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MTU's Fast F e r r y Engines U n d e r g o M e t a m o r p h e s is

Criteria used to judge the success of a propulsion system include power capability, operational reliability and low-cost maintenance and repair improvements. MTU Friedrichshafen has developed a maintenance prediction system for its 1163 fast ferry diesel engines, designed to increase the performance of its engines and cut the cost of repair. The 20-cylinder engine version, 20-V 1163 TB 73L (4), with a total output of 26,000 kW, will provide the power to further increase speeds for large passenger ferries and break the 40-knot barrier. The continuous output of the 16-cylinder version has been increased to 5,200 kW, and it too achieves impressive figures in comparison areas such as engine dimensions, power-to-weight ratio, fuel consumption and operational parameters.

The maintenance program has introduced a number of features to the 1163 engines, designed to increase the intervals between overhauls and the overall service life of the engines, thereby offering ship operators an efficient and costeffective propulsion system. These features can be described in a five-step package: • Improvement of the standard high-pressure system in order to optimize fuel consumption and exhaust emissions • Bore cooling achieved by increasing cylinder head fatigue strength • Improved power and torque characteristics achieved by modifying the proven two-stage sequential turbocharging system • Adaptation and optimization of the turbochargers to match the cylinder output of 325 kW • Intelligent electronic engine management. Other design elements include preheated intake air for idling and low-load operation, cylinder cutout systems and accommodation of turbines and exhaust piping in watercooled housings. Both engines are based on the tested design of the twin 956/1163 series, as well as the knowledge gained from operational service in a wide range of applications. For high-performance applications such as frigates, corvettes and large yachts, the 20-cylinder version continues to offer a maximum output of 7,400 kW. The reduction from 370 to 325 kW/cylinder illustrates the engine's substantial reserves with regard to operational reliability and resistance to wear. Over 200 of the V-20 engines have been delivered since 1985, while a total of 1,585 engines of the twin 956/1163 type are currently in service worldwide. Another maintenance system will be available in the future, the CAS (Condition Analysis System). This system is being developed by MTU in four stages, starting with the operating data recorder which records all data relevant to engine operation, and ending with the trend analysis and diagnosis system.

The trend analysis and diagnosis system brings recorded and historical data together. The use of these methods reportedly achieves significantly greater utilization of standard life than conventional methods.

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