Introduction to the MTU Series 8000 Mega Diesel Engine
The MTU Series 8000 is one of the most powerful high-speed diesel engines in the world, used to power modern ships, including the catamaran ferry, Jean du Lavalette. This engine is capable of reaching speeds of up to 42 knots and transporting passengers and cars between Malta and Italy.
Engine Specifications and Manufacturing Process
The MTU Series 8000 engine consists of 20 cylinders, with each unit being 7m long, 2m wide, and 3.5m high, weighing around tons, and producing 13,600 horsepower with a fuel consumption of 2,000L per hour. The engine’s core component, the crankcase, is made in a foundry in Bavaria, Germany, where steel has been molded for nearly 600 years.
- The foundry uses materials like steel scrap, pig iron, and deep drawn sheet metal to cast the crankcase.
- The crankcase requires 16 tons of material and precise temperature control of 1500° to be ready for transportation to the mold.
- A measuring sleeve is used to measure the temperature of molten metal in a steel works, where smelters add various materials to create a unique recipe.
Casting and Assembly Process
Molten metal is poured into a mold to cast a mega diesel engine, with the temperature strictly maintained above 1400° and the process requiring absolute synchronicity. The head smelter oversees the casting, ensuring the 16 tons of metal fill the mold within 70 seconds.
- After the metal cools and solidifies over several hours, it will take two weeks for it to be ready to be removed from the mold and become a durable engine component.
- The 16-ton steel block is lifted out of the casting pit using an overhead Gantry, and the sand cocoon surrounding it crumbles, exposing the new crank case.
- A welder severs the excess parts, and the block is cleaned using a mechanical vibrator to remove remaining quartz sand, which will be recycled.
Assembly and Quality Control
Engineers build a massive diesel engine with precise dimensions, requiring an accuracy of 3/400th of a millimeter, which is a significant challenge. The engine’s components, including a crank case the size of a small bus, must be measured and assembled with extreme precision to prevent disasters during operation.
- A team of 35 fitters work over several weeks to assemble the engine, using specialized tools and equipment, such as an overhead gantry and a rotary station, to ensure millimeter accuracy.
- Tiny burrs or metal splinters in the channels could cause serious problems, so the main oil channel must remain free of dirt, dust, and splinters to prevent engine destruction.
- The cam shaft, 6M long and weighing 400kg, is assembled with precision, using liquid nitrogen to chill and contract guide pins for a firm fit.
Final Assembly and Testing
The assembly of a 25 Mega diesel engine is underway, with the engine being transported to the next station by overhead Gantry after 2 days of work at Station 1. Fitters turn and wheel the engine, adding components such as the gigantic 6-ton crankshaft, which is crucial to the engine’s operation.
- The crankshaft is installed after the engine is turned upside down, and the Fitters carefully maneuver it into place to avoid damage.
- Once installed, the Fitters turn the engine to access the inlets and begin installing 20 cylinder pistons, which will house the combustion process in the power units, each with a capacity of 17.5 L.
- The engine is started with an air starter, and its performance is measured with a water brake. After passing the test, the engine is ready to be shipped to customers.
Maintenance and Repair
A catamaran ferry, powered by four mega diesel engines and water jet power units, is heading to the Sicilian Port. The vessel’s immense power and maneuverability allow it to berth and steer easily. However, one of the engines requires maintenance, and a team of mechanics must replace two cylinders within a short timeframe to minimize the expensive port stay.
- A power unit is removed from a Series 8000 Mega diesel engine using a hydraulic bolt tensioning system and pulleys, and then transported to a special frame for overhaul.
- The team has reached the halfway stage and still has 4 hours to complete the repeat procedure. The new power unit is installed, and the men hope it will start immediately.
- Diesel engines can last up to 72,000 operating hours under typical conditions before being taken out and checked for wear. After reassembly, they can be put back into service.
Conclusion
The manufacturing process of a mega diesel engine involves treating and recycling 1,000 cubic meters of water, masking sensitive engine parts, and applying two coats of paint that take 8 hours to dry. The engine spends 16 hours in the paint cabin and takes 5 weeks to manufacture, with a total cost ranging from 1 to 10 million.
The series 8,000 mega diesel engine has a capacity of 3,500 liters and an output of 13,600 horsepower, and can operate maintenance-free for up to 35 years as a marine diesel engine or emergency generator.
Key Vocabulary
| Term | Definition | Example Usage |
|---|---|---|
| Crankcase | The core component of a diesel engine that houses the crankshaft and camshaft. | The crankcase is made in a foundry in Bavaria, Germany, using steel scrap, pig iron, and deep drawn sheet metal. |
| Foundry | A factory where metal is melted and cast into shapes. | The foundry in Bavaria, Germany, has been molding steel for nearly 600 years. |
| Casting | The process of pouring molten metal into a mold to create a shape. | Molten metal is poured into a mold to cast a mega diesel engine, with the temperature strictly maintained above 1400°. |
| Gantry | A type of crane or overhead structure used to lift and move heavy objects. | The 16-ton steel block is lifted out of the casting pit using an overhead Gantry. |
| Camshaft | A rod with cams that operate the valves in an engine. | The cam shaft, 6M long and weighing 400kg, is assembled with precision, using liquid nitrogen to chill and contract guide pins for a firm fit. |
| Crankshaft | A rod that converts the up-and-down motion of the pistons into rotary motion. | The gigantic 6-ton crankshaft is crucial to the engine’s operation and is installed after the engine is turned upside down. |
| Piston | A moving part that transfers force from the expanding gas in the cylinder to the crankshaft. | The engine has 20 cylinder pistons, each with a capacity of 17.5 L, which house the combustion process in the power units. |
| Water Brake | A device used to measure the power output of an engine by absorbing its energy and converting it into heat. | The engine’s performance is measured with a water brake after it is started with an air starter. |
| Hydraulic Bolt Tensioning System | A system used to tighten bolts using hydraulic pressure. | A power unit is removed from a Series 8000 Mega diesel engine using a hydraulic bolt tensioning system and pulleys. |
| Overhaul | A major maintenance or repair operation that involves disassembling and reassembling a machine or engine. | The power unit is transported to a special frame for overhaul after being removed from the engine. |
Watch The Video
Vocabulary Quiz
1. What does the term “deep drawn sheet metal” refer to in the context of the MTU Series 8000 engine’s manufacturing process?
A) A type of steel alloy used in the engine’s crankcase
B) A process of molding steel into complex shapes
C) A material used for casting the engine block
D) A technique for cutting and shaping metal components
2. Which of the following is a critical aspect of the casting process for the MTU Series 8000 engine’s crankcase?
A) Maintaining a temperature below 1000°
B) Using a measuring sleeve to control the metal’s temperature
C) Ensuring the mold is filled with metal within 70 seconds
D) Allowing the metal to cool slowly over several days
3. What is the purpose of using liquid nitrogen in the assembly of the MTU Series 8000 engine’s cam shaft?
A) To clean the cam shaft of dirt and debris
B) To chill and contract the guide pins for a firm fit
C) To lubricate the cam shaft during operation
D) To test the cam shaft’s performance under extreme temperatures
4. What is the function of the water brake in the testing of the MTU Series 8000 engine?
A) To cool the engine during operation
B) To measure the engine’s performance and output
C) To test the engine’s durability and reliability
D) To clean the engine’s components after testing
5. What is the estimated lifespan of a mega diesel engine like the MTU Series 8000 under typical operating conditions?
A) Up to 10,000 operating hours
B) Up to 35,000 operating hours
C) Up to 72,000 operating hours
D) Up to 100,000 operating hours
Answer Key:
1. B
2. C
3. B
4. B
5. C
Grammar Focus
Grammar Focus: The Use of Passive Voice in Technical Descriptions
Grammar Quiz:
Choose the correct form of the verb in parentheses to complete each sentence in the passive voice.
- The MTU Series 8000 engine is designed design designing to be designed by engineers to power modern ships.
- The crankcase makes is made making to make in a foundry in Bavaria, Germany.
- The engine’s components measure are measured measuring to measure with extreme precision to prevent disasters during operation.
- The cam shaft assembles is assembled assembling to assemble with precision using liquid nitrogen.
- The engine starts is started starting to start with an air starter, and its performance is measured.
Answer Key:
- a) is designed
- b) is made
- b) are measured
- b) is assembled
- b) is started