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Winterthur Gas & Diesel in brief

Winterthur Gas & Diesel Ltd. (WinGD) is a leading developer of low-speed gas and diesel engines used for propulsion

power in merchant shipping. WinGD sets the industry standard for environmental sustainability, reliability, efficiency

and safety. WinGD provides designs, training and technical support to engine manufacturers, shipbuilders and ship

operators worldwide. Headquartered in Winterthur, Switzerland, since its inception as the Sulzer Diesel Engine busi

ness in 1893, it carries on the legacy of excellence in design.

www.wingd.com

Содержание X72DF

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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