I wish my father was alive to see this documentary. He was a Marine Engineer Diesel Mechanic he never worked on ships of this size he worked on prawn fishing trawlers. But he would of loved watching this as much as I did he would of told me a lot of what is going on behind the scenes R.I.P Dad but i have to say the amount of intelligence natural and artificial that has gone into its design then all the manual labor to build and maintain plus the special machinery to make it all happen mind blowing. Love documentaries showing how dar we have come as humans but how far engineering in all fields have come by means of people in the self quest to better things and ideas collaborating to make things like this happen.
I love this documentary. I actually wish it was more detailed, and showed more of the machining and testing of the engine at the MTU factory. I was amazed at the amount of special tools they use in the assembly of the engine. Every task has it's own fixture, lifting device, and wrench. Every lifting device perfectly balances the workpiece in the correct orientation for assembly. It's the German mania for perfection that makes this possible.
Yes - it's crazy to think about how each step of the assembly has unique sub components, and even that overhead gantry system is a masterpiece of engineering in terms of both hardware and software within itself
It was very detailed, one of the best I've ever seen. However, I did notice the machining was skipped and thought the same thing. Did you notice 75000 Nm of torque? Thats roughly 55000 Ft Lbs.
I work on a newly built Longliner in Alaska. The F/V Arctic Prowler. It has two twelve cylinder MTU mains. Five generators. It was supposed to be twice as big as it is. Poor management . It has so much power. When your in the chair, you feel like you are steering a mechanical Dragon. So loud.
The guy is probably a very good welder but still, this was a sloppy way to make a pipe. A single, hydroformed piece would be much better. Like the rest of the engine's construction, this part was crudely made.
Welding pieces like that is old hat. In my company that would have been bent to shape using a hydraulic manipulation tool. Constant repeatability and accuracy.. Ex British diesel engine company - much quicker. 3 hours to remove a cylinder assembly - very slow, Rustons could do it in 1.5 hours years ago.
A couple of things. 1. What is being referred to as crank case is actually an engine block. Crank case is part of the engine block 2. It was stated that these big engines do not require maintenance for 35 years. Well they require maintenance at every 4000 hours of operation and scope of maintenance keeps increasing with age. Omar Marine engineer Ex general manager Wartsila
No, in this case, crankcase is the correct term since the cylinders themselves seem to be their own castings. A block is usually one single casting, but in this case the crankcase alone is a single piece.
@@infrapunaperse With all due respect, that would be running 24 hours a day, every day of the year, for over 57 years. I suspect your numbers are wrong.
@@gheumannOn my Last ship built by sietas on 1978. Engine was Wärtsilä 6R46 and it was used from 78 To this day. Engine hours was about 330 000 and there was nothing wrong with the engine. Not any major overhauls. Just regular maintance by experienced crew.
The issue with the MTU engine is that the A10 and B10 cylinders are the closest to the intercooler which meant that they take the most thermal stress when the engine goes full rev and idle. Constant replacement. Also the exhaust thermocouples are constantly coated by carbon and they bend easily due to high temperatures, causing false temperature which activates the engine auto shutdown active.
I've always wondered how money is made out of shipping when you factor in all the man hours, the expertise and the materials to build such a thing. Then on top of that the running costs, fuel, wages etc etc. This clip has only confirmed in my mind how any money is made. It is truly amazing on a myriad of levels
You have to take into account the fact that these engines run on 2 types of fuel, mgo (marine gas oil) and hfo ( heavy fuel oil) where the hfo cost is considerably less then the mdo fuel, but has restrictions regarding where it is allowed to be the propellant of the engine
I spent 3 weeks training in the Friedrichshafen Germany MTU factory, it is amazing! I operated the 12,200 SHP MTU V20-8000 series engines, they are incredible power plants.
@@Sterlingjob I watched this documentary's german version and just saw this english one. I though man, why do they always have to use all this bullshit drama! Seems like there is even worse in the US.. (I am a german by the way).
There was a lot of BS drama here. First, the narrator or his writers dumbed down the content. Then for the rebuild in port, the narrator talked about the ticking clock, and if it could get done in time.
the CMM scan it ( measurement few hundred point in 1 square inch ) so you can read 0.01 mm accuracy to meet DIN ( Deutsches Institut für Normung ) the visual inspecting most of time is for the color of the surface it tell the quality of the cutting
''man, I do love the Tech of it all'' Diesel-power is forever power .................. Thank You for sharing this beautiful ''gem'' of a Docu. You made a 57y. old guy smile knowing what a Diesel-motor can do when you turn that ''key'' - START - and put the ''BEAST'' to the test.
The guys doing the 2 ship power unit replacements were heros... THATS pressure ... & none of the fancy factory hoists & tools/equipment available to THEM !! Hell, even the lighting was sub par for that work... 🙄😏 😎👍☘🍺
You are missing the point- if you have 2 objects, and if one of them is different from the other by a few hundredths of a millimeter- you sure as HELL can't detect the difference just by LOOKING!!
@@txd The average thickness of a human hair is about .1 millimeter- or slightly less than .004 inches. ...but you're absolutely right: 100 x .03 mm equals 3 mm- and NOBODY has hair THAT thick!
well, he is just looking for sharp edges and larger faults before they start measuring it, kinds smart to find the big faults before spending 2 weeks measuring it.
Fascinating documentary thank you I went to the now closed Ravenscraig in Scotland steelworks in 1965 and got some ideas of the process. Amazing precision terrific hard work..
You know you've got a quality, informative documentary when three minutes in, the word 'extreme' has been uttered 7 times already. And then there's the other superlatives of course.
I worked for years in a remanufacturing shop for MTU series 4000, CAT 3516, and Cummins QSK60 diesel engines... And I was always blown away by how nearly perfect the MTU engine blocks were milled... Every mainline and cylinder bore I ever measured (if it wasn't burned up or blown up) was within .0002-.0005 of spec... where Cummins was always +- .001 and CAT+- .0015.
@@justinlea2406 You aren't kidding... One of the final proceedures we performed on engine blocks was to "test bar" the mainline for the crankshaft. Essentially, we torqued up, honed, cleaned, and then oiled the mainline on a block. Then for each brand and model of block we had long custom milled metal cylinders that tested the diameter and alignment of the mainline. If the block was bent (which happened very rarely) the test bar wouldn't go and once in a blue moon it would wedge in (very not good)... Anyhow, the MTU series 4000 had such tight mainlines that you had to yank the test bar out full force as to not risk it wedging on the last 2 bores... And, it made a special sound (which I can't explain) that only MTU series 4000 mainlines made when test barred at mid spec... I always thought of it as the sound of perfection, because that was exactly what it took to make it...
"The tolerances to be adhered to are so minute that they can no longer be perceived to the naked eye" - Cut to guy using his naked eye to inspect the engine.
Inspecting an engine and measuring tolerances are two different things. Wear patterns and other indicators from operating an engine is not the same thing as measuring and assembling.
He's not taking measurements (good luck finding a caliper or micrometer that big), he's checking the surfaces for any indication of poor machining, which would indicate that the giant ass CNC needs new inserts. That's my hypothesis as a machinist anyway, he could also just be checking to make sure everything's deburred properly.
When I was an apprentice 60 years ago, we visited Ruston's at Lincoln. Thay manufactured enormous diesel engines. The awesomeness of these machines has never left me. Sadly no more - like most British industry
32:35 There's the reason the power units had to be replaced on the ferry boat. Big, long crack in the exhaust valve bridge. This happens a lot in high-power density 4-valve diesel engines.
MTU ship engines are usually coupled with Kamewa jets (both companies are owned by Rolls-Royce). It's amazing that it's even possible to build water jet impellers that can stand 10MW of power.
It's amazing that an engine like this actually produces megawatts of power. And it certainly cost Mega-$millions of dollars (or Euros) if this massive factory is only producing 25 (or 35?) engines a year.
It always blows my mind how people gather, come up with ideas, invest, work their butt off and eventually come up with something so amazing. Just think how long and how hard it was to get to what we ahve now. Insane. We are strong when we unite and pitch in.
I've worked as an electrician in shipyards for years. The engines are so cool. This video brought me a lot of great understanding about the engines... Thanks!!!
The intro theme is music to forge by. I've watched this documentary 3Xs. Reminds me of foundry classes in high school. My freshman fascination was overpowered by feeling I was a kid in dire straits! Way more fun on screen.
The biggest engines I work with are on large high killowatt generators, mining equipment, and on tugboats on the Mississippi River, and the occasional locomotive engine. These are on a whole new level, it would be a lot of fun to work with these:-).
These engines are a masterpiece of imagination, design, engineering, technology, materials, manufacturing and construction! Exacting precision at all phases and stages and in all systems, components and ancillaries is crucial. With advances in metallurgy, engineering, production and testing processes comes improved and extended refinement and reliability. Thank you for this highly informative and entertaining insight into the production and field maintenance of these superb series of high performance marine powerplants!
@@andyharman3022 That's what I said. No one is pushing anything down our throats. Gasoline engines are toxic to the Earth. It is selfish to want to continue using them for your own enjoyment.
Amazing. Reminds me: I had a submersible water well pump made by the German company Lorenz. It was powered by DC from solar panels. It could take DC from a range of voltages (up to 72!) and convert it to AC 17 volts. It's still in service after 20 yrs of daily service. German engineering is tops.
love this documentary. The ability to give us such detail and dive deep into creating this massive diesel engine is quite amazing. The creative camerawork is especially noteworthy, and appreciated
What was never specified in the video. If the engine was a 2 stroker or 4 stroke. Both have 4 valves.. The engines are similar to EMD 20-710G7B made by GM..
In the late 70's, early 80's I modified Detroit Diesel engines for marine applications. We offered some 16 cylinder, twin turbo models, rated about 1300 hp (I think...long time ago). They are john-boat engines compared to these MTU's! Amazing process to assembly these bad boys!!
Brilliant, well done! I thought, for a minute, we were at Cape Canaveral at take off to land a man on the moon, not just the start of a rebuilt Disco engine! OMG Vera! Loved it!
I'm a retired diesel engine machinist. I kept seeing people touching bare metal with bare hands which is a big no-no because it can cause future rust wherever the bare hand touches.
You can really see why exporting this type of advanced machinery is so much more incredible than raw commodities like in south america where i live. Loading up ships with fruits, grains and oil, is quite basic compared to this advanced engineering. Bravo!
Wow, those "Blowout" graphics are so killer! I've seen the entire paradigm of engineering change right in front of my eyes over the last half century...The design, materials, precision assemblies and performance of these machines would seem like science fiction 40 years ago...
I served on HSV-2 Swift, Incat hul 061, same engines and propulsion and it’s very impressive how these work and how maneuverable and fast these vessels are
Great video!. I actually have a piston from an MTU sitting beside my wood stove which I use as a resting place for my griddle pan. It was from a V16 MTU which I think was at one time fitted to a British Rail Class 43 HST. I love it...
To the fact that each part was made separately, It is very impressive that each individually made part fits, each separately formed part perfectly. Perfection in mechanics and extreme knowledge of mathematics. You won't see any high school dropouts working there. Great video.
@@inrg3688 If it was 35 years old the entire engine would be pulled out. Just 2 power units were changed because of microscopic cracks leaking fluid into the combustion chamber. Problems do occur occasionally, depending on how hard they're pushed each day they last up to 35 years USUALLY.
It's amazing the amount of materials required to build these, and then to think about all the massive ships already built and out there. I think we'll run out soon.
Great stuff. The technology is not so much the engine but more the materials and precision of the manufacturing process. Both advanced materials and precision manufacturing have been elusive for centuries. Precision was only seen in jewellery and watches. As precision is so difficult and advanced, Egyptologists are at a total loss when confronted with ancient boxes and granite blocks.
Love how they over dramatize everything...lol 29:38 "...coat the edges with a special sealing compound..." aka RTV silicone, available at your local parts store...
@@jamesmancine8350 Yeah, they do actually. Suits the purpose just fine. If it needs sealing, and isn't pressurized, why reinvent the wheel? Sincerely, a ship's engineer.
@@nathanwahl9224 ...IF IT WAS PRACTICAL TO USE ORDINARY SEALER- I'M PRETTY SURE THEY'D USE IT!!! THESE ENGINES ARE PROBABLY HARD TO SERVICE- AND DOWNTIME IS DAM EXPENSIVE!!!
This Is heavy engineering at its very best never realized b4 how much time n effort goes into designing n building an engine this size, now I even have a lot more respect for my little 1.4 diesel engine
WOW !!! I was used to seeing GE and GM EMD 16 cylinder Diesel Locomotive engines. These engines made in Germany make them look like their babies 😉!!! This is some serious power! THANK YOU FOR MAKING AND POSTING the video !!!
This looks fascinating ,but can you imagine the brain behind all the planning,preparations,who design all the components of the engine, ,human brain is so small but can do unimaginable ideas
A huge team of machinists, engineers, mechanics, physicists, and others and over a hundred years of combustion engine advancement already behind them is a far cry from the imaginary Einstein sitting down and inventing this as you imagine.
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Germans are aliens, 1945 they were destroyed second time, and today they are powerhouse, if it was not for Germans none of us in this planet would have to technology and comforts and reliability of things we use everyday
Excellent documentary, but there was an error in comparing the weight of the engine to that of a steam locomotive. Locomotives did not weight 48 tons, perhaps only the very earliest and lightest ones. Average steam freight and passenger locomotives weighed 200 to 400 tons. The Union Pacific Big Boy weighed 600 tons. My grandfather was an Engineer for the Baltimore and Ohio and used to operate the Baldwin and Mikado steam locomotives.
Not an error, a slight exagerration. Mallard (British built, service 1938 to 1963) holds the steam speed record at 126MPH (while pulling a dyno car and 6 passenger cars) and is the most obvious example I could think of for a reasonably typical European passenger locomotive which was advanced for its time (continuous running at 100MPH.) It weighed 167 metric tonnes, so a little over 3 times the 48 tonne weight of this diesel engine. So the only problem with the claim is that they mean a small steam locomotive. On the other hand the Big Boy was (according to Wikipedia) the second heaviest steam locomotive at 600 short tons (2000lb.) This video uses metric tonnes which are larger (1000kg, almost exactly the same as the 2240lb long ton.) What's weird about this video is hearing metric units in an American accent.
It is hard to identify jokes just based on the characters people type, but people who think like you are those who believe we never launched and landed on the moon. You think engineers aren't capable of designing an engine of that size? Give us the money and time and we can make anything. Yes I am an engineer. Also give credit to those technicians because they are brilliant, they are the ones who bring our theoretical work to life.
If they needed “absolute synchronicity” a slow microcontroller controlling everything will be far more synchronized than 2 or more humans in lockstep could ever be, so I found that bit comical. Just like in Star Trek where they do the same sort of things by biological timing and countdown: all for dramatic effect, not for actual precision.
This was pretty hard to watch. Most of the 'absolute precision' was performed with extremely sloppy methods. Other than good engineering, these engines are very crudely made.
dab 8430 my 7.3 PSD is pretty bad ass and I’ve only got the cold air and a hypermax programmer I bought on CL 15yrs ago for $125. Makes it quite strong and quick. And no smog crap on it.
Takes me back to my days as a marine pipefitter at the Philadelphia Naval Shipyard were one of the projects I worked on was one of the diesel generators of the USS Guadalcanal. It was huge but I think somewhat smaller than this behemoth.
Tolerance is is a restriction on a dimension. So a hole needs to be 1 inch within a tolerance of .005 inch.(that's a standard machining tolerance) .005 inch is smaller then the width of some human hairs, meaning it can't be determined by eye. He was checking the surface finish. It's an unfortunate edit but you really can't see the required tolerance.
![Twenty One Pilots - The Line (from Arcane Season 2) [Official Audio]](http://i.ytimg.com/vi/XCz7WUotXs8/mqdefault.jpg)
I love these kind of documentaries that are straight up and not dramatized in any way
I wish my father was alive to see this documentary. He was a Marine Engineer Diesel Mechanic he never worked on ships of this size he worked on prawn fishing trawlers. But he would of loved watching this as much as I did he would of told me a lot of what is going on behind the scenes R.I.P Dad but i have to say the amount of intelligence natural and artificial that has gone into its design then all the manual labor to build and maintain plus the special machinery to make it all happen mind blowing. Love documentaries showing how dar we have come as humans but how far engineering in all fields have come by means of people in the self quest to better things and ideas collaborating to make things like this happen.
RIP to your dad. it really is beautiful what humans can do when we work together and share ideas
I love this documentary. I actually wish it was more detailed, and showed more of the machining and testing of the engine at the MTU factory. I was amazed at the amount of special tools they use in the assembly of the engine. Every task has it's own fixture, lifting device, and wrench. Every lifting device perfectly balances the workpiece in the correct orientation for assembly. It's the German mania for perfection that makes this possible.
...TRADE SECRETS(?)
Yes - it's crazy to think about how each step of the assembly has unique sub components, and even that overhead gantry system is a masterpiece of engineering in terms of both hardware and software within itself
It was very detailed, one of the best I've ever seen. However, I did notice the machining was skipped and thought the same thing. Did you notice 75000 Nm of torque? Thats roughly 55000 Ft Lbs.
@@jessemurray1757 Yes, that's about how much torque the engine needs to make if it's going to produce 12000 hp @ 1150 rpm. Outstanding!
I work on a newly built Longliner in Alaska. The F/V Arctic Prowler. It has two twelve cylinder MTU mains. Five generators. It was supposed to be twice as big as it is. Poor management . It has so much power. When your in the chair, you feel like you are steering a mechanical Dragon. So loud.
I want to give props to the team that had to painstakingly model that entire engine.
That ! is the real job of precision and time. Would love to see that CAD model
41:10 welding curved sections while the work piece is turning is a challenge for every welder.
no .. it makes the job 100 times easier !!!
I was about to say the same, spend last 16 years welding
They didn't show if he stacked the dimes.
The guy is probably a very good welder but still, this was a sloppy way to make a pipe. A single, hydroformed piece would be much better. Like the rest of the engine's construction, this part was crudely made.
@blackdaan
, haha true
Welding pieces like that is old hat. In my company that would have been bent to shape using a hydraulic manipulation tool. Constant repeatability and accuracy..
Ex British diesel engine company - much quicker. 3 hours to remove a cylinder assembly - very slow, Rustons could do it in 1.5 hours years ago.
A couple of things.
1. What is being referred to as crank case is actually an engine block. Crank case is part of the engine block
2. It was stated that these big engines do not require maintenance for 35 years. Well they require maintenance at every 4000 hours of operation and scope of maintenance keeps increasing with age.
Omar
Marine engineer
Ex general manager Wartsila
No, in this case, crankcase is the correct term since the cylinders themselves seem to be their own castings. A block is usually one single casting, but in this case the crankcase alone is a single piece.
You're cool
@@franciscochacon1197 yeah, I’d say so. Intelligence is cool no matter how much society here in the west tries to tell you the opposite.
an engine block includes the cylinder bore :: here the bore is separate ::
As a hobbyist machinist, fan of engineering and motorhead - I LOVED this. What a monster motor! 75,000 hour life between rebuilds!!!!
That's an equivalent of 4 million kilometers in an average car.
That's ten years of round-the-clock duty allowing for brief spells of maintenance downtime.
@@infrapunaperse With all due respect, that would be running 24 hours a day, every day of the year, for over 57 years. I suspect your numbers are wrong.
@@gheumannOn my Last ship built by sietas on 1978. Engine was Wärtsilä 6R46 and it was used from 78 To this day. Engine hours was about 330 000 and there was nothing wrong with the engine. Not any major overhauls. Just regular maintance by experienced crew.
@@infrapunaperse That is amazing. Very cool. So the engine runs virtually 24 hours a day every day?
This is awesome. Being a guy who's done many automobile engines, this is insane.
The issue with the MTU engine is that the A10 and B10 cylinders are the closest to the intercooler which meant that they take the most thermal stress when the engine goes full rev and idle. Constant replacement. Also the exhaust thermocouples are constantly coated by carbon and they bend easily due to high temperatures, causing false temperature which activates the engine auto shutdown active.
My hat's off to the technicians at the MTU facility! Your craftsmanship and expertise is amazing!
The MTU 8000's bite and why do they do that? i pulled its tail and it bit me
I've always wondered how money is made out of shipping when you factor in all the man hours, the expertise and the materials to build such a thing. Then on top of that the running costs, fuel, wages etc etc. This clip has only confirmed in my mind how any money is made. It is truly amazing on a myriad of levels
500 gallons of diesel per hour 😮
all the money is made in the gift shop 😂😂
Underated comment.
You have to take into account the fact that these engines run on 2 types of fuel, mgo (marine gas oil) and hfo ( heavy fuel oil) where the hfo cost is considerably less then the mdo fuel, but has restrictions regarding where it is allowed to be the propellant of the engine
@@torer6203 not for much longer, we are finally going to stop burning got dang bunker oil in international waters soon
I spent 3 weeks training in the Friedrichshafen Germany MTU factory, it is amazing! I operated the 12,200 SHP MTU V20-8000 series engines, they are incredible power plants.
It's amazing that they are about twice as powerful as the largest locomotive engines used in the US.
that sounds amazing
the test at some point said 75000nm - 55000 ft pounds
Nice video. The difference between European and American documentary without bullshit drama is refreshing
Shaun oneill I think there is a bit of drama and sensationalism!
@@Sterlingjob I watched this documentary's german version and just saw this english one. I though man, why do they always have to use all this bullshit drama! Seems like there is even worse in the US.. (I am a german by the way).
宣子
Moritz Weidt US documentary’s are the worst...I can’t watch them!
There was a lot of BS drama here.
First, the narrator or his writers dumbed down the content.
Then for the rebuild in port, the narrator talked about the ticking clock, and if it could get done in time.
18:34 "The tolerances to be adhered to are so minute, that they can no longer be perceived with the naked eye." Cut to man *visually* inspecting it.
the CMM scan it ( measurement few hundred point in 1 square inch ) so you can read 0.01 mm accuracy to meet DIN ( Deutsches Institut für Normung ) the visual inspecting most of time is for the color of the surface it tell the quality of the cutting
@@lucthien601 I was joking about the way the video was edited, but that's still pretty cool.
"It's a job which calls for a lot of experience" - Shows a guy kicking sand around with his feet.
That was my favorite part.
@@nosaltadded2530 Man, you are one ignorant Nazi.
@John S Could you by any chance tell me the difference between a white nationalist and a Nazi?
muslim , nazi , white nationalist , wtf guys ! thats all internet bullshit , those things dont exist .. look around you lolll
and btw .... i m white so stfu becose white privilage ! (omggg hahahaha ;,D )
''man, I do love the Tech of it all'' Diesel-power is forever power ..................
Thank You for sharing this beautiful ''gem'' of a Docu.
You made a 57y. old guy smile knowing what a Diesel-motor can do when you turn that ''key'' - START - and put the ''BEAST'' to the test.
Oh... the german efficiency.
Im jealous of those clean workspaces and proper drawer sortings.
I also love organization
The guys doing the 2 ship power unit replacements were heros... THATS pressure ... & none of the fancy factory hoists & tools/equipment available to THEM !!
Hell, even the lighting was sub par for that work... 🙄😏
😎👍☘🍺
Pretty easy to keep it clean if they make one every 2 weeks now if it was 25 a week i would impressed
@@TheAlfast69 what? Do you realize the size and complexity of this engine... like wut
@@ronidude it wouldnt be hard to amp up products it looks like a lot of the shop sits around with a thumb up there a
Beautiful to see German Engineering at its best. Number 1 craftsmanship.
But it is owned by Rolls-Royce
It was easy to continue watching because the content has detail. The dumbing down of documentaries is a shame.
with the typical, " but wait theres a problem"
yamahonkawazuki What?
Also no ads made this 98% more watchable
agreed, this is a fairly detailed documentary but still entertaining to watch,
Rod Kirt I’m not going home
Those Germans know how to build a motor for sure.
Hats off to Those Guys !
"Cannot be perceived with the naked eye" -> guy inspects block with eyes
3 or 4 hundredths of a millimeter. Then later he goes on saying a hundredth of the width of a human hair. I dont have hair thats 3mm thick.....
You are missing the point- if you have 2 objects, and if one of them is different from the other by a few hundredths of a millimeter- you sure as HELL can't detect the difference just by LOOKING!!
@@txd If a millimeter is .03937 inches, then a hundredth of a millimeter is .0003937 inches.
@@txd The average thickness of a human hair is about .1 millimeter- or slightly less than .004 inches.
...but you're absolutely right: 100 x .03 mm equals 3 mm- and NOBODY has hair THAT thick!
well, he is just looking for sharp edges and larger faults before they start measuring it, kinds smart to find the big faults before spending 2 weeks measuring it.
Man, whoever wrote the script for this has a tenuous grasp of technical terminology.
It's entertainment, not a free education.
@@kinkaidglade2388 and nicely, for the most part, explained in terms lay people can understand.
@@r.k.edwards3994 shows what you know mother goose.
When I heard "con rod" I was like whats that. Oh he meant connecting rod.
“Millimeter accuracy”
Did anyone else notice at 14:22 the huge crack in that lifting device? I'm surprised that that has gone unnoticed at the plant.
holy fuck
In Soviet Russia cracks strengthen metals.
CRUMBS, DANGERMOUSE!!
shits going down soon
@@tim140i8 I'm pretty sure that they know what they're doing...(?)
My hats off to the men who work around all that heat!
Seeing the exploded views of this engine really gives one the real perspective of just how insanely intricate and technical it is. Magnificent!
Fascinating documentary thank you I went to the now closed Ravenscraig in Scotland steelworks in 1965 and got some ideas of the process. Amazing precision terrific hard work..
You keep hearing about this fabled German Engineering.... and then you see it...... WOW
You know you've got a quality, informative documentary when three minutes in, the word 'extreme' has been uttered 7 times already. And then there's the other superlatives of course.
It' is truly amazing how all of these pieces comes together to make such a big engine.
I worked for years in a remanufacturing shop for MTU series 4000, CAT 3516, and Cummins QSK60 diesel engines... And I was always blown away by how nearly perfect the MTU engine blocks were milled... Every mainline and cylinder bore I ever measured (if it wasn't burned up or blown up) was within .0002-.0005 of spec... where Cummins was always +- .001 and CAT+- .0015.
No one cares
Honestly
If so , they are protecting ur feelings
Cheers from West Africa
🦅
@@criessmiles3620 You cared enough to comment!😜😂✌😎
Those are crazy tight tolerances for a huge engine.
@@justinlea2406 You aren't kidding... One of the final proceedures we performed on engine blocks was to "test bar" the mainline for the crankshaft. Essentially, we torqued up, honed, cleaned, and then oiled the mainline on a block. Then for each brand and model of block we had long custom milled metal cylinders that tested the diameter and alignment of the mainline. If the block was bent (which happened very rarely) the test bar wouldn't go and once in a blue moon it would wedge in (very not good)... Anyhow, the MTU series 4000 had such tight mainlines that you had to yank the test bar out full force as to not risk it wedging on the last 2 bores... And, it made a special sound (which I can't explain) that only MTU series 4000 mainlines made when test barred at mid spec... I always thought of it as the sound of perfection, because that was exactly what it took to make it...
@@jimvick8397 that is honestly very impressive
"The tolerances to be adhered to are so minute that they can no longer be perceived to the naked eye" - Cut to guy using his naked eye to inspect the engine.
Inspecting an engine and measuring tolerances are two different things. Wear patterns and other indicators from operating an engine is not the same thing as measuring and assembling.
@@hughmac312 r/woosh
He's not taking measurements (good luck finding a caliper or micrometer that big), he's checking the surfaces for any indication of poor machining, which would indicate that the giant ass CNC needs new inserts. That's my hypothesis as a machinist anyway, he could also just be checking to make sure everything's deburred properly.
It was more of a dig at the video editing. The voice over mentions high tolerances you should cut to the technology to check them.
djtecthreat are you serious, really?
When I was an apprentice 60 years ago, we visited Ruston's at Lincoln. Thay manufactured enormous diesel engines. The awesomeness of these machines has never left me. Sadly no more - like most British industry
MTU is owned by Rolls Royce.
Those turbos are ALMOST as big as some of the ones I've seen on Supras.
It has 4
You shaft is turbo Brian?
Actually 6 there’s 4 upfront and 2 in the back
@@bronson2585 I thought the 2 in the back were some sort of pump. Also 6 doesn't divide up into 20 like 4 does. 1 turbo for 5 cylinders.
@@bronson2585..... The 2 (blue) that you see at the opposite end of the block (front), are Water Pumps, Not Turbochargers.
32:35 There's the reason the power units had to be replaced on the ferry boat. Big, long crack in the exhaust valve bridge. This happens a lot in high-power density 4-valve diesel engines.
"Only examination under a microscope" - how about that crack right there?
@assassinlexx yeah but it would make it so much more expansive
MTU ship engines are usually coupled with Kamewa jets (both companies are owned by Rolls-Royce). It's amazing that it's even possible to build water jet impellers that can stand 10MW of power.
It's amazing that an engine like this actually produces megawatts of power. And it certainly cost Mega-$millions of dollars (or Euros) if this massive factory is only producing 25 (or 35?) engines a year.
It always blows my mind how people gather, come up with ideas, invest, work their butt off and eventually come up with something so amazing. Just think how long and how hard it was to get to what we ahve now. Insane. We are strong when we unite and pitch in.
I've worked as an electrician in shipyards for years. The engines are so cool. This video brought me a lot of great understanding about the engines... Thanks!!!
@James hello,how are you doing
@@yvonnebraun7 I can't complain, I'm doing okay. How about you? How are you doing?
@@JamesSamples am good, i will be glad to know you better if you dont mind. maybe we can both communicate on google hangouts.
@twizzm What you read here was the last contact. Something just ain't right there.
I have worked on these engines. The noise it make during startup shakes the marrow in your bones it’s so loud.
MAGNIFICENT process of workmanship!
The intro theme is music to forge by. I've watched this documentary 3Xs. Reminds me of foundry classes in high school. My freshman fascination was overpowered by feeling I was a kid in dire straits! Way more fun on screen.
The biggest engines I work with are on large high killowatt generators, mining equipment, and on tugboats on the Mississippi River, and the occasional locomotive engine. These are on a whole new level, it would be a lot of fun to work with these:-).
Did you help Texas with their generators during the winter storm?
No one cares
These engines are a masterpiece of imagination, design, engineering, technology, materials, manufacturing and construction!
Exacting precision at all phases and stages and in all systems, components and ancillaries is crucial.
With advances in metallurgy, engineering, production and testing processes comes improved and extended refinement and reliability.
Thank you for this highly informative and entertaining insight into the production and field maintenance of these superb series of high performance marine powerplants!
Also a masterpiece of destroying our Earth. It's long past the time to move on from burning things for transportation.
@@casual35 When you find out how to do that effectively let us know.
@@luis_techie it's been done for decades. You think electric cars are new?
@@casual35 Electric cars came before gasoline cars, but couldn't compete. Now the gummint is trying to ram ev's down our throats.
@@andyharman3022 That's what I said. No one is pushing anything down our throats. Gasoline engines are toxic to the Earth. It is selfish to want to continue using them for your own enjoyment.
Amazing. Reminds me: I had a submersible water well pump made by the German company Lorenz. It was powered by DC from solar panels. It could take DC from a range of voltages (up to 72!) and convert it to AC 17 volts. It's still in service after 20 yrs of daily service. German engineering is tops.
love this documentary. The ability to give us such detail and dive deep into creating this massive diesel engine is quite amazing.
The creative camerawork is especially noteworthy, and appreciated
Watching this puts my boat engine problems into perspective.
But here you are talking behind your boat engines back
This made me laugh far too much
Put my house in perspective
😂
Bust Out Another Thousand
Impressively detailed. Not a second boring. Well done.
I have never seen a manifold in pieces, the same with the firing chambers, they are sectionals with 4 valves each, amazing engineering.
What was never specified in the video.
If the engine was a 2 stroker or 4 stroke.
Both have 4 valves..
The engines are similar to
EMD 20-710G7B
made by GM..
@@Butchsiek all this engines are 4 stroke, they are diesel
Fantastic engineering at work - German machines are unique. Thank you for sharing documentary, good work
I would have enjoyed seeing the crank shaft manufacturing process
@Eze&Yare Dominguez ha, maybe. But 9 ton of crankshaft flapping about on a lathe would be a cool sight.
Wonder what would happen to get it cammed lol
@@scripulance.1901 A good marine cam would wake it up. But the lathe, and grinding work would be interesting to see.
@Eze&Yare Dominguez He meant replacing the cam with bigger lobes for more performance. Not replacing it during it's lifespan.
@@InTheDogHouse3DPrinting exactly what I meant man
In the late 70's, early 80's I modified Detroit Diesel engines for marine applications. We offered some 16 cylinder, twin turbo models, rated about 1300 hp (I think...long time ago). They are john-boat engines compared to these MTU's! Amazing process to assembly these bad boys!!
Thank you for this documentary. Incredibly interesting, and good editing too.
Brilliant, well done! I thought, for a minute, we were at Cape Canaveral at take off to land a man on the moon, not just the start of a rebuilt Disco engine! OMG Vera! Loved it!
I'm a retired diesel engine machinist. I kept seeing people touching bare metal with bare hands which is a big no-no because it can cause future rust wherever the bare hand touches.
Or cut your hands up, or give you carpal tunnel, or burn your hands... gloves are a necessity
5 thousand microwave ovens? I hate when they use these comparisons. Engine weighs 40 tonne..... or the equivalent of 1.5 billion toenails.
Lol
hilarious..
Now that's funny
Is that fully pulled toenails, or trimmed clippings? Asking for a friend lmao
ha... so this is smart people humor...
You can really see why exporting this type of advanced machinery is so much more incredible than raw commodities like in south america where i live. Loading up ships with fruits, grains and oil, is quite basic compared to this advanced engineering. Bravo!
But....every bit as important!!
We all need each other's service, and are grateful for it!!
EXTRAORDINARIO DOCUMENTAL...LOS DIOSES DE LA INGENIERIA Y LA TECNOLOGIA¡
Super fascinating to watch! Man, the amount of engineering that goes into this, incredible.
Wow, those "Blowout" graphics are so killer! I've seen the entire paradigm of engineering change right in front of my eyes over the last half century...The design, materials, precision assemblies and performance of these machines would seem like science fiction 40 years ago...
It's really neat to see the *sparkles* over the proprietary mix of metals like at 5:44. Like you know that's some top quality metal there.
For some reason I just love anything about engine,i don’t know why I didn’t study mechanical engineering. I love to watch this kinds of documentaries.
I served on HSV-2 Swift, Incat hul 061, same engines and propulsion and it’s very impressive how these work and how maneuverable and fast these vessels are
HSV-2 Swift was powered by the outstanding CAT 3618 Engines.
No one cares
Great video!. I actually have a piston from an MTU sitting beside my wood stove which I use as a resting place for my griddle pan. It was from a V16 MTU which I think was at one time fitted to a British Rail Class 43 HST. I love it...
How much does it weigh?
To the fact that each part was made separately, It is very impressive that each individually made part fits, each separately formed part perfectly. Perfection in mechanics and extreme knowledge of mathematics. You won't see any high school dropouts working there. Great video.
...maybe sweeping the floors- or taking out the trash-!
Amazing documentary of highly exceptional engineering skilled and expert workers..
I love how they said won’t need servicing for 35 years then cuts back to clip of two of the power units being replaced
what if they are 35 years old?
@@inrg3688 thought about that just thought it was ironic editing lol
@@inrg3688 If it was 35 years old the entire engine would be pulled out. Just 2 power units were changed because of microscopic cracks leaking fluid into the combustion chamber.
Problems do occur occasionally, depending on how hard they're pushed each day they last up to 35 years USUALLY.
Funny thing is, a person could swim laps in the oil pan...
It's amazing the amount of materials required to build these, and then to think about all the massive ships already built and out there. I think we'll run out soon.
lol you're clearly underestimating the size of our planet and the amount of recycling of metal going on
Great documentary! Well produced and informative. Very, very pleasing.
The part of the assembly that I wanted to see the most was not shown. That was the sync and installation of the cam and crankshaft gears.
Great stuff. The technology is not so much the engine but more the materials and precision of the manufacturing process. Both advanced materials and precision manufacturing have been elusive for centuries. Precision was only seen in jewellery and watches. As precision is so difficult and advanced, Egyptologists are at a total loss when confronted with ancient boxes and granite blocks.
Some of the most important people on the planet and they don't make anywhere near what they should.
Would’ve like to have seen the manufacturing of the crankshaft from pouring the forging to cutting, polishing and balancing it.
crybaby.
Me too
Love how they over dramatize everything...lol
29:38 "...coat the edges with a special sealing compound..."
aka RTV silicone, available at your local parts store...
Yeah, I'm sure they use a regular of the shelf silicone on a $15,000,000 engine.
@@jamesmancine8350 lets be real, a ml of they’re special gasket maker doesnt cost a 1000$. Its comparable.
@@jamesmancine8350 Yeah, they do actually. Suits the purpose just fine. If it needs sealing, and isn't pressurized, why reinvent the wheel? Sincerely, a ship's engineer.
@@SirPrizeMF Yup, the off the shelf stuff works amazingly well, there's absolutely no reason to use anything else.
@@nathanwahl9224 ...IF IT WAS PRACTICAL TO USE ORDINARY SEALER- I'M PRETTY SURE THEY'D USE IT!!!
THESE ENGINES ARE PROBABLY HARD TO SERVICE- AND DOWNTIME IS DAM EXPENSIVE!!!
This Is heavy engineering at its very best never realized b4 how much time n effort goes into designing n building an engine this size, now I even have a lot more respect for my little 1.4 diesel engine
hey man don't call her little, she hates that
@@youvebeenspooked Its why I do it to get her to always give me her Best
Absolutely Awesome!.....What an amazing documentary!!
WOW !!! I was used to seeing GE and GM EMD 16 cylinder Diesel Locomotive engines. These engines made in Germany make them look like their babies 😉!!! This is some serious power! THANK YOU FOR MAKING AND POSTING the video !!!
Well done. Lots of interesting detail. Inspiring QC and craftsmanship!
This looks fascinating ,but can you imagine the brain behind all the planning,preparations,who design all the components of the engine, ,human brain is so small but can do unimaginable ideas
A huge team of machinists, engineers, mechanics, physicists, and others and over a hundred years of combustion engine advancement already behind them is a far cry from the imaginary Einstein sitting down and inventing this as you imagine.
Unimaginable ideas? I can't imagine what those are.
Who else but Germany? They have perhaps the most brilliant engineers in the world.
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Tank you man
Germans are aliens, 1945 they were destroyed second time, and today they are powerhouse, if it was not for Germans none of us in this planet would have to technology and comforts and reliability of things we use everyday
@@007supertime Don't forget that the USA helped West Germany rebuild from the war damage after WW2 Just like for Japan.
There's a lot of catch up learnings all videos doing jobs and especially the standard working.
ma ta ‘
Excellent documentary, but there was an error in comparing the weight of the engine to that of a steam locomotive. Locomotives did not weight 48 tons, perhaps only the very earliest and lightest ones. Average steam freight and passenger locomotives weighed 200 to 400 tons. The Union Pacific Big Boy weighed 600 tons. My grandfather was an Engineer for the Baltimore and Ohio and used to operate the Baldwin and Mikado steam locomotives.
Not an error, a slight exagerration. Mallard (British built, service 1938 to 1963) holds the steam speed record at 126MPH (while pulling a dyno car and 6 passenger cars) and is the most obvious example I could think of for a reasonably typical European passenger locomotive which was advanced for its time (continuous running at 100MPH.) It weighed 167 metric tonnes, so a little over 3 times the 48 tonne weight of this diesel engine. So the only problem with the claim is that they mean a small steam locomotive. On the other hand the Big Boy was (according to Wikipedia) the second heaviest steam locomotive at 600 short tons (2000lb.) This video uses metric tonnes which are larger (1000kg, almost exactly the same as the 2240lb long ton.) What's weird about this video is hearing metric units in an American accent.
Wow hat's off to the Germans. Amazing process, amazing product!
MTU is owned by Rolls Royce engineering. Rolls Royce cars is owned by BMW. You work it out.
Amazing what us humans can achieve if we really put our collective minds to a task.
its insane how it looks just like a massive inline engine. unreal
Nothing good and more fun like engineering. Truly love it with passion
not convinced this isn't tiny people assembling a regular sized engine
Lol Plot Twist
They make engines a lot bigger than this.
LMAO!!!
Jake McHargue the cleverest comment I have ever seen on RUclips . You Sir should be doing far side cartoons. Truly warped
It is hard to identify jokes just based on the characters people type, but people who think like you are those who believe we never launched and landed on the moon. You think engineers aren't capable of designing an engine of that size? Give us the money and time and we can make anything. Yes I am an engineer. Also give credit to those technicians because they are brilliant, they are the ones who bring our theoretical work to life.
Definitely won’t forget that it’s made in Germany! Narrator made that very clear.
10:15 "For now on everything has to take place with ABSOLUTE synchronicity" the head smelter stands on a ladder and yells 3-2-1-GO!
That's funny
If they needed “absolute synchronicity” a slow microcontroller controlling everything will be far more synchronized than 2 or more humans in lockstep could ever be, so I found that bit comical.
Just like in Star Trek where they do the same sort of things by biological timing and countdown: all for dramatic effect, not for actual precision.
This was pretty hard to watch. Most of the 'absolute precision' was performed with extremely sloppy methods. Other than good engineering, these engines are very crudely made.
got a taste of that southern accent too, Zwei = Zwo
@@painmagnet1 ...it only LOOKED like that-!!
This would have been a more complete documentary of how a huge engine is born if the machining of these components were discussed.
...THAT PROBABLY INVOLVES REVEALING TRADE SECRETS-(?)
Умеют немцы все-таки делать двигатели... 35 лет без технического обслуживания, заслуживает уважение к команде разработчиков и механиков
Great Documentary. I was glued to the screen the whole time.
29:45 Loctite is not a "special sealing compound." Is probably the most common actually...
Loctite made various adhesive not just any super glue u talkin
The designers, the engineers, the assemblers- -all are gods!!!
My 7.3 doesn't seem as bad ass as it did yesterday.
Mine ether:)
😂 more badass than a 6.0
J Blob I agree with that I own a 6.0 and boy is it a POS !!!!!!
It never was
dab 8430 my 7.3 PSD is pretty bad ass and I’ve only got the cold air and a hypermax programmer I bought on CL 15yrs ago for $125. Makes it quite strong and quick. And no smog crap on it.
Who doesn't love a ships ' engine room ' ?
Takes me back to my days as a marine pipefitter at the Philadelphia Naval Shipyard were one of the projects I worked on was one of the diesel generators of the USS Guadalcanal. It was huge but I think somewhat smaller than this behemoth.
whe does the MTU8000 drove monkeys to bite
i just got bit with a MTU 4000 and monkeys drive it wild
"Tolerances so minute they cannot be perceived by the naked eye"- Cuts to a guy inspecting with just his eyes
Tolerance is is a restriction on a dimension.
So a hole needs to be 1 inch within a tolerance of .005 inch.(that's a standard machining tolerance)
.005 inch is smaller then the width of some human hairs, meaning it can't be determined by eye.
He was checking the surface finish. It's an unfortunate edit but you really can't see the required tolerance.
@@kkknotcool lol I know I watch this stuff because I appreciate and understand it but I also think I'm funny sometimes :)
This ingin tow stroke or for stroke ?.....
8:06 took me by surprise - I thought the mould was a CGI rendering at first glance lol
What a marvel of engineering