Man L23/30DF, Project Manual

Page 1: ...L27 38S Project Guide Power Plant Four stroke GenSet...

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Page 3: ...D 10 28 0 1655210 7 3 Emission limits Worldbank II D 10 28 0 3700044 8 0 Moment of inertia D 10 30 0 1687148 5 2 Green Passport D 10 33 0 1699985 1 1 Overhaul recommendation Maintenance and Expected...

Page 4: ...99177 5 1 Calculation of specific fuel oil consumption SFOC B 11 01 0 3700405 6 2 Fuel oil consumption for emissions standard B 11 01 0 1693568 5 3 Fuel injection valve B 11 00 0 3700222 2 0 Fuel inje...

Page 5: ...cooling water system B 13 00 0 1665774 3 7 Two string central cooling water system B 13 00 6 1699122 4 1 Expansion tank B 13 00 0 1613419 0 5 Preheater arrangement in high temperature system B 13 23 1...

Page 6: ...uators B 17 01 2 1689484 9 0 Actuators B 17 01 6 3700319 4 1 Actuators B 17 01 7 3700320 4 1 B 19 Safety and control system Operation data set points 3700061 5 9 System description V1 5 Communication...

Page 7: ...0 0 B 50 Alternator Alternators for GenSets B 50 00 0 1699895 2 1 Alternator cable installation BG 50 00 0 1699865 3 4 Combinations of engine and alternator layout BG 50 00 0 3700084 3 10 B 98 Preser...

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Page 9: ...MAN Diesel Turbo I 00 Introduction Page 1 1 I 00 Introduction 2018 04 13 en...

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Page 11: ...ompleteness quality or fitness for any particular purpose of the information contained in the project guides MAN Diesel Turbo will issue an Installation Manual with all project related drawings and in...

Page 12: ...wing number including revision number i e 1643483 5 5 Release date The release date of the document Year Month Date This is the date the document has been created Notice When refering to a document pl...

Page 13: ...ne designation MAN Diesel Turbo 1609526 0 8 Page 1 1 Key for engine designation I 00 05 0 L27 38S L16 24S L21 31S L23 30S L28 32S L23 30DF L28 32DF V28 32H V28 32S L16 24 L21 31 L23 30H L27 38 L28 32H...

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Page 15: ...General MAN Diesel Turbo 1607568 0 2 Page 1 1 Designation of cylinders I 00 15 0 L16 24S L21 31S L23 30S L23 30DF L28 32S L27 38S L28 32DF L16 24 L21 31 L23 30H L27 38 L28 32H 2016 08 24...

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Page 17: ...ture Voltage Viscosity Sound Position A D E H I L S T X V Alarm Differential Element High Indicating Low Switching Stop Transmitting Failure Valve Actuator MAN Diesel Turbo 1687100 5 6 Page 1 3 Code i...

Page 18: ...l inlet engine prelubricating inlet rocker arms and roller guides intermediate bearing alternator bearing 28 29 level in base frame main bearings Charging air system 30 31 32 33 inlet to cooler outlet...

Page 19: ...d shutdown ready to start 88 89 90 index fuel injection pump turbocharger speed engine speed Miscellaneous 91 92 93 94 natural gas inlet to engine oil mist detector knocking sensor cylinder lubricatin...

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Page 21: ...2 1 Crossing pipes not connected 3 3 Valve three way 2 2 Crossing pipes connected 3 4 Non return valve flap straight 2 3 Tee pipe 3 5 Non return valve flap angle 2 4 Flexible pipe 3 6 Non return valv...

Page 22: ...T port in plug 4 7 Membrane 3 26 Cock four way straight through in plug 4 8 Electric motor 3 27 Cock with bottom connection 4 9 Electromagnetic 3 28 Cock straight through with bottom conn 4 10 Manual...

Page 23: ...INSTR WITH ORDINARY DESIGNATIONS 5 14 Air filter 7 1 Sight flow indicator 5 15 Air filter with manual control 7 2 Observation glass 5 16 Air filter with automatic drain 7 3 Level indicator 5 17 Water...

Page 24: ...n accordance with classifica tion or other rules General Pump general DIN 2481 Ballcock Centrifugal pump DIN 2481 Cock three way L port Centrifugal pump with electric motor DIN 2481 Double non return...

Page 25: ...essure valve Pressure reducing valve air ISO 1219 Shut off valve Oil trap DIN 28 004 Thermostatic valve Accumulator Pneumatic operated valve Pressure reducing valve with pressure gauge General Specifi...

Page 26: ...ing water 2xxx Gearbox x1xx HT cooling water 3xxx Propeller equipment x2xx Oil systems lub oil cooling oil clutch oil servo oil 4xxx Automation equipment x3xx Air systems starting air control air char...

Page 27: ...2 590 591 604 605 579 584 Valve general 585 Valve with continuous regulation 593 Valve with safety function 588 Straight way valve 592 Straight way valve with continuous regulation 590 Angle valve 591...

Page 28: ...ction valve 586 Gate valve 587 Gate valve with continuous regulation 599 Straight way cock 600 Angle cock 601 Three way cock 602 Four way cock 607 Butterfly valve 608 Butterfly valve with continuous r...

Page 29: ...64 Disc separator 589 Measuring point for thermo element Filters 1298 Air relief valve 669 Air filter Couplings Flanges 671 Fluid filter 167 Coupling Coolers 955 Flanged connection 16 03 Cooling tower...

Page 30: ...motor AC 725 Turbo axial compressor 13 15 Electrical motor DC 726 Turbo dial compressor 13 15 Electrical motor DC 720 Roots compressor 13 15 Electrical motor DC 722 Screw compressors 13 15 Electrical...

Page 31: ...MAN Diesel Turbo D 10 General information Page 1 1 D 10 General information 2018 04 13 en...

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Page 33: ...Charge air pressure Air required to dissipate heat radiation eng t2 t1 10 C C m3 h 5 kg kWh bar m3 h 50 9137 6 67 4 01 20414 53 12061 6 67 4 01 26895 55 14071 6 67 4 01 31431 56 16082 6 67 4 01 35968...

Page 34: ...oler then through lube oil cooler water temperature outlet engine regulated by mechanical thermostat Tolerance 10 for rating coolers 15 for heat recovery Basic values for layout of the coolers Under a...

Page 35: ...te Charge air pressure Air required to dissipate heat radiation eng t2 t1 10 C C m3 h 5 kg kWh bar m3 h 51 9951 6 81 4 04 21710 53 12314 6 81 4 04 26895 55 14367 6 81 4 04 31431 56 16419 6 81 4 04 359...

Page 36: ...oler then through lube oil cooler water temperature outlet engine regulated by mechanical thermostat Tolerance 10 for rating coolers 15 for heat recovery Basic values for layout of the coolers Under a...

Page 37: ...tor foot See below 12 T P panel 25 Engine VDI 2063T Alternator ISO 8528 9 DIN 6280 11 Note All measurements are specified as mm s r m s Alternator Value 1 Value 2 P 1250 kVA 20 24 P 1250 kVA 18 22 Val...

Page 38: ...NR15 NR17 2 0 1 6 2 0 4 5 2 2 4 0 TCR16 NR20 1 7 1 4 1 7 3 8 1 9 3 5 TCR18 NR20 NR24 1 4 1 1 1 4 3 2 1 6 2 9 TCR20 NR24 NR26 1 2 0 9 1 2 2 6 1 3 2 3 TCR22 0 9 0 7 0 9 1 9 1 0 1 7 Turbocharger vibrati...

Page 39: ...mally determined from Sound Pressure measurements New measurement of exhaust sound is carried out at the test bed unsilenced directly after turbo charger with a probe microphone inside the exhaust pip...

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Page 41: ...according to ISO 9611 and ISO 11689 Operating condition Levels are valid for standard resilient mounted Gen Sets on flexible rubber support of 55 sh A on rela tively stiff and well supported foundatio...

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Page 43: ...ed on the same fuel quality due to its superior effi ciency Nitrogen oxides NOX The high temperatures prevailing in the combustion chamber of an internal combustion engine causes the chemical reaction...

Page 44: ...rated power and without exhaust gas treatment 1 2 3 4 5 6 7 8 SOX according to ISO 8178 or US EPA method 6C with a sulphur content in the fuel oil of 2 5 by weight NOX according to ISO 8178 or US EPA...

Page 45: ...tion Worldbank II 2007 2008 only for liquid fuel L16 24 L21 31 L27 38 V28 32S Bore size 400 3 MWth x 50 MWth NOx 1460 mg Nm3 at 15 O2 NOx 1600 mg Nm3 at 15 O2 to maintain higher effic SOx max 1 5 sulp...

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Page 47: ...0 1189 1338 207 264 291 353 381 403 403 403 403 403 1451 1451 1451 1451 1451 69 225 346 433 554 Required moment of inertia after flywheel is based on 403 Kgm2 flywheel and the most common damper The c...

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Page 49: ...assification societies as Green Passport MAN Diesel Turbo is able to provide a list of haz ardous materials complying with the requirements of the IMO Convention This list is accepted by clas sificati...

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Page 51: ...Guide for GenSet see Lub Oil treatment in section B 12 00 0 and Fuel oil specification in section B 11 00 0 and section 14 000 for Propulsion In the Instruction Manual for GenSet and L21 31 Propulsio...

Page 52: ...4 Time can be adjusted acc to performance observations Note Time between overhaul for Crude oil is equal to HFO Time between overhaul for Biofuel is equal to MDO except for fuel equipment case by case...

Page 53: ...et see Lub Oil treatment in section B 12 00 0 and Fuel oil specification in section B 11 00 0 and section 14 000 for Propulsion In the Instruction Manual for GenSet and L21 31 Propulsion see Lub Oil t...

Page 54: ...djusted acc to performance observations Note Time between overhaul for Crude oil is equal to HFO Time between overhaul for Biofuel is equal to MDO except for fuel equipment case by case depending on T...

Page 55: ...or GenSet see Lub Oil treatment in section B 12 00 0 and Fuel oil specification in section B 11 00 0 and section 14 000 for Propulsion In the Instruction Manual for GenSet and L21 31 Propulsion see Lu...

Page 56: ...an be adjusted acc to performance observations Note Time between overhaul for Crude oil is equal to HFO Time between overhaul for Biofuel is equal to MDO except for fuel equipment case by case dependi...

Page 57: ...for GenSet see Lub Oil treatment in section B 12 00 0 and Fuel oil specification in section B 11 00 0 and section 14 000 for Propulsion In the Instruction Manual for GenSet and L21 31 Propulsion see L...

Page 58: ...can be adjusted acc to performance observations Note Time between overhaul for Crude oil is equal to HFO Time between overhaul for Biofuel is equal to MDO except for fuel equipment case by case depend...

Page 59: ...MAN Diesel Turbo B 10 Basic diesel engine Page 1 1 B 10 Basic diesel engine 2018 04 13 en...

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Page 61: ...The valve camshaft is located on the exhaust side in a very high position and the injection camshaft is located on the service side of the engine The main bearings for the underslung crankshaft are c...

Page 62: ...g The valve pattern is turned about 20 to the axis and achieves a certain intake swirl The cylinder head is tightened by means of 4 nuts and 4 studs which are screwed into the engine frame The nuts ar...

Page 63: ...behind removable covers Piston The piston which is oil cooled and of the compo site type has a body made of nodular cast iron and a crown made of forged deformation resistant steel It is fitted with...

Page 64: ...ngs and thence through channels in the connecting rods to lubricate the piston pins and cool the pistons Camshaft and camshaft drive The inlet and exhaust valves as well as the fuel pumps of the engin...

Page 65: ...heels are in mesh Front end box The front end box is fastened to the front end of the engine It contains all pipes for cooling water and lubricating oil systems and also components such as pumps filte...

Page 66: ...her by means of compensators to prevent excessive stress in the pipes due to heat expansion To avoid excessive thermal loss and to ensure a reasonably low surface temperature the exhaust gas receiver...

Page 67: ...water leaves the engine through separate three way thermostatic valves which control the water temperature It should be noted that there is no water in the engine frame Figure 8 Internal cooling water...

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Page 69: ...Cross section MAN Diesel Turbo 1665740 7 3 Page 1 1 Cross section B 10 01 1 L27 38S L27 38 2014 11 18...

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Page 71: ...ance HFO up to 700 cSt 50 C RMK700 MDO DMB MGO DMA DMZ according ISO8217 2010 Power lay out MCR version Speed rpm 720 750 Mean piston speed m sec 9 1 9 5 Mean effective pressure 5 cyl engine HFO MDO 6...

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Page 73: ...712 3712 3712 3712 3899 3899 3899 3899 3899 3899 40 0 40 0 44 5 44 5 50 4 50 4 58 2 58 2 64 7 64 7 P Q Free passage between the enginges width 600 mm and height 2000 mm Min distance between engines 29...

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Page 75: ...27 38 1520 1805 2050 2390 2680 1475 1480 1485 1490 1490 0 0 0 0 0 The values are based on water cooled alternator make Hyundai If another alternator is chosen the values will change MAN Diesel Turbo 1...

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Page 77: ...ylinder unit Low dismantlig Cover and liner separate 4201 3891 4791 H 1 H 2 For dismantling at the service side For dismantlig passing the alternator with standard alternator remaining cover not remov...

Page 78: ...Overhaul with dismantled fuel injection pump piping MAN Diesel Turbo B 10 01 1 Overhaul areas 1665770 6 6 Page 2 4 L27 38S L27 38 2015 11 27...

Page 79: ...4 connecting screws between cylinder head and the cooling water jacket 2 Dismantle the main bearing stud by means of two counter nuts and a 60 mm wrench 3 Remove the cylinder liner with fixed connecti...

Page 80: ...harge air cooler ele ment lubricating oil cooler lubricating oil filter car tridge lubricating pump and water pumps Figure 2 Overhaul areas for charge air cooler element lub oil cooler and lub oil fil...

Page 81: ...Firing pressure comparison MAN Diesel Turbo 3700366 0 0 Page 1 1 Firing pressure comparison B 10 01 1 L27 38S L27 38 2014 08 14...

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Page 83: ...clockwise MAN Diesel Turbo 1607566 7 2 Page 1 1 Engine rotation clockwise B 10 11 1 L28 32S L27 38S L23 30S L21 31S L16 24S L23 30DF V28 32S DF L28 32DF V28 32H V28 32S L16 24 L21 31 L23 30H L27 38 L2...

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Page 85: ...MAN Diesel Turbo B 11 Fuel oil system Page 1 1 B 11 Fuel oil system 2018 04 13 en...

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Page 87: ...run ning in period Note The filter must be removed before ship deliv ery or before handling over to the customer It is adviced to install the filter every time the extern fuel pipe system has been di...

Page 88: ...e pipes is led to the fuel leakage alarm unit from which it is drained into the clean leak fuel oil tank The leakage alarm unit consists of a box with a float switch for level monitoring In case of a...

Page 89: ...ad areas The most obvious benefit of applying PLO is the fuel oil saving of typically up to 5 g kWh depending on engine type model and load point Furthermore thanks to the improved combustion process...

Page 90: ...r IMO Tier III compliance New turbocharger arrangement for optimised part load operation Blow off arrangement on charge air receiver to prevent over boosting of engine at MCR oper ation New valve cam...

Page 91: ...avy fuel oil The entries in the last column of this Table provide important background infor mation and must therefore be observed The relevant international specification is ISO 8217 in the respectiv...

Page 92: ...not be connected to the fuel tank Leak oil lines should be emptied into sludge tanks Viscosity at 50 C mm2 s cSt max 700 Viscosity injection viscosity Viscosity at 100 C max 55 Viscosity injection vis...

Page 93: ...t be free of admixtures that have not been obtained from petroleum such as vegetable or coal tar oils free of tar oil and lube oil used oil and free of chemical wastes solvents or polymers Table 1 The...

Page 94: ...870 870 See 6 3 a Sulfurc m m Max Statutory requirements See 7 2 ISO 8754 ISO 14596 Flash point C Min 60 0 60 0 60 0 60 0 60 0 60 0 See 7 3 ISO 2719 Hydrogen sulfide mg kg Max 2 00 2 00 2 00 2 00 2 0...

Page 95: ...nd phosphorus mg kg mg kg The fuel shall be free from ULO A fuel shall be considered to contain ULO when either one of the following condi tions is met calcium 30 and zinc 15 or calcium 30 and phospho...

Page 96: ...6 13 D010 000 023 05 0001 EN 010 000 023 05 MAN Diesel Turbo Specification of heavy fuel oil HFO D010 000 023 05 0001 General 2017 07 11 de...

Page 97: ...in operation depends on how carefully the heavy fuel oil has been processed Particular care should be taken to ensure that highly abrasive inorganic foreign matter catalyst parti cles rust sand are e...

Page 98: ...matter and water for inorganic foreign matter and water in heavy fuel oil will be achieved at the engine inlet Results obtained during operation in practice show that the wear occurs as a result of a...

Page 99: ...lied by a factor of between 5 and 8 depending on the catalytic bond is roughly the same as the proportion of catalyst remnants in the heavy fuel oil If a homogeniser is used it must never be installed...

Page 100: ...on system to the igni tion characteristics of the fuel used as is the case with MAN Diesel Turbo piston engines The ignition quality is one of the most important properties of the fuel This value appe...

Page 101: ...determining the CCAI and assigning the CCAI ranges to engine types The engine should be operated at the coolant temperatures prescribed in the operating handbook for the relevant load If the temperat...

Page 102: ...c principle Additives that are currently used for diesel engines as well as their probable effects on the engine s operation are summarised in the table below Addi tives for heavy fuel oils and their...

Page 103: ...nd of the bunker period Sample Tec by Mar Tec in Hamburg is a suitable testing instrument which can be used to take samples on a regular basis during bunkering To ensure sufficient cleaning of the fue...

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Page 105: ...Kinematic viscosity at 40 C mm2 s cSt ISO 3104 2 0 11 1 Pour point winter grade C ISO 3016 0 Pour point summer grade C ISO 3016 6 Flash point Pensky Martens C ISO 2719 60 Total sediment content weight...

Page 106: ...e oil no longer flows The lowest temperature of the fuel in the system should be roughly 10 C above the pour point to ensure that the required pumping characteristics are main tained A minimum viscosi...

Page 107: ...890 0 Kinematic viscosity at 40 C mm2 s cSt ISO 3104 2 6 0 Filtering capability 1 in summer and in winter C C DIN EN 116 DIN EN 116 must be indicated Flash point in enclosed crucible C ISO 2719 60 Se...

Page 108: ...cating ability of diesel 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 lu...

Page 109: ...itable for operation with diesel oil See 010 005 Engine Operating Instructions section 010 000 023 07 Properties features Properties unit Testing method Density at 15 C 900 930 kg m3 DIN EN ISO 3675 E...

Page 110: ...of operating fluids Handling of operating fluids can cause serious injury and damage to the environment Observe safety data sheets of the operating fluid supplier Analyses Analysis of fuel oil samples...

Page 111: ...ard layout of fuel oil system for HFO operation has to be modified concerning fol lowing aspects In general no part of the fuel oil system must be cooled down below pour point of the used bio fuel Fue...

Page 112: ...n delay Please be aware Depending on the quality of the biofuel it may be necessary to carry out one oil change per year this is not taken into account in the details concerning lubricating oil consum...

Page 113: ...ISO 3675 or ISO 12185 CCAI max 870 ISO 8217 Water before engine max volume 0 2 ISO 3733 Sulphur max mass 4 5 ISO 8754 or ISO 14596 Ash max mass 0 15 ISO 6245 Vanadium max mg kg 600 ISO 14597 or IP 501...

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Page 115: ...the horizontal axis and the viscosity is shown on the vertical axis The diagonal lines correspond to viscosity temperature curves of fuels with different reference viscosities The vertical viscosity a...

Page 116: ...th a reference viscosity of 700 mm2 s at 50 C the maximum viscosity as defined in the international specifi cations such as ISO CIMAC or British Standard If heavy fuel oil with a low reference viscosi...

Page 117: ...as on MDO MGO Occa sionally changes in operation mode between HFO and MDO MGO are considered to be within normal operation procedures for our engine types and do thus not require special precautions R...

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Page 119: ...ence condition ISO Following description is focussed on how to calcu late a conversion from site FAT condition to refer ence condition ISO MAN Diesel Turbo 3700405 6 2 Page 1 4 Calculation of specific...

Page 120: ...nning on MGO The mentioned values are measured under control led condition on a test bed using new fuel injection pump fuel injection valve and taking into consider ation that temperature viscosity cl...

Page 121: ...ctor tbar Engine type specific reference charge air tempera ture before cylinder see Reference conditions in Fuel oil consump tion for emissions standard Legend Ref erenc e Site FAT Specific fuel cons...

Page 122: ...s temperature control ex plants with catalyst leads to increased fuel oil consumption For every increase of the exhaust gas temperature by 1 C due to activation of charge air blow off device an additi...

Page 123: ...s see below 183 1802 179 182 200 1 Tolerance 5 2 Fuel consumption at 85 MCR Table 2 Fuel consumption All data provided in this document is non binding and serves informational purposes only Depending...

Page 124: ...ided in this document is non binding and serves informational purposes only Depending on the subsequent specific individual projects the relevant data may be subject to changes and will be assessed an...

Page 125: ...where the lance goes into the cylinder head A double walled high pressure pipe connects the fuel pump with the lance Leak oil from the fuel valve or from a possible defective high pressure pipe is led...

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Page 127: ...uncover the holes A delivery valve is installed on top of the barrel In the delivery valve housing a second valve is instal led This valve will open for oscillating high pressure waves between the ne...

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Page 129: ...onents on the GenSets is it recommended to install a fuel oil filter duplex as close as possible to each GenSet The fuel oil filter duplex is with star pleated filter ele ments The fuel oil filter dup...

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Page 131: ...n existing vessels need viscosities above 2 0 cSt to function properly We recommend that the actual pump maker is con tacted for advice Installation of MDO MGO Cooler or MDO MGO Cooler Chiller To be a...

Page 132: ...pump see D 10 05 0 List of Capacities The fuel temperature to the MDO MGO cooler depends on the temperature of the fuel in the service tank and the temperature of return oil from the engine s The tem...

Page 133: ...igure 2 Chiller MAN Diesel Turbo 1689458 7 3 Page 3 3 MDO MGO cooler E 11 06 1 L28 32S L27 38S L23 30DF L23 30S L16 24S L21 31S L28 32DF V28 32H V28 32S L16 24 L21 31 L23 30H L27 38 L28 32H 2016 03 03...

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Page 135: ...between the fuel inlet valve V1 and the fuel outlet valve V2 at each GenSet as shown in fig 1 Valve control box The electrical power supply to the valve control box is 3 x 400 Volt 50 Hz or 3 x 440 V...

Page 136: ...change over to the MDO MGO position due to the built in return spring The internal piping on the GenSets will then within a few seconds be flushed with MDO MGO and be ready for start up MAN Diesel Tu...

Page 137: ...MAN Diesel Turbo B 12 Lubricating oil system Page 1 1 B 12 Lubricating oil system 2018 04 13 en...

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Page 139: ...e is equipped with Engine driven lubricating oil pump Lubricating oil cooler Lubricating oil thermostatic valve Duplex full flow depth filter Pre lubricating oil pump Centrifugal by pass filter Oil qu...

Page 140: ...ferential groove and a bore for distribution of oil to the piston From the front main bearings channels are bored in the crankshaft for lubricating of the damper 3 The lubricating oil pipes for the ca...

Page 141: ...ion ensuring stand still of the pre lubricating pump when the engine is running and running dur ing engine stand still in stand by position by the engine control system Draining of the oil sump It is...

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Page 143: ...er condensation in the pipe flowing back into the engine and should end in the open air The connection between engine C13 C30 and the ventilation pipe must be flexible The ventilation pipe must be mad...

Page 144: ...of 6000 kg h corre sponds to The crankcase ventilation flow rate will then be in the range of 19 2 27 4 m h The maximum crankcase backpressure measured right after the engine at 100 engine load must n...

Page 145: ...utes after prelubrication has failed Engine type No of cyl Pump type m3 h rpm Electric motor 3x380 V 50 Hz kW Start cur rent Amp Full load current Amp L16 24 5 6 7 8 9 Make IMO Type ACD025N6 NVBP 2 15...

Page 146: ...Amp Full load current Amp L21 31 5 6 7 8 9 Make Type R35 40 FL Z DB SO 8 3 3505 3 45 42 7 6 1 L27 38 5 6 7 8 9 Make Type R35 40 FL Z DB SO 8 3 3505 3 45 42 7 6 1 MAN Diesel Turbo B 12 07 0 Prelubricat...

Page 147: ...dern methods If it contains paraf fins they must not impair the thermal stability or oxidation stability The base oil must comply with the limit values in the table below particularly in terms of its...

Page 148: ...not contain viscosity index improver Fresh oil must not contain water or other contaminants Lubricating oil selection Engine SAE class 16 24 21 31 27 38 28 32S 32 40 32 44 35 44DF 40 54 45 60 48 60 58...

Page 149: ...trol lers with a separate oil sump unless the technical documentation for the speed governor specifies otherwise If this oil is not available when filling 15W40 oil may be used instead in exceptional...

Page 150: ...nishing the used lubricating oil If you wish to operate the engine with HFO once again it will be necessary to change over in good time to lubricating oil with a higher BN 30 55 If the lubricating oil...

Page 151: ...vigo TPEO 30 40 Navigo TPEO 40 40 Navigo TPEO 50 40 Navigo TPEO 55 40 Motor Oil Hellas S A EMO ARGO S 30 SAE 40 EMO ARGO S 40 SAE 40 EMO ARGO S 50 SAE 40 PETROBRAS Marbrax CCD 420 Marbrax CCD 430 Marb...

Page 152: ...oil must comply with the following limit values particularly in terms of its resistance to ageing Properties Characteristics Unit Test method Limit value Make up Ideally paraffin based Low temperatur...

Page 153: ...78 may be used if they are listed in the table Lube oils approved for use in MAN Diesel Turbo four stroke engines that run on gas oil and diesel fuel Lube oils not listed here may only be used after c...

Page 154: ...ions heavy fuel oil cannot be used in designated regions Low sulphur diesel fuel must be used in these regions instead If the engine is operated with low sulphur diesel fuel for less than 1 000 h a lu...

Page 155: ...ed for use in MAN Diesel Turbo four stroke engines that run on gas oil and diesel fuel The current releases are available at http dieselturbo man eu lubrication No liability assumed if these oils are...

Page 156: ...10 ppm max 20 ppm When operating with biofuels biofuel fraction max 12 FT IR Table 4 Limit values for used lubricating oil 2017 07 13 de Specification of lubricating oil SAE 40 for operation with MGO...

Page 157: ...valuate the correct engine SLOC the following circumstances must be noticed and subtracted from the engine SLOC A1 Desludging interval and sludge amount from the lubricating oil separator or automatic...

Page 158: ...alu ated after 1 000 running hours or more where only the average values of a number of lubricating oil addings are representative A deviation of 1 mm with the dipstick measurement must be expected wh...

Page 159: ...Description Specific lubricating oil consumption SLOC 1607584 6 11 MAN Diesel Turbo B 12 15 0 L28 32H L27 38 L23 30H L21 31 L16 24 V28 32S V28 32H L28 32DF L23 30DF L16 24S L21 31S L27 38S L28 32S L2...

Page 160: ...cement and cleaning The condition of the lubricating oil can be maintained re established by exchanging the lubricating oil at fixed intervals or based on analyzing oil sam ples Operation on Marine Di...

Page 161: ...rticular application depends on the engine output the type and amount of combustion residues the annual operating time and the operating mode of the plant Even with a rela tively low number of operati...

Page 162: ...o optimize the size of the filtration unit Separator units for manual cleaning can be used when the reduced effective cleaning time is taken into consideration by dimensioning the sepa rator unit capa...

Page 163: ...employing a suitable flow rate that is only a fraction of the stated maximum capacity of the centrifuge see the centrifuge manual The most important factor is the particle size risk of scratching and...

Page 164: ...n 3 for distillate fuel Example 1 For multi engine plants one separator unit per engine in operation is recom mended For example for a 1 000 kW engine operating on HFO and connected to a self cleanin...

Page 165: ...gine Container vessel 1 5 times the power of one engine For example for a bulk carrier with three 1 000 kW engines operating on HFO and connected to a common self cleaning separator unit with a daily...

Page 166: ...kg m3 l density of medium kg m3 viscosity of medium kg m sec The rate of settling V for a given capacity is determined by Stokes Law This expression takes into account the particle size the differenc...

Page 167: ...unit It is often seen that the lubricating oil pre heaters are undersized have very poor temperature control the steam supply to the pre heater is limited or the temperature set point is too low Desc...

Page 168: ...w rate the more particles are left in the oil and there fore the lower the separation efficiency As the flow rate is reduced the effi ciency with which particles are removed increases and cleaning eff...

Page 169: ...omly loses its ability to lubricate i e to form a friction decreasing oil film but it may become corrosive to the steel journals of the bearings in such a way that the surface of these journals become...

Page 170: ...ediately detrimental while the engine is in operation Naturally it should be brought down again as quickly as possible below 0 2 water content which is permissible see description B 12 15 0 504 04 cri...

Page 171: ...M D 445 DIN51562 53018 ISO 3104 Increasing viscosity indicates problems with insolu bles HFO contamination water contamination oxi dation nitration and low load operation Decreasing viscosity is gener...

Page 172: ...cts of combustion blown by the piston rings into the crankcase It also includes burnt lubricating oil additive ash rust salt wear debris and abrasive matter 7 Metal content Metal content Remarks Atten...

Page 173: ...MAN Diesel Turbo B 13 Cooling water system Page 1 1 B 13 Cooling water system 2018 04 13 en...

Page 174: ...be complied with 1 1 dGH German hardness 10 mg CaO in litre of water 17 9 mg CaCO3 l 0 357 mval l 0 179 mmol l 2 1 mg l 1 ppm The MAN Diesel Turbo water testing equipment incorporates devices that det...

Page 175: ...strong turbulence Stress corrosion cracking is a failure mechanism that occurs as a result of simultaneous dynamic and corrosive stress This may lead to cracking and rapid crack propagation in water...

Page 176: ...ratures which are usual in engines nowadays If necessary the pipes must be deplated Slushing oil This additive is an emulsifiable mineral oil with additives for corrosion protec tion A thin protective...

Page 177: ...the specific application The biocide must be compatible with the sealing materials used in the coolant system and must not react with these The biocide and its decomposition products must not contain...

Page 178: ...for an integrated analysis If chemical additives or antifreeze agents are used coolant should be replaced after 3 years at the latest If there is a high concentration of solids rust in the system the...

Page 179: ...ing chemical additives Manufacturer Product designation Initial dosing for 1 000 litres Minimum concentration ppm Product Nitrite NO2 Na Nitrite NaNO2 Drew Marine Liquidewt Maxigard 15 l 40 l 15 000 4...

Page 180: ...2 Min 20 C Max 50 C Castrol Radicool NF SF Shell Glycoshell Mobil Antifreeze agent 500 Arteco Havoline XLC Total Glacelf Auto Supra Total Organifreeze Table 4 Antifreeze agents with slushing propertie...

Page 181: ...n using chemical additives Testing equipment in accordance with the supplier s recommendations Testing kits from the supplier also include equipment that can be used to determine the fresh water quali...

Page 182: ...ine operating manual 010 000 023 14 must be complied with in all cases These recommended concentrations may be other than those specified by the manufacturer The concentration must be checked in accor...

Page 183: ...tration Duration of cleaning procedure temperature Drew HDE 777 4 5 4 h at 50 60 C Nalfleet MaxiClean 2 2 5 4 h at 60 C Unitor Aquabreak 0 05 0 5 4 h at ambient temperature Vecom Ultrasonic Multi Clea...

Page 184: ...cid will remain in the system even when the system has been neutral ised and flushed This residual acid promotes pitting We therefore rec ommend you have the cleaning carried out by a specialist The c...

Page 185: ...hale developed gases and fumes Observe Safety Data Sheets or Operating Instructions of the relevant manufacturer The applicable instructions for disposing of cleaning agents or acids are to be observe...

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Page 187: ...d has to be chosen as to ensure constant compliance with the limit values specified for the circulating water see Table 1 Additive water The system water losses caused by blowing down evaporation or l...

Page 188: ...1 Utilisation of biocides Intensive venting of the water in the cooling tower and insulation will above all during the warm sea son cause algeas and microorganisms which clog the cooling system suppor...

Page 189: ...ty at 25 o C 0 2 S cm 1 Oxygen content 0 1 mg l 0 02 mg l Table 1 Requirements for feed water in exhaust gas boilers 1 After strongly acid sample drawing cation exchanger Saltless circulating water Lo...

Page 190: ...tives according to manufac turer specifications Iron content Acid capacity of up to pH 8 2 pH value With regard to steam turbines the following has in addition to be checked weekly Copper content sili...

Page 191: ...ily determined Additional information If distillate e g from the fresh water generator or fully desalinated water ion exchanger is available this should ideally be used for the fuel water emul sion Th...

Page 192: ......

Page 193: ...olution with low installation costs which also can be interesting in case of repowering where the engine power is increased and the distance to the other engines is larger Low temperature circuit The...

Page 194: ...the exhaust valve seats and the injector valve From the cylinder heads the water is led through an integrated collector to the thermostatic valve and depending on the engine load a smaller or larger...

Page 195: ...equipped with a self controlling tem perature water circuit This is a simple solution with low installation costs which also can be interesting in case of repowering Low temperature circuit The compo...

Page 196: ...cylinder heads the water is led through an integrated collector to the thermostatic valve and depending on the engine load a smaller or larger amount of the water will be led to the external sys tem o...

Page 197: ...ust be connected to the expan sion tank below the minimum water level this pre vents oxydation of the cooling water caused by splashing from the venting pipe The expansion tank should be equipped with...

Page 198: ......

Page 199: ...ts and cylinder heads and is circulated by the engine built on HT pump The LT cooling water is used for the cooling of 2 stage charge air cooler and lubricating oil and is cir culated by the engine bu...

Page 200: ...side of the pump s The over pressure in the HT cooling system s prevents the jacket water from locally boiling Cooling water treatment The cooling water must be treated maintained and monitored in or...

Page 201: ...S 8L23 30DF 11 13 15 17 0 1 0 1 0 1 0 1 5L28 32H 5L28 32S 5L28 32DF 6L28 32H 6L28 32S 6L28 32DF 7L28 32H 7L28 32S 7L28 32DF 8L28 32H 8L28 32S 8L28 32DF 9L28 32H 9L28 32S 9L28 32DF 28 33 39 44 50 0 15...

Page 202: ......

Page 203: ...heat distribution in the engine is thus reached When the engine is in standstill an extern valve must shut off the cooling water inlet Operation Engines starting on HFO and engines in stand by positi...

Page 204: ......

Page 205: ...0 3 0 3 0 3 5L16 24 5L16 24S 6L16 24 6L16 24S 7L16 24 7L16 24S 8L16 24 8L16 24S 9L16 24 9L16 24S 4 5 5 5 6 0 1 0 1 0 1 0 1 0 1 5L21 31 5L21 31S 6L21 31 6L21 31S 7L21 31 7L21 31S 8L21 31 8L21 31S 9L21...

Page 206: ...on the manifold in such a position that it can be easily read from the filling point The filling point should be near the pressure expan sion vessel Particularly the pressure gauge in such a position...

Page 207: ...MAN Diesel Turbo B 14 Compressed air system Page 1 1 B 14 Compressed air system 2018 04 13 en...

Page 208: ...be used for the activation of some safety functions on the engine therefore the compressed air quality in this system is very important Control air must meet at least the following quality requirement...

Page 209: ...ed air for the gas valve unit control GVU must meet at least the following quality requirements according to ISO 8573 1 2010 Purity regarding solid particles Quality class 2 Purity regarding moisture...

Page 210: ......

Page 211: ...ing air receivers 30 bar through a reduction station where from compressed air at 10 bar is supplied to the engine The reduction station should be located as near the starting air receiver as possible...

Page 212: ...Pneumatic start sequence When the starting valve is opened air will be sup plied to the drive shaft housing of the air starter The air supply will by activating a piston bring the drive pinion into en...

Page 213: ...et system and the stop cylinders on each fuel injection pump On 8 and 9 cylinder engines air is supplied to the oil mist detector through a reduction valve The compressed air is supplied from the star...

Page 214: ...h activates one stop cylinder on each fuel injection pump Air supply must not be interrupted when the engine is running Pneumatic start sequence When the starting valve is opened air will be sup plied...

Page 215: ...ped with automatic drain facilities Each engine needs only one connection for com pressed air please see diagram for the compressed air system Installation In order to protect the engine s starting an...

Page 216: ......

Page 217: ...MAN Diesel Turbo B 15 Combustion air system Page 1 1 B 15 Combustion air system 2018 04 13 en...

Page 218: ......

Page 219: ...the inlet valves of each cylinder The charge air cooler is a compact two stage tube type cooler with a large cooling surface The charge air cooler is mounted in the engine s front end box It is recom...

Page 220: ...d ability Less fouling of the engine s exhaust gas ways Limitation of fuel oil index during starting proce dure The above states that the working conditions are improved under difficult circumstances...

Page 221: ...d a higher grade of filter efficiency class at least up to M5 according to EN 779 Gas engines and dual fuel engines As minimum inlet air combustion air must be cleaned by a G3 class filter as per EN77...

Page 222: ...ion air that must be complied with Explosion caused by flammable intake air Explosion caused by flammable intake air can result in severe injuries and damage Intake air must not contain any flammable...

Page 223: ...air silencer No water of condensation from the air duct must be allowed to be drawn in by the turbocharger In arctic service the air must be heated to at least 5 C If necessary air preheaters must be...

Page 224: ......

Page 225: ...ses two major parts The transportable container 6 including a hand valve with handle 5 and a plug in coupling 4 at the end of a lance Installed on the engine there is the injection tube 1 connected to...

Page 226: ......

Page 227: ...MAN Diesel Turbo B 16 Exhaust gas system Page 1 1 B 16 Exhaust gas system 2018 04 13 en...

Page 228: ......

Page 229: ...rbocharger the expansion bel lows the exhaust pipe and silencer in case of silencer with spark arrestor care must be taken that the cleaning parts are accessible must be insula ted with a suitable mat...

Page 230: ...pressure over the boiler must be included in the back pressure calculation Expansion bellows The expansion bellows which is supplied sepa rately must be mounted directly on the exhaust gas outlet see...

Page 231: ...MAN Diesel Turbo 1655213 2 6 Page 3 4 Exhaust gas system B 16 00 0 L28 32S L27 38S L23 30S L21 31S L16 24S L23 30DF L28 32DF L16 24 L21 31 L23 30H L27 38 L28 32H 2015 01 14...

Page 232: ...on 50 100 mbar Operating pressure pexh Abs pintake where a customized engine matching is needed 100 mbar Table 3 Sum of the exhaust gas back pressure after turbocharger and the absolute value of the i...

Page 233: ...n exhaust gas piping system MAN Diesel Turbo 1624460 4 2 Page 1 2 Pressure droop in exhaust gas system B 16 00 0 L28 32S L23 30S L27 38S L21 31S L16 24S V28 32S DF V28 32H L23 30DF L28 32DF V28 32S L1...

Page 234: ...owing empiric formula This formula is only valid between 20 to 60 C Example At ambient air conditions 20 C and pressure 0 98 bar the density is MAN Diesel Turbo B 16 00 0 Pressure droop in exhaust gas...

Page 235: ...h the IMO Tier III regulations on NOX emissions at any time Fuels for operation with SCR catalyst The SCR components were special designed for operation with heavy fuel oil HFO in accordance with spec...

Page 236: ...Diesel Turbo SCR system is available in different sizes to cover the whole medium speed engine portfolio The SCR system consists of the reactor the mixing unit the urea supply system the pump module...

Page 237: ...xhaust gas temperature to ensure both optimum engine SCR operation For a maximum on safety the surveillance mode is always activated Enhanced operation The MAN Diesel Turbo SCR system assures ideal en...

Page 238: ...air tempera ture in the engine room Recommended for exhaust gas line Insulation according to SOLAS standard The SCR system requires high exhaust gas tem peratures for an effective operation MAN Diese...

Page 239: ...MAN Diesel Turbo 3700467 8 1 Page 5 17 SCR Selective Catalytic Reduction B1600 0 V28 32S L28 32S L28 32H L27 38S L27 38 L23 30S L23 30H L21 31S L21 31 L16 24S L16 24...

Page 240: ...D Wit hout insul atio n W Wit hout insul atio n A Wit h anc hor age Maxi mum weight struc turally1 Serv ice spa ce N o kW mm mm mm mm kg min mm 7 6 001 7 800 3 60 0 2 90 0 2 35 0 2 93 0 8 000 750 8 7...

Page 241: ...igure 3 Mixing unit with urea lance MAN Diesel Turbo 3700467 8 1 Page 7 17 SCR Selective Catalytic Reduction B1600 0 V28 32S L28 32S L28 32H L27 38S L27 38 L23 30S L23 30H L21 31S L21 31 L16 24S L16 2...

Page 242: ...h Weight No mm mm mm kg 1 1 300 700 300 120 Table 5 Pump module Compressed air reservoir module Air mod ule Height Width Depth Weight No mm mm mm kg 1 1 050 1 500 500 250 Table 6 Compressed air reserv...

Page 243: ...e mixture of the both different solutions is not permissible Urea solution concentration 39 41 ISO 22241 2 Annex C Density at 20 C g cm3 1 105 1 115 DIN EN ISO 12185 Refractive index at 20 C 1 3930 1...

Page 244: ...O 22241 2 Annex C Biuret max 0 3 ISO 22241 2 Annex E Alkality as NH3 max 0 2 ISO 22241 2 Annex D Aldehyde mg kg max 5 ISO 22241 2 Annex F Insolubles mg kg max 20 ISO 22241 2 Annex G Phosphorus as PO4...

Page 245: ...2 ISO 22241 2 Annex I Chromium mg kg max 0 2 ISO 22241 2 Annex I Table 8 Urea 32 5 solution specification MAN Diesel Turbo 3700467 8 1 Page 11 17 SCR Selective Catalytic Reduction B1600 0 V28 32S L28...

Page 246: ...ansver sal bar The metal eyelets are designed to carry only the segments of the mixing unit further weights are not allowed e g complete welded mixing pipe SCR reactor R 001 Transport of the reactor c...

Page 247: ...p module can supply up to four SCR systems Urea quality according section Specification of urea solution is required For urea consumption calculation for Tier III read section Urea con sumption for em...

Page 248: ...ach layer The maximum temperature of the exhaust gas is 450 C and a minimum exhaust gas temperature is required to ensure a reliable operation Therefore temperature indicators are installed in the inl...

Page 249: ...e com patible with urea 40 solution to avoid any con tamination of urea and corrosion of device used In order to guarantee the urea quality the following materials for tank pipes and fittings are comp...

Page 250: ...f the catalyst Therefore a water trap has to be installed if the exhaust pipe downstream of the SCR reactor is facing upwards MAN Diesel Turbo B1600 0 SCR Selective Catalytic Reduction 3700467 8 1 Pag...

Page 251: ...SCR System Catalyst elements could reach a weight of 25 kg the reactor openings could reach a total weight of about 70 kg MAN Diesel Turbo strongly recom mends a lifting capability above the reactors...

Page 252: ......

Page 253: ...ge air in front of or after the charge air cooler is removed and released In the first case the charge air is blown off into the engine room and in the sec ond case when charge air released from the c...

Page 254: ...perature air cooler stage LT Device for accelerating the turbocharger jet assist This equipment is used where special demands exist for rapid acceleration and or load application In such cases the com...

Page 255: ...Figure 1 Overview of flaps MAN Diesel Turbo 3700546 9 0 Page 3 3 Equipment to optimize performance B1600 0 V28 32S L28 32S L28 32H L27 38S L27 38 L23 30S L23 30H L21 31S L21 31 L16 24S L16 24...

Page 256: ......

Page 257: ...2 26 7 31 2 28 2 5L23 30H Mk2 750 rpm 6L23 30H Mk2 750 rpm 7L23 30H Mk2 750 rpm 8L23 30H Mk2 750 rpm 5600 6700 7900 9000 342 342 342 342 350 400 400 450 30 4 27 9 32 5 29 4 6L23 30H Mk2 900 rpm 7L23...

Page 258: ...kW 8L16 24 1200 rpm 110 kW 9L16 24 1200 rpm 110 kW 3600 4700 5500 6300 7100 356 356 356 356 356 300 300 400 400 400 23 8 31 4 23 2 26 6 29 9 5L27 38 720 rpm 300 kW 6L27 38 720 rpm 330 kW 7L27 38 720 r...

Page 259: ...1 31 900 rpm 200 kW 6L21 31 900 rpm 220 kW 7L21 31 900 rpm 220 kW 8L21 31 900 rpm 220 kW 9L21 31 900 rpm 220 kW 7400 9800 11400 13000 14600 334 334 334 334 334 400 450 500 500 550 30 2 31 7 29 8 34 0...

Page 260: ...339 6 8 0 90 579 400 406 4 388 8 8 8 118 725 450 457 0 437 0 10 0 149 987 500 508 0 486 0 11 0 185 508 550 559 0 534 0 12 5 223 961 600 610 0 585 0 12 5 268 783 650 660 0 650 0 5 0 331 830 MAN Diesel...

Page 261: ...ur bine must be cleaned when exhaust gas tempera ture before turbine are about 20 C above the nor mal temperature ISO corrected Sea trial Practical service experience have revealed that tur bine side...

Page 262: ...e blow gun is working accord ing to the ejector principle with pressure air working air at 5 7 bar as driven medium Injection time approx 2 min Air consumption approx 5 Nm3 2 min 1 Closing valve 2 Con...

Page 263: ...esel Turbo 3700418 8 1 Page 3 6 Cleaning the turbocharger in service turbine side B 16 01 3 L28 32DF V28 32S L28 32S L28 32H L27 38S L27 38 L23 30DF L23 30S L23 30H L21 31S L21 31 L16 24S L16 24 2017...

Page 264: ...esel Turbo B 16 01 3 Cleaning the turbocharger in service turbine side 3700418 8 1 Page 4 6 L28 32DF V28 32S L28 32S L28 32H L27 38S L27 38 L23 30DF L23 30S L23 30H L21 31S L21 31 L16 24S L16 24 2017...

Page 265: ...intervals is essential to successful cleaning as excessive fouling is thus avoided Washing at inter vals of 150 hours is therefore recommended Depending on the fuel quality these intervals can be shor...

Page 266: ...The water for washing the turbine is supplied from the external fresh water system through a flexible hose with couplings The flexible hose must be dis connected after water washing By activating the...

Page 267: ...8 TCR20 8L27 38 TCR20 9L27 38 TCR20 775 5 775 5 775 5 775 5 775 5 880 2 880 2 939 8 939 8 939 8 2532 2532 2719 2719 2719 Type of turbocharger MAN Diesel Turbo 1689481 3 2 Page 1 2 Position of gas outl...

Page 268: ...30 350 kW TCR20 8L27 38 720 750 rpm 330 kW TCR20 8L27 38 720 750 rpm 350 kW TCR20 9L27 38 720 750 rpm 330 350 kW TCR20 500 550 600 650 645 703 754 805 16 20 20 20 600 650 700 750 22 22 22 22 20 20 20...

Page 269: ...MAN Diesel Turbo B 17 Speed control system Page 1 1 B 17 Speed control system 2018 04 13 en...

Page 270: ......

Page 271: ...f the engine normally runs on HFO preheated fuel must be circulated through the engine while pre heating although the engine has run or has been flushed on MDO for a short period Starting on MDO For s...

Page 272: ......

Page 273: ...trigger load transfer in to the machine It is protecting of the generator against abnormally high net voltage works with phase to phase and phase to neutral voltage each voltage is monitored separate...

Page 274: ...ults between stator and windings Stator earth faults Ground faults and faults between phases outside the alternator but within the protected zone at the terminal or on external connections Function Pr...

Page 275: ...led power 30 and the existing alternators have very old AVR s Parallel running with other GenSets with Compensation Lines Older alternators are using compensations lines the AVR have to be selected sp...

Page 276: ...Frequency FmN Hz 110 Max Frequency Hz 90 Min Freq Minutes Pole number Gen Sens Pt Pri Voltage Volt Gen Sens Pt Sec Voltage Volt Gen Sens Ct Pri Current amp Gen Sens Ct Sec Current amp AVR CT Input te...

Page 277: ...1 GL 45 120 0 96 RINA 50 115 0 93 LR 45 110 0 9 NKK 45 110 0 9 DNV 45 115 0 93 BV 50 110 0 9 ABS 50 115 0 93 MRS 45 120 0 96 Classification Cooling air Temp enc Red fact F insulation VDE 40 105 0 93...

Page 278: ...set 130 C Alarm time__3__s x Winding temp Phase L2 set 130 C Alarm time__3__s x Winding temp Phase L3 set 130 C Alarm time__3__s x Bearing temp set 85 C Alarm time___3_s x Generator differential prote...

Page 279: ...tion have to be two different systems to ensure that the power house engine room temperature is not too low caused by the ambient air temperature It is necessary to ensure that the charge air cooler c...

Page 280: ...dditional special measures are needed in this case please contact MAN Diesel Turbo MAN Diesel Turbo B 17 00 0 Engine operation under arctic conditions 1689459 9 0 Page 2 2 L27 38S L16 24S L21 31S L16...

Page 281: ...e GENSET Actuator signal Actuator input signal Regulateurs Europa type 2800 0 1 A nominal operating range Woodward type UG25 4 20mA nominal operating range Speed adjustment range Speed adjustment rang...

Page 282: ......

Page 283: ...GENSET Actuator signal Actuator input signal Regulateurs Europa type 2800 0 1 A nominal operating range Speed adjustment range Speed adjustment range is adjustable in SaCoSone Droop Droop is adjustab...

Page 284: ......

Page 285: ...via SaCoSone GENSET Actuator signal Actuator input signal Woodward type UG25 4 20mA nominal operating range Speed adjustment range Speed adjustment range is adjustable in SaCoSone Droop Droop is adju...

Page 286: ......

Page 287: ...MAN Diesel Turbo B 19 Safety and control system Page 1 1 B 19 Safety and control system 2018 04 13 en...

Page 288: ...r PI 21 4 5 5 5 Crankcase protection M C LAH 92 TAH 58 TDAH 58 high 95 4 3 3 3 LSH 92 TSH 58 TDSH 58 high 100 6 Temperature main bearing C TI 29 80 95 TAH 29 100 3 TSH 29 105 Fuel oil system Pressure...

Page 289: ...550 N 30 30 Charge air pressure after cooler bar PI 31 2 9 3 2 Charge air temperature after cooler C TI 31 40 55 55 Compressed air system Pressure inlet engine TDI Gali bar PI 70 PI 70 8 10 30 8 10 16...

Page 290: ...individual parameters A Fuel oil pressure HFO operation When operating on HFO the system pressure must be sufficient to depress any tendency to gasification of the hot fuel The system pressure has to...

Page 291: ...ning is engaged the alarm time delay is 2 sec Start failure will be activated if revolutions are below 50 rpm within 5 sec from start or revolutions are below 210 rpm 10 sec from start Start failure a...

Page 292: ...ceptance test protocol or name plate on turbocharger M Crankcase protection For engines above 2250 kW or bore 300 mm crankcase protection is standard for marine application The system is optional for...

Page 293: ...ENGINE AUTOMATION MAN Diesel Turbo SE SaCoSone GENSET System description Revision 1 5...

Page 294: ...face overview modified and corrected power supply scheme added 0 6 23 09 2009 Brendle Speed governing signals modified 0 7 04 11 2009 Karger Interface overview modified detailed interface description...

Page 295: ...ENSET_System description_m_en_V1 5 docx Table of Contents 1 General information 4 1 1 Control Unit 4 1 2 Connection Box 5 1 3 System bus 6 1 4 Technical data 7 2 System description 7 2 1 Safety system...

Page 296: ...oSone design is based on high reliable and approved components as well as modules specially designed for installation on medium speed engines The used components are harmonised to a homogenously syste...

Page 297: ...values and operating values on a touchscreen engine operation via touchscreen The safety system is electrically separated from the control system due to requirements of the classification societies Fo...

Page 298: ...t engine Connection Box terminal block to generator to ship alarm system Control Unit to ship alarm system Lub oil press HTCW temp 1 3 System bus The SaCoSone system is equipped with a redundant bus b...

Page 299: ...parties is only permitted with written consent of MAN Diesel Turbo Page 7 of 13 Last change 16 08 2010 Karger Released SaCoSone GENSET_System description_m_en_V1 5 docx 1 4 Technical data Example sho...

Page 300: ...n of engine internal parameters Emergency stop Emergency stop is an engine shutdown initiated by an operator manual action like pressing an emergency stop button An emergency stop button is placed at...

Page 301: ...nctions in single system components via system alarms Control SaCoSone controls all engine internal functions as well as external components for example Start stop sequences Local and remote start sto...

Page 302: ...st change 16 08 2010 Karger Released SaCoSone GENSET_System description_m_en_V1 5 docx Remote speed setting is either possible via 4 20mA signal or by using hardwired lower raise commands Speed adjust...

Page 303: ...nerator mode Stop from engine Remote stop Remote start Remote reset of alarms Actuator Governor Common alarm Ready to start Engine is running Start prelub oil pump Start preheater control Start failur...

Page 304: ...ion of these protocols see the document SaCoSone GENSET Communication from the GenSet 3 3 Generator Control SaCoSone provides inputs for all temperature signals for the temperatures of the generator b...

Page 305: ...r Released SaCoSone GENSET_System description_m_en_V1 5 docx Control Unit Control Module Connection Box main switchboard emergency switchboard AC DC AC DC MAN supply uninterruptible power supply Yard...

Page 306: ...MAN Diesel Turbo SaCoSone GENSET SaCoSone GENSET Communication from GenSet Revision 1 7...

Page 307: ...ESPP ESPP ESPP ESPP ESPP ESPP ESPP ESPP EESPD MAN Diesel Turbo 86224 Augsburg Germany Phone 49 821 322 0 Fax 49 821 322 3382 info de mandieselturbo com www mandieselturbo com Copyright 2012 MAN Diesel...

Page 308: ...s RTU protocol 2 2 1 Settings 2 2 2 Function Codes 2 2 3 Message Frame Separation 3 2 4 Provided Data 3 2 4 1 Contents of List of Signals 3 2 4 2 Live Bit 3 3 Modbus ASCII protocol 4 3 1 General 4 3 2...

Page 309: ...MAN Diesel Turbo Table of Contents...

Page 310: ...are generated in the system can be transferred All measuring values and alarms acquired by SaCoSone GENSET are available for transfer The following Modbus protocols are available Modbus RTU Standard...

Page 311: ...22 Standard 4 2 wire cable length 100m cable type as specified by the circuit diagram line termination 120 Ohms RS485 Standard 2 2 wire cable length 100m cable type as specified by the circuit diagram...

Page 312: ...of List of Signals For detailed information about the transferred data please refer to the list of signals of the engine s documentation set This list contains the following in formation Field Descri...

Page 313: ...referred to bytes or words these will fill out 2 or 4 charac ters respectively in the protocol The general message frame format has the following outlook SLAVE FCT DATA CHECKSUM CR LF 1 char Begin of...

Page 314: ...of subsequent bytes 1 word 1 dataword 2 word 2 dataword n word No n dataword The master sends data to the slave CMS DM starting from a particular ad dress The slave CMS DM returns the written number o...

Page 315: ...reset SF 1 CMS binary 11 F Signal fault LAH98 Alternator cooling water leakage alarm SF 1 CMS binary 12 F Signal fault Emergency generator mode SF 1 CMS binary 13 F Signal fault Speed raise SF 1 CMS b...

Page 316: ...ex tract from ASCII table Hexadecimal ASCII 30 0 31 1 32 2 33 3 34 4 35 5 36 6 37 7 38 8 39 9 41 A 42 B 43 C 44 D 45 E 45 F In this example the letter ASCII letter 1 will be translated hexadecimal va...

Page 317: ...ese operating hour counters are showing up to 65 535 hours The new register addresses for the extended operating hour counter Low word MW 130 High word MW 131 The new register addresses for the extend...

Page 318: ...SaCoSone GENSET_Communication_m_en_1 7 5 Modbus list The Modbus list is valid for Modbus ASCII and Modbus RTU The list can be found in the document SaCoS one GENSET_SignListMan_MP_EN_xx xx pdf where x...

Page 319: ...nary binary binary binary binary binary binary binary binary binary binary MW 17 11 0 1 2 3 4 5 6 7 8 9 10 11 TAH60 1 TAH60 2 TAH60 3 TAH60 4 TAH60 5 TAH60 6 TAH60 7 TAH60 8 TAH60 9 TAH60 10 TAH62 TAH...

Page 320: ...fault TE27 2 Alternator rear bearing temp CMS CMS CMS CMS CMS CMS CMS CMS CMS CMS CMS CMS binary binary binary binary binary binary binary binary binary binary binary binary MW 64 MW 65 MW 66 MW 67 MW...

Page 321: ...nary binary MW 114 72 0 4 13 15 Spare Signal fault Actuator signal Signal fault SS83 Start solenoid valve Signal fault SS32 Jet system valve CMS CMS CMS CMS binary binary binary binary MW 115 73 0 2 3...

Page 322: ...press filter outl low Shutdown Engine overspeed Shutdown OMD Shutdown overridden OMD Shutdown CCMON Shutdown overridden CCMON Shutdown Emergency stop active Shutdown Remote Shutdown DM DM DM DM DM DM...

Page 323: ...or Alarm Prelube pressure low CMS CMS CMS CMS CMS CMS CMS CMS CMS CMS CMS CMS CMS CMS CMS binary binary binary binary binary binary binary binary binary binary binary binary binary binary binary MW 12...

Page 324: ......

Page 325: ...the sen sor will activate an alarm and secondly the engine will be stopped in case of critical oil mist concen tration Furthermore there is an alarm in case of sensor failure To avoid false alarms dir...

Page 326: ......

Page 327: ...MAN Diesel Turbo B 20 Foundation Page 1 1 B 20 Foundation 2018 04 13 en...

Page 328: ......

Page 329: ...ed Mounting of base plates on concrete foundation Before the foundation base plates are placed on the concrete foundation they have to be machined according to the drawing from MAN Diesel Turbo and me...

Page 330: ...welding the filling pieces to the base plates according to the drawing from MAN Diesel Turbo see also page 4 This method of fixing the Generating Sets to the base plates is suitable for earthquake co...

Page 331: ...With landbased generating sets Richter scale Input ground accel eration g Natural frequencies horizontal Hz Output transmitted shock on generating set g Horizontal shock Displacement on mounts mm 5 9...

Page 332: ...MAN Diesel Turbo B 20 00 0 Resilient mounting system for landbased generating sets 1699989 9 5 Page 4 5 L27 38S L21 31S L16 24S 2015 05 11...

Page 333: ...MAN Diesel Turbo 1699989 9 5 Page 5 5 Resilient mounting system for landbased generating sets B 20 00 0 L27 38S L21 31S L16 24S 2015 05 11...

Page 334: ......

Page 335: ...MAN Diesel Turbo B 21 Test running Page 1 1 B 21 Test running 2018 04 13 en...

Page 336: ......

Page 337: ...r or his representative the classification s representa tive and the person responsible for the acceptance test by their signature on the test report After the accept ance test components will be chec...

Page 338: ...nce than required by IACS and therefore a standard load responce test where three load steps 3 x 33 is applied will be demostrated at factory accept ance test Minimum requirements concerning dynamic s...

Page 339: ...e nominal speed Recovery time until reach ing the tolerance band 1 of nominal speed Germanischer Lloyd 10 5 5 sec RINA Lloyd s Register American Bureau of Shipping Bureau Veritas Det Norske Veritas IS...

Page 340: ...e observed Speed droop _____ Needle valve open ______ Load nr Rated speed Hz nmax min Momentum speed Hz ni Permanent speed Hz m Momentum speed varia tion p Permanent speed varia tion t Time to steady...

Page 341: ...MAN Diesel Turbo E 23 Spare parts Page 1 1 E 23 Spare parts 2018 04 13 en...

Page 342: ......

Page 343: ...ston approx 66 kg Cylinder liner approx 140 kg Charge air cooler approx 490 kg Please note 5 cyl only for GenSet MAN Diesel Turbo 1689476 6 4 Page 1 5 Weight and dimensions of principal parts E 23 00...

Page 344: ...g rod approx 120 kg Front end box for GenSet approx 2420 kg Front end box for propulsion approx 2170 kg MAN Diesel Turbo E 23 00 0 Weight and dimensions of principal parts 1689476 6 4 Page 2 5 L27 38S...

Page 345: ...1770 mm Depending on alternator type Oil pan for propulsion Length L mm Weight kg 6 cyl 3367 1186 7 cyl 3812 1320 8 cyl 4251 1587 9 cyl 4702 1720 Width 1370 mm Turbocharger Length L mm Height H mm Wei...

Page 346: ...455 6 cyl 3015 528 7 cyl 3460 601 8 cyl 3905 674 9 cyl 4350 747 Crankshaft with counter weights Length L mm Weight kg 5 cyl 2920 2755 6 cyl 3365 3145 7 cyl 3810 3585 8 cyl 4255 4030 9 cyl 4700 4475 Pl...

Page 347: ...4053 Flywheel with gear rim only for GenSet Small 1451 kg Medium 1927 kg Large 2671 kg Flywheel with gear rim only for propulsion 1196 kg Please note 5 cyl only for GenSet MAN Diesel Turbo 1689476 6 4...

Page 348: ......

Page 349: ...ings Main bearing shell 2 2 Thrust bearing ring 51104 51104 021 033 1 2 Fuel injecting pump Fuel injecting pump complete 51401 565 1 Fuel injection valve O ring O ring Fuel valve 51402 51402 51402 033...

Page 350: ......

Page 351: ...MAN Diesel Turbo P 24 Tools Page 1 1 P 24 Tools 2018 04 13 en...

Page 352: ...can be ordered as a whole or partly in addition to the standard tool package The tool package consists of special tools needed in addition to the standard tool in case a major overhaul or a part of th...

Page 353: ...p Drawing Remarks Working Spare Item no Valve spring tightening device 1 014 Lifting tool for cylinder unit 1 038 Broad chissel 1 473 2016 10 18 en Description Standard tools for normal maintenance 37...

Page 354: ...r flame ring 1 021 Guide bush for piston 1 045 Tool for fixing of marine head for counterweight 1 060 Fit and removal device for connecting rod bearing incl eye screws 2 pcs 1 069 Description Standard...

Page 355: ...082 Lifting device for piston and connecting rod 1 104 Piston ring opener 1 190 Supporting device for con necting rod and piston in the cylinder liner 1 212 2016 10 18 en Description Standard tools fo...

Page 356: ...ip Drawing Remarks Working Spare Item no Feeler gauge 1 010 Socket wrench 1 652 Socket wrench and torque spanner 1 1 664 676 Description Standard tools for normal maintenance 3700125 2 4 2016 10 18 en...

Page 357: ...y per ship Drawing Remarks Working Spare Item no Dismantling tool for main bearing upper shell 1 035 2016 10 18 en Description Standard tools for normal maintenance 3700125 2 4 MAN Diesel Turbo P 24 0...

Page 358: ...1 036 Container complete for water washing of compres sor side 1 355 Blowgun for dry cleaning of turbocharger 1 136 Water washing of turbine side complete 1 481 Description Standard tools for normal...

Page 359: ...ctor Fuel pipe Pressure pump 1 1 1 1 050 051 053 054 Grinding device for nozzle seat incl item 747 759 Grinding paper Plier 1 1 1 074 747 759 Extractor device for injector valve 1 407 Eye screw for li...

Page 360: ...mm 1 772 Crow foot 36 mm 1 784 Long socket spanner 3 4 41 mm 1 880 Adapter for torque spanner 1 2 3 4 1 892 Torque spanner 1 2 50 300 Nm 1 902 Description Standard tools for normal maintenance 370012...

Page 361: ...e Manometer Gasket Quick coupling Distributor 1 1 1 1 1 011 023 024 025 026 Hydraulic tools box 2 consisting of Pressure part long M39 x 2 Pressure part short M39 x 2 Tension screw M39 x 2 Hydraulic t...

Page 362: ...ydraulic tool M36 x 2 Spare parts for hydraulic tool M30 x 2 Spare parts for hydraulic tool M24 x 2 Hydraulic tightening cylinder M24 27 x 2 Hydraulic tightening cylinder M36 x 2 Hydraulic tightening...

Page 363: ...ing Spare Item no Grinding tool for cylinder head liner 1 126 Max pressure indicator 0 250 bar 1 138 Handle for indicator valve 1 498 Turning device for cylinder unit 1 114 2017 02 23 en Description A...

Page 364: ...sert 1 1 1 1 1 199 208 209 210 211 Grinding tool for valves 1 283 Grinding machine for valve seat rings Frequence converter Tool holder Turning bit Pilot spindle incl stabilizer Cleaning tool Tool hol...

Page 365: ...el grain size 80 Stabilizer valve stem 10 18 mm 1 1 1 1 1 1 1 285 820 832 844 856 868 881 Fit and removing device for valve guides 1 258 Fitting device for valve seat rings 1 295 Extractor for valve s...

Page 366: ...wing Remarks Working Spare Item no Reamer for valve guide 1 748 Touching up device 1 893 Electronic indicator HLV 2000 1 903 Description Additional tools 3700126 4 11 2017 02 23 en P 24 03 9 MAN Diese...

Page 367: ...for counterweight 1 060 Fit and removal device for connecting rod bearing incl eye screws 2 pcs 1 069 Lifting device for cylinder liner 1 082 Lifting device for piston and connecting rod 1 104 Plier...

Page 368: ...nder liner incl fork 1 212 Testing mandrel for piston ring grooves 7 43 mm 1 149 Testing mandrel for piston ring grooves 6 43 mm 1 151 Testing mandrel for piston ring grooves 8 43 mm 1 163 Fit and rem...

Page 369: ...per ship Drawing Remarks Working Spare Item no Support for connecting rod 1 570 Micrometer screw 250 270 mm 1 425 2017 02 23 en Description Additional tools 3700126 4 11 MAN Diesel Turbo P 24 03 9 L27...

Page 370: ...m no Dismantling tool for main bearing upper shell 1 035 Crankshaft alignment gauge autolog 1 067 Lifting straps for main bear ing cap 1 545 Lifting handle for main bear ing cap 1 557 Description Addi...

Page 371: ...fting 1 036 Fit and removing device for cooler insert 1 401 Closing cover TCR20 Closing cover TCR18 standard with only one propulsion engine 1 1 486 450 Differential pressure tools complete 1 915 2017...

Page 372: ...00 1 929 Fuel oil system Name Sketch Supply per ship Drawing Remarks Working Spare Item no Fitting and removal of monoblock cylinder 1 031 Disassembly tools 1 043 Fitting removing device for injection...

Page 373: ...ection pump 1 342 Setting device for fuel injec tion pump 1 366 Assembly device for sealing ring complete Assembly cone Expanding sleeve Assembly cone Sizing sleeve 1 1 1 1 1 689 690 700 712 724 2017...

Page 374: ...orking Spare Item no Eye screw for lifting lubri cating oil cooler 1 032 Mandrel for lubricating oil cooler 1 508 Fitting device for lubricating oil cooler 1 521 Description Additional tools 3700126 4...

Page 375: ...tem no Resetting device for hydraulic cylinder 1 092 Air driven high pressure pump for hydraulic valve 1 653 Remote controlled unit for hydraulic bolt tensioning 1 939 2017 02 23 en Description Additi...

Page 376: ...internal hexagon 12 mm screw driver 1 6x10 mm cross head screw 2 mm cross head screw 3 mm cross head screw 4 mm 1 019 Combination spanner 10 mm Combination spanner 12 mm Combination spanner 13 mm Comb...

Page 377: ...panner square drive size 30 1 176 Socket spanner square drive size 36 1 188 Bit hexagon socket screw square drive size 8 1 247 Bit hexagon socket screw square drive size 10 1 259 Bit hexagon socket sc...

Page 378: ...spanner 30 320 Nm 1 2 1 1 1 272 284 296 Hexagon key 7 mm Hexagon key 8 mm Hexagon key 10 mm Hexagon key 12 mm Hexagon key 14 mm Hexagon key 17 mm Hexagon key 19 mm 1 1 1 1 1 1 1 331 343 355 367 379 38...

Page 379: ...MAN Diesel Turbo B 50 Alternator Page 1 1 B 50 Alternator 2018 04 13 en...

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Page 381: ...ied by the crankshaft of the engine On two bearing alternators the connection is a flexible rubber coupling and the rotor front is seated in the stator housing of the alternator In both cases the alte...

Page 382: ...180 C on the windings and 180 C operating temperature According to the GL classification rules the alterna tor must as maximum be used up to 155 C oper ating temperature corresponding to insulation cl...

Page 383: ...as a guideline The fix point of the alternator cables must be as close as possible to the centre line of the rotor Bending of the cables must follow the recommen dations of the cable supplier regardin...

Page 384: ...d foundation for stationary operation For stationary operation the Contractor must ensure that the foundation is grounded according to local legislation Engine base frame and alternator have internal...

Page 385: ...nary operation example MAN Diesel Turbo 1699865 3 4 Page 3 3 Alternator cable installation BG 50 00 0 L28 32S L27 38S L23 30S L21 31S L16 24S L23 30DF L28 32DF V28 32S L16 24 L21 31 L23 30H L27 38 L28...

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Page 387: ...pe and alternator type concerning one or two bear ings must be avoided In the below list all combina tions can be found Comments to possible combinations Standard Option X Not recommended 1 Only in co...

Page 388: ...Diesel Turbo BG 50 00 0 Combinations of engine and alternator layout 3700084 3 10 Page 2 2 L28 32S L27 38S L23 30S L21 31S L16 24S L23 30DF L28 32DF V28 32S L16 24 L21 31 L23 30H L27 38 L28 32H 2017 0...

Page 389: ...MAN Diesel Turbo B 98 Preservation and packing Page 1 1 B 98 Preservation and packing 2018 04 13 en...

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Page 391: ...of cylinders The lifting tools are to be removed after the installa tion and the protective caps should be fitted Figure 1 Lifting tools Figure 2 Lifting tools and wires placing on engine Engine Type...

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