L21/31-VBS

IMO Tier II – Propulsion package

 The Genuine Propulsion Package
All from the navigator’s finger tips to the propeller tips

• Strenght calcula­tions - ice class

• Special stern tube arrangements
• Whirling calculatins • Project guides
• Torsional vibra­tion calculations • Dimension sketches on disks
• Axial vibration calculations • Installation drawings
• Instruction books
• Optimum gear ratios
• PTO/PTI configurations • Lay-out of piping system
• Auxiliary propul­sion systems • Back-pressure calculations
• Flexstar units • Lay-out of accessories
• Waste heat recovery
• Alignment analysis and instructions
• Epoxy chock calculations
• Resilient mounting • Alphatronic controls
• Ship’s speed prognosis • Highly flexible coupling • Ambient conditions • Manoeuvring stations
• Power analysis • Noise levels • Ship’s operation profile • Operating modes
• Towing force estimation
• Engine selection • Load sharing
• Lay-out of propellers
• Jet assist • Joystick interfaces
• Pressure impulses on hull
• Two-stage charge air cooler • Alphatronic safety systems

The Genuine Propulsion Package is characterized by „„ Propulsion equipment interfaces and integration
all core elements of the package – such as main engi- matters are solved at an early stage
ne, reduction gearbox, shaftline, propeller and control „„ Torsional vibration calculations and special ice class
system – being designed, optimised, commissioned requirements are dealt with in standard quotations
and tested by one organization for integration into tai- „„ A competent contract partner during projecting,
lored propulsion solutions. planning, purchasing, installation and commissio-
ning of the propul­sion equipment
And most important – for the benefit of shipowners „„ Thorough handling of engine, gearbox, propeller
and operators – The Genuine Propulsion Package is and control systems leads to minimal shipyard
also serviced by that same organization throughout the work on a reduced number of connecting points
ship’s operating life. „„ One package of documentation providing informa-
tion on foundations, piping, electrical wiring, auxili-
Yard benefits ary systems, and covering onboard interfaces and
„„ Pre-project plant conception, power and speed alignment of the entire power train
prognosis and estimation of propulsion package pa- „„ One team of commissioning engineers responsible
rameters with a high degree of system accuracy for the entire propulsion package during start-up
„„ Layout of auxiliary systems and package enginee- and sea trials
ring based on integrated overall propulsion exper- „„ Reduced shipyard responsibility and administration,
tise reduced installation work and installation costs.

2 L21/31-VBS - Propulsion package

L21/31-VBS
Propulsion package

The responsible way in leading technology

MAN Diesel & Turbo is the world’s leading designer The foundation of MAN Diesel & Turbo’s success in all
and manufacturer of low and medium speed engines applications, marine or stationary, is our unparalleled
– an estimated 50% of the world marine trade is po- understanding of large engine technology. A vital part
wered by engines from MAN Diesel & Turbo. of our leadership stems from a firm belief in the ‘total
systems approach’ to engine building based on the
We develop two-stroke and four-stroke engines, auxi- identification of core competences and the pursuit of
liary engines, turbochargers and propulsion packages excellence in these areas.
that are manufactured both within the MAN Diesel &
Turbo Group and at our licensees.

3 L21/31-VBS - Propulsion package

Propulsion package example:
MAN 6L21/31 Propulsion Engine
MAN Alpha AMG11EV Gearbox
MAN Alpha VBS740 CP Propeller
Alphatronic 2000 Propulsion Controls

Reduced operational costs

Reduced installation costs

Single point of contact

- to one responsible organisation

L21/31-VBS - Propulsion package 4

Owner benefits Pioneers and package traditions
„„ Optimal operating economy is ensured thanks to MAN traditions are the bedrock of its excellence in inte-
the optimised layout of engine, reduction gearbox, grated propulsion packages. The first propulsion packa-
propeller, remote control and safety system ge was developed as early as 1902, based on a 4 HP
„„ Operating reliability, durability and predictable ser- Alpha vertical four-stroke hot-bulb engine, a mechanical
vice intervals are assured by a tailored package clutch coupling and a two-bladed mechanically control-
„„ One organization supplying, testing and commissi- led pitch propeller.
oning the package, together with the subsequent
lifetime accumulation of performance and opera­
ting experience for the propulsion components
„„ One package of service documentation, main­ten-
ance programmes and spare parts catalogues for
the propulsion equipment – as the basis for efficient
service routines and identification of parts
„„ MAN PrimeServ Academies offering com­plete pro-
pulsion system instruction and training for engi-
neers, operators and service staff
„„ One service organization addressing all propulsion
plant support requirements, either directly or via the
worldwide net­work of MAN PrimeServ representa-
tives, authorized workshops and service centers
„„ One service package contract or support agree­
ment available for all propulsion equipment.

L21/31-VBS - Propulsion package 5

 MAN L21/31 Engine
Reliable propulsion power

The L21/31 engine is the ideal power source in the New standards
1,290-1,935 kW output range for small to medium- - are introduced with the following features:
sized tankers, cargo vessels, ferries, RO-RO vessels, „„ Modularized unit concept with a reduced number
coasters, large fish­ing vessels, tugs, workboats and of components
supply vessels. „„ Front-end box and aft-end box
„„ Marine head connecting rod
„„ Crossflow cylinder head design
The design criteria for the engine are: „„ Pipeless engine layout
„„ Reliability in operation „„ No cooling water in the engine frame
„„ Long periods between overhauls „„ Separate camshafts - one for injection pumps and
„„ No unscheduled main­tenance and repair work one for the valve gear
„„ Unrestricted Heavy Fuel Oil operation „„ Encapsulated engine - special noise dampening
„„ Low fuel and lube oil consumption – while fulfilling covers.
legal emission limits
„„ Easy maintenance and operational friendliness
„„ Good part load behaviour A unique cylinder unit con­cept:
„„ Compact engine design „„ Quick and easy ‘pit-stop’ replacement is possible
„„ Easy installation, rigid or resiliently seated. „„ Easy withdrawal of the complete cylinder unit inclu-
ding cylinder head, liner, piston, connecting rod
and fuel injection valve
„„ Overhaul intervals of 20,000-25,000 hours
„„ Exchange service and overhaul contracts are avail-
able.

6 L21/31-VBS - Propulsion package

➊ Cylinder unit
➋ Aut. full-flow lube oil filter
➌ Lube oil cooler
➍ Lube oil pump
➎ HT cooling water pump
➏ LT cooling water pump
➐ Optional 100% PTO
➑ Optional 40 kW PTO
➒ Charge air cooler

Cylinder head – high, stiff and stable

A unique casting of nodular cast iron with:
„„ Integrated cylinder segment of the charge air recei-
ver (with quick-release sleeve coupling)
„„ Integrated cylinder segment of the cooling water
belt (with quick-release sleeve couplings)
„„ Integrated exhaust gas outlet collar connection to
the exhaust gas receiver (with quick-release clamp
ring)
„„ Integrated mountings for the rocker arm shaft and
rocker arms.

Marine head
The solidly designed marine head and connecting rod
offers the stiffness and high safety margin that ensures
an ideal housing for a good and stable long term bea-
ring condition.
The characteristics are:
„„ Optimal flow of forces and equal bearing loads
„„ No opening of bearing for piston with­drawal
„„ Easy use of hydraulic tools
„„ Low lifting height at overhaul
„„ Good access.

L21/31-VBS - Propulsion package 7

 MAN L21/31 Engine
Optimal propulsion economy

Purpose-designed front-end box Efficient fuel equipment

A propulsion-optimised engineering element ensuring: The fuel injection system, one of the most important
„„ Minimal foundation and installation work for auxiliary elements for efficient combustion, minimal consump-
equipment tion and smoke emission, is characterized by:
„„ Very short overall installation length „„ High injection pressure and good atomisation for
„„ Cooling water pipe con­nec­tions optimally positioned optimal charge air mixture – even at part load
on the sides of the box „„ High pressure connec­tions with ample stiffness for
„„ Integrated support bearing for optional 100% Power safety against vibra­tions and leakages
Take-Off „„ Robust slide connections between injection pumps
„„ All lube oil equipment in a safe, closed circuit for easy assembly/disassembly.
„„ Automatic full-flow lube oil filter – efficient cleaning
– maximum safety – and no disposal problems with
used filter cartridges
„„ Service friendliness and easy maintenance by simple
plug-out/plug-in actions.

8 L21/31-VBS - Propulsion package

Turbocharger system
Constant pressure turbocharging ensures the best effi-
ciency for all cy­linder versions.
The sy­s­tem is ba­sed on:
„„ An uncooled turbocharger with isolated turbine inlet
and outlet housing
„„ A lube oil system inte­grated with the engine lube oil
system
„„ A charge air by-pass arrangement for higher charge
air pressure at part load operation.
„„ An optional waste gate arrangement for special
propulsion plants requiring special performance
optimisation.
Integrated charge air receiver segments with
quick-release sleeve couplings

L21/31-VBS - Propulsion package 9

 MAN Alpha Reduction Gear
Proven and flexible power transmission

In the four-stroke power train the robustly designed „„ Optional hydraulic actua­ted friction clutch of the
MAN Alpha reduction gearboxes efficiently handle po- multiple disc type with sintered plates. Optimised
wer for both propulsion, auxiliary systems and elec­ clutch-in time to ensure smooth engagement of
tricity demands. propeller
„„ Thrust bearing with tilting pads designed with con-
Reduction gear features siderable safety margins
„„ Compact design contributing to a short installation „„ Common oil system for propeller servo, gearbox
length of the com­plete propulsion package clutch control and lubrication using one forced-dri-
„„ Cast housing with stiff support of bearings for main- ven built-on pump for all systems
taining an accurate tooth contact and well-dimen- „„ No separate oil tank, pumps or control sys­tems are
sioned foundation for taking up the propeller thrust needed for controlling the propeller pitch
„„ Helical gear wheels of special alloy steel, case har- „„ Built-on oil cooler and high pressure full-flow filters
dened and ground to secure high strength and low „„ Flexible Power Take-Off and Power Take-In/PTH
noise levels solutions available up to the 1500/2000 kW range.
„„ Use of robust pressure-lu­bricated slide bearings for
long reliable operating life

10 L21/31-VBS - Propulsion package

PTO package expertise Lubricating oil
Shaft alternator operation and Power Take-Off flexi- Servo oil - Pitch Astern
bility is a prime feature. A long pedigree underwrites Servo oil - Pitch Ahead
MAN’s experience in the fields of tailored layout, instal- Oil for Clutching in and out
lation and operation of PTO-driven alterna­tors.

PTI/PTH propulsion redundancy

MAN Diesel & Turbo offers various simple and cost-ef-
fective Auxiliary Propul­sion Systems with ample redun-
dancy for a “take home” mode in the event of a main
engine shutdown. Alternatively, a “take away” function
of the system can be deployed during the loading and
discharge of critical cargoes, allowing immobilization
of the main engine for service inspection and elimina-
ting the need for a standby tug.

L21/31-VBS - Propulsion package 11

 MAN Alpha CP Propeller
Tailored propulsion efficiency

Optimal design and layout of propellers are the prime CP Propeller features:
targets for the ship’s overall propulsion efficiency. Full „„ Reliable design using few and robust components
know-ledge of the entire power train is one of our most of high strength material
im­portant core competencies. Full knowledge of die- „„ Dimensioning of the propeller based on a pyrami-
sel engines, such as their load characteristics, opera-­ dal structure with increasing strength from blade
ting economy, long term performance, manoeuvring towards shafting
and acceleration characteristics, combined with wide „„ Intensive use of Finite Element calculations, Com-
package expertise embracing the fields of: pulated Fluid Dynamics and service experience
exploited to ensure that the components meet the
„„ Hydrodynamics requirement of ample safety from not only the hy-
„„ Mechanics drodynamic loads but also from impact with
„„ Hydraulics debris and ice
„„ Electronics „„ Hydraulic servo motor placed in the propeller hub
- and all their interfaces ensure the optimal design of for precise pitch setting, with a large servo motor
propeller and control systems. piston resulting in low operating pressure for pitch
setting
„„ Reliable and well-proven blade foot seals.
Company experience
Today’s MAN Alpha VBS-type propeller design is based
on experience accumulated from the design and pro-
duction of more than 7000 propellers.

12 L21/31-VBS - Propulsion package

 Hydrodynamic design
analysis based on CFD

Hydraulic Power System

Propeller blades Oil tank Pitch

forward order
Designing propellers has always been a challenge due to
PD

Stern seal PAL

PAL

PAH PI
TI

tube oil TAH

tank
the complexity of all the fac­tors involved. These fac­tors
PSL PSL

are not only related to the propeller itself but also to the
ship’s hull profile and its operating profile. Servo
piston
Lip ring seals Hydraulic
pipe

The blade design main objectives are to obtain as high

Propeller shaft
a propeller efficiency as possible and to suppress the
Monoblock Stern tube Oil Distribution Pitch
cavitation and noise to an acceptable level. hub Box type ODG feed-back

Design parameters
The propeller blades are designed and optimised on the
basis of the following parameters:
„„ Blade area
„„ Blade shape
„„ Skew angle FEM calculation of
„„ Pitch distri­bution propeller blade
„„ Profile section
„„ Rake.

L21/31-VBS - Propulsion package 13

 Safety, control and monitoring system

SaCoSone PROPULSION is the safety, control and nation of established, well-structured software and mo-
monitoring system for MAN small bore diesel engines dern embedded micro controller-based hardware. The
type L21/31 and L27/38. software has been proven extensively on standardised
All engine mounted sensors and actuators are con- PLC-technology. The new hardware is designed for very
nected to the system and controlled by the engine harsh environments and is based on standard compo-
attached SaCoSone PROPULSION. nents used by the automotive industry in their millions.
With SaCoSone, MAN Diesel & Turbo engines are well-
Optionally, the gear box and the propeller control and prepared for the future.
monitoring can be totally integrated in the system. This
means the entire propulsion plant can be operated
locally from one position as required by classification Functions
societies. SaCoSone combines all functions in a single package:
„„ Safety system
SaCoSone PROPULSION can thus control and moni- „„ Engine control
tor all engine, gear and propeller functions, including „„ Clutch control
clutch and pitch operations. Pre-alarms, system-alarms, „„ Pitch control
safety actions, operating values and status information „„ Alarm system
is visualised on the dual redundant display modules in „„ Engine media control
the Local Operator Panel. „„ Speed governing
„„ Solenoid valve actuation
„„ Auxiliary control
Fit for the future „„ Engine operating history data
SaCoSone is the result of far more than 15 years of MAN „„ Ship alarm system interface
Diesel & Turbo experience in the field of engine control „„ Remote access interface for online services
software and electronics. SaCoSone is built on a combi- „„ Human machine interface.

14 L21/31-VBS - Propulsion package

SaCoSone is designed as a modular system and can be Features
used with conventional engines as well as on engines SaCoSone offers a wide range of benefits:
with electronically controlled fuel injection. It is flexible „„ Integrated self-diagnostics
and, due to its wide range of interfaces, can be integra- „„ Sensor monitoring
ted into all modern automation environments. „„ Integrated data security
„„ High reliability and availability
SaCoSone is completely mounted on engine and gear. „„ Guaranteed long-term spare parts supply
The new design includes an economic new cabling con- „„ Ease of operation and maintenance
cept and terminates at a modern TFT touch screen ope- „„ Reduced cabling
rating panel. „„ Plug-in replaceability
„„ Standardised interfaces
„„ Complete control system, factory pre-tested.

L21/31-VBS - Propulsion package 15

 Alphatronic 2000 PCS
Propulsion control system

Manoeuvrability and overall economy Main Bridge Control Station

The Alphatronic Propulsion Control System plays a key For remote control a minimum of one control station
role in the optimising function of the entire propulsion located on the bridge is required.
plant. The control system not only optimises the func- This control station will incorporate three modules:
tion of the propeller but also the engine func­tioning
- as well as securing the vessel’s manoeuvrability and Propulsion control pa­nel
best overall economy with re­spect to engine dynamics, - with push buttons and in­dicators for machinery con-
fuel oil consumption and propeller efficiency. trol and a display with information on condition of
operation and status of system parameters. Flexible
multi-functional ‘soft-key’ buttons may be program-
Versatile functions med for individual purposes, eg clutch in/out control
The computer-controlled sy­­s­­tem contains functions for: for additional PTOs.
„„ Machinery control of en­gine start/stop, engine load
limits and possible gear clutches Propeller monitoring panel
„„ Thrust control with optimisation of propeller pitch - with back-up instruments for propeller pitch and shaft
and shaft speed speed.
„„ Selection of combinator, constant speed or sepa-
rate thrust mode is possible. The rates of changes Thrust control panel
are controlled to ensure smooth manoeuvres and - with control lever for thrust control, an emergency
avoidance of propeller cavitation stop button and push buttons for transfer of control
„„ Transfer of Responsi­bi­lity between the local control between brid­ge control stations. An independent tele-
stand, engine control room and control locations graph for communication between bridge and engine
on the bridge is incorporated in the system. room can be incorporated in the Thrust Control Panel.

16 L21/31-VBS - Propulsion package

 Main bridge

Engine control room Bridge wing

Engine load control functions:

Power (%) Load Limit and Combinator Diagram
„„ Automatic overload protection
„„ Running up load programme 100
„„ Charge air controlled torque limitation 90
„„ Automatic load reduction and slow down
80
„„ Engineer-controlled limitation of engine load.
70

60
Electric shaft system
50
To ensure bumpless transfer of manoeuvre responsi-
40
bility between the control stations on the bridge, an
electric shaft system is incorporated for automatic 30
synchronization of control levers. 20

10
0
Control station in engine room
60 65 70 75 80 85 90 95 100
A propulsion control station for the engine control Speed (%)
room can be incorporated in the system. A thrust
1
● Theoretical Propeller Curve 4
● Combinator Curve
control panel with a single control lever is standard,
but separate levers for control of engine speed and
2
● 100% MEP 5
● 50% MEP

propeller pitch are optional.

3
● Load Limit 6
● Zero Thrust Curve

L21/31-VBS - Propulsion package 17

 Propulsion Packages
Tailored to all applications

The MAN Diesel & Turbo supply is not limited to the Perfect engine characteristics
owndesigned elements in the propulsion package. Heavy-duty propulsion and manoeuvring power is the
Other propulsors, gearboxes or propulsion equipment core of the L21/31’s performance characteristics:
are often integrated in package solutions. „„ Good performance over the entire load range
„„ Quick acceleration
„„ Immediate load response
Packages can include: „„ Smokeless at idling, part load and full load
„„ Other propulsors such as Fixed Pitch Propellers, „„ Optimized for high-torque layout
Azimuth Thrusters, Z-drive and Voith-Schneider pro- „„ Low NOX emissions
pellers „„ Low fuel oil consumption.
„„ Dynamic Positioning and Control systems with joy-
stick arrangements
„„ Hybrid and multi-engine combination systems with
several ope­rating modes, inclu­ding semi-diesel elec-
tric drive.

18 L21/31-VBS - Propulsion package

 Twin engine
– twin in/single out installation

Voith-Schneider installation

Thruster installation

L21/31-VBS - Propulsion package 19

 A ‘Green’ Approach
to propulsion power

The design of the L21/31 has been performed with care- Fuel oil
ful attention to its impact on the surroundings. Some Minimal fuel oil consumption within legal emission limits
key points are: for reduced operating costs.

Exhaust gas Lube oil

A minimum of visible smo­ke during acceleration and Low and stable lube oil consumption is another im-
at any load point. Exhaust gas emissions below the portant cost factor.
IMO Tier II NOX limits.
Heat emission
Noise emission High engine efficiency, low heat emissions with good
Special noise dampening engine covers are applied. possibility to exploit surplus heat in auxiliary systems.

Vibration Man and machine

Well balanced engine with low vibration levels trans- Operator safety and handling friendliness due to ex-
mitted to foundation, ship structure and accommoda- tensive use of ergonomically correct solutions related
tion – even when rigidly seated. to lifting gear, hydraulic tools, flanges and couplings.

Waste
No disposal or chemical waste problems with used
lube oil filter cartridges – thanks to the self-cleaning
automatic full-flow lube oil filter. Easy handling and no
disposal costs.

20 L21/31-VBS - Propulsion package

L21/31-VBS - Propulsion package 21
L21/31-VBS Propulsion Package
Main data and standard package examples

Bore: 210 mm, Stroke: 310 mm Prop. Hub Gear Prop.

Speed r/min 1000 speed D VBS Q R Wmin K mass mass
Cyl. kW r/min mm mm mm mm mm mm t t*
mep bar 24.0
L21/31
kW
6 1,290 270 2,350 640 550 596 1,200 2,241 4.9 3.2
6L21/31 1,290
6 1,290 218 2,600 640 550 596 1,200 2,241 4.9 3.6
7L21/31 1,505
6 1,290 190 2,800 740 569 655 1,300 2,241 6.4 4.5
8L21/31 1,720
6 1,290 167 3,000 740 569 655 1,300 2,241 6.4 5.7
9L21/31 1,935
7 1,505 270 2,500 640 550 596 1,200 2,241 4.9 3.6
7 1,505 218 2,750 740 569 655 1,300 2,241 4.9 4.4
Specific Fuel Oil Consumption (SFOC) to ISO conditions
7 1,505 190 2,950 740 569 655 1,300 2,241 6.4 4.9
MCR 100% 85%
7 1,505 167 3,150 860 653 743 1,400 2,241 6.4 6.2
L21/31 195 g/kWh 192 g/kWh
8 1,720 278 2,550 640 550 596 1,200 2,241 6.1 3.7
Specific lube oil consumption 0.8 g/kWh
8 1,720 218 2,850 740 569 655 1,300 2,241 6.1 4.6
Engine type specific reference charge air temperature before cylinder 40 °C
8 1,720 190 3,050 740 569 655 1,300 2,241 6.4 6.1
8 1,720 167 3,250 860 653 743 1,400 2,241 6.4 6.5
Dimensions
9 1,935 278 2,600 740 569 655 1,300 2,241 6.1 4.5
Cyl. No. 6 7 8 9
9 1,935 218 2,900 740 569 655 1,300 2,241 6.1 5.0
L mm 4,544 4,899 5,254 5,609
9 1,935 194 3,100 860 653 743 1,400 2,241 8.5 6.4
L1 mm 3,424 3,779 4,134 4,489
9 1,935 182 3,200 860 653 743 1,400 2,241 8.5 7.0
H mm 3,113 3,267 3,267 3,267
W mm 1,695 1,695 1,820 1,820 * S min and propeller mass are based on 4,000 mm propeller shaft and 2,000 mm stern
Dry mass t 16.0 17.5 19.0 20.5 tube for 21/31, 27/38 and 6,000 mm propeller shaft and 3,000 mm stem tube for the
other types.
Minimum centreline distance for twin engine installation: 2,400 mm.

2,500

D
H

420

Q R S~2000 Wmin K

L1 1,065
L

L21/31-VBS - Propulsion package 22

Service Excellence
During the entire life cycle

A service package second to none

The unique “all under one roof” philosophy is particu-
larly beneficial to the owner and operator during the
service life of the package.
The Genuine Package is covered entirely – from one
source - in all service matters such as:
„„ Advisory service
„„ Performance control
„„ Diagnosis and analysis
„„ Parts Supply

MAN power - at your service

Specialists in the individual elements of The Genuine
Package provide direct back-up, contributing to a
professional life-cycle service support programme for
engines, reduction gears, CP propellers and controls.
Efficient implementation of service and repair actions
is secured by a trained team of travelling propulsion
package specialists – backed by the very large world-
wide after-sales service network of MAN PrimeServ
outlets, service centres, authorized repair shops, local
spare parts stocks and service agents.

One phone call - and you have got it all!

L27/38-VBS - Propulsion package 23

All data provided in this document is non-binding. This data serves informational
purposes only and is especially not guaranteed in any way. Depending on the
subsequent specific individual projects, the relevant data may be subject to
changes and will be assessed and determined individually for each project.
This will depend on the particular characteristics of each individual project,
especially specific site and operational conditions. Copyright©MAN Diesel & Turbo.
1510-0049-06 ppr Aug. 2012. Printed in Denmark.

MAN Diesel & Turbo

Niels Juels Vej 15
DK-9900 Frederikshavn
Denmark
Tel. +45 9620 4100
Fax +45 9620 4030
info-frh@mandieselturbo.com
www.mandieselturbo.com

MAN Diesel & Turbo – a member of the MAN Group