MAN B&W Diesel

Turning visions into tailormade solutions

1 © MAN B&W Diesel Aktiengesellschaft, Augsburg

The MAN B&W Diesel engine

Engineering
the Future

2 © MAN B&W Diesel Aktiengesellschaft, Augsburg

The large-bore
medium-speed engine family
Technically convincing and successful around the globe
in the power range of between 2 300 and 18 900 kW

Products
3 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Technical data
Engine typed 32/40 40/54 40/50 48/60 58/64

Cylinder bore 320 400 400 480 580

[mm]
Piston stroke 400 540 500 600 640
[mm]
No. of 5, 6, 7, 8, 9 6, 7, 8, 9 12, 14, 16, 6, 7, 8, 9 6, 7, 8, 9
Cylinders d 12, 14, 16, 18 18, 20 12, 14, 16, 18
Cylinder 480 720/700 750 1 050 1 390
output [kW]

Speed [rpm] a 750/720 550/514/500 600 514/500 428/400

Mean piston 10.0/9.6 9.9/9.25/9.0 10.0 10.3/10.0 9.1/8.5

speed [m/s]
Mean effect. 23.9/24.9 23.1/24.8/24.8 23.9 22.6/23.2 23.0/23.0
pressure [bar]d
Fuel cons. L: 181 L: 180
181 179 176
85% MCR [g/kWh] V: 180 V:179

Products
4 © MAN B&W Diesel Aktiengesellschaft, Augsburg
9L32/40 four-stroke engine
Output: 4 320 kW at 720/750 rpm

32/40 Products
5 © MAN B&W Diesel Aktiengesellschaft, Augsburg
12V32/40 four-stroke engine
Output: 5 760 kW at 720/750 rpm

32/40 Products
6 © MAN B&W Diesel Aktiengesellschaft, Augsburg
12V32/40 genset
for offshore application
Resilient engine mounting on base frame

32/40 Products
7 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Application

8 © MAN B&W Diesel Aktiengesellschaft, Augsburg

Propulsion plant with 6L32/40
Main dimensions

32/40 Application
9 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Propulsion package
for a container vessel with an 8L32/40 four-stroke engine

32/40 Application
10 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Propulsion plant
Arrangement with 2 x 6L32/40

32/40 Application
11 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Diesel-electric propulsion plant
for a tanker with 4 x 9L32/40 four-stroke engines

32/40 Application
12 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Power generation
with L+V32/40 four-stroke engines

with 32/40 in-line engines with 32/40 Vee-type engines

32/40 Application
13 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Power barge
Comprising of 6 x 18V32/40 four-stroke engines
Aggregate output: 52 MW

32/40 Application
14 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Power barge
Comprising of 6 x 18V32/40 four-stroke engines
Aggregate output: 52 MW

32/40 Application
15 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Design

16 © MAN B&W Diesel Aktiengesellschaft, Augsburg

32/40 cross sections

32/40 Design
17 © MAN B&W Diesel Aktiengesellschaft, Augsburg
L32/40 engine frame
Features

n High component safety

(extended main bearing and
cylinder cover bolts)

n High rigidity results in optimum

support of the bearing shells
and thus a long service life

n No cooling water in the frame

thus eliminating the risk of
water in the lube oil

32/40 Design
18 © MAN B&W Diesel Aktiengesellschaft, Augsburg
V32/40 engine frame
Features

n High component safety

(extended main bearing and
cylinder cover bolts)

n High rigidity results in optimum

support of the bearing shells
and thus a long service life

n No cooling water in the frame

thus eliminating the risk of
water in the lube oil

32/40 Design
19 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 cylinder liner
Features

n Optimised cooling

n low deformation design

n Fire ring and stepped piston

prevent bore polishing

32/40 Design
20 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 cylinder liner
with backing ring

32/40 Design
21 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Cylinder liner
Comparison of new cylinder liner with fire ring
and standard cylinder liner

with fire ring standard version

Design
22 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 improved combustion
chamber geometry
Unhindered atomisation of the injection jet, leading to:

n Improved fuel air

mixture
n Less combustion
residues (reduced
soot formation)
n Reduced fuel
New concept Series
consumption

32/40 Design
23 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Cylinder liner
Installation of a fire ring

n Precludes, in connection
with the stepped piston,
the so-called bore polishing

Design
24 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 cylinder head
Features

n Easy to maintain (only four

cylinder cover bolts)

n Low fuel consumption by

favourable flow conditions of
the exhaust gas and charge air
ducts

n Long TBO's of valves due to

small thermal deformation of
the bore-cooled lower part of
the cylinder head

32/40 Design
25 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 new cylinder head

32/40 Design
26 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 fuel injection valve
Features

n Good atomisation
results in low fuel
consumption and
minimised soot
formation

32/40 Design
27 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 new design
of injection nozzles
Improved atomisation, particularly under part load and
reduction of the sack hole volume, leading to:

n Reduced soot
formation
n Reduced fuel
consumption

32/40 Design
28 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 fuel injection pump
Features

n Low fuel consumption

by optimised injection
intensity

n Low wear by
dimensionally stable
monoblock design

32/40 Design
29 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Exhaust valve
Tangential velocity of exhaust valves at seat with
propeller-type rotating device

Design
30 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 exhaust valve
Features

n Long TBO's by
armouring of valve
seats and cooled
seat rings

n Maintenance-free
rotating device

32/40 Design
31 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 stepped piston
Features

n Step in the piston crown precludes,

in connection with fire ring,
combustion residue deposits
- no cylinder liner polishing
- low lube oil consumption
n High component safety on the basis
of conception-relevant low thermal
and mechanical stress
n Dimensional stability results in a
constantly low lube oil consumption
n Long service life of the piston rings

32/40 Design
32 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 stepped piston
Installation of piston using the tapered sleeve

32/40 Design
33 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 connecting rod
Features

n Crankpin bearing remains

closed when piston is removed

n Dimensionally stable bearing

ensures optimum performance
and long service life of bearings

n Low piston removal height

32/40 Design
34 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 camshaft drive
Our concept: separate camshafts for
injection valve timing
Advantage of the
concept:

If required, the
injection timing
and the valve
timing can be
influenced by the
installation of
adjustment
devices.

32/40 Design
35 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 turbocharging
Constant pressure turbocharging system

n High-efficiency
MAN B&W turbo-
charger
n Optimised charge
renewal
n Good combustion
even at low load
n Easy to maintain

32/40 Design
36 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 optimised turbocharger
Steps of improvement

n 1. Step
New bearing
concept
n 2. Step
Modified curbine
geometry
n 3. Step
New developed
compressor and
turbine geometry

32/40 Design
37 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 optimised turbocharger
Modifications and improvements to the design, leading to:

n Higher turbocharger
efficiency

n Better adaptation
for part load
applications

32/40 Design
38 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 resilient mounting

32/40 Design
39 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 resilient mounting
Structure-borne sound velocity in vertical direction on 9L32/40

32/40 Design
40 © MAN B&W Diesel Aktiengesellschaft, Augsburg
L32/40 Diesel genset
with engine resiliently mounted on base frame

n Very light
frame (only
static loads)

n Very low
vibration level
at engine and
generator
(engine-excited
vibrations are
dampened)

32/40 Design
41 © MAN B&W Diesel Aktiengesellschaft, Augsburg
V32/40 Diesel genset
One-part foundation
1

4
5 2 7
6

1) 12V32/40 engine
2) steel frame
3) flywheel/flexible coupling
4) generator
5) rubber elements

32/40 Design
6) foundation
7) turning gear

42 © MAN B&W Diesel Aktiengesellschaft, Augsburg

Maintenance

43 © MAN B&W Diesel Aktiengesellschaft, Augsburg

32/40 ease of maintenance
Time for removal of various components

Man Time (h)

Fuel injection nozzle 1 0.50

Fuel injection pump 2 0.75

Cylinder head 2 1

Piston 2 0.75

Cylinder liner 2 1

Big-end bearing 2 1

Crankshaft bearing 2 2

32/40 Maintenance
Assembly time equals time for removal
The values stated are for guidance only

44 © MAN B&W Diesel Aktiengesellschaft, Augsburg

32/40 ease of maintenance
Connection of charge-air pipe components

n Time-saving dismantling
and mounting of the
cylinder head by quick-
acting seals

32/40 Maintenance
45 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 ease of maintenance
Quick-acting couplings on the exhaust manifold

32/40 Maintenance
46 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 ease of maintenance
Redesigned rocker arm casing

n Faster nozzle
replacement
n Reduction of
weight
n Reduction of
moving parts

32/40 Maintenance
47 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 ease of maintenance
New concept of rocker arm gear

Abutment for
Thrust exhaust valves
plate
bearing
bolts

Abutment for
inlet valves

32/40 Maintenance
48 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 ease of maintenance
New concept of rocker arm gear

Exhaust valves

32/40 Maintenance
Inlet valves

49 © MAN B&W Diesel Aktiengesellschaft, Augsburg

32/40 ease of maintenance
Mounting and turning device for cylinder head unit

32/40 Maintenance
50 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 ease of maintenance
Suspension devices
for cylinder head for piston

32/40 Maintenance
51 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 ease of maintenance
Only two different types of hydraulic tools
are required for all the essential screwed connections

32/40 Maintenance
52 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 ease of maintenance
Hydraulic tools for all the essential screwed connections

32/40 Maintenance
53 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Operating

54 © MAN B&W Diesel Aktiengesellschaft, Augsburg

Low wear rates, long TBO's
L+V32/40 - HFO operation
Component Maintenance interval Service life
x 1 000 h x 1 000 h
Piston crown 20 – 30 60 – 80

First piston ring – 12 – 15

Cylinder liner 12 – 15 80 – 100

Inlet valve cone 12 – 15 30 – 40

Exhaust valve cone 12 – 15 30 – 40

Fuel pump element – 30 – 40

Fuel injection nozzle 3 6 – 10

Main/connecting rod bearing – 30 – 40

32/40 Operating
MAN B&W turbocharger bearing – 20 – 30
The figures quoted are guidelines for correct operation and maintenance Status 7/01

55 © MAN B&W Diesel Aktiengesellschaft, Augsburg

Low wear rates, long TBO's
L+V32/40 - MDO operation
Component Maintenance interval Service life
x 1 000 h x 1 000 h

Piston crown 30 – 40 60 – 80

First piston ring – 15 – 20

Cylinder liner 15 – 20 80 – 100

Inlet valve cone 15 – 20 30 – 40

Exhaust valve cone 15 – 20 30 – 40

Fuel pump element – 30 – 40

Fuel injection nozzle 3 6 – 10

Main/connecting rod bearing – 30 – 40

32/40 Operating
MAN B&W turbocharger bearing – 20 – 30
The figures quoted are guidelines for correct operation and maintenance Status 7/01

56 © MAN B&W Diesel Aktiengesellschaft, Augsburg

32/40 operating results
at constant speed

n Output MCR:
P = 480 kW/cylinder
n Mean effective pressure:
m.e.p. = 23.9 bar
n Speed:
n = 750 rpm
n Turbocharger:
MAN B&W NR 24/S resp.
NR 29/S resp. NR 34/S
n Heavy fuel:
up to 7 000 sec. Redw.

32/40 Operating
I/100°F

57 © MAN B&W Diesel Aktiengesellschaft, Augsburg

Low wear rates, long TBO's
Exhaust valve temperature for an L+V32/40 engine
developing 480 kW/cyl.

Seat temperature [°C]

Output [%]

32/40 Operating
Measuring point
58 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Low wear rates, long TBO's
Wear rate improvement

Operating
59 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Specific lube oil consumption

sloc [g/kWh]
1.5

1.0 9L32/40
9L58/64

6L48/60

7L40/54
0.5
12V48/60

0.0
0 10 000 20 000 30 000 40 000 50 000 60 000 70 000
Operating hours [h]
9L58/64 - MS "Scandinavian Reefer" in operation since 1992
6L48/60 - MS "City of Liverpool" in operation since 1991
7L40/54 - MS "Antje" in operation since Dec. 1989
12V48/60 - MT "Venita" in operation since Dec. 1993

Operating
9L32/40 - MS "Frisian Trader" in operation since 1994

60 © MAN B&W Diesel Aktiengesellschaft, Augsburg

Low wear rates, long TBO's
Chromium-ceramic coating -CKS 36-

Operating
61 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 optimised turbocharger
Improvements of the modified design

n Curve 1 and 2: approx. 5% points higher efficiency at full load operation

32/40 Operating
n Curve 3: turbocharger optimised for low-emission part load
operation
62 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 improved fuel consumption
Propeller operation

32/40 Operating
63 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 improved fuel consumption
Generator operation

32/40 Operating
64 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Excellent partial load performance
Guide values for permissible low-load operation on
heavy fuel oil below 15% power output

n Example:
n Max. permissible
period of operation on
heavy fuel at 7.5%
load is 15 hrs; there-
after change over to
Diesel fuel or
n operate engine with
at least 70% output
for about 1.2 hrs in
order to burn off
residues

Operating
Note: No limitation above 15% output

65 © MAN B&W Diesel Aktiengesellschaft, Augsburg

Economy

66 © MAN B&W Diesel Aktiengesellschaft, Augsburg

Additional cargo space...
Savings in the power house...
...resulting from the lower height of the 32/40 four-stroke engine
6 130 mm

L32/40 medium- Weight:

75 t
speed four-stroke
engine and two-
stroke long-stroke
4 015 mm
engine of similar
bore and same
output

Weight:
38 t

32/40 Economy
67 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Environment

68 © MAN B&W Diesel Aktiengesellschaft, Augsburg

Emission reduction methods

n primary - engine internal measures

n secondary - exhaust gas aftertreatment

n NOx - modifications of combustion process

- fuel water emulsion (FWE)
- direct water injection (DWI)
- humidification of intake air (HAM)
- selective catalytic reduction (SCR)

n soot, smoke - modifications of combustion process

- fuel oil quality
- FWE, filter

n SOx - reduction of sulphur content of fuel oil

- desulphurisation plant (DeSOx)

Environment
69 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Throughflow rates
in a state-of-the-art Diesel engine

Combustion gases 79% N2 Induced air

(7.68 kg/kWh) 21% O2 (7.5 kg/kWh)

99.7% 97% HC Fuel

N2, O2, CO2, H2O 3% S (180 g/kWh)

0.3%
Pollutants
(NOx, SOx, HC, CO,
97.5% HC
particles) Luboil
1.5% Ca
(0.8 g/kWh)
1% S

Environment
70 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Exhaust gas emissions

Total emissions [vol.%]

CO2 Pollutants 0.3%
6%
8.1% H2O
11.3% O2 Particulate matter
0.25

Pollutants [g/kWh]
CO 0.6
HC 1

74.3% N2 SOx 10

NOx 17

HFO [2.5% S]

Environment
Note:unregulated four-stroke Diesel engine
71 © MAN B&W Diesel Aktiengesellschaft, Augsburg
 Effect of fuel water emulsion on NOx
reduction and fuel consumption

100
NOx

[%]
80

60

40
0 20 40 [% wt.] 60
Water/fuel ratio
120
sfoc

[%]
100

80

60

Environment
0 20 40 [% wt.] 60
Water/fuel ratio
72 © MAN B&W Diesel Aktiengesellschaft, Augsburg
FWE booster module

Injection point

Two auto
flushing
valves

Homogeniser

Environment
73 © MAN B&W Diesel Aktiengesellschaft, Augsburg
HFO operation with exhaust gas
purification
DeSOx- and SCR-DeNOx systems installations

Environment
74 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Four-stroke Diesel engines
in relation to NOx limits
NOx [g/kWh]
20

18

16
former series
14
IMO series
12
IMO + FWE
10
IMO Limit SCR
8
HAM
6
with HAM DNV Clean Design
4

2
lowest Swedish regulations
0

Environment
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
Rated engine speed [rpm]
75 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 improved smoke reduction
Propeller operation

32/40 Environment
76 © MAN B&W Diesel Aktiengesellschaft, Augsburg
32/40 improved smoke reduction
Propeller operation

32/40 Environment
77 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Three multi-purpose container ships
MS "Planet", propelled by 1 x 9L32/40 four-stroke engine

Engine room arrangement

32/40 Reference
78 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Hopper suction dredger
"Ostsee", propelled by 2 x 6L32/40 four-stroke engines

Engine room arrangement

32/40 Reference
79 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Hopper suction dredger
"Ostsee", propelled by 2 x 6L32/40 four-stroke engines

Engine room
arrangement

32/40 Reference
80 © MAN B&W Diesel Aktiengesellschaft, Augsburg
Diesel and turbocharger
service worldwide

Service
81 © MAN B&W Diesel Aktiengesellschaft, Augsburg