels at visual recognizability and Pb free metal for
which any lead is not used.
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2.3.1 Turbocharger;
2.3.1.1 Kawasaki Heavy Industries, Ltd. (“KHI”);
KHI produced total 36 units of turbocharger in 2010 under the technical cooperation with MAN Diesel
& Turbo SE in Germany. All turbochargers produced by KHI were installed on the large marine engines
made by themselves with more than 460mm cylinder diameter. The details are shown in Table 2.3-1.
TCA turbocharger that is the newest type has been now replacing NA type. Further, it is considered that
this tendency will become more remarkable in future.
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IHI has developed AT23 type turbocharger (Fig. 2.3-1) which is further smaller than AT14 type
turbocharger favored by the good results as the turbochargers specialized for marine main engine, and
medium / high speed diesel engine for auxiliary machinery and which covers the class of 270~750kW,
and TSU delivered 8 units of them to their clients.
Also, among the A100-M series (Maximum pressure ratio: 5.8) of next generation turbocharger for 4
stroke engines developed by ABB, A140-M was introduced in Japan for the first time in the previous
year, and further, A130-M and A135-M have been domestically delivered in 2010 in addition to A140-M.
As for these applications, the application of compressor’s pressure ratio exceeding 5 has appeared and it
has contributed to clearing the Tier 2 regulation of IMO. It is anticipated that the application of high
pressure ratio will further increase in order to comply with the environmental regulation and to improve
fuel consumption ratio in future.
On the other hand, in the matter of turbocharger for 2 stroke engines, since December, 2007 TSU has
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carried out the field test of turbocharger (TPL65) equipped with VTG (Fig. 2.3-2) for marine main engine,
and they conducted overhauling inspection in May, 2010, when 11,060 hours running operation had
completed, and they made sure of the turbocharger’s capacity that could be further operated during the
time of more than 10,000 hours under the low quality oil being fired. VTG may be fitted to the next
generation turbocharger A100-L as an optional selection, which can contribute to improvement of
performance under partial loading. The turbocharger equipped with VTG has been well received by the
clients as the environmentally friendly system that contributes to energy-saving and reduction of GHG,
and ABB, the developer of the system, has already received the orders of 18 units, and further spread of
system will be much expected in future.
In 2011, MES has also received the orders of VTA for main engine of newbuilding ship. In future MES
plans to enlarge the sales market of this technology as one of technologies expected to contribute to the
improvement of fuel consumption with a view to applying not only for newbuildings but also for the
existing ships under operation. Finally, the production number of TCA turbocharger in 2010 is shown as
follows;
MHI and Hyundai Heavy Industries Co., Ltd. (Korea), for which the technical cooperation has been
provided by MHI, produced total 1,754 units of MET type turbocharger in 2010. Among those, the
number of radial turbine turbocharger METI8SRC type for small type 4 cycle engine produced by
Doosan Engine, which has become the second licensee, has accounted for 988 units that has greatly
increased from 720 units of the previous year.
On the other hand, as regards large axial-flow turbine turbocharger, 660 units were produced and the
number reduced from 781 units of the previous year.
Also, MHI produced the total 22 units of 3 kinds of power turbine, MPT33A, MPT42A, MPT53A, for
exhaust heat recovery driven by gas by-passed from 2 cycle low speed engine. Any of them is used for
marine exhaust heat recovery system to drive generator in combination with steam turbine driven by
steam generated in exhaust gas boiler. Among them, MPT33A and MPT42A are combined with steam
turbine of MHI make, and this combined system is called MERS (Mitsubishi Energy Recovery System)
and has been watched with keenest interest by many ship-owners. Fig. 2.3-4 shows the generation
apparatus for exhaust heat recovery system combined with steam turbine.
Fig. 2.3-4 Waste heat recovery system with MPT42A power turbine
MHI produced the first unit of MET66MB of MET-MB series of axial-flow turbine turbocharger of high
pressure ratio that had been developed for obtaining the high scavenging pressure demanded by the
turbocharger for engine conformable to the 2nd regulation of NOx, and it was installed on the engine,
and then, the matching operation was carried out. The pressure ratio of compressor reached to 4.5 and
satisfied the turbocharger efficiency demanded by the engine.
MHI completed the production of the first marine unit of MET83MAG of hybrid turbocharger
containing generator within itself which MHI had started the development from 2008 and installed it on
2 cycle slow speed engine of 7S65ME-C type. This is what the permanent magnetic type synchronous
generator of maximum output of 550kW has been directly connected to rotor shaft of large sized
turbocharger MET83MA and generator has been placed within silencer of turbocharger. This is different
from power turbine, and the power is generated by use of a part of exhaust gas power changed in
turbocharger turbine and this power can fully cover all demand of electric power within the ship. The
onshore operation of the engine was carried out at the end of 2010 and the expected generation and
performance of turbocharger was verified. Fig. 2.3-5 shows the hybrid turbocharger under single unit
operation. The large sized bulk carrier installed this turbocharger is scheduled to go into operation
within 2011.
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MHI developed the variable capacity turbine for large axial-flow turbine turbocharger. This is called VTI
(Variable Turbine Inlet), and the turbine capacity can be alternatively changed into 2 stages, small and
big, by opening and closing the valve fitted on casing at the gas inlet. Although the variable stages are
limited to 2 stages and the continuous variation is not possible in case of this method in comparison with
the variable method of other firms which can change the equivalent area of turbine by making turbine
nozzle rotate, it is meritorious that the structure is simple and the maintenance is easy. And further, the
retrofit demand may be expected for the existing ship under operation, since it is possible to make the
turbine variable only by replacement of the inside casing with nozzle ring at gas inlet. Fig. 2.3-6 shows
the appearance of the turbocharger fitted VTI turbine.
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Servo-valve
Stroke sensor
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