Iveco Marine Diesel Engines Installation Handbook Download Page 1

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ARINE

IESEL

NGINES

NSTALLATION

ANDBOOK

TECHNOLOGIC

AL EXCELLENCE

Summary of Contents for Marine Diesel Engines

Page 1: ...MARINE DIESEL ENGINES INSTALLATION HANDBOOK T E C H N O L O G I C A L E X C E L L E N C E ...

Page 2: ...MARCH 2004 II MARINE ENGINES INSTALLATION Publication IVECO MOTORS edited by IVECO PowerTrain Advertising Promotion Pregnana Milanese MI www ivecomotors com Printed P3D63Z001 E March 2004 Edition ...

Page 3: ... THE HULL 53 4 3 SUSPENSION 53 4 4 TILTING 56 4 5 AXIS LINE ALIGNMENT 57 AIR SUPPLY 59 5 1 SUPPLY AND VENTILATION 61 5 2 ENGINE ROOM VENTILATION 61 5 3 AIR FILTERS 62 FUEL SUPPLY 65 6 1 FUEL CHARACTERISTICS 67 6 2 HYDRAULIC CIRCUIT 67 6 3 RESERVOIR 69 6 4 ENGINE RESERVOIR PIPES 71 6 5 FUEL FILTERING 72 LUBRICATION 75 7 1 LUBRICANT CHARACTERISTICS 77 7 2 OIL FILTERS 77 7 3 OIL QUANTITY AND LEVEL DI...

Page 4: ...R CIRCUIT 111 12 3 WIRING 113 12 4 STORAGE BATTERIES 115 12 5 ENGINE ELECTRICAL CIRCUIT 117 12 6 CAN LINE 117 12 7 INSTRUMENT PANEL 118 12 8 WARNINGS AND PRECAUTIONS 118 GALVANIC CORROSION PROTECTION 119 13 1 OVERVIEW 121 13 2 GROUND CONNEXION 122 13 3 DISPOSABLE ANODES PROTECTION 122 13 4 ISOLATED POLES INSTALLATION 123 CONTROL TEST PROCEDURES 125 14 1 OVERVIEW 127 14 2 STATIC TEST 127 14 3 OPEN ...

Page 5: ...ngine to the driven elements reducer inverter propeller and relevant axis auxiliary organs etc in the correct way bearing in mind the problems linked to the drive and the resulting vibrations choose the sea water circuit or the possible keel cooling system of the right size adjust the size of the engine compartment or the engine room to facilitate access to the engine and the connected parts both ...

Page 6: ...lements foreseen by the manufacturer and the installation do not start the engine with the lubricating cooling and fuel circuits closed by plugs or obstructed Daily check the complete tightness of fluid circuits especially those of fuel and lubricants which may cause fires and thus damage people and things Make sure that the different pipes are not in contact with hot surfaces or moving elements D...

Page 7: ...l average pressure 10 Driving torque 10 Power 11 Brake real power 12 Correct power 12 Engine total efficiency 13 Fuel consumption 13 Load factor 14 Engine duration 16 1 2 BOAT 17 Types of hull 18 Displacement 19 Relative speed Taylor ratio 20 Power definitions for boat propulsion 21 Protection against galvanic corrosion 22 ...

Page 8: ...MARCH 2004 INTRODUCTION 1 8 MARINE ENGINES INSTALLATION ...

Page 9: ... eyebolts or grommets 5 Oil fill in plug 6 Coolant reservoir 7 Coolant fill in plug 8 Exhaust manifold cooled down by coolant fluid 9 Thermostatic valve for engine coolant 10 Pipe exchanger for coolant water sea 11 Auxiliary organ control pulley 12 Engine support bracket 13 Sacrificial anodes 14 Sea water suction 15 Lubricating oil draining plug 16 Heat exchanger for air sea water 17 Sea water pum...

Page 10: ...ormulas you obtain that the power is the linear function of the real average pressure and of the engine rotation speed with the same power and the same number of rpm the engines with a higher piston displacement are subject to a lower real average pressure The power needed for a boat propulsion requires if the operating rpm number is the same the appro priate consideration about the engine to be u...

Page 11: ...e 4 Power The air and fuel intake inside the cylinders and then burnt during combustion produces the same heat energy which translated into pressure and force passes to the crank mechanisms and then to the engine flywheel in the form of mechanical energy less thermo dynamic and friction losses Such energy referred to the time unit is the power that can be generated by the engine and is expressed b...

Page 12: ...correcting factors to be adopted to adjust the dif ferent power rates The rules are different basically for the choice of the number of accessories to be connected to the engine during the test and the different reference environmental conditions As a result the measurements carried out on the same engine on the basis of the different prescriptions given by different rules lead to different result...

Page 13: ... the maintenance to the fuel quality The engine efficiency index of the efficiency of transformation of the fuel energy into mechanical ener gy is inversely proportional to the fuel specific consumption an higher efficiency means a lower fuel consumption required to obtain the power yield The overall efficiency of a Diesel engine is around 0 4 with a clear loss of 60 Fuel consumption The mechanica...

Page 14: ...sons between hourly consumption rates must be made taking into consideration precise and homogeneous engine operating conditions Load factor It represents the average load in time of the power actually required to an engine expressed as a per centage of the value of its maximum power As it represents the engine heavy duty index it is a relevant indicator for the choice of the correct engine in rel...

Page 15: ... variations In the marine sector for example The continuous work corresponds to that of work boats fishing tug boats ferry boats The intermittent work corresponds to that of commercial boats coastguard and sea rescue crew transport etc Finally there is the definition of Pleasure boats yachts where the engine use is intermittent and limited to the typical life of yachts for which maximum powers hig...

Page 16: ...rom the use practical tests and the processing of the different data obtained during the bench tests It is possible to foresee the engine duration for a specific setting and load factor with a good margin of approximation on the basis of the following correlation Figure 6 illustrates the function linking the Duration with the Load Factor CAUTION The engine duration is closely linked to the correct...

Page 17: ...herefore must be interpreted as such Figure 7 illustrates the main geometrical data of a boat 1 Overall width 2 Floating width 3 Overall length 4 Floating length 5 Waterline 6 Keel 7 Draught Some parts of the hull mentioned in this handbook are identified in figure 8 1 Frame 2 Limber board 3 Side keelson 4 Bilge 5 Keel The definition of side keelson is particularly important because the engine lay...

Page 18: ... work boats and ferry boats belong to this category Semi displacing hulls These hulls rather similar to the previous type can change their trim during sailing as they lift the stem and as a result of the incidence of the bottom plane they can use a small part of the water dynamic pressure thus obtaining a partial glide Patrol hulls and cruise hulls belong to this category MARCH 2004 INTRODUCTION 1...

Page 19: ...ats belong to this category as they are required high speeds Displacement It is the actual weight of the water moved by the boat fully laden and corresponds to the total weight or mass of the boat fully laden The displacement is a weight and should not be confused with other terms such as tonnage which refer to the volume measurements When unknown the displacement of a boat can be calculated by ma...

Page 20: ...speeds correspond to compara ble waves Experiments and tests carried out on different types of boats pointed out that there is a limit value to the speed beyond which any further increase requires excessive and expensive power growth For displacing hulls the speed limit is for value ratios around an average of 1 34 At this speed the hull generates a wave as long as its floating hull length Any att...

Page 21: ...rom a qualitative point of view as follows BHP Brake horse power it is the power available to the engine flywheel as defined by the inter national regulations SHP shaft horse power it is the power available to the output shaft of the reducer inverter there fore after the mechanical losses due to the shaft efficiency DHP delivered horse power it is the power which can be actually used by the propel...

Page 22: ...f two different metals come into contact you are recommended to insulate electrically one of the components As an alternative you are advised to apply sacrificial anodes as explained in section 8 5 to which you should make reference for further details about this matter MARCH 2004 INTRODUCTION 1 22 MARINE ENGINES INSTALLATION ...

Page 23: ...E OF THE BOAT ENGINE SETTING 25 Fast short range yachts 25 Long range yachts commercial boats 25 Light service 26 Medium service 26 Continuous service 26 2 3 ENGINE PERFORMANCE 26 2 4 ENVIRONMENTAL CONDITIONS AND DERATING 29 Ambient temperature 30 Height 30 Humidity 30 2 5 MECHANICAL AND AUXILIARY COMPONENTS 31 2 6 SPEED AND POWER PERFORMANCE 31 ...

Page 24: ...MARCH 2004 ENGINE BOAT CHOICE FACTORS 2 24 MARINE ENGINES INSTALLATION ...

Page 25: ...e engine performance can be derived from the typical curves of the engine which usually include five different types of use We remind you that the engines must be used for the purpose to which their setting makes reference the non observance of this prescription makes the warranty void Fast short range yachts Boat Yachts and military boats with gliding hull and high speed boats or semi gliding hul...

Page 26: ...hours per year Power classification according to ISO 3046 7 IOFN 2 3 ENGINE PERFORMANCE The diagram of the typical curves of an engine illustrates the maximum engine power and torque according to the rotation speed and provides the engine specific consumption The engine power and torque values will be different according to the position of the accelerator lever On the basis of the power and torque...

Page 27: ...her need for energy makes the engine reduce its running speed in order to obtain the maximum torque The maximum torque speed is usually identified as the condition with the lowest specific con sumption With a speed ranging between the maximum power value and the maximum torque value the engine has a stable behaviour i e it regulates itself to adapt its speed spontaneously to the load changes Cs Sp...

Page 28: ...ions are due to a propeller which with the same rotation speed has actually been designed for an engine greater than the one installed It is possible to avoid the above mentioned cases by following this rule foresee a maximum speed reached by the engines when sailing with a new boat fully laden 3 above the engine rated speed This rule is based on the fact that the power required to the engine incr...

Page 29: ... tity regulated by the injection pump in relation to the quantity of air inlet Derating consists in the adjustment of the injected fuel quantity according to the weight variation of the air sucked by the engine without affecting the optimum ratio in the event of excessive air that the diesel engine needs and to prevent the growth of the combustion temperature and the exhaust smoke With the engine ...

Page 30: ...nce curves The lower performances depend on the characteristics of the turbocharger where present and of the engine setting i e of the air system capacity to compensate for the air rarefaction with a higher volume of air inlet On aspirated engines there might be up to 2500 m in height a power loss of 3 5 every 300 m of difference in height while on supercharged engines with turbine fitted with was...

Page 31: ...peller absorb power as a result of the friction during sailing The absorptions of the reducers inverters vary according to the type and are included in the 3 5 range The supports the axis line and the thrust bearing have an incidence amounting to approx 1 for each element 2 6 SPEED AND POWER PERFORMANCE The designed and or wished speed cannot disregard the economic and critical speed values The fo...

Page 32: ...e of the hull bot tom and the line parallel to the waterline on a vertical plane at 1 4 of the floating width in ft B L A from the longitudinal centre line of the hull Reduced values of the displacement length ratio at floating 20 DL 280 where D Displacement with the hull fully laden long tons L L A Length of the waterline ft Finally the introduction of the DL ratio in the formula enables the calc...

Page 33: ...rive V drive 38 Inboard outboard unit with astern foot 38 S drive sailing boats 39 Water jet propeller 40 3 2 PROPELLERS 41 Propeller technical characteristics 42 Dimensioning 42 Rotation direction 45 Engine with reversible blades 46 Propulsion with surface propellers 46 3 3 INVERTER REDUCER 47 Choice 47 Efficiency 47 Lubrication 48 Trailing 48 3 4 TORSIONAL VIBRATIONS 49 ...

Page 34: ...MARCH 2004 DRIVE 3 34 MARINE ENGINES INSTALLATION ...

Page 35: ...t axis and propeller sometimes ducted or in alternative a water jet propeller The size and position of the compartments available for the engine location lead to a different layouts of the engine The possible solutions are the following Figure 1 AXIS LINE DRIVE ANGLE DRIVE INBOARD OUTBOARD UNIT WITH ASTERN FOOT WATER JET PROPELLER 3 1 PROPULSION SYSTEMS ...

Page 36: ...is obtained through the stuffing box or more recently as a result of the hydrostatic tightness systems The support bearings usually made of splined rubber need water lubrication which can be collected outside with a dynamic intake or derived from the sea water exhaust for the engine cooling The metal bushing bearing possibly fitted with the rigid casing need grease lubrication The axial thrust tra...

Page 37: ...admissible values for operating angles vary according to the type of joint and the rota tion speed and cannot exceed the values prescribed by the manufacturer All the technical information needed for the installation of the universal joint drive shall be supplied by the shaft manufacturer they are about the joint admissible performance but not about the admissible characteristics of the engine red...

Page 38: ...can be horizontal thus improving and opti mising the use of spaces When universal joint shafts are used check that there is constant velocity rota tion and maintain the boss angles admitted by the joint in relation to the inverter flanges The use of the angled inverter is temporarily limited to the yacht and light commercial boat sector because of its high installation and maintenance costs Strict...

Page 39: ...ces Noise and vibration problems which can be solved more easily The drawbacks are the following Boat design for the installation of the astern foot Poor boat manoeuvrability at low speed Unsuitable use on displacing hulls S drive sailing boats It is a propulsion system for limited powers used as an auxiliary unit on sailing boats This unit similar to that with the astern foot consists of an engin...

Page 40: ...s generally of axial type with ducted blades figure 7 The lack of underwater protruding tailpieces reduces the hull travelling resistance and thus the system is particularly suitable for sailing on shallow waters with a good operating flexibility and the use in extremely safe conditions both for the damages resulting from any water obstacles and the possible injuries due to the lack of the propell...

Page 41: ...ine The propeller receives the energy transmitted by the engine deducted from the drive mechanical losses and it shall be able to translate this energy into speed for the boat progress Any propulsion solution different from the above mentioned ones requires a specific propeller PROPELLER FOR AXIS LINE PROPELLER FOR ASTERN FOOT SURFACE PROPELLER Figure 8 3 2 PROPELLERS ...

Page 42: ...tation speed in the event of exces sive slip the propeller will incur cavitation phenomena In both cases the engine performance will be reduced and the engine wear increased Average slip values per type of hull Type of hull Speed Kts Slip Flatboats Sailing boats 9 45 Heavy duty boats 9 15 26 Light duty boats Cruise boats 15 30 24 Fast gliding boats 30 45 20 Competition boats with V bottom 45 90 10...

Page 43: ...t is better to use propellers with small diameter and high rotation speeds It is suggested to size the propeller for 90 of the rated max imum power so that the engine on a new boat fully laden can reach a speed above 3 that of the maximum power This way it will be possible for the engine to reach the maximum power speed when the bottom is dirty Propellers with the wrong size do not allow the trans...

Page 44: ...fying the propeller characteristics and its rotation speed you will have all the data nec essary for the choice of the inverter reducer Considering the shipyard expertise in the choice of the best technical solutions we provide herein a reference diagram of the propeller rotation speeds according to the application Type of hull Taylor Propeller ratio rotation speeds DISPLACING HEAVY Tug boats Heav...

Page 45: ...st be the same of the inverter output shaft direction In the applications with one engine the propeller can be made turn in both directions even if it is the right propeller to be used more actually therefore with clockwise rotation at gear forward The drift effect due to the application of the single propeller is usually corrected by regulating the rudder In the twin engine applications this prob...

Page 46: ...l consumption rates The remarkable size of the hub used on this type of propellers prevents their use at high speeds and the extremely high cost limits their diffusion ENGINE WITH VARIABLE PITCH PROPELLER 1 Clutch 2 Propeller pitch control Propulsion with surface propellers The surface propellers different from the traditional ones are designed to be operated partially under water and at high rota...

Page 47: ...er since the type of hull the scope and the required performances influence the choice of the propeller The structure of the boat is fundamental for the position of the engine and the axis line just as the choice of the inverter flanged on the engine or separated The performances required to the inverter obviously compatible with the above mentioned ones in relation to the engine and its use on pl...

Page 48: ...s advisable to check the inverter suitability for the so called free wheeling or trailing i e the condition in which with the engine stationary the boat movement makes the propeller rotate thus inducing the unit kinematic motion This situation can occur in the following cases Towed boat with engine stationary or twin engine boat with separate propellers travelling with just one engine while the ot...

Page 49: ...he frequency is close to or coincides with the system frequency there is resonance The resulting effect is an additional torsional stress compared to the regular drive stress with the possibility of exceeding the stability limits and the resulting breaks due to torsion At design stage it is necessary to analyse the risks deriving from the critical speeds in order to foresee the required remedies s...

Page 50: ...MARCH 2004 DRIVE 3 50 MARINE ENGINES INSTALLATION ...

Page 51: ... ENGINES INSTALLATION ENGINE INSTALLATION Page 4 1 TRANSPORTATION 53 4 2 INSTALLATION ON THE HULL 53 4 3 SUSPENSION 53 Rigid suspension 54 Flexible suspension 54 4 4 TILTING 56 4 5 AXIS LINE ALIGNMENT 57 Check of concentricity 58 Check of parallelism 58 ...

Page 52: ...MARCH 2004 ENGINE INSTALLATION 4 52 MARINE ENGINES INSTALLATION ...

Page 53: ...udinal rigidity of the basement must be such to prevent the engine unit from having a structural function Foresee basement supports in a position corresponding to those of the engine and such to enable the use of the fastening bolts The support must be such to enable the correct hanging of the unit thus preventing the unit from having a structural function except for the engines adopted for this s...

Page 54: ...asses It is installed by placing two flexible elements between the engine brackets and the engine support keel son The flexible elements are chosen according to the weight resting on them and the level of required dampening Take particular care in the choice of the suspensions for the applications on fast boats or their use on fully developed sea In some cases special supports are required If the ...

Page 55: ...of the axis line possibly after 1 or 2 days of support settling Value X shall not be above 10 mm if it is necessary to further lift the engine support insert some shims between the flexible support and the keelson An important warning to be observed for the installation of flexible suspensions is to foresee the suit able hoses fuel exhaust etc for the engine service connections advisable also for ...

Page 56: ...ers with angled output shaft In no case the maximum values can be exceeded for not compromising the engine lubrication condi tions and its operation α Tilting angle 2 Parallel to waterline 3 Inverter 4 Stem To define the tilting angle it is necessary to consider the three reference conditions illustrated in figure 5 where it is clear that in case 2 the angle reached in a temporary condition is sub...

Page 57: ... the formation of vibrations the propeller sup porting axis the inverter reducer and the engine shall be aligned correctly ensuring the flange paral lelism and concentricity are within the values admitted by the inverter and drive manufacturer The final alignment shall be carried out after the boat has been in the water for some days The hull must be fully laden full water and fuel reservoirs incl...

Page 58: ...f the axis line as illustrated in the figure To carry out alignment operate the engine supports At the end of alignment check that the fastening screws and bolts are well tightened NOTE For particular installations e g the astern foot etc follow the indications of the specific publications of the manufacturer You are reminded that the shipyard has the whole responsibility for the alignment operati...

Page 59: ...SECTION 5 MARCH 2004 AIR SUPPLY 5 59 MARINE ENGINES INSTALLATION AIR SUPPLY Page 5 1 SUPPLY AND VENTILATION 61 5 2 ENGINE ROOM VENTILATION 61 5 3 AIR FILTERS 62 ...

Page 60: ...MARCH 2004 AIR SUPPLY 5 60 MARINE ENGINES INSTALLATION ...

Page 61: ...air intake in the engine room 5 2 ENGINE ROOM VENTILATION The shipyard must ensure an abundant and well distributed ventilation and check at fitting that during operation there is not depression in the engine room thus benefiting the correct functional behaviour and the duration of the engines and therefore the hull performance It is not possible to define a specific standard suitable for every en...

Page 62: ...vironment where the marine engine operates does not usually have a high level of dust 2 mg m3 In most cases simplified filters usually fitted on IVECO engines are sufficient In particular cases where the environment can be dusty as on work boats for the transport of dusty materials it is necessary to apply separated from the engine more efficient air filters usually adopted on industrial applicati...

Page 63: ...nside the engine room compared to that outside provided that it is compatible with the safety limits of the engines and the presence of possible electrical or electronic equipment INDICATIVE DIAGRAM OF FILTER SILENCER AND OUTSIDE AIR INLET WITH WATER SEPARATOR 1 Outside air inlet 2 Conic connection typical of aspirated engines 3 Filter silencer 4 Draining holes 5 Detail of connection with sleeve c...

Page 64: ...MARCH 2004 AIR SUPPLY 5 64 MARINE ENGINES INSTALLATION ...

Page 65: ...ECTION 6 MARCH 2004 FUEL SUPPLY 6 65 MARINE ENGINES INSTALLATION FUEL SUPPLY Page 6 1 FUEL CHARACTERISTICS 67 6 2 HYDRAULIC CIRCUIT 67 6 3 RESERVOIR 69 6 4 ENGINE RESERVOIR PIPES 71 6 5 FUEL FILTERING 72 ...

Page 66: ...MARCH 2004 FUEL SUPPLY 6 66 MARINE ENGINES INSTALLATION ...

Page 67: ...illing stations 6 2 HYDRAULIC CIRCUIT The fuel circuit function is to supply the right quantity of fuel to the engine injection system The fuel has to be clean and not polluted with remains and water and it is necessary to drain off the fuel sur plus from the reservoir A fuel circuit accurately designed and correctly implemented is fundamental for the regular engine operation in particular at star...

Page 68: ...CIRCUIT FOR COMMON RAIL SYSTEM CP1 CIRCUIT FOR COMMON RAIL SYSTEM CP3 MARCH 2004 FUEL SUPPLY 6 68 MARINE ENGINES INSTALLATION Figure 2 Figure 3 ...

Page 69: ...he boat and on the sailing autonomy according to the engine adopted In order to safeguard the boat and the fuel circuit components it is necessary to observe the following warnings The structure must be such to resist the boat bumps at sailing If it is long and low it is advisable to apply breakwater baffles inside It must be placed far from heat sources at a limited distance and at the same engin...

Page 70: ...gged and the counter pressure values of the fuel return pipe to the reservoir Further specifications are given in the installation diagrams relevant to each engine NOTE On the boats fitted with many reservoirs to prevent excessive suction depression it is suggested to use a small reservoir called service reservoir placed next to the engines and to which the main reservoirs will be connected to ens...

Page 71: ...he engine pipe union connections shall be designed for all types of engine suspensions rigid or flexible They shall be realised by inserting a flexible element between the engine and the pipe If present the rubber holder eyelet shall consist of a rubber sleeve reinforced with textile inserts suit able for diesel fuel and resisting the fire according to the rules in force in each single country and...

Page 72: ...the wear caused by the impurities and the water present in the fuel Prescriptions The pre filter shall be installed on the feeding pipe next to the reservoir in a point relatively low of the circuit and in a position easily accessible for maintenance water and deposit bleeding and prim ing The position close to the reservoir ensures that the pipe is free of water and deposits which might damage it...

Page 73: ...ual cartridge fuel filter 2 Dual cartridge fuel filter with possibility of substitution with running engine 3 Exclusion lever NOTE The design and realisation of the whole fuel system reservoirs included are part of the expertise and respon sibility of the shipyard Figure 7 1 2 3 ...

Page 74: ...MARCH 2004 FUEL SUPPLY 6 74 MARINE ENGINES INSTALLATION ...

Page 75: ...UBRICATION 7 75 MARINE ENGINES INSTALLATION LUBRICATION Page 7 1 LUBRICANT CHARACTERISTICS 77 7 2 OIL FILTERS 77 7 3 OIL QUANTITY AND LEVEL DIPSTICK 78 7 4 LOW PRESSURE SIGNALLING 78 7 5 PERIODIC CHANGE 78 7 6 ENGINE VENT 79 ...

Page 76: ...MARCH 2004 LUBRICATION 7 76 MARINE ENGINES INSTALLATION ...

Page 77: ...n the engine The filtering material of the cartridge is a special kind of paper which has a filtering level suitable to the engine type of use The number of filters varies ranging from one to more than one depending on their size and on the flow of lubricant oil in the engine Complying with the Classifying Organisms parameters the most powerful engines are fitted with a filter support which includ...

Page 78: ...ensor located on the engine block and connected to the main lubrication conduit that activates a visual and or an acoustic signal The signal must be activated with a suitable delay to avoid alarms during transient periods an electronic timer may be used for example NOTE Proper signalling which prompts intervention avoids serious damage to the engine 7 5 PERIODIC CHANGE The main cause of lubricant ...

Page 79: ... and flows into the lubrication circuits due to the high pressure at the same time the oil produces vapour due to the high tempera ture This gas mixture generally called blow by is exhausted out of the engine because of the engine overpressure In the IVECO marine engines the blow by gases are concentrated in calibrated channels before they reach the air filter to be suctioned again and taken into ...

Page 80: ...MARCH 2004 LUBRICATION 7 80 MARINE ENGINES INSTALLATION ...

Page 81: ...ING Page 8 1 INSTALLATION 83 8 2 PRIMARY CIRCUIT 84 Filling 84 Coolant tank 84 Heater 84 8 3 SECONDARY CIRCUIT 84 Water seacock fitting 85 Water filter 85 Pipes and connexions 86 Water pump 87 Heat exchangers 87 8 4 KEEL COOLING 87 8 5 GALVANIC CORROSION PROTECTION 89 ...

Page 82: ...MARCH 2004 COOLING 8 82 MARINE ENGINES INSTALLATION ...

Page 83: ...n oil heat exchangers if needed 1 Water temperature sensor 2 Water temperature sensor EDC 3 Water water heat exchanger 4 Refrigerated exhaust manifold 5 Water drain plug 6 Seawater waste gas mixer 7 Turbo compressor 8 Oil inverter heat exchanger 9 Seawater filter 10 Seawater pump 11 Air water heat exchanger 12 Engine base 13 Primary circuit water pump 14 Primary circuit thermostatic valve 15 Press...

Page 84: ... calibrated at 0 5 1 bar Pressurisation increases the liquid boiling point so cavitations in the circulation pump are avoided To increase expansion volumes an extra tank could be set up in some cases It should be connected to the main tank by a pipe fastened to the overfilled hose end valve This tank cap must have a vacuum valve for liquid reflux during engine cooling This non pressurised second t...

Page 85: ...riate sluice valve should be placed between the seacock fitting and the pump to close the seacock valve in case of emergency and extended moorings Sluice valve installation must guarantee a quick closure and remote controls may be adopted if necessary Water filter It filters the debris that the seacock fails to filter and which could damage pump impeller or obstruct the heat exchangers Once proper...

Page 86: ...f suitable thickness They must be properly flanged when necessary with a wide bending radius to avoid suction reduction Two pipes shall be connected as follows Pipes ends must have a flange The connexion must be done with fabric reinforced flexible rubber couplings They must have the appropriate length and characteristics to be used with seawater Fig 4 The coupling must be fastened to the pipe wit...

Page 87: ... obstructions The heat exchanger through which the coolant runs is placed under the keel or is incorporated to the keel itself It is an exposed underwater exchange unit fig 6 The coolant protecting function is extended to all the installation sections The dockyard personnel are responsible for sizing the keel cooling system according to the thermal bal ance information supplied by each engine data...

Page 88: ... again The charging tank 1 always at a higher position than the engine highest point works as the circuit expansion and compensation tank in the keel cooling system The tank fitted in the engine may not com ply with installation requirements A larger volume tank may be necessary when great water volumes circulate Generally the volume in the tank is equal to or near the 15 of the total engine syste...

Page 89: ... effects can also be checked by electric leakage between the engine and the sea water circuit These effects can be minimised by the use of engine electrical equipment with isolated poles and a safe and complete ground connexion It is advisable to refer to the electrical equipment section for more details All IVECO engines are supplied with protection zinc anodes all along the secondary cooling cir...

Page 90: ...PLUG WITH ANODE PROTECTION EFFECT MARCH 2004 COOLING 8 90 MARINE ENGINES INSTALLATION Figure 7 ...

Page 91: ...STALLATION DISCHARGE Page 9 1 OVERVIEW 93 9 2 DRY DISCHARGE 93 9 3 MIXED DISCHARGE 94 Engine with exhaustion gas outlet flange above the water line 94 Engine with exhaustion gas outlet flange below the water line 94 9 4 SILENCERS 96 9 5 COUNTERPRESSURE 96 ...

Page 92: ...MARCH 2004 DISCHARGE 9 92 MARINE ENGINES INSTALLATION ...

Page 93: ...ution requires the regulation of the flow of refrigeration water to avoid exhaust gases excessive cooling since this would form acid condensations and fumes during exhaus tion The three way valve regulation allows the engine circuit water drainage without causing throttling in the water circuit If secondary circuit water is used this should be drained at the circuit outlet paying special attention...

Page 94: ...t exchanger Generally it cannot be used in keel cooling systems The two main systems depend on the engine position in the hull in relation to the waterline and they are the following Engine with exhaustion gas outlet above the water line Engine with exhaustion gas outlet below the water line Engine with exhaustion gas outlet flange above the water line When planning take into account that the mixe...

Page 95: ...at may cause burning or fire danger 1 Vent pipe 2 Waterline 3 Secondary cooling circuit discharge 4 Engine 5 Secondary cooling circuit pump 6 Silencer 7 Gas and seawater flow 8 Engine discharge 9 Mixing area A Elevation depending on the type of installation It is important to choose the right gases exhaust position to avoid their flowing into vessel passenger or crew areas In the case of large sup...

Page 96: ...ipment assembly layout on the vessel IVECO provides estimates for exhaust gases volume and temperature for their own engines in case they are needed The diagram in fig 3 merely illustrates a procedure to measure the diameter of an exhaust pipe system for gas not mixed with water To size the pipes for gas mixed with water increase the diameter by 10 taking as a reference value the dry discharge pip...

Page 97: ... 97 MARINE ENGINES INSTALLATION Figure 3 Counterpressure inside pipe in mm H2O silencer excluded Pipe diameter in mm Insulated Not insulated Elbows number at 90 R 2 5 D Elbows number at 90 R 2 5 D Exhaust gas flow rate m 3 h ...

Page 98: ...MARCH 2004 DISCHARGE 9 98 MARINE ENGINES INSTALLATION ...

Page 99: ...VICES Page 10 1 OVERVIEW 101 10 2 POWER TAKE OFF ON THE FLY WHEEL 101 On the engine shafts 101 Lateral with belt transmission 102 10 3 FRONT PULLEY POWER TAKE OFF 102 On the engine shafts 102 Lateral with belt transmission 103 10 4 BUILT IN POWER TAKE OFF ON TIMING OR FLYWHEEL HOUSING 103 ...

Page 100: ...MARCH 2004 AUXILIARY SERVICES 10 100 MARINE ENGINES INSTALLATION ...

Page 101: ... A mechanic clutch similar to the shaft support which may have one or more disks depending on the power to be transmitted In relation to the shaft it has the advantage to interrupt transmission movement On the engine shafts The connexion to the driven machine must be fitted with a proper pivot joint able to transmit the rota tion torque required and avoid critical torsion speed Check the joint man...

Page 102: ... flywheel 10 3 FRONT PULLEY POWER TAKE OFF On the engine shafts If this alternative is adopted it is necessary to control that according to its mode the engine is equipped with an appropriate pulley to guarantee perfect drive and alignment by interposing an adequate joint In some engine models elastic toroid Giubo type joint may be used When mounting this type of joint the attached metallic clamp ...

Page 103: ...um attention to the rotation rate acted upon them A limited power input required for low rotation rates can be incompatible with the engine capacity since it may imply a high bending moment and to be transmitted the belts should be tightly tensed which may produce an excessive bending moment upon the engine shaft In the case of two different available transmissions they should be installed in such...

Page 104: ...MARCH 2004 AUXILIARY SERVICES 10 104 MARINE ENGINES INSTALLATION ...

Page 105: ...N 11 MARCH 2004 CONTROLS 11 105 MARINE ENGINES INSTALLATION CONTROLS Page 11 1 OVERVIEW 107 11 2 FUNCTIONS 107 Engine startup 107 Accelerator lever drive 107 Reverser selector lever drive 108 Engine stop 108 ...

Page 106: ...MARCH 2004 CONTROLS 11 106 MARINE ENGINES INSTALLATION ...

Page 107: ...electronic con trol system and under prior agreement with IVECO engineering departments software controls with CAN protocols on the specialised network can be used The most frequent case is the remote control made out of a flexible wire rope which can slide through a flexible and suitable sheath so that it can be pulled and pushed When installing the remote controls it is necessary to consider The...

Page 108: ... pump as for rotary pumps or stop carried out by an electromagnetic actuator which can work on the stop lever as for the in line injection pump In the case of engines equipped with EDC electronic control system the engine stop is caused by the fuel injection rejection generated by the electronic control unit when the enabling signal is disengaged The engine cannot be stopped with a battery circuit...

Page 109: ...round connexion 113 Positive 113 Other connexions 114 12 4 STORAGE BATTERIES 115 Storage batteries recharge 115 12 5 ENGINE ELECTRICAL CIRCUIT 117 Wiring 117 Sensors 117 Relays and short circuits protection 117 ECU Electronic central unit 117 12 6 CAN LINE 117 12 7 INSTRUMENT PANEL 118 12 8 WARNINGS AND PRECAUTIONS 118 Electromagnetic compatibility EMC 118 Welding 118 ...

Page 110: ...MARCH 2004 ELECTRICAL INSTALLATION 12 110 MARINE ENGINES INSTALLATION ...

Page 111: ...NOT USE battery circuit breakers to stop the engine PAY PROPER ATTENTION to the wiring polarisation and to the correct attachment of its fasten ing parts FOLLOW instructions to carry out the wiring and the electrical connexion 12 2 POWER CIRCUIT Connect with two independent lines the storage battery to the electrical start up motor and to the connexion electronic preheating system as well as to th...

Page 112: ...Reference chart for the conductor s choice according to their current intensity MARCH 2004 ELECTRICAL INSTALLATION 12 112 MARINE ENGINES INSTALLATION Figure 1 A B ENGINE Section I max R at 20 C mm2 A Ohm km 0 5 6 37 5 1 11 18 3 1 5 14 12 4 2 5 20 7 53 4 28 4 57 6 37 3 15 10 53 1 76 Section I max R at 20 C mm2 A Ohm km 16 75 1 11 25 100 0 75 35 125 0 53 50 160 0 37 70 200 0 26 95 240 0 19 120 280 0...

Page 113: ...nnexion electrical contact Remove protective coating completely from the connecting parts by mechanical means or with an appropriate chemical product In case any element should be fastened onto treated surfaces remove anaphoresis coating to get a smooth supporting base Apply a uniform paint coat BH44D IVECO Standard 18 1705 with a brush or an aerosol can Join the ground connexion knot within 5 min...

Page 114: ...portant to carry out high quality installations especially in the presence of electronic systems because of the reduced intensity of required currents The absence of terminals contributes to the pro gressive reduction of the installation quality and to the possible wire cut caused by the vibrations or by cuts on the lining The choice of conductor s sections and type of terminal must be based on th...

Page 115: ...rnator through the power circuit the equip ment electronic regulator ensures an effective control of the recharge parameters The led indicator powered by the regulator and generally fitted on the on board panel does not show the storage battery recharge real status which depends completely on the maintenance con dition and age The storage battery recharge for the auxiliary services not electricall...

Page 116: ...C1 BAT BAT BAT BAT MM 6 6 6 6 GG1 B AC2 10 10 GG2 B D D MM JA 29 29 JA IE1 IE2 M 30 50 6 70 BAT 6 AC1 MM BAT 10 GG B 10 70 30 86 87 85 AC2 10 10 RL D Key AC1 Main storage battery AC2 Auxiliary services storage battery IE1 Engine electric system 1 IE2 Engine electric system 2 RL Relay 50A max Services electric power Single engine installation Twin engine installation Figure 7 ...

Page 117: ...ement relays of some components and the elements that protect the electrical lines against short circuits or excessive current absorption thermal fuses or thermal switches Only fuses with nominal shutting off currents similar to the indicated on the technical documentation must be used Any difference would not be supported by the other parts of the circuits because they may be damaged due to an ex...

Page 118: ...ompatibility EMC On board electrical and electronic systems as well as other external ones may transmit or be sensitive to parasitic radio signals capable of causing malfunction IVECO provides for compatibility tests carried out under specific regulations To minimise signal sensitivity in equipment installed by the dockyard personnel the engine wiring har nesses must follow different paths from ot...

Page 119: ...04 GALVANIC CORROSION PROTECTION 13 119 MARINE ENGINES INSTALLATION GALVANIC CORROSION PROTECTION Page 13 1 OVERVIEW 121 13 2 GROUND CONNEXION 122 13 3 DISPOSABLE ANODES PROTECTION 122 13 4 ISOLATED POLES INSTALLATION 123 ...

Page 120: ...MARCH 2004 GALVANIC CORROSION PROTECTION 13 120 MARINE ENGINES INSTALLATION ...

Page 121: ... the electrochemical value index of the main metals to evaluate the potential difference caused by the contact among metals if immersed in saline solution The current intensity and the consequent corrosion effects become important at potential differences greater than 0 25V limit represented by a dotted line drawn on the central scale in Fig 1 NOTE To assess the difference in potential between two...

Page 122: ...nnul the dif ferences in potential among the several components thus eliminating the cause of the eddy currents see figure 2 The equipotential ground circuit may also eliminate such currents avoiding their circulation on elements and the consequent hazardous corrosion The ground connexions indicated resistance values must be lower than 0 01 Ω whereas the circulating stray current value in the grou...

Page 123: ...onal cathode protection with zinc anodes hanging on the hull s edge and immersed in water if necessary 13 4 ISOLATED POLES INSTALLATION The need to limit or eliminate eddy currents in the engine can be solved by using electrical compo nents with isolated poles or else with the negative pole isolated from the engine ground connexion This procedure requires an electrical line for the negative potent...

Page 124: ...ROTECTION 13 124 MARINE ENGINES INSTALLATION Figure 2 Ground connexion rod Syntherized brass ground plate Battery Engine Engine Power supply Disposable aft anodes Ground connexions for boxes Electrical accessories Electrical accessories Other metallic parts Reservoir ...

Page 125: ... INSTALLATION CONTROL TEST PROCEDURES Page 14 1 OVERVIEW 127 14 2 STATIC TEST 127 14 3 OPEN SEA TESTS 128 Power absorption curve 128 Testing the cooling and venting systems installation 128 Suction vacuum and exhaust back pressure tests 129 14 4 RECOMMENDED GAUGES 130 ...

Page 126: ...MARCH 2004 CONTROL TEST PROCEDURES 14 126 MARINE ENGINES INSTALLATION ...

Page 127: ... herein applies to the fully equipped vessel with the examined configuration and according to the test conditions under which the index parameters required to assess the operative electrical functions in the engine were measured It is clearly stated that the installation control operations cannot provide for behaviour or performance assess ments in the course of time which are typically yield by t...

Page 128: ... turbine in the case of a supercharged engine and according to the engine rotation speed In the case of engines fitted with electronic control an inverse procedure may be carried out taking from the ECU in the EDC system the fuel intake values at different rates as indicated in the checklist The test is carried out during sailing in still water following a straight route and taking the gas temper ...

Page 129: ...pe of engine Also it is advisable to check that the pressure drop of the external circuit is lower than the allowed maximum values indicated in the technical charts Check that the installation complies with the filling and degassings instructions and control the coolant tank to guarantee proper hot water pressurisation and flow The engine room ventilation test consists of measuring the maximum tem...

Page 130: ...gauges to measure the supercharging air and coolant pressures they can be the mechan ic analogue type or digital electronic type with a scale from 2 to 3 bar Pressure gauges to detect the engine lubricant oil pressure usually the mechanic analogue type with a scale of 10 bar To measure the reverser oil pressure the scale must be of 20 bar Sprit level sight to measure the engine and vessel pitch Do...

Page 131: ......

Page 132: ...Iveco S p A PowerTrain Viale Dell Industria 15 17 20010 Pregnana Milanese MI Italy Tel 39 02 93 51 01 Fax 39 02 93 59 00 29 www ivecomotors com ...

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Iveco Marine Diesel Engines, Installation Handbook

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