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All data provided in this document is non-binding. This data serves informational
purposes only and is especially not guaranteed in any way. Depending on the
subsequent specific individual projects, the relevant data may be subject to
changes and will be assessed and determined individually for each project. This
will depend on the particular characteristics of each individual project, especially
specific site and operational conditions. CopyrightMAN Diesel & Turbo.
D2366511EN Printed in Germany GKM-AUG-05130.5
32/40
Project Guide Stationary
Four-stroke diesel engines
compliant with emission limits World Bank
2366xxx_PRJ_32-40.indd 4
03.05.2013 10:42:47
Titelseite 32-40.fm
32/40
Project Guide Stationary
Four-stroke diesel engines
compliant with emission limits World Bank
Status
Version
Checked
Date
Checked
Date
05.2013
1.5
Utjesinovic
2013-05-03
Franz
2013-05-06
All data provided in this document is non-binding. This data serves informational purposes only and is
especially not guaranteed in any way.
Depending on the subsequent specific individual projects, the relevant data may be subject to changes
and will be assessed and determined individually for each project. This will depend on the particular
characteristics of each individual project, especially specific site and operational conditions.
If this document is delivered in another language than English and doubts arise concerning the translation, the English text shall prevail.
In addition, always contact MAN Diesel & Turbo at early project stage to ensure that the latest information is transferred and the latest status of project tools is used.
Titelseite 32-40.fm
www.mandieselturbo.com
Table of contents
1
Introduction ....................................................................................... 1 - 1
1.1
Four stroke diesel and gas engine programme for stationary engines.................................. 1 - 3
1.2
Approved applications.............................................................................................................. 2 - 3
2.2
Engine design............................................................................................................................ 2 - 5
PG_Power_32-40IVZ.fm
2.3
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.3.2
2.3.3
2.3.4
Speeds ............................................................................................................... 2 - 25
2.3.5
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
GenSet operation..................................................................................................................... 2 - 45
2.11.1
2.11.2
2.11.3
2.11.4
32/40
Table of contents - 1
2.13
2.14
2.15
2.16
2.12.2
2.12.3
2.12.4
2.12.5
Aging .................................................................................................................. 2 - 61
2.13.2
2.13.3
Load specific values at ISO conditions Iginition pressure 190 bar ..................... 2 - 66
2.13.4
2.13.5
2.13.6
Load specific values at ISO conditions Iginition pressure 205 bar ..................... 2 - 71
2.14.2
2.14.3
2.14.4
2.14.5
2.14.6
2.15.2
2.15.3
2.15.4
Emissions ................................................................................................................................ 2 - 95
2.16.1
2.17
2.16.2
2.16.3
Noise...................................................................................................................................... 2 - 101
2.17.1
2.17.2
2.17.3
Table of contents - 2
32/40
PG_Power_32-40IVZ.fm
2.12
2.18
2.18.1
2.18.2
2.19
2.20
3.2
3.3
Operation................................................................................................................................... 3 - 9
3.4
Functionality ........................................................................................................................... 3 - 11
3.5
Interfaces ................................................................................................................................ 3 - 13
3.6
Technical data......................................................................................................................... 3 - 15
3.7
4.2
PG_Power_32-40IVZ.fm
4.1.2
Fuel ...................................................................................................................... 4 - 3
4.1.3
4.1.4
Intake air............................................................................................................... 4 - 4
4.2.2
4.2.3
4.3
4.4
Lubricating oil (SAE 40) Specification for heavy fuel operation (HFO) (stationary) .......... 4 - 11
4.5
4.6
4.7
4.8
32/40
Table of contents - 3
4.10
4.11
4.12
4.13
4.14
4.15
5.2
5.3
5.4
5.1.2
5.2.2
5.2.3
Prelubrication/postlubrication.............................................................................. 5 - 23
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.3.2
5.3.3
Miscellaneous items............................................................................................ 5 - 51
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8
Preheating module.............................................................................................. 5 - 65
5.4.2
Marine diesel oil (MDO) supply system for diesel engines .................................... 5 - 71
5.4.3
5.4.4
Table of contents - 4
32/40
PG_Power_32-40IVZ.fm
4.9
5.5
5.5.2
5.5.3
5.6
5.7
5.7.2
Annex ................................................................................................. 7 - 1
7.1
General................................................................................................................. 7 - 3
7.1.2
7.2
7.3
7.4
Definitions ............................................................................................................................... 7 - 13
7.5
Symbols................................................................................................................................... 7 - 17
7.6
7.7
7.6.1
General information............................................................................................. 7 - 21
7.6.2
7.6.3
7.6.4
PG_Power_32-40IVZ.fm
Index ......................................................................................................... I
32/40
Table of contents - 5
PG_Power_32-40IVZ.fm
Table of contents - 6
32/40
======
Introduction
Kapiteltitel 1 AA.fm
Page 1 - 1
Page 1 - 2
Kapiteltitel 1 AA.fm
Introduction
1.1 Four stroke diesel and gas engine programme for stationary engines
0101-0201PA.fm
1.1
Figure 1-1
Figure 1-2
iJ_`
Page 1 - 3
Introduction
0101-0201PA.fm
1.1 Four stroke diesel and gas engine programme for stationary engines
Page 1 - 4
L-BC
Introduction
1.2 Engine description 32/40
1.2
General
With an electrical power output range of 4.3 to
8.7 MWe, the 32/40 engine is ideal for small- and
medium-sized applications. The well proven
320 mm bore classic is in operation around the
world day in, day out. The interacting of all important parts results in low wear rates and long
maintenance intervals.
Marine main engines
The engines output is limited to 110 % of rated
output for engines driving a alternator. Overload
above 100 % permitted briefly to prevent a frequency drop during sudden load application.
Cylinder head
0102-0000PB.fm
Valves
Fuels
B-BD
32/40
Page 1 - 5
Introduction
1.2 Engine description 32/40
0102-0000PB.fm
Page 1 - 6
32/40
B-BD
======
Kapiteltitel 2 AA.fm
Page 2 - 1
Page 2 - 2
Kapiteltitel 2 AA.fm
2.1
Approved applications
The 32/40 was designed for stationary applications and its suitability has been proven through
extensive factory tests for following applications:
Note!
0200-0000PB.fm
^J_a
32/40
Page 2 - 3
0200-0000PB.fm
Page 2 - 4
32/40
A-BD
0201-0000PB.fm
2.2
Engine design
2.2.1
Figure 2-1
A-BD
32/40
Page 2 - 5
Figure 2-2
Page 2 - 6
32/40
A-BD
2.2.2
12V32/40
Piston stroke [cm]
Cylinder bore [cm]
V=Vee engine, L= in-line engine
Cylinder number
Parameter
Value
Unit
9,
12, 14, 16, 18
Cylinder bore
320
mm
Piston stroke
400
Number of cylinders
32.17
dm3
14.5
15.2
L = 530
mm
V = 630
45
L = 290
mm
V = 320
V = 290
0201-0200PB.fm
Table 2-1
B-BD
32/40
Page 2 - 7
0201-0200PB.fm
Page 2 - 8
32/40
B-BD
2.2.3
Turbocharger assignment
32/40
No. of cylinders
Stationary, WB 1998
Stationary, WB 2007/2008
500 kW/cyl.
720 or 750 rpm
500 kW/cyl.
720 or 750 rpm
9L
NR34/S
NR34/S
12V
NR29/S
NR29/S
14V
NR29/S
NR29/S
16V
NR34/S
NR34/S
18V
NR34/S
NR34/S
Table 2-2
Turbocharger assignment
0202-0200PB.fm
^J_a
32/40
Page 2 - 9
0202-0200PB.fm
Page 2 - 10
32/40
A-BD
2.2.4
Engine L32/40
L32/40
B
C
Figure 2-3
Legend
Engine
mm
9L32/40
7,215
4,100
11,315
Weight
tons
5,125
2,715
82
0202-0201PB.fm
All weights and dimensions apply only to dry engines without a flywheel and are for guidance only.
_J_a
32/40
Page 2 - 11
Engine V32/40
V32/40
A
Figure 2-4
Legend
Engine
mm
Weight
tons
12V32/40
6,475
4,215
10,690
4,795
3,370
98
14V32/40
7,105
4,215
11,320
4,795
3,370
112
16V32/40
7,670
4,450
12,120
5,240
3,500
131
18V32/40
8,300
4,450
12,750
5,240
3,500
139
0202-0201PB.fm
All weights and dimensions apply only to dry engines without a flywheel and are for guidance only.
Page 2 - 12
32/40
B-BD
2.2.5
Stationary engines,
WB1
Stationary engines,
WB2
Slow turn
Sealing oil
X = required, O = optional
Engine equipment
0201-0300PB.fm
Table 2-3
_J_a
32/40
Page 2 - 13
Overview flaps
Page 2 - 14
32/40
B-BD
0201-0300PB.fm
Figure 2-5
starting air vessels is reduced to a pressure of approx. 4 bar before being passed into the compressor casing of the turbocharger to be admitted to
the compressor wheel via inclined bored passages. In this way, additional air is supplied to the
compressor which in turn is accelerated, thereby
increasing the charge air pressure. Operation of
the accelerating system is initiated by a control,
and limited to a fixed load range.
Slow turn
Sealing oil
0201-0300PB.fm
_J_a
32/40
Page 2 - 15
0201-0300PB.fm
Page 2 - 16
32/40
B-BD
2.3
2.3.1
kW elec.
9L32/40
4,500
4,365
12V32/40
6,000
5,820
14V32/40
7,000
6,790
16V32/40
8,000
7,760
18V32/40
9,000
8,730
Note!
Nominal alternator efficiency L-type: 97.3 %, V-type: 97.0%.
Table 2-4
K/C
298/25
Air pressure pr
kPa
100
30
K/C
316/43
Relative humidity r
Charge air temperature1)
Table 2-5
1) Specified
0201-0306PB.fm
_J_a
32/40
Page 2 - 17
2.3.2
Notes
P Application
Kind of application
100
110
2)
Island operation
100
110
2)
Electricity generation
Table 2-6
1) Maximum
0201-0306PB.fm
2)
Page 2 - 18
32/40
B-BD
P Operating: Available rating (output) under local conditions and dependent on application
Dependent on local conditions or special application demands a further load reduction of P Application, ISO
might be needed.
1. No de-rating necessary, provided the conditions listed in the respective column
(see "Table 2-7: De-rating Limits of ambient conditions") are met:
No de-rating up to
stated reference conditions (Tropic), see 1.
45 C
1,000 mbar
38 C
38 C < tcx 43 C
De-rating needed
accord. to special calculation, see 3.
> 60 C
900 mbar
> 43 C
20 mbar1)
< 40 mbar1)
30 mbar1)
> 60 mbar1)
Table 2-7
1)
2. De-rating due to ambient conditions and negative intake pressure before compressor or exhaust gas
back pressure after turbocharger.
Pr
m = m
1.2
0.7
q ~
q ~
= ------- ------------------- ----------------------
273 +
273 +
~
0.7
315
308 l r 1.2
= --------- ----------------------------- ----------------------
955
273 +
273 +
1
= 0.7 1 ------- 1
1
0201-0306PB.fm
i.e. Px Pr
_J_a
Px
Output at site [kW]
tcx
Cooling water temperature inlet charge air cooler at
site [C]
Ambient air temperature before turbocharger at site
tx
[C]
Substitute reference for charge air cooling water
Tcra
temperature = 315 [K]
Substitute reference for ambient air temperature =
Tra
308 [K]
O
Increased exhaust gas back pressure after turbocharger leads to a de-rating, calculated as increased air
temperature before turbocharger [K]:
O = (p Exhaust after turbine [mbar] 30 [mbar]) x 0.25 [K/mbar];with
O0
U
Increased negative intake pressure before compressor leads to a de-rating, calculated as increased air temperature before turbocharger [K]:
U = (20 [mbar] p Air before compressor [mbar] ) x 0.25 [K/mbar];
with U 0
32/40
Page 2 - 19
3. De-rating due to special conditions or demands. Please contact MAN Diesel & Turbo:
If limits of ambient conditions mentioned in "Table 2-7: De-rating Limits of ambient conditions" are exceeded. A special calculation is necessary.
If higher requirements for the emission level exist. For the allowed requirements see "Section: Exhaust
gas emission".
0201-0306PB.fm
If any requirements of MAN Diesel & Turbo mentioned in the project guide cannot be kept.
Page 2 - 20
32/40
B-BD
2.3.3
If the recommended exhaust gas back pressure as stated in "Section: "Planning data" "Operating/service
temperatures and pressures" cannot be kept due to exhaust gas after treatment installations following items
need to be considered.
0 ... 30 mbar
30 ... 60 mbar
> 60 mbar
0 ... 20 mbar
20 ... 40 mbar
< 40 mbar
Sum of the exhaust gas back pressure after turbocharger and the absolute value of the intake air pressure before
turbocharger
Operating pressure pexh + Abs(pintake), standard
0 ... 50 mbar
Shipyard and supplier of equipment in exhaust gas line have to ensure that pressure drop pexh over
entire exhaust gas piping incl. pipe work, scrubber, boiler, silencer, etc. must stay below stated standard operating pressure at all operating conditions.
Hereby it is recommended to consider an additional 10 mbar for consideration of aging and possible
fouling/staining of the components over lifetime.
Possible counter measures could be a proper dimensioning of the entire flow path including all installed components or even the installation of an exhaust gas blower if necessary.
At the same time the pressure drop pintake in the intake air path must be kept below stated standard
operating pressure at all operating conditions and including aging over lifetime.
If either pexh or pintake exceeds the stated standard values and even the stated values for an increased fuel oil consumption a customized engine matching becomes mandatory which will likely result in increased sfoc. For significant overruns in pressure losses even a reduction in the rated power
output may become necessary.
0201-0303bAA2.fm
In case the performance of the engine is claimed (e.g. for excessive sfoc or exhaust gas temperature),
it must be possible to install pressure sensors directly after turbine outlet and directly before compressor inlet to prove that the engine is not the root cause for poor performance.
C-BD
Page 2 - 21
It needs to be evaluated if the chosen exhaust gas after treatment installation demands a bypass for
emergency operation.
For scrubber a bypass is mandatory to ensure emergency operation of the engine in case the scrubber is blocked or damaged in such a way that the exhaust path is physically blocked or the exhaust
flow cannot be directed through the scrubber for any other reason.
The bypass needs to be dimensioned for the same pressure drop as the main installation that is bypassed otherwise the engine would operated on a differing operating point with negative influence
on the performance, e.g. a lower value of the pressure drop may result in too high turbocharger
speeds.
In general each engine must be equipped with a separate exhaust gas line as single streaming installation. This will prevent reciprocal influencing of the engines as e.g. exhaust gas backflow into an engine out of operation or within an engine running at very low load (negative pressure drop over the
cylinder can cause exhaust gas back flow into intake manifold during valve overlap).
In case a multi-streaming solution is realized (i.e. only one combined scrubber for multiple engines)
this needs to be stated on early project stage. Hereby air/exhaust gas tight flaps need to be provided
to safeguard engines out of operation. A specific layout of e.g. sealing air mass flow will be necessary
and also a power management may become necessary in order to prevent operation of several engines at very high loads while others are running on extremely low load. A detailed analysis as HAZOP
study and risk analysis by the yard becomes mandatory.
Engine to be protected from backflow of media out of exhaust gas after treatment installation
A backflow of e.g. urea, scrubbing water, condensate or even rain from the exhaust gas after treatment installation towards the engine must be prevented under all operating conditions and circumstances, including engine or equipment shutdown and maintenance/repair work.
Turbine cleaning
Both wet and dry turbine cleaning must be possible without causing malfunctions or performance
deterioration of the exhaust system incl. any installed components such as boiler, scrubber, silencer,
etc.
A visible white exhaust plume must be avoided even if it is not harmful for the environment. Especially
for scrubber counter measures as a reheating of the exhaust gas after scrubber or/and a demister to
catch any condensed water droplets to be taken.
The design of the exhaust system including exhaust gas after treatment installation has to make sure
that the exhaust flow has sufficient velocity in order not to sink down directly onboard the vessel or
near to the plant. At the same time the exhaust pressure drop must not exceed the limiting value.
Vibrations
There must be a sufficient decoupling of vibrations between engine and exhaust gas system incl. ex-
Page 2 - 22
0201-0303bAA2.fm
C-BD
Electronic data exchange between engine and exhaust gas after treatment installation.
0201-0303bAA2.fm
A specification is necessary about all engine and exhaust gas parameters that have to be provided from
the engine as input for exhaust gas after treatment installation and vice versa.
C-BD
Page 2 - 23
0201-0303bAA2.fm
2.3.3 Increased exhaust gas pressure due to exhaust gas after treatment installations in exhaust gas line
Page 2 - 24
C-BD
2.3.4
Speeds
-
Unit
Rated speed
rpm
720
750
m/s
9.6
10.0
rpm
L-engine: 60
Engine running
(activation of alarm- and safety system)
300
400
500
720
750
773
792
825
828
863
page 2-27"
60
50
concession may possibly be restricted, see "Figure 2-15: Permissible frequency deviations and corresponding max. output".
0201-0304PB.fm
1) This
Hz
^J_a
32/40
Page 2 - 25
0201-0304PB.fm
2.3.4 Speeds
Page 2 - 26
32/40
A-BD
2.3.5
The following specification represents the standard settings. For special applications, deviating
settings may be necessary.
Electronic governors
Drive
Maximum
speed at full
load
Maximum
speed at idle
running
Minimum
speed
5%
100 % (+0,5 %)
105 % (+0,5 %)
60 %
Isochronous operation
0%
100 % (+0,5 %)
100 % (+0,5 %)
60 %
GenSets/"diesel-electric plants"
0202-0400AA2.fm
Table 2-9
Speed
droop
B-BD
Page 2 - 27
0202-0400AA2.fm
Page 2 - 28
B-BD
2.4
Engine
Attached lube oil pump
Plant
Prelubrication pump with low pressure before
engine
(0.3 bar < p oil before engine < 0.6 bar)
Note!
Oil pressure > 0.3 bar to be ensured also for
lube oil temperature up to 80 C.
Note!
0201-0400PB.fm
Statements are relevant for non arctic conditions. For arctic conditions consider relevant
sections and clarify undefined details with
MAN Diesel & Turbo.
^J_a
32/40
Page 2 - 29
Engine Starting
Conditions
After Stand-Still
("Normal Start")
< 1 minute
> 2 minutes
7 days
Supervised by power management system plant.
(For longer stand-by periods in special
cases contact MAN Diesel & Turbo.)
Stand-by mode only possible after engine
has been started with normal starting procedure and has been in operation.
Required engine conditions
Start-blocking active
No
No
No
Yes
Yes
Yes
Permanent
Permanent
> 40 C
> 40 C
60 90 C
60 90 C
HT cooling water
Preheating temperature before engine
Fuel system
For MDO operation
Table 2-10
Page 2 - 30
32/40
A-BD
2.5
Denition
Generally the following load conditions are differentiated:
Full load:
Part load:
Low load:
Correlations
The ideal operating conditions for the engine prevail under even loading at 60 % to 90 % of the full
load output. Engine control and rating of all systems are based on the full load output.
In the idling mode or during low load engine operation, combustion in the cylinders is not ideal. Deposits may form in the combustion chamber,
which result in a higher soot emission and an increase of cylinder contamination.
Moreover, in low load operation and during manoeuvring of ships, the cooling water temperatures cannot be regulated optimally high for all
load conditions which, however, is of particular importance during operation on heavy fuel oil.
Better conditions
Optimization of low load operation is obtained by
cutoff of the LT stage of the charge air cooler or
perfusion of the LT stage with HT water if HT or LT
switching is available for this engine type.
For common rail engines mostly this is not necessary because optimized combustion is realized by
an electronically controlled fuel injection system.
HT: High temperature
LT: Low temperature
0206-0000AA2.fm
low load operation (on the left), duration of relieving operation (on the right)"), the engine is to be switched
over to diesel oil operation beforehand.
_J_a
Page 2 - 31
Figure 2-6
Time limits for low load operation (on the left), duration of relieving operation (on the right)
* In general the time limits in HFO operation are valid for all HFO-qualities that are in accordance to the stated specification. In
rare cases using HFO-qualitiy with a high ignition delay in combination with a high content of coke residuals it may be
needed to raise the complete limit curve for HFO-operation from a load level from 20 % to 30 % load.
Legend
P
Explanations
New running in needed after > 500 hours low load
operation (see "Section 7.3: Engine running-in, page
7-9").
Note!
Acceleration time from present output to 70 %
of full load output not less than 15 minutes.
Example
0206-0000AA2.fm
Page 2 - 32
_J_a
2.6
"Figure 2-9: Load application for GenSets; engines preheated and prelubricated, synchronization speed reached"
"Figure 2-10: Load application for GenSets; engines preheated and prelubricated, synchronization speed
reached Only emergency case" shows the shortest
80
60
40
20
0208-0300PB.fm
Figure 2-7
^J_a
20 ... 40s
Run up
10 ... 20s
Synchronization
Time [sec]
Start up times until load application from stand-by mode; engines preheated and prelubricated
32/40
Page 2 - 33
Engines in stand-by mode can be started with Normal Starting Procedure at any time.
Engine speed [%]
100
80
60
40
20
s
10
s
60
W
Prelubrication
30
s
^turn
Slow
20 ... 40s
Run up
10 ... 20s
Synchronization
Time [sec]
Start up times until load application in normal starting mode (not in stand-by mode); engines preheated
0208-0300PB.fm
Figure 2-8
Page 2 - 34
32/40
A-BD
Figure 2-9
Load application for GenSets; engines preheated and prelubricated, synchronization speed reached
Engine
load [%]
100
90
80
Emergency loading
(with / without Jet-assist)
70
60
50
40
30
20
10
0
0208-0300PB.fm
20
40
60
80
100
Time [sec]
Figure 2-10
^J_a
Load application for GenSets; engines preheated and prelubricated, synchronization speed reached Only
emergency case
32/40
Page 2 - 35
2.7
Figure 2-11
Page 2 - 36
0208-0300PB.fm
"Figure 2-9: Load application for GenSets; engines preheated and prelubricated, synchronization speed
reached".
32/40
A-BD
2.8
Engine equipment
SaCoS/SaCoSone
If engines operate under arctic conditions (intermittently or permanently), the engine equipment
and plant installation have to meet special design
features and requirements. They depend on the
possible minimum air intake temperature of the
engine and the specification of the fuel used.
Category A
+5 C > tx 15 C
Category B
15 C > tx 35 C
Category C
In case these conditions cannot be met, protective measures against climatic influences
have to be taken for the following electronic
components:
- EDS Databox APC620
- TFT-touchscreen display
- Emergency switch module BD5937
These components have to be stored at places, where the temperature is above 15 C.
+5 C
has to be ensured. The use of an optional electric heating is recommended.
tx 35 C
Special engine design requirements
Alternators
Alternator operation is possible according to suppliers specification.
Plant installation
0205-0000PA.fm
^J_a
32/40, 32/40G, 32/40DF, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
Page 2 - 37
Gas engines
- Category C
- In addition, the maximum ambient temperature has to be considered since the engine
control can only compensate a limited temperature range.
> Additionally the charge air before the cylinder is preheated by the HT circuit of the
charge air cooler (LT circuit closed).
Example:
Maximum ambient temperature .... +35 C
Temperature compensation
by engine.......................................... 20 K
> An air intake temperature of +15 C
(35 C 20 K = 15 C) has to be ensured by preheating.
Dual-fuel engines
- Category A, B
No additional actions are necessary. The
charge air before the cylinder is preheated
by the HT circuit of the charge air cooler (LT
circuit closed).
- Category C
> An air intake temperature 35 C has to
be ensured by preheating.
> Additionally the charge air before the cylinder is preheated by the HT circuit of the
charge air cooler (LT circuit closed).
> In special cases the change-over point
for the change from diesel operation to
dual-fuel mode (gas mode) has to be
shifted to a higher load.
Diesel engines
10 C and less are to be avoided, due to temporarily embrittlement of seals used in the engines fuel oil system and as a result their
possibly loss of function.
0205-0000PA.fm
- Category A, B
No additional actions are necessary. The
charge air before the cylinder is preheated
by the HT circuit of the charge air cooler (LT
circuit closed).
Page 2 - 38
32/40, 32/40G, 32/40DF, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
A-BD
Note!
The air of the power house/engine room ventilation must not be too cold (preheating is necessary) to avoid the freezing of the liquids in the
power house/engine room systems.
Insulation
The design of the insulation of the piping systems and other plant parts (tanks, heat exchanger etc.) has to be modified and designed
for the special requirements of arctic conditions.
0205-0000PA.fm
Heat tracing
To support the restart procedures in cold condition (e. g. after unmanned survival mode during winter), it is recommended to install a heat
tracing system in the piping to the engine.
^J_a
32/40, 32/40G, 32/40DF, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
Page 2 - 39
0205-0000PA.fm
Page 2 - 40
32/40, 32/40G, 32/40DF, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
A-BD
2.9
Before final engine stop the engine has to be operated for a minimum of 1 min at idling speed.
A sudden load shedding represents a rather exceptional situation e. g. opening of the diesel-electric plants alternator switch during high load.
Before final engine stop the engine has to be operated for a minimum of 1 min at idling speed.
After a sudden load shedding it has to be ensured
that system circuits remain in operation after final
engine stop for a minimum of 15 min. to dissipate
the residual engine heat.
0208-0500AA2.fm
Figure 2-12
J-BC
Run-down cooling
In order to dissipate the residual engine heat,
the system circuits should be kept in operation
after final engine stop for a minimum of 15 min.
the shortest possible times for continuously ramping down the engine and a sudden load shedding.
Page 2 - 41
0208-0500AA2.fm
Page 2 - 42
J-BC
2.10
Therefore the power management system/propeller control has to meet following requirements:
In case of a load reduction request due to predefined abnormal engine parameter (e.g. high exhaust gas temperature, high turbine speed, high
lube oil temperature) the power output (load) must
be at least ramped down as fast as possible to
60 %.
After a maximum of 5 seconds after occurrence of the load reduction signal the load must
be reduced for at least 5 %.
Engine
load [%]
Load reduction signal / request
min. 5%
prohibited range
60%
max. 60%
max. 5 sec
max. 35 sec
Time [sec]
Engine load reduction as a protective safety measure
0207-0500AA2.fm
Figure 2-13
gJ_`
Page 2 - 43
0207-0500AA2.fm
Page 2 - 44
J-BC
0208-0100AA2.fm
2.11
GenSet operation
2.11.1
Figure 2-14
fJ_a
Page 2 - 45
MCR
Maximum continuous rating.
Range I
Operating range for continuous service.
Range II
No continuous operation allowed. Maximum
operating time less than 2 minutes.
Range III
According to DIN ISO 8528-1 load > 100 % of
the rated output is permissible only for a short
time to provide additional engine power for
governing purposes only (e.g. transient load
conditions and suddenly applied load). This additional power shall not be used for the supply
of electrical consumers.
IMO certification for engines with operating range for
electric propulsion
Test cycle type E2 will be applied for the engines
certification for compliance with the NOx limits according to NOx technical code.
IMO certification for engines with operating range for
auxiliary GenSet
0208-0100AA2.fm
Page 2 - 46
fJ_a
2.11.2
General
Limiting parameters
Generating sets, which are integrated in an electricity supply system, are subjected to the frequency uctuations of the mains. Depending on the
severity of the frequency uctuations, output and
operation respectively have to be restricted.
Max. torque
0208-0400AA2.fm
Figure 2-15
^J_`
0208-0400AA2.fm
Page 2 - 48
^J_`
2.11.3
For each alternator (arranged for parallel operation) a reverse power protection device has to be
provided because if a stopped combustion engine
(fuel admission at zero) is being turned it can
cause, due to poor lubrication, excessive wear on
the engines bearings. This is also a classifications
requirement.
This facts are summarized in the "Table 2-11: Adjusting the reverse power relay".
Admissible reverse
power Pel [%]
Pel < 3
3 Pel < 8
Pel 8
Table 2-11
q=~===
=~~==
~=xz
30
3 to 10
No delay
0208-1000AA2.fm
_J_a
Page 2 - 49
0208-1000AA2.fm
Page 2 - 50
_J_a
2.11.4
General
It has to be ensured that earthing is carried out immediately after engine set-up! (If this cannot be accomplished any other way, at least provisional
earthing is to be effected right at the beginning.)
Figure 2-16
0208-1100MBQcrK2.fm
If the measured shaft voltage is lower than the result of the earlier measurement (test record), the
alternator manufacturer should be consulted.
L-BB
Page 2 - 51
Earthing conductor
The nominal cross section of the earthing conductor (equipotential bonding conductor) has to be
selected in accordance with DIN VDE 0100, part
540 (up to 1000 V) or DIN VDE 0141 (in excess of
1 KV).
Generally, the following applies:
The protective conductor to be assigned to the
largest main conductor is to be taken as a basis
for sizing the cross sections of the equipotential
bonding conductors.
Flexible conductors have to be used for the connection of resiliently mounted engines.
Execution of earthing
On vessels, earthing must be done by the shipyard
during assembly on board.
Earthing strips are not included in the MAN
Diesel & Turbo scope of supply.
Additional information regarding the use of welding
equipment
0208-1100MBQcrK2.fm
Page 2 - 52
L-BB
2.12
2.12.1
Engine 32/40 GenSet, World Bank 1998 (ignition pressure 190 bar)
500 kW/cyl., 720 rpm or 750 rpm
% Load
L32/40
V32/40
1001)
85
75
50
25
1001)
85
75
50
25
185
183
183
192
215
183
181
181
190
213
1)
Engine 32/40 GenSet, World Bank 1998 (ignition pressure 205 bar)
500 kW/cyl., 720 rpm or 750 rpm
% Load
L32/40
V32/40
1001)
85
75
50
25
1001)
85
75
50
25
182
181
181.5
191
214
180
179
179.5
189
212
1) Warranted
0209-0000PB.fm
2) Values
B-BD
32/40
Page 2 - 53
L32/40
V32/40
1001)
85
75
50
25
1001)
85
75
50
25
186
185
189
196
207
184
183
187
194
205
1)
L32/40
V32/40
1001)
85
75
50
25
1001)
85
75
50
25
189
188
192
199
210
187
186
190
197
208
1)
2)
0209-0000PB.fm
Page 2 - 54
32/40
B-BD
100
85
75
50
25
+1.0
+1.5
+1.5
+2.0
+4.0
+2.0
+2.5
+3.0
+4.0
+8.0
+2.0
9L
12V
14V
16V
18V
67
90
104
120
134
Table 2-17
25
Ambient pressure pr
bar
Relative humidity r
30
43
kJ/kg
42,700
0209-0000PB.fm
1)
B-BD
32/40
Page 2 - 55
0209-0000PB.fm
2.12.1 Fuel oil consumption for emission standard: World Bank 1998 and World Bank 2007/2008
Page 2 - 56
32/40
B-BD
2.12.2
Engine 32/40
500 kW/cyl.; 720 or 750 rpm
Specific lube oil consumption . . . . . 0.6 g/kWh
Total lube oil consumption [kg/h]1)
No. of cylinders
9L
12V
14V
16V
18V
2.7
3.6
4.2
4.8
5.4
Table 2-19
1) Tolerance
Note!
0209-0200PB.fm
As a matter of principle, the lubricating oil consumption is to be stated as total lubricating oil
consumption related to the tabulated ISO full
load output ("Section 2.3: Ratings (outputs) and
speeds, page 2-17").
B-BD
32/40
Page 2 - 57
2.12.3
Number of cylinders
9L
12V
14V
16V
18V
litre
289
386
450
515
579
Nm 2)
1.45
1.80
2.05
2.25
2.50
2.95
3.75
3.75
5.95
5.95
2.90
3.60
4.10
4.50
5.00
Table 2-20
1) The
0209-0200PB.fm
air consumption per starting manoeuvre/slow turn activation depends on the inertia moment of the unit. The stated air
consumption refers only to the engine. For the GenSets an higher air consumption needs to be considered (approx. 50 %
increased).
2)
Nm corresponds to one cubic meter of gas at 0 C and 101.32 kPa.
3)
The above-mentioned air consumption per Jet Assist activation is valid for a jet duration of 5 seconds. The jet duration may
vary between 3 sec and 10 sec, depending on the loading (average jet duration 5 sec).
4)
Required for plants with Power Management System demanding automatic engine start. The air consumption per slow turn
activation depends on the inertia moment of the unit. This value does not include the needed air consumption for the automically activated engine start after end of the slow turn manoeuvre.
Page 2 - 58
32/40
B-BD
2.12.4
Part 1: Declarations of power, fuel and lubricating oil consumptions, and test methods Additional requirements for engines for general use MAN Diesel & Turbo specifies for liquid fuel the method for recalculation of fuel con-
5 C 55 C
25 C 75 C
bx br
br
bx
tbar
Legend
^====~=
[g/kWh]
br
bx
[C]
tr
tx
[C]
tbar
tbax
[bar]
pr
px
Example
Reference values:
br = 200 g/kWh, tr = 25 C, tbar = 40 C, pr = 1.0 bar
At Site:
tx = 45 C, tbax = 50 C, px = 0.9 bar
0209-0300AA2.fm
= 1+ 0.0006 (45 25) + 0.0004 (50 40) + 0.07 (1.0 0.9) = 1.023
bx = x br = 1.023 x 200 = 204.6 g/kWh
D-BD
Page 2 - 59
0209-0300AA2.fm
Page 2 - 60
D-BD
2.12.5
Aging
Aging curve - 32/40
2,00
1,75
1,50
1,25
1,00
0,75
0,50
0,25
Note: The projected increase of fuel consumption, shown on the graph has to be seen as a standard. As this will be influenced by several basic conditions, e.g. care
and maintenance of the engine and its supply systems (fuel, lube oil, pressurized air) as well as fuel, lube oil and intake air quality. An addition to the shown value of
up to 1% absolute shall be regarded as contractually admissible and without any consequences for MAN Diesel and Turbo.
0,00
0
10
20
30
40
50
60
70
80
Figure 2-17
Influence from total engine running time and service intervals on fuel oil consumption
The fuel oil consumption will increase over the running time of the engine. Proper service can reduce
or eliminate this increase. For dependencies see
0209-0400MB2.fm
eJ_`
32/40
Page 2 - 61
0209-0400MB2.fm
2.12.5 Aging
Page 2 - 62
32/40
eJ_`
2.13
2.13.1
9L
12V
14V
16V
18V
8,000
9,000
25
25
Air pressure
bar
Relative humidity
30
Engine output
kW
Speed
rpm
4,500
6,000
7,000
720 or 750
Heat to be dissipated1)
Cooling water (C.W.) cylinder
kW
598
786
930
1,051
1,196
895
1,257
1,411
1,639
1,789
584
740
888
1,018
1,167
524
692
815
924
1,047
18
23
27
31
35
202
269
314
359
404
54
72
84
96
108
85
114
140
148
170
130
150
160
170
180
1.6
2.4
2.8
3.2
191
191
Flow rates3)
HT circuit (cylinder + charge air cooler HT
stage)
m3/h
Pumps
a) Engine driven pumps
0210-0000PB.fm
70
140
140
225
141
Table 2-21
B-BD
m/h
162
191
32/40
Page 2 - 63
Number of cylinders
9L
12V
14V
16V
18V
54
72
84
96
108
b) External pumps4)
HT circuit cooling water (4.3 bar)
m/h
150 + z
160 + z
170 + z
180 + z
1.6
2.0
2.4
2.8
3.2
3.1
4.2
4.9
5.6
6.3
1.6
2.2
2.5
2.9
3.2
3.1
4.2
4.9
5.6
6.3
Note!
You will find further planning datas for the listed subjects in the corresponding sections.
- Minimal heating power required for preheating HT cooling water see "Paragraph: H-001/Preheater, page 5-45".
- Minimal heating power required for preheating lube oil see "Paragraph: H-002/Lube oil heater Single main engine, page
5-15" and "Paragraph: H-002/Lube oil heating Multi-engine plant, page 5-15".
- Capacities of prelubrication/postlubrication pumps see "Section 5.2.3: Prelubrication/postlubrication, page 5-23".
- Capacities of preheating/postcooling pumps see "Paragraph: H-001/Preheater, page 5-45".
Table 2-21
1) Tolerance:
0210-0000PB.fm
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
Page 2 - 64
32/40
B-BD
2.13.2
25
25
Air pressure
bar
Relative humidity
30
Number of cylinders
9L
12V
14V
16V
18V
4,500
6,000
7,000
8,000
9,000
Engine output
kW
Speed
rpm
720 or 750
90
Temperature basis
HT cooling water engine outlet1)
LT cooling water air cooler inlet
25
55
60
Air data
Temperature of charge air at charge air cooler
outlet
42
40
42
41
42
m3/h
29,000
38,400
45,100
51,200
57,900
Mass flow
t/h
32
42.6
49.7
56.8
63.9
bar
4.04
4.02
4.04
4.02
4.04
m/h
61,600
82,100
95,800
109,500
123,200
m3/h
55,900
74,200
86,900
99,000
111,700
Mass flow
t/h
32.8
43.7
51.0
58.3
65.6
320
318
320
318
320
kW
1,265
1,665
1,970
2,225
2,530
0210-0000PB.fm
B-BD
mbar
< 30
32/40
Page 2 - 65
1)
HT cooling water flow first through water jacket and cylinder head, then through HT stage charge air cooler.
Under above mentioned reference conditions.
3)
Tolerances: Quantity 5 %; temperature 20 C.
4)
Under below mentioned temperature at turbine outlet and pressure according above mentioned reference conditions.
2)
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
2.13.3
100
85
75
50
kW/cyl
500
425
375
250
25
25
Air pressure
bar
Relative humidity
30
rpm
720 or 750
Engine speed
Heat to be dissipated1)
Cooling water (C.W.) cylinder
kJ/kWh
478
477
484
555
716
605
498
185
467
456
441
419
419
462
505
693
14
162
175
185
230
205
42.4
179
38.9
159
36.3
108
30.8
kg/kWh
7.10
7.35
7.37
7.40
bar
4.04
3.45
3.03
2.05
Air data
Temperature of charge air
after compressor
at charge air cooler outlet
Air flow rate
Table 2-23
Page 2 - 66
32/40
B-BD
Engine output
100
85
75
50
kW/cyl
500
425
375
250
kg/kWh
7.29
7.54
7.56
7.60
320
302
310
330
kJ/kWh
1,012
899
966
1,139
mbar
< 30
1) Tolerance:
0210-0000PB.fm
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
B-BD
32/40
Page 2 - 67
2.13.4
9L
12V
14V
16V
18V
8,000
9,000
25
25
Air pressure
bar
Relative humidity
30
Engine output
kW
Speed
rpm
4,500
6,000
7,000
720 or 750
Heat to be dissipated1)
Cooling water (C.W.) cylinder
kW
525
689
816
921
1,049
825
1,164
1,303
1,515
1,650
582
741
886
1,018
1,164
486
642
756
858
973
18
23
27
31
35
200
266
310
355
399
54
72
84
96
108
85
114
140
148
170
130
150
160
170
180
1.6
2.4
2.8
3.2
191
191
Flow rates3)
HT circuit (cylinder + charge air cooler HT
stage)
m3/h
Pumps
a) Engine driven pumps
HT circuit cooling water (4.5 bar)
70
140
140
225
141
162
191
Table 2-24
m/h
Page 2 - 68
32/40
B-BD
Number of cylinders
9L
12V
14V
16V
18V
54
72
84
96
108
b) External pumps4)
HT circuit cooling water (4.3 bar)
m/h
150 + z
160 + z
170 + z
180 + z
1.6
2.0
2.4
2.8
3.2
3.1
4.2
4.9
5.6
6.3
1.6
2.2
2.5
2.9
3.2
3.1
4.2
4.9
5.6
6.3
Note!
You will find further planning datas for the listed subjects in the corresponding sections.
- Minimal heating power required for preheating HT cooling water see "Paragraph: H-001/Preheater, page 5-45".
- Minimal heating power required for preheating lube oil see "Paragraph: H-002/Lube oil heater Single main engine, page
5-15" and "Paragraph: H-002/Lube oil heating Multi-engine plant, page 5-15".
- Capacities of prelubrication/postlubrication pumps see "Section 5.2.3: Prelubrication/postlubrication, page 5-23".
- Capacities of preheating/postcooling pumps see "Paragraph: H-001/Preheater, page 5-45".
Table 2-24
1) Tolerance:
0210-0000PB.fm
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
B-BD
32/40
Page 2 - 69
2.13.5
25
25
Air pressure
bar
Relative humidity
30
Number of cylinders
9L
12V
14V
16V
18V
4,500
6,000
7,000
8,000
9,000
Engine output
kW
Speed
rpm
720 or 750
90
Temperature basis
HT cooling water engine outlet1)
LT cooling water air cooler inlet
25
55
60
Air data
Temperature of charge air at charge air cooler
outlet
44
41
44
42
44
m3/h
28,800
38,100
44,800
50,900
57,600
Mass flow
t/h
31.6
42.2
49.2
56.2
63.3
bar
4.01
3.99
4.00
3.99
4.01
m/h
61,000
81,100
94,600
108,300
121,700
m3/h
56,100
74,500
87,200
99,300
112,200
Mass flow
t/h
32.5
43.3
50.5
57.7
65.0
328
326
328
326
328
kW
1,330
1,750
2,070
2,340
2,660
Page 2 - 70
mbar
< 30
0210-0000PB.fm
32/40
B-BD
1)
HT cooling water flow first through water jacket and cylinder head, then through HT stage charge air cooler.
Under above mentioned reference conditions.
3)
Tolerances: Quantity 5 %; temperature 20 C.
4)
Under below mentioned temperature at turbine outlet and pressure according above mentioned reference conditions.
2)
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
2.13.6
100
85
75
50
kW/cyl
500
425
375
250
25
25
Air pressure
bar
Relative humidity
30
rpm
720 or 750
Engine speed
Heat to be dissipated1)
Cooling water (C.W.) cylinder
kJ/kWh
420
437
466
572
660
547
465
161
465
448
431
404
389
428
479
655
14
160
170
180
210
200
43.7
174
39.6
157
36.8
105
31.0
kg/kWh
7.03
7.18
7.18
7.20
bar
4.01
3.47
3.05
2.04
Air data
Temperature of charge air
after compressor
at charge air cooler outlet
Air flow rate
0210-0000PB.fm
Table 2-26
B-BD
32/40
Page 2 - 71
Engine output
100
85
75
50
kW/cyl
500
425
375
250
kg/kWh
7.22
7.37
7.37
7.40
328
327
339
393
kJ/kWh
1,065
1,082
1,176
1,622
mbar
< 30
1) Tolerance:
0210-0000PB.fm
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
Page 2 - 72
32/40
B-BD
2.14
2.14.1
9L
12V
14V
16V
18V
8,000
9,000
25
25
Air pressure
bar
Relative humidity
30
Engine output
kW
Speed
rpm
4,500
6,000
7,000
720 or 750
Heat to be dissipated1)
Cooling water (C.W.) cylinder
kW
608
799
946
1,068
1,216
964
1,352
1,520
1,765
1,927
596
754
906
1,038
1,192
507
670
789
894
1,014
18
23
27
31
35
172
230
268
306
344
54
72
84
96
108
85
114
140
148
170
130
150
160
170
180
1.6
2.4
2.8
3.2
191
191
Flow rates3)
HT circuit (cylinder + charge air cooler HT
stage)
m3/h
Pumps
a) Engine driven pumps
0210-0000PB.fm
70
140
140
225
141
Table 2-27
B-BD
m/h
162
191
32/40
Page 2 - 73
Number of cylinders
9L
12V
14V
16V
18V
54
72
84
96
108
b) External pumps4)
HT circuit cooling water (4.3 bar)
m/h
150 + z
160 + z
170 + z
180 + z
1.6
2.0
2.4
2.8
3.2
3.1
4.2
4.9
5.6
6.3
1.6
2.2
2.5
2.9
3.2
3.1
4.2
4.9
5.6
6.3
Note!
You will find further planning datas for the listed subjects in the corresponding sections.
- Minimal heating power required for preheating HT cooling water see "Paragraph: H-001/Preheater, page 5-45".
- Minimal heating power required for preheating lube oil see "Paragraph: H-002/Lube oil heater Single main engine, page
5-15" and "Paragraph: H-002/Lube oil heating Multi-engine plant, page 5-15".
- Capacities of prelubrication/postlubrication pumps see "Section 5.2.3: Prelubrication/postlubrication, page 5-23".
- Capacities of preheating/postcooling pumps see "Paragraph: H-001/Preheater, page 5-45".
Table 2-27
1) Tolerance:
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
0210-0000PB.fm
Page 2 - 74
32/40
B-BD
2.14.2
25
25
Air pressure
bar
Relative humidity
30
Number of cylinders
9L
12V
14V
16V
18V
4,500
6,000
7,000
8,000
9,000
Engine output
kW
Speed
rpm
720 or 750
90
Temperature basis
HT cooling water engine outlet1)
LT cooling water air cooler inlet
25
55
60
Air data
Temperature of charge air at charge air cooler
outlet
43
41
43
41
43
m3/h
29,000
38,400
45,100
51,200
58,000
Mass flow
t/h
32
42.6
49.7
56.8
63.9
bar
4.10
4.08
4.10
4.08
4.10
m/h
52,500
70,200
81,700
93,300
104,900
m3/h
56,400
75,100
87,900
100,100
113,000
Mass flow
t/h
32.8
43.8
51.1
58.4
65.7
326
324
326
324
326
kW
1,330
1,750
2,070
2,340
2,660
0210-0000PB.fm
B-BD
mbar
< 30
32/40
Page 2 - 75
1)
HT cooling water flow first through water jacket and cylinder head, then through HT stage charge air cooler.
Under above mentioned reference conditions.
3)
Tolerances: Quantity 5 %; temperature 20 C.
4)
Under below mentioned temperature at turbine outlet and pressure according above mentioned reference conditions.
2)
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
0210-0000PB.fm
Page 2 - 76
32/40
B-BD
2.14.3
100
85
75
50
kW/cyl
500
425
375
250
25
25
Air pressure
bar
Relative humidity
30
rpm
720 or 750
Engine speed
Heat to be dissipated1)
Cooling water (C.W.) cylinder
kJ/kWh
486
494
522
621
771
675
570
268
477
463
440
413
406
463
502
666
2)
14
138
175
201
247
214
42.7
191
39.0
171
36.1
120
30.6
kg/kWh
7.10
7.27
7.22
7.24
bar
4.10
3.54
3.09
2.10
Air data
Temperature of charge air
after compressor
at charge air cooler outlet
Air flow rate
0210-0000PB.fm
Table 2-29
B-BD
32/40
Page 2 - 77
Engine output
100
85
75
50
kW/cyl
500
425
375
250
kg/kWh
7.30
7.46
7.42
7.45
326
319
335
375
kJ/kWh
1,063
1,029
1,157
1,486
mbar
< 30
1) Tolerance:
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
0210-0000PB.fm
Page 2 - 78
32/40
B-BD
2.14.4
9L
12V
14V
16V
18V
8,000
9,000
25
25
Air pressure
bar
Relative humidity
30
Engine output
kW
Speed
rpm
4,500
6,000
7,000
720 or 750
Heat to be dissipated1)
Cooling water (C.W.) cylinder
kW
606
797
943
1,065
1,212
939
1,317
1,481
1,720
1,879
584
739
888
1,017
1,168
506
669
787
893
1,012
18
23
27
31
35
172
230
268
306
344
54
72
84
96
108
85
114
140
148
170
130
150
160
170
180
1.6
2.4
2.8
3.2
191
191
Flow rates3)
HT circuit (cylinder + charge air cooler HT
stage)
m3/h
Pumps
a) Engine driven pumps
HT circuit cooling water (4.5 bar)
70
140
140
225
141
162
191
0210-0000PB.fm
Table 2-30
m/h
B-BD
32/40
Page 2 - 79
Number of cylinders
9L
12V
14V
16V
18V
54
72
84
96
108
b) External pumps4)
HT circuit cooling water (4.3 bar)
m/h
150 + z
160 + z
170 + z
180 + z
1.6
2.0
2.4
2.8
3.2
3.1
4.2
4.9
5.6
6.3
1.6
2.2
2.5
2.9
3.2
3.1
4.2
4.9
5.6
6.3
Note!
You will find further planning datas for the listed subjects in the corresponding sections.
- Minimal heating power required for preheating HT cooling water see "Paragraph: H-001/Preheater, page 5-45".
- Minimal heating power required for preheating lube oil see "Paragraph: H-002/Lube oil heater Single main engine, page
5-15" and "Paragraph: H-002/Lube oil heating Multi-engine plant, page 5-15".
- Capacities of prelubrication/postlubrication pumps see "Section 5.2.3: Prelubrication/postlubrication, page 5-23".
- Capacities of preheating/postcooling pumps see "Paragraph: H-001/Preheater, page 5-45".
Table 2-30
1) Tolerance:
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
0210-0000PB.fm
Page 2 - 80
32/40
B-BD
2.14.5
25
25
Air pressure
bar
Relative humidity
30
Number of cylinders
9L
12V
14V
16V
18V
4,500
6,000
7,000
8,000
9,000
Engine output
kW
Speed
rpm
720 or 750
90
Temperature basis
HT cooling water engine outlet1)
LT cooling water air cooler inlet
25
55
60
Air data
Temperature of charge air at charge air cooler
outlet
42
40
42
41
42
m3/h
28,600
37,800
44,400
50,500
57,100
Mass flow
t/h
31.5
42
49
56
63
bar
4.09
4.08
4.09
4.08
4.09
m/h
52,500
70,200
81,700
93,300
104,900
m3/h
55,200
73,500
85,700
97,800
110,200
Mass flow
t/h
32.4
43.2
50.3
57.5
64.7
320
319
320
319
320
kW
1,260
1,655
1,960
2,210
2,515
0210-0000PB.fm
B-BD
mbar
< 30
32/40
Page 2 - 81
1)
HT cooling water flow first through water jacket and cylinder head, then through HT stage charge air cooler.
Under above mentioned reference conditions.
3)
Tolerances: Quantity 5 %; temperature 20 C.
4)
Under below mentioned temperature at turbine outlet and pressure according above mentioned reference conditions.
2)
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
0210-0000PB.fm
Page 2 - 82
32/40
B-BD
2.14.6
100
85
75
50
kW/cyl
500
425
375
250
25
25
Air pressure
bar
Relative humidity
30
rpm
720 or 750
Engine speed
Heat to be dissipated1)
Cooling water (C.W.) cylinder
kJ/kWh
485
493
520
620
752
652
539
242
467
452
425
401
405
462
501
665
2)
14
138
175
201
247
212
42.3
189
38.5
168
35.6
117
30.4
kg/kWh
7.00
7.12
7.02
7.04
bar
4.09
3.54
3.08
2.10
Air data
Temperature of charge air
after compressor
at charge air cooler outlet
Air flow rate
0210-0000PB.fm
Table 2-32
B-BD
32/40
Page 2 - 83
Engine output
100
85
75
50
kW/cyl
500
425
375
250
kg/kWh
7.19
7.31
7.22
7.24
320
318
335
375
kJ/kWh
1,006
1,005
1,122
1,444
mbar
< 30
1) Tolerance:
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
0210-0000PB.fm
Page 2 - 84
32/40
B-BD
2.15
Planning data
2.15.1
litres
12
14
16
18
300
420
480
540
600
Lube oil
Table 2-33
Service tanks
Installation
height 1)
No. of cylinders
Cooling water cylinder
Lube oil
in double bottom 2)
in double bottom 3)
Run-down lubrication for
engine 4)
Table 2-34
12
6 ... 9
0.5
4.5
7.5
6.0
9.5
min. 14
3.0
3.5
14
16
18
7.0
11.0
8.0
12.0
9.0
13.5
5.5
6.0
4.5
0.7
1) Installation
Flow resistance
Charge air cooler (HT stage)
0210-0000PB.fm
bar
0.30 0.40
1.5
Flow resistance
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
B-BD
32/40
Page 2 - 85
2.15.2
Operating temperatures1
Air
Charge Air
Coolant
5 C, max. 45 C1)
43...63 C2)
90 C3), max. 95 C
63...68 C, alarm/stop at 70 C
40 C
45 C and viscosity before
engine: minimum 1.9 cSt, maximum 14 cSt4)
150 C and viscosity before
engine: minimum 1.9 cSt, maximum 14 cSt, recommended: 12
14 cSt4)
75 C
60 C
Operating temperatures
1) In
accordance with power definition. A reduction in power is required at higher temperatures/lower pressures.
Aim for a higher value in conditions of high air humidity (to reduce condensate amount).
3) Regulated temperature.
4)
See "Section 4.9: Viscosity-temperature diagram (VT diagram), page 4-33".
2)
Note!
0210-0000PB.fm
Operating pressure data without further specification are given below/above atmospheric pressure.
Page 2 - 86
32/40
B-BD
Operating pressures1
Intake Air
Starting air
Cylinder
Pilot air
max. 20 mbar
247 bar
Crankcase pressure
max. 3 mbar
Exhaust
Coolant
3...4 bar
2...5 bar
2...4 bar
Lubricating oil
4...5 bar
0.3...0.6 bar2)
1.3...1.7 bar
6...8 bar
1 bar
2 bar
0.5 bar
360 + 10 bar
380 bar
Note!
Variations of the mandatory values can affect the operation of the engine negative and may cause rating reduction
of the engine
Table 2-37
Operating pressures
1) At
0210-0000PB.fm
a total exhaust gas back pressure of the designed exhaust gas line of more than 30 mbar the available engine performance needs to be recalculated.
2) Note! Oil pressure > 0.3 bar must be ensured also for lube oil temperatures up to 80 C
B-BD
32/40
Page 2 - 87
Note!
Operating pressure data without further specification are given below/above atmospheric pressure.
Exhaust gas back pressure
0210-0000PB.fm
Page 2 - 88
32/40
B-BD
2.15.3
0210-0000PB.fm
Figure 2-18
B-BD
32/40
Page 2 - 89
Figure 2-19
Page 2 - 90
0210-0000PB.fm
32/40
B-BD
0210-0000PB.fm
Water system
Figure 2-20
B-BD
Water system
32/40
Page 2 - 91
Figure 2-21
Page 2 - 92
0210-0000PB.fm
32/40
B-BD
2.15.4
to ventilate the engine crankcase and the turbocharger. For layout of the ventilation system following statement should serve as a guide:
Due to normal blow by of the piston ring package
small amounts of gases of the combustion chamber get into the crankcase and carry along oil dust.
The amount of turbocharger sealing air is approx. 0.2 % of the engines air flow rate.
0210-0100PA.fm
_J_a
Page 2 - 93
0210-0100PA.fm
Page 2 - 94
_J_a
0206-0601PA.fm
2.16
Emissions
2.16.1
Figure 2-22
_J_a
32/40, 48/60B
Page 2 - 95
0206-0601PA.fm
Page 2 - 96
32/40, 48/60B
B-BD
2.16.2
The exhaust gas is composed of numerous constituents which are formed either from the combustion air, the fuel and lube oil used or see "Table
approx. [% by volume]
approx. [g/kWh]
Nitrogen N2
74.0 76.0
5,020 5,160
Oxygen O2
11.6 13.2
900 1,030
5.2 5.8
560 620
Steam H2O
5.9 8.6
260 370
0.9
75
> 99.75
7,000
approx. [% by volume]
approx. [g/kWh]
0.07
10.0
0.07 0.15
8.0 16.0
0.006 0.011
0.4 0.8
0.1 0.04
0.4 1.2
< 0.25
26
approx. [mg/Nm3]
approx. [g/kWh]
operating on
6)
operating on
7)
6)
MGO
HFO
MGO
HFO7)
50
50
0.3
0.3
Fuel ash
40
0.03
0.25
0.02
0.04
Note!
0211-0200MA2.fm
1)
SOx according to ISO-8178 or US EPA method 6C, with a sulphur content in the fuel oil of 2.5 % by weight.
2)
NOx according to ISO-8178 or US EPA method 7E, total NOx emission calculated as NO2.
J-BC
Page 2 - 97
3)
Hydrocarbons HC
0211-0200MA2.fm
Page 2 - 98
J-BC
2.16.3
Engine specific NOx-Emissions depend on the engine adjustment, engine output, media temperatures and the fuel used. These will be calculated
project specific.
For conversion from at site conditions to reference
conditions and vice versa the following formula is
used. Only the conditions stated in the formula
may vary.
(R&D Report, 100.6240.7166, Peters 2003.02.24)
NOx r = NOx x *
e 17.5* ( H ar H ax )
1 0.005 * (t bax t bar )
25 C 75 C
NOx r , NOx x:
Legend
Nitrogen oxides
Charge air temperature
before cylinder
Absolute air humidity
^====
~=
[mg/Nm3@15%O2]
NOx r
NOx x
[C]
tbar
tbax
Har
Hax
0209-0300PA.fm
A-BD
Page 2 - 99
NOx
concentration
[%]
100
90
80
70
60
50
40
30
20
10
0
0
0,01
0,02
0,03
0,04
0,05
0,06
0,07
0,08
0,09
0,1
Example
Reference values:
NOx r = 1,460 mg/Nm3@15%O2, tbar = 42 C, Har = 0.011 kg/kg
At Site:
tbax = 47 C, Hax = 0.016 kg/kg
NO xx NO xr *
e 17.5* ( H ar H ax )
1,460 *
0209-0300PA.fm
1,371 mg / Nm @ 15%O 2
Page 2 - 100
A-BD
2.17
Noise
2.17.1
Airborne noise
Engine L32/40
Output 500 kW/cyl., speed = 720/750 rpm
Sound pressure level Lp
min: . . . . . . . . . . . . . . approx. 102 dB(A)
max: . . . . . . . . . . . . . . approx. 108 dB(A)
Measuring points
A total of 19 measuring points at 1m distance
from the engine surface distributed evenly
around the engine according to ISO 6798. The
noise at the exhaust outlet is not included.
110
105
100
95
min
max
90
85
80
75
0212-0000MB2.fm
70
16
31,5
63
125
250
500
1000
2000
4000
8000
min
73
85
92
95
95
95
96
95
93
87
sum A
102
max
90
100
105
105
104
106
105
105
103
99
108
Figure 2-24
^J_a
32/40
Page 2 - 101
Engine V32/40
Output 500 kW/cyl., speed = 720/750 rpm
Sound pressure level Lp
min: . . . . . . . . . . . . . . approx. 104 dB(A)
max: . . . . . . . . . . . . . . approx. 108 dB(A)
Measuring points
A total of 19 measuring points at 1m distance
from the engine surface distributed evenly
around the engine according to ISO 6798. The
noise at the exhaust outlet is not included.
105
100
95
min
max
90
85
80
75
70
16
31,5
63
125
250
500
1000
2000
4000
8000
min
73
83
90
94
93
93
92
92
90
82
sum A
104
max
91
103
103
104
101
103
104
100
104
97
108
0212-0000MB2.fm
Figure 2-25
Page 2 - 102
32/40
A-BD
2.17.2
Intake noise
Engine L32/40
approx. 139 dB(A)
The sound power level Lw of the unsilenced intake noise in the intake pipe is approx.
139 dB(A) at rated output. The octave level of
the sound power is shown in the diagram below.
135
130
125
Lw
120
115
110
105
100
Lw
16
31,5
63
125
250
500
1000
2000
4000
8000
sum A
115
120
117
112
110
116
115
120
137
130
139
Octave level diagram L32/40 Sound power level Lw Unsilenced intake noise
0212-0200MB2.fm
Figure 2-26
^J_a
32/40
Page 2 - 103
Engine V32/40
Sound power level Lw:
The sound power level Lw of the unsilenced intake noise in the intake pipe is approx.
139 dB(A) at rated output. The octave level of
the sound power is shown in the diagram below.
135
130
125
Lw
120
115
110
105
100
Lw
16
31,5
63
125
250
500
1000
2000
4000
8000
sum A
115
120
117
112
110
116
115
120
137
130
139
Octave level diagram V32/40 Sound power level Lw Unsilenced intake noise
0212-0200MB2.fm
Figure 2-27
Page 2 - 104
32/40
A-BD
2.17.3
Engine L32/40
Sound power level Lw:
The sound power level Lw of the unsilenced exhaust noise in the exhaust pipe is approx.
142 dB(A) at rated output. The octave level of
the sound power is shown in the diagram below.
.
160
155
150
145
Lw
140
135
130
125
Lw
16
31,5
63
125
250
500
1000
2000
4000
8000
sum A
137
154
156
151
138
136
135
134
132
131
142
Octave level diagram L32/40 Sound power level Lw Unsilenced exhaust noise
0212-0300MB2.fm
Figure 2-28
^J_a
32/40
Page 2 - 105
Engine V32/40
Sound power level Lw:
The sound power level Lw of the unsilenced exhaust noise in the exhaust pipe is approx.
142 dB(A) at rated output. The octave level of
the sound power is shown in the diagram below.
.
160
155
150
145
Lw
140
135
130
125
Lw
16
31,5
63
125
250
500
1000
2000
4000
8000
sum A
139
150
152
149
138
136
135
134
132
131
142
Octave level diagram V32/40 Sound power level Lw Unsilenced exhaust noise
0212-0300MB2.fm
Figure 2-29
Page 2 - 106
32/40
A-BD
2.18
Vibration
2.18.1
Torsional vibrations
Permanently permissible power loss (W) including influencing factors (frequency, temperature)
General
Alternator
machines
Flexible coupling
^J_a
and diameters
Engine
0201-0802Pdf+g.fm
32/40, 32/40G, 32/40DF, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
Page 2 - 107
0201-0802Pdf+g.fm
Page 2 - 108
32/40, 32/40G, 32/40DF, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
A-BD
2.18.2
General
The static torque fluctuation is the summationtaking into account the correct phase-angles of
the torques acting at all cranks around the crankshaft axis. These torques are created by the gas
and mass forces acting at the crankpins, with the
crank radius being used as the lever see "Paragraph: Static torque fluctuation and exciting frquencies" in
this section. An absolutely rigid crankshaft is assumed. The values Tmax and Tmin listed in the tables represent a measure for the reaction forces
occurring at the foundation of the engine see "Figure 2-30: Static torque fluctuation". The static values
listed in the table below in each individual case a
dynamic magnification which is dependent upon
the characteristics of the foundation (design and
material thicknesses in way of the foundation, type
of chocking).
The reaction forces generated by the torque fluctuation are the most important excitations transmitted into the foundation in the case of a rigidly or
semi-resiliently mounted engine. Their frequency is
dependent upon speed and cylinder number, and
is also listed in the table of the examples.
FD L z
Tmax Tmin
2
Number of cylinders
0215-030aAA2.fm
Figure 2-30
A-BD
Page 2 - 109
0215-030aAA2.fm
Page 2 - 110
A-BD
2.19
0217-0000MB2.fm
Engine L32/40
Figure 2-31
A-BD
32/40
Page 2 - 111
Figure 2-32
Page 2 - 112
0217-0000MB2.fm
Engine V32/40
32/40
A-BD
2.20
18V32/40
Foundation plate
B11.72600-0158
B11.72600-0161
Formwork drawing
B11.72626-0682
B11.72626-0688
Reinforcement drawing
B11.72626-0683
B11.72626-0689
Table 2-39
0402-0102PBdf.fm
A-BD
32/40, 32/40DF
Page 2 - 113
Figure 2-33
Page 2 - 114
0402-0102PBdf.fm
12V32/40
32/40, 32/40DF
A-BD
0402-0102PBdf.fm
Figure 2-34
A-BD
32/40, 32/40DF
Page 2 - 115
Figure 2-35
Page 2 - 116
0402-0102PBdf.fm
18V32/40
32/40, 32/40DF
A-BD
0402-0102PBdf.fm
Figure 2-36
A-BD
32/40, 32/40DF
Page 2 - 117
Note!
All dimensions have to be checked along with
the final drawing of the engine manufacturer
and the actual situation at site.
All dimensions on the drawing are final and metrical units according to ISO 1000.
- All measurements shown on the drawing are
in millimetre (mm).
- Elevations
meter (m).
and
co-ordinates
are
in
Tolerances:
8 mm
Surface levelness
1 mm/m
Attention!
The concrete Surface has to be painted with oil
resistant paint.
The surface tensile strength of the concrete surface has to be minimum 1.5 N/mm2.
A) Concrete
General in Longitudinal direction
3 mm
12V32/40
3 mm/m
18V32/40
Weight (ton)
Engine
56.0
82.0
Alternator
34.0
32.5
Flywheel + coupling
4.0
4.5
Foundation frame +
oil content
15.0
21.3
Other things
2.0
2.4
~109.2
~142.7
~114.3
~147.0
Table 2-40
Embedded parts are not supplied by engine manufacturer unless otherwise noted. Embedments to
be placed and checked according to the drawing.
They shall be secured safely against shifting.
Page 2 - 118
32/40, 32/40DF
0402-0102PBdf.fm
A-BD
======
Engine automation
Kapiteltitel 3 M2.fm
Page 3 - 1
Page 3 - 2
Kapiteltitel 3 M2.fm
Engine automation
3.1 SaCoSone system overview
3.1
Figure 3-1
0301-0000MB2.fm
Legend
1
Control Unit
System Bus
Interface Cabinet
L-BA
During engine installation, only the bus connections and the power supply and safety related cables between the Control Unit and the
Interface/Auxiliary Cabinet are to be laid, as well as
connections to external modules and parts on
site.
32/40
Page 3 - 3
Engine automation
3.1 SaCoSone system overview
Figure 3-3
0301-0000MB2.fm
Figure 3-2
Page 3 - 4
32/40
L-BA
Engine automation
3.1 SaCoSone system overview
Interface Cabinet
The panel can be delivered as loose supply for installation in the control room desk or integra-ted in
the front door of the Interface Cabinet.
Figure 3-5
VIT Cabinet
Interface Cabinet
0301-0000MB2.fm
Figure 3-4
L-BA
32/40
Page 3 - 5
Engine automation
3.1 SaCoSone system overview
0301-0000MB2.fm
Figure 3-6
SaCoSone is connected to the plant by the Gateway Module. This module is equipped with decentral input and output channels as well as with
different interfaces for connection to the plant/ship
automation, the Remote Operating Panel and the
online service.
Page 3 - 6
32/40
L-BA
Engine automation
3.2 Power supply and distribution
3.2
The plant has to provide electric power for the automation and monitoring system. In general an uninterruptible 24 V DC power supply is required for
SaCoSone.
An uniterruptible power supply for the speed governor must also be provided. In case of electronic
0302-0000MB2.fm
Figure 3-7
B-AJ
32/40
Page 3 - 7
Engine automation
3.2 Power supply and distribution
Figure 3-8
Consumer
Notes
24 V DC
SaCoSone
230 V 50/60 Hz
SaCoSone Interface Cabinet Temperature control valves, cabinet illumination, socket, anticondensation heater.
440 V 50/60 Hz
Consumers on engine
Table 3-1
Page 3 - 8
32/40
B-AJ
Engine automation
3.3 Operation
3.3
Operation
Figure 3-9
0303-0000PA.fm
B-BD
32/40, 32/40DF, 32/40G, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
Page 3 - 9
Engine automation
3.3 Operation
Speed setting
In case of operating with one of the SaCoSone panels, the engine speed setting is carried out manually by a decrease/increase switch button. If the
operation is controlled by an external system, the
speed setting can be done either by means of binary contacts (e.g. for synchronisation) or by an
active 4 20 mA analogue signal alternatively. The
signal type for this is to be defined in the project
planning period.
Operating modes
For alternator applications:
0303-0000PA.fm
Page 3 - 10
32/40, 32/40DF, 32/40G, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
B-BD
Engine automation
3.4 Functionality
3.4
Functionality
Safety functions
Emergency stop
Overspeed protection
The safety system directly influences the emergency shut-down and the speed control.
In addition to the provisions made to permit the internal initiation of demands, binary and analogue
channels have been provided for the initiation of
safety functions by external systems.
Load reduction
After the exceeding of certain parameters the classification societies demand a load reduction to
60%. The safety system supervises these parameters and requests a load reduction, if necessary.
The load reduction has to be carried out by an external system (IAS, PMS, PCS). For safety reasons, SaCoSone will not reduce the load by itself.
Auto shutdown
0304-0000MB2.fm
G-BC
Engine shutdown
If an engine shutdown is triggered by the safety
system, the emergency stop signal has an immediate effect on the emergency shut-down device
and the speed control.
The engine speed is monitored in both Control
Modules independently. In case of overspeed
each Control Module actuates the shutdown device via a separate hardware channel.
Override
During operation, safety actions can be suppressed by the override function for the most parameters. The override has to be activated
preventively. The scope of parameters prepared
for override are different and depend to the chosen
classification society. The availability of the override function depends on the application.
Alarming
The alarm function of SaCoSone supervises all
necessary parameters and generates alarms to indicate discrepancies when required. The alarm
functions are likewise separated into Control Module and Gateway Module. In the Gateway Module
the supervision of the connected external systems
takes place. The alarm functions are processed in
an area completely independent of the safety system area in the Gateway Module.
Self-monitoring
SaCoSone carries out independent self-monitoring functions. Thus, for example, the connected
sensors are checked constantly for function and
wire break. In case of a fault, SaCoSone reports
the occurred malfunctions in single system components via system alarms.
32/40
Page 3 - 11
Engine automation
3.4 Functionality
Speed control
The engine speed control is realised by software
functions of the Control Module/Alarm and the Injection Modules. Engine speed and crankshaft
turn angle indication is carried out by means of redundant pick ups at the gear drive.
Start/stop sequences
Request of lube oil and cooling water pumps
Monitoring of the prelubrication and post-cooling period
0304-0000MB2.fm
Page 3 - 12
32/40
G-BC
Engine automation
3.5 Interfaces
3.5
Interfaces
Others
Serial
interface
(MODBUS
RTU)
RS422/RS485, Standard 5 wire with electrical
isolation (cable length <= 100 m)
Clutches
Gearbox
Power management
Hardwired interface, for remote start/stop, load
setting, etc.
control system
0305-0000MB2.fm
Standardised hardwired interface including all signals for control and safety actions between SaCoSone and the control system.
G-BC
32/40
Page 3 - 13
Engine automation
0305-0000MB2.fm
3.5 Interfaces
Page 3 - 14
32/40
G-BC
Engine automation
3.6 Technical data
3.6
Technical data
Interface Cabinet
VIT Cabinet
Design
Design
Floor-standing cabinet
Opening angle: 90
Opening angle: 90
(RAL7035)
Weight: 15 kg
Environmental Conditions
Environmental Conditions
Design
Panel for control desk installation with 3 m ca-
C-AI
32/40
Page 3 - 15
Engine automation
3.6 Technical data
Supply system
Notes
Pn
Ub
(kVA)
(V)
(Hz)
SaCoSone
0.8
24
DC
+/
40 A
SaCoSone Interface
Cabinet
0.45
400 440
50/60
6A
SaCoSone temperature
controllers
0.07*
230
50/60
10 A
Fuse/
Starter
by yard
0306-0000MB2.fm
Table 3-2
Phase
Page 3 - 16
32/40
C-AI
Engine automation
3.7 Installation requirements
3.7
Installation requirements
Location
The Interface Cabinet is designed for installation in
non-hazardous areas.
The maximum cable length between the engine
and the Interface Cabinet is 60 meters.
The cabinet must be installed at a location suitable
for service inspection.
Do not install the cabinet close to heat-generating
devices.
In case of installation at walls, the distance between cabinet and wall has to be at least 100 mm
in order to allow air convection.
Regarding the installation in engine rooms, the
cabinet should be supplied with fresh air by the
engine room ventilation through a dedicated ventilation air pipe near the engine.
Note!
If the restrictions for ambient temperature can
not be kept, the cabinet must be ordered with
an optional air condition system.
Ambient air conditions
For restrictions of ambient conditions, please refer
to the "Section 3.6: Technical data, page 3-15".
Cabling
0307-0000MB2.fm
C-AI
max. cable
length
60 m
100 m
100 m
Table 3-3
Installation Works
During the installation period the yard has to protect the cabinet against water, dust and fire. It is
not allowed to do any welding near the cabinets.
The cabinets have to be fixed to the floor by
screws.
If it is inevitable to do welding near the cabinet, the
cabinet and panels have to be protected against
heat, electric current and electromagnetic influences. To guarantee protection against current, all
of the cabling must be disconnected from the affected components.
The installation of additional components inside
the cabinets is only allowed after approval by the
responsible project manager of MAN Diesel &
Turbo only.
32/40
Page 3 - 17
Engine automation
0307-0000MB2.fm
Page 3 - 18
32/40
C-AI
======
Kapiteltitel 4 AA.fm
Page 4 - 1
Page 4 - 2
Kapiteltitel 4 AA.fm
p~===
4.1.1 Lubricating oil
4.1
4.1.1
Lubricating oil
Main fuel
Viscosity
class
SAE 40
12 mg KOH/g
12
20 mg KOH/g
MDO (ISO-F-DMB)
12
20 mg KOH/g
30
40 mg KOH/g
HFO
Table 4-1
Medium-alkaline + additives
Depends on
sulphur content
Selection of the lubricating oil must be in accordance with the relevant sections.
4.1.2
Fuel
B-BD
Engines that are normally operated with heavy fuel, can also be operated with MGO (DMA, DMZ)
for short periods.
Boundary conditions:
ature before engine 45 C. In general the minimum viscosity before engine of 1.9 cSt must
not be undershoot!
Page 4 - 3
p~===
4.1.3 Engine cooling water
In case of conventional injection system, injection pumps with sealing oil system, which can
be activated and cut off manually, are necessary
Layout of fuel system to be adapted for low-viscosity fuel (capacity and design of fuel supply
and booster pump)
perature before engine of 45 C (min. permissible viscosity before engine 1.9 cSt)
If it is intended to run continuously with low sulphur-containing heavy fuel, lube oil with a low BN
(BN30) has to be used. This is needed, in spite of
experiences that engines have been proven to be
very robust regarding to the continuous usage of
the standard lubrication oil (BN40) for this purpose.
Instruction for minimum admissible fuel temperature
10 C and less have to be avoided, due to temporarily embrittlement of seals used in the engines fuel oil system and as a result their
possibly loss of function
4.1.3
activated
page 4-3"
MDO (DMB)
no
HFO
yes
Table 4-2
4.1.4
Intake air
The quality of the intake air as stated in the relevant sections has to be ensured.
Page 4 - 4
0203-0000AA2.fm
B-BD
p~===
4.2.1 Operation with biofuel
4.2
4.2.1
4.2.2
J p====~==~=~
~=~==~=K
J o~J=
Not transesterified biofuel with pour point below
20 C is comparable to HFO (ISO-F-RM), therefore standard layout of fuel oil system for HFO-operation to be used.
Category 3 not transesterified biofuel and pour point
above 20 C
For example:
J m~=
J p~
J ^~=~
J c=~
1001-0109MP.fm
J ebJMOR===~===J
=~=Z[===K
f= = = ~= ~= ~=
======J
~====K
J i~=====~=~=
===K
For example:
Caution:
Not transesterified biofuel with a pour point above
20 C carries a risk of flocculation and may clog up
pipes and filters unless special precautions are taken.
A-BA
J f= ~= = ~= = = = =
= = = = = =
====K
J q=====
~= = = MKMNM= = ~= =
=~==MKMPQ=K
Additionally:
J c=====~==~
E= = = ~~= ~= ~=
FK
J ^====~====
~=N==OK=
a=========J
= ~= = = = = = ~
=======~=N
=O=~==~=====~J
===~=~=====
==K
32/40, 48/60B
Page 4 - 5
p~===
4.2.3 Requirements on engine
4.2.3
Requirements on engine
f===~=~=~=
~==K
c= = ~= ~= = = =
==~==~=E==
~===~=NI===~J
=O======~J
~I===~=P=~==
=~~FK
f=~=~K
k====~====~J
=O=~=PK
`~=~=~===RR `
===~K
Please be aware
a= = = ~= = = I=
~==~==~====~
=~=E===~==~==
~= = ~= = J
FK
^=~=======J
~W
O Lt=~=====E
===FK
b= ~= = = = = ~
===~==W
b==POLQMI=~==
RMMtL`K=~==J=
QJ==E=QULSM_FW
J i`s
PU=jgL=m==M=B
J i`s
PS=jgL=m==R=B
J i`s
PR=jgL=m==NM=B=
J i`s
PT=jgL=m==M=B
J i`s
PS=jgL=m==OIR=B
J i`s
PR=jgL=m==R=B
Page 4 - 6
32/40, 48/60B
1001-0109MP.fm
b==QULSM_I=~=
NMRM tL`KW
A-BA
4.3
General
The specific output achieved by modern diesel engines combined with the use of fuels that satisfy
the quality requirements more and more frequently
increase the demands on the performance of the
lubricating oil which must therefore be carefully selected.
Doped lubricating oils (HD oils) have a proven
track record as lubricants for the drive, cylinder,
turbocharger, and for cooling the piston. Doped
lubricating oils contain additives that among other
things ensure dirt absorption capability, engine
cleaning, and neutralisation of acidic combustion
products.
To fulfil strict requirements for lubricating oil in stationary operation, MAN Diesel & Turbo offers a lubricating oil based on selected additive
Properties/characteristics
Make-up
Low-temperature behaviour, still
flowable
Insoluble n-heptane
Table 4-3
The base oil (doped lubricating oil = base oil + additives) must have a narrow distillation range and
be refined using modern methods. If it contains
paraffins, they must not impair the thermal stability
or oxidation stability.
The base oil must comply with the following limit
values, particularly in terms of its resistance to
ageing.
ASTM D 2500
15
ASTM D 92
> 200
ASTM D 482
< 0.02
ASTM D 189
< 0.50
Weight %
ASTM D 4055
or DIN 51592
Weight %
<
0.2
<
0401-0000PA2.fm
1)
Base oil
Limit value
Evaporation loss
Spot test (filter paper)
Specifications
Test method
Unit
techniques, which guarantees an optimum performance also under the most adverse conditions:
PrimeServ Lube
B-BD
Page 4 - 7
Additional requirements
The base oil to which the additives have been added (doped lubricating oil) must have the following
properties:
Additives
Page 4 - 8
Engine
SAE class
40
Speed governor
Multigrade oil 5W40 should ideally be used in mechanical-hydraulic controllers with a separate oil
sump. If this oil is not available when filling, 15W40
oil can be used instead in exceptional cases. In
this case, it makes no difference whether synthetic
or mineral-based oils are used.
B-BD
0401-0000PA2.fm
If the engine is operated provisionally with low-sulphur diesel fuel for more than 1000 h and is subsequently operated once again with HFO, a
lubricating oil with a BN of 20 must be used. If the
BN 20 lubricating oil from the same manufacturer
as the lubricating oil is used for HFO operation with
higher BN (40 or 50), an oil change will not be required when effecting the changeover. It will be
sufficient to use BN 20 oil when replenishing the
used lubricating oil.
0401-0000PA2.fm
B-BD
Tests
We can analyse lubricating oil for customers at our
laboratory. A 0.5 l sample is required for the test.
Note!
Improper handling of operating fluids
If operating fluids are improperly handled, this
can pose a danger to health, safety and the environment. The relevant safety information by
the supplier of operating fluids must be observed.
Page 4 - 9
Limit value
Viscosity at 40 C
110
220 mm2/s
Procedure
ISO 3104 or ASTM D445
ISO 3771
at least 185 C
ISO 2719
Water content
n-heptane insoluble
max. 1.5 %
Metal content
Fe
max. 50 ppm
Cr
max. 10 ppm
Cu
max. 15 ppm
Pb
max. 20 ppm
Sn
max. 10 ppm
Al
max. 20 ppm
max. 12 %
FT-IR
biofuel fraction
Limit values for used lubricating oil
0401-0000PA2.fm
Table 4-5
Page 4 - 10
B-BD
p~===
4.4 Lubricating oil (SAE 40) Specification for heavy fuel operation (HFO) (stationary)
4.4
General
The specific output achieved by modern diesel engines combined with the use of fuels that satisfy
the quality requirements more and more frequently
increase the demands on the performance of the
lubricating oil which must therefore be carefully selected.
Medium alkalinity lubricating oils have a proven
track record as lubricants for the moving parts and
turbocharger cylinder and for cooling the pistons.
Lubricating oils of medium alkalinity contain additives that, in addition to other properties, ensure a
higher neutralization reserve than with fully compounded engine oils (HD oils).
International specifications do not exist for medium alkalinity lubricating oils. A test operation is
therefore necessary for a corresponding long period in accordance with the manufacturer's instructions.
Properties/characteristics
Make-up
Low-temperature behaviour, still flowable
0401-0000Phfo2.fm
Table 4-6
1)
Specifications
Base oil
The base oil (doped lubricating oil = base oil + additives) must have a narrow distillation range and
be refined using modern methods. If it contains
paraffins, they must not impair the thermal stability
or oxidation stability.
The base oil must comply with the limit values (see
"Table 4-6: Base oils Target values"), particularly in
terms of its resistance to ageing.
Test method
Limit value
ASTM D 2500
15
ASTM D 92
> 200
ASTM D 482
< 0.02
ASTM D 189
< 0.50
MAN ageing
oven1)
Weight
%
ASTM D 4055
or
DIN 51592
< 0.2
<2
Weight
%
Evaporation loss
Spot test (filter paper)
Unit
To fulfil strict requirements for lubricating oil in stationary operation, MAN Diesel & Turbo offers a lubricating oil based on selected additive
techniques, which guarantees an optimum performance also under the most adverse conditions:
PrimeServ Lube.
E-BC
Page 4 - 11
p~===
4.4 Lubricating oil (SAE 40) Specification for heavy fuel operation (HFO) (stationary)
Evaporation tendency
The evaporation tendency must be as low as possible as otherwise the oil consumption will be adversely affected.
Additives
The additives must be dissolved in the oil and their
composition must ensure that as little ash as possible is left over, even if the engine is provisionally
operated with distillate oil.
The ash must be soft. If this prerequisite is not
met, it is likely the rate of deposition in the combustion chamber will be higher, particularly at the
exhaust valves and at the turbocharger inlet casing. Hard additive ash promotes pitting of the valve
seats and causes the valves to burn out, it also increases mechanical wear of the cylinder liners.
Additives must not increase the rate at which the
filter elements in the active or used condition are
blocked.
Washing ability
The washing ability must be high enough to prevent the accumulation of tar and coke residue as
a result of fuel combustion. The lubricating oil must
not absorb the deposits produced by the fuel.
Dispersion capability
The selected dispersibility must be such that commercially-available lubricating oil cleaning systems
can remove harmful contaminants from the oil
used, i. e. the oil must possess good filtering properties and separability.
Additional requirements
The lubricating oil must not contain viscosity index
improver. Fresh oil must not contain water or other
contaminants.
Lube oil selection
Engine
SAE
class
40
Neutralisation capability
The neutralisation capability (ASTM D2896) must
be high enough to neutralise the acidic products
produced during combustion. The reaction time of
the additive must be harmonised with the process
in the combustion chamber.
Page 4 - 12
0401-0000Phfo2.fm
E-BC
p~===
4.4 Lubricating oil (SAE 40) Specification for heavy fuel operation (HFO) (stationary)
Approx. BN of fresh
oil (mg KOH/g oil)
Engines/operating conditions
20
Marine diesel oil (MDO) with a lower quality and high sulphur content or heavy fuel oil with a sulphur
content of less than 0.5 %.
30
Generally 23/30H and 28/32H. 23/30A, 28/32A and 28/32S under normal operating conditions.
For engines 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 as well as 58/64 and 51/60DF
with exclusive HFO operation only with sulphur content < 1.5 %.
40
With unfavourable operating conditions 23/30A, 28/32A and 28/32S and also where corresponding requirements in relation to the oil service life and washing ability exist.
In general 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 as well as 58/64 and 51/60DF with
exclusive HFO operation providing the sulphur content is greater than 1.5 %.
50
Table 4-8
32/40, 32/44CR, 40/54, 48/60 and 58/64, if the oil service life or engine cleanliness is insufficient
with a BN number of 40 (high sulphur content of fuel, extremely low lubricating oil consumption).
Base number to be used for various operating conditions
0401-0000Phfo2.fm
Speed governor
Multigrade oil 5W40 should ideally be used in mechanical-hydraulic controllers with a separate oil
sump, unless the technical documentation for the
speed governor specifies otherwise. If this oil is not
E-BC
available when filling, 15W40 oil may be used instead in exceptional cases. In this case, it makes
no difference whether synthetic or mineral-based
oils are used. The military specification for these
oils is O-236. Experience with the drive engine
L27/38 has shown that the operating temperature
of the Woodward controller UG10MAS and corresponding actuator for UG723 + can reach temperatures higher than 93 C. In these cases, we
recommend using synthetic oil such as Castrol Alphasyn HG150. The engines supplied after March
2005 are already filled with this oil.
Page 4 - 13
p~===
4.4 Lubricating oil (SAE 40) Specification for heavy fuel operation (HFO) (stationary)
If the engine is operated provisionally with low-sulphur diesel fuel for more than 1,000 h and is subsequently operated once again with HFO, a
lubricating oil with a BN of 20 must be used. If the
BN 20 lubricating oil by the same manufacturer as
the lubricating oil used for HFO operation with
higher BN (40 or 50), an oil change will not be required when effecting the changeover. It will be
sufficient to use BN 20 oil when replenishing the
used lubricating oil.
Limit value
Viscosity at 40 C
Base number (BN)
Flash point (PM)
Water content
110
ISO 3771
at least 185 C
ISO 2719
max. 1.5 %
max. 50 ppm
max. 10 ppm
max. 15 ppm
max. 20 ppm
max. 10 ppm
max. 20 ppm
Table 4-9
n-heptane insoluble
Metal content
220 mm2/s
Procedure
Tests
We can analyse heavy fuel oil for customers at our
laboratory. A 0.5 l sample is required for the test.
Page 4 - 14
E-BC
p~===
4.5 Specification for gas oil/diesel oil (MGO)
4.5
Diesel oil
Other designations
Gas oil, marine gas oil (MGO), diesel oil
Gas oil is a crude oil medium distillate and must
therefore not contain any residual materials.
Military specification
Diesel oils that satisfy specification F-75 or F-76
may be used.
Specification
The suitability of the fuel depends on whether it
has the properties defined in this specification
(based on its composition in the as-delivered
state).
The DIN EN 590 and ISO 8217-2010 (Class DMA
or Class DMZ) and standards have been extensively used as the basis when defining these properties. The properties correspond to the test
procedures stated.
Properties
Unit
Density at 15 C
Kinematic viscosity at 40 C
Filterability1)
in summer and
in winter
Test procedure
Typical value
kg/m
ISO 3675
820.0
890.0
mm2/s (cSt)
ISO 3104
2
6.0
DIN EN 116
0
12
60
weight %
ISO 3735
0.01
Water content
volume %
ISO 3733
0.05
Sulphur content
weight %
ISO 8754
1.5
ISO 6245
0.01
ISO CD 10370
0.10
IP 570
<2
Ash
Coke residue (MCR)
0409-0000AA2.fm
ISO 2719
Hydrogen sulphide
Table 4-10
E-BB
mg/kg
Page 4 - 15
p~===
4.5 Specification for gas oil/diesel oil (MGO)
Properties
Unit
Test procedure
Typical value
mg KOH/g
ASTM D664
< 0.5
Oxidation stability
g/m3
ISO 12205
< 25
ISO 12156-1
< 520
ISO 5165
40
ISO 2160
M1
ASTM D 975
1D/2D
Lubricity
(wear scar diameter)
Other specifications:
Table 4-10
1) The
process for determining the filterability in accordance with DIN EN 116 is similar to the process for determining the cloud
point in accordance with ISO 3015.
Additional information
Viscosity
To ensure sufficient lubrication, a minimum viscosity must be ensured at the fuel delivery pump. The
maximum temperature required to ensure that a
viscosity of more than 1.9 mm2/s is maintained
upstream of the fuel delivery pump depends on
the viscosity of the fuel. In any case the temperature of the fuel upstream of the injection pump
must not exceed 45 C.
their lubricity is sufficient. This is the case if the lubricity as specified in ISO 12156-1 does not exceed 520 m.
You can ensure that these conditions will be met
by using motor vehicle diesel fuel in accordance
with EN 590 as this characteristic value is an integral part of the specification.
Improper handling of fuels
If fuels are improperly handled, this can pose a
danger to health, safety and the environment. The
relevant safety information by the fuel supplier
must be observed.
Analyses
We can analyse fuel for customers at our laboratory. A 0.5 l sample is required for the test.
Lubricity
Page 4 - 16
0409-0000AA2.fm
E-BB
p~===
4.6 Specification for biofuel
4.6
Biofuel
Other designations
Biodiesel, FAME, vegetable oil, rapeseed oil, palm
oil, frying fat
Origin
Biofuel is derived from oil plants or old cooking oil.
Provision
Transesterified and non-transesterified vegetable
oils can be used.
Transesterified biofuels (biodiesel, FAME) must
comply with the standard EN 14214.
Unit
Test method
> 60 C
DIN EN 22719
Properties/Characteristics
Density at 15 C
Flash point
Lower calorific value
DIN 51900-3
Viscosity/50 C
Cetane number
> 40
FIA
< 0.4 %
DIN EN 12662
>5h
ISO 6886
Phosphorous content
< 15 ppm
ASTM D 3231
Na and K content
< 15 ppm
DIN 51797-3
Ash content
< 0.01 %
Water content
< 0.5 %
EN ISO 12537
Iodine number
DIN EN 14111
< 5 mg KOH/g
EN 116
Coke residue
Sediment content
Oxidation stability (110 C)
Filtrability
0414-0000AA2.fm
Table 4-11
D-BD
Page 4 - 17
p~===
4.6 Specification for biofuel
0414-0000AA2.fm
We can analyse fuel for customers at our laboratory. A 0.5 l sample is required for the test.
Page 4 - 18
D-BD
p~===
4.7 Specification for diesel oil (MDO)
4.7
Specification
Other designations
Origin
Marine diesel oil (MDO) is supplied as heavy distillate (designation ISO-F-DMB) exclusively for marine applications. MDO is manufactured from
crude oil and must be free of organic acids and
non-mineral oil products.
Properties
ISO-F specification
Density at 15 C
Kinematic viscosity at 40 C
Test method
Designation
DMB
ISO 3675
900
ISO 3104
> 2.0
kg/m
mm2/s
= cSt
< 11
Pour point (winter quality)
ISO 3016
<0
<6
ISO 2719
> 60
% by weight
ISO CD 10307
0.10
Water content
% by volume
ISO 3733
< 0.3
Sulphur content
% by weight
ISO 8754
< 2.0
ISO 6245
< 0.01
ISO CD 10370
< 0.30
ISO 5165
> 35
mg/kg
IP 570
<2
mg KOH/g
ASTM D664
< 0.5
g/m3
ISO 12205
< 25
ISO 12156-1
< 520
ISO 2160
<1
Class M2
ASTM D 975
2D
ASTM D 396
No. 2
Ash content
Carbon residue (MCR)
Cetane number or cetane index
Hydrogen sulphide
Acid value
Oxidation resistance
Lubricity
(wear scar diameter)
Copper strip test
0407-0000AA2.fm
Other specifications:
Table 4-12
J-BA
Page 4 - 19
p~===
4.7 Specification for diesel oil (MDO)
Additional information
During transshipment and transfer, MDO is handled in the same manner as residual oil. This
means that it is possible for the oil to be mixed with
high-viscosity fuel or heavy fuel oil with the remnants of these types of fuels in the bunker ship, for
example that could significantly impair the properties of the oil.
Lubricity
Normally, the lubricating ability of diesel fuel oil is
sufficient to operate the fuel injection pump. Desulphurisation of diesel fuels can reduce their lubricity. If the sulphur content is extremely low
(< 500 ppm or 0.05 %), the lubricity may no longer
be sufficient. Before using diesel fuels with low sulphur content, you should therefore ensure that
their lubricity is sufficient. This is the case if the lubricity as specified in ISO 12156-1 does not exceed 520 m.
The fuel must be free of lubricating oil (ULO (used
lubricating oil, old oil)). Fuel is considered as contaminated with lubricating oil when the following
concentrations occur:
Ca > 30 ppm and Zn > 15 ppm or Ca > 30 ppm
and P > 15 ppm.
0407-0000AA2.fm
Page 4 - 20
J-BA
p~===
4.8 Specification for heavy fuel oil (HFO)
4.8
Prerequisites
MAN four-stroke diesel engines can be operated
with any heavy fuel oil obtained from crude oil that
also satisfies the requirements in "Table 4-13: The
processing system have been designed accordingly. To ensure that the relationship between the
fuel, spare parts and repair/maintenance costs remains favourable at all times, the following points
should be observed.
Heavy fuel oil (HFO)
Origin/Refinery process
The quality of the heavy fuel oil largely depends on
the quality of crude oil and on the refining process
used. This is why the properties of heavy fuel oils
with the same viscosity may vary considerably depending on the bunker positions. Heavy fuel oil is
normally a mixture of residual oil and distillates.
The components of the mixture are normally obtained from modern refinery processes, such as
Catcracker or Visbreaker. These processes can
adversely affect the stability of the fuel as well as
its ignition and combustion properties. The
processing of the heavy fuel oil and the operating
result of the engine also depend heavily on these
factors.
Bunker positions with standardised heavy fuel oil
qualities should preferably be used. If oils need to
be purchased from independent dealers, also ensure that these also comply with the international
specifications. The engine operator is responsible
for ensuring that suitable heavy fuel oils are chosen.
Specifications
0406-0000AA2.fm
4-13: The fuel specifications and corresponding characteristics for heavy fuel oil".
D-BC
Important
Even though the fuel properties specified in "Table
4-13: The fuel specifications and corresponding characteristics for heavy fuel oil" satisfy the above require-
Blends
The addition of engine oils (old lubricating oil,
ULO used lubricating oil) and additives that are
not manufactured from mineral oils, (coal-tar oil,
for example), and residual products of chemical or
other processes such as solvents (polymers or
Page 4 - 21
p~===
4.8 Specification for heavy fuel oil (HFO)
chemical waste) is not permitted. Some of the reasons for this are as follows: abrasive and corrosive
effects, unfavourable combustion characteristics,
poor compatibility with mineral oils and, last but
not least, adverse effects on the environment. The
order for the fuel must expressly state what is not
permitted as the fuel specifications that generally
apply do not include this limitation.
If engine oils (old lubricating oil, ULO used lubricating oil) are added to fuel, this poses a particular
danger as the additives in the lubricating oil act as
emulsifiers that cause dirt, water and catfines to
be transported as fine suspension. They therefore
prevent the necessary cleaning of the fuel. In our
mm2/s
(cSt)
Viscosity
(at 50 C)
700
55
1.010
min.
60
max.
30
30
20
5 or
max.
Viscosity
(at 100 C)
Density
(at 15 C)
g/ml
Flash point
Pour point
(summer)
Pour point (winter)
Carbon residues
(Conradson)
Weight
%
Sulphur content
max.
legal requirements
Ash
content
0.15
Vanadium content
mg/kg
450
Water
content
Volume%
0.5
Sediment (potential)
Weight
%
0.1
The fuel specifications and corresponding characteristics for heavy fuel oil (1 of 2)
0406-0000AA2.fm
Table 4-13
Page 4 - 22
D-BC
p~===
4.8 Specification for heavy fuel oil (HFO)
60
mg
KOH/g
2.5
Hydrogen sulphide
mg/kg
mg/kg
Asphalt content
Weight
%
Sodium content
mg/kg
Sodium< 1/3
vanadium,
sodium< 100
mg/kg
max.
The fuel must be free of admixtures that cannot be obtained from mineral oils, such as vegetable or coal-tar oils.
It must also be free of tar oil and lubricating oil (old oil), and also chemical waste products such as solvents or
polymers.
The fuel specifications and corresponding characteristics for heavy fuel oil (2 of 2)
0406-0000AA2.fm
Table 4-13
D-BC
Page 4 - 23
p~===
Figure 4-1
Page 4 - 24
0406-0000AA2.fm
D-BC
p~===
0406-0000AA2.fm
Figure 4-2
D-BC
Page 4 - 25
p~===
4.8 Specification for heavy fuel oil (HFO)
Additional information
Viscosity/injection viscosity
Heavy fuel oils with a high viscosity may be of an
inferior quality. The maximum permissible viscosity
depends on the preheating system installed and
the capacity (flow rate) of the separator.
Settling tank
The heavy fuel oil is pre-cleaned in the settling
tank. The longer the fuel remains in the tank and
the lower the viscosity of the heavy fuel oil is, the
more effective the pre-cleaning process will be
(maximum preheating temperature of 75 C to
prevent asphalt forming in the heavy fuel oil). A settling tank is sufficient for heavy fuel oils with a viscosity of less than 380 mm2/s at 50 C. If the
heavy fuel oil has a high concentration of foreign
matter or if fuels in accordance with
ISO-F-RMG 380/500/700 or RMK 380/500/700
are to be used, two settling tanks will be required
one of which must be sized for 24-hour operation.
Before the content is moved to the service tank,
water and sludge must be drained from the settling tank.
Separators
A separator is particularly suitable for separating
material with a higher specific density water, foreign matter and sludge, for example. The separators must be self-cleaning (i. e. the cleaning
intervals must be triggered automatically). Only
separators in the new generation may be used.
They are extremely effective throughout a wide
density range with no changeover required and
can separate water from heavy fuel oils with a density of up to 1.01 g/ml at 15 C.
0406-0000AA2.fm
Page 4 - 26
D-BC
p~===
4.8 Specification for heavy fuel oil (HFO)
For the prerequisites that must be met by the separator see "Table 4-14: Obtainable contents of foreign
matter and water (after separation)". These limit values
are used by manufacturers as the basis for dimensioning the separator and ensure compliance.
The manufacturer's specifications must be complied with to maximise the cleaning effect.
Figure 4-3
Particle size
Quantity
< 5 m
< 20 mg/kg
Al+Si content
< 15 mg/kg
Water content
0406-0000AA2.fm
Table 4-14
D-BC
Page 4 - 27
p~===
4.8 Specification for heavy fuel oil (HFO)
Water
Ash
Vanadium/sodium
If the vanadium/sodium ratio is unfavourable, the
melting point of the heavy fuel oil ash may fall in the
operating range of the exhaust-gas valve which
can lead to high-temperature corrosion. Most of
the water and water-soluble sodium compounds it
contains can be removed by pre-cleaning the
heavy fuel oil in the settling tank and in the separators.
The risk of high-temperature corrosion is low if the
sodium content is one third of the vanadium content or less. It must also be ensured that sodium
does not enter the engine in the form of seawater
in the intake air.
If the sodium content is higher than 100 mg/kg,
this is likely to result in a higher quantity of salt deposits in the combustion chamber and exhaust
gas system. This will impair the function of the engine (including the suction function of the turbocharger).
Under certain conditions, high-temperature corrosion can be prevented by using a fuel additive that
increases the melting point of the heavy fuel oil ash
(see "Paragraph: Additives to heavy fuel oils, page
4-31").
Homogeniser
If a homogeniser is used, it must never be installed
between the settling tank and separator as otherwise it will not be possible to ensure satisfactory
separation of harmful contaminants, particularly
seawater.
Pump characteristics
If the viscosity of the fuel is higher than
1,000 mm2/s (cST), or the temperature is not at
least 10 C above the pour point, pumping problems will occur. For further information see "Para-
Page 4 - 28
D-BC
0406-0000AA2.fm
p~===
4.8 Specification for heavy fuel oil (HFO)
Combustion properties
If the proportion of asphalt is more than two thirds
of the coke residue (Conradson), combustion may
be delayed which in turn may increase the formation of combustion residues, leading to such as
deposits on and in the injection nozzles, large
amounts of smoke, low output, increased fuel
consumption and a rapid rise in ignition pressure
as well as combustion close to the cylinder wall
(thermal overloading of lubricating oil film). If the ratio of asphalt to coke residues reaches the limit
0.66, and if the asphalt content exceeds 8 %, the
risk of deposits forming in the combustion chamber and injection system is higher. These problems
can also occur when using unstable heavy fuel
oils, or if incompatible heavy fuel oils are mixed.
This would lead to an increased deposition of asphalt (see "Paragraph: Compatibility, page 4-31").
Ignition quality
Nowadays, to achieve the prescribed reference
viscosity, cracking-process products are used as
the low viscosity ingredients of heavy fuel oils although the ignition characteristics of these oils
may also be poor. The cetane number of these
compounds should be > 35. If the proportion of
aromatic hydrocarbons is high (more than 35 %),
this also adversely affects the ignition quality.
0406-0000AA2.fm
The ignition delay in heavy fuel oils with poor ignition characteristics is longer and combustion is
also delayed which can lead to thermal overloading of the oil film at the cylinder liner and also high
cylinder pressures. The ignition delay and accompanying increase in pressure in the cylinder are
also influenced by the end temperature and compression pressure, i. e. by the compression ratio,
the charge-air pressure and charge-air temperature.
D-BC
Page 4 - 29
p~===
4.8 Specification for heavy fuel oil (HFO)
Figure 4-4
Nomogram for the determination of CCAI Assignment of CCAI ranges to engine types
Legend
Viscosity mm/s (cSt) at 50 C
Density [kg/m] at 15 C
CCAI
Ignition properties may be poor that adjustment of engine or engine or engine operating conditions are required
Problems that have been identified may lead to engine damage, even after a short period of operation.
Engine type
The CCAI is obtained from the straight line through the density and viscosity of the heavy fuel oils.
0406-0000AA2.fm
Page 4 - 30
D-BC
p~===
4.8 Specification for heavy fuel oil (HFO)
Compatibility
The supplier must guarantee that the heavy fuel oil
is homogeneous and remains stable, even once
the standard storage period has elapsed. If different bunker oils are mixed, this can lead to separation and associated sludge formation in the fuel
system during which large quantities of sludge accumulate in the separator that block filters, prevent
atomisation and a large amount of residue as a result of combustion.
This is due to incompatibility or instability of the
oils. As much of the heavy fuel oil in the storage
tank as possible should therefore be removed before bunkering again to prevent incompatibility.
Additives that are currently used for diesel engines, as well as their probable effects on the engine's operation, are summarised in the "Table 415: Additives to heavy fuel oils Classification/ effects",
together with their supposed effect on engine operation.
Precombustion
additives
Dispersing agents/stabilisers
Emulsion breakers
Biocides
Combustion additives
Post-combustion
additives
Table 4-15
0406-0000AA2.fm
The use of heavy fuel oil additives during the warranty period must be avoided as a basic principle.
D-BC
Page 4 - 31
p~===
4.8 Specification for heavy fuel oil (HFO)
Tests
Sampling
To check whether the specification provided
and/or the necessary delivery conditions are complied with, we recommend you retain at least one
sample of every bunker oil (at least for the duration
of the engine's warranty period). To ensure that
representative samples are taken of the bunker oil,
a sample should be taken from the transfer line
when starting up, halfway through the operating
period and at the end of the bunker period. Sample Tec" by MarTec in Hamburg is a suitable testing instrument which can be used to take samples
on a regular basis during bunkering.
Analysis of samples
Our department for fuels and lubricating oils
(Augsburg factory, EQC department) will be
pleased to provide further information on request.
0406-0000AA2.fm
We can analyse fuel for customers at our laboratory. A 0.5 l sample is required for the test.
Page 4 - 32
D-BC
p~===
4.9 Viscosity-temperature diagram (VT diagram)
4.9
Figure 4-5
0413-0000AA2.fm
E-BB
Page 4 - 33
p~===
4.9 Viscosity-temperature diagram (VT diagram)
Table 4-16
Required temperature
of heavy fuel oil at
engine inlet1) in C
12
126 (line c)
14
119 (line d)
1) The
drop in temperature between the last preheating appliance and the fuel injection pump is not taken into account
in these figures.
0413-0000AA2.fm
Page 4 - 34
E-BB
4.10
General
The raw water system with cooling tower re-cooling concerns an open circulation system, which
dissipates the heat absorbed from the water by
evaporation into the cooling tower. This results at
the same time in a continuous water loss due to
evaporation. In order to restrict the incurring salt
concentration, a certain water amount must permanently be topped as additive water.
Water losses due to evaporation and blowing
down (depending on the additive water quality)
may amount up to 3 % of the circulating water
quantity.
Blowing down
0405-0000PA2.fm
iJ_`
Additive water
32/40, 32/40DF, 32/40G, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
Page 4 - 35
Circulating
water
Additive
water1)
Colourless,
clear, no sediments
Colourless,
clear, no sediments
7.5 8.5
<2,500 ppm
<1,250 ppm
<3,000 S/cm
Calcium
>20 ppm
>10 ppm
<4 dH
<71 ppm
CaCO3
<2dH
<35 ppm
CaCO3
<20 dH
<356 ppm
CaCO3
< 10 dH
< 178 ppm
CaCO3
Chloride
<200 ppm
Sulphate
<300 ppm
KMnO4 consumption
Germ number
< 10,000/ml
Appearance
pH value2)
Total salt content
Conductivity
Table 4-17
1) Minimum
0405-0000PA2.fm
Page 4 - 36
32/40, 32/40DF, 32/40G, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
iJ_`
p~===
4.11 Specification for engine cooling water
4.11
Preliminary remarks
As well as fuel and lubricating oil the engine cooling water has to be selected, handled and
checked really careful. Lack of caution may cause
corrosion, erosion and cavitation to the pumps
and piping of cooling water circuits. Deposits obstruct the transfer of heat and can cause thermal
overloading of the cooled parts. The system must
be treated with an anticorrosive agent before
bringing it into operation for the first time. The concentrations prescribed by the engine manufacturer must always be observed during subsequent
operation. The above especially applies if a chemical additive is added.
Requirements
Limit values
The properties of untreated cooling water must
correspond to the following limit values:
Properties/ characteristic
Properties
Unit
Distillate or freshwater,
free of foreign matter
Total hardness
max. 10
dH1)
pH value
6.5
max. 50
Water type
Table 4-18
mg/l2)
1) 1
dH (German hardness)
10 mg CaO in 1 litre of water
17.9 mg CaCO3/l
0.357 mval/l
0.179 mmol/l
2) 1 mg/l 1 ppm
0402-0000AA2.fm
Testing equipment
The MAN Diesel & Turbo water testing equipment
incorporates devices that determine the water
properties referred to above in a straightforward
manner. The manufacturers of anticorrosive
agents also supply user-friendly testing equip-
D-BC
Distillate
If distilled water (from a freshwater generator, for
example) or fully desalinated water (from ion exchange or reverse osmosis) is available, this
should ideally be used as the engine cooling water.
These waters are free of lime and salts which
means that deposits that could interfere with the
transfer of heat to the cooling water, and therefore
also reduce the cooling effect, cannot form. However, these waters are more corrosive than normal
hard water as the thin film of lime scale that would
otherwise provide temporary corrosion protection
does not form on the walls. This is why distilled
water must be handled particularly carefully and
the concentration of the additive must be regularly
checked.
Hardness
The total hardness of the water is the combined
effect of the temporary and permanent hardness.
The proportion of calcium and magnesium salts is
of overriding importance. The temporary hardness
is determined by the carbonate content of the calcium and magnesium salts. The permanent hardness is determined by the amount of remaining
calcium and magnesium salts (sulphates). The
temporary (carbonate) hardness is the critical factor that determines the extent of limescale deposit
in the cooling system.
Water with a total hardness of > 10dGH must be
mixed with distilled water or softened. Subsequent
hardening of extremely soft water is only necessary to prevent foaming if emulsifiable slushing oils
are used.
Damage to the cooling water system
Corrosion
Corrosion is an electrochemical process that can
widely be avoided by selecting the correct water
Page 4 - 37
p~===
4.11 Specification for engine cooling water
Flow cavitation
Flow cavitation can occur in areas in which high
flow velocities and high turbulence is present. If
the steam pressure is reached, steam bubbles
form and subsequently collapse in high pressure
zones which causes the destruction of materials in
constricted areas.
Erosion
Page 4 - 38
Required approval
D-BC
0402-0000AA2.fm
p~===
4.11 Specification for engine cooling water
Slushing oil
This additive is an emulsifiable mineral oil with added slushing ingredients. A thin film of oil forms on
the walls of the cooling system. This prevents corrosion without interfering with the transfer of heat
and also prevents limescale deposits on the walls
of the cooling system.
The significance of emulsifiable corrosion-slushing
oils is fading. Oil-based emulsions are rarely used
nowadays for environmental protection reasons
and also because stability problems are known to
occur in emulsions.
Anti-freeze agents
If temperatures below the freezing point of water in
the engine cannot be excluded, an anti-freeze solution that also prevents corrosion must be added
to the cooling system or corresponding parts.
Otherwise, the entire system must be heated. (Military specification: Sy-7025).
0402-0000AA2.fm
D-BC
the consent of the manufacturer, even if these solutions have the same composition.
Before an anti-freeze solution is used, the cooling
system must be thoroughly cleaned.
If the cooling water contains an emulsifiable slushing oil, anti-freeze solution must not be added as
otherwise the emulsion would break up and oil
sludge would form in the cooling system.
Observe the applicable environmental protection
regulations when disposing of cooling water containing additives. For more information, consult the
additive supplier.
Biocides
If you cannot avoid using a biocide because the
cooling water has been contaminated by bacteria,
observe the following steps:
must not contain corrosion-promoting components. Biocides whose decomposition products contain chloride or sulphate ions are not
permitted.
Biocides that cause foaming of the cooling water are not permitted.
Page 4 - 39
p~===
4.11 Specification for engine cooling water
Note!
Page 4 - 40
Excessively low concentrations can promote corrosion and must be avoided. If the concentration
is slightly above the recommended concentration
this will not result in damage. Concentrations that
are more than twice the recommended concentration should be avoided.
Every 2 to 6 months send a cooling water sample
to an independent laboratory or to the engine
manufacturer for integrated analysis.
Emulsifiable anticorrosive agents must generally
be replaced after abt. 12 months according to the
supplier's instructions. When carrying this out, the
entire cooling system must be flushed and, if necessary, cleaned. Once filled into the system, freshwater must be treated immediately.
If chemical additives or anti-freeze solutions are
used, cooling water should be replaced after 3
years at the latest.
If there is a high concentration of solids (rust) in the
system, the water must be completely replaced
and entire system carefully cleaned.
Deposits in the cooling system may be caused by
fluids that enter the cooling water, or the break up
of emulsion, corrosion in the system and limescale
deposits if the water is very hard. If the concentration of chloride ions has increased, this generally
indicates that seawater has entered the system.
The maximum specified concentration of 50 mg
chloride ions per kg must not be exceeded as otherwise the risk of corrosion is too high. If exhaust
gas enters the cooling water, this may lead to a
sudden drop in the pH value or to an increase in
the sulphate content.
Water losses must be compensated for by filling
with untreated water that meets the quality requirements specified in this section in "Paragraph:
Requirements, page 4-37". The concentration of the
anticorrosive agent must subsequently be
checked and adjusted if necessary.
D-BC
0402-0000AA2.fm
As contamination significantly reduces the effectiveness of the additive, the tanks, pipes, coolers
and other parts outside the engine must be free of
rust and other deposits before the engine is started up for the first time and after repairs are carried
out on the pipe system. The entire system must
therefore be cleaned with the engine switched off
using a suitable cleaning agent (see "Section 4.13:
Cooling water system cleaning, page 4-47").
p~===
4.11 Specification for engine cooling water
Subsequent checks of cooling water are especially required if the cooling water had to be drained
off in order to carry out repairs or maintenance.
Protective measures
Anticorrosive agents contain chemical compounds that can pose a risk to health or the environment if incorrectly used. Comply with the
directions in the manufacturer's material safety
data sheets.
Avoid prolonged direct contact with the skin.
Wash hands thoroughly after use. If larger quantities spray and/or soak into clothing, remove and
wash clothing before wearing it again.
If chemicals come into contact with your eyes,
rinse them immediately with plenty of water and
seek medical advice.
Anticorrosive agents are generally harmful to the
water cycle. Observe the relevant statutory requirements for disposal.
Auxiliary engines
If the same cooling water system used in a MAN
Diesel & Turbo two-stroke main engine is used in
a marine engine of type 16/24, 21/31, 23/30H,
27/38 or 28/32H, the cooling water recommendations for the main engine must be observed.
Analysis
0402-0000AA2.fm
D-BC
Page 4 - 41
p~===
4.11 Specification for engine cooling water
Product designation
Initial
dosing
per
1,000 l
Nitrite
(NO2)
Na-Nitrite
(NaNO2)
15 l
40 l
15,000
40,000
700
1,330
1,050
2,000
21.5 l
4.8 kg
21,500
4,800
2,400
2,400
3,600
3,600
Drew Marine
One Drew Plaza
Boonton
New Jersey 07005
USA
Liquidewt
Maxigard
Wilhelmsen (Unitor)
KJEMI-Service A.S.
P.O.Box 49/Norway
3140 Borgheim
Rocor NB Liquid
Dieselguard
Nalfleet Marine
Chemicals
P.O.Box 11
Northwich
Cheshire CW8DX, U.K.
3l
3,000
1,000
1,500
10 l
30 l
10,000
30,000
1,000
1,000
1,500
1,500
Nalco
Nalcool 2000
TRAC 102
TRAC 118
30 l
30 l
3l
30,000
30,000
3,000
1,000
1,000
1,000
1,500
1,500
1,500
Maritech AB
P.O.Box 143
S-29122 Kristianstad
Marisol CW
12 l
12,000
2,000
3,000
Uniservice
Via al Santuario di N.S.
della Guardia 58/A
16162 Genova, Italy
N.C.L.T.
Colorcooling
12 l
24 l
12,000
24,000
2,000
2,000
3,000
3,000
Marichem Marigases
64 Sfaktirias Street
18545 Piraeus, Greece
D.C.W.T
Non-Chromate
48 l
48,000
2,400
Marine Care
3144 NA Maasluis
The Netherlands
Caretreat 2
16 l
16,000
4,000
6,000
Vecom
Schlenzigstrae 7
21107 Hamburg
Germany
16 l
16,000
4,000
6,000
0402-0000AA2.fm
Table 4-19
Page 4 - 42
D-BC
p~===
4.11 Specification for engine cooling water
Product designation
Initial dosing
per 1,000 l
Minimum concentration
Havoline XLI
75 l
7.5 %
WT Supra
75 l
7.5 %
Q8 Corrosion Inhibitor
Long-Life
75 l
7.5 %
Product
(Designation)
Solvex WT 3
Oil 9156
0402-0000AA2.fm
Table 4-21
Diatsol M
Fedaro M
D-BC
Page 4 - 43
p~===
4.11 Specification for engine cooling water
Product
(Designation)
Glysantin G 48
Glysantin 9313
Glysantin G 05
Castrol Int.
Pipers Way
Swindon SN3 1RE, UK
Antifreeze NF, SF
Anti-frost X2270A
Deutsche Shell AG
berseering 35
22284 Hamburg
Germany
Mobil Oil AG
Steinstrae 5
20095 Hamburg
Germany
Arteco/Technologiepark
Zwijnaarde 2
B-9052 Gent
Belgium
Total Lubricants
Paris, France
35 %
Glycoshell
Frostschutz 500
Havoline XLC
0402-0000AA2.fm
Table 4-22
Minimum
concentration
Page 4 - 44
D-BC
4.12
Summary
Short specification
The freshwater used to fill the cooling water circuits must satisfy the specifications. The cooling
water in the system must be checked regularly in
accordance with the maintenance schedule.
Typical
value/property
Water type
pH value
Tools/equipment required
Chloride ion
content
Total hardness
Table 4-23
Circulating
water
Freshwater, free
of foreign matter
10 dGH1)
10 dGH1)
6.5
8 at 20 C
50 mg/l
(with additive)
7.5 at 20 C
50 mg/l2)
1) dH
= German hardness
1 dH = 10 mg/l CaO
= 17.9 mg/l CaCO
=0.179 mmol/l
2) 1 mg/l = 1 ppm
Short specification
Anticorrosive agent
Chemical
additives
Anti-freeze
agents
0403-0000AA2.fm
Table 4-24
Concentration
gJ__
Page 4 - 45
Testing
0403-0000AA2.fm
We test cooling water for customers in our laboratory. To carry out the test, we will need a representative sample of abt. 0.5 l.
Page 4 - 46
JJ__
4.13
Summary
Remove contamination/residue from operating fluid systems, ensure/reestablish operating reliability.
Cooling water systems containing deposits or
contamination prevent effective cooling of parts.
Contamination and deposits must be regularly
eliminated.
This comprises the following:
Cleaning the system and, if required, removal of
limescale deposits, flushing the system.
Cleaning
The cooling water system must be checked for
contamination at regular intervals. Cleaning is required if the degree of contamination is high. This
work should ideally be carried out by a specialist
Oil sludge
Oil sludge from lubricating oil that has entered the
cooling system or a high concentration of anticorrosive agents can be removed by flushing the system with freshwater to which some cleaning agent
has been added. Suitable cleaning agents are listed alphabetically in "Table 4-25: Cleaning agents for
removing oil sludge". Products by other manufacturers can be used providing they have similar properties. The manufacturer's instructions for use
must be strictly observed.
Manufacturer
Product
Concentration
Drew
HDE-777
4 5%
4 h at 50 60 C
Nalfleet
MaxiClean 2
25%
4 h at 60 C
Unitor
Aquabreak
0.05 0.5 %
4 h at ambient temperature
Vecom
Ultrasonic
4%
12 h at 50 60 C
Multi Cleaner
Table 4-25
0404-0000AA2.fm
Lime and rust deposits can form if the water is especially hard or if the concentration of the anticorrosive agent is too low. A thin lime scale layer can
be left on the surface as experience has shown
that this protects against corrosion. However,
limescale deposits with a thickness of more than
0.5 mm obstruct the transfer of heat and cause
thermal overloading of the components being
cooled.
Rust that has been flushed out may have an abrasive effect on other parts of the system, such as
the sealing elements of the water pumps. Together
with the elements that are responsible for water
gJ__
Page 4 - 47
Product
Concentration
SAF-Acid
5 10 %
4 h at 60 70 C
Descale-IT
5 10 %
4 h at 60 70 C
Ferroclean
10 %
4 24 h at 60 70 C
Nalfleet 9 068
5%
4 h at 60 75 C
Unitor
Descalex
5 10 %
4 6 h at approx. 60 C
Vecom
Descalant F
3 10 %
Approx. 4 h at 50 60 C
Nalfleet
In emergencies only
Hydrochloric acid diluted in water or aminosulphonic acid may only be used in exceptional cases
if a special cleaning agent that removes limescale
deposits without causing problems is not available. Observe the following during application:
The carbon dioxide bubbles that form when limescale deposits are dissolved can prevent the cleaning agent from reaching boiler scale. It is therefore
absolutely necessary to circulate the water with
the cleaning agent to flush away the gas bubbles
and allow them to escape.
Page 4 - 48
Following cleaning
The cooling system must be flushed several times
once it has been cleaned using cleaning agents.
Replace the water during this process. If acids are
used to carry out the cleaning, neutralise the cooling system afterwards with suitable chemicals
then flush. The system can then be refilled with
water that has been prepared accordingly.
Note!
Start the cleaning operation only when the engine has cooled down. Hot engine components must not come into contact with cold
water. Open the venting pipes before refilling
the cooling water system. Blocked venting
pipes prevent air from escaping which can
lead to thermal overloading of the engine.
Safety/environmental protection
The products to be used can endanger health and
may be harmful to the environment.
Follow the manufacturer's handling instructions
without fail.
The applicable regulations governing the disposal
of cleaning agents or acids must be observed.
gJ__
0404-0000AA2.fm
Table 4-26
4.14
Conditions
pH value at 25 C
With regard to steam turbines, steam generated by means of the exhaust gas temperature is
used for energy production.
0412-0000PA.fm
Hardness
Conductivity at 25 C
Oxygen content
Fe
Cu
Oil + grease
Table 4-27
< 1 mg/l
Requirements for feed water in exhaust gas
boiler plants
pH value at 25 C
Conductivity at 25 C
10.5 12
< 6,000 S/cm
1 15 mmol/l
Phosphate
10 30 mg/l
Silicate [SiO2]
Table 4-28
see EN 12953-10
Requirements for circulating water in exhaust
gas boiler plants
> 9.2
< 0.2 S/cm1)
Oxygen content
Iron, total Fe
Copper, total Cu
Silicicate, SiO2
Na + K
Table 4-29
1)
_J_a
> 9.2
32/40, 32/40G, 32/40DF, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
Page 4 - 49
Iron content
Acid capacity of up to pH 8.2 (p value)
Copper content
Silicates (SiO2)
The following values of the boiler water are to be
checked and documented regularly:
pH Value, daily
Hardness, daily
Residue softener
Oxygen binder
Conductivity, daily
Iron and copper content
Acid capacity of up to pH 8.2 (p value)
turer specifications)
Alkalising medium
Phosphate content
SiO2 content
protection in the condensate system (not compulsorily required in the case of saltless feed
water)
posits already exist in the boiler system)
MAN Diesel & Turbo recommends using combination products. This simplifies the treatment and
ensures that all vital points concerning water treatment are taken into consideration.
The recommendations of the turbine manufacturer
are to be taken into consideration for the treatment
of water used in steam turbines. General recommendations can, in this case, not be given.
Safety/environmental protection
Wrong handling of operating media may cause
harm to health, safety and environment. Respective instruction of the manufacturer have to be followed.
Water maintenance
The following values of the feed water are to be
checked and documented regularly:
pH Value, daily
Conductivity, daily
Hardness, daily
Oxygen content, resp. surplus at oxygen bind0412-0000PA.fm
er, daily
Page 4 - 50
32/40, 32/40G, 32/40DF, 35/44G, 35/44G TS, 48/60B, 48/60TS, 51/60DF, 51/60G
_J_a
4.15
General
Requirements
Liquid fuel engines: As minimum, inlet air (combustion air) must be cleaned by a G3 class lter as per
EN779, if the combustion air is drawn in from inside (e.g. from the machine room/engine room). If
the combustion air is drawn in from outside, in the
environment with a risk of higher inlet air contamination (e.g. due to sand storms, due to loading
and unloading grain cargo vessels or in the surroundings of cement plants), additional measures
must be taken. This includes the use of pre-separators, pulse lter systems and a higher grade of
lter efciency class at least up to M5 according to
EN779.
Gas engines and dual-fuel engines: As minimum, inlet air (combustion air) must be cleaned by a G3
class lter as per EN779, if the combustion air is
drawn in from inside (e.g. from machine room/engine room). Gas engines or dual-fuel engines must
be equipped with a dry lter. Oil bath lters are not
permitted because they enrich the inlet air with oil
mist. This is not permissible for gas operated engines because this may result in engine knocking.
If the combustion air is drawn in from outside, in
the environment with a risk of higher inlet air contamination (e.g. due to sand storms, due to loading and unloading grain cargo vessels or in the
surroundings of cement plants) additional measures must be taken. This includes the use of preseparators, pulse lter systems and a higher grade
of lter efciency class at least up to M5 according
to EN779.
In general, the following applies:
The inlet air path from air lter to engine shall be
designed and implemented airtight so that no false
air may be drawn in from the outdoor.
0411-0000AA2.fm
bJ_a
Page 4 - 51
Properties
Typical value
Unit1)
max. 5
mg/Nm3
max. 1.5
max. 1.25
max. 5
Salt (NaCl)
max. 1
Table 4-30
1)
One
Nm3
Note!
0411-0000AA2.fm
Intake air shall not contain any flammable gases. Make sure that the combustion air is not
explosive and is not drawn in from the ATEX
Zone.
Page 4 - 52
E-BD
======
Kapiteltitel 5 M2.fm
Page 5 - 1
Kapiteltitel 5 M2.fm
Page 5 - 2
5.1
5.1.1
Delivery side
1.0
2.0
2.0
3.5
Lube oil
0.5
1.0
1.5
2.5
Sea water
1.0
1.5
1.5
2.5
Diesel fuel
0.5
1.0
1.5
2.0
0.3
0.8
1.0
1.8
5 10
20 30
2 10
25 30
Intake air
20 25
Exhaust gas
Recommended flow rates
0501-0000MA2.fm
Table 5-1
40
K-BC
Page 5 - 3
The properties of the piping shall conform to international standards, e.g. DIN EN 10208, DIN
EN 10216, DIN EN 10217 or DIN EN 10305,
DIN EN 13480-3.
6682000.16-01E for cleaning of steel pipes before tting together with the Q10.09028-2104
for stationary power plants.
0501-0000MA2.fm
Page 5 - 4
K-BC
5.1.2
Figure 5-1
0501-0300AA2.fm
aJ_a
Page 5 - 5
Unit
Value
kW
9,000
kg/kWh
6.9
35
80
56
bar
3.0
Unit
Value
kg of water/kg of air
0.030
kg of water/kg of air
0.026
The difference between (I) and (II) is the condensed water amount (A)
A= I II = 0.030 0.026 = 0.004 kg of water/kg of air
Total amount of condensate QA:
QA= A x le x P
QA= 0.004 x 6.9 x 9,000 = 248 kg/h
Determining the condensate amount in the charge air pipe
0501-0300AA2.fm
Table 5-2
Page 5 - 6
aJ_a
Unit
Value
litre
m3
3,500
3.5
C
K
40
313
bar
30
bar
N-----2
m
31
31 x 105
Nm ------------kgxK
287
35
80
kg of water/kg of air
0.030
kg of water/kg of air
0.002
pV
31 10 3 5
m = ------------- = ------------------------------------ = 121 kg
RT
287 313
Solution acc. to above diagram:
The difference between (I) and (III) is the condensed water amount (B)
B = I III
B= 0.030 0.002 = 0.028 kg of water/kg of air
Total amount of condensate in the vessel QB:
QB = m x B
QB = 121 * 0.028 = 3.39 kg
Determining the condensate amount in the compressed air vessel
0501-0300AA2.fm
Table 5-3
aJ_a
Page 5 - 7
0501-0300AA2.fm
Page 5 - 8
aJ_a
5.2
5.2.1
0502-000bMB2.fm
G-BA
32/40
Page 5 - 9
Figure 5-2
Page 5 - 10
0502-000bMB2.fm
32/40
G-BA
Legend
CF-001
Separator
2171
Engine inlet
CF-003
MDO separator
2173
FIL-001
Automatic filter
2175
FIL-002
Indicator filter
2197
1,2FIL-004
Suction filter
2199
H-002
Preheater
2598
Vent
HE-002
Cooler
2599
NRF-001
2898
P-001
9187
P-012
Transfer pump
9197
P-074
9199
P-075
PSV-004
Safety valve
T-001
Service tank
T-006
T-021
Sludge tank
TCV-001
1,2,3TR-001
Condensate trap
V-001
By-pass valve
0502-000bMB2.fm
PCV-007
G-BA
32/40
Page 5 - 11
Figure 5-3
Page 5 - 12
0502-000bMB2.fm
32/40
G-BA
Legend
CF-001
Separator
2171
Engine inlet
CF-003
MDO separator
2197
FIL-001
Automatic filter
2199
FIL-002
Indicator filter
2598
Vent
1,2FIL-004
Suction filter
2599
H-002
Preheater
2898
HE-002
Cooler
9187
LOV-001
9197
NRV-002
9199
P-012
Transfer pump
1,2P-074
P-075
PCV-007
T-050
T-001
Service tank
T-006
T-021
Sludge tank
T-073
TCV-001
1,2,3TR-001
Condensate trap
V-001
By-pass valve
0502-000bMB2.fm
G-BA
32/40
Page 5 - 13
0502-000bMB2.fm
Page 5 - 14
32/40
G-BA
5.2.2
The diagrams represent the standard design of external lube oil service systems, with a combination
of engine mounted and detached, freestanding,
lube oil pump(s).
The internal lubrication of the engine and the turbocharger is provided with a force-feed lubrication
system.
The lubrication of the cylinder liners is designed as
a separate system attached to the engine but
served by the inner lubrication system.
In multi-engine plants, for each engine a separate
lube oil system is required.
For dual-fuel engines (gas-diesel engines) a supplement will explain additional specific requirements.
T-001/Service tank
The main purpose for the service tank is to separate air and particles from the lube oil, before being
pumped back to the engine. For the design of the
service tank the class requirements have to be
taken in consideration. For design requirements of
MAN Diesel & Turbo see "Section 5.2.5: Lube oil service tank, page 5-29".
installed close to the lube oil tank in order to prevent the lube oil backflow when the engine has
been shut off. For engine mounted pumps this
non-return flap must be by-passed by a relief valve
(PSV-004, DN50) to protect the pump seals
against high pressure because of counter rotation
(during shut down).
FIL-004/Suction strainer
The suction strainer protect the lube oil pumps
against larger dirt particles that may have accumulated in the tank. It is recommended to use a cone
type strainer with a mesh size of 1.5 mm. Two manometer installed before and after the strainer indicate when manual cleaning of filter becomes
necessary, which should preferably be done in
port.
P-001/P-074/Lube oil pumps
For ships with a single main engine drive it is preferable to design the lube oil system with a combination of an engine driven lube oil pump
(P-001) and an electrically driven stand-by pump
(P-074) (100 % capacity).
As long as the installed stand-by pump is providing 100 % capacity of the operating pump, the
class requirement to have an operating pump in
spare on board, is fulfilled.
0502-000aMA2.fm
Suction pipes
Suction pipes must be installed with a steady
slope and dimensioned for the total resistance (incl. pressure drop for suction filter) not exceeding
the pump suction head. A non-return flap must be
C-BD
Page 5 - 15
Dimensioning
Heat data, flow rates and tolerances are indicated
in "Section: Planning data for emission standard
IMO Tier II".
On the lube oil side the pressure drop shall not exceed 1.1 bar.
TCV-001/Temperature control valve
32/40
Set point
lube oil inlet
temperature
65 C
32/44CR
48/60B,
48/60CR
51/60DF
Table 5-4
55 C
1) Full
Page 5 - 16
0502-000aMA2.fm
C-BD
FIL 001
automatic filter
continuous flushing
32/44CR
ard wanted by the customer, different arrangement principles for the filters FIL-001/FIL-002 are
possible:
FIL 001
automatic filter
intermittent flushing
FIL 002
duplex filter
as indicator filter
not required
not required
engine mounted
32/40
48/60B
48/60CR
51/60DF
required
FIL-001/Automatic filter
The automatic back washing filter is to be installed
as a main filter. The back washing/flushing of the
filter elements has to be arranged in a way that
lube oil flow and pressure will not be affected. The
Engine type
Application
Location of
FIL001
32/44CR
32/40, 48/60B,
Single-main-engine-plant Engine room
48/60CR, 51/60DF Multi-main-engine-plant Close to engine
0502-000aMA2.fm
Table 5-6
34 m
(Without 2nd filter stage,
double filter 60 m required)
Automatic filter
C-BD
Intermittent flushing
type
Page 5 - 17
FIL-002/Indicator filter
The indicator filter is a duplex filter, which must be
cleaned manually. It must be installed downstream of the automatic filter, as close as possible
to the engine. The pipe section between filter and
engine inlet must be closely inspected before installation. This pipe section must be divided and
flanges have to be fitted so that all bends and
welding seams can be inspected and cleaned prior to final installation.
In case of a two-stage automatic filter, the installation of an indicator filter can be avoided. Customers who want to fulfil a higher safety level, are free
to mount an additional duplex filter close to the engine.
Application
32/40,
48/60B, 48/60CR
51/60DF
32/40,
48/60B, 48/60CR,
51/60DF
Single-main-engine-plant
Single-main-engine-plant
Single-main-engine-plant
Multi- main-engine-plant
Multi- main-engine-plant
Multi-main-engine-plant
To be installed in the
external piping system close
to the engine
Explanation of requirement
Page 5 - 18
60 m
main-engine-plants can continue to stay in operation by by-passing the automatic filter. Lube oil can
still be filtrated sufficiently in this situation by only
using the indicator filter.
In multi-engine-plants, where it is not possible to
by-pass the automatic filter without loss of lube oil
C-BD
0502-000aMA2.fm
Table 5-7
The dp main alarm "filter failure" is generated immediately. If the main alarm is still
active after 30 min, the
engine output power will be
reduced automatically.
Duplex/Indicator filter
FIL-002
Table 5-8
CF-001/Separator
The lube oil is intensively cleaned by separation in
the by-pass thus relieving the filters and allowing
an economical design.
The separator should be of the self- cleaning type.
The design is to be based on a lube oil quantity of
1.0 l/kW. This lube oil quantity should be cleaned
within 24 hours at:
0502-000aMA2.fm
HFO-operation 6 7 times
MDO-operation 4 5 times
Dual-fuel
engines
operating
on
gas
(+MDO/MGO for ignition only) 4 5 times
C-BD
1,0 P n
24
l/h
kW
Page 5 - 19
Separator equipment
The preheater H-002 must be able to heat the oil
to 95 C and the size is to be selected accordingly.
In addition to a PI-temperature control, which
avoids a thermal overloading of the oil, silting of
the preheater must be prevented by high turbulence of the oil in the preheater.
Control accuracy 1 C.
Cruise ships in arctic waters require larger preheaters. In this case the size of the preheater must
be calculated with a t of 60 K.
The freshwater supplied must be treated as specified by the separator supplier.
The supply pumps shall be of the free-standing
type, i.e. not mounted on the separator and are to
be installed in the immediate vicinity of the lube oil
service tank.
This arrangement has three advantages:
TR-001/Condensate trap
The condensate traps required for the vent pipes
of the turbocharger, the engine crankcase and the
service tank must be installed as close as possible
to the vent connections. This will prevent condensate water, which has formed on the cold venting
pipes, to enter the engine or service tank.
See "Section: Lube oil system Crankcase vent and tank
vent".
T-006/Leakage oil tank
Leaked fuel and the dirty oil drained from the lube
oil filter casings is collected in this tank. It is to be
emptied into the sludge tank. The content must
not be added to the fuel. It is not permitted to add
lube oil to the fuel.
Alternatively, separate leakage oil tanks for fuel
and lube oil can be installed.
P-012 Transfer pump
The transfer pump supplies fresh oil from the lube
oil storage tank to the operating tank. Starting and
stopping of the pump should preferably be done
automatically by float switches fitted in the tank.
P-075/Cylinder lube oil pump
The pump fitted to the engine is driven by an electric motor (asynchronous motor
Page 5 - 20
C-BD
0502-000aMA2.fm
380 420 V/50 Hz or 380 460 V/60 Hz threephase AC with pole changing).
For the cylinder lubrication MAN Diesel & Turbo
will supply a Control Unit inclusive a pump contactor, with a power consumption of about 0.5 kW for
pump, control and heating.
This value must be doubled for V-engines, as two
Control Units (one for each row) are supplied in
one cabinet.
Withdrawal points for samples
Points for drawing lube oil samples are to be provided upstream and downstream of the filters and
the separator, to verify the effectiveness of these
system components.
Piping system
0502-000aMA2.fm
C-BD
Page 5 - 21
0502-000aMA2.fm
Page 5 - 22
C-BD
5.2.3
Prelubrication/postlubrication
Prelubrication
The prelubrication oil pump must be switched on
at least 5 minutes before engine start. The prelubrication oil pump serves to assist the engine attached main lube oil pump, until this can provide a
sufficient flow rate.
Pressure before engine . . . . . . . 0.3 0.6 barg
Oil temperature . . . . . . . . . . . . . . . . min. 40 C
Note!
Above mentioned pressure must be ensured
also up to the highest possible lube oil temperature before the engine.
Engine
type
7L
8L
9L
10L
12V
14V
16V
18V
20V
32/40
24
26
29
31
36
40
44
49
32/44CR
26
29
31
34
36
37
41
46
50
54
32/44K
26
29
31
34
36
35/44DF
18
20
23
25
28
30
35
40
45
50
48/60B,
48/60CR
48/60TS
35
41
47
53
70
82
93
105
51/60DF
35
41
47
53
70
82
93
105
Table 5-9
Postlubrication
The prelubrication oil pumps are also to be used
for postlubrication when the engine is stopped.
0502-0300MA2.fm
A-BD
Page 5 - 23
0502-0300MA2.fm
5.2.3 Prelubrication/postlubrication
Page 5 - 24
A-BD
5.2.4
0502-0500MA2.fm
D-AF
Page 5 - 25
0502-0500MA2.fm
Page 5 - 26
D-AF
0502-0501MB2.fm
Figure 5-4
D-AF
32/40
Page 5 - 27
Figure 5-5
Page 5 - 28
0502-0501MB2.fm
32/40
D-AF
5.2.5
0502-0600MA2.fm
I-BB
Page 5 - 29
Figure 5-6
Page 5 - 30
0502-0600MA2.fm
I-BB
0502-0600MA2.fm
Figure 5-7
I-BB
Page 5 - 31
0502-0600MA2.fm
Page 5 - 32
I-BB
0502-1000MA2.fm
5.2.6
Figure 5-8
K-BA
Page 5 - 33
0502-1000MA2.fm
Page 5 - 34
K-BA
5.2.7
0502-0700MA2.fm
Figure 5-9
I-BC
Page 5 - 35
0502-0700MA2.fm
Figure 5-10
Page 5 - 36
I-BC
5.2.8
Vent pipes
Notes!
The vent pipes from engine crankcase, turbocharger and lube oil service tank are to be arranged according to the sketch. The required
nominal diameters ND are stated in the chart following the diagram.
Figure 5-11
0502-0800MB2.fm
Legend
1
Turbocharger venting
D-BB
32/40
Page 5 - 37
Legend
Engine
A
100
125
40
125
0502-0800MB2.fm
32/40
Page 5 - 38
32/40
D-BB
5.3
Water systems
5.3.1
0503-0000MA2.fm
Figure 5-12
C-BD
32/40, 51/60DF
Page 5 - 39
Legend
Components
1,2FIL-019
1,3FIL-021
Strainer of commissioning
MOD-004
Preheating module
H-020
MOD-005
1HE-002
1MOV-002
1,2HE-003
1MOV-003
CATCO
HE-005
MOV-016
HE-007
1P-002
1HE-008
2P-002
1HE-010
1,2P-062
HE-022
1P-076
1,2HE-024
2P-076
HE-025
T-002
HE-029
T-075
HE-032/HE-026
TC
4148
3171/3199
4173/4190
Inlet/outlet LT pump
3471/3499
4171/4199
3572/3587
N3, N4
0503-0000MA2.fm
N1, N2
Page 5 - 40
32/40, 51/60DF
C-BD
0503-0000MA2.fm
Figure 5-13
C-BD
32/40, 51/60DF
Page 5 - 41
Legend
Components
1,2FIL-019
1,2MOD-004
Preheating module
1,2,3FIL-021
Strainer of commissioning
MOD-005
1,2H-020
1,2MOV-002
1,2HE-002
1,2MOV-003
CATCO
1,2HE-003
MOV-016
HE-005
1,3P-002
HE-007
2,4P-002
1,2HE-008
1,2P-062
1,2HE-010
1,3P-076
1,2HE-024
2,4P-076
HE-025
T-002
HE-029
T-075
1,2HE-032/HE-026
TC
4173/4190
Inlet/outlet LT pump
3171/3199
4171/4199
3471/3499
4148
N3, N4
0503-0000MA2.fm
N1, N2
Page 5 - 42
32/40, 51/60DF
C-BD
The cooling water is to be conditioned using a corrosion inhibitor, see "Section 4.11: Specification for engine cooling water, page 4-37".
LT = Low temperature
HT = High temperature
0503-0000MA2.fm
gines (GenSets)
C-BD
32/40, 51/60DF
Page 5 - 43
Page 5 - 44
The three-way valve is to be designed for a pressure loss of 0.3 0.6 bar. It is to be equipped with
an actuator with normal positioning speed (high
speed not required). The actuator must permit
manual emergency adjustment.
Caution!
For engine operation with reduced NOx emission, according to IMO Tier I/IMO Tier II requirement, at 100 % engine load and a
seawater
temperature
of
25 C
(IMO Tier I/IMO Tier II reference temperature),
an LT cooling water temperature of 32 C before charge air cooler stage 2 (HE-008) is to be
maintained.
Fil-021/Strainer
In order to protect the engine and system components, several strainers are to be provided at the
places marked in the diagram before taking the
engine into operation for the first time. The mesh
size is 1 mm.
32/40, 51/60DF
0503-0000MA2.fm
C-BD
H-001/Preheater
Before starting a cold engine, it is necessary to
preheat the waterjacket up to 60 C.
For the total heating power required for preheating
the HT cooling water from 10 C to 60 C within 4
hours see "Table 5-10: Heating power".
Engine type
32/40
32/44CR
General
The HT cooling water system consists of the following coolers and heat exchangers:
0503-0000MA2.fm
C-BD
Table 5-10
48/60B
48/60CR
51/60DF
L+V
L+V
14
Heating power
32/40, 51/60DF
Page 5 - 45
The freshwater generator must be switched off automatically when the cooling water temperature at
the engine outlet drops below 88 C.
This will prevent operation of the engine at too low
temperatures.
m3/h
32/40
32/44CR
48/60B
48/60CR
51/60DF
6L
7.2
14
7L
8.4
16
HT temperature control
8L
9.6
18
9L
10.8
20
10L
12.0
12V
14.4
28
14V
16.8
30
16V
19.2
30
18V
21.6
30
20V
24.0
Table 5-11
Page 5 - 46
32/40, 51/60DF
C-BD
0503-0000MA2.fm
Numbers of cylinders
HE-026/Freshwater generator
0503-0000MA2.fm
C-BD
(MOD-004) with integrated circulation pump is installed, it is also possible to cool down the engine
with this small pump. However, the pump used to
cool down the engine, has to be electrically driven
and started automatically after engine shut down.
None of the cooling water pumps is a self-priming
centrifugal pump.
Design flow rates should not be exceeded by
more than 15 % to avoid cavitation in the engine
and its systems. A throttling orifice is to be fitted
for adjusting the specified operating point.
32/40, 51/60DF
Page 5 - 47
0503-0000MA2.fm
Page 5 - 48
32/40, 51/60DF
C-BD
5.3.2
0503-0200MA2.fm
The content of the collecting tank can be discharged into the expansion tanks by a freshwater
transfer pump.
G-AJ
Page 5 - 49
0503-0200MA2.fm
Page 5 - 50
G-AJ
5.3.3
Miscellaneous items
Piping
Coolant additives may attack a zinc layer. It is
therefore imperative to avoid to use galvanised
steel pipes. Treatment of cooling water as specified by MAN Diesel & Turbo will safely protect the
inner pipe walls against corrosion.
0503-0300MA2.fm
E-BC
Page 5 - 51
0503-0300MA2.fm
Page 5 - 52
E-BC
5.3.4
Designation
Manufacturer
Aquabreak PX
Environclean
Mastemyr
N-1410 Kolbotn/Norway
Enviromate 2000
Eskaphor N6773
74889 Sinsheim/Germany
Table 5-12
Degree of fouling
< 100 mm WC
Hardly fouled
100 200 mm WC
Slightly fouled
approx. 1 hour
200 300 mm WC
Severely fouled
> 300 mm WC
Extremely fouled
approx. 2 hour
Table 5-13
1) Increase
Note!
When using the cleaning agents:
The instructions of the manufacturers must be
observed.
0503-1100AA2.fm
iJ__
Page 5 - 53
Figure 5-14
Principle layout
Legend
1
Firehose
Ventilation
1) Required
0503-1100AA2.fm
Page 5 - 54
LJ__
0503-1200MA2.fm
5.3.5
Figure 5-15
L-AJ
Cleaning turbine
Page 5 - 55
0503-1200MA2.fm
Page 5 - 56
L-AJ
5.3.6
0503-040aMA2.fm
Figure 5-16
L-BA
Page 5 - 57
Legend
D-001
Diesel engine
T-076
FIL-021
TCV-005
HE-005
FBV-020
P-005
3471
P-031
Filling pump
3495
T-039
3499
General
T-076/Expansion tank
In diesel engines designed to operate prevalently on HFO the injection valves are to be
cooled during operation on HFO. In the case of
MGO or MDO operation exceeding 72 h, the
nozzle cooling is to be switched off and the
supply line is to be closed. The return pipe,
however, has to remain open.
In diesel engines designed to operate exclusively on MGO or MDO (no HFO operation possible), nozzle cooling is not required. The
nozzle cooling system is omitted.
In dual-fuel engines (liquid fuel and gas) the
nozzles are to be cooled according to the engine design.
Page 5 - 58
HE-005/Cooler
The cooler is to be connected in the LT cooling
water circuit according to schematic diagram.
Cooling of the nozzle cooling water is effected by
the LT cooling water.
If an antifreeze is added to the cooling water, the
resulting lower heat transfer rate must be taken
into consideration. The cooler is to be provided
with venting and draining facilities.
L-BA
0503-040aMA2.fm
Note!
FIL-021/Strainer
To protect the nozzles for the first commissioning
of the engine a strainer has to be provided. The
mesh size is 0.25 mm.
TE/Temperature sensor
0503-040aMA2.fm
L-BA
Page 5 - 59
0503-040aMA2.fm
Page 5 - 60
L-BA
5.3.7
General
In HFO operation, the nozzles of the fuel injection
valves are cooled by freshwater circulation, therefore a nozzle cooling water system is required. It is
a separate and closed system re-cooled by the LT
cooling water system, but not directly in contact
with the LT cooling water. The nozzle cooling water
is to be treated with corrosion inhibitor according
to MAN Diesel & Turbo specification see, "Section
4.11: Specification for engine cooling water, page 4-37".
Note!
In diesel engines designed to operate prevalently on HFO the injection valves are to be
cooled during operation on HFO. In the case of
MGO or MDO operation exceeding 72 h, the
nozzle cooling is to be switched off and the
supply line is to be closed. The return pipe,
however, has to remain open.
In diesel engines designed to operate exclusively on MGO or MDO (no HFO operation possible), nozzle cooling is not required. The
nozzle cooling system is omitted. In dual-fuel
engines (liquid fuel and gas) the nozzles are to
be cooled according to the engine design.
Purpose
The nozzle cooling water module serves for cooling the fuel injection nozzles on the engine in a
closed nozzle cooling water circuit.
Design
The nozzle cooling water module consists of a
storage tank, on which all components required
for nozzle cooling are mounted.
0503-0500MA2.fm
Description
By means of a circulating pump, the nozzle cooling water is pumped from the service tank through
a heat exchanger and to the fuel injection nozzles.
The return pipe is routed back to the service tank,
via a sight glass. Through the sight glass, the nozzle cooling water can be checked for contamination. The heat exchanger is integrated in the LT
D-BD
Page 5 - 61
0503-0500MA2.fm
Figure 5-17
Page 5 - 62
D-BD
0503-0500MA2.fm
Figure 5-18
D-BD
Page 5 - 63
Legend
Diesel engine
T-076
FIL-021
TCV-005
HE-005
3471
MOD-005
3495
P-005
3499
T-039
0503-0500MA2.fm
D-001
Page 5 - 64
D-BD
5.3.8
Figure 5-19
Preheating module
Legend
Main components
Electric flow heater
Switch cabinet
Circulation pump
Non-return valve
Savety valve
0503-0800MA2.fm
C-BD
Page 5 - 65
0503-0800MA2.fm
Page 5 - 66
C-BD
5.4
Fuel system
5.4.1
A prerequisite for safe and reliable engine operation with a minimum of servicing is a properly designed and well-functioning fuel oil treatment
system.
The schematic diagram shows the system components required for fuel treatment for Marine Diesel Oil (MDO).
T-015/MDO storage tank
The minimum effective capacity of the tank should
be sufficient for the operation of the propulsion
plant, as well as for the operation of the auxiliary
Diesels for the maximum duration of voyage including the resulting sediments and water.
Regarding the tank design, the requirements of
the respective classification society are to be observed.
Tank heating
The tank heater must be designed so that the
MDO in it is at a temperature of at least 10 C minimum above the pour point.
The supply of the heating medium must be automatically controlled as a function of the MDO temperature.
T-021/Sludge tank
0504-0000MA2.fm
H-019/MDO preheater
In order to achieve the separating temperature, a
separator adapted to suit the fuel viscosity should
be fitted.
CF-003/MDO separator
A self-cleaning separator must be provided. The
separator is dimensioned in accordance with the
separator manufacturers' guidelines.
The required flow rate Q can be roughly determined by the following equation:
m
n = ---------------
Q Separator flow rate . . . . . . . . . . . . . . . . . . l/h
P Total engine output . . . . . . . . . . . . . . . . . kW
of Diesel GenSets (without stand-by sets)
be Fuel consumption (see below) . . . . . . g/kWh
Density at separating temp. approx. 0.87 kg/l
With the evaluated flow rate the size of separator
has to be selected acc. to the evaluation table of
the manufacturer. MAN Diesel & Turbo strictly recommend to use evaluation tables according to a
"Certified flow rate" (CFR). The separator rating
stated by the manufacturer should be higher than
the flow rate Q calculated according to the above
formula.
For determining the maximum fuel consumption
(be), increase the specific table value by 15 %.
This increase takes into consideration:
Tropical conditions
The engine-mounted pumps
C-BD
Page 5 - 67
0504-0000MA2.fm
system".
Page 5 - 68
C-BD
0504-0000MA2.fm
Figure 5-20
C-BD
Page 5 - 69
Legend
CF-003
MDO separator
P-073
H-019
MDO preheater
T-015
MDO-008
Fuel module
T-021
Sludge tank
P-008
1, 2 T-003
P-057
0504-0000MA2.fm
Page 5 - 70
C-BD
0504-0200MA2.fm
5.4.2
Figure 5-21
B-BA
Page 5 - 71
Legend
D-001
Diesel engine
1,2 T-003
FIL-003
Automatic filter
T-006
FIL-011
Stand-by filter
T-015
FSH-001
T-021
Sludge tank
HE-007
MDO cooler
5271
MDO inlet
PCV-008
5293
1,2 P-008
Supply pumps
5294
1,2 STR-010
Strainer
5299
MDO outlet
Note!
0504-0200MA2.fm
Engines 32/44CR and L48/60B: FSH-001 attached on the engine, 5293 downstream of FSH-001.
Page 5 - 72
B-BA
0504-0200MA2.fm
5.4.2 Marine diesel oil (MDO) supply system for diesel engines
Figure 5-22
B-BA
Page 5 - 73
Legend
CF-003
MDO separator
1,2 STR-010
Strainer
1,2 D-001
Diesel engine
1,2 T-003
1,2 FBV-010
T-006
FIL-003
Automatic filter
T-015
FIL-013
T-021
Sludge tank
1,2 FSH-001
5271
MDO inlet
HE-007
MDO cooler
5293
PCV-008
5294
1,2 PCV-011
Spill valve
5299
MDO outlet
1,2 P-008
Supply pumps
Note!
Engines 32/44CR and L48/60B: FSH-001 attached on the engine, 5293 downstream of FSH-0001.
0504-0200MA2.fm
Page 5 - 74
B-BA
5.4.3
A prerequisite for safe and reliable engine operation with a minimum of servicing is a properly designed and well-functioning fuel oil treatment
system.
The schematic diagram shows the system components required for fuel treatment for HFO.
Size
Pre-cleaning by settling is the more effective the
longer the solid material is given time to settle. The
storage capacity of the settling tank should be designed to hold at least a 24-hour supply of fuel at
full load operation, including sediments and water
the fuel contains.
0504-0300MA2.fm
5.7 P
1000
V Minimum volume . . . . . . . . . . . . . . . . . . . m
C-BD
Tank heating
The heating surfaces should be so dimensioned
that the tank content can be evenly heated to
75 C within 6 to 8 hours.
The supply of heat should be automatically controlled, depending upon the fuel oil temperature.
Bunker
P Engine rating . . . . . . . . . . . . . . . . . . . . . . kW
In order to avoid:
ing coils should be arranged at a sufficient distance from the tank bottom.
The formation of asphaltene, the fuel oil temperature should not be allowed to exceed
75 C.
The formation of carbon deposits on the heating surfaces, the heat transferred per unit surface must not exceed 1.1 W/cm.
Design
The tank is to be fitted with baffle plates in longitudinal and transverse direction in order to reduce
agitation of the fuel in the tank in rough seas as far
as possible. The suction pipe of the separator
must not reach into the sludge space. One or
more sludge drain valves, depending on the slant
of the tank bottom (preferably 10), are to be provided at the lowest point. Tanks reaching to the
ship hull must be heat loss protected by a cofferdam. The settling tank is to be insulated against
thermal losses.
Sludge must be removed from the settling tank
before the separators draw fuel from it.
T-021/Sludge tank
If disposal by an incinerator plant is not planned,
the tank has to be dimensioned so that it is capable to absorb all residues which accumulate during the operation in the course of a maximum
duration of voyage. In order to render emptying of
the tank possible, it has to be heated. The heating
is to be dimensioned so that the content of the
tank can be heated to approx. 60 C
Page 5 - 75
Size
CF-002/Separator
As a rule, poor quality, high viscosity fuel is used.
Two new generation separators must therefore be
installed.
From Alfa Laval: Alcap, type SU
P be
l/h
Engine rating
kW
be
Fuel consumption
g/kWh
approx.
0.93 kg/l
1 service separator
1 stand-by separator
of self-cleaning type.
As a matter of principle, all separators are to be
equipped with an automatic programme control
for continuous desludging and monitoring.
Mode of operation
The stand-by separator is always to be put into
service, to achieve the best possible fuel cleaning
effect with the separator plant as installed.
The piping of both separators is to be arranged in
accordance with the makers advice, preferably for
both parallel and series operation.
The discharge flow of the free-standing dirty oil
pump is to be split up equally between the two
separators in parallel operation.
The freshwater supplied must be treated as specified by the separator supplier.
Tropical conditions
The engine-mounted pumps
The calorific value fluctuations
The consumption tolerance
Withdrawal points for samples
Points for drawing fuel oil samples are to be provided upstream and downstream of each separator, to verify the effectiveness of these system
components.
Page 5 - 76
C-BD
0504-0300MA2.fm
0504-0300MA2.fm
Figure 5-23
C-BD
Page 5 - 77
Legend
Heavy fuel separator (1 service, 1 standby)
1,2P-038
1,2H-008
1,2T-016
MDO-008
T-021
Sludge tank
1,2P-015
1,2T-022
0504-0300MA2.fm
1,2CF-002
Page 5 - 78
C-BD
5.4.4
Temperature after
final preheater
Evaporation
pressure
Required system
pressure
mm/s
bar
bar
180
12
126
1.4
2.4
320
12
138
2.4
3.4
380
12
142
2.7
3.7
420
12
144
2.9
3.9
500
14
141
2.7
3.7
700
14
147
3.2
4.2
Fuel
mm/50 C
Table 5-14
1)
For fuel viscosity depending on fuel temperature, see "Section 4.9: Viscosity-temperature diagram (VT diagram), page 4-33".
The indicated pressures are minimum requirements due to the fuel characteristic. Nevertheless,
to meet the required fuel pressure at the engine inlet (see "Section: Engine and operation Planning data"), the pressure in the mixing tank and booster
circuit becomes significant higher as indicated in
this table.
T-022/Heavy fuel oil service tank
0504-0400PA.fm
A remedial measure is adopting a pressurised system in which the required system pressure is 1 bar
above the evaporation pressure of water.
H-BC
48/60TS
Page 5 - 79
STR-010/Y-type strainer
QP1 = P1 x brISO x f4
Required supply pump delivery capacity with HFO at 90 C:
Engine output at 100 % MCR:
Specific engine fuel consumption (ISO)
at 100 % MCR
Factor for pump dimensioning
QP1
l/h
P1
kW
brISO
g/kWh
f4
l/g
0504-0400PA.fm
The delivery height of the supply pump shall be selected according to the required system pressure
(see "Table 5-14: Injection viscosity and temperature after final preheater") the required pressure in the mixing tank and the resistance of the automatic filter,
flow meter and piping system.
Page 5 - 80
48/60TS
H-BC
0.10
Pressure loss of the pipes between fuel module inlet and mixing tank inlet
0.20
0.80
0.10
5.70
6.70
Table 5-16
Example for the determination of the expected operating delivery height of the supply pump
Fil-003/Automatic filter
Only filters have to be used, which cause no pressure drop in the system during flushing.
Conventional fuel
injection system
32/40,
48/60B,
48/60TS
0.034
Design pressure
PN10
Table 5-17
0504-0400PA.fm
H-BC
48/60TS
Page 5 - 81
T-011/Mixing tank
The mixing tank compensates pressure surges
which occur in the pressurised part of the fuel system. For this purpose, there has to be an air cushion in the tank. As this air cushion is exhausted
during operation, compressed air (max. 10 bar)
has to be refilled via the control air connection from
time to time.
Before prolonged shutdowns the system is
changed over to MDO/MGO operation. The tank
volume shall be designed to achieve gradual tem-
8.00
2.00
Pressure loss of the fuel return pipe between engine outlet and mixing tank
inlet, e. g.
0.30
Pressure loss of the flow balancing valve (to be installed only in multi-engine
plants, pressure loss approx. 0,5 bar)
0.00
5.70
Table 5-18
Example for the determination of the expected operating pressure of the mixing tank
0504-0400PA.fm
Page 5 - 82
48/60TS
H-BC
P-003/Booster pumps
To cool the engine mounted high pressure injection pumps, the capacity of the booster pumps
QP2 = P1 x brISO x f5
Required booster pump delivery capacity with HFO at 145 C:
Engine output at 100 % MCR:
Specific engine fuel consumption (ISO) at 100 % MCR
Factor for pump dimensioning
For diesel engines operating on main fuel HFO: f5 = 3.90 x 103
QP2
l/h
P1
kWh
brISO
g/kWh
f5
l/g
For diesel engines installed in dredges operating on main fuel HFO: f5 = 3.94 x 103
Note!
The factor f5 includes the following parameters:
300 % fuel flow at 100 % MCR
Main fuel: HFO 380 mm2/50 C
Attached lube oil and cooling water pumps
Tropical conditions
Realistic lower heating value
Specific fuel weight at pumping temperature
Tolerance
In case more than one engine is connected to the same fuel system, the pump capacity has to be increased
accordingly.
Table 5-19
The delivery head of the booster pump is to be adjusted to the total resistance of the booster system.
Conventional fuel injection
system
32/40, 48/60B, 48/60TS
0504-0400PA.fm
bar
Pressure difference between fuel inlet and outlet engine
2.00
Pressure loss of the flow balancing valve (to be installed only in multi-engine
plants, pressure loss approx. 0.5 bar)
0.00
0.50
0.80
0.80
4.10
Table 5-20
H-BC
Example for the determination of the expected operating delivery height of the booster pump
48/60TS
Page 5 - 83
0.034
Design pressure
PN16
Table 5-21
Engine Type
Attached
on the
engine
To be installed in
the plant close to
the engine
L32/40
V32/40
L48/60B, 48/60TS
V48/60B, 48/60TS
Table 5-22
Page 5 - 84
48/60TS
0504-0400PA.fm
H-BC
Engine
Type
Leakage fuel
monitoring
tanks
attached on
the engine
L32/40
V32/40
L48/60B,
48/60TS
V48/60B,
48/60TS
Table 5-23
l/cyl. x h
l/cyl. x h
32/40
0.6 1.1
48/60B,
48/60TS
0.9 1.5
Table 5-24
PC = P1 x brISO x f1
QC = P1 x brISO x f2
Tout
PC
kW
Qc
l/h
P1
kW
brISO
g/kWh
f1
kWh/g
f2
l/g
Tout = 45 C
Leak rate (fuel and lube oil together) for conventional injection
Points for drawing fuel oil samples are to be provided upstream and downstream of each filter, to
verify the effectiveness of these system components.
H-BC
103
Note!
In case more than one engine, or different engines are
connected to the same fuel system, the cooler capacity has to be increased accordingly.
Table 5-25
1) This
48/60TS
Page 5 - 85
Page 5 - 86
48/60TS
0504-0400PA.fm
H-BC
0504-0400PA.fm
Figure 5-24
H-BC
48/60TS
Page 5 - 87
Legend
CF-002
1,2P-003
Booster pump
CF-003
1,2P-018
CK-002
PCV-009
CK-003
1,2STR-010
Strainer
D-001
Diesel engine
1,2T-003
FIL-003
T-006
FIL-013
T-008
FQ-003
T-011
FSH-001
T-015
1,2H-004
T-016
HE-007
T-021
Sludge tank
HE-025
1,2T-022
MOD-008
VI-001
Viscosimeter
Note!
0504-0400PA.fm
Page 5 - 88
48/60TS
H-BC
0504-0400PA.fm
Figure 5-25
H-BC
48/60TS
Page 5 - 89
Legend
CF-002
1,2 P-018
CF-003
PCV-009
CK-002
PCV-011
CK-003
1,2 STR-010
Strainer
1,2 FBV-010
1,2 T-003
FIL-003
T-006
1,2 FIL-013
T-008
FQ-003
T-011
1,2 FSH-001
T-015
1,2 H-004
T-016
HE-007
T-021
HE-025
1,2 T-022
MOD-008
V-002
Shut-off cock
1,2 P-003
Booster pump
VI-001
Viscosimeter
Note!
0504-0400PA.fm
Page 5 - 90
48/60TS
H-BC
5.5
5.5.1
The compressed air supply to the engine plant requires air vessels and air compressors of a capacity and air delivery rating which will meet the
requirements of the relevant classification society
(see "Section: Compressed air system Starting air vessels, compressors").
The installation situation of the air vessels must ensure a good drainage of condensed water. Air vessels must be installed with a downward slope
sufficiently to ensure a good drainage of accumulated condensate water.
0505-0000MA2.fm
E-BB
Page 5 - 91
Compressors
Two or more starting air compressors must be
provided. At least one of the air compressors must
be driven independently of the main engine and
must supply at least 50 % of the required total capacity.
The total capacity of the starting air compressors
is to be calculated so that the air volume necessary for the required number of starts is topped up
from atmospheric pressure within one hour.
The compressor capacities are calculated as follows:
V 30
1000
Page 5 - 92
m/h
0505-0000MA2.fm
E-BB
V
V Vst fDrive z st z Safe Jet z Jet tJet Vsl z sl fDrive
5sec
litre
Vst
litre
fDrive
pmax pmin
(1.0 = Diesel-mechanic,
1.5 = alternator drive)
zst
zSafe
VJet
zJet
tJet
sec.
Vsl
zsl
pmax
bar
pmin
bar
1)
litre
0505-0000MA2.fm
E-BB
Page 5 - 93
Figure 5-26
Page 5 - 94
0505-0000MA2.fm
E-BB
Legend
Starting air compressor (service)
T-018
2 C-001
TR-005
Water trap
3 C-001
1, 2, 3 TR-006
FIL-001
7171
FIL-003
7172
M-019
7177
MSV-001
7451
2 T-007
7461
TY-001
Typhon
9771
0505-0000MA2.fm
1 C-001
E-BB
Page 5 - 95
0505-0000MA2.fm
Page 5 - 96
E-BB
5.5.2
General
0505-0200PDts.fm
H-BC
48/60TS
Page 5 - 97
0505-0200PDts.fm
Page 5 - 98
48/60TS
H-BC
5.5.3
Jet Assist
General
Jet Assist is a system for acceleration of the turbocharger. By means of nozzles in the turbocharger,
compressed air is directed to accelerate the compressor wheel. This causes the turbocharger to
adapt more rapidly to a new load condition and
improves the response of the engine.
Air consumption
The air consumption for Jet Assist is, to a great extent, dependent on the load profile of the ship. In
case of frequently and quickly changing load
steps, Jet Assist will be actuated more often than
this will be the case during long routes at largely
constant load.
For air consumption (litre) see "Section: Compressed
air system Starting air vessels, compressors".
General data
Jet Assist air pressure (overpressure) ........ 4 bar
At the engine connection the pressure is max.
30 bar. The air pressure will reduced on the engine
by an orifice to max. 4 bar (overpressure).
Jet Assist activating time:
0505-0300MA2.fm
D-BD
Page 5 - 99
Figure 5-27
0505-0300MA2.fm
In each case the delivery capacity of the compressors is to be adapted to the expected Jet Assist
requirement per unit of time.
Page 5 - 100
D-BD
5.6
General information
Combustion air
The combustion air must be free from spray water,
snow, dust and oil mist.
This is achieved by:
the openings of exhaust air ducts from the engine and separator room as well as vent pipes
from lube oil and fuel oil tanks and the air intake
louvres. (The influence of winds must be taken
into consideration).
0506-0000MA2.fm
A-BD
Page 5 - 101
Radiant heat
The heat radiated from the main and auxiliary engines, from the exhaust manifolds, waste heat
boilers, silencers, alternators, compressors, electrical equipment, steam and condensate pipes,
heated tanks and other auxiliaries is absorbed by
the engine room air.
The amount of air V required to carry off this radiant heat can be calculated as follows:
Q
t cp t
Air required
m/h
Heat to be dissipated
kJ/h
cp
kJ/kg*k
kg/m
Ventilator capacity
The capacity of the air ventilators (without separator room) must be large enough to cover at least
the sum of the following tasks:
0506-0000MA2.fm
Page 5 - 102
A-BD
5.7
5.7.1
General information
Layout
Installation
checking of the exhaust gas system back pressure by means of a temporarily connected
measuring device may become necessary. For
this purpose, a measuring socket is to be provided approximately 1 to 2 metres after the exhaust gas outlet of the turbocharger, in a
straight length of pipe at an easily accessed
position. Standard pressure measuring devices
usually require a measuring socket size of 1/2".
This measuring socket is to be provided to ensure back pressure can be measured without
any damage to the exhaust gas pipe insulation.
0507-0000MA2.fm
exhaust pipes must be able to expand. The expansion joints to be provided for this purpose
are to be mounted between fixed-point pipe
supports installed in suitable positions. One
sturdy fixed-point support must be provided for
the expansion joint directly after the turbocharger. It should be positioned, if possible, immediately above the expansion joint in order to
prevent the transmission of forces to the turbocharger itself. These forces include those resulting from the weight, thermal expansion or
lateral displacement of the exhaust piping.
K-BC
Page 5 - 103
0507-0000MA2.fm
Page 5 - 104
K-BC
5.7.2
Mode of operation
The silencer operates on the absorption principle
so it is effective in a wide frequency band. The flow
path, which runs through the silencer in a straight
line, ensures optimum noise reduction with minimum flow resistance. The silencer must be
equipped with a spark arrestor.
Installation
If possible, the silencer should be installed towards the end of the exhaust line. A vertical installation situation is to be preferred in order to avoid
formations of gas fuel pockets in the silencer. The
cleaning ports of the spark arrestor are to be easily
accessible.
Insulation
The exhaust gas system (from outlet of turbocharger, boiler, silencer to the outlet stack) is to be
insulated to reduce the external surface temperature to the required level. The relevant provisions
concerning accident prevention and those of the
classification societies must be observed.
The insulation is also required to avoid temperatures below the dew point on the interior side. In
case of insufficient insulation intensified corrosion
and soot deposits on the interior surface are the
consequence. During fast load changes, such deposits might flake off and be entrained by exhaust
in the form of soot flakes.
0507-0200MA2.fm
K-BC
Page 5 - 105
0507-0200MA2.fm
Page 5 - 106
K-BC
======
Kapiteltitel 6 M2.fm
Page 6 - 1
Page 6 - 2
Kapiteltitel 6 M2.fm
6.0.1
0601-0500MB2.fm
E-BB
32/40
Page 6 - 3
0601-0500MB2.fm
Page 6 - 4
32/40
E-BB
0601-0500MB2.fm
E-BB
32/40
Page 6 - 5
0601-0500MB2.fm
Page 6 - 6
32/40
E-BB
======
Annex
Kapiteltitel 8 AA.fm
Page 7 - 1
Page 7 - 2
Kapiteltitel 8 AA.fm
Annex
7.1.1 General
7.1
7.1.1
General
All relevant classification rules, rules, regulations and laws are considered, evaluated and
are included in the system planning.
0800-0000AA2.fm
D-BB
Page 7 - 3
Annex
7.1.2 Safety equipment/measures provided by plant-side
7.1.2
Special care must be taken, inter alia, to prevent from: ejection of parts, contact with moving machine parts and falling into the flywheel
area.
The connection between the exhaust port turbocharger and exhaust gas system of the plant
has to be executed gas tight and must be
equipped with a fire proof insulation. The surface temperature of the fire insulation must not
exceed 220 C.
In workspaces and traffic areas, a suitable contact protection has to be provided whose surface temperature must not exceed 60 C.
Page 7 - 4
D-BB
0800-0000AA2.fm
Annex
7.1.2 Safety equipment/measures provided by plant-side
The connection has to be equipped with compensators for longitudinal expansion and axis
displacement in consideration of the occurring
vibrations. (The flange of the turbocharger
reaches temperatures of up to 450 C).
In any case, optical and acoustic warning devices are necessary while using the turning
gear and while starting/stopping the engine.
Signs
a) Following figure exemplarily shows the declared risks in the area of a combustion engine.
This may vary slightly for the specific engine:
0800-0000AA2.fm
D-BB
sibly leaking from the flanges of the plants piping system. The emerging media must be
drained off and collected safely.
Page 7 - 5
Annex
7.1.2 Safety equipment/measures provided by plant-side
Adequate lighting
Light sources for an adequate and sufficient
lighting must be provided by plant-side. The
current guidelines should be followed (100 Lux
is recommended, see also DIN EN 1679-1).
Working platforms/scaffolds
For work on the engine, working platforms/
scaffolds must be provided and further safety
precautions must be taken into consideration.
Among other things, it must be possible to
work secured by safety belts. Corresponding
lifting points/devices have to be provided.
0800-0000AA2.fm
Intake air quality according to the relevant section of the project guide has to be guaranteed.
Page 7 - 6
D-BB
Annex
7.2 Programme for works test
7.2
Cons. No.
Engine rating
Operating time
% site rating
min
C (ISO)
100
60
25
100
30
85
30
Table 7-1
Service records for above load points in accordance with ISO Standard 3046-1.
Note!
Further load points can only be demonstrated
during the acceptance test run (30 min each),
if this is part of the contract.
1001-0000PA.fm
_J_a
Page 7 - 7
Annex
1001-0000PA.fm
Page 7 - 8
_J_a
Annex
7.3 Engine running-in
7.3
Engine running-in
Prerequisites
Operating media
the pistons or bearings were dismantled for inspection or if the engine was partially or fully
dismantled for transport.
as cylinder liners, pistons, piston rings, crankshaft bearings, big-end bearings and piston pin
bearings.
Supplementary information
Operating Instructions
During the run-in procedure the unevenness of the
piston-ring surfaces and cylinder contact surfaces
is removed. The run-in period is completed once
the first piston ring perfectly seals the combustion
chamber. I.e. the first piston ring should show an
evenly worn contact surface. If the engine is subjected to higher loads, prior to having been run-in,
then the hot exhaust gases will pass between the
piston rings and the contact surfaces of the cylinder. The oil film will be destroyed in such locations.
The result is material damage (e.g. burn marks) on
the contact surface of the piston rings and the cylinder liner. Later, this may result in increased engine wear and high oil consumption.
Diesel-gas engines are run in using diesel operation with the fuel intended as the ignition oil.
Lube oil
The run-in lube oil must match the quality standards, with regard to the fuel quality.
Engine run-in
Checks
Inspections of the bearing temperature and crankcase must be conducted during the run-in period:
0802-0000AA2.fm
_J_a
Page 7 - 9
Annex
7.3 Engine running-in
0802-0000AA2.fm
Page 7 - 10
B-BD
Annex
7.3 Engine running-in
Speed [%]
Output [%]
100
90
Engine speed
80
70
60
50
Engine output
(specified range)
40
30
20
10
0
0
Figure 7-2
0,5
1,5
2
2,5
3
3,5
Running in period [h]
4,5
5,5
Standard running-in programme for engines operated with constant speed of the types: 32/40, 32/40DF,
32/40G, 32/44K, 32/44CR, 35/44DF, 35/44G
Speed [%]
Output [%]
100
90
Engine speed
80
70
60
50
Engine output
(specified range)
40
30
20
10
0802-0000AA2.fm
0
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8
Running in period [h]
Figure 7-3
_J_a
Standard running-in programme for engines operated with constant speed of the types: 48/60B, 48/60TS,
48/60CR, 51/60DF, 51/60G
Page 7 - 11
Annex
7.3 Engine running-in
Speed [%]
Output [%]
100
A
90
80
70
60
50
40
30
Engine output
(specified range)
0
Figure 7-4
0,5
1,5
2
2,5
3
3,5
Running in period [h]
4,5
20
10
0
5,5
Standard running-in programme for marine engines (variable speed) of the types: 28/33D, 28/33D STC, 32/40,
32/44CR
Speed [%]
Output [%]
100
A
90
80
70
60
50
40
30
20
10
0
Page 7 - 12
Standard running-in programme for marine engines (variable speed) of the types: 48/60B, 48/60CR, 51/60DF
B-BD
0802-0000AA2.fm
Engine output
(specified range)
Annex
7.4 Definitions
7.4
Definitions
Figure 7-6
Designation of cylinders
Designation of cylinders
1001-1006PA.fm
^J_a
Page 7 - 13
Annex
7.4 Definitions
Direction of rotation
Island operation
An engine driven alternator feeds its electrical energy in a small electrical grid, which consists of
only few energy alternators. There is no connection to a large grid system. To prevent of collapsing
of the island network (blackout), high reliability of
the engine has to be ensured. It is not possible to
disconnect the engine from the electrical grid at
any time. In order to have a reserve for power regulation processes the engines rated output is reduced up to 85 % and its available output is
blocked at 110 %.
Figure 7-7
Designation of cylinders
Page 7 - 14
1001-1006PA.fm
A-BD
Annex
7.4 Definitions
MCR
Output
ISO-standard-output
Operating-standard-output
ECR
Economic continuous rating = output of the engine with the lowest fuel consumption.
Peak load application
Peak load applications are defined as stationary
plants only used a few hours per day to compensate peak demands of electrical power.
Stationary application
110 % of rated power, that can be demonstrated for marine engines for an uninterrupted period of one hour.
Output explanation
Power of the engine at distinct speed and distinct torque.
100 % Output
1001-1006PA.fm
Nominal Output
= rated power.
^J_a
Page 7 - 15
Annex
1001-1006PA.fm
7.4 Definitions
Page 7 - 16
A-BD
Annex
7.5 Symbols
7.5
Symbols
Note!
The symbols shown should only be seen as examples and can differ from the symbols in the
diagrams.
0805-0000AA2 .fm
Figure 7-8
hJ^g
Page 7 - 17
Annex
7.5 Symbols
Figure 7-9
Page 7 - 18
hJ^g
Annex
7.5 Symbols
0805-0000AA2 .fm
Figure 7-10
hJ^g
Page 7 - 19
Annex
7.5 Symbols
0805-0000AA2 .fm
Figure 7-11
Page 7 - 20
hJ^g
Annex
7.6.1 General information
7.6
7.6.1
General information
Introduction
Engines are internally and externally treated with
preservation agent before delivery.
The type of preservation and packaging must be
adjusted to the means of transport and to the type
and period of storage.
Improper storage may cause severe damage to
the product.
Packaging and preservation of engine
The type of packaging depends on the requirements imposed by means of transport and storage period, climatic and environmental effects
during transport and storage conditions as well as
on the preservative agent used.
As standard, engines are preserved for a storage
period of 12 months and for sea transport.
Note!
The packaging must be protected against
damage. It must only be removed when a follow-up preservation is required or when the
packaged material is to be used.
Preservation and packaging of assemblies and engine
parts
Unless stated otherwise in the order text, the preservation and packaging of assemblies and engine
parts must be performed in such a way that the
parts will not be damaged during transport and
that the corrosion protection remains fully intact for
a period of at least 12 months when stored in a
roofed dry room.
Transport
0806-0000AA2.fm
Transport and packaging of the engine, assemblies and engine parts must be coordinated.
After transportation, any damage to the corrosion
protection and packaging must be rectified,
and/or MAN Diesel & Turbo must be notified immediately.
bJ_^
Page 7 - 21
Annex
7.6.2 Storage location and duration
7.6.2
Storage location
Storage conditions
Storage period
Before the
reached:
maximum
storage
period
is
Note!
0806-0000AA2.fm
Page 7 - 22
bJ_^
Annex
7.6.3 Follow-up preservation when preservation period is exceeded
7.6.3
A follow-up preservation must be performed before the maximum storage period has elapsed, i.e.
generally after 12 months.
0806-0000AA2.fm
bJ_^
Page 7 - 23
Annex
7.6.4 Removal of corrosion protection
7.6.4
0806-0000AA2.fm
Page 7 - 24
bJ_^
Annex
7.7 Engine colour
7.7
Engine colour
RAL 9006
0807-0000AA2.fm
fJ_`
Page 7 - 25
Annex
0807-0000AA2.fm
TKT=b==
Page 7 - 26
IJ_`
Index
A
Aging (Increase of S.F.O.C.). . . . . . . . . . . . . . . . . . . . . 2-61
Air
Consumption (Jet Assist) . . . . . . . . . . . . . . . . . . .
Flow rates, temperature . . . . . . . . . . . . . . . . . . . .
Starting air consumption. . . . . . . . . . . . . . . . . . . .
Starting air vessels, compressors . . . . . . . . . . . . .
5-99
2-65
2-58
5-97
Air vessel
Condensate amount . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Alternator
Reverse power protection. . . . . . . . . . . . . . . . . . . 2-49
Ambient conditions causes de-rating . . . . . . . . . . . . . . 2-19
Approved applications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Arctic conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Arrangement
Attached pumps. . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Attached pumps
Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Capacities . . . . . . . . . . . . . . . . 2-63I 2-68I 2-73I 2-79
Available outputs
Permissible frequency deviations . . . . . . . . . . . . . 2-47
Related reference conditions . . . . . . . . . . . . . . . . 2-18
C
Capacities
Pumps . . . . . . . . . . . . . . . . . . . 2-63I 2-68I 2-73I 2-79
Charge air cooler
Condensate amount . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Flow rates. . . . . . . . . . . . . . . . . 2-63I 2-68I 2-73I 2-79
Heat to be dissipated . . . . . . . . 2-63I 2-68I 2-73I 2-79
Combustion air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
Flow rate . . . . . . . . . . . . . . . . . 2-65I 2-70I 2-75I 2-81
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Common rail injection system . . . . . . . . . . . . . . . . . . . 5-81
Composition of exhaust gas. . . . . . . . . . . . . . . . . . . . . 2-97
PG_Power_32-40SIX.fm
Consumption
Fuel oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jet Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lube oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-53
5-99
2-57
2-58
Cooler
Flow rates . . . . . . . . . . . . . . . . . 2-63I 2-68I 2-73I 2-79
Heat to be dissipated . . . . . . . . 2-63I 2-68I 2-73I 2-79
Temperatures . . . . . . . . . . . . . . 2-65I 2-70I 2-75I 2-81
Cooler specification
Nominal values . . . . . . . . . . . . . 2-63I 2-68I 2-73I 2-79
Cooling water
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specification for cleaning. . . . . . . . . . . . . . . . . . . .
System diagram . . . . . . . . . . . . . . . . . . . . . . . . . .
4-45
4-37
4-47
5-39
D
De-rating, due to ambient conditions . . . . . . . . . . . . . . 2-19
Diesel fuel see Fuel oil
Diesel-electric propulsion (definition) . . . . . . . . . . . . . . . 7-14
E
Earthing
Bearing insulation . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Use of welding equipment . . . . . . . . . . . . . . . . . . . 2-52
ECR (definition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Emissions
Static torque fluctuation. . . . . . . . . . . . . . . . . . . . 2-109
Engine
Definition of engine rating . . . . . . . . . . . . . . . . . . . 2-17
Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Equipment for various applicatons. . . . . . . . . . . . . 2-13
Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Room ventilation . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
Running-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Engine atutomation
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
32/40
Index - I
Engine automation
Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Installation requirements . . . . . . . . . . . . . . . . . . . . 3-17
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Supply and distribution . . . . . . . . . . . . . . . . . . . . . . 3-7
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Engine operation
Arctic conditions. . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Exhaust gas
Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Flow rates. . . . . . . . . . . . . . . . . 2-65I 2-70I 2-75I 2-81
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
System description . . . . . . . . . . . . . . . . . . . . . . . 5-103
Temperature. . . . . . . . . . . . . . . 2-65I 2-70I 2-75I 2-81
Explanatory notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
G
Gas oil
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
GenSet operation
Operating range . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Grid parallel operation (definition) . . . . . . . . . . . . . . . . . 7-14
Gross calorific value (GCV)
Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
H
Heat radiation . . . .2-63I 2-65I 2-68I 2-70I 2-73I 2-75I 2-79I
2-81
Heat to be dissipated . . . . . . . . . . . . 2-63I 2-68I 2-73I 2-79
Heavy fuel oil see Fuel oil
HT switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
I
Intake noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Island operation (definition) . . . . . . . . . . . . . . . . . . . . . . 7-14
ISO
Reference Conditions . . . . . . . . . . . . . . . . . . . . . . 2-17
Standard output . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
2-53
5-87
5-77
5-71
5-69
5-79
5-75
5-69
2-59
4-17
4-21
4-19
4-15
4-33
J
Jet Assist
Air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
L
Layout of pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Load
Low load operation . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Load application
Cold engine (only emergency case) . . . . . . . . . . . . 2-36
Preheated engine . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Low load operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
PG_Power_32-40SIX.fm
LT switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Index - II
32/40
Lube oil
Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Specification (HFO) . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Specification (MGO/MDO) . . . . . . . . . . . . . . . . . . . 4-7
System description . . . . . . . . . . . . . . . . . . . . . . . . 5-15
System diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Lube oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
MDO
Diagram of treatment system . . . . . . . . . . . . . . . . 5-69
see Fuel oil
MGO see Fuel oil
Postlubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Preheated engine
Load application . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
N
Net calorific value (NCV)
Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Noise
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Nominal Output (definition) . . . . . . . . . . . . . . . . . . . . . . 7-15
NOx Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
Nozzle cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
O
Operating
Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86I 2-87
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Operating range
GenSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
PG_Power_32-40SIX.fm
Output
Available outputs, related reference condition . . . . 2-18
Permissible frequency deviations . . . . . . . . . . . . . . 2-47
Table of ratings, speeds . . . . . . . . . . . . . . . . . . . . 2-17
Preheating
Lube oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Prelubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Pumps
Capacities . . . . . . . . . . . . . . . . . 2-63I 2-68I 2-73I 2-79
Q
Quality requirements
Raw-water, cooling tower . . . . . . . . . . . . . . . . . . . 4-35
Water, exhaust gas boiler . . . . . . . . . . . . . . . . . . . 4-49
R
Rated power (definition) . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Raw-water, cooling tower
Quality requirements . . . . . . . . . . . . . . . . . . . . . . . 4-35
Reduction of load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Operation
Load reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Low load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Running-in of engine. . . . . . . . . . . . . . . . . . . . . . . . 7-9
32/40
Index - III
SaCoSone
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Temperature
Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
Cooling water . . . . . . . . . . . . . . 2-65I 2-70I 2-75I 2-81
Exhaust gas . . . . . . . . . . . . . . . 2-65I 2-70I 2-75I 2-81
Lube oil . . . . . . . . . . . . . . . . . . . 2-65I 2-70I 2-75I 2-81
Safety
Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Specification
Biofuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Cleaning agents for cooling water . . . . . . . . . . . . . 4-47
Combustion air . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Cooling water inspecting . . . . . . . . . . . . . . . . . . . 4-45
Cooling water system cleaning . . . . . . . . . . . . . . . 4-47
Diesel oil (MDO) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Engine cooling water . . . . . . . . . . . . . . . . . . . . . . 4-37
Fuel oil (HFO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Fuel oil (MDO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Fuel oil (MGO). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Gas oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Heavy fuel oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Lube oil (HFO). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Lube oil (MGO/MDO) . . . . . . . . . . . . . . . . . . . . . . . 4-7
Viscosity-diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Speed
Adjusting range . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Starting air
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jet Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System description . . . . . . . . . . . . . . . . . . . . . . . .
System diagram . . . . . . . . . . . . . . . . . . . . . . . . . .
Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-97
2-58
5-99
5-91
5-94
5-97
U
Unloading the engine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
V
Venting
Crankcase, turbocharger. . . . . . . . . . . . . . . . . . . . 2-93
Vibrations, torsional . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Viscosity-temperature-diagram . . . . . . . . . . . . . . . . . . . 4-33
W
Water
Specification for engine cooling water . . . . . . . . . . 4-37
Water systems
Cooling water collecting and supply system . . . . .
Engine cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbine washing device . . . . . . . . . . . . . . . . . . . . .
5-49
5-39
5-57
5-55
Index - IV
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PG_Power_32-40SIX.fm
Switching HT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
32/40
Project Guide Stationary
All data provided in this document is non-binding. This data serves informational
purposes only and is especially not guaranteed in any way. Depending on the
subsequent specific individual projects, the relevant data may be subject to
changes and will be assessed and determined individually for each project. This
will depend on the particular characteristics of each individual project, especially
specific site and operational conditions. CopyrightMAN Diesel & Turbo.
D2366511EN Printed in Germany GKM-AUG-05130.5
32/40
Project Guide Stationary
Four-stroke diesel engines
compliant with emission limits World Bank
MAN Diesel & Turbo