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WinGD X72-B, Operation Manual

The WinGD X72-B Operation Manual is available for free download on our website. This comprehensive manual provides detailed instructions for operating your X72-B engine, ensuring optimal performance and maintenance. Download it now from 88.208.23.73:8080 to enhance your operating experience.

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10-32

Fuel pressure in the fuel rail is too high (for X35/-B or X40/-B engine) .......

398

10-33

Fuel pressure in the fuel rail is too low (for X35/-B or X40/-B engine) ........

398

10-34

Gas concentration in piston underside is too high .......................................

399

10-35

Difference pressure of pilot fuel filter is too high .........................................

399

10-36

Gas supply pressure is too low ...................................................................

399

10-37

Exhaust gas temperature downstream of a cylinder is too high ..................

400

10-38

Exhaust gas temperature difference downstream of all cylinders is too

high ..............................................................................................................

400

10-39

Exhaust gas temperature upstream of a turbocharger is too high ..............

400

10-40

Exhaust gas temperature downstream of a turbocharger is too high ..........

401

10-41

Exhaust valve does not operate, unwanted noise .......................................

401

10-42

Smoke is too dark ........................................................................................

401

10-43

Scavenge air temperature in the receiver is too high ..................................

402

10-44

Scavenge air temperature in the receiver is too low ...................................

402

10-45

Scavenge air pressure is too high ...............................................................

402

10-46

Scavenge air pressure is too low ................................................................

402

10-47

Condensation flow at a water separator is too high ....................................

403

10-48

Condensation flow upstream of a water separator is too high ....................

403

10-49

Scavenge air temperature in the piston underside is too high ....................

403

10-50

Starting air supply pressure is too low  ........................................................

403

10-51

Pressure of the air spring air supply is too high  .........................................

403

10-52

Pressure of the air spring air supply is too low  ...........................................

404

10-53

Oil leakage flow in the collector for leakage oil from the air spring is too

high  .............................................................................................................

404

10-54

Control air supply pressure is too low (usual supply)  .................................

404

10-55

Control air supply pressure is too low (stand-by supply)  ............................

404

10-56

Control air supply pressure is too low (safety supply)  ................................

404

10-57

Temperature of a thrust bearing pad is too high  ........................................

405

10-58

Cylinder liner wall temperature is too high  .................................................

405

10-59

A fuel pump actuator has a failure  ..............................................................

405

10-60

Power supply to the power supply box E85 has a failure  ...........................

406

10-61

Unwanted engine speed decrease  .............................................................

406

10-62

Unwanted engine stop  ................................................................................

406

10-63

Hardwired ID failure to MCM #n  .................................................................

462

10-64

CAN interface failure  ..................................................................................

462

10-65

Urea dosing failure  .....................................................................................

463

10-66

Temperature sensor failure  ........................................................................

463

10-67

SCR system failure  .....................................................................................

464

10-68

SCR sequence failure  ................................................................................

464

10-69

SCR alarm failure  .......................................................................................

464

10-70

Sensor failure  .............................................................................................

464

10-71

External system failure  ...............................................................................

465

10-72

Emergency bypass failure  ..........................................................................

465

10-73

Bypass switch activation failure  ..................................................................

465

10-74

Outputs to SCR system failure  ...................................................................

466

11

Technical data

11-1

General data  ...............................................................................................

482

X72-B

Operation Manual

Winterthur Gas & Diesel Ltd.

- 11 -

Issue 003  2021-12

Summary of Contents for X72-B

Page 1: ...X72 B Issue 003 2021 12 Winterthur Gas Diesel Ltd Sch tzenstrasse 3 Tel 41 0 52 264 8844 Winterthur Gas Diesel AG P O Box 414 8401 Fax 41 0 52 264 8866 Winterthur Gas Diesel S A Winterthur Switzerlan...

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

Page 3: ...n the crankcase 56 2 7 Access to engine spaces 58 2 8 General safety lifting instructions 60 3 Design and function of the engine 3 1 Short description of the engine 62 3 2 Use of the engine 64 3 3 The...

Page 4: ...5 Connecting rod and connecting rod bearing 170 5 3 6 Crosshead and guide shoe 172 5 3 7 Piston 174 5 4 Group 4 Supply unit drive and control components 5 4 1 Supply unit drive 176 5 4 2 Starting air...

Page 5: ...250 6 5 4 MCP page GAS SYSTEM 254 6 5 5 MCP page MAIN 256 6 5 6 MCP page Adjust user parameters 260 6 5 7 MCP page SYSTEM INFO Option for WiCE 270 6 5 8 MCP page TREND Option for WiCE 272 6 5 9 MCP pa...

Page 6: ...of the cylinder oil 366 9 3 Replace the filter element of the duplex filter 370 9 4 Clean the turbocharger during operation 372 9 5 Clean the scavenge air cooler during operation 374 9 6 Do a test of...

Page 7: ...troubleshooting 462 10 21 Special running condition Turbocharger cut out 468 10 22 Special running condition Cylinder cut out 476 11 Technical data 11 1 Engine data 482 11 2 List of usual values and s...

Page 8: ...X72 B Operation Manual Page left intentionally blank Winterthur Gas Diesel Ltd 8 Issue 003 2021 12...

Page 9: ...unction of components 5 1 iELBA control cabinet 216 5 2 iELBA error indication 217 6 Control system 6 1 MCP navigation menu 248 6 2 MCP buttons function 249 6 3 MCP page Fuel mode control Diesel mode...

Page 10: ...rvo oil leakage flow from the servo oil supply unit is too high 394 10 13 Servo oil flow at a servo oil pump inlet is too low 394 10 14 Bearing oil temperature at a bearing outlet is too high 394 10 1...

Page 11: ...iston underside is too high 403 10 50 Starting air supply pressure is too low 403 10 51 Pressure of the air spring air supply is too high 403 10 52 Pressure of the air spring air supply is too low 404...

Page 12: ...2 11 10 Oil systems XX2NNN part 4 493 11 11 Fuel system XX34NN 494 11 12 Exhaust gas system XX37NN 495 11 13 Air systems XX40NN to XX44NN 496 11 14 Miscellaneous items XX45NN to XX52NN 497 11 15 Failu...

Page 13: ...SCR system change from Tier III to bypass 100 4 12 HP SCR system purging and venting 101 4 13 HP SCR system emergency bypass 102 4 14 HP SCR system preparation 103 4 15 HP SCR system Tier III 104 4 16...

Page 14: ...ion damper generic 166 5 15 Axial vibration damper monitor generic 167 5 16 Turning gear generic 168 5 17 Connecting rod and connecting rod bearing generic 170 5 18 Crosshead and guide shoe example 17...

Page 15: ...ameter 263 6 22 MCP page Injection ICU Venting 264 6 23 MCP page Exhaust Valve Parameter 265 6 24 MCP page GAV Gas Admission Valve 266 6 25 MCP page Cylinder Lubrication 267 6 26 MCP page EWG Exhaust...

Page 16: ...n of flanges 442 10 8 Assembly of roller lifter tool 443 10 9 Not all turbochargers are defective example 445 10 10 All turbochargers are defective example 446 10 11 SCR system covers example for 1 tu...

Page 17: ...13 2 Process codes 523 13 3 Signal codes 524 13 4 Color codes and symbols electric connection diagram 526 X72 B Operation Manual Winterthur Gas Diesel Ltd 17 Issue 003 2021 12...

Page 18: ...X72 B Operation Manual Page left intentionally blank Winterthur Gas Diesel Ltd 18 Issue 003 2021 12...

Page 19: ...2 1 3 Technical documentation set 24 1 4 Data module codes descriptive data 26 1 5 Data module codes procedural data 28 1 6 About this book 30 1 7 About the engine 32 1 8 List of abbreviations 36 X72...

Page 20: ...Updated the Design and functions of systems section Updated the Design and functions of components section Updated the Engine control system section Added new chapters for WiCE engine control system...

Page 21: ...X72 B AA00 0000 00AAA 003A A Operation Manual Operation Manual change record Page left intentionally blank Winterthur Gas Diesel Ltd 21 Issue 003 2021 12...

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

Page 23: ...X72 B AA00 0000 00AAA 018A A Operation Manual Preface Page left intentionally blank Winterthur Gas Diesel Ltd 23 Issue 003 2021 12...

Page 24: ...ual gives data about the standard engine with all cylinder numbers alternative designs and special equipment In this manual the engine connections refer to the pipe connection plan are the interface o...

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

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

Page 27: ...X72 B AA00 0000 00AAA 018D A Operation Manual Data module codes descriptive data Page left intentionally blank Winterthur Gas Diesel Ltd 27 Issue 003 2021 12...

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

Page 29: ...has been removed from the prod uct D information related to all three locations A B and C No other combi nations are allowed 1 alphabetic character A D Shipdex specif ic A 1 Placeholder symbol for al...

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

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

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

Page 33: ...e that has the equipment for the discard of the exhaust gas and for the supply of scavenge air Fig 1 1 Side view generic DE FE n n 1 2 1 005 004 001 002 003 Legend FE Free end DE Driving end 001 Turbo...

Page 34: ...D uses the definitions for the numbering of items as follows refer to Figure 1 2 In axial direction the numbering starts from the flywheel In radial direction the numbering starts from the center of t...

Page 35: ...X72 B AA00 0000 00AAA 018L A Operation Manual About the engine Page left intentionally blank Winterthur Gas Diesel Ltd 35 Issue 003 2021 12...

Page 36: ...C Brake Specific Gas Consumption BSPC Brake Specific Pilot fuel Consumption CAN Controller Area Network CCAI Calculated Carbon Aromaticity Index CCM Cylinder Control Module CCU Cylinder Control Unit C...

Page 37: ...lve FPP Fixed Pitch Propeller FQS Fuel Quality Setting FS Fuel Side FZG Forschungsstelle f r Zahnr der und Getriebebau gear research center GAV Gas Admission Valve GSS Gas Safety System GTD General Te...

Page 38: ...Heating Value LLT Low Load Tuning LNG Liquefied Natural Gas LP Low Pressure LT Low Temperature MARPOL International Convention for the Prevention of Pollution from Ships MARine POLlution MCM Main Con...

Page 39: ...Scavenge Air Cooler SAE Society of Automotive Engineers SCR Selective Catalytic Reduction SCS Speed Control System SHD shutdown SLD slowdown SOI Start Of Injection SPC Spare Parts Catalogue SPC Steam...

Page 40: ...R Waste Heat Recovery WiCE WinGD Integrated Control Electronics WinGD Winterthur Gas Diesel Ltd WLL Work Load Limit X72 B AA00 0000 00AAA 005A A Operation Manual List of abbreviations Winterthur Gas D...

Page 41: ...ire in the scavenge air spaces 50 2 4 Fire fighting in the scavenge air space 52 2 5 Explosions in the crankcase 54 2 6 Prevent explosions in the crankcase 56 2 7 Access to engine spaces 58 2 8 Genera...

Page 42: ...ected service experience The service letter deals with specific engine types and contain general instructions and recommendations for all engine types The service letters are used as a reference to pr...

Page 43: ...X72 B AA00 0000 00AAA 030L A Operation Manual Service Letters Page left intentionally blank Winterthur Gas Diesel Ltd 43 Issue 003 2021 12...

Page 44: ...except if done in closed and protected environment this will prevent spread of grit or swarf particles Make sure that the turbocharger intake filters are covered Keep the external part of the engine c...

Page 45: ...and the engine is not in operation the water in the pipe systems can freeze To prevent this drain the pipe systems or increase the temperature in the engine room Alarms Make sure that all the alarms...

Page 46: ...se personal injury or loss of life Warning This warning is used when an operation procedure or use may cause a latently dangerous state of personal injury or loss of life Caution This warning is used...

Page 47: ...elated system injury to personnel can occur WARNING Injury hazard Do not repair the hydraulic servo oil or rail system when pumps are in operation Injury to personnel can occur WARNING Injury hazard D...

Page 48: ...delines for hot work Outside of safe workspaces The safety officer ensures that the hot work is carried out safely The safety officer provides a permit to everybody related to hot work Hot work proced...

Page 49: ...el to the cables of electronic units Only use DC power supply and OCV below 70 volts Make sure that the connection clamp is near to the work area Make sure that electronic parts have protection to pre...

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

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

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

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

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

Page 55: ...X72 B AA00 0000 00AAA 012C A Operation Manual Explosions in the crankcase Page left intentionally blank Winterthur Gas Diesel Ltd 55 Issue 003 2021 12...

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

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

Page 58: ...crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Be careful of the sl...

Page 59: ...losed ball valves 30 8605_E0_6 and 30 8605_E0_7 are open 6 Engage the turning gear and lock the lever in this position NOTE Other ships in the water cause currents which cause the movement of the prop...

Page 60: ...ed properly to the lifting component Always use correct dedicated lifting points Do not exceed the lowest safe working load SWL of the lifting equipment in the lifting chain Keep away lifting equipmen...

Page 61: ...and function of the engine 3 1 Short description of the engine 62 3 2 Use of the engine 64 3 3 The relation between engine and propeller 68 X72 B Operation Manual Winterthur Gas Diesel Ltd 61 Issue 00...

Page 62: ...operation Related to the design the engine turns clockwise or counterclockwise for the ahead direction For the astern direction the engine can turn in the other direction The engine control system EC...

Page 63: ...ases expand and push the piston down The pressure in the combustion chamber decreases Sequence 4 1 The scavenge air replaces the exhaust gas as follows At 4 the exhaust valve opens At a the scavenge p...

Page 64: ...nge Fig 3 2 Operating range R1 R1 R2 R2 R4 R4 R3 S P Legend R1 Highest power at highest speed R3 Highest power at lowest speed R1 Highest power at highest speed extended R4 Lowest power at lowest spee...

Page 65: ...rect use will be the responsibility of the operating company The actions that follow must be looked as examples to be an incorrect use Operation of the engine with disabled changed or defective safety...

Page 66: ...ass tuning The delta bypass tuning decreases the fuel consumption below 50 engine power compared to delta tuning For more than 50 of engine power the fuel consumption is the same as delta tuning but t...

Page 67: ...X72 B AA00 0000 00AAA 020C A Operation Manual Use of the engine Page left intentionally blank Winterthur Gas Diesel Ltd 67 Issue 003 2021 12...

Page 68: ...clean hull the applicable power is lower and the operation point is below the nominal propeller property During operation a higher torque is necessary for the propeller to keep its speed than at the t...

Page 69: ...he timing of dry dock intervals This margin is usually subtracted from the CMCR Thus to get the 100 power line you divide the power at point D by between 0 85 to 0 90 3 3 2 3 Load range limits Fig 3 4...

Page 70: ...ine speed and power is near the data in Line 5 there will be a decrease in scavenge air which has an effect on the engine The area between Lines 1 3 and 5 show the range in which the engine must be op...

Page 71: ...4 6 Cylinder oil system 82 4 7 Starting air system 84 4 8 Scavenge air system 86 4 9 Control air system 88 4 10 Exhaust gas system 90 4 11 Fuel system 92 4 12 HP Selective catalytic reduction system 9...

Page 72: ...e codes in Figure 4 1 Fig 4 1 Line codes for systems 001 002 003 004 007 006 008 009 005 Legend 001 Main supply pipe 006 Double wall pipe 002 Drain leakage pipe 007 Heating pipe 003 Vent pipe 008 Insu...

Page 73: ...X72 B AA00 0000 00AAA 043U A Operation Manual General for systems Page left intentionally blank Winterthur Gas Diesel Ltd 73 Issue 003 2021 12...

Page 74: ...water drain outlet Connection 07 SAC LT cooling water inlet not shown Connection 08 SAC LT cooling water outlet not shown If the supply at the engine connection 02 is installed the cylinder liner is s...

Page 75: ...003 001 002 004 005 03 PLANT ENGINE Legend 001 Automatic venting unit 004 Drain valve 002 Shut off valve cooling water outlet 005 Orifice 003 Shut off valve X72 B AA00 0000 00AAA 043A A Operation Manu...

Page 76: ...utlet Connection 11 water for cleaning plant for TC and SAC inlet Connection 12 air for cleaning plant for TC and SAC inlet Connection 13 oily water from receiver outlet Connection 16 SAC condensate w...

Page 77: ...ooler ENGINE PLANT 11 12 08 07 16 18 13 001 002 003 004 005 ENGINE PLANT Legend 001 Turbocharger 004 Auxiliary blower 002 Scavenge air cooler SAC 005 Wash water tank 003 Cyclone separator X72 B AA00 0...

Page 78: ...oil inlet Connection 26 lubricating oil turbocharger inlet in case of external oil supply optional Connection 27 lubricating oil turbocharger outlet Connection 30 lubricating oil crosshead inlet opti...

Page 79: ...36 37 22 23 30 26 25 27 Legend 001 Turbocharger 007 Crosshead 002 iELBA optional 008 Thrust bearing 003 Torsional vibration damper optional 009 Oil sample valve 004 Axial vibration damper 010 Lever 0...

Page 80: ...oil pump number related to the configuration The servo oil pumps 004 supply the servo oil system with oil during usual operation Servo oil rail The servo oil rail 007 supplies the exhaust valve contr...

Page 81: ...X72 B AA00 0000 00AAA 043Q A Operation Manual Servo oil system Page left intentionally blank Winterthur Gas Diesel Ltd 81 Issue 003 2021 12...

Page 82: ...der lubricating pump Each cylinder has a cylinder lubricating pump 003 Servo oil operates the cylinder lubricating pumps The ECS controls the cylinder lubricating pumps Lubricating quill The lubricati...

Page 83: ...X72 B AA00 0000 00AAA 043R A Operation Manual Cylinder oil system Page left intentionally blank Winterthur Gas Diesel Ltd 83 Issue 003 2021 12...

Page 84: ...starting air supply pipe 007 supplies the starting valves of each cylinder with starting air The starting air supply pipe has a safety valve 003 and two drain valves 004 Starting valve Each cylinder h...

Page 85: ...id valve 006 Disengaging device turning gear 002 Flame arrestor 007 Starting air supply pipe 003 Safety valve 008 Starting air shut off valve 004 Drain valve 009 Valve unit for start E 005 Control air...

Page 86: ...liary blowers 010 supply the scavenge air at the engine start and during low load operation Auxiliary blower switch box The auxiliary blower switch box controls the auxiliary blowers Scavenge air cool...

Page 87: ...as outlet 010 Auxiliary blower 003 Scavenge air inlet 011 Piston underside 004 Turbine 012 Piston 005 Compressor 013 Scavenge air receiver 006 Scavenge air cooler 014 Cylinder liner 007 Water separato...

Page 88: ...er for control air If the two plant air supply systems become defective the air tank supplies control air to the engine for a short period Air bottle The air bottle 001 collects condensation from the...

Page 89: ...X72 B AA00 0000 00AAA 043T A Operation Manual Control air system Page left intentionally blank Winterthur Gas Diesel Ltd 89 Issue 003 2021 12...

Page 90: ...gas system has the parts that follow Exhaust valve The exhaust valve 004 of each cylinder releases the exhaust gas of the combustion into the exhaust gas manifold Exhaust gas manifold The exhaust gas...

Page 91: ...X72 B AA00 0000 00AAA 043D A Operation Manual Exhaust gas system Page left intentionally blank Winterthur Gas Diesel Ltd 91 Issue 003 2021 12...

Page 92: ...ECS cuts out a different injection valve at regular intervals to get an equal thermal load in the combustion chamber There is no time limit to operate the engine at low load The fuel system has the p...

Page 93: ...iting valves 003 can be installed on the fuel rail supply fuel to the related injection valves with the adjusted quantity of fuel Injection control unit optional The injection control units 003 can be...

Page 94: ...004 005 006 007 008 009 Cyl 1 Legend 001 Pressure control valve 006 Injection valve 002 Relief valve 007 Supply unit 003 Flow limiting valve FLV 008 Fuel pump 004 Fuel rail 009 Pressure retaining valv...

Page 95: ...001 002 004 005 003 007 008 009 006 Legend 001 Pressure control valve 006 Injection valve 002 Relief valve 007 Supply unit 003 Injection control unit ICU 008 Fuel pump 004 Fuel rail 009 Pressure reta...

Page 96: ...on pump unit supplies the urea solution from the tank to the urea solution dosing unit and keeps the applicable pressure in the related pipes The urea solution dosing unit controls the supply of urea...

Page 97: ...n of the valves if there is a complete stop of the current supply fail position V1 Reactor inlet valve FO fail open V2 Reactor outlet valve FO fail open V3 Reactor bypass valve FO fail open V4 Turbine...

Page 98: ...gas temperature after exhaust gas manifold Operation mode Tmin Tmax Preparation urea injection OFF 200 C 470 C Use of low sulphur fuel 0 5 S urea injection ON 310 C 470 C Use of high sulphur fuel 0 5...

Page 99: ...peration of the HP SCR system is not given for example if a bus connection is defective The valves have the conditions that follow V1 Closed V2 Closed V3 Open V4 Controlled by the ECS V7 Closed can be...

Page 100: ...ease the exhaust gas temperature V7 Closed can be opened to decrease the pressure in the reactor Then the preservation sequence starts as follows to prevent corrosion of the reactor and of the pipes r...

Page 101: ...ne After that procedure or directly the venting sealing unit supplies compressed air to keep a pressure in the reactor and in the pipes This makes a seal against the exhaust gas to prevent damage of t...

Page 102: ...egend 001 Mixing duct 005 Venting sealing unit 002 Reactor 006 Urea solution supply unit 003 Turbine of turbocharger 007 Soot blowing unit 004 Engine X72 B AA00 9270 00AAA 043A A Operation Manual HP S...

Page 103: ...4 Controlled by the ECS V7 Closed If necessary you can operate the engine in this mode for longer periods for example to be ready for a fast change to Tier III mode Fig 4 14 HP SCR system preparation...

Page 104: ...ge air flow and thus to increase the exhaust gas temperature V7 Closed can be opened to decrease the pressure in the reactor Fig 4 15 HP SCR system Tier III V1 V2 V3 V7 V4 003 001 007 006 005 004 002...

Page 105: ...te the HP SCR system 4 12 3 HP SCR control system The HP SCR control system has the three control boxes that follow Control box E48 Control box E49 Control box E50 Each control box is connected throug...

Page 106: ...dication SPC running 002 Option SPC SPC bypass switch 008 Indication urea injection 003 Indication minor failure 009 Indication major failure 004 Indication SCR pre heating on 010 Hour meter 005 Optio...

Page 107: ...and has switches below the LDU 20 Fig 4 18 Control box E49 00562 001 002 003 Legend 001 LDU 20 003 Option SPC SPC bypass switch 002 SCR bypass switch X72 B AA00 9270 00AAA 043A A Operation Manual HP...

Page 108: ...are as follows SCR ON This message shows that the HP SCR system is set to ON SCR minor failure This message shows a failure that does not have an effect on HP SCR system operation SCR major failure T...

Page 109: ...trol system if button is active 007 FUEL button Selects the fuel in use 008 Status indication Shows the control location 009 Status indication Shows the SCR status 010 Button and indication Starts and...

Page 110: ...ve 006 Status indication Shows the SCR status failure and mode 007 Status indication Shows the SCR status 008 Value indication Shows the values 009 Status indication Shows the V4 setpoint if E48 has c...

Page 111: ...rol system if button is active 006 Status indication Shows the SCR status failure and mode 007 Status indication Shows the control location 008 Status indication Shows the auxiliary blower status in p...

Page 112: ...Button and indication Starts and stops the set automatic valve movement as test se quence serviceable only if the manual mode is permitted The indication shows the status of the test sequence NOTE If...

Page 113: ...if button is active 004 Application type Shows the name of the application 005 Software version Shows the software version number major middle minor for example 1 2 0 006 Application CRC Cyclic Redun...

Page 114: ...ex page 002 SCREENSHOT button Makes a screenshot of the current screen 003 RCS CTRL ON button Gets control from the remote control system if button is active 004 Page button Opens the selected page X7...

Page 115: ...X72 B AA00 9270 00AAA 043A A Operation Manual HP Selective catalytic reduction system Page left intentionally blank Winterthur Gas Diesel Ltd 115 Issue 003 2021 12...

Page 116: ...used in diesel mode NOTE For further details about the operation maintenance and troubleshooting aspects of the LP SCR system please refer to the manuals of the manufacturer 4 13 1 Description of the...

Page 117: ...tuning LLT or for steam production control SPC 4 13 1 2 Layout The LP SCR system can be designed in different layouts related to the project Two examples are shown in Figure 4 26 and Figure 4 27 Fig 4...

Page 118: ...s than the permitted limit can cause the catalyst elements to clog A temperature that is more than the permitted limit can cause the catalyst elements to become worn quickly 4 13 2 1 LP SCR system eme...

Page 119: ...e If the operator does not change to Tier III and the timer stops the ECS changes back to bypass mode Tier II 4 13 2 3 LP SCR system Tier III In this operation mode the LP SCR system is set to ON The...

Page 120: ...LP SCR control system layout 001 002 003 Legend 001 Input signals 003 Output signals 002 LP SCR control system The main input signals are as follows Engine parameters Prepare Tier III command from RC...

Page 121: ...This message shows that the LP SCR system is set to ON and thus urea is injected LP SCR minor failure This message shows a failure that does not have an effect on LP SCR system operation LP SCR major...

Page 122: ...pass switch 006 Indication orange SPC bypass 002 Indication red SCR failure 007 Indication green SPC running 003 Indication orange SCR bypass 008 Indication green SCR running 004 Indication red SPC fa...

Page 123: ...room and has switches below the LDU 20 Fig 4 31 Control box E71 with option SPC 001 002 003 Legend 001 LDU 20 003 SCR bypass switch 002 SPC bypass switch X72 B AA00 9270 00AAA 043B A Operation Manual...

Page 124: ...room and has switches below the LDU 20 Fig 4 32 Control boxes E72 and E73 001 002 003 004 Legend 001 LDU 20 003 SPC bypass switch 002 SCR bypass switch 004 Conductor terminal block X72 B AA00 9270 00A...

Page 125: ...ge 004 SCREENSHOT button Makes a screenshot of the current screen 005 RCS CTRL OFF button Gets control from the remote control system if button is active 006 Status indication Shows the SCR status 007...

Page 126: ...S CTRL OFF button Gets control from the remote control system if button is active 005 Status indication Shows the SCR status 006 Status indication Shows the control location 007 Status indication Show...

Page 127: ...t of the current screen 004 RCS CTRL OFF button Gets control from the remote control system if button is active 005 Status indication Shows the SCR status 006 Status indication Shows the control locat...

Page 128: ...ion type Shows the name of the application 005 Software version Shows the software version number major middle minor for example 1 2 0 006 Application CRC Cyclic Redun dancy Check Shows the check sum...

Page 129: ...dex page 002 SCREENSHOT button Makes a screenshot of the current screen 003 RCS CTRL ON button Gets control from the remote control system if button is active 004 Page button Opens the selected page X...

Page 130: ...alve EWG opens a part of the exhaust gas bypasses the turbocharger 007 As a result the temperature of the exhaust gas increases which is supplied to the steam production 005 The supply of the turbocha...

Page 131: ...values 006 SPC EXT CONTROL button Changes to the external control of the SPC 007 MinEWGPos mode button Sets the minimum permitted EWG position Other SPC modes than the initial mode MinEWGPos are only...

Page 132: ...limitations Too wide EWG opening decreases the scavenge air pressure This will start the auxiliary blowers The limit of the EWG opening prevents the scavenge air pres sure to decrease below the switc...

Page 133: ...14 4 LDU screen for steam boost mode Fig 4 40 LDU for the steam boost mode X72 B AA00 9270 00AAA 043C A Operation Manual Steam production control system Winterthur Gas Diesel Ltd 133 Issue 003 2021 1...

Page 134: ...is running with correct power ranges for the steam boost mode The load range 8 indicates OK The steam boost mode is activated 1 a On the right side of LDU Screen turn the control key to the left to de...

Page 135: ...connecting rod bearing 170 5 3 6 Crosshead and guide shoe 172 5 3 7 Piston 174 5 4 Group 4 Supply unit drive and control components 5 4 1 Supply unit drive 176 5 4 2 Starting air shut off valve 178 5...

Page 136: ...210 5 7 2 Integrated electrical balancer iELBA 212 5 8 Group 8 Pipes 5 8 1 Exhaust waste gate 218 5 9 Group 9 Monitoring instruments 5 9 1 Crank angle sensor unit 220 5 9 2 Water in oil monitor 222 5...

Page 137: ...X72 B Operation Manual Page left intentionally blank Winterthur Gas Diesel Ltd 137 Issue 003 2021 12...

Page 138: ...t The bottom part of the bedplate is the crankcase and collects lubricating oil This oil flows back to the oil supply system through oil drains 002 The length of the bedplate is related to the number...

Page 139: ...X72 B AA00 1115 00AAA 043A A Operation Manual Bedplate Page left intentionally blank Winterthur Gas Diesel Ltd 139 Issue 003 2021 12...

Page 140: ...nstall procedure The round nuts 002 keep the bearing cover 003 against the bearing girder For the main bearings adjacent to the thrust bearing the oil flows through the oil bore 013 to the running sur...

Page 141: ...X72 B AA00 1132 00AAA 043A A Operation Manual Main bearing Page left intentionally blank Winterthur Gas Diesel Ltd 141 Issue 003 2021 12...

Page 142: ...n the driving end adapt the propeller thrust of the astern direction The thrust pads adapt to the clockwise or counterclockwise rotation of the engine The arbor supports 004 prevent circular movement...

Page 143: ...pipe 010 2 part oil baffle 003 Nozzle 011 Flywheel 004 Arbor support 012 Bedplate 005 Bedplate 013 Thrust pad engine side 006 Thrust pad driving end 014 Thrust bearing flange 007 Bearing cover 015 Co...

Page 144: ...he fuel side FS the monoblock column has one door 002 per cylinder During normal operation the doors are closed and locked For maintenance or inspection work the doors can be opened Obey the safety ru...

Page 145: ...X72 B AA00 1406 00AAA 043A A Operation Manual Monoblock column Page left intentionally blank Winterthur Gas Diesel Ltd 145 Issue 003 2021 12...

Page 146: ...Tie rod generic 001 002 003 004 005 001 Legend 001 Protection cover 004 Tie rod 002 Cylinder block 005 Bedplate 003 Column If a tie rod breaks in the bottom area a special device makes sure that the...

Page 147: ...X72 B AA00 1903 00AAA 043A A Operation Manual Tie rod Page left intentionally blank Winterthur Gas Diesel Ltd 147 Issue 003 2021 12...

Page 148: ...contamination at the piston crown during operation Fig 5 6 Cylinder cooling water outlet generic Legend 001 Exhaust valve cage 003 Cooling water outlet 002 Cylinder cover Cooling water flows from the...

Page 149: ...X72 B AA00 2124 00AAA 043A A Operation Manual Cylinder liner Page left intentionally blank Winterthur Gas Diesel Ltd 149 Issue 003 2021 12...

Page 150: ...out of the nozzle tip 003 and the lubricating point 004 as a spray Some of the cylinder oil flows into the grooves of the cylinder liner wall The non return valve 009 prevents the exhaust gas to flow...

Page 151: ...X72 B AA00 2138 00AAA 043A A Operation Manual Lubricating quill Page left intentionally blank Winterthur Gas Diesel Ltd 151 Issue 003 2021 12...

Page 152: ...Neutral space 010 Gasket 4 part 005 Cylinder jacket 011 Tension spring 006 Support During operation the two scraper rings 001 Figure 5 8 remove dirty oil from the piston rod The dirty oil flows throug...

Page 153: ...X72 B AA00 2303 00AAA 043A A Operation Manual Piston rod gland Page left intentionally blank Winterthur Gas Diesel Ltd 153 Issue 003 2021 12...

Page 154: ...spray the fuel into the combustion chamber The ECS controls the pilot valve of the injection valves indirectly through the solenoid valve ECS also controls the timing and the quantity of the injected...

Page 155: ...X72 B AA00 2722 00AAA 043A A Operation Manual Direct controlled injection valve Page left intentionally blank Winterthur Gas Diesel Ltd 155 Issue 003 2021 12...

Page 156: ...closes at the correct crank angle of the related cylinder This makes the piston move down for engine start or makes the piston speed decrease for engine speed decrease As soon as combustion starts th...

Page 157: ...X72 B AA00 2728 00AAA 043A A Operation Manual Starting valve Page left intentionally blank Winterthur Gas Diesel Ltd 157 Issue 003 2021 12...

Page 158: ...ng piston 011 Air spring 005 Valve spindle 012 Leakage oil collection space 006 Valve cage 013 Hydraulic oil inlet 007 Valve seat 014 Damper The exhaust valve has the parts that follow Inside piston a...

Page 159: ...outer piston and inner piston 002 lubricates the air spring piston 004 Oil in the leakage oil collection space 012 drains to the leakage oil drain While the exhaust valve closes oil flows through the...

Page 160: ...ankshaft gear wheel 005 is part of the thrust bearing On the driving end of the crankshaft there is a flywheel 004 This flywheel decreases the pulsation from the cylinders The length of the crankshaft...

Page 161: ...X72 B AA00 3103 00AAA 043A A Operation Manual Crankshaft Page left intentionally blank Winterthur Gas Diesel Ltd 161 Issue 003 2021 12...

Page 162: ...ns in the shafting system and in other components of the engine If a torsional vibration damper is necessary for the engine one of the two damper types that follow can be used X72 B AA00 3130 00AAA 04...

Page 163: ...vibrations move the steel springs oil is pressurized on one side of the oil chambers and pushed through small clearances to the other side of the chambers This small oil flow creates the damping effec...

Page 164: ...t speeds This difference shears the silicone oil and thus decreases the vibration The damping work causes heat This heat increases the temperature of the outer side of the damper The heat dissipates t...

Page 165: ...X72 B AA00 3130 00AAA 043A A Operation Manual Torsional vibration damper Page left intentionally blank Winterthur Gas Diesel Ltd 165 Issue 003 2021 12...

Page 166: ...half 002 Figure 5 14 and a bottom cylinder half 006 Fig 5 14 Axial vibration damper generic Legend 001 Control plate 007 Bearing girder part of bedplate 002 Top cylinder half 008 Small sealing ring 00...

Page 167: ...ore in the top cylinder half 002 keeps air away from the annular spaces 003 The small oil leakage through the gap of the large sealing rings 005 drains into the crankcase 5 3 3 2 Axial vibration dampe...

Page 168: ...rns the pinion 002 and is attached on the driving end of the engine Related to the ratio of the gear wheels there is approximately one full turn of the crankshaft in ten minutes Fig 5 16 Turning gear...

Page 169: ...X72 B AA00 3206 00AAA 043A A Operation Manual Turning gear Page left intentionally blank Winterthur Gas Diesel Ltd 169 Issue 003 2021 12...

Page 170: ...oil flows through the guide shoe into the crosshead pin A hole in the crosshead pin lets lubricating oil flow into the bearing shells Fig 5 17 Connecting rod and connecting rod bearing generic Legend...

Page 171: ...X72 B AA00 3303 00AAA 043A A Operation Manual Connecting rod and connecting rod bearing Page left intentionally blank Winterthur Gas Diesel Ltd 171 Issue 003 2021 12...

Page 172: ...nto the crankcase The guide shoes 004 are attached to the crosshead pin 006 and move up and down on the guide ways of the column The guide rails 008 hold the guide shoes 004 and thus the crosshead in...

Page 173: ...X72 B AA00 3326 00AAA 043A A Operation Manual Crosshead and guide shoe Page left intentionally blank Winterthur Gas Diesel Ltd 173 Issue 003 2021 12...

Page 174: ...ied compression ratio System oil is used to keep cool the piston crown 001 This oil flows from the crosshead pin into the space 005 between the oil pipe 007 and the piston rod 004 The oil then flows t...

Page 175: ...X72 B AA00 3403 00AAA 043A A Operation Manual Piston Page left intentionally blank Winterthur Gas Diesel Ltd 175 Issue 003 2021 12...

Page 176: ...els 004 for the servo oil pumps The camshaft of the gear wheel 005 also operates the fuel pumps Oil flows through an oil inlet to lubricate the bearings of the gear wheels 004 Oil also flows through t...

Page 177: ...3 007 Legend 001 Intermediate wheel 005 Gear wheel servo oil pumps 002 Flywheel 006 Intermediate wheel 003 Crankshaft gear wheel 007 Crankshaft 004 Gear wheel servo oil pump X72 B AA00 4104 00AAA 043A...

Page 178: ...05 To test valve 014 Solenoid valve CV7014C 006 Spring 015 Double check valve 007 Valve 016 Solenoid valve CV7013C 008 Starting air inlet 017 Control air inlet 009 Balance bore 018 Lever With the leve...

Page 179: ...rom the inlet chamber 012 flows through the non return valve 010 to the starting air outlet 011 When the control valve 001 closes starting air flows through the balance bores 009 and fills the inlet c...

Page 180: ...by supply The non return valves 007 and 010 control the automatic change over of the compressed air supply Fig 5 22 Control air supply generic 003 004 005 006 007 008 009 010 011 012 001 002 Legend 00...

Page 181: ...X72 B AA00 4605 00AAA 043A A Operation Manual Control air supply Page left intentionally blank Winterthur Gas Diesel Ltd 181 Issue 003 2021 12...

Page 182: ...mity sensors measure the speed of the flywheel 003 Figure 5 23 When the flywheel turns the proximity sensors 002 sense the movement of the teeth The engine control system sends signals to the RCS to m...

Page 183: ...X72 B AA00 4628 00AAA 043A A Operation Manual Pick up for speed measurement Page left intentionally blank Winterthur Gas Diesel Ltd 183 Issue 003 2021 12...

Page 184: ...engine load Flow sensors monitor the oil supply in each inlet pipe of the servo oil pumps A malfunction of a servo oil pump will show in the alarm and monitoring system If a servo oil pump cannot turn...

Page 185: ...X72 B AA00 5551 00AAA 043A A Operation Manual Servo oil pump Page left intentionally blank Winterthur Gas Diesel Ltd 185 Issue 003 2021 12...

Page 186: ...gear wheels and intermediate wheels in the supply unit operate the fuel pumps and servo oil pumps refer to section 5 4 1 Supply unit drive Fig 5 24 Supply unit example Legend 001 Fuel pump 004 Bedpla...

Page 187: ...X72 B AA00 5552 00AAA 043A A Operation Manual Supply unit Page left intentionally blank Winterthur Gas Diesel Ltd 187 Issue 003 2021 12...

Page 188: ...he pump plunger 003 control the fuel quantity When the toothed rack 011 moves the teeth engage with the teeth on the regulating sleeve 010 and the regulating sleeve turns The regulating sleeve 010 tur...

Page 189: ...e fuel pump If a fuel pump is unserviceable eg the pump plunger cannot move or the HP fuel pipe is broken between the fuel pump and the fuel rail the fault must be repaired immediately If the fault ca...

Page 190: ...essure If this occurs longer engine operation time must be prevented to save fuel After this operation mode do a check of the valve for a tight seal The seal can be damaged You can hear a loud sound l...

Page 191: ...X72 B AA00 5562 00AAA 043A A Operation Manual Pressure control valve Page left intentionally blank Winterthur Gas Diesel Ltd 191 Issue 003 2021 12...

Page 192: ...the piston 003 moves back to the start position If the injection time is too long for example if an injection valve is stuck open the piston 003 closes the supply If an injection valve is damaged the...

Page 193: ...X72 B AA00 5565 00AAA 043A A Operation Manual Flow limiting valve Page left intentionally blank Winterthur Gas Diesel Ltd 193 Issue 003 2021 12...

Page 194: ...he exhaust valve control units are attached to the servo oil rail When the solenoid valve operates servo oil is released to the slide rod This releases servo oil to the piston 003 and thus oil opens t...

Page 195: ...X72 B AA00 5612 00AAA 043A A Operation Manual Exhaust valve control unit Page left intentionally blank Winterthur Gas Diesel Ltd 195 Issue 003 2021 12...

Page 196: ...two fuels pumps are connected to there related actuator The ECS controls the fuel pump actuators During operation the fuel pump actuators move at the same time Each fuel pump actuator has an overload...

Page 197: ...X72 B AA00 5583 00AAA 043A A Operation Manual Fuel pump actuator Page left intentionally blank Winterthur Gas Diesel Ltd 197 Issue 003 2021 12...

Page 198: ...data about the scavenge air system refer to section 4 8 Scavenge air system Fig 5 27 Scavenge air receiver example 001 002 003 004 005 Legend 001 Scavenge air from turbocharger 004 Auxiliary blower 0...

Page 199: ...example 001 002 005 004 003 Legend 001 Air space 004 Outlet to piston underside 002 Longitudinal wall 005 Flap 003 Receiver space X72 B AA00 6420 00AAA 043A A Operation Manual Scavenge air receiver Wi...

Page 200: ...f a turbocharger becomes defective you must stop the engine as quickly as possible to prevent damage If repair or replacement of a turbocharger is not immediately possible you can cut out the defectiv...

Page 201: ...X72 B AA00 6500 00AAA 043A A Operation Manual Turbocharger Page left intentionally blank Winterthur Gas Diesel Ltd 201 Issue 003 2021 12...

Page 202: ...ir inlet 004 Electric motor During the engine start operation the auxiliary blowers start one by one at two or three seconds interval to avoid electric overload Minimum one auxiliary blower is necessa...

Page 203: ...X72 B AA00 6545 00AAA 043A A Operation Manual Auxiliary blower Page left intentionally blank Winterthur Gas Diesel Ltd 203 Issue 003 2021 12...

Page 204: ...stop the auxiliary blowers manually In Off mode the auxiliary blowers are switch off Fig 5 31 Switch box 001 002 003 004 005 006 007 008 009 010 011 012 013 014 Legend 001 Indicator auxiliary blower...

Page 205: ...X72 B AA00 6547 00AAA 043A A Operation Manual Auxiliary blower switch box Page left intentionally blank Winterthur Gas Diesel Ltd 205 Issue 003 2021 12...

Page 206: ...SAC has a cover 004 Figure 5 32 For maintenance you can remove the cover Fig 5 32 Scavenge air cooler generic 001 002 003 004 Legend 001 Air flow 003 Cooling water inlet 002 Cooling water outlet 004...

Page 207: ...X72 B AA00 6606 00AAA 043A A Operation Manual Scavenge air cooler Page left intentionally blank Winterthur Gas Diesel Ltd 207 Issue 003 2021 12...

Page 208: ...f wet air Water also occurs during the wash procedure of the SAC The profiles 002 Figure 5 33 hold back the water in the air flow This water collects at the bottom of the frame 003 and then flows back...

Page 209: ...X72 B AA00 6708 00AAA 043A A Operation Manual Water separator Page left intentionally blank Winterthur Gas Diesel Ltd 209 Issue 003 2021 12...

Page 210: ...t the cylinder lubrication oil refer to section 12 1 General for operating media For information about the cylinder oil system in general refer to section 4 6 Cylinder oil system X72 B AA00 7218 00AAA...

Page 211: ...X72 B AA00 7218 00AAA 043A A Operation Manual Cylinder lubrication Page left intentionally blank Winterthur Gas Diesel Ltd 211 Issue 003 2021 12...

Page 212: ...he forces F are always canceled The vertical elements Fvert are always added to a resulting vertical force This resulting force operates up and down with the same frequency as the counterweights 002 t...

Page 213: ...function Legend 001 Gear wheel 004 Housing 002 Counterweight 005 Column 003 Bearing X72 B AA00 7752 00AAA 043A A Operation Manual Integrated electrical balancer iELBA Winterthur Gas Diesel Ltd 213 Iss...

Page 214: ...eavy sea mode the iELBA does not operate The engine can also operate if one or the two balancers do not operate eg in manual mode or if a balancer is defective Then it is possible that there are more...

Page 215: ...6 shows the buttons and indications on the control cabinet of the iELBA Fig 5 36 iELBA control cabinet X72 B AA00 7752 00AAA 043A A Operation Manual Integrated electrical balancer iELBA Winterthur Gas...

Page 216: ...Shows the state of the running iELBA Lamp blinks iELBA is in swing state Lamp is steady iELBA is in run state H4 Synch OK indicator light Shows the synchronisation state of the iELBA Lamp is steady iE...

Page 217: ...st to Control Speed Threshold not OK OFF 2 Start OK Setpoint Speed not OK in 60 s OFF 3 Start OK speed OK Phase Synchronisation not OK in 60 s OFF 4 Overspeed error OFF 5 Electric motor error OFF 6 Th...

Page 218: ...001 002 003 004 005 006 007 008 Legend 001 Air inlet 005 Exhaust gas manifold 002 Compressor 006 Turbine 003 Scavenge air receiver 007 Valve 004 Engine 008 Exhaust gas outlet If the turbochargers del...

Page 219: ...X72 B AA00 8135 00AAA 043A A Operation Manual Exhaust waste gate Page left intentionally blank Winterthur Gas Diesel Ltd 219 Issue 003 2021 12...

Page 220: ...ve at the driving end There are two crank angle systems that monitor the teeth on the intermediate wheel The two sets of proximity sensors operate independently to sense the teeth on the intermediate...

Page 221: ...ollows First sensor pair to MCM 20 and CCM 20 1 Second sensor pair from CCM 20 2 to CCM 20 n TDC and BDC to all CCM 20 Fig 5 38 Crank angle sensor unit on flywheel example Legend 001 Cover 003 Flywhee...

Page 222: ...l to the alarm and monitoring system AMS On the display 001 Figure 5 39 you can see the data that follow aw water activity T temperature in C H2O water content in ppm Fig 5 39 Water in oil monitor gen...

Page 223: ...X72 B AA00 9313 00AAA 043A A Operation Manual Water in oil monitor Page left intentionally blank Winterthur Gas Diesel Ltd 223 Issue 003 2021 12...

Page 224: ...and explosions in the crankcase can be prevented The system includes the sensors 002 Figure 5 40 and the control unit 003 on the engine Fig 5 40 Oil mist detector example 004 003 001 002 Legend 001 D...

Page 225: ...adjustments can be programmed in the display unit 001 The menu driven software has three user levels User Read only of data Operator Password protected level for access to most adjustments and functio...

Page 226: ...X72 B AA00 9314 00AAA 043A A Operation Manual Oil mist detector Page left intentionally blank Winterthur Gas Diesel Ltd 226 Issue 003 2021 12...

Page 227: ...260 6 5 7 MCP page SYSTEM INFO Option for WiCE 270 6 5 8 MCP page TREND Option for WiCE 272 6 5 9 MCP page INSTRUMENTS 274 6 5 10 MCP page FUEL LUBRICATION SYSTEM 276 6 5 11 Local control panel gener...

Page 228: ...ut off valve Gateway unit GTU 1 and 2 The gateway units GTU 1 and 2 are installed on the rail unit in the terminal box E90 The GTU transmits data to and from external control systems Manual control pa...

Page 229: ...1 4 External control systems The Diesel Engine Control and Optimizing Specification DENIS and the engine control system ECS are designed so that different remote controls can be used All nodes are fu...

Page 230: ...rol manufacturer All commands to operate the engine for example AHEAD or ASTERN come from the RCS Engine safety system The engine safety system ESS has the primary functions that follow Emergency stop...

Page 231: ...X72 B AA00 0000 00AAC 043K A Operation Manual Engine control system WiCE Page left intentionally blank Winterthur Gas Diesel Ltd 231 Issue 003 2021 12...

Page 232: ...d exhaust valve closing time for each cylinder This decreases the excessive wear of engine components This decreases the risk of an engine overload This prevents manual adjustment failures In the ECS...

Page 233: ...of ignition pI is smaller than the compression pressure at TDC pC The pressure increase is the difference between the maximum firing pressure pF and the pressure at start of ignition pI The ICC system...

Page 234: ...he sensors and then transmits these signals to a controller The measured value is adjusted to the correct setpoint value and is related to the engine load This real time site correction and comparison...

Page 235: ...X72 B AA00 9308 00AAA 043A A Operation Manual Intelligent combustion control Page left intentionally blank Winterthur Gas Diesel Ltd 235 Issue 003 2021 12...

Page 236: ...re and pressure of the gas Fig 6 4 iGPR schematic diagram In the chapters that follow you find a short description of the automatic control functions for the iGPR control system 6 3 1 Transfer to gas...

Page 237: ...tion and stabilisation Activates the pressure stabilisation OK signal from iGPR to PCS and ECS Deactivates the pressure stabilisation active signal from iGPR to PCS and ECS Activates the transfer prep...

Page 238: ...utomatic inerting A gas trip with automatic inerting is necessary in the conditions that follow Emergency gas trip switches are active Gas trip from gas detection system is active Incorrect gas inlet...

Page 239: ...es the inerting failed signal from iGPR to PCS 6 3 6 Engine maintenance If you have to do maintenance on the engine or on the iGPR or on the supply line you have to start the related maintenance mode...

Page 240: ...SELECT 00209 001 009 008 008 008 008 008 008 007 006 002 003 005 004 Legend 001 Power LED 006 CHECK button used to accept the action or enter data 002 Status LED 007 HOME button push to show the main...

Page 241: ...n orange arrow 001 shows the active item A 3D rectangle 002 indicates a command button An orange frame 003 indicates the edit mode A black dotted frame 004 around an item shows the position of the cur...

Page 242: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None S...

Page 243: ...OTE It is possible to use other MCP pages even if the function buttons are locked Fig 6 7 MCP page MAIN locked 001 002 Legend 001 UNLOCK button 002 Navigation field X72 B AA00 4618 00AAC 131A A Operat...

Page 244: ...ou only can start one function at the same time also when you touch two or more function buttons 4 To change the control location do the steps that follow 4 1 Shortly touch the function button for the...

Page 245: ...speed command setting turn the fuel dial knob clockwise 6 2 To decrease the speed command setting turn the fuel dial knob counterclockwise CLOSE UP None X72 B AA00 4618 00AAC 131A A Operation Manual O...

Page 246: ...y 004 002 004 001 003 Legend 001 Navigation Menu 003 Rotary Encoder 002 Main Screen 004 Function Buttons 6 5 2 2 Navigation menu The navigation menu on the left side of the MCP display has below butto...

Page 247: ...Fig 6 10 MCP page navigation menu 001 002 003 004 X72 B AA00 4618 01AAB 043B A Operation Manual MCP page DISPLAY Winterthur Gas Diesel Ltd 247 Issue 003 2021 12...

Page 248: ...hows link to the remaining pages Information page Trending page User parameters page 6 5 2 3 Function buttons Function buttons are given on the bottom part of the MCP display They are used in case of...

Page 249: ...ual control function 007 ECR MANUAL CONTROL Starts the ECR manual control function 008 SAFETY SYSTEM RESET Starts the safety system reset control function 009 SLOWTURNING FAIL RESET Starts the slowtur...

Page 250: ...ol Diesel mode information 003 004 005 002 001 Tab 6 3 MCP page Fuel mode control Diesel mode information Item Function Effect 003 DIESEL button Switches to the diesel mode green LED turns on 004 Indi...

Page 251: ...ansfer mode green LED turns on 002 Indication field Shows the data for transfer status Shows Gas Request FGSS Ready FGSS Not Ready iGPR Leak Test OK iGPR Leak Test Fail iGPR Flushing OK iGPR Flushing...

Page 252: ...on 002 Indication field Shows the data for gas mode Gas interlock info Shows Fuel cmd Mode Active Speed Load not in range HFO Fuel in use Heavy Sea Mode Active External Gas Trip PCS External Gas Trip...

Page 253: ...a Shows Fuel cmd Mode Active Speed Load not in range HFO Fuel in use Heavy Sea Mode Active External Sea Mode Active External Gas Trip PCS External Gas Trip iGPR Engine Stopped Engine Running Astern In...

Page 254: ...s Pressure Shows the FGSS gas pressure value in bar 002 MAN PILOT PUMP CTRL Starts the manual pilot pump control function 003 PILOT PUMP START STOP Starts the pilot pump start stop function 004 FAIL R...

Page 255: ...Passed 011 iGPR Status Shows the iGPR status Shows Normal Degassing Fail Flushing Fail Leak Test Fail Inerting Fail FGSS Prepare Fail iGPR Gas Trip 012 iGPR Ctrl State Shows the iGPR Ctrl State Shows...

Page 256: ...e main page contains the overview of the main data Fig 6 17 MCP page MAIN 003 001 002 004 005 006 008 009 010 007 X72 B AA00 4618 01AAA 043B A Operation Manual MCP page MAIN Winterthur Gas Diesel Ltd...

Page 257: ...p Operational 007 Control Shows the control mode Shows Bridge ECR Remote ECR Manual Local 008 Engine Shows the engine status Shows Air Run Slowturning Start Interlock Stopped Shut down Running Startin...

Page 258: ...Engine Load Crank Angle If the engine is stopped there will be a CA indication When engine is in operation then the actual engine load will be shown X72 B AA00 4618 01AAA 043B A Operation Manual MCP...

Page 259: ...X72 B AA00 4618 01AAA 043B A Operation Manual MCP page MAIN Page left intentionally blank Winterthur Gas Diesel Ltd 259 Issue 003 2021 12...

Page 260: ...Opens the sub navigation fields INFO TRENDING USER PARAMETERS 002 Sub navigation field USER PA RAMETERS Opens the user parameter options VIT FQS deg Heavy Sea Mode Compressor Balancing Firing Balanci...

Page 261: ...10 MCP page Select user parameter Item Function Effect 001 User parameter Makes the related user parameter adjustable X72 B AA00 4618 05AAA 043B A Operation Manual MCP page Adjust user parameters Win...

Page 262: ...g Shows the fuel electr heating is ON OFF 004 Firing Control Shows the firing control is ON OFF 005 Firing Balancing Shows the firing balancing is ON OFF 006 Compression balancing Shows the compressio...

Page 263: ...ection button Shows the fuel injection user parameters Injection beginning offset can be adjusted individually at 1 5 Injection cut off Adjusting the amount of injected fuel on individual cylin ders 8...

Page 264: ...fault value To rise the fuel rail pressure execute an air run Indications Inactive Waiting for air run Waiting for correct fuel pressure During the fuel injection venting the fuel injection venting st...

Page 265: ...xhaust valve user parameters Parameters At engine stop manual EXV operation and it is necessary to activate air spring and servo oil run using servo oil service pump EXV closing offset can be adjusted...

Page 266: ...g oil Manual activation of GAV sealing oil Manual Test Request 002 GAV Test Conditions Shows the GAV test conditions is ready not Ready 003 GAV Test Status Shows the GAV test status is Active Not acti...

Page 267: ...ion button Opens the cylinder lubrication user parameter Parameters Manual adjustment of the lubrication feed rate for High BN Low BN and Gas Manual adjustment of the sulphur content for HFO and MDO X...

Page 268: ...eposit Cleaning Command Shows the deposit cleaning command is ON OFF 003 EWG Manual Setpoint Shows the EWG manual setpoint is in percentage 004 EWG Manual Mode Request Shows the manual mode request is...

Page 269: ...X72 B AA00 4618 05AAA 043B A Operation Manual MCP page Adjust user parameters Page left intentionally blank Winterthur Gas Diesel Ltd 269 Issue 003 2021 12...

Page 270: ...O 001 002 003 Tab 6 18 SYSTEM INFO Item Function Effect 001 NOx Compliance Shows the data for the IMO CRC compliance 002 Engine Software Shows the data for the engine software 003 Engine Shows the dat...

Page 271: ...X72 B AA00 4618 03AAA 043B A Operation Manual MCP page SYSTEM INFO Option for WiCE Page left intentionally blank Winterthur Gas Diesel Ltd 271 Issue 003 2021 12...

Page 272: ...een Signals are predefined Fig 6 28 MCP page TREND 002 001 Tab 6 19 MCP page TREND Item Function Effect 001 Selection field Highlights the selected parameters 002 Diagram field Shows the trend of the...

Page 273: ...X72 B AA00 4618 04AAA 043B A Operation Manual MCP page TREND Option for WiCE Page left intentionally blank Winterthur Gas Diesel Ltd 273 Issue 003 2021 12...

Page 274: ...Air Spring Shows the air spring pressure value in bar 005 Scavenge Air Shows the scavenge air pressure value in bar 006 Starting Air Shows the starting air pressure value in bar 007 Indication Field...

Page 275: ...Oil optional Shows the X head oil pressure value in bar 010 Bearing Oil Shows the bearing oil pressure value in bar X72 B AA00 4618 02AAA 043B A Operation Manual MCP page INSTRUMENTS Winterthur Gas D...

Page 276: ...MODE 001 Figure 6 30 button from the navigation menu 2 Select the FUEL LUB SYSTEM 013 button from the sub menu Fig 6 30 MCP Page FUEL LUBRICATION SYSTEM 001 002 003 004 005 006 007 008 009 010 011 01...

Page 277: ...ges to high BN cylinder oil 008 HFO button Changes to HFO Heavy Fuel Oil 009 AUX SO PUMP START STOP Starts and stops the auxiliary electric servo oil pump servo oil service pump NOTE If necessary star...

Page 278: ...dication field 003 17 function buttons 004 with a LED indication refer to Table 6 23 Function buttons of the manual control panel MCP Navigation menu 005 for sub menus refer to Table 6 22 Navigation m...

Page 279: ...as complet ed one full turn or when there was a malfunction AIR RUN Green Starts the air run mode of the engine green LED comes on Operates only when the engine is stopped AUX BLOWER PRESEL Green Sets...

Page 280: ...EMOTE CONTROL Green Changes from local manual control to bridge remote control during control transfer the two green LEDs flash then the green LED shows the current control position SAFETY SYSTEM RESE...

Page 281: ...X72 B AA00 4618 00AAC 043B A Operation Manual Local control panel general Page left intentionally blank Winterthur Gas Diesel Ltd 281 Issue 003 2021 12...

Page 282: ...setpoints the relative phase angle offset between the two engines is adjusted The main applications of the Synchro Phasing System SPS are given below Compensate the second order vertical mass moment M...

Page 283: ...actual crank angle offset of the engine This speed setpoint offset with a limit of 0 5 rpm gets transmitted to the speed controller of each engine The operator can use an additional LDU to monitor and...

Page 284: ...imate Only 001 see Figure 6 34 on the LDU The two engines operate ahead and within the minimum and maximum synchro phasing speed The maximum permitted difference between the engines speed set point is...

Page 285: ...ngines speed set point is configure to 0 5 rpm Heavy sea mode is not active on any engine No major failure of synchro phasing system is shown No machinery protection action is active on any engine For...

Page 286: ...adjust and control the phase angle offset 2 Use the LDU wheel to get the correct values for SPS Phase Angle Offsets 001 see Figure 6 36 page 3 Push the LDU wheel to select the field rotate the LDU whe...

Page 287: ...es which shows the below data The TDC data received from the engines The current reference speed of the engines The running ahead of the engines The actual speed of the engines The speed set points di...

Page 288: ...Fig 6 37 Crank Angle and Speed States LDU page X72 B AA00 0000 00AAA 043V A Operation Manual Synchro phasing system Winterthur Gas Diesel Ltd 288 Issue 003 2021 12...

Page 289: ...X72 B AA00 0000 00AAA 043V A Operation Manual Synchro phasing system Page left intentionally blank Winterthur Gas Diesel Ltd 289 Issue 003 2021 12...

Page 290: ...OTE Make sure that there are labels attached to the cables 9 Loosen the cables fixing rail from the module housing 003 10 Loosen the six screws 006 NOTE Make sure that you do not remove them completel...

Page 291: ...ware and config image check initiated U CK software and config image check initiated U PU pull update check initi ated U PU pull update check initiated U PU pull update check initiated U SI push singl...

Page 292: ...en the cables fixing rail from the module housing 004 9 Loosen the six screws 005 NOTE Make sure do not remove them completely 10 Remove the control module carefully 006 11 Attach a Faulty label to th...

Page 293: ...g image check initiated U PU pull update check initiat ed U PU pull update check initiated U PU pull update check initiated U SI push single update initiat ed U SI push single update initiated SM I US...

Page 294: ...el to the control module NOTE If the part need to be returned to WinGD service station fill the return sheet attached to the box of the spare control module 12 Install the new control module 006 13 Ti...

Page 295: ...te initiat ed U SI push single update initiated SM I USM state Initialization U SW software update initiated U CF config update initiated SM R USM state Ready Reboot Reboot Blank Fig 6 40 WiCE Cylinde...

Page 296: ...t need to be returned to WinGD service station fill the return sheet attached to the box of the spare control module 9 Install the new control module 004 10 Tighten the six screws 003 to attach the co...

Page 297: ...WiCE Angle Control Unit ACM20 module replacement 002 001 003 004 X72 B AA00 0000 00AAA 200E A Operation Manual WiCE Angle Control Unit ACM20 module replacment Winterthur Gas Diesel Ltd 297 Issue 003...

Page 298: ...tach a Faulty label to the control module NOTE If the part need to be returned to WinGD service station fill the return sheet attached to the box of the spare control module 9 Attach new MCP either to...

Page 299: ...replacement E26 001 002 Fig 6 43 WiCE Manual Control Panel MCP replacement Back Cover 003 002 004 001 X72 B AA00 0000 00AAA 200F A Operation Manual WiCE Manual Control Panel MCP replacement Winterthu...

Page 300: ...g 2 right link down Re establish the wiring of the Ethernet Ring 2 TRX R2 to the adjacent control module E L1 Ethernet ring 1 left link down Re establish the wiring of the Ethernet Ring 1 TRX L1 to th...

Page 301: ...7 Installation 7 1 Installation 302 X72 B Operation Manual Winterthur Gas Diesel Ltd 301 Issue 003 2021 12...

Page 302: ...es Outline views Platform arrangement Engine seating Engine coupling Propulsion shaft earthing Engine stays Extinguishing system Auxiliary systems NOTE The latest version of the Marine Installation Ma...

Page 303: ...eneral 332 8 11 Change over the diesel fuel automatically 336 8 12 Change over from HFO to MDO manually 338 8 13 Change over from MDO to HFO manually 340 8 14 Stop the engine general 342 8 15 Stop the...

Page 304: ...il system Make sure that the quality of the system oil obeys the related specifications Make sure that main lubricating oil is available at the engine connection 25 main lubricating oil inlet Make sur...

Page 305: ...ure that the quality of the gas obeys the related specifications in section section not applicable for this engine Make sure that gas is available at the engine connection 78 gas supply inlet Pilot fu...

Page 306: ...ion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No C...

Page 307: ...tem ECS and the remote control system RCS 2 2 Set to ON all circuit breakers in the power supply box E85 2 3 Set to ON the control box for the cylinder oil filter refer to the documentation of the man...

Page 308: ...valves 003 in the cylinder liner supply pipes of the first half of cylinders for example cylinder 1 to 3 for a 5 or 6 cylinder engine NOTE This increases again the pressure and thus the flow rate to t...

Page 309: ...Close the shut off valves 001 in the cylinder liner supply pipes of the first half of cylinders for example cylinder 1 to 3 for a 5 or 6 cylinder engine NOTE This increases the pressure and thus the...

Page 310: ...he other cylinder liners for approximately ten minutes 3 3 3 Open the shut off valves 003 in the cylinder liner supply pipes of the first half of cylinders 3 3 4 Do Step 3 3 1 to Step 3 3 3 again for...

Page 311: ...ure in the oil supply pipes Pressure before the torsional vibration damper if applicable Pressure in the servo oil rail only pressure of servo oil service pump Pressure in the distributor pipe mini ra...

Page 312: ...the engine has been stopped for more than approximately five days start a manual pre lubrication procedure NOTE This makes sure that the cylinders get sufficient lubrication before start up 13 Turn t...

Page 313: ...X72 B AA00 0000 00AAA 121A A Operation Manual Prepare the engine before start Page left intentionally blank Winterthur Gas Diesel Ltd 313 Issue 003 2021 12...

Page 314: ...on You can find data about the barred speed ranges near the telegraph on the bridge near the local control panel and in the related documentation of vibration calculations 8 3 2 Start conditions limit...

Page 315: ...etween 10 as a minimum to approximately 15 related to the power of the auxiliary blowers 8 3 2 2 One or more cylinders are unservicable Obey the rules for operation if one or more cylinders are unserv...

Page 316: ...completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description P...

Page 317: ...panel to 30 5 Push the button START AHD or START AST to start the engine NOTE The ECS starts an automatic pre lubrication sequence with a specified number of pulses NOTE The ECS increases the engine s...

Page 318: ...erences in the values find the causes and repair the faults Do not open the covers of the rail unit during engine operation NOTE For data about regular maintenance work refer to the Maintenance Manual...

Page 319: ...X72 B AA00 0000 00AAA 130B A Operation Manual Do checks during operation general Page left intentionally blank Winterthur Gas Diesel Ltd 319 Issue 003 2021 12...

Page 320: ...s after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts De...

Page 321: ...ontrol air Pressure difference of the oil filter For a DF engine also pressure of gas 8 If there are unusual operating values find the cause and repair the fault 9 Do regular checks of pipes for leaks...

Page 322: ...replace the related pressure transmitter refer to the Maintenance Manual 13 4 Do daily a check of the cylinder liner wall temperatures on the related control panel 13 5 If there is a drift that is to...

Page 323: ...X72 B AA00 0000 00AAA 131B A Operation Manual Do checks during operation Page left intentionally blank Winterthur Gas Diesel Ltd 323 Issue 003 2021 12...

Page 324: ...50 1 Smoke test instrument N A 1 Ampere meter N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Equipment Hazard Leaks can cause faults in the...

Page 325: ...s 3 5 Decrease the pressure to less than the SHD pressure 3 6 Make sure that the pressure switch closes at the related pressure 3 7 If the pressure switch does not close find the cause and repair the...

Page 326: ...a check of the wiring to the starter box 7 9 Stop the auxiliary blowers 7 10 On the IOM 10 connect terminal X11 7 11 Get control at the local control panel 7 12 Do Step 7 1 to Step 7 10 again from th...

Page 327: ...id valves CV7013C and CV7014C 8 11 Disengage the turning gear NOTE On each control panel the indication changes to Turning Gear Disengaged The start command is canceled in the remote control 9 If ther...

Page 328: ...ction Load changes must be done slowly to let the piston rings adapt the new conditions This also prevents increased wear and contamination of the piston rings and the cylinder liners The total time t...

Page 329: ...gine If there are unusual indications you must decrease the load power The load indication fuel injection quantity and the exhaust gas temperature upstream of the turbocharger show the engine load The...

Page 330: ...quirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare...

Page 331: ...er the ship general 3 To operate the engine in the opposite direction do the steps that follow 3 1 Use the rotary button to select the fuel command button 3 2 Turn the rotary button to set the fuel in...

Page 332: ...ample fuel pump plungers The safety functions decrease the risk of damage because of thermal loads You can do the change over procedure at a load of up to 100 CMCR The time period for automatic change...

Page 333: ...as no iCAT system integrated Cylinder lubricant Auto Transfer system WinGD recommends to monitor the change over of the cylinder oil Do a calculation of the cylinder lubricant quantity and make sure t...

Page 334: ...ensity of the cylinder lubricant can be found in the technical data sheet If not available an average value of 920 3 is suitable for this purpose Lead time until new lubricant is in use 1000 00595 X72...

Page 335: ...X72 B AA00 0000 00AAA 130D A Operation Manual Change over the diesel fuel general Page left intentionally blank Winterthur Gas Diesel Ltd 335 Issue 003 2021 12...

Page 336: ...lization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINAR...

Page 337: ...omatic change over procedure refer to the instructions of the manufacturer CLOSE UP None X72 B AA00 0000 00AAA 131E A Operation Manual Change over the diesel fuel automatically Winterthur Gas Diesel L...

Page 338: ...zation QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY...

Page 339: ...the procedure Try to decrease the temperature as linearly as possible 9 When the temperature of the fuel is near the applicable value you can start the cooler slowly to give a linear and smooth temper...

Page 340: ...zation QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY...

Page 341: ...ple the larger the mixing tank the less decrease in load is necessary 8 Set the viscosimeter to 13 cSt to increase the temperature of the fuel NOTE The viscosimeter controls the end heater which keeps...

Page 342: ...burns NOTE If the crankshaft cannot turn 360 the ECS sends a signal for an exhaust ventilation request The ESS or ECS sends a cancelable shutdown signal The engine safety system ESS or the ECS sends...

Page 343: ...X72 B AA00 0000 00AAA 130G A Operation Manual Stop the engine general Page left intentionally blank Winterthur Gas Diesel Ltd 343 Issue 003 2021 12...

Page 344: ...completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description P...

Page 345: ...rol panel push the STOP button NOTE The ECS shuts down the engine in a controlled manner 4 For a DF engine start the exhaust ventilation sequence if there is a ventilation request CLOSE UP None X72 B...

Page 346: ...neral To stop the engine in an emergency do the procedure given in section 8 17 Emergency stop the engine X72 B AA00 0000 00AAA 140A A Operation Manual Emergency stop the engine general Winterthur Gas...

Page 347: ...X72 B AA00 0000 00AAA 140A A Operation Manual Emergency stop the engine general Page left intentionally blank Winterthur Gas Diesel Ltd 347 Issue 003 2021 12...

Page 348: ...letion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part N...

Page 349: ...r an emergency stop you must reset the EMERGENCY STOP button CAUTION Damage Hazard Do this step only as a last alternative selection if the EMERGENCY STOP button is not working Damage to the engine ca...

Page 350: ...er an engine stop of one week or less usually you keep the auxiliary systems in operation refer to section 8 19 Prepare the engine for a short service break For a long period after an engine stop of m...

Page 351: ...X72 B AA00 0000 00AAA 150A A Operation Manual Prepare the engine after stop general Page left intentionally blank Winterthur Gas Diesel Ltd 351 Issue 003 2021 12...

Page 352: ...ours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None S...

Page 353: ...rd Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine 5 Operate the turning gear for a short period at the intervals that follow Daily in damp clima...

Page 354: ...ours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None S...

Page 355: ...lubricating oil supply to the engine as follows 6 1 Stop the oil supply systems from the plant 6 2 Close the shut off valves to the engine at engine connection 33 cylinder oil inlet 6 3 Set to OFF the...

Page 356: ...are in degassing state 8 2 2 On the iGPR cabinet switch the button S8 to maintenance to activate the maintenance mode 8 2 3 On the LDU 20 iGPR page make sure that all conditions are satisfactory 8 2 4...

Page 357: ...sary apply anti corrosion oil to give protection 11 5 Close the covers 12 Do a check of the supply unit as follows 12 1 Make sure that there is no condensation or corrosion 12 2 If you find condensati...

Page 358: ...t is possible to change directly from Tier II mode to Tier III mode without changing to Prepare to Tier III mode However this direct change can fail It is recommended to change from Tier II to Prepare...

Page 359: ...Fig 8 5 Select Prepare Tier III X72 B AA00 9270 00AAA 100B A Operation Manual LP SCR system Change Tier mode Winterthur Gas Diesel Ltd 359 Issue 003 2021 12...

Page 360: ...Fig 8 6 Select Tier III X72 B AA00 9270 00AAA 100B A Operation Manual LP SCR system Change Tier mode Winterthur Gas Diesel Ltd 360 Issue 003 2021 12...

Page 361: ...major failure occurs or if the emergency bypass switch is operated the LP SCR will change back to Tier II mode X72 B AA00 9270 00AAA 100B A Operation Manual LP SCR system Change Tier mode Winterthur G...

Page 362: ...X72 B AA00 9270 00AAA 100B A Operation Manual LP SCR system Change Tier mode Page left intentionally blank Winterthur Gas Diesel Ltd 362 Issue 003 2021 12...

Page 363: ...element of the duplex filter 370 9 4 Clean the turbocharger during operation 372 9 5 Clean the scavenge air cooler during operation 374 9 6 Do a test of the exhaust waste valve 378 9 7 Running in of n...

Page 364: ...one Supplies Description QTY Sample bottles A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard The system oil is hot Put on gloves and safety goggles to prevent...

Page 365: ...l the sample bottle NOTE The necessary quantity of oil is as follows 100 ml for regular oil analysis 5 l for FZG and particle count analysis 2 3 Close the sample valve 2 4 Close the sample bottle tigh...

Page 366: ...ialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Sample bottles A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTIO...

Page 367: ...valve 001 to flush out oil and possible dirt 2 4 Close the oil sample valve 001 2 5 Open the ball valve 002 to drain the remaining oil from the dirty oil pipe 003 2 6 Close the ball valve 002 3 Get a...

Page 368: ...om 8 Send the oil samples to a laboratory for an oil analysis 8 1 Make sure that the sample bottles are tightly closed 8 2 Put the sample bottles in an applicable package 9 Compare the oil analysis fr...

Page 369: ...X72 B AA00 0000 00AAA 371A A Operation Manual Do an analysis of the cylinder oil Page left intentionally blank Winterthur Gas Diesel Ltd 369 Issue 003 2021 12...

Page 370: ...er job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Pa...

Page 371: ...lean the filter chamber 6 Clean the filter element or take a new filter element 7 Install the new filter element into the filter chamber 8 Install the cover on the filter chamber 9 Make sure that the...

Page 372: ...termediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Cleaning fluid A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Damage Hazard For an...

Page 373: ...turbocharger refer to the documentation of the manufacturer 3 Clean the turbine of the turbocharger refer to the documentation of the manufacturer CLOSE UP None X72 B AA00 6500 00AAA 200A A Operation...

Page 374: ...s after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Cleaning fluid A R...

Page 375: ...Aux Blower 13 LS 4075A LS 4071A PI 1361L TI 1371L TI 1381L PT 1361A TE 1371A TE 1381A Washing Plant SAC PLANT ENGINE PLANT ENGINE 003 00520 004 005 006 007 008 009 001 002 X72 B AA00 6600 00AAA 200A...

Page 376: ...e tank 006 NOTE You can also use a hand held container filled with cleaning fluid mixed with fresh water to put into the funnel When you use this method make sure that the shut off valve in the supply...

Page 377: ...X72 B AA00 6600 00AAA 200A A Operation Manual Clean the scavenge air cooler during operation Page left intentionally blank Winterthur Gas Diesel Ltd 377 Issue 003 2021 12...

Page 378: ...crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS This procedur...

Page 379: ...e sure that the exhaust waste gate is open 3 Close the exhaust waste valve 4 If the check is incorrect find the cause and repair the fault CLOSE UP None X72 B AA00 8135 00AAA 320A A Operation Manual D...

Page 380: ...her feed rate refer to Figure 9 3 WinGD recommends an inspection of the cylinder liners and of the piston rings after 24 operation hours and after 72 operation hours 001 Figure 9 3 For this running in...

Page 381: ...X72 B AA00 0000 00AAA 950B A Operation Manual Running in of new components general Page left intentionally blank Winterthur Gas Diesel Ltd 381 Issue 003 2021 12...

Page 382: ...Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIO...

Page 383: ...8 Set the feed rate to 1 0 g kWh 9 Operate the engine for 24 hours 10 Inspect the components for damage 11 If damage occurs find the cause and repair the fault 12 If it is necessary to replace parts...

Page 384: ...X72 B AA00 0000 00AAA 950A A Operation Manual Running in of new components Page left intentionally blank Winterthur Gas Diesel Ltd 384 Issue 003 2021 12...

Page 385: ...age 426 10 10 Servo oil pump troubleshooting 428 10 11 Servo oil pump Calibration for Bosch pump 430 10 12 Servo oil pump Calibration for Hawe pump 432 10 13 Fuel pump cutting out 434 10 14 Fuel pump...

Page 386: ...repair malfunctions on the engine The tables give the data that follow Title of the table The title of the table gives the description of the malfunction Indication This list specifies the number of...

Page 387: ...X72 B AA00 0000 00AAA 410B A Operation Manual Troubleshooting general data Page left intentionally blank Winterthur Gas Diesel Ltd 387 Issue 003 2021 12...

Page 388: ...flow at a servo oil pump inlet is too low Table 10 14 Bearing oil temperature at a bearing outlet is too high Table 10 15 Oil mist concentration is too high Table 10 16 Piston cooling oil temperature...

Page 389: ...ble 10 43 Scavenge air temperature in the receiver is too high Table 10 44 Scavenge air temperature in the receiver is too low Table 10 45 Scavenge air pressure is too high Table 10 46 Scavenge air pr...

Page 390: ...e 10 61 Unwanted engine speed decrease Table 10 62 Unwanted engine stop X72 B AA00 0000 00AAA 410C A Operation Manual Malfunctions of systems and components Winterthur Gas Diesel Ltd 390 Issue 003 202...

Page 391: ...rature downstream of a cylinder is too high Indication Possible cause Procedure TE1121 nnA This is a result of the malfunction in Table 10 1 Supply pressure of the cylinder cooling water is too low Do...

Page 392: ...too high Indication Possible cause Procedure TE1381 nnA This is a result of the malfunction in Table 10 4 Supply pressure of the cooling water to the SAC is too low Do the repair shown there This is...

Page 393: ...ion Possible cause Procedure TE2011A TE2012A if applica ble The oil supply system is defective Find the cause and repair the fault Tab 10 10 Lubricating oil supply pressure upstream of the crossheads...

Page 394: ...nnA TE2201 nnA TE2301 nnA This is a result of the malfunction in Table 10 7 Lubricating oil supply pressure at the engine inlet is too low Do the repair shown there A bearing is defective Find the cau...

Page 395: ...oil temperature at a turbocharger outlet is too high Indication Possible cause Procedure TE2601 nnA This is a result of the malfunction in Table 10 9 Lubricating oil supply temperature at the engine i...

Page 396: ...ent is clogged Change over to the other filter chamber Replace or clean the clogged filter element The cylinder oil tank is empty Fill the cylinder oil tank Tab 10 24 Cylinder oil flow is too low Indi...

Page 397: ...ible cause Procedure TE3431 nnA Flow control valve of a fuel pump is defective Clean or replace the defective flow control valve One of the two fuel pumps is de fective Replace the defective fuel pump...

Page 398: ...related fuel pump Flow control valve of a fuel pump is defective Clean or replace the defective flow control valve Tab 10 33 Fuel pressure in the fuel rail is too low for X35 B or X40 B engine Indica...

Page 399: ...ication Possible cause Procedure PS3464A The pilot fuel filter is clogged Replace the filter element Tab 10 36 Gas supply pressure is too low Indication Possible cause Procedure PT3901C The gas supply...

Page 400: ...example cracks in a cylinder liner Find the cause and repair the fault There is a fire in the piston under side Do the procedure in section 2 4 Fire fighting in the scavenge air space Tab 10 38 Exhaus...

Page 401: ...ng air pressure is too low Find the cause and repair the fault The opening oil pressure is too low Find the cause and repair the fault An exhaust valve is defective pis ton cannot move or a piston is...

Page 402: ...malfunction in Table 10 5 Supply temperature of the cooling water to the SAC is too low Do the repair shown there Tab 10 45 Scavenge air pressure is too high Indication Possible cause Procedure PT404...

Page 403: ...fire in the piston underside Refer to section 2 4 Fire fighting in the scav enge air space A piston ring is defective As a temporary procedure decrease the load and cut out the injection of the relate...

Page 404: ...air supply system is de fective Find the cause and repair the fault There is an incorrect setting of the control air supply Set the control air supply to the correct val ue Tab 10 55 Control air suppl...

Page 405: ...tive injection nozzle This is a result of the malfunction in Table 10 1 Supply pressure of the cylinder cooling water is too low or in Table 10 3 Cylinder cooling wa ter temperature downstream of a cy...

Page 406: ...ection quantity from the speed control system is decreased A procedure is not necessary because the control system prevents too much load in heavy sea The fuel injection system is defec tive Find the...

Page 407: ...X72 B AA00 0000 00AAA 410C A Operation Manual Malfunctions of systems and components Page left intentionally blank Winterthur Gas Diesel Ltd 407 Issue 003 2021 12...

Page 408: ...the requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare...

Page 409: ...003 Screw plug 002 Flange 4 Do Step 3 again for the other inspection points NOTE Step 5 to Step 8 are only applicable for an X82 engine 5 Do a check of the level switch LS2076A if applicable also LS2...

Page 410: ...mum of two turns 8 2 Do a check for oil flow 8 3 If there is an oil flow shut off the related connecting pipe an repair it at the next occasion refer to the Maintenance Manual 8 4 Tighten the screw pl...

Page 411: ...X72 B AA00 0000 00AAA 311A A Operation Manual Examine the supply unit for servo oil leakage Page left intentionally blank Winterthur Gas Diesel Ltd 411 Issue 003 2021 12...

Page 412: ...ngine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Always put on...

Page 413: ...005 at the highest inspection point 004 for leaks 4 1 Carefully loosen the screw plug a maximum of two turns 4 2 Do a check for fuel flow 4 3 If there is fuel flow repair the cause of the fuel flow a...

Page 414: ...fuel pump refer to the Maintenance Manual 5556 1 NOTE If the defective HP fuel pipe cannot be replaced immediately or the engine must continue to operate the related fuel pump must be cut out CLOSE U...

Page 415: ...X72 B AA00 0000 00AAA 311B A Operation Manual Examine the supply unit for fuel leakage Page left intentionally blank Winterthur Gas Diesel Ltd 415 Issue 003 2021 12...

Page 416: ...alization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard...

Page 417: ...2 Carefully look into the rail unit to find the cause of the leakage NOTE Possible causes can be a defective pipe to the exhaust valve a defective flange or an other defective item 3 Repair the defec...

Page 418: ...ngine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Always put on...

Page 419: ...3 1 Make sure that the screws 002 are tightened correctly refer to the Maintenance Manual 8733 1 3 2 On the fuel leakage pipe 004 carefully loosen the screw in union 003 a maximum of two turns 3 3 Do...

Page 420: ...nion 007 a maximum of two turns 4 3 Do a check of the fuel flow 4 4 If fuel flows from the screw in union 007 more than usual compared to the amount of leakage from the other FLV the piston rod is def...

Page 421: ...X72 B AA00 0000 00AAA 311C A Operation Manual Examine the FLV or fuel pipes for fuel leakage Page left intentionally blank Winterthur Gas Diesel Ltd 421 Issue 003 2021 12...

Page 422: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Pa...

Page 423: ...tion from the injection control unit ICU 4 If it is necessary to operate the engine with the injection cut out for an extended period do as follows 4 1 Record the settings of the cylinder oil feed rat...

Page 424: ...nel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS...

Page 425: ...the related exhaust valve control unit VCU 3 Repair the fault as soon as possible refer to the Maintenance Manual CLOSE UP The engine can be started and operated at decreased load refer to section 8...

Page 426: ...tion Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY Pressure element 94259 A R Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY P...

Page 427: ...the pressure element 003 4 Cut out the defective cylinder from the injection refer to section 10 7 Temporary cut out a defective injection valve 5 Disconnect the electrical connection to the related e...

Page 428: ...ervo oil pump operation 10 10 2 Servo oil pump operation check To check for the servo oil pump operation refer to the following instructions 1 Engine must be at low load 2 Remove the solenoid connecto...

Page 429: ...X72 B AA00 5551 00AAA 410A A Operation Manual Servo oil pump troubleshooting Page left intentionally blank Winterthur Gas Diesel Ltd 429 Issue 003 2021 12...

Page 430: ...t 7 Monitor the condition for 5 minutes on the pump angle indicators NOTE If the pump angle indicators show different angles an adjustment of the pump angles is required 8 Put the plastic cover on the...

Page 431: ...X72 B AA00 5551 00AAB 273A A Operation Manual Servo oil pump Calibration for Bosch pump Page left intentionally blank Winterthur Gas Diesel Ltd 431 Issue 003 2021 12...

Page 432: ...degrees 5 Tighten the locknut 6 Monitor the condition for 5 minutes on the pump angle indicators NOTE If the pump angle indicators show different angles an adjustment of the pump angles is required 7...

Page 433: ...X72 B AA00 5551 00AAC 273A A Operation Manual Servo oil pump Calibration for Hawe pump Page left intentionally blank Winterthur Gas Diesel Ltd 433 Issue 003 2021 12...

Page 434: ...escription QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury hazard The cutting out procedure can only be done when the engine is stop WARNING Injury hazard Befor...

Page 435: ...tation in available engine power based on engine configuration and rating Power can be increased to that when the fuel rail pressure starts to drop PRELIMINARY OPERATIONS The engine must be stopped an...

Page 436: ...DURE Fig 10 4 Location of flanges 1 Release the pressure of the fuel supply unit to 0 bar X72 B AA00 5556 00AAB 510B A Operation Manual Fuel pump cutting out Winterthur Gas Diesel Ltd 436 Issue 003 20...

Page 437: ...g 004 NOTE Make sure that the applicable supply unit cam is at TDC and if not do Step 7 Fig 10 5 Roller lifting tool assembly 7 Operate the turning gear to turn the supply unit cam at TDC to push the...

Page 438: ...4 Remove the pre tensioner 005 Refer to the Maintenance Manual for more information 15 Make sure that the roller 007 is approximately 3 0 mm above the cam 006 16 Install the cover 006 Figure 10 5 NOTE...

Page 439: ...X72 B AA00 5556 00AAB 510B A Operation Manual Fuel pump cutting out Page left intentionally blank Winterthur Gas Diesel Ltd 439 Issue 003 2021 12...

Page 440: ...Pre tensioner 94430A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury hazard The cutting in procedure can only be done when the engine is...

Page 441: ...engine must be stopped and prepared for maintenance refer to section 8 18 Prepare the engine after stop general X72 B AA00 5556 00AAB 730B A Operation Manual Fuel pump cutting in Winterthur Gas Diesel...

Page 442: ...DURE Fig 10 7 Location of flanges 1 Release the pressure of the fuel supply unit to 0 bar X72 B AA00 5556 00AAB 730B A Operation Manual Fuel pump cutting in Winterthur Gas Diesel Ltd 442 Issue 003 202...

Page 443: ...er 007 Figure 10 8 of the guide piston 001 is at the highest position 8 Install the pre tensioner 005 on to the elastic bolt 004 9 Make sure that pre tensioner 005 touches the pad 003 10 Use the pre t...

Page 444: ...job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY Cover A R Cover A R Cover A R Cover A R Supplies Descript...

Page 445: ...er and the exhaust gas manifold 2 3 Install the covers 94653A and 94653B 001 and 002 2 4 Remove the expansion joint 005 between the defective turbocharger air outlet and the diffusor 2 5 Install the c...

Page 446: ...001 if the turbochargers are connected to a suction duct 3 4 Open the covers 003 and 004 on the scavenge air receiver 3 5 Set to ON the auxiliary blowers Fig 10 10 All turbochargers are defective exam...

Page 447: ...X72 B AA00 6500 00AAA 662A A Operation Manual Temporary isolate a defective turbocharger Page left intentionally blank Winterthur Gas Diesel Ltd 447 Issue 003 2021 12...

Page 448: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Pa...

Page 449: ...PROCEDURE X72 B AA00 8135 00AAA 662A A Operation Manual Temporary isolate the exhaust waste gate Winterthur Gas Diesel Ltd 449 Issue 003 2021 12...

Page 450: ...o middle screws 3 Turn the flange 008 to close the exhaust waste gate 4 Tighten the screws to attach the flange 008 5 Start the engine CLOSE UP None X72 B AA00 8135 00AAA 662A A Operation Manual Tempo...

Page 451: ...X72 B AA00 8135 00AAA 662A A Operation Manual Temporary isolate the exhaust waste gate Page left intentionally blank Winterthur Gas Diesel Ltd 451 Issue 003 2021 12...

Page 452: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Pa...

Page 453: ...e shaft clutch are unserviceable make sure that you operate the auxiliary systems 4 If installed change the pitch of the controllable propeller CPP to the lowest resistance WARNING Injury Hazard Do no...

Page 454: ...l Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY Cover 2 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PREC...

Page 455: ...overs example for 1 turbocharger V1 001 001 V2 Legend 001 Cover V2 SCR outlet valve V1 SCR inlet valve X72 B AA00 9270 00AAA 720C A Operation Manual Temporary isolate the HP SCR system Winterthur Gas...

Page 456: ...the flange downstream of the valve V1 2 Install the Cover 001 Figure 10 11 or Figure 10 12 to the flange 3 Remove the pipe to the SCR system from the flange upstream of the valve V2 4 Install the cov...

Page 457: ...X72 B AA00 9270 00AAA 720C A Operation Manual Temporary isolate the HP SCR system Page left intentionally blank Winterthur Gas Diesel Ltd 457 Issue 003 2021 12...

Page 458: ...nel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECA...

Page 459: ...rs example for 1 turbocharger V1 001 001 V2 Legend 001 Cover V2 SCR outlet valve V1 SCR inlet valve X72 B AA00 9270 00AAA 520C A Operation Manual Connect the HP SCR system after isolation Winterthur G...

Page 460: ...re 10 14 from the flange downstream of the valve V1 2 Install the pipe to the SCR system to the flange 3 Remove the cover 001 from the flange upstream of the valve V2 4 Install the pipe to the SCR sys...

Page 461: ...X72 B AA00 9270 00AAA 520C A Operation Manual Connect the HP SCR system after isolation Page left intentionally blank Winterthur Gas Diesel Ltd 461 Issue 003 2021 12...

Page 462: ...em failure 10 20 2 Failures in LP SCR Tab 10 63 Hardwired ID failure to MCM n Indication on LDU Possible cause Procedure Hardwired ID failure MCM 1 Hardwire ID failure to MCM 1 Re establish the cablin...

Page 463: ...s bit for hardware signal failure Urea dosing setpoint NOTE This failure can occur due to short circuit or wire break Re establish the wiring between E70 and external dosing system Urea feedback input...

Page 464: ...point is not reached when the urea dosing in requested Do a detail check of the external dosing system Tab 10 69 SCR alarm failure Indication on LDU Possible cause Procedure SCR Alarm Stop CAN sent a...

Page 465: ...the auxiliary blower 2 op erating signal in specified time inter val Parameter PAR_AuxBI_FailDelay Do a check of the auxiliary blow er control box External SCR common alarm SCR system sends common ala...

Page 466: ...cables for power input 1 and 2 For power input 1 Re establish the cabling X24 1 2 For power input 2 Re establish the cabling X34 1 2 10 20 3 Sequence failure A sequence failure occurs when a specifie...

Page 467: ...X72 B AA00 0000 00AAD 410A A Operation Manual LP SCR Alarm failure troubleshooting Page left intentionally blank Winterthur Gas Diesel Ltd 467 Issue 003 2021 12...

Page 468: ...engine under special running conditions for more than 2 5 days can damage the engine If the engine is run under special running conditions for more than that contact the engine builder to obtain advic...

Page 469: ...s is 40 The load restriction for 1 out of 3 turbochargers is 55 The load restriction can be increased considerably if an orifice plate is also inserted in the turbine inlet NOTE If reducing the load d...

Page 470: ...ial running condition E For engines with two or more turbochargers 1 Stop the engine 2 Open the cover E 3 Lock the rotor of the faulty turbocharger check your turbocharger manual for details 4 Remove...

Page 471: ...Lock the rotor of the faulty turbocharger check your turbocharger manual for details 4 Insert the blanking plate T1 T2 T3 T4 according to your turbocharger manual 5 Remove the compensator 1 between t...

Page 472: ...Fig 10 16 Turbocharger cut out procedure Illustration 2 X72 B AA00 0000 00AAB 100A A Operation Manual Special running condition Turbocharger cut out Winterthur Gas Diesel Ltd 472 Issue 003 2021 12...

Page 473: ...Fig 10 17 Turbocharger cut out procedure Illustration 3 X72 B AA00 0000 00AAB 100A A Operation Manual Special running condition Turbocharger cut out Winterthur Gas Diesel Ltd 473 Issue 003 2021 12...

Page 474: ...Fig 10 18 Turbocharger cut out procedure Illustration 4 X72 B AA00 0000 00AAB 100A A Operation Manual Special running condition Turbocharger cut out Winterthur Gas Diesel Ltd 474 Issue 003 2021 12...

Page 475: ...is chapter an auxiliary blower becomes inoperative it will automatically be cut out thanks to the built in non return valve This will restrict the operation of the engine X72 B AA00 0000 00AAB 100A A...

Page 476: ...s for more than that contact the engine builder to obtain advice NOTE If only the fuel for the respective cylinders is cut off while the same time the starting air connections remain intact then the e...

Page 477: ...exhaust valve are still working and the compression is off 1 On the LDU access the Fuel Injection Adjust Page 2 On the page turn off the fuel injection for the corresponding cylinder 3 Disconnect the...

Page 478: ...If the exhaust valve isn t completely closed disconnect the plug for the cylinder starting valve 8 After 15 minutes of running open the crankcase and check The bearings The temporarily secured parts T...

Page 479: ...now cut out and the engine performs under special running conditions E Cylinder cut out while the piston piston rod crosshead and connecting rod are all totally out 1 Stop the engine 2 On the LDU acc...

Page 480: ...bearings The temporarily secured parts The oil flow through bearings The tightness of blanked off openings The cylinder is now cut out and the engine performs under special running conditions Fig 10 2...

Page 481: ...Engine data 482 11 2 List of usual values and safeguard settings general 484 11 3 List of usual values and safeguard settings 488 11 4 Section views 500 X72 B Operation Manual Winterthur Gas Diesel Lt...

Page 482: ...d reference conditions Total barometric pressure is 1 0 bar Suction air temperature is 25 C Relative humidity is 30 Cooling water temperature at the engine inlet is 25 C BSFC This list gives the Brake...

Page 483: ...5 4 15 4 R3 66 2910 163 8 6 8 21 21 R4 66 2120 159 3 6 8 15 4 15 4 Fig 11 1 Operating range R1 R2 R4 R3 S P Legend R1 Highest power at highest speed R4 Lowest power at lowest speed R2 Lowest power at...

Page 484: ...operation the current values can have small differences to the given values Signal number This list gives the signal number as follows refer also to Para 11 2 2 First two letters XX Function code Four...

Page 485: ...ximum concentration For the level switches LS and flow switches FS min minimum or no flow max maximum flow Delay This list gives the delay of the action in seconds after the trigger value occurs X72 B...

Page 486: ...de Code First position Second position A Analysis n a C Control Control E n a Element F Flow n a G Gauge n a H Hand n a I n a Indication J Power n a L Level n a P Pressure n a S Speed Switch T Tempera...

Page 487: ...o 49 Signals from the engine Air systems 50 to 59 Signals from the engine Miscellaneous 60 to 69 Signals from the engine Spare 70 to 79 Signals to the engine Miscellaneous 80 to 89 Signals to the engi...

Page 488: ...2NNN part 1 Table 11 8 Oil systems XX2NNN part 2 Table 11 9 Oil systems XX2NNN part 3 turbocharger bearing oil Table 11 10 Oil systems XX2NNN part 4 Table 11 11 Fuel system XX34NN Table 11 12 Exhaust...

Page 489: ...ion 03 90 2 1 90 4 2 TE1121 nnA ALM H 95 0 SLD H 97 60 Scavenge air cooler SAC SAC LT cooling water pressure bar en gine inlet connection 07 2 5 to 4 PT1361A ALM L 2 0 0 SAC LT cooling water temperatu...

Page 490: ...bricating oil pressure bar inlet injectors 4 2 to 5 PT2003A ALM L 2 6 4 0 Bearing oil Main bearing oil temperature C outlet each main bearing optional 45 to 60 TE2101 nnA ALM H 65 0 SLD H 70 60 Crank...

Page 491: ...H max 0 AS2401A ALM H max 0 AS2401S SLD H max 60 Oil mist concentration gearcase AE2415A ALM H max 0 Oil mist concentration fuel supply unit AE2421A ALM H max 0 Piston cooling oil Piston cooling oil t...

Page 492: ...ger 45 to 80 TE2621A ALM H 85 0 SLD H 90 60 TC bearing oil temperature C outlet each turbocharger 45 to 120 TE2601 nnA ALM H 130 0 SLD H 140 60 Bearing oil turbocharger MHI MET with internal oil TC be...

Page 493: ...t side 1 8 to 5 0 PT2721A ALM L 1 7 60 Damper oil pressure bar axial vibration damper space fore side 1 8 to 5 0 PT2722A ALM L 1 7 60 Cylinder oil Cylinder oil pressure bar cylinder oil rail 0 3 PT312...

Page 494: ...fuel supply unit 7 5 to 10 2 PT3421A ALM L 7 0 Fuel temperature C inlet fuel supply unit 3 20 to 150 TE3411A ALM H 50 to 160 0 ALM L 20 to 130 0 Fuel leakage flow outlet fuel supply unit LS3426A ALM H...

Page 495: ...gas temperature C outlet each cylinder TE3701 nnA ALM H 515 0 ALM D 50 0 SLD H 530 60 SLD D 70 60 Exhaust gas temperature C inlet each turbocharger TE3721 nnA ALM H 515 0 SLD H 530 60 Exhaust gas tem...

Page 496: ...ng air supply Starting air supply pressure bar engine inlet connection 40 20 to 30 Control air supply unit Control air supply pressure bar engine inlet connection 45 7 to 9 Control air pressure bar ou...

Page 497: ...ide 230 TE4841 nnC ALM H 250 0 SLD H 270 60 Powertrain Crankshaft speed of CMCR crankshaft ST5111 12S SHD H 110 0 Tachometer turbocharger Impeller shaft overspeed rpm each ABB turbocharger ST5201 nnA...

Page 498: ...o Table 11 15 Failure messages Tab 11 15 Failure messages Medium location Signal number Delay Failure of oil mist detector XS2411A 0 Failure of fuel heating XS3463A 0 Failure of fuel pump actuator XS5...

Page 499: ...X72 B AA00 0000 00AAA 033B A Operation Manual List of usual values and safeguard settings Page left intentionally blank Winterthur Gas Diesel Ltd 499 Issue 003 2021 12...

Page 500: ...11 4 Section views X72 B AA00 0000 00AAA 034A A Operation Manual Section views Winterthur Gas Diesel Ltd 500 Issue 003 2021 12...

Page 501: ...2 Operating media 12 1 General for operating media 502 12 2 Compressed air 504 12 3 Scavenge air 506 12 4 Diesel engine fuels 508 X72 B Operation Manual Winterthur Gas Diesel Ltd 501 Issue 003 2021 12...

Page 502: ...ating media that follow Fuel Lubricants Water NOTE On the WinGD website go to your engine type then to OPERATION MAINTENANCE then to FUEL LUBRICANTS WATER On the pages that follow the specifications a...

Page 503: ...X72 B AA00 0000 00AAA 018M A Operation Manual General for operating media Page left intentionally blank Winterthur Gas Diesel Ltd 503 Issue 003 2021 12...

Page 504: ...ss 2 4 2 ISO 8573 1 12 2 2 Recommended procedures for compressed air WinGD recommends to regularly do the procedures that follow to prevent explosions Regularly drain the starting air bottles to remov...

Page 505: ...X72 B AA00 0000 00AAA 030E A Operation Manual Compressed air Page left intentionally blank Winterthur Gas Diesel Ltd 505 Issue 003 2021 12...

Page 506: ...piston rings turbocharger compressor etc to a minimum Silencers are installed to the suction part The silencers have filter mats in them which help to keep the air clean The filter mats must be servi...

Page 507: ...X72 B AA00 0000 00AAA 030D A Operation Manual Scavenge air Page left intentionally blank Winterthur Gas Diesel Ltd 507 Issue 003 2021 12...

Page 508: ...n bunkering it is possible that the fuel suppliers will report only some of the values given in the Quality Specifications Frequently only the density and maximum viscosity is given This makes the ful...

Page 509: ...8217 2017 RMK700 show the minimum quality of heavy fuel as supplied and bunkered to the ship installation Good operation results come from commercially available fuels that are in the ISO 8217 2017 li...

Page 510: ...pm ISO 10478 IP501 IP470 Used lubricating oils ULO must not be present Calcium Ca and zinc Zn ULO shows if Ca 30 and Zn 15 or Ca 30 and P 15 Do no use if Ca 30 and Zn 15 or Ca 30 and P 15 mg kg ppm IP...

Page 511: ...xhaust gas 12 4 3 Data about heavy fuel oil specifications The paragraphs that follow give more data about the specifications for HFO 12 4 3 1 Viscosity WinGD recommends a viscosity range at the engin...

Page 512: ...ommended viscosity range for Generation X X DF and RT flex engines Required viscosity range for Generation X X DF and RT flex engines X72 B AA00 0000 00AAA 030A A Operation Manual Diesel engine fuels...

Page 513: ...sary equipment related to the statutory specifications 12 4 3 5 Flash point The flash point is an important safety and fire hazard parameter for diesel fuels Fuel is always a fire hazard There can be...

Page 514: ...in relation to the viscosity For high viscosity fuels the separation temperature must be increased and the flow rate must be decreased in relation to the nominal capacity of the separator For the reco...

Page 515: ...nation The limits in ISO 8217 2017 and the WinGD specifications make sure that no used lubricating oil is in the fuel Chemical waste eg polymers styrene and other chemical substances must not be added...

Page 516: ...Water Maximum 0 3 Maximum 0 2 volume ISO 3733 Ash Maximum 0 01 Maximum 0 01 mass ISO 6245 Lubricity corrected wear scar diameter WSD at 60 C 7 Maximum 520 Maximum 520 m 1 1 mm2 s 1 cSt Centistoke 2 Th...

Page 517: ...composition of the fuel A high density indicates a high aromatic quantity 12 4 5 4 Cetane index The ignition and combustion properties of a distillate fuel in a diesel engine is related to the specifi...

Page 518: ...ure of the fuel must be kept between approximately 5 C and 10 C above the pour point to make sure that the fuel flows easily It is possible that in very cold conditions there could be problems for dis...

Page 519: ...D 6751 FAME has good ignition properties and very good lubrication and environmental properties but FAME has also known negative properties as follows Possible oxidation and thus long term storage pro...

Page 520: ...Objection Letters done by W rtsil Switzerland Ltd are no longer applicable and have no more support by WinGD NOTE WinGD does not accept liability or responsibility for the performance or potential dam...

Page 521: ...13 Attachments 13 1 Schematic diagrams general 522 X72 B Operation Manual Winterthur Gas Diesel Ltd 521 Issue 003 2021 12...

Page 522: ...gram 13 1 1 1 Area codes in the engine control diagram The area codes in the engine control diagram are as follows A Control air supply unit B Fuel supply D Servo oil supply E Valve unit for start K L...

Page 523: ...99 Pipe diagram Code 900 Engine room 13 1 1 4 Component codes in the engine control diagram The component codes in the engine control diagram are shown as example in Figure 13 2 Fig 13 2 Process codes...

Page 524: ...osition A Analysis n a C Control Control E n a Element F Flow n a G Gauge n a H Hand n a I n a Indication J Power n a L Level n a P Pressure n a S Speed Switch T Temperature Transmitter V n a Valve X...

Page 525: ...ust gas 40 to 49 Signals from the engine Air systems 50 to 59 Signals from the engine Miscellaneous 60 to 69 Signals from the engine Spare 70 to 79 Signals to the engine Miscellaneous 80 to 89 Signals...

Page 526: ...4 Color codes and symbols electric connection diagram 00221 ECR component Color codes Power Option Diesel Speed Bus CCM 20 A1 Cylinder 1 13 1 3 Piping and instrumentation diagram The piping and instr...

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