Man B&W S50ME-B9.3-TII Project Manual Download Page 8

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MAN B&W

Contents

Chapter

Section

MAN Diesel

MAN B&W S50ME-B9.3

14 Scavenge Air

Scavenge air system

14.01

1984006-5.3

Auxiliary blowers

14.02

1986586-2.3

Operation panel for auxiliary blowers

14.02

1986587-4.0

Electric motor for auxiliary blower

14.04

1986677-3.2

Scavenge air cooler cleaning system

14.05

1987684-9.1

Air cooler cleaning unit

14.05

1987686-2.0

Scavenge air box drain system

14.06

1987693-3.2

Fire extinguishing system for scavenge air space

14.07

1984044-7.5

Fire extinguishing pipes in scavenge air space

14.07

1987681-3.2

15 Exhaust Gas

Exhaust gas system

15.01

1984045-9.5

Exhaust gas pipes

15.02

1984069-9.4

Cleaning systems, water and soft blast

15.02

1987916-4.0

Exhaust gas system for main engine

15.03

1984074-6.3

Components of the exhaust gas system

15.04

1984075-8.7

Exhaust gas silencer

15.04

1986396-8.0

Calculation of exhaust gas back-pressure

15.05

1984094-9.3

Forces and moments at turbocharger

15.06

1990055-0.0

Diameter of exhaust gas pipe

15.07

1985892-3.2

16 Engine Control System

Engine Control System ME-B

16.01

1985184-2.3

Pneumatic manoeuvring diagram

16.01

1987619-3.1

17 Vibration Aspects

2nd order moments on 4, 5 and 6-cylinder engines

17.01

1984140-5.3

1st order moments on 4-cylinder engines

17.02

1986884-5.4

Electrically driven moment compensator

17.02

1983925-0.5

Power Related Unbalance (PRU)

17.03

1986978-1.2

Guide force moments

17.04

1987680-1.1

Guide force moments, data

17.05

1984223-3.5

Vibration limits valid for single order harmonics

17.05

1987987-0.2

Axial vibrations

17.05

1988264-9.0

Critical running

17.06

1984224-5.4

External forces and moments in layout point

17.06

1984226-9.3

17.07

1989149-4.0

18 Monitoring Systems and Instrumentation

PMI Auto-tuning system

18.01

1988529-9.2

CoCoS-EDS systems

18.02

1988530-9.2

Alarm - slow down and shut down system

18.03

1984582-6.8

Class and MAN Diesel & Turbo requirements

18.04

1987040-3.4

Local instruments

18.04

1984583-8.10

Other alarm functions

18.05

1984586-3.9

Bearing monitoring systems

18.06

1984587-5.13

LDCL cooling water monitoring system

18.06

1986727-7.5

Control devices

18.06

1990197-5.0

Identification of instruments

18.06

1986728-9.4

18.07

1984585-1.6

Summary of Contents for B&W S50ME-B9.3-TII

Page 1: ... available at a later date however for a specific project the data can be requested Pages and table entries marked Not applicable represent an option function or selection which is not valid The latest most current version of the individual Project Guide sections are available on the Internet at www marine man eu Two Stroke Extent of Delivery The final and binding design and outlines are to be sup...

Page 2: ...to modification in the interest of technical progress Reproduction permitted provided source is given 7020 0215 00ppr May 2014 All data provided in this document is non binding This data serves informational purposes only and is espe cially not guaranteed in any way Depending on the subsequent specific individual projects the relevant data may be subject to changes and will be assessed and determi...

Page 3: ...haust Gas 6 Fuel 7 Lubricating Oil 8 Cylinder Lubrication 9 Piston Rod Stuffing Box Drain Oil 10 Central Cooling Water System 11 Seawater Cooling System 12 Starting and Control Air 13 Scavenge Air 14 Exhaust Gas 15 Engine Control System 16 Vibration Aspects 17 Monitoring Systems and Instrumentation 18 Dispatch Pattern Testing Spares and Tools 19 Project Support and Documentation 20 Appendix A Cont...

Page 4: ......

Page 5: ...2 06 1983836 3 4 SFOC for high efficiency turbochargers 2 07 1987016 5 2 SFOC reference conditions and guarantee 2 08 1988341 6 1 Examples of graphic calculation of SFOC 2 08 1988278 2 2 SFOC calculations 80 85 2 09 1988790 8 0 SFOC calculations example 2 10 1988782 5 0 Fuel consumption at an arbitrary load 2 11 1983843 4 5 3 Turbocharger Selection Exhaust Gas Bypass Turbocharger selection 3 01 19...

Page 6: ...Control System 5 18 1985322 1 5 6 List of Capacities Pumps Coolers Exhaust Gas Calculation of capacities 6 01 1988291 2 0 List of capacities and cooling water systems 6 02 1987463 3 0 List of capacities S50ME B9 3 6 03 1988718 1 0 Auxiliary system capacities for derated engines 6 04 1987149 5 6 Pump capacities pressures and flow velocities 6 04 1984385 0 3 Example 1 Pumps and Cooler Capacity 6 04 ...

Page 7: ...tem 9 02 1987611 9 1 Alpha Adaptive Cylinder Oil Control Alpha ACC 9 02 1987614 4 1 Cylinder oil pipe heating 9 02 1987612 0 1 Cylinder lubricating oil pipes 9 02 1985328 2 2 Small heating box with filter suggestion for 9 02 1987937 9 1 10 Piston Rod Stuffing Box Drain Oil Stuffing box drain oil system 10 01 1983974 0 7 11 Central Cooling Water System Central cooling 11 01 1984696 5 5 Central cool...

Page 8: ...5892 3 2 16 Engine Control System Engine Control System ME B 16 01 1985184 2 3 Pneumatic manoeuvring diagram 16 01 1987619 3 1 17 Vibration Aspects 2nd order moments on 4 5 and 6 cylinder engines 17 01 1984140 5 3 1st order moments on 4 cylinder engines 17 02 1986884 5 4 Electrically driven moment compensator 17 02 1983925 0 5 Power Related Unbalance PRU 17 03 1986978 1 2 Guide force moments 17 04...

Page 9: ...icted service 19 05 1984612 7 8 Additional spares 19 06 1985324 5 12 Wearing parts 19 07 1985323 3 4 Large spare parts dimensions and masses 19 08 1988371 5 2 Rotor for turbocharger 19 09 1987832 4 1 20 Project Support and Documentation Project support and documentation 20 01 1984588 7 5 Installation data application 20 02 1984590 9 3 Extent of Delivery 20 03 1984591 0 6 Installation documentation...

Page 10: ......

Page 11: ...MAN B W MAN Diesel Engine Design 1 ...

Page 12: ......

Page 13: ...p tion at low load To have common spare parts the exhaust valve used for the ME B is the same as the one used for the MC C The exhaust valve is of the DuraSpin dle type with a W seat bottom piece In the hydraulic system the normal lube oil is used as the medium It is filtered and pressurised by an electrically driven Hydraulic Power Supply unit mounted on the engine The starting valves are opened ...

Page 14: ... 50 85 or low load 25 70 range requires selection of a tuning method ECT Engine Control Tuning VT Variable Turbine Area EGB Exhaust Gas Bypass HPT High Pressure Tuning only for ME C Each tuning method makes it possible to optimise the fuel consumption when normally operating at low loads while maintaining the possibility of op erating at high load when needed The tuning methods are available for a...

Page 15: ...ston in cm G Green Ultra long stroke S Super long stroke L Long stroke K Short stroke Stroke bore ratio Number of cylinders Concept E Electronically controlled C Camshaft controlled Fuel injection concept blank Fuel oil only GI Gas injection Emission regulation TII IMO Tier level Design C Compact engine B Exhaust valve controlled by camshaft Mark number Version number ...

Page 16: ...0 bar SFOC optimised load range Tuning 50 75 100 High load 85 100 167 5 165 0 168 0 Part load 50 85 ECT 166 5 164 0 171 0 VT 164 5 163 5 168 5 EGB 164 5 163 5 169 5 Low load 25 70 ECT 165 0 164 5 169 5 VT 162 5 164 5 168 5 EGB 162 5 164 5 169 5 SFOC for engines with layout on L2 L4 line g kWh L2 L4 MEP 16 8 bar SFOC optimised load range Tuning 50 75 100 High load 85 100 163 5 159 5 162 0 Part load...

Page 17: ...ricating oil data The cylinder oil consumption figures stated in the tables are valid under normal conditions During running in periods and under special con ditions feed rates of up to 1 5 times the stated values should be used Engine Power The following tables contain data regarding the power speed and specific fuel oil consumption of the engine Engine power is specified in kW for each cylinder ...

Page 18: ... 1 MAN Diesel 198 53 31 6 2 MAN B W MC MC C ME ME C ME B GI engines Performance Curves 1 05 Updated engine and capacities data is available from the CEAS program on www marine man eu Two Stroke CEAS Engine Calculations ...

Page 19: ...confirmed by the engine builder The main bearings consist of thin walled steel shells lined with bearing metal The main bearing bottom shell can be rotated out and in by means of special tools in combination with hydraulic tools for lifting the crankshaft The shells are kept in po sition by a bearing cap Frame Box The frame box is of welded design On the ex haust side it is provided with relief va...

Page 20: ...re not nor mally supplied Thrust Bearing The propeller thrust is transferred through the thrust collar the segments and the bedplate to the end chocks and engine seating and thus to the ship s hull The thrust bearing is located in the aft end of the engine The thrust bearing is of the B W Michell type and consists primarily of a thrust collar on the crankshaft a bearing support and segments of ste...

Page 21: ... running surface for safe running in of the pis ton ring The uppermost piston ring is higher than the oth ers The piston skirt is of cast iron with a bronze band Piston Rod The piston rod is of forged steel and is surface hardened on the running surface for the stuffing box The piston rod is connected to the crosshead with four bolts The piston rod has a central bore which in conjunction with a co...

Page 22: ...Turbocharger Three turbocharger makes are available for the ME B engines i e MAN ABB and MHI As an op tion MAN TCA turbochargers can be delivered with variable nozzle area technology that reduce the fuel consumption at part load by controlling the scavenge air pressure The turbocharger selection is described in Chap ter 3 and the exhaust gas system in Chapter 15 Camshaft and Cams The camshaft is m...

Page 23: ... fuel oil pressure booster for each cylinder Fuel injection is activated by a proportional valve which is electronically controlled by the Cylinder Control Unit The fuel oil high pressure pipes are double walled and insulated but not heated Further information is given in Section 7 01 Fuel Valves and Starting Air Valve Each cylinder cover is equipped with two fuel valves starting valve and indicat...

Page 24: ...lubricates the exhaust valve spindle guide and sealing ring as well Reversing On reversible engines with Fixed Pitch Propellers mainly reversing of the engine is performed in the Engine Control System by letting the starting air distributor supply air to the cylinders in order of the desired direction of rotation and by timing the fuel injection accordingly The exhaust valve gear is not to be reve...

Page 25: ...n the manoeuvring side Piping Arrangements The engine is delivered with piping arrangements for Fuel oil Heating of fuel oil pipes Lubricating oil piston cooling oil and hydraulic oil pipes Cylinder lubricating oil Cooling water to scavenge air cooler Jacket and turbocharger cooling water Cleaning of turbocharger Fire extinguishing in scavenge air space Starting air Control air Oil mist detector V...

Page 26: ...MAN B W 1 07 Page 1 of 1 MAN Diesel 198 83 34 5 0 MAN B W S50ME B9 Engine Cross Section of S50ME B9 526 56 24 2 0 0 Fig 1 07 01 Engine cross section ...

Page 27: ...MAN B W MAN Diesel Engine Layout and Load Diagrams SFOC 2 ...

Page 28: ......

Page 29: ...urves in logarithmic scales Thus propeller curves will be parallel to lines hav ing the inclination i 3 and lines with constant mep will be parallel to lines with the inclination i 1 Therefore in the Layout Diagrams and Load Dia grams for diesel engines logarithmic scales are used giving simple diagrams with straight lines Propulsion and Engine Running Points Propeller curve The relation between p...

Page 30: ...eller diameter is used taking into consideration the total propul sion efficiency See definition of in Section 2 02 Note Light heavy running fouling and sea margin are overlapping terms Light heavy running of the propeller refers to hull and propeller deterioration and heavy weather whereas sea margin i e extra power to the propeller refers to the influence of the wind and the sea However the degr...

Page 31: ...d a design speed of 14 5 knots When the optimum propeller diameter D is in creased from 6 6 m to 7 2 m the power demand is reduced from about 9 290 kW to 8 820 kW and the optimum propeller speed is reduced from 120 r min to 100 r min corresponding to the constant ship speed coefficient 0 28 see definition of in Section 2 02 page 2 Once an optimum propeller diameter of maximum 7 2 m has been chosen...

Page 32: ...int MP1 selected in the layout area and parallel to one of the lines another specified propulsion MCR point MP2 upon this line can be chosen to give the ship the same speed for the new combination of engine power and speed Fig 2 02 02 shows an example of the required power speed point MP1 through which a constant ship speed curve 0 25 is drawn obtaining point MP2 with a lower engine power and a lo...

Page 33: ... C ME C8 2 G S50ME B9 3 S50MC C ME C8 2 ME B8 3 S46MC C ME B8 3 G45ME B9 3 G S40ME B9 3 S40MC C S35MC C ME B9 3 S30ME B9 3 100 80 power and 100 87 5 speed range valid for the types G95ME C9 2 100 80 power and 100 90 speed range valid for the types K80ME C9 2 100 80 power and 100 85 7 speed range valid for the types S90ME C10 2 S90ME C9 2 S80ME C8 2 Fig 2 03 01 Layout diagram sizes Layout Diagram S...

Page 34: ...rawn in The SMCR point M must be inside the limitation lines of the layout diagram if it is not the propeller speed will have to be changed or another main engine type must be chosen The selected SMCR has an influence on the turbocharger and its matching and the compression ratio For ME and ME C GI engines the timing of the fuel injection and the exhaust valve activation are electronically optimis...

Page 35: ...mum speed may be extended to 107 of M see line 9 The above limits may in general be extended to 105 and during trial conditions to 107 of the nominal L1 speed of the engine provided the tor sional vibration conditions permit The overspeed set point is 109 of the speed in M however it may be moved to 109 of the nominal speed in L1 provided that torsional vibra tion conditions permit Running at low ...

Page 36: ... increased later on this may involve a change of the pump and cooler capacities change of the fuel valve nozzles ad justing of the cylinder liner cooling as well as rematching of the turbocharger or even a change to a larger size of turbocharger In some cases it can also require larger dimensions of the piping systems It is therefore of utmost importance to consider already at the project stage if...

Page 37: ... the torque speed limit line 4 Such cases could be for ships sailing in areas with very heavy weather ships operating in ice ships with two fixed pitch propellers two main engines where one propeller one engine is de clutched for one or the other reason The increase of the operating speed range be tween line 6 and line 4 of the standard load dia gram see Fig 2 04 02 may be carried out as shown for...

Page 38: ...ntrollable pitch propeller with or without a shaft generator constant speed or combinator curve operation For a specific project the layout diagram for actu al project shown later in this chapter may be used for construction of the actual load diagram 80 100 105 85 55 90 95 60 Engine speed A M Specified engine MCR Engine shaft power A Heavy running operation Normal operation 50 70 80 90 100 40 110...

Page 39: ... M L1 L2 L3 L4 L1 L2 L3 L4 M Specified MCR of engine S Continuous service rating of engine MP Specified MCR for propulsion SP Continuous service rating of propulsion 178 05 44 0 9 The specified MCR M and its propeller curve 1 will normally be selected on the engine service curve 2 Once point M has been selected in the layout diagram the load diagram can be drawn as shown in the figure and hence th...

Page 40: ...erator s electrical power production In the figure the engine service curve shown for heavy running incorporates this extra power The specified MCR M will then be chosen and the load diagram can be drawn as shown in the figure Engine speed of L1 100 Power of L1 100 7 5 4 1 2 6 1 2 6 Propulsion curve for fouled hull and heavy weather Engine service curve 7 M S SP SG SG MP Engine speed of L1 100 Pow...

Page 41: ...the electrical power production of the shaft generator when running in the upper propulsion power range In choosing the latter solution the required specified MCR power can be reduced from point M to point M as shown Therefore when running in the upper propulsion power range a diesel generator has to take over all or part of the electrical power production However such a situation will seldom occu...

Page 42: ...ropeller Therefore it is recommended to use a light run ning combinator curve the dotted curve which includes the sea power margin as shown in the figure to obtain an increased operation margin of the diesel engine in heavy weather to the limit indi cated by curves 4 and 5 Layout diagram with shaft generator The hatched area shows the recommended speed range between 100 and 96 7 of the specified M...

Page 43: ...40MC C8 2 G40ME B9 3 S40ME B9 3 2 S35MC C8 2 S35ME B9 3 2 TII S30ME B9 3 TII Fig 2 05 01 Construction of layout diagram 70 75 80 85 90 95 100 105 110 40 50 60 70 80 90 100 110 7 7 5 5 5 4 2 6 1 3 3 A 5 A A Engine speed of L1 Power of L1 5 L1 L1 L2 L3 L 4 Diagram for actual project This figure contains a layout diagram that can be used for constructing the load diagram for an actual project using t...

Page 44: ...e great advan tage of the ME engine is a lower SFOC at part loads It is also noted that the lowest SFOC for the ME ME C engine is at 70 of M whereas it is at 80 of M for the MC MC C ME B engine For the ME engine only the turbocharger matching and the compression ratio shims under the piston rod remain as variables to be determined by the engine maker MAN Diesel Turbo The calculation of the expecte...

Page 45: ... power of specified MCR High efficiency turbocharger For standard high load optimised ME B engines the lowest SFOC may be obtained at 80 of the specified MCR For more information visit www marine man eu Two Stroke Turbocharger Selection All engines are as standard fitted with high effi ciency turbochargers option 4 59 104 The high efficiency turbocharger is applied to the engine in the basic desig...

Page 46: ...rs as this will reduce the fuel consumption of the engine i e the engine performance will be improved However shipyards often specify a constant maximum central cooling water temperature of 36 C not only for tropical ambient temperature conditions but also for lower ambient temperature conditions The purpose is probably to reduce the electric power consumption of the cooling water pumps and or to ...

Page 47: ... or c A straight line along the constant mep curves parallel to L1 L3 is drawn through point M The intersections of this line and the curves indicate the reduction in specific fuel oil consumption at 100 80 and 50 of the SMCR point M related to the SFOC stated for the nomi nal MCR L1 rating An example of the calculated SFOC curves are shown in Diagram a and is valid for an engine with fixed pitch ...

Page 48: ...ciency TC Engine kW r min g kWh 5 S50ME B9 3 8 900 117 168 6 S50ME B9 3 10 680 7 S50ME B9 3 12 460 8 S50ME B9 3 14 240 9 S50ME B9 3 16 020 Data SMCR point M cyl No Power 100 of M kW Speed 100 of M r min SFOC found g kWh 40 50 60 70 80 90 100 110 Nominal SFOC Diagram a Part Load SFOC curve of SMCR SFOC g kWh SFOC g kWh 4 3 2 1 0 170 165 168 160 155 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ...

Page 49: ... Reduction of SFOC in g kWh relative to the nominal in L1 Diagram b Fig 2 09 02 100 95 85 80 90 Constant ship speed lines 105 40 50 60 70 80 90 100 Power of L1 Speed of L1 75 80 85 90 95 100 Nominal propeller curve 0 15 0 25 0 30 0 20 mep 50 SMCR 80 SMCR 100 SMCR 0 1 2 3 4 3 4 5 6 7 8 9 0 1 2 3 4 5 6 Reduction of SFOC in g kWh relative to the nominal in L1 Diagram c Fig 2 09 03 178 65 07 8 0 178 6...

Page 50: ... 3 Power 100 10 680 kW Speed 100 117 r min Nominal SFOC High efficiency turbocharger 168 g kWh Example of specified MCR M Power 9 612 kW 90 L1 Speed 111 2 r min 95 L1 Turbocharger type High efficiency SFOC found in M 166 4 g kWh The SMCR point M used in the above example for the SFOC calculations M 90 L1 power and 95 L1 speed SFOC calculations example ...

Page 51: ... 8 9 10 11 g kWh SFOC 165 160 168 170 80 Constant ship speed lines 105 40 50 60 70 80 90 100 Power of L1 Speed of L1 75 80 85 90 95 100 Nominal propeller curve 0 15 0 25 0 20 0 30 mep 100 95 85 90 50 SMCR 80 SMCR 100 SMCR 1 2 3 4 5 3 4 5 6 7 8 9 0 1 2 3 4 5 6 Reduction of SFOC in g kWh relative to the nominal in L1 90 95 M Diagram b 178 65 00 5 0 178 65 03 0 0 The reductions see diagram b in g kWh...

Page 52: ... point S1 can be calculated as an interpolation between the SFOC in points 1 and 2 and for point S3 as an extrapolation The SFOC curve through points S2 on the left of point 1 is symmetrical about point 1 i e at speeds lower than that of point 1 the SFOC will also increase The above mentioned method provides only an approximate value A more precise indication of the expected SFOC at any load can b...

Page 53: ...MAN B W MAN Diesel Turbocharger Selection Exhaust Gas By pass 3 ...

Page 54: ......

Page 55: ...tandard equipped with as few turbochargers as possible see Table 3 01 01 One more turbocharger can be applied than the number stated in the tables if this is desirable due to space requirements or for other reasons Ad ditional costs are to be expected However we recommend the Turbocharger Se lection program on the Internet which can be used to identify a list of applicable turbochargers for a spec...

Page 56: ...matic temperatures winter and summer in arctic as well as tropical areas These variations cause changes of the scavenge air pressure the maximum combustion pressure the exhaust gas amount and temperatures as well as the specific fuel oil consumption For further information about the possible coun termeasures please refer to our publication titled Influence of Ambient Temperature Conditions The pub...

Page 57: ...by IMO for future enforcement the engine must fulfil the more restrictive IMO Tier III NOx requirements when sailing in a NOx Emission Control Area NOx ECA The Tier III NOx requirements can be met by Ex haust Gas Recirculation EGR a method which directly affects the combustion process by lower ing the generation of NOx Alternatively the required NOx level could be met by installing Selective Catal...

Page 58: ......

Page 59: ...MAN B W MAN Diesel Electricity Production 4 ...

Page 60: ......

Page 61: ... type for plants with a fixed pitch propeller FPP The BW III RCF requires no separate seating in the ship and only little atten tion from the shipyard with respect to alignment Introduction Next to power for propulsion electricity produc tion is the largest fuel consumer on board The electricity is produced by using one or more of the following types of machinery either running alone or in parrall...

Page 62: ... RCF On engine 88 91 vertical generator 2a 2b BW II RCF On tank top 88 91 3a 3b BW III RCF On engine 88 91 4a 4b BW IV RCF On tank top 88 91 5a 5b DMG CFE On engine 84 88 6a 6b SMG CFE On tank top 89 91 7 BW I GCR On engine 92 vertical generator 8 BW II GCR On tank top 92 9 BW III GCR On engine 92 10 BW IV GCR On tank top 92 PTO RCF PTO CFE PTO GCR Fig 4 01 01 Types of PTO 178 63 68 7 0 ...

Page 63: ...equency unit CFE Electrically frequency controlled unit GCR Step up gear with constant ratio Mark version Engine type on which it is applied Layout of PTO See Fig 4 01 01 Make MAN Diesel Turbo Fig 4 01 02 Example of designation of PTO 178 39 55 6 0 For further information please refer to our publi cation titled Shaft Generators for MC and ME engines The publication is available at www marine man e...

Page 64: ...olating the gear drive against torsional and axial vibrations By means of a simple arrangement the shaft in the crankshaft gear carrying the first gear wheel and the female part of the toothed coupling can be moved forward thus disconnecting the two parts of the toothed coupling The power from the crankshaft gear is trans ferred via a multi disc clutch to an epicyclic variable ratio gear and the g...

Page 65: ...ultidisc clutch Toothed coupling Servo valve Hydrostatic motor Generator Annulus ring Sun wheel Planetary gear wheel Crankshaft Bearings Engine crankcase structure Elastic damping coupling Toothed coupling 1st crankshaft gear wheel Toothed coupling Fig 4 01 04 Power take off with RENK constant frequency gear BW III RCF option 4 85 253 178 23 22 2 2 Internal control circuits and interlocking functi...

Page 66: ...ted in Fig 4 03 02 Extent of delivery for BW III RCF units The delivery comprises a complete unit ready to be built on to the main engine Fig 4 02 01 shows the required space and the standard electrical output range on the generator terminals Standard sizes of the crankshaft gears and the RCF units are designed for 700 1200 1800 and 2600 kW while the generator sizes of make A van Kaick are Type DS...

Page 67: ...k generator type DSG enclosure IP23 frequency 60 Hz speed 1 800 r min Fig 4 02 01 Space requirement for side mounted generator PTO RCF type BWlll S50 C RCF H G S FORE F B A C D Z J kW generator 700 kW 1 200 kW 1 800 kW 2 600 kW A 2 550 2 550 2 690 2 690 B 870 870 870 870 C 3 250 3 250 3 500 3 200 D 3 550 3 550 3 800 3 800 F 1 850 1 950 2 100 2 200 G 2 250 2 250 2 550 2 550 H 2 300 2 800 3 200 4 55...

Page 68: ... 50MC MC C ME ME C ME B GI Toothed coupling Alternator Bedframe RCF gear if ordered Crankshaft gear 16 15 13 14 12 10 21 2 11 6 2 2 8 18 17 3 4 5 7 1 2 9 19 20 22 Fig 4 03 01a Engine preparations for PTO BWIII RCF system 178 57 15 7 1 Engine preparations for PTO ...

Page 69: ...hims for mounting of RCF generator unit on the brackets 16 Shims studs and nuts for connection between crankshaft gear and RCF generator unit 17 Engine cover with connecting bolts to bedplate frame box to be used for shop test without PTO 18 Intermediate shaft between crankshaft and PTO 19 Oil sealing for intermediate shaft 20 Engine cover with hole for intermediate shaft and connecting bolts to b...

Page 70: ...n lube oil pressure 2 25 bar Lube oil pressure at crankshaft gear min 1 bar Lube oil working temperature 50 C Lube oil type SAE 30 Table 4 03 02 Necessary capacities for PTO RCF BW III RCF system 178 33 85 0 0 Cooling water inlet temperature 36 C Pressure drop across cooler approximately 0 5 bar Fill pipe for lube oil system store tank ø32 Drain pipe to lube oil system drain tank ø40 Electric cabl...

Page 71: ...emens and AEG but similar types of gene rator can be supplied by others e g Fuji Taiyo and Nishishiba in Japan For generators in the normal output range the mass of the rotor can normally be carried by the foremost main bearing without exceeding the per missible bearing load see Fig 4 03 05 but this must be checked by the engine manufacturer in each case If the permissible load on the foremost mai...

Page 72: ...g Air cooler Pole wheel Stator shell Stuffing box Crankshaft Main bearing No 1 Standard engine with direct mounted generator and tuning wheel Tuning wheel Fig 4 03 05 Standard engine with direct mounted generator and tuning wheel 178 06 63 7 1 Mains constant frequency Excitation converter Synchronous condenser G Diesel engine DMG Static converter Smoothing reactor Fig 4 03 06 Diagram of DMG CFE wi...

Page 73: ...diate link no reactive power can be sup plied to the electric mains To supply this reactive power a synchronous condenser is used The synchronous condenser consists of an ordinary synchronous generator coupled to the electric mains Extent of delivery for DMG CFE units The delivery extent is a generator fully built on to the main engine including the synchronous condenser unit and the static conver...

Page 74: ...owever there is some scope for limiting the space require ment depending on the configuration chosen PTO type BW IV GCR Power Take Off Gear Constant Ratio The shaft generator system type PTO BW IV GCR installed in the shaft line Fig 4 01 01 al ternative 6 can generate power on board ships equipped with a controllable pitch propeller run ning at constant speed The PTO system can be delivered as a t...

Page 75: ...ntegrated in the shaft line The hollow flexible coupling consists of flexible segments and connecting pieces which allow replacement of the coupling segments without dismounting the shaft line see Fig 4 04 02 Fig 4 04 02 Generic outline of BW IV GCR tunnel gear 178 18 25 0 1 Generator step up gear and flexible coupling integrated in the shaft line For higher power take off loads a generator step u...

Page 76: ...ENK PSC clutch When the clutch is engaged the thrust is transferred statically to the engine thrust bearing through the thrust bearing built into the clutch To obtain high propeller efficiency in the auxiliary propulsion mode and thus also to minimise the auxiliary power required a two speed tunnel gear which provides lower propeller speed in the auxil iary propulsion mode is used The two speed tu...

Page 77: ...MAN B W Page 1 of 1 MAN Diesel This section is not applicable Waste Heat Recovery Systems WHRS 4 05 198 66 47 4 1 MAN B W 50 26 MC MC C ME C ME B GI engines ...

Page 78: ... 490 4 516 2 457 10 5 6 1 200 r min 3 026 1 490 4 516 2 457 10 5 7 1 000 r min 3 501 1 585 5 086 2 457 11 4 7 1 200 r min 3 501 1 585 5 086 2 495 11 4 8 1 000 r min 3 776 1 680 5 456 2 495 12 4 8 1 200 r min 3 776 1 680 5 456 2 495 12 4 9 1 000 r min 4 051 1 680 5 731 2 495 13 1 9 1 200 r min 4 051 1 680 5 731 2 495 13 1 178 23 03 1 0 P Free passage between the engines width 600 mm and height 2 00...

Page 79: ...1 10 C C m3 h 5 kg kWh bar m3 h 49 51 52 54 55 2 721 3 446 4 021 4 595 5 169 6 62 6 62 6 62 6 62 6 62 4 13 4 860 6 157 7 453 8 425 9 397 Exhaust gas data 6 Volume flow temperature turbocharger outlet Mass flow Temperature at turbine outlet Heat content 190 C Permissible exhaust back pressure m3 h 7 t h C kW mbar 5 710 7 233 8 438 9 644 10 849 3 1 3 9 4 5 5 2 5 8 375 375 375 375 375 170 216 252 288...

Page 80: ... t1 10 C C m3 h 5 kg kWh bar m3 h 51 53 55 56 57 3 169 4 183 4 880 5 578 6 275 6 94 6 94 6 94 6 94 6 94 3 92 5 509 7 453 8 425 9 721 11 017 Exhaust gas data 6 Volume flow temperature turbocharger outlet Mass flow Temperature at turbine outlet Heat content 190 C Permissible exhaust back pressure m3 h 7 t h C kW mbar 6 448 8 511 9 929 11 348 12 766 3 6 4 7 5 5 6 3 7 1 356 356 356 356 356 178 235 274...

Page 81: ... mm and height 2 000 mm Q Min distance between engines 2 400 mm without gallery and 2 600 mm with galley Depending on alternator Weight incl standard alternator based on a Uljanik alternator All dimensions and masses are approximate and subject to changes without prior notice Cyl no A mm B mm C mm H mm Dry weight GenSet t 5 900 rpm 3 959 1 870 5 829 3 183 21 5 5 1000 rpm 3 959 1 870 5 829 3 183 21...

Page 82: ...Engine output Speed kW rpm 1 000 1 320 1 540 1 760 1 980 1 000 Heat to be dissipated 3 Cooling water C W Cylinder Charge air cooler cooling water HT Charge air cooler cooling water LT Lube oil L O cooler Heat radiation engine kW kW kW kW kW 176 233 272 310 349 294 370 418 462 504 163 205 232 258 284 180 237 277 316 356 56 74 86 98 110 Flow rates 4 Internal inside engine HT circuit cylinder charge ...

Page 83: ...in 60 Hz 750 r min 50 Hz 900 r min 60 Hz Eng kW Gen kW Eng kW Gen kW Eng kW Gen kW 5L23 30H 650 620 675 640 6L23 30H 780 740 810 770 960 910 7L23 30H 910 865 945 900 1 120 1 065 8L23 30H 1 040 990 1 080 1 025 1 280 1 215 178 23 06 7 0 No of Cyls A mm B mm C mm H mm Dry weight GenSet t 5 720 r min 3 369 2 155 5 524 2 383 18 0 5 750 r min 3 369 2 155 5 524 2 383 18 0 6 720 r min 3 738 2 265 6 004 2 ...

Page 84: ... W Cylinder Charge air cooler cooling water HT Charge air cooler cooling water LT Lube oil L O cooler Heat radiation engine kW kW kW kW kW 182 219 257 294 1 stage cooler no HT stage 251 299 348 395 69 84 98 112 27 33 38 44 Air data Temperature of charge air at charge air cooler outlet max Air flow rate Charge air pressure Air required to dissipate heat radiation engine t2 t1 10 C C m3 h 4 kg kWh b...

Page 85: ... 1 Cooling water C W Cylinder Charge air cooler cooling water HT Charge air cooler cooling water LT Lube oil L O cooler Heat radiation engine kW kW kW kW kW 244 285 326 1 stage cooler no HT stage 369 428 487 117 137 158 32 37 43 Air data Temperature of charge air at charge air cooler outlet max Air flow rate Charge air pressure Air required to dissipate heat radiation engine t2 t1 10 C C m3 h 4 kg...

Page 86: ... 2 486 6 832 3 712 42 3 5 750 r min 4 346 2 486 6 832 3 712 42 3 6 720 r min 4 791 2 766 7 557 3 712 45 8 6 750 r min 4 791 2 766 7 557 3 712 46 1 7 720 r min 5 236 2 766 8 002 3 899 52 1 7 750 r min 5 236 2 766 8 002 3 899 52 1 8 720 r min 5 681 2 986 8 667 3 899 56 3 8 750 r min 5 681 2 986 8 667 3 899 58 3 9 720 r min 6 126 2 986 9 112 3 899 63 9 9 750 r min 6 126 2 986 9 112 3 899 63 9 Fig 4 0...

Page 87: ...2 682 26 247 30 135 33 699 Exhaust gas data 6 Volume flow temperature turbocharger outlet Mass flow Temperature at turbine outlet Heat content 190 C Permissible exhaust back pressure m3 h 7 t h C kW mbar 27 381 31 944 36 508 41 071 14 4 16 8 19 2 21 6 388 388 388 388 857 1 000 1 143 1 285 30 Pumps a Engine driven pumps HT circuit cooling water 2 5 bar LT circuit cooling water 2 5 bar Lube oil 4 5 ...

Page 88: ... W Cylinder Charge air cooler cooling water HT Charge air cooler cooling water LT Lube oil L O cooler Heat radiation engine kW kW kW kW kW 315 368 421 473 679 797 916 1037 181 208 234 258 282 329 376 423 70 81 93 104 Flow rates 4 Internal inside engine HT circuit cylinder charge air cooler HT stage LT circuit lube oil charge air cooler LT stage Lube oil External from engine to system HT water flow...

Page 89: ...184 32 6 6 720 r min 4 759 2 510 7 269 3 184 36 3 6 750 r min 4 759 2 510 7 269 3 184 36 3 7 720 r min 5 499 2 680 8 179 3 374 39 4 7 750 r min 5 499 2 680 8 179 3 374 39 4 8 720 r min 5 979 2 770 8 749 3 374 40 7 8 750 r min 5 979 2 770 8 749 3 374 40 7 9 720 r min 6 199 2 690 8 889 3 534 47 1 9 750 r min 6 199 2 690 8 889 3 534 47 1 P Free passage between the engines width 600 mm and height 2 00...

Page 90: ...ates 2 Internal inside engine HT cooling water cylinder LT cooling water lube oil cooler LT cooling water lube oil cooler LT cooling water charge air cooler m3 h m3 h m3 h m3 h 37 45 50 55 60 7 8 9 4 11 12 7 14 4 28 28 40 40 40 37 45 55 65 75 Air data Temperature of charge air at charge air cooler outlet Air flow rate Charge air pressure Air required to dissipate heat radiation engine t2 t1 10 C C...

Page 91: ...ates 2 Internal inside engine HT cooling water cylinder LT cooling water lube oil cooler LT cooling water lube oil cooler LT cooling water charge air cooler m3 h m3 h m3 h m3 h 37 45 50 55 60 7 8 9 4 11 12 7 14 4 28 28 40 40 40 37 45 55 65 75 Air data Temperature of charge air at charge air cooler outlet Air flow rate Charge air pressure Air required to dissipate heat radiation engine t2 t1 10 C C...

Page 92: ......

Page 93: ...MAN B W MAN Diesel Installation Aspects 5 ...

Page 94: ......

Page 95: ...uirements stated in Section 5 02 are valid for engines rated at nominal MCR L1 The additional space needed for engines equipped with PTO is stated in Chapter 4 If during the project stage the outer dimensions of the turbocharger seem to cause problems it is possible for the same number of cylinders to use turbochargers with smaller dimensions by increasing the indicated number of turbochargers by ...

Page 96: ...re fastened to the ship structure or to columns that are located on the top platform of the engine The lifting capacity of the crane beam for the heaviest component W is indicated in Fig 5 03 01b for the various turbocharger makes The crane beam shall be dimensioned for lifting the weight W with a deflection of some 5 mm only HB indicates the position of the crane hook in the vertical plane relate...

Page 97: ... ME B9 S35MC C ME B9 Crane beam for turbochargers Crane beam for transportation of components Crane beam for dismantling of components Spares Crane beam for transportation of components Crane beam for dismantling of components 178 52 74 6 0 Fig 5 03 02 Crane beam for turbocharger ...

Page 98: ...rane beam mounted on the engine 4 Turn the cooler insert to an upright position 5 Dismantle the platforms below the air cooler Engine room crane 5 4 8 1 2 3 6 7 6 Lower down the cooler insert between the gal lery brackets and down to the engine room floor Make sure that the cooler insert is supported e g on a wooden support 7 Move the air cooler insert to an area covered by the engine room crane u...

Page 99: ...oler The text and figures are for guidance only Valid for all engines with aft mounted Turbocharger 1 Dismantle all the pipes in the area around the air cooler 2 Dismantle all the pipes around the inlet cover for the cooler 3 Take out the cooler insert by using the above placed crane beam mounted on the engine 4 Turn the cooler insert to an upright position 5 By using the engine room crane the air...

Page 100: ...used it may not fit directly to the overhaul tools and the use of an interme diate shackle or similar between the lifting tool and the crane hook will affect the requirements for the minimum lifting height in the engine room dimension H 2 The hatched area shows the height where an MAN B W Double Jib Crane has to be used The crane hook travelling area must cover at least the full length of the engi...

Page 101: ...e Jib crane Centre line crankshaft The MAN B W Double Jib crane is available from Danish Crane Building A S P O Box 54 Østerlandsvej 2 DK 9240 Nibe Denmark Telephone 45 98 35 31 33 Telefax 45 98 35 30 33 E mail dcb dcb dk 178 24 86 3 2 Fig 5 04 02 Overhaul with Double Jib crane Overhaul with MAN B W Double Jib Crane ...

Page 102: ... C ME GI ME B engines 198 45 41 9 2 MAN B W Double Jib Crane Deck beam Chain collecting box M 30 Fig 5 04 03 MAN B W Double Jib crane option 4 88 701 This crane is adapted to the special tool for low overhaul Dimensions are available on request 178 37 30 1 1 ...

Page 103: ...m Section 19 04 Dispatch Pattern to which the masses of water and oil in the engine Section 5 08 are to be added The centre of gravity is shown in Section 5 07 in both cases including the water and oil in the engine but without moment compensators or PTO Gallery outline Section 5 06 show the gallery outline for engines rated at nominal MCR L1 Engine pipe connections The positions of the external p...

Page 104: ...ewed from Aft Fore Aft Viewed from Fore Y Y Z X Centre of Gravity For engines with two turbochargers No of cylinders 5 6 7 8 9 Distance X mm 5 10 15 25 Available on re quest Distance Y mm 1 925 2 425 2 875 3 325 Distance Z mm 2 275 2 325 2 350 2 375 All values stated are approximate Data for engines with a different number of turbochargers is available on request Dry mass tonnes 525 79 29 3 0 0 ...

Page 105: ... 283 463 1 358 420 1 200 560 1 373 140 150 26 ø17 5 TCA77 1 694 720 1 524 550 1 612 480 1 440 664 1 628 160 160 28 ø22 TCA88 2 012 855 1 810 653 1 914 570 1 710 788 1 934 190 190 28 ø22 TCA99 2 207 938 1 985 717 2 100 624 1 872 866 2 120 208 208 28 ø22 IL L A C E G I F IW W F K J H D B N x diameter O Type TCA series TC L W IL IW A B C D E F G H I J K N O TCA33 802 492 690 400 755 448 712 427 568 1...

Page 106: ...491 634 1 650 630 1 485 786 150 135 36 ø30 A185 A285 L 1 955 958 1 663 707 1 860 725 1 595 886 145 145 36 ø30 A190 A290 L 2 100 1 050 1 834 781 2 000 750 1 760 970 150 160 36 ø30 ABB Type A100 A200 L Counterflanges Connection D MAN Type TCR Type TCR series Round type TC Dia 1 Dia 2 PCD N O TCR18 425 310 395 12 ø22 TCR20 540 373 495 15 ø22 TCR22 595 434 550 16 ø22 PC D L C A IL G Dia 1 Dia 2 W IW D...

Page 107: ...0 741 175 175 34 ø24 Series MA MET33 700 310 605 222 670 0 550 280 130 110 18 ø15 MET42 883 365 793 275 850 240 630 335 80 90 24 ø15 MET53 1 122 465 1 006 349 1 073 300 945 420 100 105 28 ø20 MET60 1 230 500 1 120 388 1 190 315 1 050 460 105 105 30 ø20 MET66 1 380 560 1 254 434 1 330 345 1 200 510 115 120 30 ø20 MET71 1 520 600 1 400 480 1 475 345 1 265 555 115 115 34 ø20 MET83 1 740 700 1 586 550...

Page 108: ... 142 158 8 13 18 A185 A285 L 115 157 178 8 13 18 A190 A290 L 115 175 197 8 13 18 TC Dia ISO Dia JIS PCD N O Thickness of flanges TCA44 61 77 90 4 14 14 Dia Dia Dia 1 Dia 2 PCD W N x diameter O N x diameter O N x diameter O PCD N x diameter O Dia 1 Dia 1 N x diameter O PCD W L Dia W L L D i a 2 N x diameter O PCD N x diameter O PCD W L Dia Dia Dia 1 N x diamet N x diameter O PCD N x diameter O Dia ...

Page 109: ...a 2 PCD N O Thickness of flanges A MET42MB 95 43 75 4 12 10 MET60MB 120 49 95 4 14 12 MET66MB 120 49 95 4 14 12 MET71MB 120 49 95 4 14 12 MET83MB 120 49 95 4 14 12 Dia 1 Dia 2 PCD N x diameter O N x diameter O PCD Dia 1 Dia 1 N x diameter O PCD Dia W L D i a 2 N x diameter O PCD N x diameter O PCD W L Dia 1 Dia 2 PCD N x diameter O N x diameter O PCD N x diameter O PCD Dia W L D i a 2 W L N x diam...

Page 110: ...a 2 PCD N x diameter O N x diameter O PCD Dia 1 N x diameter O PCD Dia W L D i a 2 W L N x diameter O PCD N x diameter O PCD L Dia Dia Dia 1 Dia 2 PCD W N x diameter O N x diameter O N x diameter O PCD N x diameter O Dia 1 Dia 1 N x diameter O PCD W L Dia W L L D i a 2 N x diameter O PCD N x diameter O PCD W L Dia Dia Dia 1 Dia 2 PCD W N x diameter O N x diameter O N x diameter O PCD N x diameter ...

Page 111: ...ilable for download Engine seating and arrangement of holding down bolts The dimensions of the seating stated in Figs 5 12 01 and 5 12 02 are for guidance only The engine is designed for mounting on epoxy chocks EoD 4 82 102 in which case the under side of the bedplate s lower flanges has no taper The epoxy types approved by MAN Diesel Turbo are Chockfast Orange PR 610 TCF from ITW Philadelphia Re...

Page 112: ...be kept free from pipes etc along both sides of the engine in order to facilitate the overhaul work on holding down bolts supporting chocks and side chocks Thickness of floorplates between main engine girders 22mm Continuous girder to extend with full dimensions at least to ship s frame forward of engine and at least to ship s frame aft of the aft end of end chock Corners of floorplates to be cut ...

Page 113: ...4 Spherical washer 5 Spherical washer 6 Protecting cap End chock liner option 4 82 612 includes 7 Liner for end chock End chock brackets option 4 82 614 includes 8 End chock bracket Fig 5 12 02b Profile of engine seating end chocks option 4 82 620 Fig 5 12 02c Profile of engine seating end chocks option 4 82 610 079 40 88 6 2 0b 079 29 22 7 2 0 Taper 1 100 about 350 about ø190 65 575 15 15 125 ø66...

Page 114: ...ith and without top bracing If a vibration measurement in the first vessel of a series shows that the vibration level is acceptable without the top bracing we have no objection to the top bracing being removed and the rest of the series produced without top bracing It is our experience that especially the 7 cylinder engine will often have a lower vibration level without top bracing Without top bra...

Page 115: ...trol from the control panel is also possible When active the hydraulic cylinder provides a pressure on the engine in proportion to the vibra tion level When the distance between the hull and engine increases oil flows into the cylinder under pressure from the accumulator When the dis tance decreases a non return valve prevents the oil from flowing back to the accumulator and the pressure rises If ...

Page 116: ... a a e d 0 6 f C 1 T C 2 3 4 5 a f c 0 b 6 g C 1 T C 2 3 4 5 a a g e 0 6 h 7 7 8 T C T C Centreline crankshaft 0 0 2 108 P 4 715 Q Min R Centreline cylinder 1 1 2 3 4 C T C Cyl 1 Turbocharger Chain box Cylinder number This symbol indicates that the top bracing is attached at point P This symbol indicates that the top bracing is attached at point Q ...

Page 117: ...ent is the major excitation source and for larger cylinder numbers an X moment is the major excitation source For engines with vibrations excited by an X moment bracing at the centre of the engine are of only minor importance Top bracing should only be installed on one side either the exhaust side or the manoeuvring side If top bracing has to be installed on manoeuvring side please contact MAN Die...

Page 118: ...tatus of the ECS Via the PMI CoCoS PC the operator can view the status and operating history of the ECS and the engine The PMI Auto tuning application is run on a stand ard PC The PMI Auto tuning system is used to optimize the combustion process with minimal operator attendance and improve the efficiency of the engine See Section 18 02 CoCoS EDS ME Basic is included as part of the standard softwar...

Page 119: ...rect dimming control 0 100 USB connection at front IP54 resistant front Pointing device Keyboard model UK version 104 keys USB connection Trackball mouse USB connection PMI CoCos Display LCD TFT monitor 19 Active matrix Resolution 1 280x1 024 auto scaling Direct dimming control 0 100 IP65 resistant front PMI CoCos PC Standard industry PC with MS Windows operating system UK version Router Ethernet ...

Page 120: ...es 198 82 74 5 0 188 04 91 4 4 0 Fig 5 16 03 The EICU cabinet unit for the ME B Engine Control System Printer Network printer ink colour printer EICU Cabinet Engine interface control cabinet for ME ECS for installation in ECR recommended or ER 188 23 16 6 1 0 ...

Page 121: ...two arrangements for holding brushes including connecting cables and monitoring equipment with a mV meter and an output signal for alarm The slip rings should be made of solid silver or back up rings of cobber with a silver layer all over The expected life span of the silver layer on the slip rings should be minimum 5 years The brushes should be made of minimum 80 silver and 20 graphite to ensure ...

Page 122: ...haftline earthing device in an engine plant without shaft mounted generator Shaftline earthing device installations The shaftline earthing device slip rings must be mounted on the foremost intermediate shaft as close to the engine as possible see Fig 5 17 02 Brush holder arrangement Cable connected to the hull Monitoring equipment with mV meter Cable connected to the hull Cable to alarm system Bru...

Page 123: ...ent Thrust bearing Main bearings Propeller Shaft mounted alternator where the rotor is part of the intermediate shaft 079 21 82 1 3 3 0 Fig 5 17 03 Installation of shaftline earthing device in an engine plant with shaft mounted generator When a generator is fitted in the propeller shaft system where the rotor of the generator is part of the intermediate shaft the shaftline earthing de vice must be...

Page 124: ......

Page 125: ... setting the pitch is built into the pro peller hub A range of different hub sizes is avail able to select an optimum hub for any given com bination of power revolutions and ice class Standard blade hub materials are Ni Al bronze Stainless steel is available as an option The pro pellers are based on no ice class but are avail able up to the highest ice classes 0 1 000 2 000 3 000 4 000 5 000 6 000...

Page 126: ...m model tank re sistance test self propulsion test and wake measurement In case model test is not avail able the next page should be filled in 5 Drawing of lines plan 6 Classification Society ___________ Ice class notation ______________ 7 Maximum rated power of shaft generator kW 8 Optimisation condition for the propeller To obtain the highest propeller efficiency please identify the most common ...

Page 127: ...ance To reduce pressure impulses and vibrations emit ted from the propeller to the hull MAN Diesel Turbo recommends a minimum tip clearance as shown in Fig 5 18 04 For ships with slender aft body and favourable inflow conditions the lower values can be used whereas full afterbody and large variations in wake field cause the upper values to be used In twin screw ships the blade tip may protrude bel...

Page 128: ... The design principle of the servo oil system for MAN Diesel Turbo s MAN Alpha VBS type CP propeller is shown in Fig 5 18 05 The VBS system consists of a servo oil tank unit the Hydraulic Power Unit and a coupling flange with electrical pitch feedback box and oil distribu tor ring The electrical pitch feedback box continuously measures the position of the pitch feedback ring and compares this sign...

Page 129: ...f two pumps are in service during normal operation while the second will start up at power ful manoeuvring A servo oil pressure adjusting valve ensures mini mum servo oil pressure at any time hereby mini mizing the electrical power consumption Maximum system pressure is set on the safety valve The return oil is led back to the tank via a thermo static valve cooler and paper filter The servo oil un...

Page 130: ...rbo s MAN Alphatronic 2000 Pro pulsion Control System PCS is designed for con trol of propulsion plants based on diesel engines with CP propellers The plant could for instance include tunnel gear with PTO PTI PTO gear mul tiple engines on one gearbox as well as multiple propeller plants As shown in Fig 5 18 07 the propulsion control system comprises a computer controlled system with interconnectio...

Page 131: ...ted on the bridge is required This control station will incorporate three mod ules as shown in Fig 5 18 08 Propulsion control panel with push buttons and indicators for machinery control and a dis play with information of condition of operation and status of system parameters Propeller monitoring panel with back up in struments for propeller pitch and shaft speed Thrust control panel with control ...

Page 132: ...litates reliable and simple take home and take away functions in two stroke engine plants It is described in Sec tion 4 04 Further information about MAN Alpha CP pro peller For further information about MAN Diesel Turbo s MAN Alpha Controllable Pitch CP propeller and the Alpha tronic 2000 Remote Control System please refer to our publications CP Propeller Product Information Alphatronic 2000 PCS P...

Page 133: ...MAN B W MAN Diesel List of Capacities Pumps Coolers Exhaust Gas 6 ...

Page 134: ......

Page 135: ...apacities fresh water production and exhaust gas amounts and temperatures will be described in details Nomenclature In the following description and examples of the auxiliary machinery capacities freshwater generator pro duction and exhaust gas data the below nomenclatures are used Fig 6 01 01 Nomenclature of basic engine ratings Fig 6 01 02 Nomenclature of coolers and volume flows etc Engine conf...

Page 136: ... for seawater cooling system Scavenge air cooler Seawater 32 C 45 C Lubricating oil cooler 38 C Jacket water cooler 80 C Seawater outlet Seawater outlet Central cooler Seawater inlet 32 C Central coolant 36 C Scavenge air cooler s Jaket water cooler Lubricating oil cooler 80 C 43 C 45 C Fig 6 02 02 Diagram for central cooling water system 178 11 27 6 1 The List of Capacities contain data regarding...

Page 137: ...ter flow m h 92 93 96 92 93 96 Seawater flow m h 110 111 114 110 111 114 Central cooler Heat diss app kW 5 450 5 460 5 480 5 560 5 570 5 590 Central water flow m h 210 212 214 214 215 218 Seawater flow m h 267 267 268 272 272 273 Starting air system 30 0 bar g 12 starts Fixed pitch propeller reversible engine Receiver volume m 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0...

Page 138: ...al water flow m h 109 112 112 110 112 114 Seawater flow m h 129 133 134 131 133 136 Central cooler Heat diss app kW 6 520 6 550 6 550 6 670 6 680 6 700 Central water flow m h 250 253 254 257 258 261 Seawater flow m h 319 320 320 326 327 328 Starting air system 30 0 bar g 12 starts Fixed pitch propeller reversible engine Receiver volume m 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x ...

Page 139: ...113 113 113 Central water flow m h 128 129 132 128 129 132 Seawater flow m h 152 154 157 152 154 157 Central cooler Heat diss app kW 7 620 7 630 7 650 7 770 7 780 7 800 Central water flow m h 293 295 297 299 300 303 Seawater flow m h 372 373 374 380 380 381 Starting air system 30 0 bar g 12 starts Fixed pitch propeller reversible engine Receiver volume m 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x...

Page 140: ...129 Central water flow m h 146 150 152 146 150 152 Seawater flow m h 173 179 182 173 179 182 Central cooler Heat diss app kW 8 700 8 740 8 760 8 870 8 910 8 930 Central water flow m h 335 339 342 341 346 348 Seawater flow m h 425 427 428 434 436 436 Starting air system 30 0 bar g 12 starts Fixed pitch propeller reversible engine Receiver volume m 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x...

Page 141: ...5 Central water flow m h 163 168 170 166 168 170 Seawater flow m h 194 200 202 197 200 202 Central cooler Heat diss app kW 9 790 9 830 9 840 10 000 10 020 10 030 Central water flow m h 376 381 383 385 388 390 Seawater flow m h 478 480 481 489 490 490 Starting air system 30 0 bar g 12 starts Fixed pitch propeller reversible engine Receiver volume m 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 x 5 0 2 ...

Page 142: ... stated in the List of Capacities valid for nominal MCR L1 The percentage power PM and speed nM of L1 ie PM PM PL1 x 100 nM nM nL1 x 100 for specified MCR M of the derated engine is used as input in the above mentioned diagrams giving the heat dissipation figures relative to those in the List of Capacities Qair 100 x PM PL1 1 68 x nM nL1 0 83 1 178 63 63 8 0 Fig 6 04 01 Scavenge air cooler heat di...

Page 143: ...6 04 03 respectively i e as follows Vsw air M Vsw air L1 x Qair 100 Vsw lub M Vsw lub L1 x Qlub 100 Vsw jw M Vsw lub M However regarding the scavenge air cooler s the engine maker has to approve this reduction in order to avoid too low a water velocity in the scav enge air cooler pipes As the jacket water cooler is connected in series with the lube oil cooler the seawater flow capac ity for the la...

Page 144: ... As the seawater pump capacity and the central cooler heat dissipation for the nominal rated en gine found in the List of Capacities are 326 m3 h and 6 670 kW the derated seawater pump flow equals Seawater pump Vsw cent M Vsw cent L1 x Qcent M Qcent L1 326 x 5 986 6 670 293 m3 h The method of calculating the reduced capaci ties for point M nM 95 0 and PM 90 0 is shown below The values valid for th...

Page 145: ...58 Jacket cooling water flow m3 h 97 97 Central cooling water flow m3 h 110 105 Central cooler Heat dissipation kW 6 670 5 986 Central cooling water flow m3 h 256 233 Seawater flow m3 h 326 293 Fuel oil heater kW 84 75 Gases at ISO ambient conditions Exhaust gas amount kg h 80 800 72 600 Exhaust gas temperature C 235 231 Air consumption kg s 21 0 19 8 Starting air system 30 bar gauge Reversible en...

Page 146: ... age correction factor Qjw and hence for specified MCR power PM Qjw M Qjw L1 x Qjw ___ 100 x 0 9 0 88 1 2 Engine power lower than specified MCR power For powers lower than the specified MCR power the value Qjw M found for point M by means of the above equation 1 is to be mul tiplied by the correction factor kp found in Fig 6 04 04 and hence Qjw Qjw M x kp 15 0 2 where Part load correction factor f...

Page 147: ... cooling water temperature at the outlet from the engine does not fall below a certain level 178 23 70 0 0 Jacket cooling water system Freshwater generator system Expansion tank Jacket cooling water circuit min Tjw max Tjw L M K Seawater In Out Condensator Produced freshwater Evaporator Brine out B Jacket water cooler Cooling water Deaerating tank Jacket water pumps Main engine A jacket cooling wa...

Page 148: ...eference conditions Air temperature Tair 20 C Scavenge air coolant temperature TCW 18 C Barometric pressure pbar 1 013 mbar Exhaust gas back pressure at specified MCR pM 300 mm WC The expected available jacket cooling water heat at service rating is found as follows Qjw L1 1 690 kW from List of Capacities Qjw 92 2 using 90 0 power and 95 0 speed for M in Fig 6 04 02 By means of equation 1 and usin...

Page 149: ...following method of calculation may be used The partial calculations based on the above influ encing factors have been summarised in equations 4 and 5 Fig 6 04 06 Summarising equations for exhaust gas amounts and temperatures The partial calculations based on the influencing factors are described in the following a Correction for choice of specified MCR point When choosing a specified MCR point M ...

Page 150: ...Change of exhaust gas temperature Change of exhaust gas amount Blower inlet temperature 10 C 16 0 C 4 1 Blower inlet pressure barometric pressure 10 mbar 0 1 C 0 3 Charge air coolant temperature seawater temperature 10 C 1 0 C 1 9 Exhaust gas back pressure at the specified MCR point 100 mm WC 5 0 C 1 1 Fig 6 04 09 Correction of exhaust gas data for ambient conditions and exhaust gas back pressure ...

Page 151: ...PM 130 Fig 6 04 12 Change of exhaust gas temperature TS in C at part load and valid for FPP and CPP 178 24 62 3 0 178 24 63 5 0 c Correction for engine load Figs 6 04 11 and 6 04 12 may be used as guidance to determine the relative changes in the specific exhaust gas data when running at part load compared to the values in the specified MCR point i e using as input PS PS PM x 100 ms change in spec...

Page 152: ... 117 0 r min 100 0 Specified MCR M PM 9 612 kW 90 0 and 111 2 r min 95 0 Service rating S PS 7 689 kW and 103 2 r min PS 80 0 of PM Reference conditions Air temperature Tair 20 C Scavenge air coolant temperature TCW 18 C Barometric pressure pbar 1 013 mbar Exhaust gas back pressure at specified MCR pM 300 mm WC a Correction for choice of specified MCR point M PM 9 612 _____ 10 680 x 100 90 0 nM 11...

Page 153: ...100 x 1 0 0 ___ 100 x 1 0 0 ___ 100 x 100 0 ____ 100 72 558 kg h Mexh M 72 600 kg h 15 Texh M 235 3 9 0 0 231 1 C Texh M 231 1 C 5 C The air consumption will be 72 558 x 0 982 kg h 71 252 kg h 71 252 3 600 kg s 19 8 kg s Final calculation By means of equations 4 and 5 the final result is found taking the exhaust gas flow ML1 and tempera ture TL1 from the List of Capacities ML1 80 800 kg h Mexh 80 ...

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Page 155: ...MAN B W MAN Diesel Fuel 7 ...

Page 156: ......

Page 157: ...he fuel oil system on the engine The fuel oil pressure measured on the engine at fuel pump level should be 7 8 bar equivalent to a circulating pump pressure of 10 bar Fuel considerations When the engine is stopped the circulating pump will continue to circulate heated heavy fuel through the fuel oil system on the engine thereby keeping the fuel pumps heated and the fuel valves deaerated This autom...

Page 158: ...7 03 01 F X AF b a BD To storage settling tank To freshwater cooling pump suction To drain tank Fuel oil drain tank If the fuel oil pipe to engine is made as a straight line immediately before the engine it will be necessary to mount an expansion unit If the connection is made as indicated with a bend immediately before the engine no expansion unit is required Full flow filter For filter type see ...

Page 159: ...on society rules and on whether it may be vented directly to the engine room Drain AF is shown in Fig 7 03 01 Drain of contaminated fuel etc Leakage oil in shape of fuel and lubricating oil contaminated with water dirt etc and collected by the HCU Base Plate top plate is drained off through the bedplate drains AE Drain AE is shown in Fig 8 07 02 Heating of fuel drain pipes Owing to the relatively ...

Page 160: ...e combustion properties of the oil This means that service results depend on oil properties which cannot be known beforehand This especially applies to the tendency of the oil to form deposits in combustion chambers gas passages and turbines It may therefore be nec essary to rule out some oils that cause difficulties Guiding heavy fuel oil specification Based on our general service experience we h...

Page 161: ...ig 7 03 01 Fuel oil and drain pipes Fuel valves Fore Aft Leakage alarm Leakage high press pipes Baseplate Counter pressure valve Mixed oil drain Fuel oil inlet Fuel valves Pressure booster Fuel oil outlet umbrella Drain for fuel oil Fuel oil return pipe AF AE F X To sludge tank To sludge tank Clean HFO return to HFO service tank or settling tank Cyl 1 Baseplate drain alarm AE LS 4112 AH PI 8001 TI...

Page 162: ... to the pressure tests speci fied and approved by the respective classification society and or authorities Fig 7 04 01 The directions mentioned below include insulation of hot pipes flanges and valves with a surface temperature of the complete insulation of maxi mum 55 C at a room temperature of maximum 38 C As for the choice of material and if required approval for the specific purpose reference ...

Page 163: ...ines Engine Selection Guide 198 40 51 8 3 Fig 7 04 02 Heat loss Pipe cover Insu l a t i o n t h i c k n e s s 20 30 40 50 60 70 80 90 100 120 160 200 Temperature difference between pipe and room C Pipe diameter mm Heat loss watt meter pipe 178 50 60 2 0 Heat Loss in Piping ...

Page 164: ...supply lines 2 When the circulation pump is stopped with heavy fuel oil in the piping and the pipes have cooled down to engine room temperature as it is not possible to pump the heavy fuel oil In this situation the fuel oil must be heated to pumping temperature of about 50 ºC To heat the pipe to pumping level we recom mend to use 100 watt leaking meter pipe 178 52 55 5 2 Fig 7 04 04b Spray Shields...

Page 165: ...or Marine Diesel Oil MDO is not a must However MAN Diesel Turbo recommends that at least one of the HFO purifiers can also treat MDO If it is decided after all to install an individual puri fier for MDO on board the capacity should be based on the above recommendation or it should be a centrifuge of the same size as that for HFO The Nominal MCR is used to determine the to tal installed capacity An...

Page 166: ...cified up to 700 cSt at 50 C Fuel oil flow see capacity of fuel oil circulating pump Heat dissipation see List of Capacities Pressure drop on fuel oil side maximum 1 bar Working pressure 10 bar Fuel oil inlet temperature approx 100 C Fuel oil outlet temperature 150 C Steam supply saturated 7 bar abs To maintain a correct and constant viscosity of the fuel oil at the inlet to the main engine the st...

Page 167: ... oil flow see List of capacities Working pressure 10 bar Test pressure according to class rule Absolute fineness 50 µm Working temperature maximum 150 C Oil viscosity at working temperature 15 cSt Pressure drop at clean filter maximum 0 3 bar Filter to be cleaned at a pressure drop of maximum 0 5 bar Note Absolute fineness corresponds to a nominal fine ness of approximately 35 µm at a retaining ra...

Page 168: ...ormation in the system The inlet pressure is thus set to 13 bar In order to avoid temperature chock when mixing water into the fuel in the homogeniser the water inlet temperature is to be set to 70 90 C Safety system In case the pressure in the fuel oil line drops the water homogenised into the Water In Fuel emul sion will evaporate damaging the emulsion and creating supply problems This situation...

Page 169: ...98 99 01 8 3 From centrifuges Deck Diesel oil service tank Heavy fuel oil service tank Overflow valve adjusted to 12 bar Supply pumps Filter Booster pump Compressed air S Safety pump air operated Fresh water supply To special safety tank Automatic de aerating valve Venting box Common fuel oil supply unit Homogeniser Full flow filter Water in oil measuring Circulating pumps Heater BX F BF X AD AF B...

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Page 171: ...MAN B W MAN Diesel Lubricating Oil 8 ...

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Page 173: ...crosshead bear ings crankpin bearings It also supplies oil to the Hydraulic Power Supply unit and to the torsional vibration damper From the engine the oil collects in the oil pan from where it is drained off to the bottom tank see Fig 8 06 01a and b Lubricating oil tank with cofferdam By class demand a cofferdam must be placed underneath the lubricating oil tank The engine crankcase is vented thr...

Page 174: ...RW is the oil outlet from the automatic backflush ing filter The HPS in service The max operating pressure for the hydraulic oil to the HCUs is 300 bar At start and in service both pumps are activated Each of the pumps has a capacity sufficient to op erate the engine with 55 engine power enabling around 80 ship speed should one pump fail The hydraulic oil is supplied to the Hydraulic Cyl inder Uni...

Page 175: ...d engines with PTO on fore end RU Pressure booster Starting air distributor AR HCU HCU RW Hydraulic oil Safety valve and accumulator Hydraulic Power Supply unit Filter unit Main filter Back flushing oil Redundancy filter Automatic by pass valve Electrically driven pumps M M WT 8812 I AH Y LS 4112 AH PI 8108 PT 8108 AL Y PS 8109 Z TI 8112 TE 8112 AH Y XS 8150 AH FS 8114 AL Y TE 8113 AH TI 8113 TE 8...

Page 176: ...rbocharger AB TE 8117 I AH TI 8117 PI 8103 PT 8103 I AL E Fig 8 03 01 MAN turbocharger type TCA 121 14 96 6 1 2 From system oil MET turbocharger AB E TE 8117 I AH TI 8117 PI 8103 Fig 8 03 03 Mitsubishi turbocharger type MET Fig 8 03 03 ABB turbocharger type A100L 126 40 87 1 2 0 524 26 81 4 0 0 AB E PI 8103 PT 8103 I AL TE 8117 I AH TI 8117 From system oil ABB A100L Turbocharger ...

Page 177: ... 8 5 Fig 8 03 02 ABB turbocharger type TPL85B14 16 TPL 91B12 Fig 8 03 02 ABB turbocharger type TPL65B12 TPL85B12 515 85 30 3 1 0 126 40 85 8 3 0 AB E PI 8103 PT 8103 I AL TE 8117 I AH TI 8117 From system oil ABB TPL turbocharger From system oil ABB TPL turbocharger AB TE 8117 I AH TI 8117 PI 8103 PT 8103 I AL ...

Page 178: ...egean Alfasys 305 BP OE HT 30 Castrol CDX 30 Chevron Veritas 800 Marine 30 ExxonMobil Mobilgard 300 Gulf Oil Marine GulfSea Superbear 3006 Lukoil Navigo 6 SO JX Marine S30 Shell Melina S 30 Sinopec System Oil 3005 Total Atlanta Marine D3005 List of lubricating oils The circulating oil lubricating and cooling oil must be of the rust and oxidation inhibited type of oil of SAE 30 viscosity grade In s...

Page 179: ...ing the engine with cold oil It is recommended to install a 25 mm valve pos 006 with a hose connection after the main lubri cating oil pumps for checking the cleanliness of the lubricating oil system during the flushing pro cedure The valve is to be located on the under side of a horizontal pipe just after the discharge from the lubricating oil pumps Lubricating oil cooler The lubricating oil cool...

Page 180: ...ngine If a double filter duplex is installed it should have sufficient capacity to allow the specified full amount of oil to flow through each side of the filter at a given working temperature with a pressure drop across the filter of maximum 0 2 bar clean filter If a filter with a back flushing arrangement is in stalled the following should be noted The required oil flow specified in the List of ...

Page 181: ...cid treat ed followed by neutralisation cleaned and cor rosion protected Both ends of all pipes must be closed sealed during transport Before final installation carefully check the in side of the pipes for rust and other kinds of for eign particles Never leave a pipe end uncovered during as sembly Bunkering and filling the system Tanks must be cleaned manually and inspected before filling with oil...

Page 182: ...or the remaining part of the lubricating oil system The amount of contamination contained in sys tem samples can be estimated by means of the Pall Fluid Contamination Comparator combined with the Portable Analysis Kit HPCA Kit 0 which is used by MAN Diesel Turbo This kit and the Comparator included is supplied by Pall Corporation USA www pall com It is important to record the flushing condition in...

Page 183: ...ng oil outlet A protecting ring position 1 4 is to be installed if required by class rules and is placed loose on the tanktop and guided by the hole in the flange In the vertical direction it is secured by means of screw position 4 in order to prevent wear of the rubber plate Engine builder s supply 2 3 4 1 Oil and temperature resistant rubber 3 layers yard s supply ...

Page 184: ...me Fore Hydraulic Cylinder Unit LS 4112 AH Oil filter HPS Hole diam 55 mm To be equipped with flame screen if required by class rules Drain cowl Inside diameter of drain pipe 10 mm Deck Inside diam of pipe 80 mm To drain tank To be laid with inclination Venting from crankcase inside diam of pipe 50 mm This pipe to be delivered with the engine AR Vapour discharge from engine 178 57 79 2 0 Fig 8 07 ...

Page 185: ... scavenge air drain tank Deck To drain tank Venting chamber Fig 8 07 03a Separate venting of all systems directly to outside air above deck 079 61 00 5 1 1 Venting of engine plant equipment separately The various tanks engine crankcases and turbo chargers should be provided with sufficient vent ing to the outside air MAN Diesel Turbo recommends to vent the in dividual components directly to outsid...

Page 186: ...e to back flushing oil drain tank see Fig 8 08 01 As the pipes have the same diameters but a different length the resis tance is larger in the branch pipe to back flushing oil drain tank and therefore the purifier will suck primarily from the sump tank The oil level in the sump tank and the back flush ing oil drain tank will remain to be about equal be cause the tanks are interconnected at the top...

Page 187: ...MAN B W Page 1 of 1 MAN Diesel Separate System for Hydraulic Control Unit 8 09 198 53 15 0 1 MAN B W ME B engines This section is not applicable ...

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Page 189: ...MAN B W MAN Diesel Cylinder Lubrication 9 ...

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Page 191: ...as its opera tion is optimised Cylinder oils In short MAN Diesel and Turbo recommends the use of cylinder oils with the following main proper ties SAE 50 viscosity grade high detergency BN 100 for high sulphur fuel BN 40 for low sulphur fuel A BN 100 cylinder oil is to be used as the default choice of oil and it may be used on all fuel types However in case of the engine running on fuel with sulph...

Page 192: ...are 50100 100 JX Nippon Oil Energy Marine C405 40 MC 1005 8 internal code 100 Lukoil Navigo 40 MCL 40 Navigo 100 MCL 100 Shell Alexia S6 100 Sinopec Marine Cylinder Oil 5040 40 Total Talusia LS 40 40 Talusia Universal 100 100 List of cylinder oils The major international cylinder oil brands listed below have been tested in service with acceptable results Some of the oils have also given satisfac t...

Page 193: ...ce tank may alter natively be one and the same tank The oil fed to the injectors is pressurised by means of the Alpha Lubricator which is placed on the HCU and equipped with small multi piston pumps The oil pipes fitted on the engine is shown in Fig 9 02 04 The whole system is controlled by the Cylinder Control Unit CCU which controls the injection frequency on the basis of the engine speed signal...

Page 194: ...inciple The feed rate control should be adjusted in rela tion to the actual fuel quality and amount being burnt at any given time The following criteria determine the control The cylinder oil dosage shall be proportional to the sulphur percentage in the fuel The cylinder oil dosage shall be proportional to the engine load i e the amount of fuel entering the cylinders The actual feed rate is depend...

Page 195: ...e en gine Moreover the engine builder is to mount the junction box and the thermostat on the engine See Fig 9 02 03 The ship yard is to make the insulation of the cylinder oil pipe in the engine room The heat ing cable supplied by the engine builder is to be mounted from the small tank to the juntion box on the engine See Figs 9 02 02a and 9 02 02b Deck AC Cylinder oil storage or service tank Heat...

Page 196: ...raulic Cylinder Unit Solenoid valve Terminal box Temperature switch Forward cyl Aft cyl Terminal box Temperature switch AC Cylinder lubrication Power input Heating cable ship builder supply Heating cable ship builder supply Power input Fig 9 02 02b Cylinder lubricating oil system Example from S60 50ME B 178 55 64 6 1 Fig 9 02 03 Electric heating of cylinder oil pipes 178 53 71 6 1 The number of cy...

Page 197: ...5ME B 60 50ME B Lubricator Drain Venting AC Solonoid valve ZV 8204 C Feed back sensor ZT 8203 C TE 8202 I AH Level switch LS 8208 C 178 55 67 1 1 Fig 9 02 04 Cylinder lubricating oil pipes The item No refer to Guidance Values Automation The letters refer to list of Counterflanges ...

Page 198: ...4 113 460 74 425 850 920 91 112 To venting of cylinder oil service tank Flange ø140 4xø18 PCD 100 EN36F00420 4xø19 for mounting Coupling box for heating element and level switch Temperature indicator To engine connection AC Flange ø140 4xø18 PCD 100 EN362F0042 Heating element 750 W Set point 40 ºC Drain from tray G 3 8 193 239 260 268 410 178 52 75 8 1 Fig 9 02 05 Suggestion for small heating box ...

Page 199: ...MAN B W MAN Diesel Piston Rod Stuffing Box Drain Oil 10 ...

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Page 201: ...l as the oil drained from the stuffing box is mixed with sludge from the scavenge air space The performance of the piston rod stuffing box on the engines has proved to be very efficient pri marily because the hardened piston rod allows a higher scraper ring pressure Stuffing Box Drain Oil System The amount of drain oil from the stuffing boxes is about 5 10 litres 24 hours per cylinder during norma...

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Page 203: ...MAN B W MAN Diesel Central Cooling Water System 11 ...

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Page 205: ...aintenance of coolers and compo nents Increased heat utilisation Disadvantages of the central cooling system Three sets of cooling water pumps seawater central water and jacket water Higher first cost For information on the alternative Seawater Cool ing System see Chapter 12 An arrangement common for the main engine and MAN Diesel Turbo auxiliary engines is available on request For further informa...

Page 206: ...to be set to minimum 10 C whereby the temperature follows the outboard seawater tem perature when central cooling water temperature exceeds 10 C For external pipe connections we prescribe the following maximum water velocities Jacket water 3 0 m s Central cooling water 3 0 m s Seawater 3 0 m s 178 52 77 1 1 TI TI TI TI TI TI PI PI PI TI Seawater outlet Central cooler Seawater pumps Central cooling...

Page 207: ...ling pumps The pumps are to be of the centrifugal type Seawater flow see List of Capacities Pump head 2 5 bar Test pressure according to class rules Working temperature normal 0 32 C Working temperature maximum 50 C The flow capacity must be within a range from 100 to 110 of the capacity stated The differential pressure of the pumps is to be de termined on the basis of the total actual pressure dr...

Page 208: ...al pressure drop across the cooling water system Scavenge air cooler The scavenge air cooler is an integrated part of the main engine Heat dissipation see List of Capacities Central cooling water flow see List of Capacities Central cooling temperature inlet 36 C Pressure drop on FW LT water side approx 0 5 bar Lubricating oil cooler See Chapter 8 Lubricating Oil Cooling water pipes Diagrams of coo...

Page 209: ...MAN B W MAN Diesel Seawater Cooling System 12 ...

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Page 211: ...cooling system and a jacket cool ing water system The advantages of the seawater cooling system are mainly related to first cost viz Only two sets of cooling water pumps seawater and jacket water Simple installation with few piping systems Whereas the disadvantages are Seawater to all coolers and thereby higher maintenance cost Expensive seawater piping of non corrosive ma terials such as galvanis...

Page 212: ...cal conditions i e a maximum tem perature increase of 18 C The valves located in the system fitted to adjust the distribution of cooling water flow are to be provided with graduated scales The inter related positioning of the coolers in the system serves to achieve The lowest possible cooling water inlet tem perature to the lubricating oil cooler in order to obtain the cheapest cooler On the other...

Page 213: ...35MC C9 S L35MC S35ME B S30ME B9 S26MC 198 39 78 8 7 Cooling Water Pipes Scavenge air cooler AS AS P N TI 8422 TI 8423 TE 8422 I PI 8421 PT 8421 I AL TE 8423 I 178 50 38 7 1 Fig 12 03 01 Cooling water pipes for engines with one turbocharger The letters refer to list of Counterflanges The item No refer to Guidance values automation ...

Page 214: ...mperature level must be a minimum of 10 C Seawater flow see List of Capacities Temperature range adjustable within 5 to 32 C Seawater cooling pump The pumps are to be of the centrifugal type Seawater flow see List of Capacities Pump head 2 5 bar Test pressure according to class rule Working temperature maximum 50 C The flow capacity must be within a range from 100 to 110 of the capacity stated Lub...

Page 215: ...he jacket water cooler outlet and delivers it to the engine At the inlet to the jacket water cooler there is a thermostatically controlled regulating valve with a sensor at the engine cooling water outlet which keeps the main engine cooling water outlet at a temperature between 88 and 92 C The engine jacket water must be carefully treated maintained and monitored so as to avoid corro sion corrosio...

Page 216: ...ater treatment MAN Diesel Turbo s recommendations for treat ment of the jacket water freshwater are available on request Jacket water cooling pump The pumps are to be of the centrifugal type Jacket water flow see List of Capacities Pump head 3 0 bar Delivery pressure depends on position of expansion tank Test pressure according to class rule Working temperature 80 C max 100 C The flow capacity mus...

Page 217: ...00 A 600 800 B 125 210 C 5 5 D 150 150 E 300 500 F 910 1 195 G 250 350 øH 300 500 øI 320 520 øJ ND 50 ND 80 øK ND 32 ND 50 øJ øK Diameter corresponding to pipe diameter in engine room 90 B F A 90 øI øH G 5 E D C LS 8412 AL Level switch Level switch float in position for alarm Level switch float in normal position no alarm Alarm device From deaerating tank Expansion tank ø15 Level switch float 178 ...

Page 218: ...ature of 50 C should be obtained before the above described normal start load up procedure may be continued Controllable pitch propeller plants Normal start of engine Normally a minimum engine jacket water temperature of 50 C is recommended before the engine may be started and run up gradu ally from 50 to 75 of specified MCR load SMCR power during 30 minutes For running up between 75 and 100 of SM...

Page 219: ...iation in thermal expansions and possible leakages The jacket cooling water outlet temperature should be kept as high as possible and should before starting up be increased to at least 50 C either by means of cooling water from the auxiliary en gines or by means of a built in preheater in the jacket cooling water system or a combination Fig 12 08 01 Jacket water preheater example 178 16 63 1 1 Tem...

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Page 221: ...MAN B W MAN Diesel Starting and Control Air 13 ...

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Page 223: ...r for exhaust valve and for fuel valve testing unit are momentary requirements of the consumers The components of the starting and control air systems are further desribed in Section 13 02 For information about a common starting air sys tem for main engines and MAN Diesel auxiliary engines please refer to our publication Uni concept Auxiliary Systems for Two Stroke Main Engines and Four Stroke Aux...

Page 224: ...min equal to 0 035 m3 s Filter fineness 40 µm Reduction valve for turbocharger cleaning etc Reduction from 30 10 bar to 7 bar Tolerance 10 Flow rate free air 2 600 Normal liters min equal to 0 043 m3 s The consumption of compressed air for control air exhaust valve air springs and safety air as well as air for turbocharger cleaning and fuel valve testing is covered by the capacities stated for air...

Page 225: ...xiliary Systems for Two Stroke Main Engines and Four Stroke Auxiliary Engines The publication is available at www marine man eu Two Stroke Technical Papers The starting air pipes Fig 13 03 01 contain a main starting valve a ball valve with actuator a non return valve a solenoid valve and a starting valve The main starting valve is controlled by the Engine Control System Slow turning before start o...

Page 226: ...c system Safety relief valve Safety relief valve PT 8505 A I AL B PT 8505 B I AL Exhaust Valve Air Spring Pipes The exhaust valve is opened hydraulically and the closing force is provided by an air spring which leaves the valve spindle free to rotate see Fig 13 03 02 The item Nos refer to Guidance values automation The piping is delivered with and fitted onto the engine 121 36 87 1 1 1c ...

Page 227: ...MAN B W MAN Diesel Scavenge Air 14 ...

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Page 229: ...e scavenge air cooler is provided with a water mist catcher which prevents condensated water from being carried with the air into the scav enge air receiver and to the combustion chamber The scavenge air system see Figs 14 01 01 and 14 02 01 is an integrated part of the main engine The engine power figures and the data in the list of capacities are based on MCR at tropical con ditions i e a seawat...

Page 230: ...rt automatically whenever the blower inlet pressure drops below a preset pressure corresponding to an engine load of approximately 25 35 The blowers will continue to operate until the blower inlet pressure again exceeds the preset pressure plus an appropriate hysteresis i e taking recent pressure history into account correspond ing to an engine load of approximately 30 40 Emergency running If one ...

Page 231: ...is yard s supply It can be or dered as an option 4 55 650 The starter panels with starters for the auxiliary blower motors are not included they can be or dered as an option 4 55 653 The starter panel design and function is according to MAN Diesel s diagram however the physical layout and choice of components has to be decided by the manu facturer Heaters for the blower motors are available as an ...

Page 232: ...2 03 Control panel including operation panel wiring harness and terminal row option 4 55 650 Operation Panel for the Auxiliary Blowers On the operation panel three control modes are available to run stop the blowers AUTO Run stop is automatically controlled by scavenge air pressure MANUAL Start of all blowers in sequence at intervals of 6 sec OFF The auxiliary blowers are stopped after a set perio...

Page 233: ...well as space requirements Motor start method and size Direct Online Start DOL is required for all auxil iary blower electric motors to ensure proper op eration under all conditions For typical engine configurations the installed size of the electric motors for auxiliary blowers are listed in Table 14 04 01 Special operating conditions For engines with Dynamic Positioning DP mode in manoeuvring sy...

Page 234: ... water mist catcher The water is led through an orifice to pre vent major losses of scavenge air The system is equipped with a drain box with a level switch indicating any excessive water level The piping delivered with and fitted on the engine is shown in Fig 14 05 01 Auto Pump Overboard System It is common practice on board to lead drain wa ter directly overboard via a collecting tank Before pum...

Page 235: ...AK Recirculation AL DX DN 50 mm DN 50 mm Circulation pump Filter 1 mm mesh size Drain from air cooler cleaning water mist catcher in air cooler DN 25 mm PI Freshwater from hydrophor TI Chemical cleaning tank 079 21 94 1 0 1a Air Cooler Cleaning Unit DX AL Clean bilge tank bilge holding tank Drain water collecting tank Overboard High level alarm Start pump Stop pump Low level alarm Oil in water mon...

Page 236: ...eam pressure avail able The system delivered with and fitted on the engine is shown in Fig 14 03 02 Scavenge air space drain pipes 079 61 03 0 4 1 Deck Roof Orifice 10 mm DN 15 mm BV AV Min 15 DN 50 mm 1 000 mm DN 65 mm DN 50 mm AV1 Drain tank Normally open To be closed in case of fire in the scavenge air box Steam inlet pressure 3 10 bar If steam is not available 7 bar compressed air can be used ...

Page 237: ...shing for scavenge air space Freshwater pressure min 3 5 bar Freshwater quantity approx 1 7 kg cyl CO2 fire extinguishing for scavenge air space CO2 test pressure 150 bar CO2 quantity approx 4 3 kg cyl The letters refer to list of Counterflanges 079 61 02 9 0 0a AT AT AT Basic solution Steam extinguishing Steam pressure 3 10 bar DN 40mm Normal position open to bilge Normal position open to bilge O...

Page 238: ... S30ME B S26MC 198 76 81 3 2 The letters refer to list of Counterflanges Fig 14 07 02 Fire extinguishing pipes in scavenge air space 126 40 81 0 6 0a TE 8610 I AH Y Cyl 1 AT Extinguishing agent CO2 Steam or Freshwater Exhaust side Manoeuvering side Drain pipe bedplate Only for steam or freshwater Fire Extinguishing Pipes in Scavenge Air Space ...

Page 239: ...MAN B W MAN Diesel Exhaust Gas 15 ...

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Page 241: ... covered by steel plating Turbochargerarrangement andcleaningsystems The turbocharger can either be located on the aft end of the engine option 4 59 121 or on the exhaust side of the engine option 4 59 123 How ever if the engine is fitted with two turbochargers they are always located on the exhaust side The engine is designed for the installation of the MAN turbocharger types TCA 4 59 101 ABB tur...

Page 242: ...eiver To scavenge air receiver Turbocharger Flange connection D ST 8801 IR PI 8601 TI 8702 The letters refer to List of flanges The position numbers refer to List of instruments The piping is delivered with and fitted onto the engine 178 38 69 2 2 Fig 15 02 01a Exhaust gas pipes with turbocharger located on aft end of engine option 4 59 121 Cyl 1 Flange connection D Turbocharger To scavenge air re...

Page 243: ... Cleaning Systems Fig 15 02 02 MAN TCA turbocharger water washing of compressor side option 4 59 145 178 61 90 0 0 178 61 87 7 0 0 Compressor cleaning MAN Diesel TCA turbocharger To bedplate drain AE AP Drain Dry cleaning turbine side PI 8803 ABB Turbocharger Compressor cleaning To bedplate drain AE Fig 15 02 03 Soft blast cleaning of turbine side and water washing of compressor side for ABB turbo...

Page 244: ...plies with the above mentioned requirements the pressure losses across each component may be chosen in dependently see proposed measuring points M in Fig 15 05 01 The general design guidelines for each component described below can be used for guidance purposes at the initial project stage Exhaust gas piping system for main engine The exhaust gas piping system conveys the gas from the outlet of th...

Page 245: ... the expansion joint on the turbochar ger gas outlet transition piece option 4 60 601 the exhaust gas piece and components are to be so arranged that the thermal expansions are ab sorbed by expansion joints The heat expansion of the pipes and the components is to be calculated based on a temperature increase from 20 C to 250 C The max expected vertical transversal and longitudinal heat expansion o...

Page 246: ...s given on the graph In the event that an exhaust gas silencer is re quired this depends on the actual noise level requirement on the bridge wing which is normally maximum 60 70 dB A a simple flow silencer of the absorption type is recommended Depending on the manufacturer this type of silencer nor mally has a pressure loss of around 20 mm WC at specified MCR Spark arrester To prevent sparks from ...

Page 247: ... after the turbo charger s depends on the total pressure drop in the exhaust gas piping system The components exhaust gas boiler silencer and spark arrester if fitted usually contribute with a major part of the dynamic pressure drop through the entire exhaust gas piping system The components mentioned are to be specified so that the sum of the dynamic pressure drop through the different components...

Page 248: ...ive an indication of the wall pressure i e the static pressure of the gas flow It is therefore very important that the back pres sure measuring points are located on a straight part of the exhaust gas pipe and at some dis tance from an obstruction i e at a point where the gas flow and thereby also the static pressure is stable Taking measurements for example in a transition piece may lead to an un...

Page 249: ...2 0 M Measuring points Fig 15 05 01 Pressure losses and coefficients of resistance in exhaust pipes 178 32 09 1 0 178 06 85 3 0 R D ζ 0 28 R 1 5D ζ 0 20 R 2D ζ 0 17 R D ζ 0 16 R 1 5D ζ 0 12 R 2D ζ 0 11 ζ 0 05 R D ζ 0 45 R 1 5D ζ 0 35 R 2D ζ 0 30 ζ 0 14 Outlet from ζ 1 00 top of exhaust gas uptake Inlet from turbocharger ζ 1 00 Pressure losses and coefficients of resistance in exhaust pipes Spark a...

Page 250: ...ents of the exhaust gas flange resulting from thermal expansion TC on exhaust side No of cylinders 5 9 5 6 7 8 9 Turbocharger DA DB DC DC DC DC DC Make Type mm mm mm mm mm mm mm MAN TCA44 Available on request TCA55 TCA66 TCA77 ABB A265 A170 A270 A175 A275 A180 MHI MET42 MET48 MET53 MET60 MET66 MET71 DA Max movement of the turbocharger flange in the vertical direction DB Max movement of the turboch...

Page 251: ...haust gas flange resulting from thermal expansion TC on aft end No of cylinders 5 9 5 6 7 8 9 Turbocharger DA DC DC DC DC DC Make Type mm mm mm mm mm mm MAN TCA44 Available on request TCA55 TCA66 TCA77 ABB A265 A170 A270 A175 A275 A180 MHI MET42 MET48 MET53 MET60 MET66 MET71 DA Max movement of the turbocharger flange in the vertical direction DC Max movement of the turbocharger flange in the longi...

Page 252: ...900 10 900 5 400 ABB A265 1 200 1 200 2 800 1 800 1 800 A170 A270 1 900 1 900 3 600 2 400 2 400 A175 A275 3 300 3 300 5 400 3 500 3 500 A180 4 600 4 600 6 800 4 400 4 400 MHI MET42 3 400 1 700 5 800 2 000 1 800 MET48 Available on request MET53 4 900 2 500 7 300 2 600 2 300 MET60 6 000 3 000 8 300 2 900 3 000 MET66 6 800 3 400 9 300 3 200 3 000 MET71 7 000 3 500 9 600 3 300 3 100 078 38 48 6 2 2 M1...

Page 253: ... 400 1 000 800 1 400 41 7 47 7 53 7 59 6 1 500 1 050 850 1 500 47 5 54 3 61 1 67 8 1 600 1 150 900 1 600 D0 Fixed point Centre line turbocharger D0 Expansion joint option 4 60 610 Transition piece option 4 60 601 178 31 59 8 1r Fig 15 07 01a Exhaust pipe system with turbocharger located on exhaust side of engine option 4 59 123 Fig 15 07 01b Exhaust pipe system with single turbo charger located on...

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Page 255: ...MAN B W MAN Diesel Engine Control System 16 ...

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Page 257: ...dentical and in the event of a failure of a CCU for two cylinders only these cylin ders will automatically be put out of operation It should be noted that any electronic part could be replaced without stopping the engine which will revert to normal operation immediately after the replacement of the defective unit Cooling Water Control Unit On engines with load dependent cylinder liner LDCL cooling...

Page 258: ... as potential free contacts AC power UPS battery mode Batteries not available fuse fail High Low voltage protection may be integrated in the DC DC converter functionality or implemented separately The output voltage must be in the range 18 31V DC Hydraulic Power Supply HPS The purpose of the HPS unit is to deliver the necessary high pressure hydraulic oil flow to the hydraulic cylinder units HCU o...

Page 259: ...RS CPS CCU 1 MOP A ELFI ELFI ALS ALS Pressure Booster Pressure Booster HCU cyl m n ELFI ELFI ALS ALS Pressure Booster Pressure Booster HCU cyl 1 2 MOP B MPC Multi Purpose Controller EICU Engine Interface Control Unit MPC CCU Cylinder Control Unit MPC MOP Main Operating Panel HPS Hydraulic Power Supply CPS Crankshaft Position Sensors ESC Engine Side Console ALS Alpha Lubricator System Actuator EICU...

Page 260: ...ine lubricating oil Distributor block Cylinder lubricator Hydraulic Power Supply unit Fuel oil drain Fuel oil inlet Pressure booster Fuel injection plunger Hydraulic piston High pressure pipes Umbrella sealing Fuel oil outlet X F AD Safety block Filter unit RU Lube oil inlet to engine Fuel valves Main filter XC 1231 AL RW Back flushing oil M M PT 1204 1 ZL PT 1204 2 ZL PT 1201 1 C PT 1201 2 C ZV 8...

Page 261: ... classification society and MAN Diesel Turbo If a critical value is reached for one of the meas uring points the input signal from the safety system must cause either a cancellable or a non cancellable shut down signal to the ECS The safety system is included in the basic extent of delivery Telegraph system The telegraph system is an independent system This system enables the navigator to transfer...

Page 262: ...d partly from the ECS turning gear disengaged main starting valve open control air valve for sealing air open control air valve for air spring open auxiliary blowers running hydraulic power supply ready Instrumentation Chapter 18 in the Project Guide for the specific engine type includes lists of instrumentation for The class requirements and MAN Diesel Turbo s requirements for alarms slow down an...

Page 263: ... 1 4 A R1 P1 50 ø16x2 ø16x2 A R2P2 Slow turning 28 ZV 1114 C PS 1118 2 C PS 1118 1 C PS 1130 1 C 83 107 PS 8503 2 AH PT 8503 AL I 2 4 138 PT 8505 AL ZV 1110 C PT 1101 C 160 One pressure transmitter per CCU unit 108 20 L Pipe dimension ø10x1 5 except where otherwise stated The drawing shows the system in the following conditions Manual control Stop and ahead position Pneumatic pressure on El power ...

Page 264: ... ZV 1137 C ZV 1109 C ZS 1112 C ZS 1111 C ø16x2 ø16x2 A R2P2 Slow turning 28 ZV 1114 C PS 1118 2 C PS 1118 1 C PS 1130 1 C 83 107 PS 8503 2 AH PT 8503 AL I 2 4 138 PT 8505 AL ZV 1110 C PT 1101 C 160 One pressure transmitter per CCU unit 108 20 L Pipe dimevnsion ø10x1 5 except where otherwise stated The drawing shows the system in the following conditions Manual control Stop position Pneumatic press...

Page 265: ...MAN B W MAN Diesel Vibration Aspects 17 ...

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Page 267: ... zero Of these moments the 1st order one cycle per revo lution and the 2nd order two cycles per revolution need to be considered for engines with a low num ber of cylinders On 7 cylinder engines also the 4th order external moment may have to be examined The inertia forces on engines with more than 6 cylin ders tend more or less to neutralise themselves Countermeasures have to be taken if hull reso...

Page 268: ...y speaking solution 1 is applicable if the node is located far from the engine or the engine is positioned more or less between nodes Due to its position in the steering gear room solution 2 is not particularly sensitive to the position of the node Determine the need A decision regarding the vibrational aspects and the possible use of compensators should prefer ably be taken at the contract stage ...

Page 269: ...tive regarding hull vibrations exited by 2nd order moments than the larger bore engines Therefore engines type 40 and 35 do not have engine driven 2nd order moment compensators specified as standard For 5 and 6 cylinder engines type 50 the basic design regarding 2nd order moment compensa tors is With MAN B W external electrically driven mo ment compensator RotComp EoD 4 31 255 The available option...

Page 270: ...ndard four cylinder engines are fitted with 1st order moment balancers in shape of adjust able counterweights as illustrated in Fig 17 02 02 These can reduce the vertical moment to an insig nificant value although increasing correspond ingly the horizontal moment so this resonance is easily dealt with A solution with zero horizontal moment is also available 1st order moment compensators In rare ca...

Page 271: ... engines with a higher number of cylinders than is normally con sidered relevant if found necessary The compensator only needs to be active at speeds critical for the hull girder vibration Thus it may be activated or deactivated at specified speeds automatically or manually Combinations with and without moment com pensators are not required in torsional and axial vibration calculations since the e...

Page 272: ... B9 GI 40 30MC C9 Fig 17 03 02 Compensation of 2nd order vertical external moments 178 61 15 9 1 4 Node 3 Node 3 and 4 node vertical hull girder mode Electrically driven moment compensator Compensating moment FD Lnode outbalances M2V M2V Node Aft L D node FD Nodes and Compensators ...

Page 273: ...alues have been classified in four groups as follows Table 17 04 01 Power Related Unbalance PRU values in Nm kW Calculation of External Moments In the table at the end of this chapter the exter nal moments M1 are stated at the speed n1 and MCR rating in point L1 of the layout diagram For other speeds nA the corresponding external mo ments MA are calculated by means of the formula MA M1 x nA __ n1 ...

Page 274: ...urbo strongly recommend as standard that top bracing is installed between the engine s upper platform brackets and the casing side The vibration level on the engine when installed in the vessel must comply with MAN Diesel Turbo vibration limits as stated in Fig 17 05 02 We recommend using the hydraulic top bracing which allow adjustment to the loading conditions of the ship Mechanical top bracings...

Page 275: ...orceZ total Ntop bracing total kN X type Guide Force Moment MX The X type guide force moment is calculated based on the same force couple as described above However as the deflection shape is twist ing the engine each cylinder unit does not con tribute with an equal amount The centre units do not contribute very much whereas the units at each end contributes much A so called Bi moment can be calcu...

Page 276: ... D i s p l a c e m e n t Acceleration 10 m m s 2 10 2 m m s 2 1 m m 1 0 m m Velocity 2 m m 50mm s 1 0 m s 2 1 m m 25mm s 1 Hz 10 Hz 100 Hz Frequency Zone Ι Acceptable Zone ΙΙ Vibration will not damage the main engine however under adverse conditions annoying harmful vibration responses may appear in the connected structures Zone ΙΙΙ Not acceptable 078 81 27 6 1 Fig 17 05 02 Vibration limits Vibrat...

Page 277: ...eed may arise for the following types of installation Plants with controllable pitch propeller Plants with unusual shafting layout and for special owner yard requirements Plants with 8 cylinder engines The so called QPT Quick Passage of a barred speed range Technique is an alternative to a torsional vibration damper on a plant equipped with a control lable pitch propeller The QPT could be implemen...

Page 278: ...y The characteristics of overcritical conditions are Tuning wheel may be necessary on crankshaft fore end Turning wheel with relatively high inertia Shafts with relatively small diameters requiring shafting material with a relatively high ultimate tensile strength With barred speed range EoD 4 07 015 of about 10 with respect to the critical engine speed Torsional vibrations in overcritical conditi...

Page 279: ... 6 Order Vertical 0 10 0 0 0 External moments kNm 1 Order Horizontal a 102 0 61 203 209 1 Order Vertical a 102 0 61 203 209 2 Order Vertical 1 210 842 244 0 275 4 Order Vertical 8 60 172 70 87 6 Order Vertical 1 0 0 0 22 Guide force H moments in kNm 1 x No of cyl 952 758 594 442 302 2 x No of cyl 103 30 11 17 27 3 x No of cyl Guide force X moments in kNm 1 Order 85 0 50 169 174 2 Order 216 150 44 ...

Page 280: ......

Page 281: ...MAN B W MAN Diesel Monitoring Systems and Instrumentation 18 ...

Page 282: ......

Page 283: ...ngine s lifetime In its basic design the ME engine instrumentation consists of Engine Control System Shut down sensors EoD 4 75 124 PMI Auto tuning system EoD 4 75 216 CoCoS EDS ME Basic EoD 4 09 658 Sensors for alarm slow down and remote indi cation according to the classification society s and MAN Diesel Turbo s requirements for UMS EoD 4 75 127 see Section 18 04 The optional extras are CoCoS ED...

Page 284: ...cified as standard EoD 4 75 216 and completely replaces the PMI Offline system The auto tuning concept is based on the online measurement of the combustion chamber pres sures from permanently mounted sensors The engine control system constantly monitors and compares the measured combustion pres sures to a reference value As such the control system automatically adjusts the fuel injection and valve...

Page 285: ...ogging monitoring trending and reporting The CoCoS EDS Full version is recommended as an extension for the Engine Control System and the PMI System in order to obtain an easier more versatile performance monitoring system For the CoCoS EDS Full version additional sen sors are required option 4 75 129 The sensors are listed in Table 18 03 01 CoCoS EDS ME basic All MAN B W ME and ME B engines are as...

Page 286: ...ir receiver temperature Rec 0 100 C 0 1 C TE 8612 T C air intake temperature T C 0 100 C 0 1 C Exhaust gas system TC 8701 Exhaust gas temperature at turbine inlet T C 0 600 C 0 1 C TC 8702 Exhaust gas temperature after exhaust valve Cyl 0 600 C 0 1 C PT 8706 Exhaust gas receiver pressure Rec 0 4 bar 0 01 bar TC 8707 Exhaust gas temperature at turbine outlet T C 0 600 C 0 1 C PT 8708 Turbine back p...

Page 287: ... sequence must be adapted to the actual plant parameters such as for FPP or CPP engine with or without shaft generator and to the required operating mode The shut down system must be electrically sepa rated from other systems by using independent sensors or sensors common to the alarm system and the monitoring system but with galvanically separated electrical circuits i e one sensor with two sets ...

Page 288: ...ors Required by Class and MAN Diesel Turbo option 4 75 127 Slow down panel and Shut down panel Option 4 75 630 or 4 75 614 or 4 75 615 Additional sensors option 4 75 128 or 4 75 129 Included in option 4 75 124 One common power supply might be used in stead of the three indicated provided that the systems are equipped with separate fuses The figure shows the concept approved by all classification s...

Page 289: ...icating oil outlet from turbocharger turbocharger 1 TE 8123 AH Main bearing oil outlet temperature main bearing S40 35ME B9 only 1 XC 8126 AH Bearing wear All types except S40 35ME B9 sensor common to XC 8126 27 1 XS 8127 A Bearing wear detector failure All types except S40 35ME B 1 1 1 1 1 PDS 8140 AH Lubricating oil differential pressure cross filter 1 XS 8150 AH Water in lubricating oil sensor ...

Page 290: ...ling water outlet common pipe 1 1 1 1 1 1 1 1 1 1 1 PT 8421 AL Cooling water inlet air cooler 1 1 TE 8422 AH Cooling water inlet air cooler air cooler Compressed air 1 1 1 1 1 1 1 1 1 1 1 PT 8501 AL Starting air inlet to main starting valve 1 1 1 1 1 1 1 1 1 1 1 1 PT 8503 AL Control air inlet and finished with engine 1 1 PT 8505 AL Air inlet to air cylinder for exhaust valve Scavenge air 1 1 1 PS ...

Page 291: ...ure 1 XC 2202 A A ME common failure ME GI only 1 XC 2213 A Double pipe HC alarm ME GI only Power Supply Units to Alarm System 1 XC 2901 A Low voltage ME power supply A 1 XC 2902 A Low voltage ME power supply B 1 XC 2903 A Earth failure ME power supply 1 Indicates that the sensor is required The sensors in the MAN Diesel and relevant Class columns are included in the basic Extent of Delivery EoD 4 ...

Page 292: ...1 TE 8610 YH Scavenge air box fire alarm cylinder cylinder 1 1 1 TC 8701 YH Exhaust gas before turbocharger turbocharger 1 1 1 1 1 1 1 1 1 1 1 TC 8702 YH Exhaust gas after exhaust valve cylinder cylinder 1 1 TC 8702 YH Exhaust gas after exhaust valve cylinder cylinder deviation from average 1 WT 8812 YH Axial vibration monitor 2 1 1 1 1 1 1 1 1 1 1 XS 8813 YH Oil mist in crankcase cylinder 1 XS XT...

Page 293: ...nsor and function Point of location 1 1 1 1 1 1 1 1 1 1 1 1 PS PT 8109 Z Lubricating oil inlet to main engine and thrust bearing 1 1 1 1 1 1 1 1 1 1 1 1 ZT 4020 Z Engine overspeed 1 1 1 1 1 1 1 1 TE TS 8107 Z Thrust bearing segment 1 PS PT 8402 Z Jacket cooling water inlet 1 XS 8813 Z Oil mist in crankcase cylinder International Association of Classification Societies The members of the Internatio...

Page 294: ...bearing S40 35ME B9 only Cylinder lubricating oil TE 8202 Cylinder lubricating oil inlet TS 8213 Cylinder lubricating heating High temperature cooling water jacket cooling water TI 8407 TE 8407 Jacket cooling water inlet TI 8408 TE 8408 Jacket cooling water outlet cylinder cylinder TI 8409 TE 8409 Jacket cooling water outlet turbocharger TI 8410 TT 8410 Cylinder cover cooling water outlet cylinder...

Page 295: ...LDCL PDT 8405 Jacket cooling water across cylinder covers and exhaust valves Only for LDCL PT 8413 Jacket cooling water outlet common pipe Low temperature cooling water seawater or freshwater for central cooling PI 8421 PT 8421 Cooling water inlet air cooler Compressed air PI 8501 PT 8501 Starting air inlet to main starting valve PI 8503 PT 8503 Control air inlet PT 8505 Air inlet to air cylinder ...

Page 296: ...ypes except S40 35ME B9 XS 8150 Water in lubricating oil XS 8151 Water in lubricating oil too high XS 8152 Water in lubricating oil sensor not ready Cylinder lube oil LS 8208 Level switch LS 8212 Small box for heating element low level Scavenge air LS 8611 Water mist catcher water level Miscellaneous functions ZT 8801 I Turbocharger speed turbocharger WI 8812 WT 8812 Axial vibration monitor For ce...

Page 297: ... early warning is a combined bearing wear and temperature monitoring system For all types of error situations detected by the different bearing condition monitoring systems applies that in addition to damaging the compo nents in extreme cases a risk of a crankcase explosion exists Oil Mist Detector The oil mist detector system constantly measures samples of the atmosphere in the crankcase com part...

Page 298: ...g air connection Exhaust air connection to crank space Siphon block XS 8813 AH Y Fig 18 06 01a Oil mist detector wiring on engine example based on type Graviner MK6 from Kidde Fire Protection option 4 75 161 178 49 80 9 3 Fig 18 06 01b Oil mist detector pipes on engine type Visatron VN215 93 from Schaller Automation option 4 75 163 178 49 81 0 3 ...

Page 299: ...40ME B9 and S35ME B9 engines are as stand ard specified with option 4 75 133 Bearing Wear Monitoring System The Bearing Wear Monitoring BWM system mon itors all three principal crank train bearings using two proximity sensors forward aft per cylinder unit and placed inside the frame box Targeting the guide shoe bottom ends continu ously the sensors measure the distance to the crosshead in Bottom D...

Page 300: ...tion point in order to avoid free water in the lubricating oil If the aw 0 9 alarm level is reached within a short time after the aw 0 5 alarm this may be an indication of a water leak into the lubricating oil system Please note Corrosion of the overlayer is a poten tial problem only for crosshead bearings because only crosshead bearings are designed with an overlayer Main thrust and crankpin bear...

Page 301: ...ependent alarm limit Fig 18 06 02 Example of set points versus slow down and alarm limits for LDCL cooling water system An example of the limits is shown in Fig 18 06 02 The load dependent limits must include at least one break point to allow cut in out of the lower limits The upper limits are fixed limits without breakpoints The values of the load dependent limits are de fined as a temperature di...

Page 302: ......

Page 303: ... PT 1204 1 2 3 C Lubricating oil pressure after filter suction side Tacho crankshaft position ZT 4020 Tacho for safety Engine cylinder components XC 4108 C ELVA NC valve ZT 4111 C Exhaust valve position ZT 4114 C Fuel plunger position 1 Fuel oil ZV 8020 Z Fuel oil cut off at engine inlet shut down Germanischer Lloyd only Cylinder lubricating oil ZT 8203 C Confirm cylinder lubricator piston movemen...

Page 304: ...meas urement point and xx the serial number 11xx Manoeuvring system 12xx Hydraulic power supply system HPS 13xx Hydraulic control oil system separate oil to HPS 14xx Combustion pressure supervision 15xx Top bracing pressure stand alone type 16xx Exhaust Gas Recirculation EGR 20xx ECS to from safety system 21xx ECS to from remote control system 22xx ECS to from alarm system 24xx ME ECS outputs 29xx...

Page 305: ...asure ments for each cylinder or turbocharger are pro vided with a suffix number indicating the location 1 for cylinder 1 etc If redundant sensors are applied for the same measuring point the suffix is a letter A B C etc Table 18 07 01b Identification of instruments Examples TI 8005 indicates a local temperature indication thermometer in the fuel oil system ZS 1112 A C and ZS 1112 B C indicate two...

Page 306: ......

Page 307: ...MAN B W MAN Diesel Dispatch Pattern Testing Spares and Tools 19 ...

Page 308: ......

Page 309: ...o a suitable extent Note Long term preservation and seaworthy packing are always to be used for class B Furthermore the dispatch patterns are divided into several degrees of dismantling in which 1 comprises the complete or almost complete en gine Other degrees of dismantling can be agreed upon in each case When determining the degree of dismantling con sideration should be given to the lifting cap...

Page 310: ... Additional Spare Parts Rec ommended by MAN Diesel Turbo option 4 87 603 which facilitates maintenance because in that case all the components such as gaskets sealings etc required for an overhaul will be read ily available see Section 19 07 Wearing parts The consumable spare parts for a certain period are not included in the above mentioned sets but can be ordered for the first 1 2 up to 10 years...

Page 311: ...y standard is in a primed and finished painted condition unless other wise stated in the contract In accordance with corrosivity categories C2 Medium ISO 12944 5 Engine alkyd primer weather resistant 1 2 layer s Total NDTF 80 µm Free Final alkyd paint resistant to salt water and oil option 4 81 103 1 layer Total NDTF 40 µm Total NDTF 120 µm Light green RAL 6019 DIN 23 2 2 MUNSELL 10GY 8 4 3 Gas pi...

Page 312: ...th EGR mix point to scavenge air receiver non return valves 500 μm Normal air cooler housing inside from outlet air cooler through reversing cham ber and water mist catcher to non return valves housing in scavenge air receiver Vinyl ESTER acrylic copolymer Note Duplex Stainless steel is not to be painted Total NDTF 500 1 200 µm Free 8 Purchased equipment and instruments painted in maker s colour a...

Page 313: ...readings Fuel oil analysis is to be presented All tests are to be carried out on diesel or gas oil EIAPP certificate Most marine engines installed on ocean going vessels are required to have an Engine Interna tional Air Pollution Prevention EIAPP Certificate or similar Therefore a pre certification survey is to be carried out for all engines according to the survey method described in the engine s...

Page 314: ...ssure pipe from fuel oil pressure booster to fuel valve Turbocharger plate 5472 0700 1 set Maker s standard spare parts Cylinder cover plate 2272 0300 1 Cylinder cover with fuel exhaust and starting valves indicator valve and sealing rings disas sembled set Studs for 1 cylinder cover Piston plate 2272 0400 1 Piston complete with cooling pipe piston rod piston rings and stuffing box studs and nuts ...

Page 315: ...1 Main bearing shell in 2 2 of each size 1 set Studs and nuts for 1 main bearing 1 MD required spare parts 2 All spare parts are requested by all Classes Please note Plate numbers refer to Instruction Book Vol II III containing plates with spare parts Fig 19 06 01b List of spare parts unrestricted service option 4 87 601 ...

Page 316: ...valve set O rings for cooling jacket 1 Cooling jacket set Sealing between cylinder cover and liner 4 Spring housings for fuel valve Hydraulic tool for cylinder cover plate 7670 0100 2270 0315 1 set Hydraulic hoses with protection hose complete with couplings 8 pcs O rings with backup rings upper 8 pcs O rings with backup rings lower Piston and piston rod plate 2272 0400 1 box Locking wire L 63 m 5...

Page 317: ...0200 1 set Fuel nozzles 1 set O rings for fuel valve 3 Spindle guides complete set Springs set Discs 30 bar 3 Thrust spindles 3 Non return valve if mounted Fuel oil high pressure pipes plate 4272 0100 1 High pressure pipe from fuel oil pressure booster to fuel valve 1 High pressure pipe from actuator to exhaust valve 1 set O rings for high pressure pipes By pass valve plate 4272 0030 1 By pass val...

Page 318: ...er cylinder x x x Top scraper ring 1 pc per cylinder x x x O rings 1 set per cylinder x x x x x x Cylinder liner x O rings for cylinder liner 1 set per cylinder x O rings for cooling water jacket 1 set per cylinder x O rings for cooling water connections 1 set per cyl x Exhaust valve DuraSpindle 1 pc per cylinder x x Nimonic spindle 1 pc per cylinder x Bottom piece 1 pc per cylinder x x Piston rin...

Page 319: ...s 1 set per engine x x x ELFI valve 1 pc per cylinder x Fuel oil pressure booster 1 pc per cylinder x Angle encoder 2 pcs per engine x MPC 1 pc per 2 cylinders 1 pc x MOP A 1 pc per engine x MOP B 1 pc per engine x Proportional valve for main hydraulic pump x x x x Hydrostatic bearings for main hydraulic pump x x x Sealings for pressure relief valve for main hydr pump x x Static sealing rings for ...

Page 320: ...ass Dimensions mm kg A B C D E 1 Cylinder liner incl cooling jacket 2 076 740 2 413 555 2 Exhaust valve 440 1 310 665 494 3 Piston complete with piston rod 342 ø500 349 188 3 064 300 4 Cylinder cover incl valves 1 100 938 419 Fig 19 09 01 Large spare parts dimensions and masses 178 51 59 7 3 E A B C D A B C A C D A B C B 1 2 3 4 ...

Page 321: ...790 1 470 620 A185 L 460 880 1 640 690 A190 L 610 970 1 810 760 A265 L 100 500 930 395 A270 L 140 580 1 090 455 A275 L 240 700 1 320 550 A280 L 350 790 1 490 620 A285 L 490 880 1 660 690 561 66 78 9 0 0 MHI Type Max Mass Dimensions mm kg A ø B C ø MET33MA 45 373 662 364 MET33MB 55 373 692 364 MET42MA 68 5 462 807 451 MET42MB 85 462 847 451 MET48MB 155 524 954 511 MET53MA 190 586 1 035 571 MET53MB ...

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Page 323: ...MAN B W MAN Diesel Project Support and Documentation 20 ...

Page 324: ......

Page 325: ...nes and in clude information on the following subjects Engine data Engine layout and load diagrams specific fuel oil consumption Turbocharger selection Electricity production including power take off Installation aspects Auxiliary systems Vibration aspects After selecting the engine type on the basis of this general information and after making sure that the engine fits into the ship s design then...

Page 326: ...s of SFOC and exhaust gas data Heat dissipation of engine Water condensation separation in air coolers Noise engine room exhaust gas structure borne Preheating of diesel engine Alternative engines and turbochargers further reading Links to related MAN Diesel Turbo publications and papers are provided too Supplementary project data on request Further to the data generated by the CEAS appli cation t...

Page 327: ...c or additional items available to fulfil the requirements functions for a specific project Copenhagen Standard Extent of Delivery At MAN Diesel Turbo Copenhagen we base our first quotations on a mostly required scope of supply This is the so called Copenhagen Standard Extent of Delivery which is made up by options marked with an asterisk in the far left col umn in the EoD The Copenhagen Standard ...

Page 328: ... parts Installation Documentation When a final contract is signed a complete set of documentation in the following called Installation Documentation will be supplied to the buyer by the engine maker The extent of Installation Documentation is decid ed by the engine maker and may vary from order to order As an example for an engine delivered according to MAN Diesel Turbo s Copenhagen Standard Exten...

Page 329: ...plicable Pressure gauge pipes Engine room relevant documentation Engine data in engine room List of capacities Basic symbols for piping Instrument symbols for piping Lubricating and cooling oil Lubricating oil bottom tank Lubricating oil filter Crankcase venting Lubricating and hydraulic oil system Lubricating oil outlet Cylinder lubrication Cylinder lubricating oil system Piston rod stuffing box ...

Page 330: ...ck bolt End chock Round nut Spherical washer concave Spherical washer convex Assembly of end chock bolt Liner for end chock Protecting cap Engine top bracing Top bracing outline Top bracing arrangement Friction materials Top bracing instructions Top bracing forces Top bracing tension data Shaft line in engine room Static thrust shaft load Fitted bolt Power Take Off List of capacities PTO RCF arran...

Page 331: ...Production schedule Inspection after shop trials Dispatch pattern outline Preservation instructions Shop trials Shop trials delivery test Shop trial report Quay trial and sea trial Stuffing box drain cleaning Fuel oil preheating chart Flushing of lubricating oil system Freshwater system treatment Freshwater system preheating Quay trial and sea trial Adjustment of control air system Adjustment of f...

Page 332: ......

Page 333: ...MAN B W MAN Diesel Appendix A ...

Page 334: ......

Page 335: ...leeve 2 9 Joint quick releasing 2 10 Expansion joint with gland 2 11 Expansion pipe 2 12 Cap nut 2 13 Blank flange No Symbol Symbol designation 2 14 Spectacle flange 2 15 Bulkhead fitting water tight flange 2 16 Bulkhead crossing non watertight 2 17 Pipe going upwards 2 18 Pipe going downwards 2 19 Orifice 3 Valves gate valves cocks and flaps 3 1 Valve straight through 3 2 Valves angle 3 3 Valves ...

Page 336: ...gh 3 27 Cock angle 3 28 Cock three way L port in plug 3 29 Cock three way T port in plug 3 30 Cock four way straight through in plug 3 31 Cock with bottom connection 3 32 Cock straight through with bottom conn 3 33 Cock angle with bottom connection 3 34 Cock three way with bottom connec tion No Symbol Symbol designation 4 Control and regulation parts 4 1 Hand operated 4 2 Remote control 4 3 Spring...

Page 337: ...ir pipe 6 4 Air pipe with net 6 5 Air pipe with cover 6 6 Air pipe with cover and net 6 7 Air pipe with pressure vacuum valve 6 8 Air pipe with pressure vacuum valve with net 6 9 Deck fittings for sounding or filling pipe 6 10 Short sounding pipe with selfclosing cock 6 11 Stop for sounding rod No Symbol Symbol designation 7 Indicating instruments with ordinary symbol designations 7 1 Sight flow i...

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