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WinGD X92DF, Operation Manual

The WinGD X92DF operation manual is essential for properly operating this powerful engine. You can easily download the manual for free from manualshive.com. Ensure smooth and efficient performance of your engine by following the detailed instructions provided in the manual. Get your copy now!

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Table of contents

1

Introduction

1.1

Operation Manual - change record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

1.2

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

1.3

Technical documentation set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

1.4

Data module codes (descriptive data). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

1.5

Data module codes (procedural data). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

1.6

About this book. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

1.7

About the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

1.8

List of abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

2

Safety

2.1

Safety precautions and safety rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

2.2

Safety precautions and safety rules for natural gas. . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

2.3

Contamination and fire in the scavenge air spaces. . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

2.4

Fire-fighting in the scavenge air space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

2.5

Explosions in the crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

2.6

Prevent explosions in the crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

2.7

Prevention of explosions in the exhaust gas system (gas mode). . . . . . . . . . . . . . . . .

58

2.8

Access to engine spaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

3

Design and function of the engine

3.1

Short description of the DF engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

3.2

Use of the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68

3.3

The relation between engine and propeller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

4

Design and function of systems

4.1

General for systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78

4.2

Cooling water system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

4.3

Wash-water system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

4.4

System oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84

4.5

Servo oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

4.6

Cylinder oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88

4.7

Starting air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90

4.8

Scavenge air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92

4.9

Control air system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94

4.10

Exhaust gas system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96

4.11

Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98

4.12

Gas system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102

4.13

Pilot fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104

X92DF

Operation Manual

Winterthur Gas & Diesel Ltd.

- 3 -

Issue 002 2020-08

Summary of Contents for X92DF

Page 1: ...X92DF Issue 002 2020 08 Winterthur Gas Diesel Ltd Sch tzenstrasse 3 Tel 41 0 52 264 8844 Winterthur Gas Diesel AG P O Box 414 8401 Fax 41 0 52 264 8866 Winterthur Gas Diesel S A Winterthur Switzerlan...

Page 2: ...ght holder Winterthur Gas Diesel Ltd makes no representation warranty express or implied in this publication and assumes no responsibility for the correctness errors or omissions of information contai...

Page 3: ...54 2 6 Prevent explosions in the crankcase 56 2 7 Prevention of explosions in the exhaust gas system gas mode 58 2 8 Access to engine spaces 60 3 Design and function of the engine 3 1 Short descriptio...

Page 4: ...haft connecting rod and piston 5 3 1 Crankshaft 176 5 3 2 Torsional vibration damper 178 5 3 3 Axial vibration damper 182 5 3 4 Turning gear 184 5 3 5 Connecting rod and connecting rod bearing 186 5 3...

Page 5: ...e control system WiCE 270 6 4 Intelligent combustion control 274 6 5 Gas valve unit and external gas supply system 278 6 6 Integrated gas pressure regulation 284 6 7 Local display unit LDU 20 general...

Page 6: ...TOOLS 364 6 8 35 LDU 20 page SYSTEM STATUS 366 6 8 36 LDU 20 page SYSTEM SETTINGS 368 6 8 37 LDU 20 page TEMPERATURES 370 6 8 38 LDU 20 page USER PARAMETERS 372 6 8 39 LDU 20 page GAS LEAK TEST 374 6...

Page 7: ...ually 466 8 15 Change over to and from gas 468 8 16 Stop the engine general 470 8 17 Stop the engine 472 8 18 Emergency stop the engine general 474 8 19 Emergency stop the engine 476 8 20 Prepare the...

Page 8: ...ct the fuel pump 558 10 12 Temporary isolate a defective turbocharger 562 10 13 Temporary isolate the exhaust waste gate 566 10 14 Isolate a defective engine at twin engine installation 570 11 Technic...

Page 9: ...4 11 HP SCR SOFTWARE INFO 137 4 12 HP SCR PAGE INDEX 138 4 13 STEAM PRODUCTION CONTROL SPC 141 5 Design and function of components 5 1 iELBA control cabinet 240 5 2 iELBA error indication 241 6 Contr...

Page 10: ...EM 405 6 48 Navigation menu of the manual control panel MCP 407 6 49 Function buttons of the manual control panel MCP 407 6 50 WECS 9520 manual control panel 413 6 51 User parameters 416 6 52 Maintena...

Page 11: ...521 10 26 Fuel supply pressure at the engine inlet is too low 521 10 27 Fuel leakage flow from the fuel supply unit is too high 521 10 28 Temperature difference of the fuel outlet of the two fuel pump...

Page 12: ...o the power supply box E85 has a failure 530 10 61 Unwanted engine speed decrease 530 10 62 Unwanted engine stop 530 11 Technical data 11 1 General data 574 11 2 Rated power 575 11 3 Function code 578...

Page 13: ...linder oil system generic and simplified with and without iCAT 89 4 7 Starting air system generic and simplified 91 4 8 Scavenge air system 93 4 9 Control air system generic and simplified 95 4 10 Exh...

Page 14: ...3 Thrust bearing generic 153 5 4 Monoblock column generic 154 5 5 Tie rod generic 156 5 6 Cylinder liner generic 158 5 7 Cylinder cooling water outlet generic 159 5 8 Lubricating quill generic 160 5 9...

Page 15: ...l supply 235 5 50 Effect of second order moments M2v of the engine 236 5 51 iELBA function 237 5 52 iELBA control cabinet 239 5 53 Exhaust waste gate generic 242 5 54 Crank angle sensor unit on interm...

Page 16: ...PERFORMANCE DATA GAS 350 6 39 PILOT FUEL INJECTION 352 6 40 PILOT FUEL PRESSURE 354 6 41 SCAVENGE AIR EWG optional 356 6 42 SOFTWARE INFO 360 6 43 IMO CRC INFO 362 6 44 SOFTWARE TOOLS 364 6 45 SYSTEM...

Page 17: ...f inspection point 537 10 3 Leakage on ICU and pipes generic 543 10 4 Leakage on connecting pipes generic 545 10 5 Exhaust valve with pressure element 551 10 6 Fuel pump example isolate 555 10 7 Fuel...

Page 18: ...X92DF Operation Manual Page left intentionally blank Winterthur Gas Diesel Ltd 18 Issue 002 2020 08...

Page 19: ...2 1 3 Technical documentation set 24 1 4 Data module codes descriptive data 26 1 5 Data module codes procedural data 28 1 6 About this book 30 1 7 About the engine 32 1 8 List of abbreviations 38 X92D...

Page 20: ...e engine general Adjusted some values in the chapter List of usual values and safeguard settings Added instructions about the steam boost mode functionality in the chapter Steam produc tion control sy...

Page 21: ...X92DF AA00 0000 00AAA 003A A Operation Manual Operation Manual change record Page left intentionally blank Winterthur Gas Diesel Ltd 21 Issue 002 2020 08...

Page 22: ...s manual are related to drawings from WinGD These data relate to the date of issue of the manual the year of the issue is shown on the title page and on the footer All instructions graphics and illust...

Page 23: ...X92DF AA00 0000 00AAA 018A A Operation Manual Preface Page left intentionally blank Winterthur Gas Diesel Ltd 23 Issue 002 2020 08...

Page 24: ...he standard engine with all cylinder numbers alternative designs and special equipment In this manual the engine connections refer to the pipe connection plan are the interface of the description For...

Page 25: ...e setting tables shop trial documents schematic diagrams and survey certificates of the related engine are given with the first supply of the documentation 1 3 6 Marine Installation Manual The Marine...

Page 26: ...numeric char acters 0 9 arbitrary 5551 2 Used for sequential numbering of data modules 2 numeric char acters 0 9 sequential starts with 00 00 1 Used for alternative items differing in design but not...

Page 27: ...X92DF AA00 0000 00AAA 018D A Operation Manual Data module codes descriptive data Page left intentionally blank Winterthur Gas Diesel Ltd 27 Issue 002 2020 08...

Page 28: ...ylinders 2 numeric char acters 0 9 arbitrary 00 2 WinGD design group number 4 numeric char acters 0 9 arbitrary 5556 2 Used for sequential numbering for the physical breakdown of components 00 complet...

Page 29: ...m has been re moved from the product D informa tion related to all three locations A B and C No other combinations are al lowed 1 alphabetic character A D Shipdex specif ic A 1 Placeholder symbol for...

Page 30: ...itle of the section for example refer to section 1 2 Preface In the electronic version a mouse click on the blue text shows the related section NOTE The text section not applicable for this engine sho...

Page 31: ...ation The signal words have the different hazard levels that follow WARNING The signal word WARNING gives a dangerous situation at which death or large injury are possible Do the related procedure to...

Page 32: ...of the number into 9 groups Group 1 Engine frame and bearings Group 2 Cylinder Group 3 Crankshaft connecting rod and piston Group 4 Supply unit drive and control components Group 5 Supply unit pumps...

Page 33: ...nd other operating media FE Free End end that is closed with a cover ES Exhaust Side side that has the equipment for the discard of the exhaust gas and for the supply of scavenge air Fig 1 1 Side view...

Page 34: ...S ES 001 002 003 005 004 Legend ES Exhaust side FS Fuel side 001 Turbocharger 004 Supply unit 002 Auxiliary blower 005 Rail unit 003 Flywheel X92DF AA00 0000 00AAA 018L A Operation Manual About the en...

Page 35: ...g 1 3 Standard and LEFT engine generic seen from the driving end 001 002 003 ES FS FS Legend 001 Standard engine ES Exhaust side 002 LEFT engine FS Fuel side 003 Exhaust gas manifold NOTE In the Spare...

Page 36: ...radial direction the numbering starts from the center of the flywheel Fig 1 4 Engine numbering generic FE DE n n 004 003 001 002 n 1 n 1 4 3 2 1 2 1 Legend FE Free end DE Driving end 001 Cylinder num...

Page 37: ...X92DF AA00 0000 00AAA 018L A Operation Manual About the engine Page left intentionally blank Winterthur Gas Diesel Ltd 37 Issue 002 2020 08...

Page 38: ...C Brake Specific Gas Consumption BSPC Brake Specific Pilot fuel Consumption CAN Controller Area Network CCAI Calculated Carbon Aromaticity Index CCM Cylinder Control Module CCU Cylinder Control Unit C...

Page 39: ...lve FPP Fixed Pitch Propeller FQS Fuel Quality Setting FS Fuel Side FZG Forschungsstelle f r Zahnr der und Getriebebau gear research center GAV Gas Admission Valve GSS Gas Safety System GTD General Te...

Page 40: ...Heating Value LLT Low Load Tuning LNG Liquefied Natural Gas LP Low Pressure LT Low Temperature MARPOL International Convention for the Prevention of Pollution from Ships MARine POLlution MCM Main Con...

Page 41: ...Scavenge Air Cooler SAE Society of Automotive Engineers SCR Selective Catalytic Reduction SCS Speed Control System SHD shutdown SLD slowdown SOI Start Of Injection SPC Spare Parts Catalogue SPC Steam...

Page 42: ...R Waste Heat Recovery WiCE WinGD Integrated Control Electronics WinGD Winterthur Gas Diesel Ltd WLL Work Load Limit X92DF AA00 0000 00AAA 005A A Operation Manual List of abbreviations Winterthur Gas D...

Page 43: ...nd fire in the scavenge air spaces 50 2 4 Fire fighting in the scavenge air space 52 2 5 Explosions in the crankcase 54 2 6 Prevent explosions in the crankcase 56 2 7 Prevention of explosions in the e...

Page 44: ...t hand tools in locations where you can easily get access to them Put special tools and devices in positions in the engine room near the area where you use them Make sure that all tools have protectio...

Page 45: ...eep unauthorized persons away from the engine Clean walk ways and stays regularly Open valves and shut off devices carefully to prevent injury from released media Do not use water or cleaning fluid to...

Page 46: ...ce Make sure that there are no explosive fluids or gases in the work area Apply protection to electronic parts to prevent damage from sparks and heat Place the connection to earth as near as possible...

Page 47: ...X92DF AA00 0000 00AAA 012A A Operation Manual Safety precautions and safety rules Page left intentionally blank Winterthur Gas Diesel Ltd 47 Issue 002 2020 08...

Page 48: ...This is an area in which an explosive gas atmosphere is continuously present or is present for long periods Examples Combustion chamber gas pipes Zone Z1 This is an area in which an explosive gas atmo...

Page 49: ...fire Put on antistatic clothes Make sure that your safety shoes are in good condition Steel toe caps can cause sparks Use only approved tools that do not cause sparks and test equipment that will not...

Page 50: ...The silencer and diffuser on the air side of the turbocharger has contamination The wire mesh and nozzle ring upstream of the turbocharger has contamination The exhaust gas boiler the air cooler and...

Page 51: ...You must do regular checks of the bottom of the cylinder block and scavenge air receiver to keep clean the cylinder block and scavenge air receiver refer to section 8 5 Do checks during operation gene...

Page 52: ...0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QT...

Page 53: ...y 5 minutes to 15 minutes do the checks as follows 3 1 Do a check of the exhaust gas temperature 3 2 Do a careful check of the temperatures of the doors to the piston underside space 4 Find the causes...

Page 54: ...y The cause of crankcase explosions is oil mist Oil mist comes from components that have become unusually hot The engine has oil mist detectors refer to section 5 9 3 Oil mist detector Correct engine...

Page 55: ...X92DF AA00 0000 00AAA 012C A Operation Manual Explosions in the crankcase Page left intentionally blank Winterthur Gas Diesel Ltd 55 Issue 002 2020 08...

Page 56: ...QTY None SAFETY PRECAUTIONS WARNING Danger If an oil mist alarm is activated keep away from the engine There is a risk of explosion WARNING Danger Do not open the crankcase doors or the covers for a...

Page 57: ...ature decrease for a minimum of 20 minutes 1 4 Find the cause and repair the fault NOTE If no fire extinguishing system is installed or not in use a portable fire extinguisher must be kept ready when...

Page 58: ...ctions that follow The components of the exhaust gas system upstream of the turbochargers are resistant to explosions The gas pipes of the engine and of the related gas system have connection points f...

Page 59: ...opped NOTE If necessary the operator can manually send a signal Ventilation Request Manual The operator must always start the ventilation sequence manually The operator starts the auxiliary blowers Th...

Page 60: ...nel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS...

Page 61: ...E0_7 are open 6 Engage the turning gear and lock the lever in this position NOTE Other ships in the water cause currents which cause the movement of the propeller and the engine The engine and propell...

Page 62: ...X92DF AA00 0000 00AAA 012E A Operation Manual Access to engine spaces Page left intentionally blank Winterthur Gas Diesel Ltd 62 Issue 002 2020 08...

Page 63: ...d function of the engine 3 1 Short description of the DF engine 64 3 2 Use of the engine 68 3 3 The relation between engine and propeller 72 X92DF Operation Manual Winterthur Gas Diesel Ltd 63 Issue 0...

Page 64: ...a mixture of MDO HFO and LNG in the given range The engine obeys the IGC International Code for the Construction and Equipment of Ships Carrying Liquefied Gases in Bulk and the IGF International Code...

Page 65: ...3 4 The gases expand and push the piston down The pressure in the combustion chamber decreases Sequence 4 1 The scavenge air replaces the exhaust gas as follows At 4 the exhaust valve opens At a the...

Page 66: ...s Sequence 3 4 The gases expand and push the piston down The pressure in the combustion chamber decreases Sequence 4 1 The scavenge air replaces the exhaust gas as follows At 4 the exhaust valve opens...

Page 67: ...ed quantity of liquid fuel The gas and the liquid fuel combust at the same time The speed governor controls the quantity of the two fuels to the selected ratio 3 1 4 Dynamic Combustion Control Dynamic...

Page 68: ...nge Fig 3 3 Operating range R1 R1 R2 R2 R4 R4 R3 S P Legend R1 Highest power at highest speed R3 Highest power at lowest speed R1 Highest power at highest speed extended R4 Lowest power at lowest spee...

Page 69: ...rect use will be the responsibility of the operating company The actions that follow must be looked as examples to be an incorrect use Operation of the engine with disabled changed or defective safety...

Page 70: ...ass tuning The delta bypass tuning decreases the fuel consumption below 50 engine power compared to delta tuning For more than 50 of engine power the fuel consumption is the same as delta tuning but t...

Page 71: ...the classification societies and of WinGD You can operate the two engines in different modes for example port engine 001 is in diesel mode and if gas mode is applicable starboard engine 002 is in gas...

Page 72: ...clean hull the applicable power is lower and the operation point is below the nominal propeller property During operation a higher torque is necessary for the propeller to keep its speed than at the t...

Page 73: ...he timing of dry dock intervals This margin is usually subtracted from the CMCR Thus to get the 100 power line you divide the power at point D by between 0 85 to 0 90 3 3 2 3 Load range limits Fig 3 6...

Page 74: ...ngine speed and power is near the data in Line 5 there will be a decrease in scavenge air which has an effect on the engine The area between Lines 1 3 and 5 show the range in which the engine must be...

Page 75: ...s calculation Along Line 8 the power increase from 37 point F to 100 power CMCR at 100 speed is the constant speed mode for the shaft generator operation Line 5 is the top load limit and relates to th...

Page 76: ...ion with shaft generators During maneuvering the combinator curve follows the Line 9 At sea the engine is operated between point F and 100 power Line 8 at constant speed For manual and or emergency op...

Page 77: ...88 4 7 Starting air system 90 4 8 Scavenge air system 92 4 9 Control air system 94 4 10 Exhaust gas system 96 4 11 Fuel system 98 4 12 Gas system 102 4 13 Pilot fuel system 104 4 14 LP Selective catal...

Page 78: ...e codes in Figure 4 1 Fig 4 1 Line codes for systems 001 002 003 004 007 006 008 009 005 Legend 001 Main supply pipe 006 Double wall pipe 002 Drain leakage pipe 007 Heating pipe 003 Vent pipe 008 Insu...

Page 79: ...X92DF AA00 0000 00AAA 043U A Operation Manual General for systems Page left intentionally blank Winterthur Gas Diesel Ltd 79 Issue 002 2020 08...

Page 80: ...e parts that follow Automatic venting unit The automatic venting unit 001 constantly releases unwanted air from the cooling water Cyclone separator The cyclone separator 002 separates the air and the...

Page 81: ...unit 006 Orifice 002 Cyclone separator 007 Shut off valve cooling water inlet 003 Temperature control valve 008 Drain valve usually closed 004 Check valve 009 Vent valve usually closed 005 Booster pu...

Page 82: ...ning plant for TC and SAC inlet Connection 12 air for cleaning plant for TC and SAC inlet Connection 13 oily water from receiver outlet Connection 16 SAC condensate water outlet Connection 17 SAC wash...

Page 83: ...GINE 13 18 16 06 17 06 005 002 002 003 003 001 004 Legend 001 Wash water tank 004 Cyclone separator 002 Scavenge air cooler SAC 005 Turbocharger 003 Auxiliary blower X92DF AA00 0000 00AAA 043P A Opera...

Page 84: ...bedplate vertical Connection 25 main oil inlet Connection 26 lubricating oil turbocharger inlet optional Connection 27 lubricating oil turbocharger outlet Connection 30 lubricating oil crosshead inle...

Page 85: ...nd 001 Turbocharger 007 Crosshead 002 iELBA optional 008 Thrust bearing 003 Torsional vibration damper optional 009 Oil sample valve 004 Axial vibration damper 010 Lever 005 Main bearing 011 Supply pi...

Page 86: ...e double wall Inspection points in the pipes let find oil leaks Servo oil service pump The servo oil service pump 005 can supply the servo oil system with oil before the engine start or during mainten...

Page 87: ...trol unit ICU for X82 and X92 006 Oil pipe to exhaust valve 002 Exhaust valve control unit VCU 007 Servo oil rail 003 Square collector pipe 008 Rail unit 004 Servo oil pump 009 Pressure reducing valve...

Page 88: ...x oil filter 004 filters the oil before it flows to the cylinder lubricating pumps The change over valve makes it possible to shut off one filter chamber Cylinder lubricating pump Each cylinder has a...

Page 89: ...AT 007 004 003 002 001 Legend 001 Oil sample valve 005 Square collector pipe 002 Lubricating quill 006 Rail unit 003 Cylinder lubricating pump 007 Change over valve 004 Duplex oil filter 008 Servo oil...

Page 90: ...starting air supply pipe 007 supplies the starting valves of each cylinder with starting air The starting air supply pipe has a safety valve 003 and two drain valves 004 Starting valve Each cylinder h...

Page 91: ...id valve 006 Disengaging device turning gear 002 Flame arrestor 007 Starting air supply pipe 003 Safety valve 008 Valve unit for start E 004 Drain valve 009 Starting air shut off valve 005 Control air...

Page 92: ...liary blowers 010 supply the scavenge air at the engine start and during low load operation Auxiliary blower switch box The auxiliary blower switch box controls the auxiliary blowers Scavenge air cool...

Page 93: ...as outlet 010 Auxiliary blower 003 Scavenge air inlet 011 Piston underside 004 Turbine 012 Piston 005 Compressor 013 Scavenge air receiver 006 Scavenge air cooler 014 Cylinder liner 007 Water separato...

Page 94: ...supply The control air supply 002 decreases the supply air pressure to the specified pressures Air tank The air tank 003 is a container for control air If the two plant air supply systems become defe...

Page 95: ...03 004 Cyl 1 Cyl n Legend 001 Air bottle 005 Starting air shut off valve 002 Control air supply 006 Valve unit for start 003 Air tank 007 Collector for leakage oil from the air spring 004 Disengaging...

Page 96: ...engine connection 71 exhaust gas turbocharger outlet in Figure 4 10 marked with a circle The exhaust gas system has the parts that follow Exhaust valve The exhaust valve 004 of each cylinder releases...

Page 97: ...N G I N E 003 001 002 Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl n 004 Legend 001 Turbocharger bypass pipe 003 Exhaust gas manifold 002 Turbocharger 004 Exhaust valve X92DF AA00 0000 00AAA 043D A Operation Manual E...

Page 98: ...el consumption The ECS cuts out a different injection valve at regular intervals to get an equal thermal load in the combustion chamber There is no time limit to operate the engine at low load The fue...

Page 99: ...ex and related DF engines installed on the fuel rail supply fuel to the related injection valves with the adjusted quantity of fuel Injection control unit The injection control units 003 ICU for X82 X...

Page 100: ...004 005 006 007 008 009 Cyl 1 Legend 001 Pressure control valve 006 Injection valve 002 Relief valve 007 Supply unit 003 Flow limiting valve FLV 008 Fuel pump 004 Fuel rail 009 Pressure retaining valv...

Page 101: ...001 002 004 005 003 007 008 009 006 Legend 001 Pressure control valve 006 Injection valve 002 Relief valve 007 Supply unit 003 Injection control unit ICU 008 Fuel pump 004 Fuel rail 009 Pressure reta...

Page 102: ...e an alarm When there is a fire alarm in the engine room and the engine operates in gas mode the engine control system automatically changes to diesel mode gas trip and closes the master gas fuel valv...

Page 103: ...05 Shut off valve 002 Exhaust valve control unit VCU 006 Gas admission valve GAV 003 Pilot fuel pump unit 007 Vent valve 004 Control air supply 008 Pilot fuel valve X92DF AA00 0000 00AAA 043F A Operat...

Page 104: ...so operates with a decreased quantity of fuel injection during engine operation in diesel mode This prevents contamination on the ends of the pilot injection valves and the prechambers The pilot fuel...

Page 105: ...X92DF AA00 0000 00AAA 043M A Operation Manual Pilot fuel system Page left intentionally blank Winterthur Gas Diesel Ltd 105 Issue 002 2020 08...

Page 106: ...used in diesel mode NOTE For further details about the operation maintenance and troubleshooting aspects of the LP SCR system please refer to the manuals of the manufacturer 4 14 1 Description of the...

Page 107: ...tuning LLT or for steam production control SPC 4 14 1 2 Layout The LP SCR system can be designed in different layouts related to the project Two examples are shown in Figure 4 14 and Figure 4 15 Fig 4...

Page 108: ...s than the permitted limit can cause the catalyst elements to clog A temperature that is more than the permitted limit can cause the catalyst elements to become worn quickly 4 14 2 1 LP SCR system eme...

Page 109: ...e If the operator does not change to Tier III and the timer stops the ECS changes back to bypass mode Tier II 4 14 2 3 LP SCR system Tier III In this operation mode the LP SCR system is set to ON The...

Page 110: ...LP SCR control system layout 001 002 003 Legend 001 Input signals 003 Output signals 002 LP SCR control system The main input signals are as follows Engine parameters Prepare Tier III command from RC...

Page 111: ...This message shows that the LP SCR system is set to ON and thus urea is injected LP SCR minor failure This message shows a failure that does not have an effect on LP SCR system operation LP SCR major...

Page 112: ...pass switch 006 Indication orange SPC bypass 002 Indication red SCR failure 007 Indication green SPC running 003 Indication orange SCR bypass 008 Indication green SCR running 004 Indication red SPC fa...

Page 113: ...room and has switches below the LDU 20 Fig 4 19 Control box E71 with option SPC 001 002 003 Legend 001 LDU 20 003 SCR bypass switch 002 SPC bypass switch X92DF AA00 9270 00AAA 043B A Operation Manual...

Page 114: ...room and has switches below the LDU 20 Fig 4 20 Control boxes E72 and E73 001 002 003 004 Legend 001 LDU 20 003 SPC bypass switch 002 SCR bypass switch 004 Conductor terminal block X92DF AA00 9270 00A...

Page 115: ...ge 004 SCREENSHOT button Makes a screenshot of the current screen 005 RCS CTRL OFF button Gets control from the remote control system if button is ac tive 006 Status indication Shows the SCR status 00...

Page 116: ...CTRL OFF button Gets control from the remote control system if button is ac tive 005 Status indication Shows the SCR status 006 Status indication Shows the control location 007 Status indication Show...

Page 117: ...of the current screen 004 RCS CTRL OFF button Gets control from the remote control system if button is ac tive 005 Status indication Shows the SCR status 006 Status indication Shows the control locat...

Page 118: ...ion type Shows the name of the application 005 Software version Shows the software version number major middle minor for example 1 2 0 006 Application CRC Cyclic Redun dancy Check Shows the check sum...

Page 119: ...ex page 002 SCREENSHOT button Makes a screenshot of the current screen 003 RCS CTRL ON button Gets control from the remote control system if button is ac tive 004 Page button Opens the selected page X...

Page 120: ...on pump unit supplies the urea solution from the tank to the urea solution dosing unit and keeps the applicable pressure in the related pipes The urea solution dosing unit controls the supply of urea...

Page 121: ...of the valves if there is a complete stop of the current supply fail position V1 Reactor inlet valve FO fail open V2 Reactor outlet valve FO fail open V3 Reactor bypass valve FO fail open V4 Turbine...

Page 122: ...gas temperature after exhaust gas manifold Operation mode Tmin Tmax Preparation urea injection OFF 200 C 470 C Use of low sulphur fuel 0 5 S urea injection ON 310 C 470 C Use of high sulphur fuel 0 5...

Page 123: ...peration of the HP SCR system is not given for example if a bus connection is defective The valves have the conditions that follow V1 Closed V2 Closed V3 Open V4 Controlled by the ECS V7 Closed can be...

Page 124: ...ease the exhaust gas temperature V7 Closed can be opened to decrease the pressure in the reactor Then the preservation sequence starts as follows to prevent corrosion of the reactor and of the pipes r...

Page 125: ...ne After that procedure or directly the venting sealing unit supplies compressed air to keep a pressure in the reactor and in the pipes This makes a seal against the exhaust gas to prevent damage of t...

Page 126: ...egend 001 Mixing duct 005 Venting sealing unit 002 Reactor 006 Urea solution supply unit 003 Turbine of turbocharger 007 Soot blowing unit 004 Engine X92DF AA00 9270 00AAA 043A A Operation Manual HP S...

Page 127: ...4 Controlled by the ECS V7 Closed If necessary you can operate the engine in this mode for longer periods for example to be ready for a fast change to Tier III mode Fig 4 31 HP SCR system preparation...

Page 128: ...ge air flow and thus to increase the exhaust gas temperature V7 Closed can be opened to decrease the pressure in the reactor Fig 4 32 HP SCR system Tier III V1 V2 V3 V7 V4 003 001 007 006 005 004 002...

Page 129: ...le for this engine 4 15 3 HP SCR control system The HP SCR control system has the three control boxes that follow Control box E48 Control box E49 Control box E50 Each control box is connected through...

Page 130: ...dication SPC running 002 Option SPC SPC bypass switch 008 Indication urea injection 003 Indication minor failure 009 Indication major failure 004 Indication SCR pre heating on 010 Hour meter 005 Optio...

Page 131: ...and has switches below the LDU 20 Fig 4 35 Control box E49 00562 001 002 003 Legend 001 LDU 20 003 Option SPC SPC bypass switch 002 SCR bypass switch X92DF AA00 9270 00AAA 043A A Operation Manual HP...

Page 132: ...are as follows SCR ON This message shows that the HP SCR system is set to ON SCR minor failure This message shows a failure that does not have an effect on HP SCR system operation SCR major failure T...

Page 133: ...rol system if button is ac tive 007 FUEL button Selects the fuel in use 008 Status indication Shows the control location 009 Status indication Shows the SCR status 010 Button and indication Starts and...

Page 134: ...ve 006 Status indication Shows the SCR status failure and mode 007 Status indication Shows the SCR status 008 Value indication Shows the values 009 Status indication Shows the V4 setpoint if E48 has c...

Page 135: ...rol system if button is ac tive 006 Status indication Shows the SCR status failure and mode 007 Status indication Shows the control location 008 Status indication Shows the auxiliary blower status in...

Page 136: ...ailure and mode 007 Status indication Shows the control location 008 Button and indication Starts and stops the set automatic valve movement as test se quence serviceable only if the manual mode is pe...

Page 137: ...a screenshot of the current screen 003 RCS CTRL ON button Gets control from the remote control system if button is ac tive 004 Application type Shows the name of the application 005 Software version S...

Page 138: ...tion Effect 001 INDEX button Opens the index page 002 SCREENSHOT button Makes a screenshot of the current screen 003 RCS CTRL ON button Gets control from the remote control system if button is ac tive...

Page 139: ...X92DF AA00 9270 00AAA 043A A Operation Manual HP Selective catalytic reduction system Page left intentionally blank Winterthur Gas Diesel Ltd 139 Issue 002 2020 08...

Page 140: ...alve EWG opens a part of the exhaust gas bypasses the turbocharger 007 As a result the temperature of the exhaust gas increases which is supplied to the steam production 005 The supply of the turbocha...

Page 141: ...e values 006 SPC EXT CONTROL button Changes to the external control of the SPC 007 MinEWGPos mode button Sets the minimum permitted EWG position Other SPC modes than the initial mode MinEWGPos are onl...

Page 142: ...ether with the actual mini mum and maximum limitations Too wide EWG opening decreases the scavenge air pressure This will start the auxiliary blowers The limit of the EWG opening prevents the scavenge...

Page 143: ...16 4 LDU screen for steam boost mode Fig 4 45 LDU for the steam boost mode X92DF AA00 9270 00AAA 043C A Operation Manual Steam production control system Winterthur Gas Diesel Ltd 143 Issue 002 2020 0...

Page 144: ...4 16 7 Adjust the steam boost mode offset Before adjusting the steam boost mode offset make sure the following conditions are met The engine is running with partial load The steam boost mode is activa...

Page 145: ...ibration damper 182 5 3 4 Turning gear 184 5 3 5 Connecting rod and connecting rod bearing 186 5 3 6 Crosshead and guide shoe 188 5 3 7 Piston 190 5 4 Group 4 Supply unit drive and control components...

Page 146: ...enge air cooler 230 5 6 6 Water separator 232 5 7 Group 7 Cylinder lubrication 5 7 1 Cylinder lubrication 234 5 7 2 Integrated electrical balancer iELBA 236 5 8 Group 8 Pipes 5 8 1 Exhaust waste gate...

Page 147: ...X92DF Operation Manual Page left intentionally blank Winterthur Gas Diesel Ltd 147 Issue 002 2020 08...

Page 148: ...t The bottom part of the bedplate is the crankcase and collects lubricating oil This oil flows back to the oil supply system through oil drains 002 The length of the bedplate is related to the number...

Page 149: ...X92DF AA00 1115 00AAA 043A A Operation Manual Bedplate Page left intentionally blank Winterthur Gas Diesel Ltd 149 Issue 002 2020 08...

Page 150: ...nstall procedure The round nuts 002 keep the bearing cover 003 against the bearing girder For the main bearings adjacent to the thrust bearing the oil flows through the oil bore 013 to the running sur...

Page 151: ...X92DF AA00 1132 00AAA 043A A Operation Manual Main bearing Page left intentionally blank Winterthur Gas Diesel Ltd 151 Issue 002 2020 08...

Page 152: ...n the driving end adapt the propeller thrust of the astern direction The thrust pads adapt to the clockwise or counterclockwise rotation of the engine The arbor supports 004 prevent circular movement...

Page 153: ...pipe 010 2 part oil baffle 003 Nozzle 011 Flywheel 004 Arbor support 012 Bedplate 005 Bedplate 013 Thrust pad engine side 006 Thrust pad driving end 014 Thrust bearing flange 007 Bearing cover 015 Co...

Page 154: ...he fuel side FS the monoblock column has one door 002 per cylinder During normal operation the doors are closed and locked For maintenance or inspection work the doors can be opened Obey the safety ru...

Page 155: ...X92DF AA00 1406 00AAA 043A A Operation Manual Monoblock column Page left intentionally blank Winterthur Gas Diesel Ltd 155 Issue 002 2020 08...

Page 156: ...Tie rod generic 001 002 003 004 005 001 Legend 001 Protection cover 004 Tie rod 002 Cylinder block 005 Bedplate 003 Column If a tie rod breaks in the bottom area a special device makes sure that the...

Page 157: ...X92DF AA00 1903 00AAA 043A A Operation Manual Tie rod Page left intentionally blank Winterthur Gas Diesel Ltd 157 Issue 002 2020 08...

Page 158: ...llic seal 005 A non hardening compound is applied around the surface of the metallic seal to prevent leakage The antipolishing ring 001 is installed in the top part of the cylinder liner 004 The antip...

Page 159: ...002 Figure 5 7 and the exhaust valve cage 001 The cooling water flows back through the cooling water outlet 003 to the cooling water system of the plant To prevent unwanted tension in the top part of...

Page 160: ...out of the nozzle tip 003 and the lubricating point 004 as a spray Some of the cylinder oil flows into the grooves of the cylinder liner wall The non return valve 009 prevents the exhaust gas to flow...

Page 161: ...X92DF AA00 2138 00AAA 043A A Operation Manual Lubricating quill Page left intentionally blank Winterthur Gas Diesel Ltd 161 Issue 002 2020 08...

Page 162: ...alve stroke sensor installed in the cover 006 transmits signals to the ECS The ECS uses these signals to adjust the timing of the gas supply which is related to the engine load If the GAV has a leak g...

Page 163: ...X92DF AA00 2140 00AAA 043A A Operation Manual Gas admission valve Page left intentionally blank Winterthur Gas Diesel Ltd 163 Issue 002 2020 08...

Page 164: ...Neutral space 010 Gasket 4 part 005 Cylinder jacket 011 Tension spring 006 Support During operation the two scraper rings 001 Figure 5 10 remove dirty oil from the piston rod The dirty oil flows throu...

Page 165: ...X92DF AA00 2303 00AAA 043A A Operation Manual Piston rod gland Page left intentionally blank Winterthur Gas Diesel Ltd 165 Issue 002 2020 08...

Page 166: ...11 into the combustion chamber as a spray When the pressure from the ICU decreases a spring closes the needle again The nozzle usually has the Fuel Actuated Sacless Technology FAST for better combusti...

Page 167: ...X92DF AA00 2722 00AAA 043B A Operation Manual Conventional injection valve Page left intentionally blank Winterthur Gas Diesel Ltd 167 Issue 002 2020 08...

Page 168: ...closes at the correct crank angle of the related cylinder This makes the piston move down for engine start or makes the piston speed decrease for engine speed decrease As soon as combustion starts the...

Page 169: ...X92DF AA00 2728 00AAA 043A A Operation Manual Starting valve Page left intentionally blank Winterthur Gas Diesel Ltd 169 Issue 002 2020 08...

Page 170: ...relief the air from the cylinder for slow turning NOTE Do not open the relief valve to release pressure during engine operation Fig 5 13 Relief valve generic I I I I 001 Legend 001 Valve body X92DF AA...

Page 171: ...X92DF AA00 2740 00AAA 043A A Operation Manual Relief valve Page left intentionally blank Winterthur Gas Diesel Ltd 171 Issue 002 2020 08...

Page 172: ...ng piston 011 Air spring 005 Valve spindle 012 Leakage oil collection space 006 Valve cage 013 Hydraulic oil inlet 007 Valve seat 014 Damper The exhaust valve has the parts that follow Inside piston a...

Page 173: ...outer piston and inner piston 002 lubricates the air spring piston 004 Oil in the leakage oil collection space 012 drains to the leakage oil drain While the exhaust valve closes oil flows through the...

Page 174: ...he best ignition timing and a stable combustion Cooling water in the cylinder cover keeps cool the prechamber System oil is used to lubricate and to seal the pilot injection valve The fuel and system...

Page 175: ...X92DF AA00 2790 00AAA 043A A Operation Manual Pilot injection valve Page left intentionally blank Winterthur Gas Diesel Ltd 175 Issue 002 2020 08...

Page 176: ...ankshaft gear wheel 005 is part of the thrust bearing On the driving end of the crankshaft there is a flywheel 004 This flywheel decreases the pulsation from the cylinders The length of the crankshaft...

Page 177: ...X92DF AA00 3103 00AAA 043A A Operation Manual Crankshaft Page left intentionally blank Winterthur Gas Diesel Ltd 177 Issue 002 2020 08...

Page 178: ...ns in the shafting system and in other components of the engine If a torsional vibration damper is necessary for the engine one of the two damper types that follow can be used X92DF AA00 3130 00AAA 04...

Page 179: ...vibrations move the steel springs oil is pressurized on one side of the oil chambers and pushed through small clearances to the other side of the chambers This small oil flow creates the damping effec...

Page 180: ...t speeds This difference shears the silicone oil and thus decreases the vibration The damping work causes heat This heat increases the temperature of the outer side of the damper The heat dissipates t...

Page 181: ...X92DF AA00 3130 00AAA 043A A Operation Manual Torsional vibration damper Page left intentionally blank Winterthur Gas Diesel Ltd 181 Issue 002 2020 08...

Page 182: ...half 002 Figure 5 19 and a bottom cylinder half 006 Fig 5 19 Axial vibration damper generic Legend 001 Control plate 007 Bearing girder part of bedplate 002 Top cylinder half 008 Small sealing ring 00...

Page 183: ...ore in the top cylinder half 002 keeps air away from the annular spaces 003 The small oil leakage through the gap of the large sealing rings 005 drains into the crankcase 5 3 3 2 Axial vibration dampe...

Page 184: ...rns the pinion 002 and is attached on the driving end of the engine Related to the ratio of the gear wheels there is approximately one full turn of the crankshaft in ten minutes Fig 5 21 Turning gear...

Page 185: ...X92DF AA00 3206 00AAA 043A A Operation Manual Turning gear Page left intentionally blank Winterthur Gas Diesel Ltd 185 Issue 002 2020 08...

Page 186: ...oil flows through the guide shoe into the crosshead pin A hole in the crosshead pin lets lubricating oil flow into the bearing shells Fig 5 22 Connecting rod and connecting rod bearing generic Legend...

Page 187: ...X92DF AA00 3303 00AAA 043A A Operation Manual Connecting rod and connecting rod bearing Page left intentionally blank Winterthur Gas Diesel Ltd 187 Issue 002 2020 08...

Page 188: ...nto the crankcase The guide shoes 004 are attached to the crosshead pin 006 and move up and down on the guide ways of the column The guide rails 008 hold the guide shoes 004 and thus the crosshead in...

Page 189: ...X92DF AA00 3326 00AAA 043A A Operation Manual Crosshead and guide shoe Page left intentionally blank Winterthur Gas Diesel Ltd 189 Issue 002 2020 08...

Page 190: ...ied compression ratio System oil is used to keep cool the piston crown 001 This oil flows from the crosshead pin into the space 005 between the oil pipe 007 and the piston rod 004 The oil then flows t...

Page 191: ...X92DF AA00 3403 00AAA 043A A Operation Manual Piston Page left intentionally blank Winterthur Gas Diesel Ltd 191 Issue 002 2020 08...

Page 192: ...els 004 for the servo oil pumps The camshaft of the gear wheel 005 also operates the fuel pumps Oil flows through an oil inlet to lubricate the bearings of the gear wheels 004 Oil also flows through t...

Page 193: ...3 007 Legend 001 Intermediate wheel 005 Gear wheel servo oil pumps 002 Flywheel 006 Intermediate wheel 003 Crankshaft gear wheel 007 Crankshaft 004 Gear wheel servo oil pump X92DF AA00 4104 00AAA 043A...

Page 194: ...05 To test valve 014 Solenoid valve CV7014C 006 Spring 015 Double check valve 007 Valve 016 Solenoid valve CV7013C 008 Starting air inlet 017 Control air inlet 009 Balance bore 018 Lever With the leve...

Page 195: ...rom the inlet chamber 012 flows through the non return valve 010 to the starting air outlet 011 When the control valve 001 closes starting air flows through the balance bores 009 and fills the inlet c...

Page 196: ...by supply The non return valves 007 and 010 control the automatic change over of the compressed air supply Fig 5 27 Control air supply generic 003 004 005 006 007 008 009 010 011 012 001 002 Legend 00...

Page 197: ...X92DF AA00 4605 00AAA 043A A Operation Manual Control air supply Page left intentionally blank Winterthur Gas Diesel Ltd 197 Issue 002 2020 08...

Page 198: ...s can look different because the remote control manufacturer supplies the local control panel 001 For data about maneuvering instructions refer to section 8 8 Maneuver the ship general Fig 5 28 Local...

Page 199: ...ometer The ME tachometer 003 shows the engine speed in the ahead or astern directions Emergency stop button NOTE Not all local control panels have an emergency stop button installed When you operate t...

Page 200: ...acturer supplies the local control panel 001 For data about maneuvering instructions refer to section 8 8 Maneuver the ship general Fig 5 29 Local maneuvering stand generic SPEED FUEL AST AHD RPM EMER...

Page 201: ...l refer to section 6 10 2 WECS 9520 manual control panel NOTE You can only use the function buttons on the manual control panel that has control Rotary knob You use the rotary knob 005 to adjust the s...

Page 202: ...nents can look different because the remote control manufacturer supplies the terminal boxes For data about maneuvering instructions refer to section 8 8 Maneuver the ship general Fig 5 30 Local maneu...

Page 203: ...X92DF AA00 4618 00AAC 043A A Operation Manual Local maneuvering stand Option C Page left intentionally blank Winterthur Gas Diesel Ltd 203 Issue 002 2020 08...

Page 204: ...mity sensors measure the speed of the flywheel 003 Figure 5 31 When the flywheel turns the proximity sensors 002 sense the movement of the teeth The engine control system sends signals to the RCS to m...

Page 205: ...X92DF AA00 4628 00AAA 043A A Operation Manual Pick up for speed measurement Page left intentionally blank Winterthur Gas Diesel Ltd 205 Issue 002 2020 08...

Page 206: ...of the servo oil pumps A malfunction of a servo oil pump will show in the alarm and monitoring system If a servo oil pump cannot turn for safety the waisted shaft 003 will break This will prevent too...

Page 207: ...X92DF AA00 5551 00AAA 043A A Operation Manual Servo oil pump Page left intentionally blank Winterthur Gas Diesel Ltd 207 Issue 002 2020 08...

Page 208: ...gear wheels and intermediate wheels in the supply unit operate the fuel pumps and servo oil pumps refer to section 5 4 1 Supply unit drive Fig 5 33 Supply unit example Legend 001 Fuel pump 004 Bedpla...

Page 209: ...X92DF AA00 5552 00AAA 043A A Operation Manual Supply unit Page left intentionally blank Winterthur Gas Diesel Ltd 209 Issue 002 2020 08...

Page 210: ...and built in relief valve Relief valve 007 Duplex filter 002 Needle valve 006 Main leakage collector Leakage pipes Fig 5 34 Supply unit pilot fuel generic Legend 001 HP fuel pipe 005 Measuring unit 0...

Page 211: ...X92DF AA00 5555 00AAA 043A A Operation Manual Supply unit pilot fuel Page left intentionally blank Winterthur Gas Diesel Ltd 211 Issue 002 2020 08...

Page 212: ...ession spring 004 The pump plunger 003 then moves up The control grooves in the pump plunger 003 control the fuel quantity When the toothed rack 011 moves the teeth engage with the teeth on the regula...

Page 213: ...l lubricates the pump plunger 003 The leakage fuel and the engine lubricating oil from the regulating sleeve 010 flows through the drain bore This mixture then flows into an internal bore in the housi...

Page 214: ...servo oil supply and thus moves the piston in the sleeve 003 of the ICU This releases the fuel through the connection 001 to the injection valves When the solenoid valve closes the piston moves back a...

Page 215: ...X92DF AA00 5564 00AAA 043A A Operation Manual Injection control unit Page left intentionally blank Winterthur Gas Diesel Ltd 215 Issue 002 2020 08...

Page 216: ...ressure Prevent a longer engine operation time in this operation mode to prevent a possible damage to the PCV After this operation mode do a check of the PCV for a tight seal The seal can be damaged Y...

Page 217: ...001 Solenoid valve ZV7061S 005 Fuel return pipe 002 Pressure control valve 10 5562_E0_5 006 Rail unit 003 Relief valve 007 Fuel rail 004 Fuel return pipe 008 Drain pipe X92DF AA00 5562 00AAA 043A A O...

Page 218: ...the piston 003 moves back to the start position If the injection time is too long for example if an injection valve is stuck open the piston 003 closes the supply If an injection valve is damaged the...

Page 219: ...X92DF AA00 5565 00AAA 043A A Operation Manual Flow limiting valve Page left intentionally blank Winterthur Gas Diesel Ltd 219 Issue 002 2020 08...

Page 220: ...erates servo oil is released to the slide rod 001 Figure 5 40 This releases servo oil to the piston 003 Thus servo oil from the servo oil outlet 004 opens the exhaust valve Fig 5 40 Exhaust valve cont...

Page 221: ...X92DF AA00 5612 00AAA 043A A Operation Manual Exhaust valve control unit Page left intentionally blank Winterthur Gas Diesel Ltd 221 Issue 002 2020 08...

Page 222: ...data about the scavenge air system refer to section 4 8 Scavenge air system Fig 5 41 Scavenge air receiver example 001 002 003 004 005 Legend 001 Scavenge air from turbocharger 004 Auxiliary blower 0...

Page 223: ...example 001 002 005 004 003 Legend 001 Air space 004 Outlet to piston underside 002 Longitudinal wall 005 Flap 003 Receiver space X92DF AA00 6420 00AAA 043A A Operation Manual Scavenge air receiver Wi...

Page 224: ...f a turbocharger becomes defective you must stop the engine as quickly as possible to prevent damage If repair or replacement of a turbocharger is not immediately possible you can cut out the defectiv...

Page 225: ...X92DF AA00 6500 00AAA 043A A Operation Manual Turbocharger Page left intentionally blank Winterthur Gas Diesel Ltd 225 Issue 002 2020 08...

Page 226: ...t auxiliary blower starts immediately After approximately two to three seconds the other auxiliary blower starts If one of the auxiliary blowers becomes defective you also can start and operate the en...

Page 227: ...X92DF AA00 6545 00AAA 043A A Operation Manual Auxiliary blower Page left intentionally blank Winterthur Gas Diesel Ltd 227 Issue 002 2020 08...

Page 228: ...erload 009 Ampere meter auxiliary blower No 1 003 Hour counter auxiliary blower No 2 010 Hour counter auxiliary blower No 1 004 Ampere meter auxiliary blower No 2 011 Supply fault indicator 005 Main s...

Page 229: ...X92DF AA00 6547 00AAA 043A A Operation Manual Auxiliary blower switch box Page left intentionally blank Winterthur Gas Diesel Ltd 229 Issue 002 2020 08...

Page 230: ...SAC has a cover 004 Figure 5 46 For maintenance you can remove the cover Fig 5 46 Scavenge air cooler generic 001 002 003 004 Legend 001 Air flow 003 Cooling water inlet 002 Cooling water outlet 004...

Page 231: ...X92DF AA00 6606 00AAA 043A A Operation Manual Scavenge air cooler Page left intentionally blank Winterthur Gas Diesel Ltd 231 Issue 002 2020 08...

Page 232: ...f wet air Water also occurs during the wash procedure of the SAC The profiles 002 Figure 5 47 hold back the water in the air flow This water collects at the bottom of the frame 003 and then flows back...

Page 233: ...X92DF AA00 6708 00AAA 043A A Operation Manual Water separator Page left intentionally blank Winterthur Gas Diesel Ltd 233 Issue 002 2020 08...

Page 234: ...ates the cylinder lubricating pumps when the related control signals are released from the ECS When the ECS sends a signal to the related solenoid valve 003 Figure 5 48 of the cylinder lubricating pum...

Page 235: ...ives equal lubrication on to the cylinder liner wall The ECS parameters adjust the timing which gives the position and percentage of cylinder oil on the cylinder liner wall and between the piston ring...

Page 236: ...he forces F are always canceled The vertical elements Fvert are always added to a resulting vertical force This resulting force operates up and down with the same frequency as the counterweights 002 t...

Page 237: ...function Legend 001 Gear wheel 004 Housing 002 Counterweight 005 Column 003 Bearing X92DF AA00 7752 00AAA 043A A Operation Manual Integrated electrical balancer iELBA Winterthur Gas Diesel Ltd 237 Iss...

Page 238: ...eavy sea mode the iELBA does not operate The engine can also operate if one or the two balancers do not operate eg in manual mode or if a balancer is defective Then it is possible that there are more...

Page 239: ...2 shows the buttons and indications on the control cabinet of the iELBA Fig 5 52 iELBA control cabinet X92DF AA00 7752 00AAA 043A A Operation Manual Integrated electrical balancer iELBA Winterthur Gas...

Page 240: ...Shows the state of the running iELBA Lamp blinks iELBA is in swing state Lamp is steady iELBA is in run state H4 Synch OK indicator light Shows the synchronisation state of the iELBA Lamp is steady i...

Page 241: ...st to Control Speed Threshold not OK OFF 2 Start OK Setpoint Speed not OK in 60 s OFF 3 Start OK speed OK Phase Synchronisation not OK in 60 s OFF 4 Overspeed error OFF 5 Electric motor error OFF 6 Th...

Page 242: ...001 002 003 004 005 006 007 008 Legend 001 Air inlet 005 Exhaust gas manifold 002 Compressor 006 Turbine 003 Scavenge air receiver 007 Valve 004 Engine 008 Exhaust gas outlet If the turbochargers del...

Page 243: ...X92DF AA00 8135 00AAA 043A A Operation Manual Exhaust waste gate Page left intentionally blank Winterthur Gas Diesel Ltd 243 Issue 002 2020 08...

Page 244: ...teeth on the intermediate wheel The two sets of proximity sensors 003 Figure 5 54 operate independently to sense the teeth on the intermediate wheel 002 Fig 5 54 Crank angle sensor unit on intermediat...

Page 245: ...ollows First sensor pair to MCM 20 and CCM 20 1 Second sensor pair from CCM 20 2 to CCM 20 n TDC and BDC to all CCM 20 Fig 5 55 Crank angle sensor unit on flywheel example Legend 001 Cover 003 Flywhee...

Page 246: ...l to the alarm and monitoring system AMS On the display 001 Figure 5 56 you can see the data that follow aw water activity T temperature in C H2O water content in ppm Fig 5 56 Water in oil monitor gen...

Page 247: ...X92DF AA00 9313 00AAA 043A A Operation Manual Water in oil monitor Page left intentionally blank Winterthur Gas Diesel Ltd 247 Issue 002 2020 08...

Page 248: ...and explosions in the crankcase can be prevented The system includes the sensors 002 Figure 5 57 and the control unit 003 on the engine Fig 5 57 Oil mist detector example 004 003 001 002 Legend 001 D...

Page 249: ...adjustments can be programmed in the display unit 001 The menu driven software has three user levels User Read only of data Operator Password protected level for access to most adjustments and functio...

Page 250: ...X92DF AA00 9314 00AAA 043A A Operation Manual Oil mist detector Page left intentionally blank Winterthur Gas Diesel Ltd 250 Issue 002 2020 08...

Page 251: ...20 page DYNAMIC COMBUSTION CONTROL DCC 318 6 8 12 LDU 20 page EXHAUST VENTILATION 320 6 8 13 LDU 20 page EXHAUST VALVES 322 6 8 14 LDU 20 page FAILURE LIST 324 6 8 15 LDU 20 page FAILURE SIMULATION 3...

Page 252: ...MCP 384 6 9 2 MCP page SYSTEM INFO Option for WiCE 388 6 9 3 MCP page TREND Option for WiCE 390 6 9 4 MCP page FUEL MODE CONTROL Option for WiCE 392 6 9 5 MCP page GAS SYSTEM 394 6 9 6 MCP page MAIN...

Page 253: ...X92DF Operation Manual Page left intentionally blank Winterthur Gas Diesel Ltd 253 Issue 002 2020 08...

Page 254: ...data and system adjustments Input output module IOM 10 The input output module IOM 10 is installed at the rail unit in the terminal box E90 The IOM 10 has the engine control functions eg exhaust wast...

Page 255: ...in functions of the engine control system are as follows Starting valve control Servo oil pressure control Exhaust valve control Cylinder lubricating control Engine speed and crank angle sensor monito...

Page 256: ...n 13 1 Schematic diagrams general NOTE The communications between the systems can be different See the related documentation from the approved propulsion control system manufacturer 6 1 3 1 Propulsion...

Page 257: ...nd satisfactory engine operation The functions of the AMS are specified in the diesel engine control and optimizing specification DENIS The AMS sends signals to the engine safety system to slow down o...

Page 258: ...D E N I S U N I C E n g i n e S p e c i f i c a t i o n Fuel Gas Supply System Only for Dual Fuel Engines 2 x AMS CANBus Signals for Alarm Indication Indications Command Orders from RCS Ethernet to E...

Page 259: ...X92DF AA00 0000 00AAA 043K A Operation Manual Engine control system UNIC Page left intentionally blank Winterthur Gas Diesel Ltd 259 Issue 002 2020 08...

Page 260: ...nterface between the operator and engine control Software updates must be done only with the supervision of a WinGD service engineer and in accordance with regulations that WinGD has set 6 2 2 Compone...

Page 261: ...ne operation The fuel pressure is related to the engine load The control loop for the fuel rail pressure is given as follows The WECS 9520 generates a control signal which is related to the engine spe...

Page 262: ...setpoint 6 2 3 2 1 Pressure setpoint Each servo oil pump has an internal mechanical pressure controller with an electrical setpoint A pulse width modulation PWM signal gives this setpoint The setpoint...

Page 263: ...alve control Each injection valve related to the rail valve of a cylinder is controlled independently but with one common feedback signal for the injected fuel quantity Fuel injection starts at the sa...

Page 264: ...en controlled with timed injection 6 2 4 2 Exhaust valve control 6 2 4 2 1 Exhaust valve function The exhaust valve opens and closes once during each full turn of the crankshaft The valve stroke senso...

Page 265: ...transmits signals through CAN bus M 4 to FCM 20 4 of the WECS 9520 The other ACM 20 transmits signals through CAN bus M 5 to FCM 20 module 05 The two ACM 20 modules send the crank angle data to all FC...

Page 266: ...IS and the WECS 9520 are designed so that different propulsion control systems can be used All nodes are fully specified The terminal boxes are installed on the engine to which the cable ends from the...

Page 267: ...fuel quality setting FQS The operator selects the necessary command on the RCS eg AHEAD or ASTERN The RCS sends the commands to operate the engine If there is a malfunction the WECS 9520 sends an alar...

Page 268: ...of the fuel quantity at the local control panel ECR BACKUP mode from the BACKUP control panel in the control room 6 2 5 4 Safety system The safety system has the primary functions that follow Emergenc...

Page 269: ...X92DF AA00 0000 00AAB 043K A Operation Manual Engine control system WECS 9520 Page left intentionally blank Winterthur Gas Diesel Ltd 269 Issue 002 2020 08...

Page 270: ...ol and common engine functions for example starting air shut off valve Gateway unit GTU 1 and 2 The gateway units GTU 1 and 2 are installed on the rail unit in the terminal box E90 The GTU transmits d...

Page 271: ...l pressure control Exhaust valve control Cylinder lubricating control Engine speed and crank angle sensor monitoring Diesel fuel pressure control Diesel fuel injection control For a DF engine also gas...

Page 272: ...documentation from the approved propulsion control system manufacturer 6 3 3 1 Propulsion control system The propulsion control system PCS has the subsystems that follow Remote control system The rem...

Page 273: ...nd satisfactory engine operation The functions of the AMS are specified in the diesel engine control and optimizing specification DENIS The AMS sends signals to the engine safety system to slow down o...

Page 274: ...ssion and firing pressures in the engine eg injection time offsets and exhaust valve closing time for each cylinder This decreases the excessive wear of engine components This decreases the risk of an...

Page 275: ...injection and approximately 20 CA after TDC The pressure increase is the difference between the firing pressure and the compression pressure The ICC sets the pressure increase limit eg to 40 bar to p...

Page 276: ...he sensors and then transmits these signals to a controller The measured value is adjusted to the correct setpoint value and is related to the engine load This real time site correction and comparison...

Page 277: ...X92DF AA00 9308 00AAA 043A A Operation Manual Intelligent combustion control Page left intentionally blank Winterthur Gas Diesel Ltd 277 Issue 002 2020 08...

Page 278: ...gine room the engine control room or the bridge In some conditions the shut off valve is automatically closed 6 5 4 Gas valve unit GVU It is necessary for dual fuel engines to have accurate control of...

Page 279: ...itored To make sure that the airflow is sufficient the ventilation system of the GVU ED must operate independently from all other ventilation systems Gas detectors constantly monitor the double wall p...

Page 280: ...ve pressure in the GVU room The air in the GVU room and the air in the pipes are replaced 30 times per hour 4 The gas pipes between the GVU room and the engine have double walls 5 The maximum GVU room...

Page 281: ...rface HMI is installed on the GVU control panel Figure 6 8 With the GVU Control Panel you can monitor 1 The status of the GVU 2 The valve positions 3 The data that comes from the sensors 4 Possible al...

Page 282: ...This calibrated sequence replaces the volume in the fuel gas pipes at least three times This guarantees the removal of residual gas in the system Before maintenance on the engine or the GVU it is nec...

Page 283: ...6 9 Fuel gas removal from the fuel gas pipes Schematic Diagram X92DF AA00 8014 00AAA 042A A Operation Manual Gas valve unit and external gas supply system Winterthur Gas Diesel Ltd 283 Issue 002 2020...

Page 284: ...follow you find a short description of the automatic control functions for the iGPR control system 6 6 1 Transfer to gas operation If you have to change to gas operation you have to start the gas mod...

Page 285: ...ransfer preparation OK signal from iGPR to PCS and ECS NOTE The ECS uses this signal to start the GAV operation NOTE If one of the transfer preparation steps is not successful the iGPR control system...

Page 286: ...ion failure of the double wall pipes In these conditions the iGPR control system automatically starts the steps that follow Closes the master shut off valve of the FGSS Opens the vent valve of the FGS...

Page 287: ...he engine or on the iGPR or on the supply line you have to start the related maintenance mode refer to section 8 22 Prepare the engine for standstill maintenance Then the iGPR control system automatic...

Page 288: ...SELECT 00209 001 009 008 008 008 008 008 008 007 006 002 003 005 004 Legend 001 Power LED 006 CHECK button used to accept the action or enter data 002 Status LED 007 HOME button push to show the main...

Page 289: ...orange arrow 001 shows the active item A 3D rectangle 002 indicates a command button An orange frame 003 indicates the edit mode A black dotted frame 004 around an item shows the position of the curso...

Page 290: ...the requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Non...

Page 291: ...he rotary button to change to the selected page and to close the navigation menu 2 To edit a selected item on a LDU 20 page do the steps that follow NOTE Values and settings that the operator can chan...

Page 292: ...ry button to move the cursor to the related text field 5 2 Push the rotary button to enter the edit mode 5 3 Turn the rotary button to adjust the value turn clockwise to increase or counterclockwise t...

Page 293: ...ilters eg All Safety Event Info Error 8 2 Use the rotary button to move the cursor up or down in the list of available filters 8 3 Push the rotary button to select or deselect the filters 8 4 Push the...

Page 294: ...1 3 When the export is done disconnect the USB drive from the LDU 20 This prevents an unwanted LDU 20 shutdown because of a too high power consumption 12 To use the partial upgrade wizard from the SOF...

Page 295: ...X92DF AA00 0000 00AAA 131I A Operation Manual Operate the local display unit LDU 20 Page left intentionally blank Winterthur Gas Diesel Ltd 295 Issue 002 2020 08...

Page 296: ...ge FUEL SYSTEM 6 8 18 LDU 20 page GAS PRESSURE 6 8 39 LDU 20 page GAS LEAK TEST 6 8 19 LDU 20 page GAS ADMISSION VALVES 6 8 20 LDU 20 page GAV MANUAL VALVE TEST 6 8 21 LDU 20 page GVU VALVE TEST 6 8 2...

Page 297: ...ETERS 6 8 40 LDU 20 page LOG ENTRY DATA 6 8 41 LDU 20 page DATE 6 8 42 LDU 20 page ETHERNET 6 8 43 LDU 20 page iELBA Control optional X92DF AA00 9606 01AAA 043B A Operation Manual LDU 20 pages general...

Page 298: ...6 14 MAIN 002 001 004 003 006 005 008 007 010 016 007 015 009 013 014 011 012 018 017 019 024 025 022 023 020 021 X92DF AA00 9606 02AAA 043B A Operation Manual LDU 20 page MAIN Winterthur Gas Diesel...

Page 299: ...e Shows engine rpm in ahead AHD or astern AST direction 014 Indication of this LDU 20 Shows if Local has control or does not have control 015 Control transfer request indication Text flashes to show a...

Page 300: ...el Command button Changes to manual fuel command mode NOTE The fuel command mode is only applicable if the control location is Local or ECR manual NOTE If the control location is Local or ECR manual o...

Page 301: ...X92DF AA00 9606 02AAA 043B A Operation Manual LDU 20 page MAIN Page left intentionally blank Winterthur Gas Diesel Ltd 301 Issue 002 2020 08...

Page 302: ...NTROL LOCATIONS Fig 6 15 CONTROL LOCATIONS 00153 002 001 004 003 012 009 007 010 011 008 006 005 X92DF AA00 9606 03AAA 043B A Operation Manual LDU 20 page CONTROL LOCATIONS Winterthur Gas Diesel Ltd 3...

Page 303: ...S Communication lines between the ECS and the remote control system Shows OK or ERROR 008 Local button Requests or accepts a control transfer to or from the LDU 20 on the engine 009 ECR manual button...

Page 304: ...FUEL MODE CONTROL Fig 6 16 FUEL MODE CONTROL 002 001 004 003 007 011 008 012 006 005 009 010 X92DF AA00 9606 04AAA 043B A Operation Manual LDU 20 page FUEL MODE CONTROL Winterthur Gas Diesel Ltd 304...

Page 305: ...il Reset button Resets a failure that occurred during gas preparation NOTE Use this button only when you have done the related measures to repair the failure 008 Active mode Shows the active operation...

Page 306: ...U 20 page CA SENSOR STATUS Fig 6 17 CA SENSOR STATUS 002 001 004 003 008 006 005 007 X92DF AA00 9606 05AAA 043B A Operation Manual LDU 20 page CA SENSOR STATUS Winterthur Gas Diesel Ltd 306 Issue 002...

Page 307: ...control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 Status indication Shows the s...

Page 308: ...DER BALANCING DIESEL Fig 6 18 CYLINDER BALANCING DIESEL 002 001 004 003 009 008 006 005 007 X92DF AA00 9606 06AAA 043B A Operation Manual LDU 20 page CYLINDER BALANCING DIESEL Winterthur Gas Diesel Lt...

Page 309: ...T button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 Compr Balancing button Changes the compression balancing function Gre...

Page 310: ...CYLINDER BALANCING GAS Fig 6 19 CYLINDER BALANCING GAS 002 001 004 003 008 006 005 007 X92DF AA00 9606 07AAA 043B A Operation Manual LDU 20 page CYLINDER BALANCING GAS Winterthur Gas Diesel Ltd 310 I...

Page 311: ...ontrol transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 Compr Balancing button Changes...

Page 312: ...002 001 004 003 016 008 006 005 009 010 011 012 007 014 013 015 NOTE Some indications on this LDU 20 page are only applicable for a DF engine X92DF AA00 9606 08AAA 043B A Operation Manual LDU 20 page...

Page 313: ...mode of the cylinder lubrication with the green indicator 010 On Off button Sets to ON and OFF the auxiliary electric servo oil pump ser vo oil service pump NOTE If necessary start this pump only in...

Page 314: ...iCAT integrated Cylinder lubricant Auto Transfer 002 001 004 003 006 005 007 009 008 011 012 013 010 014 015 017 018 016 X92DF AA00 9606 09AAA 043B A Operation Manual LDU 20 page iCAT Winterthur Gas...

Page 315: ...diesel ratio in for the change over of the cylin der oil NOTE These values are only applicable if the diesel fuel is HFO 009 Fuel Mode Shows the active fuel mode and the used cylinder oil illumina te...

Page 316: ...ent Shows the sulfur content of the fuels related to the settings in the RCS NOTE Here you only can change these values if the RCS has failed 018 Force Transfer button Starts a transfer only applicabl...

Page 317: ...X92DF AA00 9606 09AAA 043B A Operation Manual LDU 20 page iCAT Page left intentionally blank Winterthur Gas Diesel Ltd 317 Issue 002 2020 08...

Page 318: ...COMBUSTION CONTROL DCC Fig 6 22 DYNAMIC COMBUSTION CONTROL DCC 002 001 004 003 006 005 007 X92DF AA00 9606 10AAA 043B A Operation Manual LDU 20 page DYNAMIC COMBUSTION CONTROL DCC Winterthur Gas Diese...

Page 319: ...in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 INDEX bu...

Page 320: ...e EXHAUST VENTILATION Fig 6 23 EXHAUST VENTILATION 002 001 004 003 010 006 005 007 008 009 X92DF AA00 9606 11AAA 043B A Operation Manual LDU 20 page EXHAUST VENTILATION Winterthur Gas Diesel Ltd 320 I...

Page 321: ...light shows that you should start the auxiliary electrical servo oil pump for sufficient servo oil pressure NOTE You only can start the auxiliary electrical servo oil pump if the conditions that foll...

Page 322: ...U 20 page EXHAUST VALVES Fig 6 24 EXHAUST VALVES 002 001 004 003 008 009 010 006 005 007 X92DF AA00 9606 12AAA 043B A Operation Manual LDU 20 page EXHAUST VALVES Winterthur Gas Diesel Ltd 322 Issue 00...

Page 323: ...on mode selection button Selects the operation mode of the related exhaust valve On manual operation mode valve opens if conditions are OK Off automatic operation mode valve closes 008 Closing Offset...

Page 324: ...14 LDU 20 page FAILURE LIST Fig 6 25 FAILURE LIST 002 001 004 003 008 006 005 007 009 X92DF AA00 9606 13AAA 043B A Operation Manual LDU 20 page FAILURE LIST Winterthur Gas Diesel Ltd 324 Issue 002 202...

Page 325: ...ol transfer to this LDU 20 005 LOG MSG button Opens the LOG MESSAGE page 006 INDEX button Opens the INDEX page 007 Filter button Manually select the applicable type filter for the related failure 008...

Page 326: ...20 page FAILURE SIMULATION Fig 6 26 FAILURE SIMULATION 002 001 004 003 007 008 006 005 X92DF AA00 9606 14AAA 043B A Operation Manual LDU 20 page FAILURE SIMULATION Winterthur Gas Diesel Ltd 326 Issue...

Page 327: ...ns the INDEX page 007 Failure Test Mode button Sets to ON and OFF the failure test mode NOTE You only can start the test mode if the conditions that follow are OK Engine at standstill green indicator...

Page 328: ...NG if applicable Fig 6 27 FUEL SHARING if applicable 002 001 004 003 011 006 005 007 008 009 010 X92DF AA00 9606 15AAA 043B A Operation Manual LDU 20 page FUEL SHARING if applicable Winterthur Gas Die...

Page 329: ...a failure that occurred during gas preparation NOTE Use this button only when you have done the related measures to repair the failure 008 Active mode Shows the active operation mode orange frame NOT...

Page 330: ...28 FUEL SYSTEM 002 001 004 003 006 005 NOTE Some indications on this LDU 20 page are only applicable for a DF engine X92DF AA00 9606 16AAA 043B A Operation Manual LDU 20 page FUEL SYSTEM Winterthur G...

Page 331: ...button Starts the engine in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 pa...

Page 332: ...8 18 LDU 20 page GAS PRESSURE Fig 6 29 GAS PRESSURE 002 001 004 003 008 006 005 007 X92DF AA00 9606 17AAA 043B A Operation Manual LDU 20 page GAS PRESSURE Winterthur Gas Diesel Ltd 332 Issue 002 2020...

Page 333: ...utton Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 Leak Test button Opens the GAS LEAK TEST...

Page 334: ...page GAS ADMISSION VALVES Fig 6 30 GAS ADMISSION VALVES 002 001 004 003 007 008 006 005 X92DF AA00 9606 18AAA 043B A Operation Manual LDU 20 page GAS ADMISSION VALVES Winterthur Gas Diesel Ltd 334 Iss...

Page 335: ...l transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 GAV Feedback status Shows the statu...

Page 336: ...GAV MANUAL VALVE TEST Fig 6 31 GAV MANUAL VALVE TEST 002 001 004 003 009 006 005 007 008 X92DF AA00 9606 19AAA 043B A Operation Manual LDU 20 page GAV MANUAL VALVE TEST Winterthur Gas Diesel Ltd 336...

Page 337: ...s admission valve GAV if manual test request is active and conditions are OK black fill valve closed no fill valve open NOTE Do a check of the sound of the movement of the gas admission valve 008 Manu...

Page 338: ...20 page GVU VALVE TEST Fig 6 32 GVU VALVE TEST 002 001 004 003 011 006 005 007 008 009 010 X92DF AA00 9606 20AAA 043B A Operation Manual LDU 20 page GVU VALVE TEST Winterthur Gas Diesel Ltd 338 Issue...

Page 339: ...es the vent valves in the GVU NOTE These valves are not shown on the display 009 GVU Shut off button In test mode opens and closes the shut off valves in the GVU NOTE These valves are not shown on the...

Page 340: ...8 22 LDU 20 page KNOCK CONTROL Fig 6 33 KNOCK CONTROL 002 001 004 003 006 005 007 X92DF AA00 9606 21AAA 043B A Operation Manual LDU 20 page KNOCK CONTROL Winterthur Gas Diesel Ltd 340 Issue 002 2020 0...

Page 341: ...ion 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 INDEX button Opens the...

Page 342: ...U 20 page LOG MESSAGES Fig 6 34 LOG MESSAGES 00164 002 001 004 003 008 007 009 010 006 005 X92DF AA00 9606 22AAA 043B A Operation Manual LDU 20 page LOG MESSAGES Winterthur Gas Diesel Ltd 342 Issue 00...

Page 343: ...nshot of the current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 Selected log message Shows the selected log message with a blue background 008 List of log...

Page 344: ...age MAIN FUEL INJECTION Fig 6 35 MAIN FUEL INJECTION 002 001 004 003 009 008 006 005 007 X92DF AA00 9606 23AAA 043B A Operation Manual LDU 20 page MAIN FUEL INJECTION Winterthur Gas Diesel Ltd 344 Iss...

Page 345: ...current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 Inj Begin Offset Manually adjust the injection begin offset 1 5 to 1 5 de grees 008 Inj Quant Corr Manu...

Page 346: ...6 8 25 LDU 20 page PAGE INDEX Fig 6 36 PAGE INDEX 002 001 004 003 005 006 X92DF AA00 9606 24AAA 043B A Operation Manual LDU 20 page PAGE INDEX Winterthur Gas Diesel Ltd 346 Issue 002 2020 08...

Page 347: ...button Starts the engine in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 pag...

Page 348: ...age PERFORMANCE DATA DIESEL Fig 6 37 PERFORMANCE DATA DIESEL 002 001 004 003 006 005 X92DF AA00 9606 25AAA 043B A Operation Manual LDU 20 page PERFORMANCE DATA DIESEL Winterthur Gas Diesel Ltd 348 Iss...

Page 349: ...button Starts the engine in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 pa...

Page 350: ...20 page PERFORMANCE DATA GAS Fig 6 38 PERFORMANCE DATA GAS 002 001 004 003 006 005 X92DF AA00 9606 26AAA 043B A Operation Manual LDU 20 page PERFORMANCE DATA GAS Winterthur Gas Diesel Ltd 350 Issue 0...

Page 351: ...button Starts the engine in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 pa...

Page 352: ...20 page PILOT FUEL INJECTION Fig 6 39 PILOT FUEL INJECTION 002 001 004 003 006 005 X92DF AA00 9606 27AAA 043B A Operation Manual LDU 20 page PILOT FUEL INJECTION Winterthur Gas Diesel Ltd 352 Issue 0...

Page 353: ...button Starts the engine in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 pa...

Page 354: ...page PILOT FUEL PRESSURE Fig 6 40 PILOT FUEL PRESSURE 002 001 004 003 008 006 005 007 X92DF AA00 9606 28AAA 043B A Operation Manual LDU 20 page PILOT FUEL PRESSURE Winterthur Gas Diesel Ltd 354 Issue...

Page 355: ...REENSHOT 006 INDEX button Opens the INDEX page 007 Auto Manual button Changes between automatic and manual control mode of the pilot fuel pump 008 Start Stop button In manual mode Starts and stops the...

Page 356: ...E AIR EWG optional Fig 6 41 SCAVENGE AIR EWG optional 002 001 004 003 006 005 007 008 009 010 X92DF AA00 9606 29AAA 043B A Operation Manual LDU 20 page SCAVENGE AIR EWG optional Winterthur Gas Diesel...

Page 357: ...gate valve manually adjust the opening of the valve from 0 closed to 100 open 008 Manual Open Close Cmd button Sends a signal for a manual command to open close the ex haust waste gate 009 Manual Cont...

Page 358: ...tom right hand corner of the display If no USB drive is connected or if there was an error during the save procedure to the USB drive the pop up message shows USB Mounting failed NOTE When the export...

Page 359: ...X92DF AA00 9606 30AAA 043B A Operation Manual LDU 20 page SCREENSHOT Page left intentionally blank Winterthur Gas Diesel Ltd 359 Issue 002 2020 08...

Page 360: ...8 32 LDU 20 page SOFTWARE INFO Fig 6 42 SOFTWARE INFO 002 001 004 003 006 005 007 X92DF AA00 9606 31AAA 043B A Operation Manual LDU 20 page SOFTWARE INFO Winterthur Gas Diesel Ltd 360 Issue 002 2020 0...

Page 361: ...ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 INDEX butto...

Page 362: ...6 8 33 LDU 20 page IMO CRC INFO Fig 6 43 IMO CRC INFO 002 001 004 003 006 005 007 X92DF AA00 9606 32AAA 043B A Operation Manual LDU 20 page IMO CRC INFO Winterthur Gas Diesel Ltd 362 Issue 002 2020 08...

Page 363: ...n 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 page SCREENSHOT 006 INDEX button Opens the IN...

Page 364: ...20 page SOFTWARE TOOLS Fig 6 44 SOFTWARE TOOLS 00167 007 008 006 009 002 001 005 003 004 X92DF AA00 9606 33AAA 043B A Operation Manual LDU 20 page SOFTWARE TOOLS Winterthur Gas Diesel Ltd 364 Issue 0...

Page 365: ...button Sends a signal for a control transfer to this LDU 20 005 INDEX button Opens the INDEX page 006 Mount Unmount button Handles the USB drive 007 Export button Exports all log messages to a file o...

Page 366: ...LDU 20 page SYSTEM STATUS Fig 6 45 SYSTEM STATUS 00166 002 001 004 003 006 007 008 005 X92DF AA00 9606 34AAA 043B A Operation Manual LDU 20 page SYSTEM STATUS Winterthur Gas Diesel Ltd 366 Issue 002 2...

Page 367: ...o synchronize the module with the rest of the system Pre operational synchronization Module is booting up and waits for synchronization Pre operational ready Module is booting up every thing set up su...

Page 368: ...SETTINGS Fig 6 46 SYSTEM SETTINGS 00169 007 008 010 009 016 015 012 011 014 013 002 001 003 004 006 005 X92DF AA00 9606 35AAA 043B A Operation Manual LDU 20 page SYSTEM SETTINGS Winterthur Gas Diesel...

Page 369: ...ff display Adjusts the time period to turn off the display after inactivity Set to between 1 min and 100 min Set to 0 to never turn off the display 011 Test screensaver button Starts and stops the scr...

Page 370: ...6 8 37 LDU 20 page TEMPERATURES Fig 6 47 TEMPERATURES 002 001 004 003 006 005 X92DF AA00 9606 36AAA 043B A Operation Manual LDU 20 page TEMPERATURES Winterthur Gas Diesel Ltd 370 Issue 002 2020 08...

Page 371: ...button Starts the engine in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 8 31 LDU 20 pa...

Page 372: ...PARAMETERS Fig 6 48 USER PARAMETERS 00159 002 001 004 003 006 005 010 009 008 007 011 013 012 015 014 X92DF AA00 9606 37AAA 043B A Operation Manual LDU 20 page USER PARAMETERS Winterthur Gas Diesel Lt...

Page 373: ...nk angle determination failure the related indicator is on 009 FQS Manually adjust the parameter for the fuel quality setting FQS from 5 to 5 A negative correction angle makes an earlier injection sta...

Page 374: ...ge GAS LEAK TEST Fig 6 49 GAS LEAK TEST 002 001 004 003 006 005 008 007 009 010 011 012 013 014 X92DF AA00 9606 38AAA 043B A Operation Manual LDU 20 page GAS LEAK TEST Winterthur Gas Diesel Ltd 374 Is...

Page 375: ...ill Turning gear is engaged NOTE Each test is OK if during the test period of 1000 seconds the pressure drop is less than 700 mbar 009 Fuel Side Test Req button Starts the automatic gas leak test of t...

Page 376: ...0 page LOG ENTRY DATA Fig 6 50 LOG ENTRY DATA 00165 002 001 005 007 009 010 008 006 004 003 X92DF AA00 9606 39AAA 043B A Operation Manual LDU 20 page LOG ENTRY DATA Winterthur Gas Diesel Ltd 376 Issue...

Page 377: ...Sends a signal for a control transfer to this LDU 20 005 INDEX button Opens the INDEX page 006 Acknowledge button Has no function 007 Module identifier Shows the source module that sent this log entr...

Page 378: ...6 8 41 LDU 20 page DATE Fig 6 51 DATE 002 001 004 003 008 009 010 012 011 006 005 007 X92DF AA00 9606 40AAA 043B A Operation Manual LDU 20 page DATE Winterthur Gas Diesel Ltd 378 Issue 002 2020 08...

Page 379: ...006 Cancel button Cancels the changes and goes back to the last saved settings 007 Time Synchronization Mode but ton Selects a Network Time Protocol NTP Not used 008 Local time Shows the time offset f...

Page 380: ...LDU 20 page ETHERNET Fig 6 52 ETHERNET 002 001 004 003 008 009 010 012 013 011 006 005 007 X92DF AA00 9606 41AAA 043B A Operation Manual LDU 20 page ETHERNET Winterthur Gas Diesel Ltd 380 Issue 002 2...

Page 381: ...ult is 010 001 001 001 008 Enabled button Manually enable or disable the ethernet ports ETH 1 plug X31 ETH 2 plug X32 The two ports must be enabled by default 009 Address field Manually configure the...

Page 382: ...age iELBA Control optional Fig 6 53 iELBA Control 002 001 004 003 005 006 007 008 009 X92DF AA00 9606 42AAA 043B A Operation Manual LDU 20 page iELBA Control optional Winterthur Gas Diesel Ltd 382 Iss...

Page 383: ...Auto Mode Changes between automatic and manual control mode of the iELBA 007 Free End ON OFF In manual mode starts and stops the iELBA on the related engine end 008 Operator Phase Setpoint In manual...

Page 384: ...the requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Non...

Page 385: ...he LED indication comes on NOTE You only can start one function at the same time also when you touch two or more function buttons 3 To change the control location do the steps that follow 3 1 Shortly...

Page 386: ...speed command setting turn the fuel dial knob clockwise 5 2 To decrease the speed command setting turn the fuel dial knob counterclockwise CLOSE UP None X92DF AA00 4618 00AAC 131A A Operation Manual O...

Page 387: ...X92DF AA00 4618 00AAC 131A A Operation Manual Operate the manual control panel MCP Page left intentionally blank Winterthur Gas Diesel Ltd 387 Issue 002 2020 08...

Page 388: ...Effect 001 Engine Shows data for the engine 002 Engine Software Shows data for the engine software 003 NOx Compliance Shows data for the IMO CRC compliance NOTE CRC Cyclic Redundancy Check X92DF AA00...

Page 389: ...X92DF AA00 4618 03AAA 043B A Operation Manual MCP page SYSTEM INFO Option for WiCE Page left intentionally blank Winterthur Gas Diesel Ltd 389 Issue 002 2020 08...

Page 390: ...6 42 TREND Item Function Effect 001 Selection field Highlights the selected parameters 002 Diagram field Shows the trend of the selected parameters X92DF AA00 4618 04AAA 043B A Operation Manual MCP pa...

Page 391: ...X92DF AA00 4618 04AAA 043B A Operation Manual MCP page TREND Option for WiCE Page left intentionally blank Winterthur Gas Diesel Ltd 391 Issue 002 2020 08...

Page 392: ...CONTROL Option for WiCE Fig 6 57 MCP page FUEL MODE CONTROL 001 003 002 006 005 007 004 X92DF AA00 4618 06AAA 043B A Operation Manual MCP page FUEL MODE CONTROL Option for WiCE Winterthur Gas Diesel L...

Page 393: ...GPR Flushing Fail iGPR Pressure OK iGPR Pressure Fail Trans fer Prep OK 005 GAS button Starts transfer to gas mode operation Green LED comes on if engine is in gas mode 006 Indication field Shows data...

Page 394: ...d measures to repair the failure 002 REQUEST VENTILATION button Sends a signal for ventilation request 003 CANCEL VENTILATION button WARNING Explosion hazard Cancel the exhaust ventilation only in an...

Page 395: ...X92DF AA00 4618 07AAA 043B A Operation Manual MCP page GAS SYSTEM Page left intentionally blank Winterthur Gas Diesel Ltd 395 Issue 002 2020 08...

Page 396: ...6 9 6 MCP page MAIN Fig 6 59 MCP page MAIN 001 002 003 005 004 X92DF AA00 4618 01AAA 043B A Operation Manual MCP page MAIN Winterthur Gas Diesel Ltd 396 Issue 002 2020 08...

Page 397: ...e Shows the fuel mode Shows Diesel Transfer Gas Gas DCC Active Fuel Shar ing Diesel Manual 003 Gas System Shows data for the gas system Shows Available Int Gas Trip Ext Gas Trip Transfer Prep Operatio...

Page 398: ...Shows the values of the displayed instruments NOTE The number of the displayed instruments is related to the engine NOTE If an instrument is unservicable the background of the related instrument chang...

Page 399: ...X92DF AA00 4618 02AAA 043B A Operation Manual MCP page INSTRUMENTS Page left intentionally blank Winterthur Gas Diesel Ltd 399 Issue 002 2020 08...

Page 400: ...vigation fields INFO TRENDING USER PARAMETERS 002 Sub navigation field USER PARAMETERS Opens the user parameter options VIT FQS deg Heavy Sea Mode Compressor Balancing Firing Balancing Firing Control...

Page 401: ...parameter Item Name Effect when touched 001 User parameter Makes the related user parameter ad justable X92DF AA00 4618 05AAA 043B A Operation Manual MCP page Adjust user parameters Winterthur Gas Die...

Page 402: ...n adjustable 002 User parameter regulators Two possible effects Increase or decrease user pa rameter value or Set user parameter value to on off 003 Enter field Makes the related adjustable user pa ra...

Page 403: ...X92DF AA00 4618 05AAA 043B A Operation Manual MCP page Adjust user parameters Page left intentionally blank Winterthur Gas Diesel Ltd 403 Issue 002 2020 08...

Page 404: ...ATION SYSTEM Fig 6 64 MCP page FUEL LUBRICATION SYSTEM 001 008 011 010 009 007 002 003 004 005 006 X92DF AA00 4618 08AAA 043B A Operation Manual MCP page FUEL LUBRICATION SYSTEM Winterthur Gas Diesel...

Page 405: ...r buttons Manually select the cylinder for manual lubrication Set 1 to n for the related cylinder Set 0 zero for all cylinders 008 Manual Lub Pulses buttons Manually set the number of injections for l...

Page 406: ...dication field 003 17 function buttons 004 with a LED indication refer to Table 6 49 Function buttons of the manual control panel MCP Navigation menu 005 for sub menus refer to Table 6 48 Navigation m...

Page 407: ...comple ted one full turn or when there was a malfunction AIR RUN Green Starts the air run mode of the engine green LED comes on Operates only when the engine is stopped AUX BLOWER PRESEL Green Sets t...

Page 408: ...TE CONTROL Green Changes from local manual control to bridge remote control during control transfer the two green LEDs flash then the green LED shows the current control position SAFETY SYSTEM RESET R...

Page 409: ...X92DF AA00 4618 00AAC 043B A Operation Manual Local control cabinet general Page left intentionally blank Winterthur Gas Diesel Ltd 409 Issue 002 2020 08...

Page 410: ...n Unscheduled Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS None X92DF AA...

Page 411: ...e is stopped eg during the engine start procedure 2 3 Do a check of the pressure switch PS5017C as follows NOTE If the pressure switch PS5017C on the 3 2 way valve 35 4325_E0_3 is defective you cannot...

Page 412: ...CONTROL MODE LOCAL MANUAL CONTROL SOUND OFF ALM ACKN WECS 9520 MANUAL CONTROL xx xx xx xx xx xx xx 001 003 002 Legend 001 LCD display 003 Function button 002 LED indication Important conditions are sh...

Page 413: ...e ECS automatically changes to fuel control mode if the speed control system becomes defec tive or if fuel injection quantity adjustment is neces sary REMOTE AUTOM CONTROL Green Changes from local man...

Page 414: ...s that flash to alarm indications that come on constantly Shows data about the version and does a check of the soft ware on the display when you push the button for approxi mately five seconds X92DF A...

Page 415: ...X92DF AA00 4618 00AAB 043B A Operation Manual WECS 9520 manual control panel Page left intentionally blank Winterthur Gas Diesel Ltd 415 Issue 002 2020 08...

Page 416: ...njection start and increase maximum pressure A positive correction angle will retard the injection start and decrease maximum pressure 002 VIT Variable injection timing ON OFF VIT is usually set to ON...

Page 417: ...valve opens while the crankshaft turns through the crank angle sector for the selected exhaust valve 006 Start Valves Checking Common start valves 1 2 enable disable To do checks of the control valves...

Page 418: ...d to do checks of the measured values 002 Exv closing offset Exhaust valve closing offset Cylinder pressure fine tuning in service Lets you ad just the compression pressure 003 Inj begin offset Inject...

Page 419: ...X92DF AA00 0000 00AAB 043L A Operation Manual User parameters and maintenance settings for WECS 9520 Page left intentionally blank Winterthur Gas Diesel Ltd 419 Issue 002 2020 08...

Page 420: ...ID code For a three digit number the display shows one or two dots for the first digit e g 2 5 for 125 5 8 for 258 6 10 4 1 FCM 20 The front view of a FCM 20 is shown in the figure that follows Fig 6...

Page 421: ...10 4 3 Failures of pulse lubrication For failures of the pulse lubrication there are more groups as follows Tab 6 54 Failures of pulse lubrication Type of failure Failure effect Procedure WECS 9520 lu...

Page 422: ...ed fail LED and two digit LED display Failure status Fail LED Two digit LED display Active Flashes Flashes Not active failure recovery Stays on Flashes No failure Off None 6 10 4 5 Function The failur...

Page 423: ...examples of failure IDs Tab 6 57 Examples of Failure IDs ID Display Failure text Failure group 1 1 ME crank angle 1 2 fail WECS 9520 criti cal 10 10 ME scavenge air pressure meas fail diff high WECS...

Page 424: ...a check of the related cable or plugs for damage Do a check of the related item for damage Use a multimeter to do a check of the power supply Use a multimeter to do a check of the sensor signal Use a...

Page 425: ...7 Installation 7 1 Installation 426 X92DF Operation Manual Winterthur Gas Diesel Ltd 425 Issue 002 2020 08...

Page 426: ...es Outline views Platform arrangement Engine seating Engine coupling Propulsion shaft earthing Engine stays Extinguishing system Auxiliary systems NOTE The latest version of the Marine Installation Ma...

Page 427: ...ange over to and from gas general 460 8 12 Change over the diesel fuel automatically 462 8 13 Change over from HFO to MDO manually 464 8 14 Change over from MDO to HFO manually 466 8 15 Change over to...

Page 428: ...il system Make sure that the quality of the system oil obeys the related specifications Make sure that main lubricating oil is available at the engine connection 25 main lubricating oil inlet Make sur...

Page 429: ...ystem Make sure that the quality of the gas obeys the related specifications in section 12 4 Gas fuels Make sure that gas is available at the engine connection 78 gas supply inlet Pilot fuel system Ma...

Page 430: ...ion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No C...

Page 431: ...operation 2 1 Set to ON the engine control system ECS and the remote control system RCS 2 2 Set to ON all circuit breakers in the power supply box E85 2 3 Set to ON the control box for the cylinder o...

Page 432: ...valves 003 in the cylinder liner supply pipes of the first half of cylinders for example cylinder 1 to 3 for a 5 or 6 cylinder engine NOTE This increases again the pressure and thus the flow rate to t...

Page 433: ...Close the shut off valves 001 in the cylinder liner supply pipes of the first half of cylinders for example cylinder 1 to 3 for a 5 or 6 cylinder engine NOTE This increases the pressure and thus the...

Page 434: ...he other cylinder liners for approximately ten minutes 3 3 3 Open the shut off valves 003 in the cylinder liner supply pipes of the first half of cylinders 3 3 4 Do Step 3 3 1 to Step 3 3 3 again for...

Page 435: ...ure in the oil supply pipes Pressure before the torsional vibration damper if applicable Pressure in the servo oil rail only pressure of servo oil service pump Pressure in the distributor pipe mini ra...

Page 436: ...the engine has been stopped for more than approximately five days start a manual pre lubrication procedure NOTE This makes sure that the cylinders get sufficient lubrication before start up 13 Turn t...

Page 437: ...X92DF AA00 0000 00AAA 121A A Operation Manual Prepare the engine before start Page left intentionally blank Winterthur Gas Diesel Ltd 437 Issue 002 2020 08...

Page 438: ...on You can find data about the barred speed ranges near the telegraph on the bridge near the local control panel and in the related documentation of vibration calculations 8 3 2 Start conditions limit...

Page 439: ...etween 10 as a minimum to approximately 15 related to the power of the auxiliary blowers 8 3 2 2 One or more cylinders are unservicable Obey the rules for operation if one or more cylinders are unserv...

Page 440: ...completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description P...

Page 441: ...roximately 15 for a WECS 9520 engine Approximately 30 for each other engine 5 Push the button START AHD or START AST to start the engine NOTE The ECS starts an automatic pre lubrication sequence with...

Page 442: ...erences in the values find the causes and repair the faults Do not open the covers of the rail unit during engine operation NOTE For data about regular maintenance work refer to the Maintenance Manual...

Page 443: ...X92DF AA00 0000 00AAA 130B A Operation Manual Do checks during operation general Page left intentionally blank Winterthur Gas Diesel Ltd 443 Issue 002 2020 08...

Page 444: ...s after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts De...

Page 445: ...ater tanks Temperatures of oil cooling water bearings and exhaust gas Pressures of oil cooling water and control air Pressure difference of the oil filter For a DF engine also pressure of gas 9 If the...

Page 446: ...replace the related pressure transmitter refer to the Maintenance Manual 14 4 Do daily a check of the cylinder liner wall temperatures on the related control panel 14 5 If there is a drift that is to...

Page 447: ...X92DF AA00 0000 00AAA 131B A Operation Manual Do checks during operation Page left intentionally blank Winterthur Gas Diesel Ltd 447 Issue 002 2020 08...

Page 448: ...50 1 Smoke test instrument N A 1 Ampere meter N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Equipment Hazard Leaks can cause faults in the...

Page 449: ...rate the pressure calibration hand pump to increase the pressure to more than the SHD pressure of the pressure switch NOTE For the related SHD pressure refer to section 11 2 List of usual values and s...

Page 450: ...again from the control panel in the ECR 7 Do a check of the auxiliary blowers from the control panel in the engine control room ECR 7 1 On the MCM 11 disconnect terminal X33 7 2 Start the auxiliary b...

Page 451: ...rol panel 8 6 Select the button START AHD 8 7 Make sure that the indication Turning Gear Engaged is shown on each control panel 8 8 Make sure that no start command is released 8 9 Do Step 8 1 to Step...

Page 452: ...ction Load changes must be done slowly to let the piston rings adapt the new conditions This also prevents increased wear and contamination of the piston rings and the cylinder liners The total time t...

Page 453: ...gine If there are unusual indications you must decrease the load power The load indication fuel injection quantity and the exhaust gas temperature upstream of the turbocharger show the engine load The...

Page 454: ...quirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare...

Page 455: ...er the ship general 3 To operate the engine in the opposite direction do the steps that follow 3 1 Use the rotary button to select the fuel command button 3 2 Turn the rotary button to set the fuel in...

Page 456: ...ample fuel pump plungers The safety functions decrease the risk of damage because of thermal loads You can do the change over procedure at a load of up to 100 CMCR The time period for automatic change...

Page 457: ...as no iCAT system integrated Cylinder lubricant Auto Transfer system WinGD recommends to monitor the change over of the cylinder oil Do a calculation of the cylinder lubricant quantity and make sure t...

Page 458: ...ensity of the cylinder lubricant can be found in the technical data sheet If not available an average value of 920 3 is suitable for this purpose Lead time until new lubricant is in use 1000 00595 X92...

Page 459: ...X92DF AA00 0000 00AAA 130D A Operation Manual Change over the diesel fuel general Page left intentionally blank Winterthur Gas Diesel Ltd 459 Issue 002 2020 08...

Page 460: ...ends to change back to diesel mode one time each week In diesel mode operate the engine for approximately 5 to 10 minutes at a high load of a minimum of 60 The injection of diesel fuel makes free the...

Page 461: ...change over to HFO if necessary Fuel sharing to liquid fuel The change over from fuel sharing to liquid fuel has the limits that follow The engine load is in the range of 50 to 100 of CMCR If the eng...

Page 462: ...lization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINAR...

Page 463: ...omatic change over procedure refer to the instructions of the manufacturer CLOSE UP None X92DF AA00 0000 00AAA 131E A Operation Manual Change over the diesel fuel automatically Winterthur Gas Diesel L...

Page 464: ...zation QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY...

Page 465: ...the procedure Try to decrease the temperature as linearly as possible 9 When the temperature of the fuel is near the applicable value you can start the cooler slowly to give a linear and smooth temper...

Page 466: ...zation QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY...

Page 467: ...ple the larger the mixing tank the less decrease in load is necessary 8 Set the viscosimeter to 13 cSt to increase the temperature of the fuel NOTE The viscosimeter controls the end heater which keeps...

Page 468: ...er job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Descrip...

Page 469: ...essure control system This system automatically starts the transfer preparation When this transfer procedure is finished the ECS slowly changes to gas mode 2 To change over from gas to liquid fuel do...

Page 470: ...burns NOTE If the crankshaft cannot turn 360 the ECS sends a signal for an exhaust ventilation request The ESS or ECS sends a cancelable shutdown signal The engine safety system ESS or the ECS sends...

Page 471: ...X92DF AA00 0000 00AAA 130G A Operation Manual Stop the engine general Page left intentionally blank Winterthur Gas Diesel Ltd 471 Issue 002 2020 08...

Page 472: ...completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description P...

Page 473: ...rol panel push the STOP button NOTE The ECS shuts down the engine in a controlled manner 4 For a DF engine start the exhaust ventilation sequence if there is a ventilation request CLOSE UP None X92DF...

Page 474: ...neral To stop the engine in an emergency do the procedure given in section 8 19 Emergency stop the engine X92DF AA00 0000 00AAA 140A A Operation Manual Emergency stop the engine general Winterthur Gas...

Page 475: ...X92DF AA00 0000 00AAA 140A A Operation Manual Emergency stop the engine general Page left intentionally blank Winterthur Gas Diesel Ltd 475 Issue 002 2020 08...

Page 476: ...letion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part N...

Page 477: ...r an emergency stop you must reset the EMERGENCY STOP button CAUTION Damage Hazard Do this step only as a last alternative selection if the EMERGENCY STOP button is not working Damage to the engine ca...

Page 478: ...after an engine stop of one week or less usually you keep the auxiliary systems in operation refer to section 8 21 Prepare the engine for a short service break For a long period after an engine stop...

Page 479: ...X92DF AA00 0000 00AAA 150A A Operation Manual Prepare the engine after stop general Page left intentionally blank Winterthur Gas Diesel Ltd 479 Issue 002 2020 08...

Page 480: ...ours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None S...

Page 481: ...rd Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine 5 Operate the turning gear for a short period at the intervals that follow Daily in damp clima...

Page 482: ...ours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None S...

Page 483: ...the lubricating oil supply to the engine as follows 6 1 Stop the oil supply systems from the plant 6 2 Close the shut off valves to the engine at engine connection 33 cylinder oil inlet 6 3 Set to OFF...

Page 484: ...ons are in degassing state 8 2 2 On the iGPR cabinet switch the button S8 to maintenance to activate the maintenance mode 8 2 3 On the LDU 20 iGPR page make sure that all conditions are satisfactory 8...

Page 485: ...ecessary apply anti corrosion oil to give protection 11 5 Close the covers 12 Do a check of the supply unit as follows 12 1 Make sure that there is no condensation or corrosion 12 2 If you find conden...

Page 486: ...X92DF AA00 0000 00AAA 151B A Operation Manual Prepare the engine for standstill maintenance Page left intentionally blank Winterthur Gas Diesel Ltd 486 Issue 002 2020 08...

Page 487: ...element of the duplex filter 494 9 4 Clean the turbocharger during operation 496 9 5 Clean the scavenge air cooler during operation 498 9 6 Do a test of the exhaust waste valve 502 9 7 Running in of n...

Page 488: ...one Supplies Description QTY Sample bottles A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard The system oil is hot Put on gloves and safety goggles to prevent...

Page 489: ...l the sample bottle NOTE The necessary quantity of oil is as follows 100 ml for regular oil analysis 5 l for FZG and particle count analysis 2 3 Close the sample valve 2 4 Close the sample bottle tigh...

Page 490: ...ialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Sample bottles A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTIO...

Page 491: ...wly open the oil sample valve 001 to flush out oil and possible dirt 2 4 Close the oil sample valve 001 2 5 Open the ball valve 002 to drain the remaining oil from the dirty oil pipe 003 2 6 Close the...

Page 492: ...ebsite https www wingd com 8 Send the oil samples to a laboratory for an oil analysis 8 1 Make sure that the sample bottles are tightly closed 8 2 Put the sample bottles in an applicable package 9 Com...

Page 493: ...X92DF AA00 0000 00AAA 371A A Operation Manual Do an analysis of the cylinder oil Page left intentionally blank Winterthur Gas Diesel Ltd 493 Issue 002 2020 08...

Page 494: ...er job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Pa...

Page 495: ...lean the filter chamber 6 Clean the filter element or take a new filter element 7 Install the new filter element into the filter chamber 8 Install the cover on the filter chamber 9 Make sure that the...

Page 496: ...termediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Cleaning fluid A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Damage Hazard For an...

Page 497: ...turbocharger refer to the documentation of the manufacturer 3 Clean the turbine of the turbocharger refer to the documentation of the manufacturer CLOSE UP None X92DF AA00 6500 00AAA 200A A Operation...

Page 498: ...s after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Cleaning fluid A R...

Page 499: ...Aux Blower 13 LS 4075A LS 4071A PI 1361L TI 1371L TI 1381L PT 1361A TE 1371A TE 1381A Washing Plant SAC PLANT ENGINE PLANT ENGINE 003 00520 004 005 006 007 008 009 001 002 X92DF AA00 6600 00AAA 200A...

Page 500: ...re that the shut off valve in the supply pipe stays closed 3 3 Close the shut off valve 009 in the water supply pipe 3 4 Close the vent valve 002 and the valve 007 of the tank 006 4 Open the shut off...

Page 501: ...X92DF AA00 6600 00AAA 200A A Operation Manual Clean the scavenge air cooler during operation Page left intentionally blank Winterthur Gas Diesel Ltd 501 Issue 002 2020 08...

Page 502: ...crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS This procedur...

Page 503: ...e sure that the exhaust waste gate is open 3 Close the exhaust waste valve 4 If the check is incorrect find the cause and repair the fault CLOSE UP None X92DF AA00 8135 00AAA 320A A Operation Manual D...

Page 504: ...her feed rate refer to Figure 9 3 WinGD recommends an inspection of the cylinder liners and of the piston rings after 24 operation hours and after 72 operation hours 001 Figure 9 3 For this running in...

Page 505: ...X92DF AA00 0000 00AAA 950B A Operation Manual Running in of new components general Page left intentionally blank Winterthur Gas Diesel Ltd 505 Issue 002 2020 08...

Page 506: ...Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIO...

Page 507: ...8 Set the feed rate to 1 0 g kWh 9 Operate the engine for 24 hours 10 Inspect the components for damage 11 If damage occurs find the cause and repair the fault 12 If it is necessary to replace parts...

Page 508: ...X92DF AA00 0000 00AAA 950A A Operation Manual Running in of new components Page left intentionally blank Winterthur Gas Diesel Ltd 508 Issue 002 2020 08...

Page 509: ...leakage 542 10 7 Temporary cut out a defective injection valve 546 10 8 Temporary cut out a defective exhaust valve drive 548 10 9 Temporary isolate a cylinder with cooling water leakage 550 10 10 Dis...

Page 510: ...repair malfunctions on the engine The tables give the data that follow Title of the table The title of the table gives the description of the malfunction Indication This list specifies the number of...

Page 511: ...X92DF AA00 0000 00AAA 410B A Operation Manual Troubleshooting general data Page left intentionally blank Winterthur Gas Diesel Ltd 511 Issue 002 2020 08...

Page 512: ...e servo oil supply unit is too high Table 10 13 Servo oil flow at a servo oil pump inlet is too low Table 10 14 Bearing oil temperature at a bearing outlet is too high Table 10 15 Oil mist concentrati...

Page 513: ...does not operate unwanted noise Table 10 42 Smoke is too dark Malfunctions of the air systems XX40NN to XX44NN Table 10 43 Scavenge air temperature in the receiver is too high Table 10 44 Scavenge ai...

Page 514: ...wer supply to the power supply box E85 has a failure Table 10 61 Unwanted engine speed decrease Table 10 62 Unwanted engine stop X92DF AA00 0000 00AAA 410C A Operation Manual Malfunctions of systems a...

Page 515: ...erature downstream of a cylinder is too high Indication Possible cause Procedure TE1121 nnA This is a result of the malfunction in Table 10 1 Supply pressure of the cylinder cooling water is too low D...

Page 516: ...too high Indication Possible cause Procedure TE1381 nnA This is a result of the malfunction in Table 10 4 Supply pressure of the cooling water to the SAC is too low Do the repair shown there This is a...

Page 517: ...ion Possible cause Procedure TE2011A TE2012A if appli cable The oil supply system is defective Find the cause and repair the fault Tab 10 10 Lubricating oil supply pressure upstream of the crossheads...

Page 518: ...nA TE2201 nnA TE2301 nnA This is a result of the malfunction in Table 10 7 Lubricating oil sup ply pressure at the engine inlet is too low Do the repair shown there A bearing is defective Find the cau...

Page 519: ...oil temperature at a turbocharger outlet is too high Indication Possible cause Procedure TE2601 nnA This is a result of the malfunction in Table 10 9 Lubricating oil sup ply temperature at the engine...

Page 520: ...nt is clogged Change over to the other filter chamber Replace or clean the clogged filter ele ment The cylinder oil tank is empty Fill the cylinder oil tank Tab 10 24 Cylinder oil flow is too low Indi...

Page 521: ...high for X35 B or X40 B engine Indication Possible cause Procedure TE3431 nnA Flow control valve of a fuel pump is defective Clean or replace the defective flow control valve One of the two fuel pump...

Page 522: ...lve 10 8752_E0_3 4 in the HP fuel pipe of the related fuel pump Flow control valve of a fuel pump is defective Clean or replace the defective flow control valve Tab 10 33 Fuel pressure in the fuel rai...

Page 523: ...ication Possible cause Procedure PS3464A The pilot fuel filter is clogged Replace the filter element Tab 10 36 Gas supply pressure is too low Indication Possible cause Procedure PT3901C The gas supply...

Page 524: ...xample cracks in a cylinder liner Find the cause and repair the fault There is a fire in the piston under side Do the procedure in section 2 4 Fire fight ing in the scavenge air space Tab 10 38 Exhaus...

Page 525: ...ng air pressure is too low Find the cause and repair the fault The opening oil pressure is too low Find the cause and repair the fault An exhaust valve is defective pis ton cannot move or a piston is...

Page 526: ...malfunction in Table 10 5 Supply tempera ture of the cooling water to the SAC is too low Do the repair shown there Tab 10 45 Scavenge air pressure is too high Indication Possible cause Procedure PT40...

Page 527: ...fire in the piston under side Refer to section 2 4 Fire fighting in the scavenge air space A piston ring is defective As a temporary procedure decrease the load and cut out the injection of the relat...

Page 528: ...air supply system is defective Find the cause and repair the fault There is an incorrect setting of the control air supply Set the control air supply to the correct val ue Tab 10 55 Control air supply...

Page 529: ...ective injection nozzle This is a result of the malfunction in Table 10 1 Supply pressure of the cylinder cooling water is too low or in Table 10 3 Cylinder cooling water temperature down stream of a...

Page 530: ...ection quantity from the speed control system is de creased A procedure is not necessary because the control system prevents too much load in heavy sea The fuel injection system is defec tive Find the...

Page 531: ...X92DF AA00 0000 00AAA 410C A Operation Manual Malfunctions of systems and components Page left intentionally blank Winterthur Gas Diesel Ltd 531 Issue 002 2020 08...

Page 532: ...the requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare...

Page 533: ...003 Screw plug 002 Flange 4 Do Step 3 again for the other inspection points NOTE Step 5 to Step 8 are only applicable for an X82 engine 5 Do a check of the level switch LS2076A if applicable also LS2...

Page 534: ...mum of two turns 8 2 Do a check for oil flow 8 3 If there is an oil flow shut off the related connecting pipe an repair it at the next occasion refer to the Maintenance Manual 8 4 Tighten the screw pl...

Page 535: ...X92DF AA00 0000 00AAA 311A A Operation Manual Examine the supply unit for servo oil leakage Page left intentionally blank Winterthur Gas Diesel Ltd 535 Issue 002 2020 08...

Page 536: ...ngine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Always put on...

Page 537: ...005 at the highest inspection point 004 for leaks 4 1 Carefully loosen the screw plug a maximum of two turns 4 2 Do a check for fuel flow 4 3 If there is fuel flow repair the cause of the fuel flow a...

Page 538: ...fuel pump refer to the Maintenance Manual 5556 1 NOTE If the defective HP fuel pipe cannot be replaced immediately or the engine must continue to operate the related fuel pump must be cut out CLOSE U...

Page 539: ...X92DF AA00 0000 00AAA 311B A Operation Manual Examine the supply unit for fuel leakage Page left intentionally blank Winterthur Gas Diesel Ltd 539 Issue 002 2020 08...

Page 540: ...alization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard...

Page 541: ...2 Carefully look into the rail unit to find the cause of the leakage NOTE Possible causes can be a defective pipe to the exhaust valve a defective flange or an other defective item 3 Repair the defec...

Page 542: ...ngine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Always put on...

Page 543: ...There is a fuel flow in the leakage pipe that has a higher temperature than the other leakage pipes NOTE As an alternative you can carefully open and close the screw in union 003 of each ICU a maximum...

Page 544: ...e fuel leakage pipe 003 Figure 10 4 carefully loosen the screw in union 005 a maximum of two turns 4 2 Do a check for fuel flow 4 3 If there is no fuel flow tighten the screw in union 005 and continue...

Page 545: ...crew in union 008 Figure 10 3 of the fuel leakage pipe 007 to collect the usual fuel flow 5 2 Carefully loosen the screw in union 008 a maximum of two turns 5 3 Do a check of the fuel flow 5 4 If fuel...

Page 546: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Pa...

Page 547: ...tion from the injection control unit ICU 4 If it is necessary to operate the engine with the injection cut out for an extended period do as follows 4 1 Record the settings of the cylinder oil feed rat...

Page 548: ...nel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS...

Page 549: ...the related exhaust valve control unit VCU 3 Repair the fault as soon as possible refer to the Maintenance Manual CLOSE UP The engine can be started and operated at decreased load refer to section 8...

Page 550: ...tion Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY Pressure element 94259 A R Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY P...

Page 551: ...the pressure element 003 Fig 10 5 Exhaust valve with pressure element 001 002 003 004 Legend 001 Top housing 003 Pressure element 002 Damper 004 Shim 4 Cut out the defective cylinder from the injecti...

Page 552: ...ted and operated at decreased load refer to section 8 3 Start the engine general X92DF AA00 0000 00AAA 662B A Operation Manual Temporary isolate a cylinder with cooling water leakage Winterthur Gas Di...

Page 553: ...X92DF AA00 0000 00AAA 662B A Operation Manual Temporary isolate a cylinder with cooling water leakage Page left intentionally blank Winterthur Gas Diesel Ltd 553 Issue 002 2020 08...

Page 554: ...asic 1 Support equipment Description Part No CSN QTY Flange 94569 pc 1 Flange 94569A pc 1 Roller lifting tool 94430 pc 1 Claw 94430A pc 1 Screw 94430B pc 1 Supplies Description QTY None Spare Parts De...

Page 555: ...o the Maintenance Manual 3 Install the flange 005 to the fuel pump 002 4 Install the flange 006 to the HP fuel pipe 007 5 Remove the related cover from the supply unit 003 6 Remove the related plug 00...

Page 556: ...l 002 with the mark 001 points down 9 Turn the roller lifting tool 002 180 until the mark 001 points up NOTE This gives a clearance X and thus the cam 006 cannot move the roller 007 10 Install the cla...

Page 557: ...X92DF AA00 5556 00AAA 510B A Operation Manual Disconnect the fuel pump Page left intentionally blank Winterthur Gas Diesel Ltd 557 Issue 002 2020 08...

Page 558: ...asic 1 Support equipment Description Part No CSN QTY Flange 94569 pc 1 Flange 94569A pc 1 Roller lifting tool 94430 pc 1 Claw 94430A pc 1 Screw 94430B pc 1 Supplies Description QTY None Spare Parts De...

Page 559: ...06 from the HP fuel pipe 007 4 Install the related HP fuel pipe 001 to the fuel pump 002 For the applicable procedure refer to the Maintenance Manual 5 Remove the related cover from the supply unit 00...

Page 560: ...8 Turn the roller lifting tool 002 180 until the mark 001 points down 9 Remove the roller lifting tool 002 10 Install the plug 004 Figure 10 8 to the supply unit 003 11 Install the cover to the supply...

Page 561: ...X92DF AA00 5556 00AAA 730B A Operation Manual Connect the fuel pump Page left intentionally blank Winterthur Gas Diesel Ltd 561 Issue 002 2020 08...

Page 562: ...0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY Cover 94653A A R Cover 94653B A R Cover 94653C A R Cover 94653D A R Sup...

Page 563: ...er and the exhaust gas manifold 2 3 Install the covers 94653A and 94653B 001 and 002 2 4 Remove the expansion joint 005 between the defective turbocharger air outlet and the diffusor 2 5 Install the c...

Page 564: ...001 if the turbochargers are connected to a suction duct 3 4 Open the covers 003 and 004 on the scavenge air receiver 3 5 Set to ON the auxiliary blowers Fig 10 11 All turbochargers are defective exam...

Page 565: ...X92DF AA00 6500 00AAA 662A A Operation Manual Temporary isolate a defective turbocharger Page left intentionally blank Winterthur Gas Diesel Ltd 565 Issue 002 2020 08...

Page 566: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Pa...

Page 567: ...cator 002 Cardan rod 007 Ball valve 50 8135_E0_3 air spring air 003 Positioner and feedback with EMC module 008 Flange 004 Actuator 009 Valve 005 Plate X92DF AA00 8135 00AAA 662A A Operation Manual Te...

Page 568: ...f the two middle screws 3 Turn the flange 008 to close the exhaust waste gate 4 Tighten the screws to attach the flange 008 5 Start the engine CLOSE UP None X92DF AA00 8135 00AAA 662A A Operation Manu...

Page 569: ...X92DF AA00 8135 00AAA 662A A Operation Manual Temporary isolate the exhaust waste gate Page left intentionally blank Winterthur Gas Diesel Ltd 569 Issue 002 2020 08...

Page 570: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Pa...

Page 571: ...e shaft clutch are unserviceable make sure that you operate the auxiliary systems 4 If installed change the pitch of the controllable propeller CPP to the lowest resistance WARNING Injury Hazard Do no...

Page 572: ...X92DF AA00 0000 00AAA 662C A Operation Manual Isolate a defective engine at twin engine installation Page left intentionally blank Winterthur Gas Diesel Ltd 572 Issue 002 2020 08...

Page 573: ...ata 574 11 2 List of usual values and safeguard settings general 576 11 3 List of usual values and safeguard settings 580 11 4 Section views Generic engine 592 X92DF Operation Manual Winterthur Gas Di...

Page 574: ...gine inlet is 25 C BSFC This list gives the Brake Specific Fuel Consumption BSFC for fuel of lower heating value 42 7 MJ kg 10 200 kcal kg and standard tuning BSGC This list gives the Brake Specific G...

Page 575: ...430 178 9 136 2 0 8 9 2 14 4 R3 70 4655 180 9 143 2 0 7 8 1 17 3 R4 70 3875 178 9 138 2 0 9 8 1 14 4 Fig 11 1 Operating range R1 R2 R4 R3 S P Legend R1 Highest power at highest speed R4 Lowest power a...

Page 576: ...he range for usual operation Signal number This list gives the signal number as follows refer also to Para 11 2 2 First two letters XX Function code Four digit number of the signal for example 10NN Fi...

Page 577: ...ximum concentration For the level switches LS and flow switches FS min minimum or no flow max maximum flow Delay This list gives the delay of the action in seconds after the trigger value occurs X92DF...

Page 578: ...de Code First position Second position A Analysis n a C Control Control E n a Element F Flow n a G Gauge n a H Hand n a I n a Indication J Power n a L Level n a P Pressure n a S Speed Switch T Tempera...

Page 579: ...o 49 Signals from the engine Air systems 50 to 59 Signals from the engine Miscellaneous 60 to 69 Signals from the engine Spare 70 to 79 Signals to the engine Miscellaneous 80 to 89 Signals to the engi...

Page 580: ...8 Oil systems XX2NNN part 2 Table 11 9 Oil systems XX2NNN part 3 turbocharger bearing oil Table 11 10 Oil systems XX2NNN part 4 Table 11 11 Gas system XX33NN and XX39NN Table 11 12 Fuel system XX34NN...

Page 581: ...utlet connection 03 80 2 1 80 4 2 TE1121 nnA ALM H 85 0 SLD H 87 60 Scavenge air cooler SAC SAC LT cooling water pressure bar en gine inlet connection 07 2 5 to 4 PT1361A ALM L 2 0 0 SAC LT cooling wa...

Page 582: ...ernal oil SAE 40 temper ature C inlet fuel pump 50 2 1 50 4 2 TE2012A ALM H 55 0 SLD H 60 0 If applicable external crosshead bearing oil pressure bar engine inlet connection 30 10 2 to 13 PT2021A ALM...

Page 583: ...AS2401 02A ALM H max 0 AS2401S SLD H max 60 Oil mist concentration gearcase AE2415A ALM H max 0 Oil mist concentration fuel supply unit AE2421 22A ALM H max 0 Piston cooling oil Piston cooling oil te...

Page 584: ...ger 45 to 80 TE2621A ALM H 85 0 SLD H 90 60 TC bearing oil temperature C outlet each turbocharger 45 to 120 TE2601 nnA ALM H 130 0 SLD H 140 60 Bearing oil turbocharger MHI MET with internal oil TC be...

Page 585: ...M L 1 7 60 Damper oil pressure bar axial vibration damper space fore side 1 8 to 5 0 PT2722A ALM L 1 7 60 Cylinder oil Cylinder oil pressure bar cylinder oil rail 2 0 4 PT3124A ALM L 0 1 30 Cylinder o...

Page 586: ...ter 20 to 50 4 TT3901C TS3901S GTrip H 60 3 TS3902S GTrip L 0 4 3 Gas underpressure mbar iGPR enclo sure 10 to 20 PT3903C Inert gas pressure bar engine inlet con nection 83 5 to 15 PT3905C Gas pressur...

Page 587: ...411A ALM H 50 to 160 0 ALM L 20 to 130 0 Fuel leakage flow outlet fuel supply unit LS3426A ALM H max 10 Fuel leakage flow outlet fuel rail items LS3446 47A ALM H max 10 Rail unit Leakage flow outlet r...

Page 588: ...gas temperature C outlet each cylinder TE3701 nnA ALM H 515 0 ALM D 50 0 SLD H 530 60 SLD D 70 60 Exhaust gas temperature C inlet each turbocharger TE3721 nnA ALM H 515 0 SLD H 530 60 Exhaust gas tem...

Page 589: ...ng air supply Starting air supply pressure bar engine inlet connection 40 20 to 30 Control air supply unit Control air supply pressure bar engine inlet connection 45 7 to 9 Control air pressure bar ou...

Page 590: ...ALM H 260 0 SLD H 290 60 Powertrain Crankshaft speed of CMCR crank shaft ST5111 12S SHD H 110 0 Tachometer turbocharger if signal is available as alarm Impeller shaft overspeed rpm each ABB turbocharg...

Page 591: ...o Table 11 16 Failure messages Tab 11 16 Failure messages Medium location Signal number Delay Failure of oil mist detector XS2411A 0 Failure of fuel heating XS3463A 0 Failure of fuel pump actuator XS5...

Page 592: ...11 4 Section views Generic engine X92DF AA00 0000 00AAA 034A A Operation Manual Section views Generic engine Winterthur Gas Diesel Ltd 592 Issue 002 2020 08...

Page 593: ...11 4 1 Engine cross section Fig 11 3 Cross section X92DF AA00 0000 00AAA 034A A Operation Manual Section views Generic engine Winterthur Gas Diesel Ltd 593 Issue 002 2020 08...

Page 594: ...on NOTE The numbers shown in the figures relate to the four numbers shown in the data module code eg WINGDX92 AA00 HA1 51 1132 00AAA 520A A X92DF AA00 0000 00AAA 034A A Operation Manual Section views...

Page 595: ...12 Operating media 12 1 General for operating media 596 12 2 Compressed air 598 12 3 Scavenge air 600 12 4 Gas fuels 602 X92DF Operation Manual Winterthur Gas Diesel Ltd 595 Issue 002 2020 08...

Page 596: ...ating media that follow Fuel Lubricants Water NOTE On the WinGD website go to your engine type then to OPERATION MAINTENANCE then to FUEL LUBRICANTS WATER On the pages that follow the specifications a...

Page 597: ...X92DF AA00 0000 00AAA 018M A Operation Manual General for operating media Page left intentionally blank Winterthur Gas Diesel Ltd 597 Issue 002 2020 08...

Page 598: ...ss 2 4 2 ISO 8573 1 12 2 2 Recommended procedures for compressed air WinGD recommends to regularly do the procedures that follow to prevent explosions Regularly drain the starting air bottles to remov...

Page 599: ...X92DF AA00 0000 00AAA 030E A Operation Manual Compressed air Page left intentionally blank Winterthur Gas Diesel Ltd 599 Issue 002 2020 08...

Page 600: ...piston rings turbocharger compressor etc to a minimum Silencers are installed to the suction part The silencers have filter mats in them which help to keep the air clean The filter mats must be servi...

Page 601: ...X92DF AA00 0000 00AAA 030D A Operation Manual Scavenge air Page left intentionally blank Winterthur Gas Diesel Ltd 601 Issue 002 2020 08...

Page 602: ...Hydrogen H2 3 volume Ammonia 25 mg Nm3 Chlorine and fluorine 50 mg Nm3 Dew point of water 20 C Oil aerosol liquid and vapour 1 mg Nm3 Gas cleanliness Gas is thought as sufficiently clean 2 Gas temper...

Page 603: ...13 Schematic diagrams 13 1 Schematic diagrams general 604 X92DF Operation Manual Winterthur Gas Diesel Ltd 603 Issue 002 2020 08...

Page 604: ...gram 13 1 1 1 Area codes in the engine control diagram The area codes in the engine control diagram are as follows A Control air supply unit B Fuel supply D Servo oil supply E Valve unit for start K L...

Page 605: ...99 Pipe diagram Code 900 Engine room 13 1 1 4 Component codes in the engine control diagram The component codes in the engine control diagram are shown as example in Figure 13 2 Fig 13 2 Process codes...

Page 606: ...osition A Analysis n a C Control Control E n a Element F Flow n a G Gauge n a H Hand n a I n a Indication J Power n a L Level n a P Pressure n a S Speed Switch T Temperature Transmitter V n a Valve X...

Page 607: ...ust gas 40 to 49 Signals from the engine Air systems 50 to 59 Signals from the engine Miscellaneous 60 to 69 Signals from the engine Spare 70 to 79 Signals to the engine Miscellaneous 80 to 89 Signals...

Page 608: ...4 Color codes and symbols electric connection diagram 00221 ECR component Color codes Power Option Diesel Speed Bus CCM 20 A1 Cylinder 1 13 1 3 Piping and instrumentation diagram The piping and instr...

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