CCR_2011_Layout 1 16.01.12 16:50 Seite 1

Cat Common Rail – The Benefits

With Cat Common Rail, the injection pres- sure is independent from load and speed. Utilizing injection maps the injection characteristics are optimized for every engine operating point. ® For areas that are especially emissions- In addition to that, the fuel system is Significant decrease of specific sensitive, soot emissions at low engine capable of multiple injection. Multiple fuel oil consumption: Cat Common Rail load remain well below the visibility injection allows optimal combustion and ■ for main propulsion engine M 32 C limit. Furthermore, during normal load low emissions at all loads. Characteristic with Cat CR up to 3% improvement, operation NOx emissions can be reduced of Cat Common Rail is the approach of ■ for generating set M 32 C with Cat CR Less Fuel and Reduced Emissions Mean More Environmental Care without sacrificing fuel consumption. using the fuel (whether it’s heavy fuel up to 2% improvement, Depending on application, as well as oil, marine diesel oil or diesel oil) as the ■ optimized combustion. operating conditions, engines equipped control fluid for the injector, thus avoiding with Cat Common Rail fuel system the added complexity of a separate technology can positively impact the control fluid system. transient response. During the development, the retrofit aspect of the complete system has been In general, the Cat Common Rail fuel emphasized. As a result, the Cat Common system enables vessel operation with- Rail fuel system can be retro fitted to out visible soot throughout the whole existing M 32 C engines. This means operating range. increased customer value to reach future environmental regulations.

Rail Segment with Three Injectors Caterpillar Marine Power Systems

Headquarters Europe, Africa, Middle East Americas Asia Pacific

Caterpillar Marine Caterpillar Marine MaK Americas Inc. Caterpillar Marine Trading Caterpillar Marine Asia Power Systems Power Systems (Shanghai) Co., Ltd. Pacific Pte Ltd A Division of A Division of Caterpillar Motoren GmbH & Co.KG Caterpillar Motoren GmbH & Co.KG 3450 Executive Way 25/F, Caterpillar Marine Center No. 5 Tukang Innovation Grove Neumühlen 9 Neumühlen 9 Miramar Park of Commerce 1319, Yan’an West Road Singapore 618304 22763 Hamburg/Germany 22763 Hamburg/Germany Miramar, FL. 33025/USA 200050 Shanghai/P.R.China Republic of Singapore

Phone: +49 40 2380-3000 Phone: +49 40 2380-3000 Phone: +1 954 885 3200 Phone: +86 21 6226 2200 Phone: +65 68287-600 Cat CR Telefax: +49 40 2380-3535 Telefax: +49 40 2380-3535 Telefax: +1 954 885 3131 Telefax: +86 21 6226 4500 Telefax: +65 68287-625

For more information please visit our website: Subject to change without notice. © 2011 Caterpillar All Rights Reserved. Printed in Germany. CAT, CATERPILLAR, their MARINE.CAT.COM Leaflet No. 245 · 12.11 · e · L+S · VM3 respective logos, ACERT, ADEM, „Caterpillar Yellow“ and the POWER EDGE trade dress, as well as corporate identity used herein, are trademarks of Caterpillar and may not be used without permission Caterpillar Marine Power Systems is committed to sustainability. This document TM is printed on PEFC certificated paper.

® ® CCR_2011_Layout 1 16.01.12 16:51 Seite 2

Cat Common Rail – Fuel System Cat Common Rail – Technology Cat Common Rail – Technology

From its introduction the MaK long-stroke generation of main diesel engines has been recognized for good Caterpillar has chosen “inside the en- Furthermore, redundant speed pick-ups Pump Drive ■ Injector performance and reasonable fuel consumption, alongside outstanding reliability and long component life. gine” measures as the technology with and pressure sensors, a safety gear Caterpillar has chosen a simple and MaK engines are compliant with current emission regulations without the need for additional aftertreatment. the highest customer value. In combina- between pump and engine, a pressure robust approach by using the actual fuel To fulfil the upcoming emission legislations the development of new combustion process supporting techno- tion with the long-stroke concept and relief valve and flow limiters all increase as control fluid, thereby eliminating the logies is necessary. high performance air systems the Cat operational safety. need for a separate control fluid system. Common Rail (Cat CR) fuel system is The injector nozzle is cooled by lube oil, 1,5 Caterpillar has made a huge investment Soot Emission the most effective technology to meet ■ High Pressure Pump a typical feature for heavy fuel operation. FCT Switch Point IMO I of M 32 C Cat CR, to develop an emission reduction techno- 1,25 IMO II w/o FCT emission regulations and customer Two high pressure pumps deliver the For the Cat CR injector, the lube oil circuit IMO II, logy now marketed as ACERT® Techno- IMO II with FCT expectations. required amount of fuel to the rail and has been extended to provide cooling to Injector Cable constant speed logy for Caterpillar high-speed engines. 1,0 IMO II Cat CR w/o FCT The key features of the Cat Common Rail provide the desired rail pressure in closed the electrical components within the in- After a successful demonstration in technology are: loop control. The pump itself is based on jector, thereby increasing the lifetime. 0,75 the on-highway high-speed engines, ■ Well adapted injection pressure over a proven design and has been modified The injector design is simple, robust and Visibility Limit Caterpillar embarked on a stepwise 0,5 the entire engine operating range. for HFO operation. By having two pumps compact; the key features are:

migration of selected elements of ACERT® Soot Emissions (FSN) ■ Fully flexible fuel injection system for all in-line engines the amount of HP ■ Electronically controlled. 0,25 Technology across the entire product line enabling optimized emissions and connections and components is drastic - ■ Flexible injection timing and duration. and range of applications. The broad 0 engine performance. ally reduced and thus increases reliability. ■ Capability of multi shot injections. 80 ■ Electronics range of Caterpillar’s marine program 0 20 40 60 100 ■ Suitable for HFO, MDO and DO. The inlet metering control of the pump Power Output (%) The key component is the Caterpillar The engine protection system operates calls for a differentiated approach. ■ 100% retrofittable system. ensures a high pump efficiency. A4E4 (or ADEM™) Electronic Control independently of the engine control system The key features are: Module (ECM). The ECM acts as the brain and has its own independent sensor equip- Key criteria are: The goals are: ■ Cat CR System ■ Two pumps for redundancy. of the Cat Common Rail fuel system. Pio- ment. This en sures that engine operation ■ Prevailing emission limits for the Keeping in mind the high reliability expec- ■ Invisible smoke under all engine The main components of the Cat Common ■ Inlet metering control. neered by Caterpillar 20 years ago, the is monitored independently of other control respective power range and timing tations of customers, Caterpillar decided operating conditions. Rail fuel system are a high pressure (HP) ■ Well adapted injection pressure. Rail and Cylinder ADEM™ controller coordinates and en- systems. of their introduction. to adopt a two step approach providing ■ Reduce emissions beyond current pump, rail, injector and electronics. Cater- ■ Closed loop control of rail pressure. hances fuel delivery, air supply and other ■ Customer expectations in terms of the most effective solutions with lowest and future IMO regulations, offering pillar’s broad experience with electroni- The ECM functions can be divided into a engine functions to maxi mize overall per- engine performance, maintenance complexity. an attractive technology for emissions cally controlled engines, range of product ■ Rail core system and a performance system. formance and reduce emissions output. practices, fuel quality and mode of sensitive areas. lines and in-house design and analysis The double-walled rails are pressurized The core system consists of: operation. Flexible Camshaft Technology (FCT) has ■ Maintain or improve engine perform- expertise allow for a unique system and act as an accumulator, with one rail Having in-house expertise for core elec- ■ Control device A4E4. been developed and put into production. ance by taking advantage of the approach. All components are developed segment feeding fuel to three injectors, tronic components and software puts By adopting well proven elements of this ■ One crankshaft speed pick-up. The next milestone in emissions techno- capabilities and benefits of a fully under Caterpillar design control. i. e. a nine cylinder engine has only three Caterpillar in a unique position and allows technology for medium-speed engines, it ■ Two camshaft speed pick-ups. logy is a fully flexible fuel system suitable flexible fuel system. rail segments, an eight cylinder engine for an advantageous systems approach. is our goal to meet and exceed customer In addition Caterpillar’s expertise in elec- ■ Two high-pressure sensors. for HFO, MDO and DO, called the Cat ■ Continue to meet the level of reliability has two rail segments, each feeding four Injector expectations by maximizing product value tronics is a major asset to the Cat Com- Based on existing software and engine ■ Inlet metering valve. Common Rail (Cat CR) fuel system. Cat in heavy fuel operation expected by injectors. This layout reduces the number through: mon Rail technology. control strategies, the specific needs of ■ Injector drivers. Common Rail is considered one major our marine customers. of parts and the number of high pressure ■ Superior reliability in heavy fuel heavy fuel burning engines and applica- building block towards low emissions, connections. Flow limiters prevent the The performance system ensures optimal operation. ■ Safety Concept tions can be easily adopted. Depending high performance and highest customer cylinders from overfueling; a safety valve engine settings under all operating condi- ■ Best fuel efficiency in its class. Safety considerations and high customer on engine type, application and boundary value. acts as pressure relief in case of an un- tions, using information like exhaust gas ■ Lowest engine emissions with value were the main focus throughout the conditions, a tailor made version allows wanted overpressurized rail. temperature, charge air pressure, ambient minimum additional complexity. development, resulting in a state-of-the- for optimal operation. conditions and lube oil temperature. art design with the following features: ■ Two high pressure pumps for Less Fuel and Reduced Emissions Mean More Environmental Care: Specific Fuel Oil Consumption M 32 C Cat CR IMO II Specific Fuel Oil Consumption M 32 C Cat CR @ 600 rpm redundancy. (from 0,6% up to 3% Improvement) (from 1% up to 2% Improvement) ■ Double-walled lines and rails. Gateway Commu- M32C nications Module External to Control System – 240 250 (PL1000E) supplied by Caterpillar Motoren or OEM M 32 C Common Rail System 230 Constant Speed Common Rail 240 Standard Engine J1939 Modbus Combinator Curve VD 8744-4 Common Rail Optimized Common Rail 220 230 Constant Speed Standard Engine Common Rail Partload Optimized Modbus FieldBus Combinator Curve VD 8744-4 StandardEengine 220 J1 Module 210 Cat CR Pump 1 210 200 J2 J1 Atmospheric Pressure 200 190

sfoc [g/kWh] 190 Cat CR Pump 2 180 sfoc [g/kWh] Intake Manifold Pressure 180 170 170 Engine Intake Manifold Air Temperature Dual Cam Speed/Timing Electronic 160 160 Secondary Cam Controle Module 0 50 100 150 200 250 300 350 400 450 500 550 0 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% (A4E4v2) Engine Coolant Block Power [ kW/cyl] Power [ kW/cyl] Primary Cam Outlet Temperature High Pressure Pump Safety Gear Control Device A4E4 Fuel Rail Pressure I Fuel Rail Temperature Main Propulsion (Inline engine M 32 C Cat CR with kW/cyl. @ 600 rpm; ISO 3046/1 Generator Set (6, 8 and 9 M 32 C Cat CR IMO II; SFOC acc. ISO 3046/1, LCV 42,7 Single Crank Speed/Timing and LCV 42,7 MJ/kg; 5% tolerance, + 1% engine driven pump). Values for information only. MJ/KG; 5% tolerance, + 1% engine driven pump). Values for information only. Fuel Rail Pressure II

Turbine Inlet Temperature LH