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Marine Installation Manual

2021-08

3-4

3 Engine Installation

3.1 Engine dimensions and masses

X72DF

3.1.4

Content of fluids in the engine

For the quantity of a specific fluid in the engine please refer to the relevant MIDS
drawings as listed below:

•

Fuel oil —

Fuel oil system

•

Lubricating oil —

Lubricating oil system

•

Cylinder cooling water —

Cooling water systems

•

Freshwater in scavenge air cooler —

Cooling water systems

Summary of Contents for X72DF

Page 1: ...Marine Installation Manual X72DF Issue 2021 08...

Page 2: ...copyright holder Winterthur Gas Diesel Ltd makes no representation warranty express or implied in this publication and assumes no re sponsibility for the correctness errors or omissions of informatio...

Page 3: ...er system Section restructured and content updated 4 2 2 High temperature circuit Buffer unit LSH and LSL specification updated 4 2 5 Cooling water treatment Table 4 2 updated and note added 4 3 5 Cyl...

Page 4: ...e name changed to function name 1 3 Components and sizes of the engine Design features This section removed table 1 1 added on page 1 1 instead 1 4 Fuel operating modes Figure 1 3 changed remark refer...

Page 5: ...Gas fuel system engines with iGPR New section added 4 8 2 System specification Starting air compressors Starting air receivers Delivery gauge pressure defined more precisely Working gauge pressure def...

Page 6: ...ystem components Mixing unit Term MDO changed to MDO MGO 4 5 Pilot fuel oil system Functionality Sulphur content WinGD MDO MGO definition clarified New paragraph added 4 6 3 Gas specifications Table 4...

Page 7: ...xternal document document name and link name updated 4 3 5 Cylinder lubricating oil system Alternatives to finished cylinder oils Changeover between cylinder lubricating oils Electrical trace heating...

Page 8: ...el oil feed pump specification corrected 4 6 Gas fuel system Whole section revised more detailed information added 4 6 3 Gas specifications Table 4 10 updated 4 6 4 Gas supply pressure Figure 4 21 new...

Page 9: ...iesel mode 1 8 1 3 2 The Flex system 1 9 1 3 3 Operation in fuel sharing mode 1 10 1 3 4 Changeover between operating modes 1 12 Transfers and gas trips 1 12 2 Engine Power and Speed 2 1 2 1 Introduct...

Page 10: ...1 3 6 2 Installation of a complete engine 3 12 3 6 3 Installation of an engine from assembled subassemblies 3 12 3 6 4 Installation of an engine in ship on slipway 3 12 3 7 Engine and shaft alignment...

Page 11: ...Gas specifications 4 36 Methane number dependent engine output 4 37 Methane number calculation 4 37 4 4 4 Fuel gas supply system 4 38 Master fuel gas engine shut off valve 4 38 Tank type 4 38 Supplyi...

Page 12: ...An automatically bottom drained sludge oil trap 4 89 4 8 2 Draining of exhaust uptakes 4 91 4 8 3 Air vents 4 91 4 9 Exhaust gas system 4 92 4 10 Engine room ventilation 4 93 4 10 1 Ventilation requir...

Page 13: ...oments 6 3 Integrated electrical balancer iELBA 6 3 Electrically driven compensator external compensator 6 4 Power related unbalance 6 5 6 2 External lateral forces and moments 6 6 6 2 1 Lateral vibra...

Page 14: ...1 Air borne noise 7 4 7 2 2 Exhaust noise 7 6 7 2 3 Structure borne noise 7 8 8 Engine Dispatch 8 1 8 1 Engines to be transported as part assemblies 8 1 8 2 Protection of disassembled engines 8 1 8 3...

Page 15: ...engine installations 4 2 4 2 Recommended specifications for raw water 4 15 4 3 Heating cable specification 4 25 4 4 Minimum inclination angles for full operability of the engine 1 4 30 4 5 Minimum in...

Page 16: ...ems 5 4 5 2 Recommended manoeuvring steps and warm up times for FPP 5 9 5 3 Recommended manoeuvring steps and warm up times for CPP 5 10 5 4 Additional class requirements for alarm sensors and safety...

Page 17: ...diagram of an engine with a PTO 2 10 2 5 Power range limits for PTO operation Method 1 2 11 2 6 Power range limits for PTO operation Method 2 2 12 2 7 The prohibited operation area CMCR speed R1 R2 2...

Page 18: ...or alternatively a single grade cylinder lubricating oil is applied for fuel with very low sulphur content maximum 0 50 sulphur m m 4 24 4 13 Trace heating cable arrangement 4 25 4 14 Dimensioning an...

Page 19: ...1 4 38 Pilot fuel high pressure system 4 62 4 39 Fuel oil system 4 64 4 40 Mixing unit 4 67 4 41 Mesh size difference between absolute and nominal 4 70 4 42 Fuel oil filter arrangement A 4 71 4 43 Fue...

Page 20: ...PP CPP installations 5 8 5 6 Full sea load steps in FPP load up program 5 9 5 7 Full sea load steps in CPP load up program 5 10 5 8 The WiDE system 5 13 5 9 The WiDE installation process map 5 15 6 1...

Page 21: ...NOx emissions 7 1 7 2 Low pressure SCR Arrangement 7 2 7 3 High pressure SCR Arrangement 7 3 7 4 Sound pressure level at 1m distance from engine 7 5 7 5 Exhaust noise reference point 7 6 7 6 Sound pre...

Page 22: ...ling them to optimise plant components and machinery space and to carry out instal lation design work The MIM is not to be considered as a specification The build specification is subject to the laws...

Page 23: ...ion which is considered important or they draw the reader s attention to special facts Example Weblinks Weblinks are written in blue italics They are preceded by the following symbols and refer to Dra...

Page 24: ...lignment 9710 Engine Seating Foundation 9710 01 Tool Engine Alignment 9715 Engine Stays 9721 Cooling Water Systems 9722 Lubricating Oil Systems 9723 Fuel Oil System 9724 Leakage Collection Washing Sys...

Page 25: ...wer requirement for ancillary systems and output data suitable for estimating the size of ancillary equipment Furthermore the GTD can generate data such as the available components and options for spe...

Page 26: ...ed pilot fuel is less than 1 of the total energy consumption of the engine Gas injection is hydraulically actuated and electronically controlled Inde pendent micro injectors and the pilot fuel system...

Page 27: ...cooled piston crown This is made possible by combined jet shaker oil cooling 4 3 2 If contracted the Integrated Cylinder lubricant Auto Transfer iCAT unit is available as an option for auto mated ada...

Page 28: ...ines For detailed engine data see Table 1 3 1 4 Figure 1 1 Power speed range of the WinGD X DF engines SM 0014 60 50 2000 3000 4000 6000 8000 10 000 20 000 30 000 40 000 50 000 60 000 70 000 80 000 70...

Page 29: ...rgy Consumption BSEC kJ kWh 100 power gas mode All cyl 7 148 6 905 7 247 7 003 Brake Specific Fuel Consumption BSFC g kWh 100 power diesel mode All cyl 182 0 180 0 182 0 180 0 Mean effective pressure...

Page 30: ...ns and masses 3 1 Table 1 4 Principal engine dimension values No of cylinders Length A mm Piston dismantling height F1a crank centre crane hook mm a For F2 and F3 piston removal with double jib crane...

Page 31: ...diate action always available while a mode with gas opera tion is selected Figure 1 3 Operating modes of the X DF engine Table 1 5 Fuel split energy based for different operating modes NOTE To have th...

Page 32: ...Dynamic combustion control Dynamic Combustion Control DCC allows full power output for gas mixtures with a methane number of 65 and higher see subsection Methane number de pendent engine output 4 37 i...

Page 33: ...fail safe The main fuel injectors inject the main fuel while the pilot fuel micro injectors remain in operation at a reduced injection rate to avoid clogging of the nozzles approximately 0 5 of total...

Page 34: ...for different fuels Optimised part load operation Optimised fuel consumption Precise speed regulation especially at very low speed operation Smokeless operation across the entire engine power range Be...

Page 35: ...adjusting the ratio of gas to liquid fuel Figure 1 6 Fuel sharing mode available operating window The fuel sharing mode is available in a defined working window see Figure 1 6 The minimum amount of l...

Page 36: ...utomatic control is also possible through the Propulsion Control System PCS Depending on the liquid fuel s sulphur content the base number of the cylinder lubricating oil might need to be changed as d...

Page 37: ...ngeover introduces or continues to use gas fuel it is called a transfer If the changeover between operation mode stops the use of gas fuel therefore de faulting to diesel mode then the changeover is c...

Page 38: ...ncept Transfer introducing gas The transfer from diesel mode to either gas mode or fuel sharing mode introduces gas fuel Both the GVU and the iGPR must complete a system safety test before this gradua...

Page 39: ...f design conditions The sections below outline the specifics to aid in this process 2 2 Engine rating field The rating field shown in Figure 2 1 is the area of selectable engine design power and engin...

Page 40: ...selected within the entire rating field to meet the re quirements of each specific project Such rating points require specific engine ad aptations 2 3 Influence of propeller diameter and revolutions I...

Page 41: ...rement for a constant speed The slope of this line depends on the ship s characteristics see coefficient in Formula 2 1 2 2 Any other point on this line represents a new power speed combination for ex...

Page 42: ...and schedules of the ship The location of reference point A and the magnitude of the sea margin are part of the new building contract and are determined between the shipbuilder and the owner Typicall...

Page 43: ...the other hand the same ship at the same speed under service conditions with aged hull and under average weather conditions requires a power speed combination according to point B In that case point...

Page 44: ...to diesel mode at 102 power Line 3 Speed Limit Maximum speed limit for continuous engine running is set to 104 of CMCR speed However in diesel mode this limit can be extended to 106 Line 3a if Rx spee...

Page 45: ...margin typically between 4 and 7 The curve is defined by the propeller law with a constant governed by the se lected light running margin Formula 2 4 Formula 2 4 where PLR propeller power at selected...

Page 46: ...alled then the operating char acteristics of the engine will differ see section 2 6 2 10 for further details re garding PTO characteristics Overload Power Range Line 6 Line 2 and Line 13 form the curv...

Page 47: ...r during sea trials and in the presence of an authorised engine builder representative The area between Lines 1 5 and 6 Figure 2 3 2 6 called service range with operational time limit is only applicab...

Page 48: ...avy sea conditions Mechanical power absorption of the PTO must be considered PTO incorporation of Method 1 CMCR Method 1 This first method considers the PTO as an addition to the previously defined pr...

Page 49: ...the PTO operation is using a significant percentage of engine power Line 10 PTO Layout Limit The PTO layout limit Line 10 in Figure 2 5 defines the power limit for the re sulting combination of the pr...

Page 50: ...ill not exceed Line 10 Further information The following disadvantages must be observed for Method 2 With the reduction of the light running margin as a consequence of the ageing hull and propeller th...

Page 51: ...ngine will not enter this prohibited area However if the propeller is disconnected from the engine the engine would be capable of entering the prohibited operation area which is strictly forbidden Fig...

Page 52: ...and shown in Figure 2 7 2 13 at 70 of R1 R2 speed the minimum engine power equals approximately 5 8 of the CMCR power point E The minimum power requirement at 100 CMCR speed point F must be calculated...

Page 53: ...ng of the engine is lowered Figure 2 8 Calculating the prohibited operation area for the CMCR speed Figure 2 8 shows an engine with a CMCR speed which is rated at 85 of the R1 R2 speed and therefore i...

Page 54: ...ited area of operation for the CPP at small to zero pitch and discon nected propeller Point E is always defined at 70 of the R1 R2 speed and has a minimum power of 5 8 however in Figure 2 9 this equat...

Page 55: ...d At this speed a minimum engine power point F of 7 9 is required Below this is the prohibited area of operation for a disconnected propeller Figure 2 10 The prohibited operation area CMCR speed R3 R4...

Page 56: ...curve is freely selected in field A At sea the engine is operated at constant speed on Line 12 between point F and CMCR For manual and emergency operation separate set points for speed and pitch are u...

Page 57: ...rms A B C D E F1b b Min height for vertical removal of piston with standard crane F2c c Min height for vertical removal of piston with double jib crane F3d d Min height for tilted removal of piston wi...

Page 58: ...information is required For details see also drawings Dismantling Dimensions DG 0812 provided on the WinGD webpage under the following links 5 cyl engine 6 cyl engine 7 cyl engine 8 cyl engine 3 1 2 C...

Page 59: ...rmal expansion dim X Y Z Calculating thermal expansion x y z X Y Z T where x y z thermal expansion X Y Z distance as per relevant pipe connection plan and outline drawing 1 15 10 5 coefficient of ther...

Page 60: ...Content of fluids in the engine For the quantity of a specific fluid in the engine please refer to the relevant MIDS drawings as listed below Fuel oil Fuel oil system Lubricating oil Lubricating oil s...

Page 61: ...utside ambient air temperature 4 99 For project specific support please contact WinGD Reference conditions Engine performance data like BSEC BSEF tEaT and others are based on reference conditions Thes...

Page 62: ...ters must be considered in the plant design to ensure a proper function of the engine and its ancillary sys tems Gas mode output can depend on ambient conditions and gas quality The cyl inder water ou...

Page 63: ...6 2 x 70 7 2 x 88 8 2 x 88 Turning gear 5 7 5 440V 60Hz 6 7 5 7 7 5 8 7 5 Engine control system 5 0 7 220V 60Hz 6 0 9 7 0 9 8 1 0 Pilot fuel pump All 25 5 440V 60Hz Trace heating of injection pipes 5...

Page 64: ...ine Installation 3 3 Engine outline views X72DF 3 3 Engine outline views The latest versions of the Engine Outline Drawings DG 0812 are provided on the WinGD webpage under the following links 5 cyl en...

Page 65: ...Minimum requirements for headroom Important The minimum sizes are to be taken into account when installing the engine Special attention is to be given to the minimum distance between the ship s platf...

Page 66: ...d with the intermediate propeller shaft The longitudinal beams situated under the engine are to protrude from the engine room bulkhead by at least half the length of the engine and aft as far as possi...

Page 67: ...0 6mm higher than the calculated figures Place the bearing caps in position and install the turning gear Ensure that the crankshaft deflections are as recorded in the Engine As sembly Records Check th...

Page 68: ...great care to avoid stresses and distortions to the bedplate Regular crankshaft deflection readings have to be taken to observe the ef fects and any noticed deviation has to be rectified immediately 3...

Page 69: ...the design figures In the event of discrepan cies the responsible parties e g shipyard are to advise the representative of the engine builder or WinGD directly 3 7 1 Instructions and limits Alignment...

Page 70: ...ition in the coupling with the same mark stamped adjacent to the hole The following tolerances have to be met bolt hole tolerance H7 bolt tolerance g6 clearance fit If there is any doubt that a fitted...

Page 71: ...our see chapter 6 Engine Dynamics 6 1 are reduced by fitting lateral stays refer to section 6 2 External lateral forces and moments 6 6 and longitudinal stays refer to 6 3 Longitudinal vibration pitch...

Page 72: ...ices are protected by automatic fuses Isolation of instrument wiring Ensure that instrument wiring meets the building and classification society spec ifications and that it is shielded and isolated to...

Page 73: ...electric cables are connected as shown in Figure 3 5 3 18 with the op tional voltmeter This instrument is at the discretion of the owner but it is useful to observe that the potential to earth does no...

Page 74: ...arthing with condition monitoring facility Shaft monitoring Propeller shaft 35 mm2 2 5 mm2 Insulated spindle Hull structure earths to be separately connected Slip ring condition voltmeter SM 0056 PM P...

Page 75: ...sification society involved Steam as an alternative fire extinguishing medium is permissible for the scavenge air spaces of the piston underside but may cause corrosion if countermeasures are not take...

Page 76: ...ng field to be obtained However for convenience or final confirmation when opti mising the plant WinGD provides a computerised calculation service All pipework systems must be flushed and proved clean...

Page 77: ...LO cooler and HT cooling water cooler from common LT cooling water circuit HT cooling water system X Main LO system X Cylinder LO system see Figure 4 11 4 23 and Figure 4 12 4 24 X Day tanks for high...

Page 78: ...ine installation SM 0191 1 Scavenge air cooler SAC 2 HT cooling water cooler engine 1 3 Lubricating oil cooler engine 1 4 HT cooling water cooler engine 2 5 Lubricating oil cooler engine 2 6 Ancillary...

Page 79: ...ovides for more effi cient cooling as it allows a higher heat load than seawater i e freshwater can be heated up to a higher temperature level and along with a lower flow rate allows the same cooling...

Page 80: ...BSFC and respectively BSEC than in ISO standard design condition as well as in earlier DCC activation A scavenge air temperature increase by 1 degree Celsius results in a reduction of the DCC activati...

Page 81: ...set to 25 C WinGD specification The ancillary plant temperature control valve can be set differently as the specific project requires for example between 25 and 36 C Figure 4 4 LT cooling water circu...

Page 82: ...tomised by the shipyard or ship designer Figure 4 5 is a proposal only and the seawater pump and other equipment layout might be different As such the shipyard is free to design their own seawater sys...

Page 83: ...assage of large particles and debris that could damage the pumps and impair the heat transfer across the coolers Central seawater cooler Pump type Centrifugal Capacity According to GTD The seawater fl...

Page 84: ...t Removal of air from the cooling water is es sential to maintain an optimal cooling effect of the engine cylinder liner Due to the gas safety requirement for the X DF engines the ventilation pipe fro...

Page 85: ...than 10 Pump capacity According to GTD The flow capacity is to be within a tolerance of 10 to 20 of the GTD value Delivery headb b The pump delivery head pp will be bar where pei pressure at engine in...

Page 86: ...red and water feeding is started Control air pressure regulating valve DN15 with pressure reduction and air release function This valve reduces the control air pressure to the de sired buffer unit pre...

Page 87: ...to classification societies require ments Automatic temperature control valve Pump type Centrifugal or positive displacement Capacity 0 5m3 h Delivery head 4bar can be adjusted depending on project sp...

Page 88: ...ol is to be provided by a dedicated temperature sensor at the CCW outlet of the engine The flow through the heater is set by throttling discs but not by valves Use of separate pre heating pump If the...

Page 89: ...of heat available which in turn is dependent on the service power rating of the engine The latest version of the Concept Guidance for freshwater generator installation DG 9721 is provided on the WinG...

Page 90: ...eposits For details refer to the chemical supply companies Monitoring the level of the corrosion inhibitor and water softness is essential to prevent down times due to component failures resulting fro...

Page 91: ...water generator is started up or shut down The cylinder cooling water system is to be totally separated from steam sys tems Under no circumstances must there be any possibility of steam en tering the...

Page 92: ...Lubricants provided on the WinGD webpage under the following link Lubricants 4 3 2 Main lubricating oil system Field of application Lubrication of the main bearings thrust bearings bottom end bearings...

Page 93: ...erance of 10 to 10 of the GTD value plus back flushing flow of automatic self cleaning filter if such filter is installed oil flow to torsional vibration damper if such damper is installed Delivery he...

Page 94: ...tself automatically using reverse flow or compressed air techniques Back flushing oil treatment by sludge checker Oil flow Refer to GTD Working viscosity 95cSt at working temperature Working pressure...

Page 95: ...22 which is provided on the WinGD webpage under the fol lowing link Instruction for flushing Lubricating oil system 4 3 4 Lubrication for turbochargers For lubricating oil for turbochargers equipped w...

Page 96: ...el sharing mode 1 10 Since the introduction of the global limitation of sulphur content in fuels the global cap of 0 50 sulphur m m the maximum required BN is limited This permits the use of certain B...

Page 97: ...ual cylinder lubricating oil installation with iCAT as an optional applica tion enabling independent gas and liquid fuel maximum 0 50 sulphur m m operation with automatic iCAT changeover SM 0188 HIGH...

Page 98: ...referred cylinder lubricating oil according to the fuel in use Figure 4 11 Dual cylinder lubricating oil installation without iCAT enabling inde pendent gas and liquid fuel maximum 0 50 sulphur m m op...

Page 99: ...gas and diesel mode operation Figure 4 12 Cylinder lubricating oil system for fuel with ultra low sulphur content maximum 0 10 sulphur m m or alternatively a single grade cylinder lu bricating oil is...

Page 100: ...erature of 40 10 5 C the proper length of heating cable must be selected for the engine and traced along the system side piping spirally or in parallel depending on the cable pipe ratio see Figure 4 1...

Page 101: ...cylinder LO pipe To maintain the desired temperature the system side cylinder LO pipe must be well insulated The following requirements must be considered Insulation material such as mineral wool glas...

Page 102: ...set up as purifiers and completely isolated from the fuel oil treatment systems there must be no possibility of cross contam ination Oil separator Oil samples To ensure that representative samples of...

Page 103: ...4 The total tank size is normally 5 10 greater than the amount of lubricating oil required for an initial filling Figure 4 14 Dimensioning and filling process of lubricating oil drain tank NOTE The cl...

Page 104: ...the actual config uration or the stage of development nor the type of the engine con cerned For all relevant and prevailing information see MIDS drawings 4 17 SM 0038 1 2 3 4 5 6 2 1 1 Driving end Fr...

Page 105: ...4 1 1 7 9 C 1 1 2 4 3 1 1 1 2 1 7 1 1 6 1 6 2 Heel to each side 22 5 c 22 5 22 5 c 22 5 c Rolling to each side 22 5 c 22 5 22 5 c 22 5 c Trim 10 10 10 10 Pitching 10 10 10 10 Electrical installation...

Page 106: ...to each side 22 5 c 22 5 c 22 5 c Trim 10 a 10 10 Pitching 10 10 10 Electrical installation Abbreviation 4 1 3 2 2 2 2 1 4 1 1 1 7 1 7 1 5 1 103 1 Heel to each side 22 5 b c 22 5 b c 22 5 b c Rolling...

Page 107: ...2 5 c Rolling to each side 22 5 c 22 5 b c 22 5 c 22 5 c 22 5 c Trim 10 10 b 10 10 10 Pitching 10 10 b 10 10 10 Electrical installation Abbreviation 6 2 1 1 10 H 1 1 1 7 VIII 2 2 1 2 2 C 2 2 1 6 XI 2...

Page 108: ...the gas fuel system DG 9727 is provided on the WinGD webpage under the following link MIDS The document Flushing Instruction for Gas Fuel Piping System is accessible under the following link Flushing...

Page 109: ...ee Figure 4 16 4 35 Fuel gas admission is hydraulically actuated and electronically controlled With the lean fuel gas mixture it is possible to achieve good engine characteris tics regarding output ef...

Page 110: ...1 08 4 35 4 Ancillary Systems 4 4 Fuel gas system X72DF Figure 4 16 Lean burn with pilot ignition Figure 4 17 Lean burn operation window SM 0112 Scavenging Compression gas admission Ignition Expansion...

Page 111: ...point of water 20 C Oil aerosol liquid and vapour 1mg Nm3 Gas cleanliness Gas is considered as sufficiently clean b b Contamination from the fuel gas supply system must be avoided e g by correct pipe...

Page 112: ...lculation An application provided by the European Association of Internal Combustion Engine Manufacturers EUROMOT allows calculating the methane number of natural gas mixtures The application is free...

Page 113: ...s recom mended that each fuel gas consumer s supply line is equipped with an inde pendent fuel gas shut off valve At least one of these shut off valves should close in suitable time to prevent unneces...

Page 114: ...layer and an air gap layer This reduces the thermal impact on the LNG from the environment therefore reducing the BOG This gap also allows for a given ex pansion of the tank wall which is a result of...

Page 115: ...secondary barrier Figure 4 21 Section view of a free standing Type B tank of moss design Free standing Type C tank Type C tanks are designed using conventional pressure vessel codes for pressure rang...

Page 116: ...side on the deck if this is preferred see Figure 4 23 For example this could be particularly useful if the hold space is used for other bulk materials An advantage to this arrangement is that in the e...

Page 117: ...distin guish from FBOG The relative amount of liquid in relation to the total tank volume which evaporates from the LNG tank per day determines the Boil Off Rate BOR The BOR is provided as a percentag...

Page 118: ...required depending on the design tank pressure and the gas feed pressure demand of the gensets Figure 4 24 Pressurised Type C tank solution with NBOG handling by the gensets Type C tank Solution 2 Fi...

Page 119: ...ank solution drawn for an LNGC SM 0684 BOG LNG GVU GVU GVU iGPR GVU Emergency pressure release From the bunkering station Pre heater NBOG compressor Low pressure vaporiser Up to 16 bar g Cryogenic sub...

Page 120: ...process of the compressed NBOG Cooling by the Reversed Brayton effect The alternative method for cooling is a refrigeration process where a heat ex changer is able to remove enough heat from the NBOG...

Page 121: ...this approach are that it is a much simpler system setup re quiring usually a smaller plant size As a result it also requires less maintenance while being more energy efficient However a sub cooler sy...

Page 122: ...f pressure fluctuation and a safety margin for pressure losses Design fuel gas supply pressure selection The graph in Figure 4 28 4 48 indicates the required minimum design fuel gas supply pressure at...

Page 123: ...an 90 CMCR power if the LHV is just as low as 32MJ Nm3 A pressure drop of 0 5bar across the FGSS is considered The real pressure drop needs to be calculated by the shipyard or the FGSS supplier see se...

Page 124: ...HV the engine can still operate with high output if the fuel gas is supplied with an LHV of 28MJ Nm3 e g more than 90 CMCR power if designed for an LHV of 32MJ Nm3 A pressure drop of 0 5bar across the...

Page 125: ...interfaces The data transmitted to the FGSS includes an additional pressure offset to ac commodate for pressure losses and dynamic load changes in the system The pressure offset is a project specific...

Page 126: ...for ac quiring the FGSS delivery pressure Figure 4 31 provides an overview of the gas pressure from the FGSS input by way of the iGPR or the GVU inlet to the final pressure level at the engine s gas a...

Page 127: ...ert gas and venting Fuel gas temperature monitoring The iGPR is mounted on the engine and has the same installation principles as applied to the fuel gas supply system which is located in the engine r...

Page 128: ...ging Purging and venting valves The iGPR is installed with multiple valves that isolate inert gas and vent lines from the main fuel gas piping In the event that a gas trip is initiated by the safety s...

Page 129: ...proof GVU room GVU within a housing The GVU within a housing e g GVU ED enclosed design from W rtsil see Figure 4 34 4 55 is a solution where all the equipment is mounted inside a gas tight casing Th...

Page 130: ...e load command This is done by means of a pressure regulating valve that is controlled by the PCS A smaller gas volume between the pressure control valve and the engine improves the response time of t...

Page 131: ...of venting to the atmosphere other means of disposal such as a suitable furnace or gas recovery system can be considered However this kind of arrangement must be accepted by the classification societ...

Page 132: ...ure is below the dew point of the annular space ventilation air then dry air needs to be supplied for the engine s annular space ventilation to prevent condensation This can be achieved by supplying c...

Page 133: ...n Vi 3Va Nm3 where Vi minimum required inert gas volume Nm3 Va total volume of the space to be purged including the main en gine s internal gas piping the external gas supply piping and the rel evant...

Page 134: ...ferential before and after the valve The valve supplier must provide a suitable valve for the calculated Vi and the selected pi as well as the re sulting purging duration time Shipyards can consult th...

Page 135: ...ections of the fuel gas pipe as shown in Figure 4 35 and Figure 4 36 Figure 4 35 Gas leak test sequence engines with iGPR Figure 4 36 Gas leak test sequence engines with GVU NOTE If the inert gas pres...

Page 136: ...combustion chamber to ignite the gas charge The pilot fuel system is designed for operation on MDO DMB DFB grades and MGO DMA DFA DMZ DFZ grades The diesel oil is delivered by a fuel oil feed pump vi...

Page 137: ...n acts as a pressure accumulator against pressure pulses Pilot injection valves and pre chambers The X DF engine uses pilot injectors with built in solenoid valves The injectors are electronically con...

Page 138: ...s cover the needs of the engine only If a filter of automatic back flushing type is in stalled the feed and booster pump capacities must be in creased by the quantity needed for back flushing of the f...

Page 139: ...the project specific GTD data sheet 4 6 1 Fuel oil system components The following components are associated with a fuel oil system of maximum fuel flexibility i e operation on heavy fuel oils and di...

Page 140: ...it to prevent water in the system from vaporising into steam The pump whilst considering system pressure drop must provide a minimum of 1bar above the water vapour pressure and al ways be above a 3bar...

Page 141: ...operation only a small mixing unit is required It is recommended that the tank contains no more than approx 100 litres This is to avoid the changeover from HFO to MDO MGO or vice versa taking too lon...

Page 142: ...provided on the WinGD webpage under the following link Concept Guidance Distillate Fuels Figure 4 40 Mixing unit Type Cylindrical steel fabricated pressure vessel as shown in Figure 4 40 Capacity Refe...

Page 143: ...otor The electric motor driving the HP booster pump must be sized large enough for the power absorbed by the pump at maximum pressure head difference between inlet and outlet pressure maximum fuel oil...

Page 144: ...hanger that is included as shown in Concept Guidance Distillate Fuels uses low temperature cooling water A chiller unit cooling from refrigeration is not required if the fuel properties are in line wi...

Page 145: ...referred to as the absolute sphere passing mesh size Approximately all particles larger than the specified size will be trapped on or within the filter Nominal Filtration Grade This value is typically...

Page 146: ...fineness SM 0206 Main Engine 1 HFO LSHFO settling storage and separation system 2 MDO MGO settling storage and separation system 3 Automatic fuel changeover unit 4 Feed pump Low pressure 5 Automatic s...

Page 147: ...isadvantage Engine is not optimally protected against booster pump wear particles Working viscosity 100cSt for HFO of 700cSt at 50 C Flow rate According to GTD The capacities cover the needs of the en...

Page 148: ...ity 10 20cSt required for HFO 13 17cSt recommended Flow rate According to GTD The capacities cover the needs of the engine only If a filter of automatic back flushing type is in stalled the feed and b...

Page 149: ...d for HFO 13 17cSt recommended Flow rate According to GTD The capacities cover the needs of the engine only If a filter of automatic back flushing type is in stalled the feed and booster pump capaciti...

Page 150: ...the fuel oil treatment system and gives no indi cation when the automatic self cleaning filter fails NOTE The self cleaning performance must be suitable for the required filter fineness NOTE WinGD rec...

Page 151: ...can be replaced with a single delivery pump If this option is selected the pump must be located in the recircula tion piping and must not be too high relative to the fuel oil tanks see H in Figure 4 4...

Page 152: ...may be needed for off spec fuels that are not supported by WinGD Fuel oil filter An automatic self cleaning filter with a maximum of 10 m mesh size must be in stalled close to engine inlet as indicat...

Page 153: ...ting line with an inlet just above the bottom of the service tank leads back to the settling tanks Diesel oil service tanks are similar to heavy oil service tanks with the possible exception of tank h...

Page 154: ...separator Certified Flow Rate To express the performance of separators according to a common standard the term Certified Flow Rate CFR has been introduced CFR is defined as the flow rate in litres hou...

Page 155: ...ded in rare cases only for instance due to maintenance or before stopping the engine i e at relatively low loads Automatic changeover unit Consequently a well proven automatic changeover unit is nowad...

Page 156: ...000 20 000 10 000 5 000 3 000 2 000 1 500 1 000 800 600 400 300 200 150 100 80 70 60 50 45 40 36 Seconds Saybolt Universal Seconds Redwood No 1 Kinematic viscosity mm 2 s cSt 10 0 10 20 30 40 50 60 7...

Page 157: ...starting and control air system shown in Figure 4 46 comprises two air com pressors two air receivers and systems of pipework and valves connected to the engine starting air manifold Figure 4 46 Air...

Page 158: ...must not exceed 90 C and the air supply to the compressors is to be as clean as possible without oil vapour Starting air receivers 1 Propeller inertia includes the part of entrained water 2 The GTD ap...

Page 159: ...purity class 5 4 3 ac cording to ISO 8573 1 2010 04 15 Control air consumption The required control air flow capacities are shown in Table 4 14 These data can be used for sizing the relevant engine e...

Page 160: ...On the main engine side the maximum scavenge air pressure in the scavenge air receiver is approximately 3 5 4 0 bar g Therefore the tank pressure must be designed and produced ac cordingly Installatio...

Page 161: ...solids from the liquids will significantly reduce the risk of solid particles causing the orifice to become blocked The sludge oil trap collects the solids from the bottom of the piston underside are...

Page 162: ...oil drain is working properly If instead there is an oil flow this would indicate that the orifice of the overflow pipe is blocked and requires manual cleaning For manual sludge removal partially unsc...

Page 163: ...ickly and as soon as the sludge oil trap becomes empty Otherwise the sludge oil tank will become pressurised by the scavenge air Transfer to the sludge oil tank by pump If the manual bottom drain is c...

Page 164: ...g device at the bottom of the sludge oil trap must be installed to ensure that the sludge emulsion can be properly drained through the automatic bottom drain which is designed as an automatic valve Au...

Page 165: ...of an automatically bottom drained sludge oil trap SM 0772 Sludge oil drain from piston underside Drain to sludge oil tank or to sludge oil pump Sight glass Orifice 5 10 mm Automatic bottom drain val...

Page 166: ...have to be fully functional at all incli nation angles of the ship at which the engine must be operational This is nor mally achieved if the vent pipes have an uninterrupted inclination of min 5 Such...

Page 167: ...e achieved with an exhaust gas duct leading to the open deck or in the case of a twin engine installation by sending a control signal that triggers a shutdown of the engine If either of these options...

Page 168: ...and typically provided as part of the overall engine room ventilation system Approximately 50 of the overall en gine room ventilation air is for the main engine s combustion while the other half is us...

Page 169: ...or mance especially during tropical conditions Alternatively a ventilation system with a direct air suction layout can be ar ranged where the ventilation system connects the outside ambient air direct...

Page 170: ...ngine room ventilation system By ensuring that the air flow from the ventilation outlet to the turbocharger inlet is as direct as possible the air intake is at its coolest The ventilation arrangement...

Page 171: ...no need for ventilation fans in this arrangement However it is still essential that the ventilation inlet is protected typically with a weather hood and louvres A separate filter unit if required can...

Page 172: ...f increased wear to the piston rings and cylinder liners Table 4 15 Guidance for air filtration All filters surfaces must be sized correctly to ensure full functionality of the fil tration This is dep...

Page 173: ...0 12 40 25 35 30 4 5 3 8 14 16 20 7 9 4 3 5 50 45 25 20 35 40 30 12 10 6 8 14 16 Required filtration area enabling a pressure drop 20 mbar Engine power MW SM 0167 I n e r t i a l s e p a r a t o r R o...

Page 174: ...ements of the turbocharger maker as outlined in Table 4 16 must be considered When operating above 45 C the power output of the engine may be limited please contact WinGD for case by case calculations...

Page 175: ...ngine 8 cyl engine 4 11 2 Flow rates and velocities For the different media in piping WinGD recommends flow rates and velocities as stated in the document Fluid velocities and flow rates Note that the...

Page 176: ...lution can be applied either in the shaft line or at engine s free end 4 12 1 Requirements After selecting the engine 1 Define the shaft power and the shaft speed 2 Estimate the electric power demand...

Page 177: ...AC AC 6 AC AC 5 AC AC AC AC 2 AC AC AC AC 10 AC AC 11 3 1 2 AC AC 13 AC AC 14 AC AC 12 4 1 2 CPP Clutch Gear box Tunnel gear box 1 2 2 speed tunnel gear box FPP AC AC Generator Machine Torsional coup...

Page 178: ...15 16 X X X X X X X X X X X X X X X X X X the arrangement is possible the arrangement may not be possible too high nominal generator el motor torque due to too low nominal engine speed and or high ge...

Page 179: ...t bearing layout has to be properly selected and adjusted to comply with the given alignment rules For further details refer to section 3 7 Engine and shaft alignment 3 13 Bearing load due to external...

Page 180: ...or several cases which are illustrated below Operation area and prohibited area The following illustrations indicate how the engine generator unit can be oper ated The prohibited operation area is de...

Page 181: ...igure 4 58 CPP in constant speed operation without frequency converter SM 0202 100 0 0 100 speed power power curve Valid for CPP with a frequency converter Applicable to options 2 6 8 10 12 14 operati...

Page 182: ...or applications X72DF Figure 4 59 CPP with two fixed operation speeds without frequency converter SM 0204 prohibited operation area operation area Valid for CPP without a frequency converter in combin...

Page 183: ...h is in line with approved propulsion control systems DENIS The Diesel Engine CoNtrol and optImising Specification DENIS interface contains specifications for the engine management of all WinGD two st...

Page 184: ...s to the common rail system engines The data bus connection pro vides clear signal exchange 5 2 2 Approved propulsion control systems Propulsion control systems including remote control safety and tel...

Page 185: ...omponents for control alarm and indication the specification contains the following List of alarm and display functions to be realised in the vessel s AMS Control diagram of the engine Signal list inc...

Page 186: ...bridge see Figure 5 3 5 5 The different items normally communicate via se rial bus connections The engine signals described in the DENIS specification are usually connected via terminal boxes on the e...

Page 187: ...t cases built to be placed either inside the ECR console or in a separate cabinet to be located in the ECR The operator panels are to be inserted in the ECR console s surface SM 0282 Ship Alarm System...

Page 188: ...to these indications the RCS applied to the common rail system engine includes displaying the primary values from the ECS like fuel pressure servo oil pressure etc Safety system Main functions Emergen...

Page 189: ...021 08 5 7 5 Engine Automation 5 4 Propulsion control systems X72DF Options Bridge wing control Command recorder Figure 5 4 Propulsion control A A E H D A S T E R N STOP SLOW HALF FULL FULL HALF SLOW...

Page 190: ...he magnitude of any change in power it takes time to reach the re quired engine output see the following graphs and tables Figure 5 5 Manoeuvring speed power settings for FPP CPP installations For fur...

Page 191: ...CMCR speed Corresponding power Recommended warm up time per load step min Min warm up time per load step min DEAD SLOW 25 35 1 5 4 5 0 0 SLOW 35 45 4 9 0 0 HALF 45 55 9 17 0 1 0 1 FULL 60 70 22 34 0 5...

Page 192: ...warm up times for CPP Load reduction is possible in half the time of values mentioned in Table 5 3 Figure 5 7 Full sea load steps in CPP load up program Manoeuvring position Recommended CMCR power Rec...

Page 193: ...builder for mounting on the engine and con necting to the sensors The integrated solution facilitates commissioning and testing of the alarm signals set on the engine maker s testbed and limits the w...

Page 194: ...to operational requirements When decreasing the values for slow down times the delay times for the respec tive shut down functions are to be adjusted accordingly 5 6 2 Requirements of WinGD and classi...

Page 195: ...g the crew with live trouble shooting and diagnostics Figure 5 8 The WiDE system 5 7 1 Data collection and monitoring WiDE uses the DCM unit to collect data from the engine and other ship systems This...

Page 196: ...e recognised from a combination of DCM monitoring and historical sample data that is uploaded to the EDS during installation ena bling progressive performance improvement Prediction and troubleshootin...

Page 197: ...trial period on all their en gines If there are any questions regarding this please contact the WinGD repre sentative 5 7 3 WiDE installation process The process map below shows the steps towards ins...

Page 198: ...ideration the causes and relevance After considering the external forces and moments types this section explores the resulting vibration along with recommended considerations and counter measures rele...

Page 199: ...s and moments Forces With a regular firing order of evenly distributed crank angles an engine will in herently balance the summation of all vertical FV and horizontal FH free forces Sometimes the firi...

Page 200: ...ures for second order vertical mass moments WinGD strongly recommends the use of either of the following countermeasures for 5 and 6 cylinder engines Engine fitted electric balancer s iELBA An electri...

Page 201: ...mpensator external compensator Alternatively or if the ship s vibration pattern is not known at an early stage an electrically driven compensator can be installed or retrofitted if disturbing second o...

Page 202: ...RU values of an engine are dependent on the number of cylinders The resulting PRU values are graphically displayed in the link below along with the likelihood of needing a compensator External forces...

Page 203: ...ne speed Figure 6 4 Forces through the engine The forces between the piston and the connecting rod reaction cause a lateral force to act on the crosshead guide rails The lateral forces at the guide ra...

Page 204: ...e where both sides of the top of the engine the driving and free end vibrate together in phase The lat eral guide forces FL result in a lateral moment expressed as resulting lateral H type moment MLH...

Page 205: ...al speed In addition some damping effect is provided by the hydraulic type stays Such hydraulic type stays can be either for both side or one side installation Hydraulic type stays for one side instal...

Page 206: ...upper platform in the longitudinal centre point of the engine This re duces the lateral engine vibrations and the effect on the ship s superstruc ture Alternatively two compensators one fitted at each...

Page 207: ...s with oversized diam eters which is no longer common today Longitudinal stays to prevent vibration in superstructure However there can be installations where it might be beneficial to install longi t...

Page 208: ...acceptable espe cially the friction coefficient of the shim and the disc spring properties which must follow exact specifications For the assembly of friction type stays please see the latest version...

Page 209: ...ship during sea trials All data required for torsional vibration calculations should be made available to the engine supplier in an early design stage see section 6 9 6 22 Barred speed range BSR At a...

Page 210: ...supplied with oil from the engine s lubricating oil system Depending on the torsional vibration energy to be absorbed the damper can dissipate up to 180kW of energy this will be based on the number o...

Page 211: ...problematic if it is below approximately 1 5Hz Here there is a risk of engine speed instability where the engine constantly adjusts its speed to compensate the rotating vibration this must be conside...

Page 212: ...brating and resonating at several frequencies This would result in excessive stress in the crankshaft and in some cases can lead to excessive vibration of the upper part of the engine Reduction of axi...

Page 213: ...evant in propulsion shafting with di rectly coupled low speed 2 stroke engines Typically whirling vibrations are only relevant in 2 stroke installations having a very long shaft line longer than 60m M...

Page 214: ...ire the fitting of second order mass moment compensators lateral longitudinal stays electrical H type or X type compensators and or torsional vibration dampers Avoiding problematic hull vibrations can...

Page 215: ...rmeasure is not relevant No of cyl Lateral stays Longitudinal stays 5 A C Aa a A for installations having the main torsional critical above nominal speed installations with in creased shaft diameters...

Page 216: ...nce in the surrounding vessel structure Alteration of phase angles With twin engine vessels the resulting vibration amplitude is equal to the sum of both engines and is therefore dependent on the phas...

Page 217: ...system Main controller and user interface in ECR The main controller is installed in the engine control room along with the user in terface where the relative phase difference angle provided by WinGD...

Page 218: ...trol On and Esti mate Only modes These conditions are Both engines are running in ahead direction in normal operational condi tion and unrestricted operation conditions no protective actions of the en...

Page 219: ...stem dynamics and vibration analysis All questionnaires and forms can be downloaded from the WinGD webpage under the following link Questionnaires for shaft calculations Forms should be filled in and...

Page 220: ...lation regarding NOx emissions Regulation 13 of Annex IV specifies a limit for the nitrogen oxides NOx emis sions of engines installed on ships which has a direct implication on the design of propulsi...

Page 221: ...he drawings relevant for the SCR system DG 9726 are provided on the WinGD webpage under the following link MIDS Low pressure SCR The SCR reactor is located on the low pressure side after the turbine F...

Page 222: ...e and multi turbo charger applications Furthermore WinGD allows high pressure SCR suppliers to interface third party branded products to the engine provided that interface specifications are met Figur...

Page 223: ...ith ISO NR Curves Overall average values LpA in dB A and expected maximal overall single point values Free field conditions Near the turbocharger air intake the maximum measured noise level will nor m...

Page 224: ...90 110 120 40 50 NR70 60 30 1 8X72DF 2 5X72DF 31 5 63 125 250 500 1k 2k 4k 8k 120 110 100 90 80 70 Octave band centre frequency in Hz Lp dB NR80 110 120 40 50 NR70 60 30 100 Overall average LpA in dB...

Page 225: ...by about 6dB Figure 7 5 Exhaust noise reference point Silencer after exhaust gas boiler Depending on the actual noise level allowed on the bridge wing which is nor mally between 60 and 70dB A a simple...

Page 226: ...F Figure 7 6 Sound pressure level at funnel top of exhaust gas system SM 0142 NR60 70 90 80 110 120 130 31 5 63 125 250 500 1k 2k 4k 8k 130 120 110 100 90 80 70 60 50 Octave band centre frequency in H...

Page 227: ...starts to vibrate and thus emits noise The sound pressure levels in the accommodations can be estimated with the aid of standard empirical formulas and the vibration velocity levels Figure 7 7 Struct...

Page 228: ...gs and running gear are clearly marked cylinder by cylinder 8 2 Protection of disassembled engines All parts have to be protected against damage by careful crating and from corro sion by applying rust...

Page 229: ...s can also be found here 9 1 Classification societies Table 9 1 List of classification societies IACS International Association of Classification Societies ABS American Bureau of Shipping KR Korean Re...

Page 230: ...t fuel Consumption FBOG Forced Boil Off Gas BSR Barred Speed Range FGSS Fuel Gas Supply System CCR Conradson Carbon Residue FPP Fixed Pitch Propeller CCW Cylinder Cooling Water FQS Fuel Quality Settin...

Page 231: ...m Low LCV Lower Calorific Value PCS Propulsion Control System LDU Local Display Unit PI Proportional plus Integral LFO Light Fuel Oil PLS Pulse Lubricating System LHV Lower Heating Value PMS Planned M...

Page 232: ...scosity Index Std Standard tuning VIT Variable Injection Timing SW Seawater WECS WinGD Engine Control System TBO Time Between Overhauls WHR Waste Heat Recovery TC Turbocharger WiCE WinGD Integrated Co...

Page 233: ...Force N MN kN f v Frequency Hz 1 s I Current A I J Moment of inertia radius kgm2 l L Length m cm mm la lp Second moment of area m4 K Coefficient of heat transfer W m2K L Angular momentum Nsm L A TOT T...

Page 234: ...J kJ MJ kWh Z W Section modulus m3 T Temperature interval K C Angular acceleration rad s2 Linear expansion coefficient 1 K Angle rad Surface tension N m Dynamic viscosity Ns m2 Thermal conductivity W...

Page 235: ...1 short ton 907 2 kg 1 tonne 1000 kg Volume fluids 1 Imp pint 0 568 l 1 U S pint 0 473 l 1 Imp quart 1 136 l 1 U S quart 0 946 l 1 Imp gal 4 546 l 1 U S gal 3 785 l 1 Imp barrel 36 Imp gal 163 66 l 1...

Page 236: ...Marine Installation Manual 2021 08 9 8 9 Appendix 9 4 Approximate conversion factors X72DF Area 1 in2 6 45 cm2 1 ft2 929 cm2 1 yd2 0 836 m2 1 acre 4047 m2 1 sq mile of land 640 acres 2 59 km2...

Page 237: ...the industry standard for environmental sustainability reliability efficiency and safety WinGD provides designs training and technical support to engine manufacturers shipbuilders and ship operators...

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