Professional Documents
Culture Documents
Introduction
The 1/1998 issue replaces all previous issues of the Wrtsil 32 Project Guide. Major revisions of issue 1/1998 are: Technical data sheets revised Some engine dimensions have been revised Leak oil pipes on engine changed Pump curves of engine driven water pumps added Airborne noise figures added Start & stop sequences revised Chapter on control & monitoring revised Modbus addresses revised Holding down bolt instructions revised Drilling scheme of V-engines revised Lifting tool of V-engines changed
Application Technology, Wrtsil NSD Finland Oy, Marine Vaasa, 6 August 1998
THIS PUBLICATION IS DESIGNED TO PROVIDE AS ACCURATE AND AUTHORITIVE INFORMATION REGARDING THE SUBJECTS COVERED AS WAS AVAILABLE AT THE TIME OF WRITING. HOWEVER, THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS AND THE DESIGN OF THE SUBJECT AND PRODUCTS IS SUBJECT TO REGULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES. CONSEQUENTLY, THE PUBLISHER AND COPYRIGHT OWNER OF THIS PUBLICATION CANNOT TAKE ANY RESPONSIBILITY OR LIABILITY FOR ANY ERRORS OR OMISSIONS IN THIS PUBLICATION OR FOR DISCREPANCIES ARISING FROMTHE FEATURES OF ANY ACTUAL ITEM IN THE RESPECTIVE PRODUCT BEING DIFFERENT FROM THOSE SHOWN IN THIS PUBLICATION. THE PUBLISHER AND COPYRIGHT OWNER SHALL NOT BE LIABLE UNDER ANY CIRCUMSTANCES, FOR ANY CONSEQUENTIAL, SPECIAL, CONTINGENT, OR INCIDENTAL DAMAGES OR INJURY, FINANCIAL OR OTHERWISE, SUFFERED BY ANY PART ARISING OUT OF, CONNECTED WITH, OR RESULTING FROMTHE USE OF THIS PUBLICATION OR THE INFORMATION CONTAINED THEREIN.
COPYRIGHT 1998 BY WRTSIL NSD FINLAND OY ALL RIGHTS RESERVED. NO PART OF THIS PUBLICATION MAY BE REPRODUCED OR COPIED IN ANY FORM OR BY ANY MEANS,
Table of contents
Table of contents
Page 1. 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 2. 2.1 2.2. 2.3. 2.4. General data and outputs . . . . . . . . . . . . . Technical main data . . . . . . . . . . . . . . . . . . . Fuel specification . . . . . . . . . . . . . . . . . . . . . Lubricating oil quality . . . . . . . . . . . . . . . . . . Max. continuous output . . . . . . . . . . . . . . . . Reference conditions . . . . . . . . . . . . . . . . . . Principal dimensions and weights . . . . . . . . 3 3 3 3 4 4 5 11. 12. 13. 13.1. 13.2. 13.3. 13.4. 13.5. 13.6. 13.7. 13.8. 13.9. 13.10. 14. 14.1. 14.2. 14.3. 14.4. 15. 15.1. 15.2. 15.3. 16. 16.1. 16.2. Page Crankcase ventilation . . . . . . . . . . . . . . . . 63 Exhaust gas system . . . . . . . . . . . . . . . . . 64 Control and monitoring system . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power supply . . . . . . . . . . . . . . . . . . . . . . . . Speed measuring. . . . . . . . . . . . . . . . . . . . . Safety system . . . . . . . . . . . . . . . . . . . . . . . Speed control. . . . . . . . . . . . . . . . . . . . . . . . Electric prelubricating pump . . . . . . . . . . . . Preheating of cooling water . . . . . . . . . . . . . Monitoring and alarm sensors . . . . . . . . . . . Instrumentation . . . . . . . . . . . . . . . . . . . . . . Modbus communication. . . . . . . . . . . . . . . . Foundation . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rigid mounting. . . . . . . . . . . . . . . . . . . . . . . Flexible mounting of generating sets . . . . . . Flexible pipe connections . . . . . . . . . . . . . . Dynamic characteristics . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . External forces and couples . . . . . . . . . . . . Airborne noise . . . . . . . . . . . . . . . . . . . . . . . 66 66 67 67 68 74 75 75 75 76 77 80 80 81 90 91 92 92 92 93
Operational data . . . . . . . . . . . . . . . . . . . . . 9 Dimensioning of propellers . . . . . . . . . . . . . . 9 Loading capacity for generating sets . . . . . 10 Restrictions for low load operation and idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Overhaul intervals and expected lifetime of engine components . . . . . . . . . . . . . . . . 11 Technical data . . . . . . . . . . . . . . . . . . . . . Diesel engine Wrtsil 6L32. . . . . . . . . . . . Diesel engine Wrtsil 8L32. . . . . . . . . . . . Diesel engine Wrtsil 9L32. . . . . . . . . . . . Diesel engine Wrtsil 12V32 . . . . . . . . . . Diesel engine Wrtsil 16V32 . . . . . . . . . . Diesel engine Wrtsil 18V32 . . . . . . . . . . 12 12 14 16 18 20 22
3. 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 4. 5. 5.1. 5.2. 5.3. 5.4. 6. 6.1. 6.2. 7. 7.1. 7.2. 7.3. 8. 8.1. 8.2. 9. 10.
Description of the engine . . . . . . . . . . . . 24 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . General. . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal fuel system on the engine . . . . . . . Design of the external fuel system . . . . . . . Flushing instructions. . . . . . . . . . . . . . . . . . 26 26 26 26 36
Power transmission. . . . . . . . . . . . . . . . . . 94 Connection to driven equipment . . . . . . . . . 94 Data and drawings required for torsional vibration analysis . . . . . . . . . . . . . . . . . . . . . 96 Lifting of engines and generating sets . . 97 Lifting of engines . . . . . . . . . . . . . . . . . . . . . 97 Lifting of generating sets . . . . . . . . . . . . . . . 98 Engine room arrangement . . . . . . . . . . . . 99 Arrangement of generating sets . . . . . . . . . 99 Arrangement of main engines . . . . . . . . . . 100 Dimensions and weights of engine components . . . . . . . . . . . . . . . . . . . . . . . 102 List of symbols . . . . . . . . . . . . . . . . . . . . 104
Lubricating oil system . . . . . . . . . . . . . . . 37 Internal lubricating oil system on the engine 37 Design of the external lubricating oil system 40 Cooling water system . . . . . . . . . . . . . . . General. . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal cooling water system on the engine. Design of the external cooling water system. 44 44 44 46
Starting air system . . . . . . . . . . . . . . . . . . 57 Internal starting air system on the engine . 57 Design of the external starting air system . 59 Turbocharger turbine washing system . 61 Engine room ventilation and combustion air . . . . . . . . . . . . . . . . . . . . . 62
20.
RPM kW hp
Speed governor
The speed governor can use engine oil.
The cylinder output P1 can be calculated as follows: P1 [kW] = pe [bar] x n [RPM] x 0.0268 pe [bar] x n [RPM] x 0.0365 P1 [hp] = where P1 = output per cylinder pe = mean effective pressure n = engine speed
Auxiliary engines
Engine 720 RPM, 60 Hz Engine kW 6L32 8L32 9L32 12V32 16V32 18V32 2700 3600 4050 5400 7200 8100 Alternator kVA 3250 4340 4880 6510 8680 9770 kW 2600 3470 3900 5210 6940 7810 750 RPM, 50 Hz Engine kW 2760 3680 4140 5520 7360 8280 Alternator kVA 3320 4430 4990 6650 8870 9980 kW 2660 3550 3990 5320 7100 7990
total barometric pressure air temperature relative humidity charge air coolant temperature
For other than ISO 3046/I conditions the same standard gives correction factors. The influence of an engine driven lube oil pump on the specific fuel consumption is about 2 g/kWh and of each engine driven cooling water pump about 1 g/kWh, at full load and nominal speed.
For auxiliary engines the permissible overload is 10% for one hour every twelve hours. The maximum fuel rack position is mechanically limited to 110% 2% continuous output. The alternator outputs are calculated for an efficiency of 0.965 and a power factor of 0.8. The above output is also available from the free end of the engine for in-line engines, if necessary. See section 16. Power Transmission.
Weight [ton]** 32 42 48
* Turbocharger at flywheel end ** Weight with liquids (wet sump), but without flywheel
V-engines (3V58E0476a)
* Turbocharger at flywheel end ** Weight with liquids (wet sump), but without flywheel
Weight* [ton] 56 73 79
2. Operation data
2. Operation data
2.1. Dimensioning of propellers
Controllable pitch (CP) propellers
Controllable pitch propellers are designed so that 100% of the maximum continuous engine output at nominal engine speed is utilized when the ship is on trial at specified speed and draft. Shaft generators or generators connected to the free end of the engine should be considered when dimensioning propellers in case continuous generator output is to be used at sea. Overload protection or load control is recommended in all installations. In installations where several engines are connected to the same propeller, overload protection or load control is required. The graph, 4V93L0687, shows the operating range for a CP-propeller installation. The recommended combinator curve and the 100% load curve are valid for a single-engine installation. In case of a twin-engine installation a lighter combinator program shall be used, when only one engine is in operation. The idling (clutch-in) speed should be as high as possible and will be decided separately in each case.
2. Operation data
In ships intended for operation in heavy ice, the additional torque must be considered. The graph, 4V93L0688, shows the permissible operating range for an FP-propeller installation as well as the recommended design point at 85% MCR at engine flywheel and nominal speed. The min. speed will be decided separately for each installation. It is recommended that the speed control system is designed to give a speed boost signal to the speed governor in order to prevent the engine speed from decreasing when clutching-in. The clutch should be dimensioned for a slipping time of 5 - 8 seconds. A propeller shaft brake should be used to enable fast maneuvering (crash-stop).
Absolute idling
(declutched main engine, unloaded generator) Max. 10 min., (recommended 3 - 5 min.), if the engine is to be stopped after the idling. Max. 6 hours after which the engine must be loaded to min. 70% of the rated load for at least 1 hour.
10
2. Operation data
Fuel quality Fuel viscosity (max.) at 50C [cSt] Component - Piston - Piston rings - Cylinder liner - Cylinder head - Inlet valve - Exhaust valve - Injection valve nozzle - Injection pump element - Main bearing - Big end bearing
HFO 700
MDO 10
HFO 700
MDO 10
Time between overhauls [h] 12000 - 20000 12000 - 20000 12000 - 20000 12000 - 20000 12000 - 20000 12000 - 20000 4000 24000 16000 - 20000 12000 - 20000 20000 - 24000 20000 - 24000 20000 - 24000 20000 - 24000 20000 - 24000 20000 - 24000 4000 24000 16000 - 20000 20000 - 24000
Expected lifetime [h] 48000 - 60000 12000 - 20000 60000 - 100000 60000 - 100000 36000 - 40000 24000 - 40000 4000 - 8000 24000 - 48000 32000 - 40000 24000 - 40000 60000 - 100000 20000 - 24000 > 100000 > 100000 40000 - 48000 20000 - 48000 8000 - 12000 24000 - 48000 32000 - 40000 24000 - 40000
11
3. Technical data
3. Technical data
3.1. Diesel engine Wrtsil 6L32
Engine speed Engine output Engine output Cylinder bore Stroke Swept volume Compression ratio Compression pressure, max. Firing pressure, max Charge air pressure Mean effective pressure Mean piston speed Idling speed RPM kW HP mm mm dm bar bar bar bar m/s RPM kg/s C C C kg/s kg/s kg/s kg/s 2) 2) 2) 2) C C C C C mmWC mm kW kW kW kW kW kW kW kW bar g/kWh g/kWh g/kWh kg/h bar bar bar bar bar 720 2700 3670 320 400 193 16:1 160 190 2.65 23.3 9.6 500 5.4 45 55 75 5.6 5.1 4.3 3.1 344 339 329 304 500 300 600 744 403 341 743 421 322 1864 142 7...8 182 183 189 2.0 4.5 3 2 0.5 0.3 183 184 191 765 414 351 764 433 331 1938 147 5.8 5.3 4.5 3.2 342 337 327 302 5.65 2.7 22.9 10.0 750 2760 3750
1)
Heat balance
HT-circuit, total Jacket water, HT-circuit Charge air, HT-circuit LT-circuit, total Charge air, LT-circuit Lubricating oil, LT-circuit Exhaust gases Radiation
3)
Fuel system
Pressure before injection pumps Fuel consumption (100% load) ( 75% load) ( 50% load) Leak fuel quantity, clean fuel (100% load) 5) 5) 5)
12
3. Technical data
Engine speed Temperature before engine, nom. Temperature before engine, alarm Temperature after engine, abt. Pump capacity (main), direct driven Pump capacity (main), separate Pump capacity (priming) Oil volume, wet sump, nom. Oil volume in separate system oil tank, nom. Filter fineness, mesh size Filters difference pressure, alarm. Oil consumption (100% load) abt.
750
81 70
4)
7)
6)
13
3. Technical data
1)
Heat balance
HT-circuit, total Jacket water, HT-circuit Charge air, HT-circuit LT-circuit, total Charge air, LT-circuit Lubricating oil, LT-circuit Exhaust gases Radiation
3)
Fuel system
Pressure before injection pumps Fuel consumption (100%load) ( 75%load) ( 50%load) Leak fuel quantity, clean fuel (100%load) 5) 5) 5)
14
3. Technical data
Engine speed Pump capacity (main), direct driven Pump capacity (main), separate Pump capacity (priming) Oil volume, wet sump, nom. Oil volume in separate system oil tank, nom. Filter fineness, mesh size Filters difference pressure, alarm. Oil consumption (100% load), abt.
750 105 95
4)
7)
6)
1) 2) 3) 4) 5) 6) 7)
If priming pump is connected, 400 RPM At an ambient temperature of 25C. The figures are without margins at 100% load and constant speed. Capacities at 50 and 60 Hz respectively. According to ISO 3046/l, lower calorific value 42 700 kJ/kg, at constant engine speed, with engine driven pumps. Tolerance + 5%. At remote and automatic starting the consumption is 2...3 times higher First alarm/second alarm
15
3. Technical data
1)
Heat balance
HT-circuit, total Jacket water, HT-circuit Charge air, HT-circuit LT-circuit, total Charge air, LT-circuit Lubricating oil, LT-circuit Exhaust gases Radiation
3)
Fuel system
Pressure before injection pumps Fuel consumption (100% load) ( 75% load) ( 50% load) Leak fuel quantity, clean fuel (100% load) 5) 5) 5)
16
3. Technical data
Engine speed Pump capacity (main), direct driven Pump capacity (main), separate Pump capacity (priming) Oil volume, wet sump, nom. Oil volume in separate system oil tank, nom. Filter fineness, mesh size Filters difference pressure, alarm. Oil consumption (100% load) abt.
4)
7)
6)
1) 2) 3) 4) 5) 6) 7)
If priming pump is connected, 400 RPM At an ambient temperature of 25C. The figures are without margins at 100% load and constant speed. Capacities at 50 and 60 Hz respectively. According to ISO 3046/l, lower calorific value 42 700 kJ/kg, at constant engine speed, with engine driven pumps. Tolerance + 5%. At remote and automatic starting the consumption is 2...3 times higher First alarm/second alarm
17
3. Technical data
1)
Heat balance
HT-circuit, total Jacket water, HT-circuit Charge air, HT-circuit LT-circuit, total Charge air, LT-circuit Lubricating oil, LT-circuit Exhaust gases Radiation
3)
Fuel system
Pressure before injection pumps Fuel consumption (100% load) ( 75% load) ( 50% load) Leak fuel quantity, clean fuel (100% load) 5) 5) 5)
18
3. Technical data
Engine speed Temperature after engine, abt. Pump capacity (main), direct driven Pump capacity (main), separate Pump capacity (priming) Oil volume, wet sump, nom. Oil volume in separate system oil tank, nom. Filter fineness, mesh size Filters difference pressure, alarm. Oil consumption (100% load), abt.
750
120 110
4)
8)
6)
7)
1) 2) 3) 4) 5) 6) 7) 8)
If priming pump is connected, 400 RPM At an ambient temperature of 25C. The figures are without margins at 100% load and constant speed. Capacities at 50 and 60 Hz respectively. According to ISO 3046/l, lower calorific value 42 700 kJ/kg, at constant engine speed, with engine driven pumps. Tolerance + 5%. Including lubricating oil cooler. At remote and automatic starting the consumption is 2...3 times higher First alarm/second alarm
19
3. Technical data
1)
Heat balance
HT-circuit, total Jacket water, HT-circuit Charge air, HT-circuit LT-circuit, total Charge air, LT-circuit Lubricating oil, LT-circuit Exhaust gases Radiation
3)
Fuel system
Pressure before injection pumps Fuel consumption (100% load) ( 75% load) ( 50% load) Leak fuel quantity, clean fuel (100% load) 5) 5) 5)
20
3. Technical data
Engine speed Temperature after engine, abt. Pump capacity (main), direct driven Pump capacity (main), separate Pump capacity (priming) Oil volume, wet sump, nom. Oil volume in separate system oil tank, nom. Filter fineness, mesh size Filters difference pressure, alarm. Oil consumption (100% load) abt.
750
158 135
4)
8)
6)
7)
1) 2) 3) 4) 5) 6) 7) 8)
If priming pump is connected, 400 RPM At an ambient temperature of 25C. The figures are without margins at 100% load and constant speed. Capacities at 50 and 60 Hz respectively. According to ISO 3046/l, lower calorific value 42 700 kJ/kg, at constant engine speed, with engine driven pumps. Tolerance + 5%. Including lubricating oil cooler. At remote and automatic starting the consumption is 2...3 times higher First alarm/second alarm
21
3. Technical data
1)
Heat balance
HT-circuit, total Jacket water, HT-circuit Charge air, HT-circuit LT-circuit, total Charge air, LT-circuit Lubricating oil, LT-circuit Exhaust gases Radiation
3)
Fuel system
Pressure before injection pumps Fuel consumption (100% load) ( 75% load) ( 50% load) Leak fuel quantity, clean fuel (100% load) 5) 5) 5)
22
3. Technical data
Engine speed Temperature after engine, abt. Pump capacity (main), direct driven Pump capacity (main), separate Pump capacity (priming) Oil volume, wet sump, nom. Oil volume in separate system oil tank, nom. Filter fineness, mesh size Filters difference pressure, alarm. Oil consumption (100% load) abt.
750
180 150
4)
8)
6)
7)
1) 2) 3) 4) 5) 6) 7) 8)
If priming pump is connected, 400 RPM At an ambient temperature of 25C. The figures are without margins at 100% load and constant speed. Capacities at 50 and 60 Hz respectively. According to ISO 3046/l, lower calorific value 42 700 kJ/kg, at constant engine speed, with engine driven pumps. Tolerance + 5%. Including lubricating oil cooler. At remote and automatic starting the consumption is 2...3 times higher First alarm/second alarm
23
Cylinder liner
The cylinder liners are centrifugally cast of special alloyed cast iron. The top collar of the cylinder liner is provided with bore cooling for efficient control of the liner temperature. The liner is equipped with an anti-polishing ring, preventing bore polishing.
Piston
The piston is of the composite type with steel crown and nodular cast iron skirt. The piston skirt/cylinder liner is lubricated by a piston skirt lubricating system featuring four lubricating bores in a groove on the piston skirt. The piston top is cooled by means of The shaker effect. The piston ring grooves are hardened.
Piston rings
The piston ring set consists of two chromium-plated compression rings and one spring-loaded oil scraper ring with chromium-plated edges.
Cylinder head
The cylinder head is made of nodular cast iron. The flame plate, which is thermally loaded, is relatively thin and is efficiently cooled by cooling water led from the periphery of the head radially towards the centre. In the bridges between the valves cooling channels are drilled to provide the best possible heat transfer. The mechanical load is absorbed by a strong intermediate deck, which together with the upper deck and the side walls form a box section in the four corners at which the hydraulically tightened cylinder head bolts are situated. The exhaust valve seats are directly water cooled. The valve seat rings are made of specially alloyed cast iron with good wear resistance. The inlet valves as well as the exhaust valves have stellite-plated seat faces and chromium-plated stems. In HFO operated engines nimonic exhaust gas valves are used. All valves are equipped with valve rotators. A multi-duct casting is fitted to the cylinder head. It connects the following media with the cylinder head: charge air from air receiver exhaust gas to exhaust system cooling water from cylinder head to the return pipe
Crankshaft
The crankshaft is forged in one piece. The connecting rods, at the same crank in the V-engines, are arranged side-by-side. For the same reason the diameters of the crank pins and journals are equal irrespective of the cylinder number. The crankshaft is fully balanced to counteract bearing loads from eccentric masses. If necessary, it is provided with a torsional vibration damper at the free end of the engine.
Connecting rod
The three-piece connecting rod design gives a minimum dismantling height and possibility to dismount the piston without opening the big end bearing. The connecting rod of alloy steel is forged and machined with round sections. All connecting rod studs are hydraulically tightened. The gudgeon pin bearing is of tri-metal type. Lubricating oil flows to the gudgeon pin bearing and piston through a bore in the connecting rod.
24
The fuel injection is stopped by setting the fuel rack to zero position. For emergencies the fuel rack of each injection pump is fitted with a stop cylinder. The blocking device can be operated by the operator. The fuel pump and pump bracket are adjusted in manufacturing to tight tolerances. This means that adjustments are not necessary after initial assembly. The fuel injection pump design is a reliable mono-element type designed for injection pressures up to 2000 bar. The constant pressure relief valve system provides for optimum injection, which guarantees long intervals between overhauls. The injector holder is designed for easy maintenance.
Exhaust pipes
The exhaust pipes are cast of nodular iron. The connections are of flange type. The exhaust system is enclosed in an insulated box consisting of easily removable plates supported on the multi-duct. Mineral wool is used as insulating material.
Camshaft drive
The camshafts are driven by the crankshaft through a gear train. The driving gear is fixed to the camshaft by means of flange connections.
Injection equipment
The fuel injection equipment and system piping are located in a hot-box, providing maximum reliability and safety when using preheated heavy fuels. The fuel oil feed pipes are mounted directly to the injection pumps, using a specially designed connecting piece. The return pipe is integrated in the tappet housing. There is one fuel injection pump per cylinder with shielded high pressure pipe to the injector. The injection pumps, which are of the flow-through type, ensure good performance with all types of fuel. The pumps are completely sealed off from the camshaft compartment.
25
5. Fuel system
5. Fuel system
5.1. General
The Wrtsil 32 diesel engine is designed for continuous heavy fuel duty. It is, however, possible to operate the engine on diesel fuel without making any alterations. Main engines as well as auxiliary engines can be started and stopped on heavy fuel provided that the engine and fuel system are preheated to operating temperature. Also standby engines in unattended engine rooms can be started on heavy fuel. Usually only the tank, from which fuel is pumped to the settling tank, is heated to 40 - 50C, while the other tanks remain at a lower temperature. The heat consumption calculations are mainly based on heat losses from the day tank and the settling tank, to maintain the largest bunker tank at pumping temperature and simultaneously heating up the next largest tank. The design of the external fuel system may vary from ship to ship but every system should provide well cleaned fuel with the correct temperature and pressure to each engine. When using heavy fuel it is most important that the fuel is properly cleaned from solid particles and water. In addition to the harm poorly centrifuged fuel will do to the engine, high content of water may cause big problems for the heavy fuel feed system. Well-proven components should be used for the feed system. The fuel treatment system should comprise a settling tank and purifiers to supply the engine(s) with sufficiently clean fuel. When operating on heavy fuel the dimensioning of the purifier is of greatest importance and therefore the recommendations for the design of the purifier must be followed closely. In multi-engine installations, the main principles for dimensioning the fuel system are: Recommended maximum number of engines connected in parallel to the same fuel feed system is three. For main engines, separate fuel feed circuits are recommended for each propeller shaft (two-engine installations); in four-engine installations one engine from each shaft is fed from the same circuit. Main and auxiliary engines are recommended to be connected to separate circuits.
26
5. Fuel system
Pipe connections 101 102 1031 1033 1041 1043 Fuel inlet Fuel outlet Clean fuel leakage, outlet Clean fuel leakage, outlet Dirty fuel leakage, outlet Dirty fuel leakage, outlet DN25 DN25 DN20 M16x1.5 18 M16x1.5
Sensor for broken injection pipe Abnormal leakage, clean fuel Abnormal leakage, dirty fuel
27
5. Fuel system
Preheater, separator
The preheater is dimensioned according to the feed pump capacity and a given settling tank temperature. The heater surface temperature must not be too high in order to avoid cracking of the fuel. The heater should be thermostatically controlled for maintaining the fuel temperature within 2C. The recommended preheating temperature for heavy fuel is 98C. Design data: The required minimum capacity of the heater is:
P kW = m l / h t C 1700
m = capacity of the separator feed pump t = temperature rise in heater For heavy fuels t = 38C can be used, i.e. a settling tank temperature of 60C. Fuels having a viscosity higher than 5 cSt at 50C need preheating before the separator.
28
5. Fuel system
System components 01 02 03 04 05 Settling tank Suction filter Feed pump Heater Separator
06 07 08 09 10
Transfer pump Bunker tank Overflow tank Sludge tank Day tank
29
5. Fuel system
Alfa-Laval fuel separators / Engine MCR [MW] Separator GO MDO 60 MMPX 303 MMPX 304 MOPX 205 MOPX 207 MOPX 309 MOPX 310 MOPX 213 FOPX 605 MFPX 307 FOPX 609 FOPX 610 FOPX 613 5.2 9.3 17.7 29.0 41.9 60.9 77.0 12.2 27.3 41.6 41.6 63.9 4.8 8.1 15.3 25.0 35.9 52.4 58.1 12.2 27.3 41.6 41.6 63.9 3.2 5.6 10.5 17.7 25.4 36.7 40.7 9.2 20.6 31.5 31.5 48.3 100 3.0 5.2 10.1 16.9 24.2 35.1 39.1 8.8 19.8 30.2 30.2 46.2 HFO fuel viscosity [cSt/50C] 180 2.8 4.8 8.9 14.9 21.4 31.4 34.7 8.0 17.6 26.9 28.4 40.3 380 1.8 3.0 6.0 9.7 14.1 20.2 22.6 5.0 11.3 17.6 21.0 29.4 460 600 700
Westfalia fuel separators / Engine MCR [MW] Separator GO MDO 60 OCS 4-nn-066/3 OCS 4-nn-066/4 OCS 4-nn-066/5 OSA 7-nn-066/7 OSA 7-nn-066/8 OSA 20-nn-066/14 OSA 20-nn-066/20 OSA 20-nn-066/25 OSB 30-nn-066/30 OSB 35-nn-066/35 OSB 35-nn-066/40 6.4 8.0 10.2 13.8 17.3 27.9 37.7 46.6 57.6 70.9 94.9 4.9 6.2 8.0 10.6 14.6 21.3 29.3 39.2 44.3 54.5 73.6 4.9 6.2 8.0 10.6 14.6 21.3 29.3 39.2 44.3 54.5 73.6 100 4.7 6.0 7.7 10.3 14.2 20.6 28.4 38.0 42.8 52.9 71.3 HFO fuel viscosity [cSt/50C] 180 4.2 5.3 6.6 8.9 12.4 17.7 24.8 33.2 36.8 46.6 62.1 380 2.6 3.1 4.0 5.3 7.3 10.6 14.8 19.5 22.0 27.9 37.2 460 2.0 2.4 3.1 4.3 5.8 8.6 11.8 15.7 17.8 22.3 29.7 600 1.6 2.0 2.5 3.5 4.6 7.1 9.3 12.4 14.0 17.7 23.5 700 1.4 1.7 2.3 3.1 4.2 6.2 8.4 11.3 12.6 15.7 21.3
In the above table: Substitute -nn- by -02-(Varizone, 991 kg/m) or by -0136- (Unitrol, 1010 kg/m) The table shows engine MCR in MW for each corresponding separator type.
Separator
The fuel oil separator shall be sized according to the recommendations of the separator maker. The maximum service throughput of a separator for the specific application should be:
Q l/h =
P= b= = t=
P kW b g / kWh 24 h kg / m3 t h
in which
The percentage can vary according to fuel type and separator make. For final dimensioning the separator maker should be consulted. For MDO (max. viscosity 11 cSt at 50C) a flow rate of 80% and a preheating temperature of 45C are recommended. The flow rates recommended for the separator and the grade of fuel in use must not be exceeded. The lower the flow rate the better the separation efficiency. Suitable Alfa Laval and Westfalia separators are presented in the tables above.
max. continuous rating of the diesel engine specific fuel consumption + 15% safety margin density of the fuel daily separating time for self cleaning separator (usually = 23 h or 23.5 h)
This maximum service throughput of the separator depends on the type of HFO. It is typically expressed as a percentage of the nominal capacity of the separator.
30
5. Fuel system
gravity tank min. 15 m above the engine centerline pneumatic emergency pump single phase electric motor driven pump fed from an emergency supply
Suction strainer
A suction strainer with a fineness of 0.5 mm should be installed for protecting the feed pumps. The strainer should be equipped with jacket heating. The strainer may be either of duplex type with changeover valves or two simplex strainers in parallel. The design should be such that air suction is prevented.
Feed pump
The feed pump maintains the pressure in the fuel feed system. It is recommended to use a high temperature resistant screw pump as feed pump. Design data: capacity to cover the total consumption of the engines and flushing of the automatic filter operating pressure operating temperature viscosity (for dimensioning the electric motor) 6 bar 100C 1000 cSt
De-aeration tank
The volume of the tank should be about 100 l. It shall be insulated and equipped with a heating coil and a vent valve, controlled by a level switch. The valve shall be insulated and equipped with trace heating. The vent pipe should, if possible, be led downwards, e.g. to the overflow tank.
The tank and pumps should be placed so that a positive static pressure of 0.3...0.5 bar is obtained on the suction side of the pumps.
Circulation pump
The purpose of this pump is to maintain a pressure of 7 bar at the injection pumps. It also circulates the fuel in the system to maintain the viscosity, and keeps the piping and injection pumps at operating temperature. Design data: capacity min. operating pressure operating temperature viscosity (for dimensioning the electric motor) 4 x the maximum consumption of the engines 10 bar 150C 500 cSt
Black-out start
In installations where standby generating sets are fed from the diesel fuel day tank sufficient fuel pressure for a safe start must be ensured also in the case of a black-out. This can be done with:
31
5. Fuel system
System components 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 Day tank, heavy fuel Day tank, diesel fuel Change over valve Suction strainer Feed pumps Orifice Flow meter Deaeration tank Circulation pumps Heater Automatic filter Viscosimeter Overflow valve Safety filter Leak fuel tank, clean fuel Leak fuel tank, dirty fuel Radiator
Pipe connections, engine 101 102 103 104 Fuel inlet Fuel outlet Leak fuel drain, clean fuel Leak fuel drain, dirty fuel
Pipe dimensions Connection Size 101 DN25 102 DN25 103 DN20 104 DN32
32
5. Fuel system
System components 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 Orifice Day tank, heavy fuel Day tank, diesel fuel Change over valve Suction strainer, HFO Fuel feed pump, HFO MDO pressure control valve Flow meter Deaeration tank Circulation pumps Heater Automatic filter Viscosimeter Overflow valve 3-way change over valve MDO fine filter MDO pump Suction strainer, MDO
19 20 21 22 23
Pressure regulating valve Leak fuel tank, clean fuel Leak fuel tank, dirty fuel HFO safety filter Radiator
Pipe connections, engine 101 102 103 104 Fuel inlet Fuel outlet Leak fuel drain, clean fuel Leak fuel drain, dirty fuel
Pipe dimensions Connection Size 101 DN25 102 DN25 103 DN20 104 DN32
33
5. Fuel system
Heater
The heater(s) is dimensioned to maintain an injection viscosity of 14 cSt (for fuels having a viscosity higher than 380 cSt/50C, the temperature at the engine inlet should not exceed 135C), according to the maximum fuel consumption and a given tank temperature. To avoid cracking of the fuel the surface temperature in the heater must not be too high. The surface power of electric heaters must not be higher than about 1.5 W/cm. The output of the heater is controlled by a viscosimeter. As a reserve a thermostat control may be fitted. The set point of the viscosimeter shall be somewhat lower than the required viscosity at the injection pumps to compensate for losses in the pipes. Design data: The required minimum capacity of the heater is:
P [kW] = m [l / h] t [ C] 1700
maximum recommended pressure drop for normal filters at 14 cSt: - clean filter 0.2 bar - dirty filter 0.8 bar - alarm 1.5 bar If a finer mesh size than 25 m is specified, the automatic filter must be placed between the feeder pumps and the deaeration tank to avoid clogging of the filter mesh due to cracking of the fuel.
Viscosimeter
For the control of the heater(s) a viscosimeter has to be installed. A thermostatic control shall be fitted, to be used as safety when the viscosimeter is out of order. The viscosimeter should be of a design that withstands the pressure peaks caused by the injection pumps of the diesel engine. Design data: viscosity range at injection pumps 10 - 24 cSt operating temperature 180C operating pressure 40 bar
m=
evaluated by multiplying the specific fuel consumption of the engines by the total max. output of the engines temperature rise, higher with increased fuel viscosity.
t =
The following values can be used: Fuel viscosity [cSt at 50C] 700 380 180 Temperature rise in heater [C] 80 (65 in day tank) 75 (60 in day tank) 65 (55 in day tank)
Safety filter
Since no fuel filters are built on the engine, one duplex type safety filter shall be installed between the booster module and the engine. The filter shall be located as close to the engines as possible. A common filter for all engines shall be used. The filter shall be equipped with an alarm contact for high differential pressure. fineness 34 - 37 m
To compensate for heat losses due to radiation the above values should be increased by 10 % + 5 kW.
34
5. Fuel system
With steam heaters Booster module for engine output of A B C D F H K L P R HFO inlet Fuel to engine Drain from unit Deaeration line to overflow tank MDO inlet Return from engine Steam inlet Condensate outlet Sludge from automatic filter Instrument air inlet Weight dry [kg] 3, 5, 7 and 12 MW DN50 DN32 R2" DN32 DN50 DN32 DN32 DN32 DN50 10 mm 2100 15 and 18 MW DN65 DN50 R2" DN50 DN65 DN50 DN32 DN32 DN50 10 mm 2300
With electric heaters 3, 5, 7 and 12 MW DN50 DN32 R2" DN32 DN50 DN32 DN32 DN32 DN50 10 mm 2450 15 and 18 MW DN65 DN50 R2" DN50 DN65 DN50 DN32 DN32 DN50 10 mm 2650
35
5. Fuel system
36
Thermostatic valve
A thermostatic valve of the direct acting type is installed on all engines. Design data:
The lubricating oil module is equipped with a fully automatic continuous back-flushing filter. Design data 30 m absolute mesh size 100 m absolute mesh size
full flow fine filter full flow safety filter alarm for high pressure
drop over the filter - first alarm - second alarm
Prelubricating pump
The prelubricating pump is an electric motor driven gear wheel pump equipped with a safety overflow valve. The pump is used for:
materials:
- fine filter elements - safety mesh
Continuous prelubrication of a stopped diesel engine(s) in a multi-engine installation always when one of the engines is running Concerning flow rates and pressures, see chapter 3. Technical data. The suction height of the built-on prelubricating pump should not exceed 3.5 m.
Centrifugal filter
A centrifugal filter is installed to clean the back-flushing oil from the automatic filter.
Running in filters
All dry sump engines are provided with a full-flow wiremesh filter in the oil inlet line to each main bearing. Running in filters are removed after commissioning.
37
System components 01 02 03 04 05 06 07 Lubricating oil main pump Prelubricating oil pump Lubricating oil cooler Thermostatic valve Automatic filter Centrifugal filter Pressure control valve
Pipe connections 202 203 205 207 208 213 214 Lubricating oil outlet (if dry sump) Lubricating oil to engine driven pump (if dry sump) Lubricating oil to priming pump (if dry sump) Lubricating oil to el. driven pump Lubricating oil from el. driven pump Lubricating oil from separator and filling (if wet sump) Lubricating oil to separator and drain (if wet sump)
38
System components 01 02 03 04 05 06 07 Lubricating oil main pump Prelubricating oil pump Lubricating oil cooler Thermostatic valve Automatic filter Centrifugal filter Pressure control valve
Pipe connections 202 203 205 207 208 213 214 231 232 Lubricating oil outlet (if dry sump) Lubricating oil to engine driven pump (if dry sump) Lubricating oil to priming pump Lubricating oil to el. driven pump Lubricating oil from el. driven pump Lubricating oil from separator and filling (if wet sump) Lubricating oil to separator and drain (if wet sump) Lubricating oil to external system Lubricating oil from external system
Size DN150 DN250 DN125 DN200 DN125 DN40 DN40 DN125 DN125
All connections DIN 2576, PN 10 F) Note! W12V32 has only one centrifugal filter
39
Suitable Alfa-Laval and Westfalia separators are presented in the tables below:
The following rule, based on the above data and a separation time of 23 h/day, can be used for estimating the nominal capacity of the separator: Vnom [l/h] = 1.2 - 1.5 P [kW] P = total engine output
40
Separator pump
The separator pump can be directly driven by the separator or separately driven by a motor. The flow should be adapted to achieve the above mentioned optimal flow.
Suction strainer
If necessary, a suction strainer completed by magnetic bars can be fitted in the suction pipe to protect the lubricating oil pump. The suction strainer as well as the suction pipe diameter should be amply dimensioned to minimize the flow loss. The suction strainer should always be provided with alarm for high differential pressure.
Separator preheater
The separator preheater can be a steam or an electric heater. The surface temperature of the heater must not be too high in order to avoid coking of the oil. Design data: For main engines with centrifuging during operation, the heater should be dimensioned for this operating condition. The temperature in the separate system oil tank in the ships bottom is normally 65 - 75C. For auxiliary engines with centrifuging when stopped engine, the heater should be dimensioned large enough to allow centrifuging at optimal rate of the separator without heat supply from the diesel engine.
Fineness
System oil tank (separate)
0.5 - 1.0 mm
Valve system
In auxiliary engines with wet sump operation, the standard engine is delivered with interconnected valves to make a replacement of flexible connections possible without draining the oil sump. Normally these valves will be open and the valves in the outside pipes have to be closed and opened when the oil is centrifuged.
The engine dry sump has two drain outlets at each end. On V-engines both outlets shall be used. The pipe connection between the sump and the system oil tank should be arranged flexible enough to prevent damages due to thermal expansion. The drain pipe from the oil sump to the system oil tank shall end below the min. oil level and shall not be led to the same place as the suction pipe. The end of the suction pipe should be trumpet-shaped or conical in order to reduce the pressure loss. For the same reason the suction pipe shall be as short and straight as possible. Also the suction and return pipes for the separator should not be located near each other. Recommendation for the design of the tank is given in the drawing of the engine room arrangement. The tank must not be placed so that the oil is cooled so much that the recommended lubricating oil temperature cannot be obtained. A cofferdam between the system oil tank and the hull plating is recommended. Design data:
41
System components 01 02 03 04 05 06 07 08 09 10 11 12 13 14 Lubricating oil main pump Prelubricating oil pump Lubricating oil cooler Thermostatic valve Automatic filter Pressure control valve Suction strainer Separator pump Separator heater Separator System oil tank Sludge tank Suction strainer Lubricating oil pump, standby
Pipe connections 202 203 208 Lubricating oil outlet (if dry sump) Lubricating oil to engine driven pump Lubricating oil from el. driven pump
42
System components 01 02 03 04 05 06 07 08 09 10 11 12 13 14 Lubricating oil main pump Prelubricating oil pump Lubricating oil cooler Thermostatic valve Automatic filter Pressure control valve Suction strainer Separator pump Separator heater Separator System oil tank Sludge tank New oil tank Renovated oil tank
Pipe connections 213 214 215 Lubricating oil from separator and filling Lubricating oil to separator and drain Lubricating oil filling
43
Pump curves for standard engines are shown in diagrams below. These pumps are driven by the engine crankshaft through gear transmission. On request, outlet and inlet connections for a separate standby pump can be provided. Shut-off valves are provided on the suction side of the engine driven pumps and non-return valves on the delivery side.
44
Pump diagram for engine driven HT- and LT-water pumps, in-line engines, 720 RPM (4V19L0291)
Pump diagram for engine driven HT- and LT-water pumps, in-line engines, 750 RPM (4V19L0292)
45
Pump diagram for engine driven HT- and LT-water pumps, 12V32, 720 / 750 RPM (4V19L0293a)
Pump diagram for engine driven HT- and LT-water pumps, 16V32 and 18V32, 720 / 750 RPM (4V19L0294a)
46
System components 01 02 03 04 05 06 07 08 09 HT-cooling water pump LT-cooling water pump Charge air cooler (LT) Lubricating oil cooler HT-thermostatic valve LT-thermostatic valve Turbocharger Shut-off valve Charge air cooler (HT)
Pipe connections 401 402 404 406 408 451 452 454 457 HT-water inlet HT-water outlet HT-water air vent Water from preheater to HT-circuit HT-water from standby pump LT-water inlet LT-water outlet LT-water air vent LT-water from standby pump
Size L32 DN100 DN100 OD12 OD28 DN100 DN100 DN100 OD15 DN100
DIN 2576, PN 10 (401, 402, 408, 451, 452 and 457) DIN 2353 (404, 406 and 454)
47
The fresh water pipes should be designed to minimize the flow resistance as much as possible. The smaller the pressure drop in the pipes the bigger pressure drop can be allowed for the cooler.
Drain tank
It is recommended to provide a tank for draining the cooling water from the engines during maintenance so that the water and cooling water treatment can be collected and reused.
Engine
P [kW]
Medium
Flow [m/h]
Pressure drop [bar] 0.6 1.2 0.6 1.2 0.6 1.2 0.6 1.2 0.6 1.2 0.6 1.2
Weight [kg] dry 312 349 366 870 927 951 operating 377 437 466 1000 1110 1150
Model size
A [mm]
B [mm]
C [mm]
FW SW FW SW FW SW FW SW FW SW FW SW
75 97 100 130 112 146 130 169 175 227 195 253
1 1 1 2 2 2
48
49
The tank should be equipped so that it is possible to dose water treatment agents. The vent pipe of each engine should drain to the tank separately, continuously rising, and so that mixing of air into the water cannot occur (the outlet should be below the water level).
Preheating pump
Engines which are started on heavy fuel require preheating of the high temperature cooling water. Standby auxiliary engines should have preheated cooling water, also if in standby on MDO. Design data of the pump: Capacity 0.4 m/h x cyl. about 0.8 bar Pressure
q m 3 / h = q LT +
where qLT [m/h] = [kW] = Tout = Tin =
nominal LT-pump capacity, see Technical Data heat dissipated from jackets and charge air (HT-section) HT-water temperature after engine (= 91C) HT-water temperature before engine (= 38C) 0.6 bar.
Preheater
The energy required for heating of the HT-cooling water in the main and auxiliary engines can be taken from a running engine or a separate source. In both cases a separate circulating pump should be used. If the cooling water systems of the main and auxiliary engines are separated from each other in other respects, the energy is recommended to be transmitted through heat exchangers. When preheating, the cooling water temperature of the engines should be kept as near the operating value as possible. Design data: Preheating temperature Required heating power min. 70C about 3 kW/cyl
If the flow resistance in the external pipes is high it should be observed when designing the cooler. Sea water flow acc. to cooler manufacturer, normally 1.2 - 1.5 x the fresh water flow
Pressure drop on sea water side normally 0.8 - 1.4 bar Fresh water temperature after cooler (before engine), max. 38C Heat to be dissipated see the heat balance in Technical Data
Preheating unit
A complete preheating unit can be supplied as an option. The unit consists of the following parts: Electric or steam heaters Circulating pump Control cabinet for heaters and pump Safety valve One set of thermometers For installations with several engines the preheater unit can be chosen for heating up several engines. The heat from a running engine can be used and therefore the power consumption of the heaters will be less than the nominal capacity.
Expansion tank
The expansion tank should compensate for volume changes in the cooling water system, serve as venting arrangement and provide sufficient static pressure for the circulating pumps. Pressure from the expansion tank Volume 0.7 - 1.5 bar min. 10% of the system water volume, however, min. 100 litres
50
Pipe connection in/outlet DN40 DN40 DN40 DN40 DN40 DN40 DN40 DN40 DN40 DN40 DN40
Dimensions [mm] A 1050 1050 1050 1250 1050 1250 1050 1250 1250 1250 1260 B 720 550 720 900 720 900 720 900 720 900 900 C 610 660 660 660 700 700 700 700 755 755 805 D 190 240 240 240 290 290 290 290 350 350 400 E 460 460 460 460 480 480 480 480 510 510 550
51
Counter flanges DIN 2633 or DIN 2576 NP16 included. Pump capacity [m/h] DN50 DN50 DN25 DN25 3 3 5.4 8 8 10 13 13
Dimensions Heater capacity [kW] 12 18 36 24 54 72 72 108 Type 3-12S 3-18S 5, 4-36S 8-24S 8-54S 10-72S 13-72S 13-108S
52
80
60
40
20
53
System components 01 02 03 04 05 06 07 08 09 10 11 12 13 14 HT-cooling water pump LT-cooling water pump Charge air cooler LT Lubricating oil cooler HT-thermostatic valve LT-thermostatic valve Expansion tank HT-preheating pump HT-preheater HT-standby pump LT-standby pump Central cooler Sea-water pump Sea-water standby pump
15 16 17 18
Sea-water filter Discharge valve Charge air cooler HT Other sea-water cooled equipment
Pipe connections 401 402 404 406 408 451 452 454 457 HT-water inlet HT-water outlet HT-water air vent Water from preheater to HT-circuit HT-water from stand-by pump LT-water inlet LT-water outlet LT-water air vent LT-water from standby pump
Pipe dimensions Connection size L V 401 DN100 DN125 402 DN100 DN125 404 OD12 OD12 406 OD28 408 DN100 DN125 451 DN100 DN125 452 DN100 DN125 454 OD15 OD15 457 DN100 DN125
54
System components 01 02 03 04 05 06 07 08 09 10 11 12 13 HT-cooling water pump LT-cooling water pump Charge air cooler LT Lubricating oil cooler HT-thermostatic valve LT-thermostatic valve Expansion tank HT-preheating pump HT-preheater Thermostatic valve Heat recovery Central cooler Charge air cooler HT
Pipe connections 401 402 404 406 451 452 454 HT-water inlet HT-water outlet HT-water air vent Water from preheater to HT-circuit LT-water inlet LT-water outlet LT-water air vent
Pipe dimensions Connection size L V 401 DN100 DN125 402 DN100 DN125 404 OD12 OD12 406 OD28 451 DN100 DN125 452 DN100 DN125 454 OD15 OD15
55
Cooling water system, auxiliary engines in common water system with main engine (3V76C2634a)
System components 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 HT-cooling water pump LT-cooling water pump Charge air cooler LT Lubricating oil cooler HT-thermostatic valve LT-thermostatic valve HT-preheating pump HT-preheater HT-cooling water pump HT-stand-by pump Heat recovery LT-cooling water pump LT-standby pump Alternator cooler Charge air cooler HT Central cooler
Pipe connections 401 402 404 406 451 452 454 460 461 HT-water inlet HT-water outlet HT-water air vent Water from preheater to HT-circuit LT-water inlet LT-water outlet LT-water air vent LT-water to alternator cooler LT-water from alternator cooler
Pipe dimensions Connection size L V 401 DN100 DN125 402 DN100 DN125 404 OD12 OD12 406 OD28 451 DN100 DN125 452 DN100 DN125 454 OD15 OD15 460 461
56
System components 01 02 03 04 05 06 07 08 09 Main starting air valve Starting air distributor Starting air valve in cylinder head Blocking valve, when turning gear engaged Air container Pneumatic stop cylinder at each injection pump Non-return valve Starting booster for speed governor Flame arrester
Size DN32
DIN 2635, PN 40
57
System components 01 02 03 Starting air vessel Oil and water separator Starting air compressor
Size DN32
58
In multi-engine installations, the number of starts is dependent on the number of engines. To determine the required volume of the starting air vessel the following values can be used: Engine 6L32 8L32 9L32 12V32 16V32 18V32 A= B= A 30 30 30 30 30 30 B 10 10 10 10 10 10 C 0.7 0.9 0.9 1.0 1.2 1.3
1.5
Nominal maximum pressure in bar (absolute maximum pressure 33 bar) Minimum air pressure in bar for a safe start. Applies to an engine room temperature of 20C. At lower temperature higher pressure is required. Starting air consumption (average) per start, in Nm, at 20C.
1.5
C=
The above air consumptions apply to a 2 - 3 sec long start impulse. This is also the shortest time required for a safe start.
59
Leg. A B C D E F G
Connection Starting air outlet Filling, 125 l Filling, 250 l and 500 l Manometer connect. Condense drain Overpressure relief Air relief valve Drain
Weight [kg]
60
System components 01 02 03 Shut-off and flow adjusting valve Rubber hose Bilge or sludge tank
Pipe dimensions Connection size Note! 01 02 Shut-off and flow adjusting valve bulkhead mounted in the engine room Rubber hose length ~ 10 m 502 OD18 503 OD28
Pipe connections, engine 502 503 Cleaning water to turbine, Quick coupling PN4 Cleaning water from turbine, DIN 2391
61
Combustion air
Usually, the air required for combustion is taken from the engine room through a filter fitted on the turbocharger. This reduces the risk for too low temperatures and contamination of the combustion air. It is imperative that the combustion air is free from sea water, dust, fumes, etc. The combustion air should be delivered through a dedicated duct close to the turbocharger(s), directed towards the turbocharger air intake(s). Also auxiliary engines shall be served by dedicated combustion air ducts. For the required amount of combustion air, see Technical Data. If necessary, the combustion air duct can be directly connected to the turbocharger with a flexible connection piece. To protect the turbocharger a filter must be built into the air duct. The permissible pressure drop in the duct is max. 100 mmWC. See also Cold operating conditions below.
Ventilation
The amount of air required for ventilation is calculated from the total heat emission to evacuate. To determine , all heat sources shall be considered, e.g.: Main and auxiliary diesel engines Exhaust gas piping Alternators Electric appliances and lighting Boilers Steam and condensate piping Tanks It is recommended to consider an outside air temperature of not less than 35C and a temperature rise of 11C for the ventilation air. The amount of air required for ventilation is then calculated from the formula:
qv =
qv = = = t = c=
t c
amount of ventilation air [m/s] total heat emission to be evacuated [kW] density of ventilation air 1.15 kg/m temperature rise in the engine room [C] specific heat capacity of the ventilation air 1.01 kJ/kgK
62
L32 V32
63
Pipe dimensions 6L32 8L32 9L32 12V32 16V32 18V32 NS600 NS700 NS700 2 x NS600 2 x NS700 2 x NS700
Turbocharger
Wrtsil L32: TC at free end 0 90 to rear side 0 45 to rear side 90 to rear side TC at flywheel end 0 90 to rear side 0 45 to rear side 90 to rear side
0 / 30 (A-bank) 0 / 45 (A-bank)
64
Silencer
When included in the scope of supply, the standard silencer is an absorption silencer, equipped with spark arrester. It is also provided with a soot collector and water drain, but is without mounting brackets and insulation. The silencer can be mounted either horizontally or vertically. The noise attenuation of the standard silencer is either 25 or 35 dB(A).
*inner diameter
Attenuation Engine 6L32 8L32, 9L32 12V32 16V32 18V32 NS 600 700 800 900 1000 D 1300 1500 1700 1800 1900 A 705 810 920 1020 1120 B 300 300 300 300 300 L
65
Hardwired signals
External system
WECS 2000
Engine mounted
START
ENGINE SPEED
STOP
STOP RELAY HARDWIRED START BLOCKI NG HARDWIRED START ECU START FUEL LIM ITER SLOW TURNI NG FAILURE ALARM SPEED SWITCH 1 SPEED SWITCH 2
U1
U2
U3
U4
U5 BACKUP
LUBE OIL
RESET
OPTIO NAL SHUTDO WN ECU STOP/SHU TDOWN HARDWIRED STOP OVERSPEED SHUTDO WN EMER GENC Y STOP ECU WATCHDO G STOP/SHUTDO WNOVERR IDE SHUTDOWN RESET
CAN
VAISALA
RS-485
VAISALA
RELAY MODULE
REMOTE
HT-WATER
Relay Module
The exact structure of the system, i.e. the number of Distributed Control Units (DCU) and Sensor Multiplexer Units (SMU), depends on the cylinder configuration. All sensors on the engine are connected to the DCUs, SMUs, Relay Module or Local Control Panel (LCP), while the signals to and from the external system are connected to the Main Control Unit (MCU) and the Relay Module (RM). The engine parameters are shown on the Local Display Unit (LDU).
WECS comprises: Measuring of the engine and turbocharger speed Engine safety system - starting of the engine - stopping of the engine - start blocking - automatic shutdown of the engine - load reduction request Signal processing of all monitoring and alarm sensors Readout of important engine parameters on a graphical display Data communication with external systems (e.g. alarm and monitoring systems).
66
The backup supply is recommended to have a separate power supply. Both power supplies are recommended to be: galvanically isolated from other equipment in accordance with the classification societies requirements. fed from the UPS system of the ship Main and auxiliary supply: Backup supply: Max. ripple 24 V DC / 5 A (18 - 32 VDC) 24 V DC / 3 A (18 - 32 VDC) 500 mVp-p
WECS units
DCU1 supply 24 VDC DCU2 supply 24 VDC LDU supply 24 VDC Stop supply 24 VDC
Relay module
External system
Yard connections
The following hardwired signals are available from the speed measuring function: Engine running output, potential free contact (closed = running) Overspeed alarm switch output, potential free contact (closed = overspeed alarm) Engine speed output, 4 - 20 mA for engine speed 0 - 1000 RPM, max. load 50 Turbocharger speed output, 4 - 20 mA for turbocharger speed 0 - 30000 RPM, max. load 50 Engine speed pulse output, potential free opto connection, 0 - 400 Hz for engine speed 0 - 1000 RPM Speed switch 3 output, potential free opto connection (closed = speed over limit), (optional) Speed switch 4 output, potential free opto connection (closed = speed over limit), (optional)
67
STOPPING
The engine is stopped by turning the stop lever to the stop position or by energizing two solenoid valves. One valve operates the pneumatic cylinders on the injection pumps cutting the fuel injection. The other valve acts on the speed governor. The solenoid valves are energized by pressing the STOP button on the engine or remotely via the remote stop input. Optionally the solenoid valves can also be activated via the Modbus communication link. When two engines are connected to a common reduction gear it is recommended that the clutches are blocked in the OUT position when the engine is not running. When an engine is stopped, the clutch should open to prevent the engine from being driven through the gear. At an overspeed shutdown signal the clutch should remain closed. The stop sequence of the MCU is shown in Fig 4. The following hardwired signals are available to/from the stopping function: Inputs remote stop input, potential free contact required (stop = closed) remote reset shutdown input, potential free contact required (reset = closed) external shutdown 1 input, potential free contact required (shutdown = closed) external shutdown 2 input, potential free contact required (shutdown = closed), (optional) shutdown override input, potential free contact required (override = closed) Outputs indication output: shutdown, potential free opto connection (shutdown = closed) engine stop/shutdown output, potential free contact (stop/shutdown = closed) run/stop output to the electronic speed governor (if used), potential free opto connection (closed = stop) Engine stop/shutdown output is always closed when the stop signal is active, while indication output shutdown only is closed when an automatic shutdown has occurred. Consequently indication output shutdown can be used to control the shutdown reset indicator lamp.
68
2.0
BLACK OUT START HW: X6:17-18 AND ENGINE WITHOUT SLOW TURNING FEATURE
BLACK OUT START HW: X6:17-18 AND ENGINE WITH SLOW TURNING FEATURE
2.3
2.9
2.4
=1
NO SLOW TURNING
2.5 3.7
=1 2.7
SLOW TURNING
2.0
2.6
ACTIVATE SLOW TURNING SOLENOID 5s C IF SPEED < START L SPEED LIMIT (IF W32, WV32) ACTIVATE START C L SOLENOID 5s IF SPEED
=1
=1
2.8
NO OPERATION
2.9
2.10
L S L S L S
SET MODBUS: FAILED START ATTEMPT t = 20 s SET MODBUS: START BLOCKED MODE ACTIVATE HW: X1:8 START FAILURE IND t = 20 s
20 s / X2.10
2.0
69
70
START BLOCKING
An engine start is blocked by the following conditions: low prelubricating oil pressure turning gear engaged stop lever in stop position local/remote switch in local position (blocks the remote start) local/remote switch in remote position (blocks the local start) external start blocking 1 input external start blocking 2 input, (optional) The following hardwired signals are available to/from the start blocking function: Inputs external start blocking 1 input, potential free contact required (start blocked = closed) external start blocking 2 input, potential free contact required (start blocked = closed), (optional) Outputs indication output: local control mode, potential free opto connection (local mode = closed) If a start blocking is active, it is not possible to start the engine. On the Modbus communication link an alarm is raised for each active start blocking. Start blockings are ignored in case of a blackout start.
SHUTDOWNS
An engine shutdown is carried out in the same way as a normal stop, i.e. by energizing two solenoid valves. The sensors used for shutdown are of analogue type, and the shutdown levels are defined in the WECS software. The shutdown is latching, and a shutdown reset has to be given before it is possible to re-start. Naturally, before this, the reason of the shutdown must be investigated. The reason of any shutdown will be indicated on the Modbus communication link to the external systems.
71
When the alarm condition is over, the following actions are taken: On the LDU the measured value is shown as normal text On the Modbus the alarm bit is set to value 0 Common engine alarm is deactivated, if there are no other active alarms The following hardwired signals are available from the alarm function: Common engine alarm, potential free opto connection (alarm = open) RM failure, potential free contact (alarm = open) WECS failure, potential free opto connection (alarm = open) Load switch, potential free opto connection (high load = closed) Note! WECS shall not be considered an alarm system. The Modbus link shall be connected to the ships alarm system, where latching and acknowledge of alarms shall be handled.
ALARMS
The following settings can be configured for any measured data item Alarm limit Alarm condition Blocked at standstill Startup delay These settings are documented in the Modbus list of the engine. An alarm condition generates the following actions: On the LDU the measured value is shown inverted An alarm message is printed on the history page of the LDU On the Modbus the alarm bit is set to value 1 Common engine alarm is activated
72
External system
Option
Shutdown override Emergency stop
Option
Relay module
Yard connections
An overview of the hardwired output signals is shown in Fig 6. There are two types of ON/OFF output signals: potential free contacts and potential free opto connections.
Turbo A speed (4 - 20 mA) Turbo B speed (4 - 20 mA) Local control mode indication Ready for start indication Start failure indication Shutdown indication Supply to indications
External system
Prelubricating pump control Load reduction request Common engine alarm WECS failure
Prelubricating pump control Load reduction request Common engine alarm WECS failure Engine speed pulse Run / stop
Relay Module
RM failure Engine running Overspeed alarm switch Engine stop / shutdown Speed switch 3
Option
Speed switch 4 Load switch Fuel oil standby pump control Lube oil standby pump control HT water standby pump control LT water standby pump control
Speed switch 4 Load switch Fuel oil standby pump control Lube oil standby pump control HT water standby pump control LT water standby pump control
Option
Yard connections
73
0V
0V
Yard connection
Yard connection
74
Code LS103A LS103B LS106A LS106B LS108A LS108B PT101 TE101 LS204 PT201-1 PT241 PDY243 TE201 TE231 PT301 PT311 PT401 PT471 TE401 TE402-1 TEZ402 TE422A TE422B TE432 TE432A TE471 TE472 TE482 TE511 TE517 TE51CA.. TE622 PT622 PDT623 PDT633 QU700 TE700... TE711A... PT700 GT165 GS171 ST173 ST174 SE518 SE528 GS792 PSZ201
Name Fuel oil leakage, inj. pipe A-bank Fuel oil leakage, inj. pipe B-bank Fuel oil leakage, clean fuel A-bank Fuel oil leakage, clean fuel B-bank Fuel oil leakage, dirty fuel A-bank Fuel oil leakage, dirty fuel B-bank Fuel oil pressure, inlet Fuel oil temperature, inlet Lube oil level (if wet sump) Lube oil pressure, inlet Lube oil pressure, filter inlet Lube oil filter pressure difference1) Lube oil temperature, inlet Lube oil temperature, LOC inlet Start air pressure Control air pressure HT-water pressure, inlet LT-water pressure, inlet HT-water temperature, inlet HT-water temperature, outlet HT-water temperature, engine outlet HT-water temperature, TC A outlet 5) HT-water temperature, TC B outlet 5, 6) HT-water temperature, CAC outlet 7) HT-water temperature, CAC outlet LT-water temperature, CAC inlet LT-water temperature, CAC outlet LT-water temperature, LOC outlet Exhaust gas temp., turbo inlet 2) Exhaust gas temp., turbo outlet Exhaust gas temp., cylinder outlet 3) Charge air temperature, inlet Charge air pressure, inlet CAC pressure difference, A-bank CAC pressure difference, B-bank 6) Oil mist detector, alarm Main bearing 0 temperature 4) Cylinder liner temperature1 3) Crankcase pressure Fuel rack position Stop lever in stop position Engine speed Engine speed, backup system Turbocharger A speed Turbocharger B speed 6) Turning gear engaged Lube oil pressure, inlet (backup syst.)
Type b b b b b b a a b a a a a a a a a a a a a a a a a a a a a a a a a a a b a a a a b a a a a b b
calculated value (not a separate sensor) 1 - 4 pcs, depending on exhaust gas system 3) 2 pcs/cylinder 4) (n + 2) pcs, where n = number of cylinders / bank 5) Only if EGT turbocharger 6) Only if V-engine 7) Only if two stage CAC
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Note! All sensors are connected to WECS and can only communicate with the remote alarm & monitoring system by means of the Modbus communication link. The only hardwired signals existing are those listed in the Safety system, see paragraph 13.4. Even if the above mentioned sensors are considered as standard the amount and type of sensors can vary, depending on the needs for various installations. The actual set of sensors and other electrical equipment mounted on the engine, as well as alarm set points, can be found in the installation specific instructions.
The load balance of the cylinders is shown as temperature deviation for each cylinder from the average temperature of all cylinders. In the lower part of the meter window the following pressures and temperatures are normally shown: Fuel oil pressure, inlet Lube oil pressure, inlet HT-water pressure, inlet LT-water pressure, inlet Charge air pressure, inlet Fuel oil temperature, inlet Lube oil temperature, inlet HT-water temperature, outlet LT-water temperature, inlet Charge air temperature, inlet The message window is the bottom part of the display area. The window shows the status of the engine.
13.9. Instrumentation
LOCAL DISPLAY UNIT
The Local Display Unit (LDU) replaces the traditional pressure gauge panel, the thermometers and other instruments. It is connected to the MCU, which sends the necessary data to the display. Three different pages can be displayed: the meter page the history page the status pages
Meter page
The meter page is divided into two different sub windows: the meter window and the message window. In the meter window the parameters are shown as graphical meter images with explanatory text and exact numerical value below the meter. Abnormal values are shown in inverted colours. Three important parameters of the engine are at the upper part of the meter window: the engine speed the load balance of the cylinders the fuel rack position
BACKUP INSTRUMENTS
In addition to the LDU there are three backup instruments that are independent of the rest of the system. The three instruments are: engine speed, HT cooling water temperature and lubricating oil pressure.
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04
05
Standard Modbus RDStandard Modbus RD+ Standard Modbus SDStandard Modbus SD+
External system
The WECS returns exception response in case of an illegal query. This kind of situation may occur if the master tries to use function that is not supported by the WECS. The exception response is formed according to instructions given in Appendix A of the Modicon Modbus Protocol Reference Guide. Note! The commands follow the Modicon Modbus Protocol Reference Guide, PI-MBUS-300 Rev. D, March 1992. A misprint on page 113 should be noticed. The reference guide states in section Placing the CRC into the Message that When the 16-bit CRC (2 8-bit bytes) is transmitted in the message, the low-order byte will be transmitted first, followed by the high-order byte. It should be the other way around, i.e. When the 16-bit CRC (2 8-bit bytes) is transmitted in the message, the high-order byte will be transmitted first, followed by the low-order byte. For example, if the CRC value is 1241 hex (0001 0010 0100 0001).
Option Modbus RDOption Modbus RD+ Option Modbus SDOption Modbus SD+
Option
Option
Addr
Func
Data count
Data
Data
Data
Data
CRC Hi 12
CRC Lo 41
77
Packets in Modbus
Modbus packets are binary. The packets are recognized with delays in communications. All communication is initiated by a master, the slaved can send data only when requested. A 1.5 character delay means that the packet was interrupted and should be discarded by recipients. A 2.5 character delay means that the next character starts a new packet.
Reply message: 01 03 ... FF FF slave address, same as in the poll message function code, same as in the poll message data CRC high byte CRC low byte
Message format
The general message format is described below. Poll message: 01 03 ... FF FF slave address (id) function code parameters CRC high byte CRC low byte
Code name Norm. External commands: OS731 Engine start OS732 Engine stop Fuel oil: LS103A LS106A LS108A PT101 TE101 Lube oil: LS204 PT201-1 PT241 PDY243 TE201 TE231 Fuel oil leakage, injection pipe Fuel oil leakage, clean fuel Fuel oil leakage, dirty fuel Fuel oil pressure, inlet Fuel oil temperature, inlet Lube oil level Lube oil pressure, inlet Lube oil pressure, filter inlet Lube oil filter pressure difference Lube oil temperature, inlet Lube oil temperature, LOC inlet
WECS scale
Alarm condition
00001 00002 10001 10002 10003 10004 high high high low
30004 30005
10 1
11008
12011
10 10 10 1 1
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Two examples of sequences are shown in the following: Sequence 1: 30001 ... 30125 10001 ... 10250 11001 ... 11250 12001 ... 12250 30126 ... 30250 10001 ... 10250 11001 ... 11250 12001 ... 12250 30001 ... 30125 ... The bus is 55 - 60% loaded when analog addresses are read once every 2 seconds and binary addresses once every second. Sequence 2: 30001 ... 30085 10001 ... 10250 11001 ... 11250 12001 ... 12250 30086 ... 30170 10001 ... 10250 11001 ... 11250 12001 ... 12250 30171 ... 30250 10001 ... 10250 11001 ... 11250 12001 ... 12250 30001 .. .30085 ... The bus is 55 - 60% loaded when analog addresses are read once every 2.5 seconds and binary addresses once every 0.83 second. Update rate of analog blocks may also vary. In the sequence 2, the update frequency is lower for analog addresses and higher for binary addresses than in the sequence 1. Messages are also shorter in sequence 2, which is good in case of failed transmission. The purpose of this example is to show that in every project the correct update rate must be carefully investigated for all data blocks. This is the only way to guarantee safe and optimized communication. More detailed information about addresses and alarm/ stop/load reduction limits is represented in installation specific instructions.
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14. Seating
14. Seating
14.1. General
Main engines are usually rigidly mounted to the foundation, either on steel or resin chocks. Diesel generator sets are flexibly mounted on rubber elements. Also main engines can be flexibly mounted, if required. The foundation should be stiff in all directions to absorb the dynamic forces caused by the engine. Especially the foundation of the propeller thrust bearing (the reduction gear) should be dimensioned and designed so that harmful deformations are avoided. Dynamic forces caused by the engine appear from the table.
Speed [RPM] 720 750 720 750 720 750 720 750
MZ [kNm] 44 47 57 62
MZ [kNm] 22 24
80
14. Seating
The design of the clearance and the fitted bolts is shown in drawings 1V69A0144 and 1V69A0145. The bolts are designed as tensile bolts, with a reduced diameter, 35, to ensure a sufficient elongation and thus avoid loosening. The bolts are dimensioned so that a sufficient elongation is achieved if using St 52-3 and tightening the bolts to 80% of the yield point. It is however recommended to use 34CrNiMo6V (or similar) which will result in a better elongation already when tightened to 60% of the yield point. In order to assure proper fastening and avoid bending stress in the bolts, the contact faces of the nuts shall be spotfaced. Oil pressure to be used for the hydraulic tool: 34CrNiMo6V Tightened to 60% of yield point bolt = 60% x 785 N/mm = 471 N/mm Fbolt = 471 N/mm x Phyd = St 52-3
352 = 453155 N 4
bolt = 80% x 335 N/mm = 268 N/mm Fbolt = 268 N/mm x Phyd =
352 = 257846 N 4
Side supports must be installed for all engines. On six, eight, twelve and sixteen cylinder engines, two supports on each side of the engine are used and on nine and eighteen cylinder engines three on each side. If resin chocks are used, an additional side support shall be fitted on each side closest to the flywheel. The side supports are to be welded to the seating top plate before aligning the engine and fitting the chocks. An acceptable bearing surface must be obtained on the wedges of the side supports.
81
14. Seating
View B - B
View A - A
82
14. Seating
83
14. Seating
View B - B
View A - A
84
14. Seating
85
14. Seating
View B - B
86
14. Seating
87
14. Seating
View B - B
88
14. Seating
89
14. Seating
Normally, conical rubber mounts are used; in special cases also other types of mounts can be considered. The rubber element in the mounts is designed to withstand both compression and shear loads. In addition, the mounts have built-in buffers to limit the movements of the generating set due to the sea state. The mounts are made of natural rubber and care must be taken that the mounts will not come in contact with oil, oily water or fuel. The compression of all mounts must be equal when the generating set is installed and aligned on the ships foundation. The maximum permissible variation in compression is 2.0 mm when using conical mounts. Adjustments in height are made using steel chocks. If shims are used, the minimum thickness of a shim is 0.5 mm and only one shim per mount is permitted. The transmission of forces emitted by the engine is 10 20% when using conical mounts. For the foundation design, see drawing 3V46L0295 (in-line engines) and 3V46L0294 (V-engines).
90
14. Seating
The external pipe must be precisely aligned to the fitting or the flange of the engine. Observe that the pipe clamp for the pipe outside the flexible connection must be very rigid and welded to the steel structure of the foundation to prevent vibrations, which could damage the flexible connections. Most problems with bursting of the flexible connection originate from poor clamping. See drawing 4V60L0796 showing how pipes shall be clamped.
91
92
126
110 90 70 50
76 82 70 94
90% Min.
124 121
109 98
113
117
114
112
103
* Corresponding sound pressure level for 18V32 is 110 dB(A) when reverberation time in engine room is 1.5 second.
A-weight*
Linear
63
125
250
500
1000
2000
4000
8000
31.5
90% Min.
90
108
121 98
119
116
70 50
The values are based on measurements perpendicular to the free exhaust pipe outlet (no exhaust gas silencer installed in the piping).
A-weight*
Linear
63
125
250
500
1000
2000
4000
31.5
93
94
D1 200
D2 200
D3 300
D4 260
95
96
97
98
* ** ***
Piston and connecting rod can be freely transported over adjacent cylinder heads Piston and connecting rod can be freely transported over insulation box The breadth of the common baseplate can vary with the type of alternator
99
* Piston and connecting rod can be freely transported over adjacent cylinder head covers ** Piston and connecting rod can be freely transported over insulation box
100
* Piston and connecting rod can be freely transported over adjacent cylinder head covers ** Piston and connecting rod can be freely transported over insulation box
101
3. Turbocharger
Engine 1. 6L32 8L32 9L32 12V32 16V32 18V32 87 120 120 180 180 180
Item weight [kg] 2. 385 500 500 770 1000 1000 3. 690 870 870 2 x 690 2 x 870 2 x 870 A 730 1220 1220 1338 1338 1338 B 369.4 369.4 369.4 479.4 479.4 479.4
Dimensions C 963 963 963 1896 1896 1896 D 630 630 630 630 630 630 E 400 400 400 400 400 400
Engine Na-7 series F 6L32 8L32 9L32 12V32 16V32 18V32 1186 1445 1445 1186 1445 1445
Dimensions TPL F 1313 1574 1574 1313 1574 1574 G 880 1036 1036 880 1036 1036
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Item 1. 2. 3. 4. 5. 6. 7.
Connecting rod Piston Cylinder liner Cylinder head Inlet valve Exhuast valve Injection pump
Injection valve Starting valve Main bearing shell Split gear wheel Small intermediate gear Large intermediate gear Camshaft gear wheel Piston ring
103
Tank Flexible pipe, hose Insulated pipe Insulated and heated pipe Orifice Quick-coupling Temperature sensor Local and remote display Pressure transmitter Local and remote display
104