New Turbo Charged Diesel 2-stroke For The Stag!

[MyStag260]

So don't know if you guys have seen this before but i thought it was pretty bloody cool! haha

The worlds biggest engine is the Wartsila-Sulzer RTA96-C. It is a turbo charged two stroke diesel engine and it is the most powerful and efficient low revolution engine in the world today.The Wartsila-Sulser is manufactured by the Aioi Works in Japan and is part of Japans Diesel United Ltd engine manufacturers.Below is an 89 foot long 44 foot wide 12 cylinder engine, literally as big as a house ! What I find confusing is why they haven't actually built the ship around the engine ? How they actually get the 2000 ton engine out of the plant and moreover install an engine of this size into a ship makes the mindoggle.The pistons travel 16 ft each revolution.

These large engines are designed to power the worlds super oil tankers and large container ships. They are built to the shipowners preferences. They usually request an engine construction of a single unit and single propeller design for ease of maintenance, and not surprisingly any later troubleshooting. A single unit and single screw design has also proved over time to have a longer life span than double or even quad screws.

These engines are built in 6, 8, 10, 12 and 14 cylinder configurations. All the engines are straight or 'inline'. The diameter of each cylinder is 3 foot 2 inches with a stroke of 8 foot 2 inches. The 12 cylinder version weighs in at 2000 metric tons and delivers 90,000 Horse Power at 100 Revs per minute, with best fuel economy at 53,244 HP at 90 Rpm.When I mention economy, the 14 cylinder engine for example with a displacement of 25,480 Litres ( 1.56 million cubic inches ) burns up 1,660 gallons of crude ('bunker') oil every hour.

n the image below a worker at the plant is finalising work on the cylinder block. This image shows the piston sleeves. The worker could quite easily have a nap inside one of the bores and no one would notice !

Below are the pistons that will soon be fitted into the engine. Unlike normal car sized pistons these 3 foot diameter pistons incorporate lots of holes and it is through these holes that oil is injected through valves to keep all the working parts at a maximum low wear tolerance. Despite the colossal amounts of power output produced by these engines, surprisingly low wear rates have actually been recorded. Cylinder liner wear for example is only about 0.03 mm down for every 1000 hours of engine use.It must be remembered here that these engines work at about 20 times slower than a normal 2.0 Litre car engine and this is a major contributor to the life of the engine.

The image below depicts the 300 ton crankshaft of the 10 cylinder engine. You may notice here that there are steps on the wall of the casing to climb down into the engines sump !

In the image below the pistons shell bearings are being fitted into the engine block. They are lowered into place by a crane and guided in by two workers and a supervisor. They keep all surfaces of the engine clean at this stage as any grit or dirt could later add wear to the engine or worse destroy it, so the workers are wearing special cloth overshoes so as not to leave any abrasions on the fine working surfaces. Also you may notice that sheeting is covering the rest of the engines crankcase bearing housing to keep the dust off. These engines cost many millions upon millions of dollars; in fact, more than the ship itself that they are installed into.

100,000 HP was actually achieved on a test bed in the workshop with the 14 cylinder model, running the engine flat out at just under 102 RPM.102 Rpm may sound slow compared to a normal sized car engine that operates at about 2-4000 rpm, but when an engine is as big as this then fast engine revolutions are made obsolete by the sheer power output

So its basically a big RB? hehe Japanese inline turbo haha... the boat builder looked at a stag n went hmmm if that RB can move that boat/car if i make a really big one it will move my big mother of an oil tanker HAHA! I'M A GENIOUS!

[GTR91]

In the first picture, the writing on the wall looks Korean, not Japanese ???

[Daleo]

Have seen these pics before, I used to build GM V16 2 stroke diesel turbo/supercharged engines for a crust a few years back.

They were a pretty amazing piece of gear (better than 3000hp at 1000rpm) but they wouldn't even be a starter motor for the sulzer.

Gives you a real appreciation of design and manufacture, when you see equipment like that in it's sock and undies.

[MyStag260]

Yeah its crazy... i often marvel at man kinds incredible ability to do combustion engines, we really do it very very well like look 1 single tiny cylinder RC car engines right through to these massive things its f**king incredible the sorts of output we can achieve by simple igniting a combustible liquid in a chamber. This is kind of the reason why i think we are probably doomed in the long run, unless we can come up with some super fantastic way of getting hydrogen and continue to use the same sorts of engines we're screwed. No matter how good the battery/electric power will be it will never be powerful enough to move what needs to be moved. There will be entire tips dedicated to prius's with dead batteries.

Oh well interesting years ahead i guess

[zei20l]

i wonder if they have a VTEC equipped model?? kidding, i know its a 2 stroke..........

[iamhe77]

This is kind of the reason why i think we are probably doomed in the long run, unless we can come up with some super fantastic way of getting hydrogen and continue to use the same sorts of engines we're screwed. No matter how good the battery/electric power will be it will never be powerful enough to move what needs to be moved. There will be entire tips dedicated to prius's with dead batteries.

Oh well interesting years ahead i guess

Nonsense. Bring on the dark matter engines!

[MyStag260]

Nonsense. Bring on the dark matter engines!

hahaha so we just need to find one of these little fellas

[Daleo]

i wonder if they have a VTEC equipped model?? kidding, i know its a 2 stroke..........

2 stroke diesels still use camshafts and valves for exhaust, only the compressed inlet charge comes in through the liner porting.

Feel the VTEC kickin' in at 50rpm yo!

[zei20l]

no way! so im guessing they would be turbo-charged to force the gas into the chamber?

[Daleo]

That's right. Diesels are the perfect engines to apply forced induction to.

The engines I used to build, (piston ported 2 stroke diesel locomotive engines) actually had a gear drive on the turbocharger turbine shaft (driven by the crank) to produce boost pressure until the engine could produce enough exhaust gas flow to drive the turbo. At that point a sprag clutch, driving the turbo shaft at low speed will disengage, and the turbo would build boost based on engine load. The turbo could accelerate to speeds of 35000 rpm as compared to car turbos which tend to top out around 100,000 -110,000rpm.

Given the size of the turbines and impellers, (around 500mm) the tip speeds are enormous, compared to car applications. Internally, these turbos are the same in construction as your cars turbo; just much larger.

Another interesting thing, one brand of turbo we used had roller bearing element, (instead of plain bearings) rpm? 100,000rpm, versus 35,000 rpm. This simply allowed us to use a smaller tubo that came on boost earlier. See? Roller bearings are better...

Edited July 23, 2009 by Daleo

[zei20l]

effing hell!! something that large doing 35000rpm! youd get sucked into it if you werent careful lol

so the turbo was almost used as a supercharger till it became a turbo again. very smart, less parts required to do the same job!

[Daleo]

Yeah it's funny, people still think diesels are a primitive low tech engine, but some contain really innovative design and are surprisingly effective in the right application.

Oncebuilt and balanced a turbo, supposedly for a submarine, impellers 3 feet in diameter...

[zei20l]

massive!! picsorban!!!! lol

nah diesel is good, heaps of technology comes from there anyway. trucks/busses have had variable vane turbos for how long? i think only porche use them in a production car. does anyone else?

[Daleo]

massive!! picsorban!!!! lol

nah diesel is good, heaps of technology comes from there anyway. trucks/busses have had variable vane turbos for how long? i think only porche use them in a production car. does anyone else?

Sorry, no pics unfortunately, that was over ten years ago.

At a guess, I'd say you're right, porsche seem to be leading the charge, in petrol engines. I think there's a couple of turbodiesel cars, (merc is one) that use variable vane.

[zei20l]

just wait till nissan use it and flog porches ass again hahaha

damn, shame about the pics!

[MyStag260]

actually had a gear drive on the turbocharger turbine shaft (driven by the crank) to produce boost pressure until the engine could produce enough exhaust gas flow to drive the turbo.

What has stopped car builders using this kind of technology with car turbos? some kind of gear that was running the turbo just on positive boost then as engine speed increase the gear is disengaged via a clutch? surely that would make for instant boost off the line and in between gear changes etc?

[nickcorr]

Ah, so you have seen the VW 1.4GT motor with both supercharger, for low down grunt, that then declutches and passes onto the turbo at higher revs...

Lancia also had this on their rally cars in the 80s, super and turbo changers...

and most importantly....

Nissan on the Micra...

Aren't Nissan great!!!

What has stopped car builders using this kind of technology with car turbos? some kind of gear that was running the turbo just on positive boost then as engine speed increase the gear is disengaged via a clutch? surely that would make for instant boost off the line and in between gear changes etc?

[zei20l]

yeah but they are two seperate pieces of equipment. this is a mechanically driven turbo till exhaust gases power it more efficiently

[nickcorr]

Only need the mechanical assistance to spin up these big heavy turbines on these low reving engines. For automotive, seperate small, light units are more efficient and give the same benefits...

For these ships and train motors, we are talking about some massive units... The cathedral engines in the tankers red line at 50rpm, and actually run backwards for reverse.. they have turbos the size of my house...

Got to love heavy engineering...

yeah but they are two seperate pieces of equipment. this is a mechanically driven turbo till exhaust gases power it more efficiently

[MyStag260]

Only need the mechanical assistance to spin up these big heavy turbines on these low reving engines. For automotive, seperate small, light units are more efficient and give the same benefits...

For these ships and train motors, we are talking about some massive units... The cathedral engines in the tankers red line at 50rpm, and actually run backwards for reverse.. they have turbos the size of my house...

Got to love heavy engineering...

haha thats funny its like they gave it a shot on a go-cart motor first