Design for Life - Bergen B33:45 diesel engine

Introducing the Bergen B33:45

A new family of medium speed diesel engines producing 600kW per cylinder maximises the integration of today’s technology to reduce operating costs.

Design goals

Developed to be more powerful and efficient as well as extending service intervals, the new Bergen B33:45 harnesses today’s technologies to the full.

  • Reduced life cycle costs was the number one design objective, which resulted in five clear goals.
  • Lowest fuel consumption and the highest power per cylinder in class
  • Dynamic/extended service intervals
  • Increased power within the same footprint
  • Compact modular design
  • Base engine suitable for liquid and gas fuel

The ship designer and shipyard can use to advantage the new engine’s compactness and ease of installation.

600kW per cylinder

The new B33:45 comes with a 20 per cent increase in power per cylinder compared with current B-series engines.

Bore is 330mm and stroke 450mm. CFD analysis of the combustion process was undertaken together with the MTU R&D centre in Friedrichschafen.

In-line engines are the first to be produced, with V engines to follow later. In-line six, seven, eight and nine cylinder units span a power range from 3,600 to 5,400kW and V engines 6,000 to 8,400kW.

Low fuel consumption

Specific fuel consumption is 175g/kWh at 85 per cent MCR and 177g/kWh at full load.

The engine control system is the electronic engine management system from MTU which is developed in-house. It monitors and controls all key engine functions and exhaust aftertreatment.

A totally new turbocharger is matched to the exhaust system which provides multi-pulse charging with charge air taken through a two stage intercooler, which gives a high turbo efficiency. Modular design has been applied throughout for ease of maintenance.

Robust

Looking more closely at the design of the B33:45, the foundation is a more rigid SG iron block than the current B-series, which has reduced vibration levels to 10-11m/sec. It supports the balanced crankshaft which is the same for both propulsion and generator applications. Cylinders are individual units that can be removed complete within a service height of 2.52m above the crankshaft centre-line. Connecting rods are of the marine three-piece type allowing piston removal without disturbing big end bearings. The strengthened camshaft design has one section per cylinder for ease of replacement.

Another feature is a reduction in the amount of external pipework, that ensures a safe, yet simple fuel system design. This has been achieved by putting the oil bores into the cylinder heads and the passages are joined by simple transfer blocks. The system is common rail ready, with the conventional system providing maximum flexibility for different applications.

Meets IMO Tier III

Meeting IMO Tier III NOx emission requirements was another important goal and is achieved with selective catalytic reactor (SCR) technology. The system uses urea to convert the NOx into nitrogen and water vapour. An SCR system was part of the development programme and NOx  levels within IMO levels have been successfully validated running from 10 – 100 per cent load. The control unit is integrated into the engine controller and compact SCR units will come in various sizes to match the engine power selected.

Extended maintenance intervals

The B33:45 family is designed for 25,000hrs between major maintenance when operating at average loads within a specified window. This enables major engine maintenance to be alined with the vessels reclassification intervals, normally every five years, which significantly reduces vessel down time. When overhauls are finally needed owners can benefit from the Bergen worldwide exchange pool system which offers cylinder heads, injection components and other parts by exchange and later return, with warranty.

Naming ceremony for HMS Queen Elizabeth

Naming ceremony of HMS Queen Elizabeth

Friday 4th July saw the naming ceremony for the Royal Navy’s new aircraft carrier HMS Queen Elizabeth. Built at the Rosyth shipyard in Scotland, and weighing in at 65,000 tonnes she, and sister ship HMS Prince of Wales will be the largest naval ships in Europe. Rolls-Royce is working in an alliance with Thales, L-3 and GE delivering the power and propulsion for both ships.

Our equipment includes the MT30 – the world’s most power-dense marine gas turbine. A pair of MT30s each rated at 36 megawatts, will power these magnificent ships. We are also supplying the giant propellers that measure 7 metres in diameter and produce around 50,000 horsepower. And we’re supplying shaft lines that drive the propellers, the low voltage electrical systems, steering gear and rudders.

Our Neptune stabilising fins, which deploy under the water in rough seas, will steady the ships during aircraft operations.

This was a hugely proud day for the Rolls-Royce team. We congratulate everyone at the Aircraft Carrier Alliance, MoD and the Royal Navy, and we are privileged to have been a part of this historic day.

New Rolls-Royce UK Discs Facility official opening

Rolls-Royce has marked the official opening of its new £100m advanced aerospace disc manufacturing facility in Washington, Tyne and Wear, UK.

When fully operational in 2016, the 18,000m2 facility will have the capacity to manufacture 2,500 fan and turbine discs a year. These discs will feature in a wide-range of Trent aero engines including the world’s most efficient aero engine the Rolls-Royce Trent XWB. Fan Discs and Turbine Discs are at the heart of the engine, operating in extreme conditions providing the engine’s thrust.

Ground-breaking manufacturing techniques

These include the introduction of robotics and automation for our shot peen, painting and chemical processing operations as well as the latest advanced platforms for machining, grinding, broaching and inspection processes. This has reduced the time it takes to manufacture a disc by 50 per cent while producing a step-change in component performance. The state of the art facility makes use of manufacturing methods developed at the Advanced Manufacturing Research Centre (AMRC) in Rotherham. The AMRC is part of a network of research centres which aim to work with businesses to apply university research to accelerate the commercialisation of new and emerging manufacturing technologies.

Tony Wood, President – Aerospace, Rolls-Royce said: “Rolls-Royce is committed to investing for future growth in order to deliver for our customers. We invested £687m in facilities and equipment around the world last year. This facility will use ground breaking manufacturing techniques to produce discs for our Trent engines including the world’s most efficient aero engine, the Trent XWB.”

Fan and turbine discs

There are two types of disc manufactured at the Washington plant: fan discs and turbine discs. Located at the front of the engine, the fan disc holds the fan blades. There are typically 20 blades in each engine. They rotate about 2,700 times per minute and move 1.25 tonnes of air per second, the equivalent of the volume of air in a squash court. The fan discs remain in service for over 20 years.

The turbine discs hold blades in the hottest part of the engine where the operating conditions are at their most severe. The disc is made of some of the strongest materials available, created using refined powders which are specially processed and machined to the accuracy of a fraction of the thickness of a human hair.

The blades that these discs hold each generate the power of a Formula 1 racing car and there are 68 of them. The temperature within the high pressure turbine is 1,700 degrees centigrade, hotter than the melting point of the turbine blades themselves so they have to be coated with a special ceramic and cooled with air passed through the discs and out of a series of precise holes in the blade.