MAN B & W Engine Automation

Vol. 1 - Operation Manual

Index

Text Content Warning Frontpage Introduction Safety Precautions and Engine Data Table of Contents Safety precautions Guidance Value Automation Instrumentation Testbed Adjustments IMO NOx Components and technical file Checks during Standstill Periods Table of Contents Checks during Standstill Periods Starting, Manoeuvring and Running 703 702 701 700

Index

Drawing No.

S900-1 700-00 700-01

S900-0001 V70000-0002 V70001-0002

701TOC 701-01 701-02 701-03 701-04 701-05

V701-0002TOC V70101-0004 V70102-0003 V70103-0002 V70104-0002 V70105-0002

702TOC 702-01

V702-0002TOC V70201-0002

Table of Contents Preparations for Starting Starting-up Loading Running Preparations PRIOR to arrival in Port Stopping Operations AFTER arrival in Port Engine Control System, FPP Plants, 50-70 MC Engines Engine Control System, CPP Plants, 50-70 MC Engines Engine Control System, FPP Plants, 80-108MC/MC-C Engines Chrash-Stop, (FPP-Plants and Reversible CPP-Plants) Manual Control from Engine Side Control Console Change-over from Normal to Manual Control Manoeuvring Gear Starting Air System Sequence Diagram, FPP Plant Control Room Control, STOP. Safety System Control Room Control, START, AHEAD, ASTERN Control from Engine Side Control Console STOP, START, AHEAD, ASTERN Sequence Diagram, CPP Plant Control Room Control, STOP, START, AHEAD, ASTERN. Safety System Bridge Control, Restart of Engine (Showing START AHEAD) Remote Control, STOP, START Safety System Control from Engine Side Control Console, STOP, START Control Room Control, STOP Safety System Control Room Control, START, AHEAD, ASTERN Control from Engine Side Control Console, STOP, START, AHEAD, ASTERN

703TOC 703-01 703-02 703-03 703-04 703-05 703-06 703-07 703-10 703-11 703-12 703-13 Plate 70301 Plate 70302 Plate 70303 Plate 70304 Plate 70305 Plate 70306 Plate 70307 Plate 70308 Plate 70309 Plate 70310 Plate 70311 Plate 70312 Plate 70313 Plate 70314 Plate 70315 Plate 70316

V703-0002TOC V70301-0005 V70302-0002 V70303-0002 V70304-0002 V70305-0002 V70306-0002 V70307-0002 V70310-0001 V70311-0001 V70312-0001 V70313-0001 VP70301-0002 VP70302-0003 VP70303-0002 VP70304-0002 VP70305-0002 VP70306-0001 VP70307-0001 VP70308-0001 VP70309-0001 VP70310-0001 VP70311-0001 VP70312-0001 VP70313-0001 VP70314-0001 VP70315-0001 VP70316-0001

Index


Text Special Running Conditions Table of Contents Fire in Scavenge Air Box Ignition in Crankcase Turbocharger Surging (Stalling) Running with Cylinders or Turbochargers Out of Operation Cutting Cylinders out of Action Scavenge air drain pipes Cutting turbochargers out of action Turbocharger surging Scavenge air spaces, fire exting. systems Fuel and Fuel Treatment Table of Contents Fuel oil Pressurised Fuel Oil System Fuel treatment Residual marine fuel standards Fuel Oil System Fuel oil pipes on engine Fuel oil centrifuges. Modes of operation Centrifuge flow rate and separation temp. (preheating) Preheating of heavy fuel oil (prior to injection) Performance Evaluation and General Operation 706 705 704

Index

Drawing No.

704TOC 704-01 704-02 704-03 704-04 Plate 70401 Plate 70402 Plate 70403 Plate 70404 Plate 70405

V704-0002TOC V70401-0002 V70402-0002 V70403-0002 V70404-0003 VP70401-0002 VP70402-0002 VP70403-0001 VP70404-0001 VP70405-0001

705TOC 705-01 705-02 705-03 Plate 70501 Plate 70502 Plate 70503 Plate 70504 Plate 70505 Plate 70506

V705-0001TOC V70501-0001 V70502-0002 V70503-0001 VP70501-0001 VP70502-0002 VP70503-0001 VP70504-0001 VP70505-0001 VP70506-0001

Table of Contents Observations during Operation Evaluation of Records Cleaning of Turbochargers and Air Coolers Measuring Instruments Pressure Measurements and Engine Power Calculations Correction of Performance Parameters Turbocharger Efficiency Estimation of the Effective Engine Power without Indicator Diagrams Load Diagram for Propulsion alone Load Diagram for Propulsion and Main Engine Driven Generator Performance Observations (2 pages) Readings relating to Thermodynamic Conditions Synopsis Diagrams - for engine (Pi) (2 - pages) Synopsis Diagrams - for engine (Pmax) (2 - pages) Synopsis Diagrams - for engine (Pe) (2-pages) Synopsis Diagrams - for turbocharger (Pscav-Pe) (2-pages) Synopsis Diagrams - for turbocharger (Pscav-Compressor) (2-pages) Synopsis Diagrams - for air cooler (Pscav-Tair) (2-pages) Specific Fuel Oil Consumption (Corrections) Dry Cleaning of Turbocharger (Turbine side) Water Cleaning Turbocharger (Turbine side) Air Cooler Cleaning System (Option) Normal Indicator Diagram

706TOC 706-01 706-02 706-03 706-04 706-05 706-06 706-07 706-08 Plate 70601 Plate 70602 Plate 70603 Plate 70604 Plate 70605 Plate 70606 Plate 70607 Plate 70608 Plate 70609 Plate 70610 Plate 70611 Plate 70612 Plate 70613 Plate 70614 Plate 70615

V706-0004TOC V70601-0004 V70602-0002 V70603-0002 V70604-0002 V70605-0002 V70606-0002 V70607-0003 V70608-0002 VP70601-0002 VP70602-0002 VP70603-0002 VP70604-0001 VP70605-0001 VP70606-0001 VP70607-0001 VP70608-0001 VP70609-0001 VP70610-0001 VP70611-0001 VP70612-0001 VP70613-0001 VP70614-0001 VP70615-0001


Index

Text Adjustment of Indicator Drive Faulty Indicator Diagrams Information from Indicator and Draw Diagrams Using the Planimeter Correction to ISO Reference Ambient Conditions. (Pmax) Correction to ISO Reference Ambient Conditions. (Texh.) Correction to ISO Reference Ambient Conditions (Pcomp.) Correction to ISO Reference Ambient Conditions. (Pscav.) Correction to ISO Reference Ambient Conditions. (Example) Calculation of Compressor Efficiency Calculation of Total Turbocharger Efficiency Power Estimation Turbocharger Compressor Wheel Diameter and Slip Factor Cylinder Condition 707

Index Plate 70616 Plate 70617 Plate 70618 Plate 70619 Plate 70620 Plate 70621 Plate 70622 Plate 70623 Plate 70624 Plate 70625 Plate 70626 Plate 70627 Plate 70628

Drawing No. VP70616-0002 VP70617-0002 VP70618-0002 VP70619-0002 VP70620-0002 VP70621-0002 VP70622-0002 VP70623-0002 VP70624-0003 VP70625-0002 VP70626-0002 VP70627-0002 VP70628-0003

Table of Contents Cylinder Condition Cylinder Lubrication Inspection of Nimonic Exhaust Valve Spindles Inspection through Scavenge Ports Inspection through Scavenge Ports (Record) Inspection through Scavenge Ports, Symbols Inspection through Scavenge Ports (Pictures) Inspection through Scavenge Ports, Evaluation Factors influencing Cylinder Wear Abrasive Particles Abrasive Particles Abrasive Particles Cylinder oil Feed Rate during Running-in. S/K/L MC/MC-C Engines (3-pages) Cylinder Condition Report Calculation of Condensate Amount Cylinder Lubricating Oil Pipes Running-in Load Bearings and Circulating Oil 708

707TOC 707-01 707-02 707-03 Plate 70701 Plate 70702 Plate 70703 Plate 70704 Plate 70705 Plate 70706 Plate 70707 Plate 70708 Plate 70709 Plate 70710 Plate 70711 Plate 70712 Plate 70713 Plate 70714

V707-0004TOC V70701-0004 V70702-0002 V70703-0002 VP70701-0001 VP70702-0001 VP70703-0001 VP70704-0001 VP70705-0001 VP70706-0002 VP70707-0001 VP70708-0001 VP70709-0001 VP70710-0002 VP70711-0002 VP70712-0001 VP70713-0002 70714-0001

Table of Contents Bearings Alignment of Main Bearings Circulating Oil and Oil System Maintenance of the Circulating Oil Turbocharger Lubrication Separate Camshaft Lubricating Oil System (Option) Camshaft Lubrication for Engines with Uni-Lube System Main Bearing, Thick Shell Design Main Bearing, Thin Shell Design Crosshead Bearing Crankpin Bearing Main Bearing Assemblies Guide Shoes and Strips Thrust Bearing Assembly

708TOC 708-01 708-02 708-03 708-04 708-05 708-06 708-07 Plate 70801 Plate 70802 Plate 70803 Plate 70804 Plate 70805 Plate 70806 Plate 70807

V708-0002TOC V70801-0002 V70802-0002 V70803-0002 V70804-0002 V70805-0001 V70806-0001 V70807-0001 VP70801-0002 VP70802-0002 VP70803-0002 VP70804-0001 VP70805-0001 VP70806-0001 VP70807-0001

Index


Text Camshaft Bearing Assemblies Inspection of Bearings. Recording of Observations. Inspection of Bearings. Location and Size of Damage in Bearing Shells Acceptance Criteria for Tin-Aluminium Bearings with Overlayer (Crosshead Bearing Lower Shells) Inspection of bearings. Location of Damage on Pin/Journal Inspection of Bearings. Observations Inspection of Bearings. Inspection Records, Example Inspection of Bearings. Inspection Records, Blank Report: Crankshaft Deflections (Autolog) Crankshaft Deflection, Limits Circulating Oil System (Outside Engine) (Engines with Uni-Lube System) Circulating Oil System (Outside Engine) (Engines without Uni-Lube System) Circulating Oil System (Inside Engine) Flushing of Main Lubricating Oil System. Location of Checkbag and Blank Flanges Flushing of Main Lubricating Oil System. Dimension of Checkbag and Blank Flanges Flushing of Main Lubricating Oil System. Flushing Log Cleaning System, Stuffing Box Drain Oil (Option) Camshaft Lubricating Oil Pipes (Engines with Uni-Lube System) Camshaft Lubricating Oil Pipes (Engines without Uni-Lube System) Flushing of Camshaft Lubrication Oil System Turbocharger Lubricating Oil Pipes Check Measurements Water Cooling Systems Table of Contents Water Cooling Systems Cooling Water Treatment Seawater Cooling System. Main and Auxiliary Engines Jacket Cooling Water System Central Cooling System Preheating of Jacket Cooling Water 709

Index Plate 70808 Plate 70809 Plate 70810 Plate 70811 Plate 70812 Plate 70813 Plate 70814 Plate 70815 Plate 70816 Plate 70817 Plate 70818 Plate 70819 Plate 70820 Plate 70821 Plate 70822 Plate 70823 Plate 70824 Plate 70825 Plate 70826 Plate 70827 Plate 70828 Plate 70829

Drawing No. VP70808-0002 VP70809-0002 VP70810-0002 VP70811-0002 VP70812-0002 VP70813-0002 VP70814-0002 VP70815-0002 VP70816-0002 VP70817-0002 VP70818-0003 VP70819-0002 VP70820-0002 VP70821-0002 VP70822-0002 VP70823-0002 VP70824-0002 VP70825-0001 VP70826-0001 VP70827-0001 VP70828-0001 VP70829-0001

709TOC 709-01 709-02 Plate 70901 Plate 70902 Plate 70903 Plate 70904

V709-0001TOC V70901-0001 V70902-0001 VP70901-0001 VP70902-0001 VP70903-0001 VP70904-0001

Warning

S900-1

0001 S900-1

Warning! It is important that all MAN B&W Diesel A/S engines are operated within the given specifications and performance tolerances specified in the engines Technical Files and are maintained according to the MAN B&W Diesel A/S maintenance instructions in order to comply with given emissions regulations. In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C, 94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations, Part 94, Subpart K, 94.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions, including, but not limited to, the instructions to that effect included in the Technical File.

When referring to this page, please quote Instruction S900 Edition 0001 MAN B&W Diesel A/S

Page 1 (1)

50-108MC/MC-CEdition 0002 2004

VOLUME I OPERATION

Introduction

Chapter 701

700-01

Instruction Book Operation for 50-108MC/MC-C EnginesGeneral Edition 0002

In view of the continued development of our diesel engines, the present instruction book has been made to apply generally to our engines of the types: 50 108 MC/MC-C The different systems are explained on the basis of standard systems, whereas each particular engine is built to the specification in the contract for the plant in question, i.e. the information in this book is for guidance purposes only. All references to this instruction book should include title, edition No., and possibly page No. Example: Instruction book OPERATION, Edition 0002, Section 701-02, Page 3(12). For a specific engine, also the name of the vessel, the engine number and the engine builder should be specified. Further details may be found in: Plant installation drawings Instruction book Vol. I Operation Instruction book Vol. II Maintenance Instruction book Vol. III Components, Descriptions Shop trial/report Sea trial/report

for the engine concerned. This book is subject to copyright protection. The book should therefore not, in whole or in part, be copied, reproduced, made public, or in any other way made available to any third party, without the written consent to this effect from MAN B&W Diesel A/S.

MAN B&W Diesel A/STeglholmsgade 41 DK-2450 Copenhagen Denmark Teleph.:+45 33 85 11 00 Telex :16592 manbw dk Telefax:+45 33 85 10 30

CVR. No. 39 66 13 14

When referring to this page, please quote Operation 700-01, Edition 0002 MAN B&W Diesel A/S

Page 1 (3)

Chapter 701

700-01

IntroductionContents

This instruction book is divided into nine Chapters and an Index as listed below:

Chapter 701 702 703 704 705 706 707 708 709 710

Title Safety Precautions and Engine Data Checks during Standstill Periods Starting, Manoeuvring and Running Special Running Conditions Fuel and Fuel Treatment Performance Evaluation & General Operation Cylinder Condition Bearings and Circulating Oil Water Cooling Systems Index

Each Chapter is subdivided into separate sections and sub-sections. For convenience, the main titles and topics are summarized on the first page(s) of each chapter. The Index gives a comprehensive list of the subjects covered.

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IntroductionService Letters

Chapter 701

700-01

In order to ensure the most efficient, economic, and up-to-date operation of the MAN B&W engines, we, and our licensees, regularly send out Service Letters, containing first-hand information regarding accumulated service experience. The Service Letters can either deal with specific engine types, or contain general instructions and recommendations for all engine types, and are used as a reference when we prepare up-dated instruction book editions. Therefore, since new Service Letters could be of great importance to the operation of the plant, we recommend that the engine staff file them to supplement the relevant chapters of this instruction book.


Page 3 (3)

Safety Precautions and Engine Data

Chapter 701

Table of Contents701-01 Safety PrecautionsSpecial Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Order/Tidiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Low Temperatures freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check and Maintain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Entering the Crankcase or Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turning Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Slow-turning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Feeling over. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sealing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety Cap in Starting Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

701-02 Guidance Value AutomationGeneral Basis for Guidance Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

701-03 Instrumentation1. Measuring Instruments, Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2. List of Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3. Instrumentation on Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

701-04 Testbed AdjustmentsTestbed results scheme (to be filled in by engine builder) . . . . . . . . . . . . . . . . . . . . . . . . . 1

701-05 IMO NOx Components1. Check of IMO-ID, Markings on Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Fuel Valve Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.2 Fuel Pump Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.3 Fuel Pump Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.4 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.5 Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6When referring to this page, please quote Operation Chapter 701 Edition 0002 MAN B&W Diesel A/SPage 1 (2)

Chapter 701

Safety Precautions and Engine Data

Table of Contents1.6 Piston Crown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.7 Exhaust Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.8 Fuel Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2. Checking Setting Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.1 Checking the VIT-adjustments (Engines with VIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2 Checking the Shims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3. Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1 Turbocharger Specifications (Nameplate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.2 Air Cooler Specifications (Nameplate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.3 Auxiliary Blower Specifications (Nameplate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4. Survey methods including on-board verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.1 IMO surveys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.2 Definitions and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.2.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.2.2 Standard MAN B&W performance check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4.2.3 Tolerances for load points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4.2.4 Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4.2.5 Back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4.3 Survey cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.3.1 Load-point corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.3.2 Testbed survey All engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.3.3 On board Engine without VIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.3.4 On board Engine with VIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.3.5 Scavenging-air temperature corrections on board. . . . . . . . . . . . . . . . . . . . . . 15 4.3.6 Sea-water cooling system (SW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.3.7 Central cooling system Optimal cooling (CC-O) . . . . . . . . . . . . . . . . . . . . . 15 4.3.8 Central cooling system Fixed cooler out temperature (CC-F) . . . . . . . . . . . 16 4.3.9 Test-bed cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4.4 Correction to ISO ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4.4.1 Performance parameters correction to ISO ambient conditions . . . . . . . . . . . 16 4.4.2 NOx emission correction to ISO ambient conditions . . . . . . . . . . . . . . . . . . . . 16 4.5 Correction to reference performance conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5. MAN B&W survey procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.1 On-board survey code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5.2 Manual procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.3 Comments on component checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.4 Survey example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 5.5 Flow Chart for Survey Methods (Fig. B.1.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Page 2 (2)

When referring to this page, please quote Operation Chapter 701 Edition 0002 MAN B&W Diesel A/S

Safety Precautions

Chapter 701

701-01

701-01

Safety PrecautionsGeneral:Correct operation and maintenance, which is the aim of this book, are crucial points for obtaining optimum safety in the engine room. The general measures mentioned here should therefore be routine practice for the entire engine room staff.

Special Dangers

WARNING !Keep clear of space below crane with load. The opening of cocks may cause discharge of hot liquids or gases. Carefully consider which way liquids, gases or flames will move, and keep clear. The dismantling of parts may cause the release of springs. The removal of fuel valves (or other valves in the cylinder cover) may cause oil to run down onto the piston crown. If the piston is hot, an explosion might blow out the valve. When testing fuel valves, do not touch the spray holes as the jets may pierce the skin. Do not stand near crankcase doors or relief valves nor in corridors near doors to the engine room casing when alarms for oil mist, high lube oil temperature, no piston cooling oil flow, or scavenge box fire is registered. See also Chapter 704.

WARNING !In the design and layout of the engines, MAN B&W Diesel A/S has the basic philosophy that the failure of one part should not result in the engine becoming inoperative. As some mechanical and electronical parts are essential for the safe functioning of the engine, such parts are duplicated to achieve redundant capability. Should such a redundant part become wholly or partly inoperative, the failing part must be changed or repaired immediately to re-establish redundancy of the part or if an emergency situation requires operation of the engine as soon as the vessel calls at the nearest port.


Page 1 (4)

Chapter 701

701-01

Safety Precautions

CleanlinessThe engine room should be kept clean both above and below the floor plates. If there is a risk of grit or sand blowing into the engine room when the ship is in port, the ventilation should be stopped and ventilating ducts, skylights and engine room doors closed. Welding, or other work which causes spreading of grit and/or swarf, must not be carried out near the engine unless it is closed or protected, and the turbocharger air intake filters covered. The exterior of the engine should be kept clean, and the paintwork maintained, so that leakages can be easily detected.

Fire

WARNING !Keep the areas around the relief valves free of oil, grease, etc. to prevent the risk of fire caused by the emitted hot air/gas in the event that the relief valves open.

Do not weld or use naked lights in the engine room, until it has been ascertained that no explosive gases, vapour or liquids are present. If the crankcase is opened before the engine is cold, welding and the use of naked flames will involve the risk of explosions and fire. The same applies to inspection of oil tanks and of the spaces below the floor. Attention is furthermore drawn to the danger of fire when using paint and solvents having a low flash point. Porous insulating material, soaked with oil from leakages, is easily inflammable and should be renewed. See also Sections 704-01, 02 and Sealing Materials in this Section.

Order/TidinessHand tools should be placed on easily accessible tool panels. Special tools should be fastened in the engine room, close to the area of application. No major objects must be left unfastened, and the floor and passages should be kept clear.

SparesLarge spare parts should, as far as possible, be placed near the area of application, well secured, and accessible by crane.

Page 2 (4)


Safety Precautions

Chapter 701

701-01

All spares should be protected against corrosion and mechanical damage. The stock should be checked at intervals and replenished in good time.

LightingAmple working light should be permanently installed at appropriate places in the engine room, and portable working light should be obtainable everywhere. Special lamps should be available for insertion through the scavenge ports.

Low Temperatures freezingIf there is a risk of freezing, then all engines, pumps, coolers, and pipe systems should be emptied of cooling water, or the cooling water treated to avoid freezing.

Check and MaintainMeasuring equipment, filter elements, and lubricating oil condition.

Entering the Crankcase or Cylinder

WARNING !Always ensure that the turning gear is engaged; even at the quay, the wake from other ships may turn the propeller and thus the engine.

Check beforehand that the starting air supply to the engine and the starting air distributor, is shut off. In case of oil mist alarm, precautions must be taken before opening to crankcase (see Section 704-02).

Turning GearBefore engaging the turning gear, check that the starting air supply is shut off, and that the indicator cocks are open. When the turning gear is engaged, check that the indicator lamp Turning gear in has switched on. Check turning gear starting blocking once every year.

Slow-turningIf the engine has been stopped for more than 30 minutes, slow-turning should always be effected, just before starting in order to safeguard free rotation of the engine, see Chapter 703.


Page 3 (4)

Chapter 701

701-01

Safety Precautions

Feeling overWhenever repairs or alterations have been made to moving parts, bearings, etc., apply the Feel-over sequence (see Section 703-03) until satisfied that there is no undue heating (friction, oil-mist formation, blow-by, failure of cooling water or lubricating oil systems, etc.). Feel over after 10-15 minutes running, again after 1 hours running, and finally shortly after the engine has reached full load. See Section 703-03.

Sealing MaterialsUse gloves when removing O-rings and other rubber/plastic-based sealing materials which have been subjected to abnormally high temperatures. These materials may have a caustic effect when being touched directly. The gloves should be made of neoprene or PVC. Used gloves must be discarded.

Safety Cap in Starting Air LineIf the bursting disc of the safety cap is damaged due to excessive pressure in the starting air line, overhaul or replace the starting valve which caused the burst, and mount a new disc. If a new disc is not available immediately, turn the cover in relation to the cylinder, in order to reduce the leakage of starting air. Mount a new bursting disc and return the cover to the open position at the first opportunity.

AlarmsIt is important that all alarms lead to prompt investigation and remedy of the error. No alarm is insignificant. The most serious alarms are equipped with slow-down and/or shut-down functions. It is therefore important that all engine crew members are familiar with and well trained in the use and importance of the alarm system.

Page 4 (4)


Guidance Value Automation

Chapter 701

701-02

701-02


General Basis for Guidance ValuesThe values stated in the list on the following pages refer to layout point L1. (Nominal max. continuous rating).The values must only be used as a guidance in connection with the List of Capacities of Auxiliary Machinery for dimensioning of auxiliary systems, and must not be used for determining the extent of the alarms or actions. The item numbers refer to the drawings showing the extent and placement of sensors for standard alarms and indicators on the engine, if the signal equipment is fitted. See Section 701-03, furtheron. For sensors placed in the systems outside the engine, see the actual pipe arrangements in the appropriate chapters. If the engine is provided with special equipment, some values may differ from this list. The correct values shall in such a case be obtained from the Plant Installation Drawings. The engine slow-down level corresponds to 40% of nominal MCR r/min. Engines specified and optimised at derated power may have other normal service values depending on layout power/revolutions and application.

For derated engines, the testbed/trial values should be used. Attention must be paid to the temperature levels stated under Nos. 8120 to 8125 (incl.), as two different values have been indicated, one value for metal temperature and another for oil outlet temperature.When setting the limits, maximum limits must be set at rising parameter and minimum limits at falling parameter.


Page 1 (17)

Chapter 701

701-02


Guidance Alarm Limits and Measuring Values (at max. continuous rating with engine running steadily)The list applies to MC/MC-C Engines. For items marked with an Fuel Oil SystemNormal Service Value 78 Set point 6.5 6.5 0.2 0.5 10 15 20 7 Fuel oil inlet (after filter) Leakage from high pressure pipes Fuel pump roller guide gear activated. K80MC-C, L80MC, S80MC, S80MC-C, K90MC-C, K90MC, L90MC-C, S90MC-C, K98MC-C, K98MC T Level high 0 2.0 Bar C

, further details are given in a footnote.

Sensor Code PT 8001 PT 8002 PDT 8003 VT 8004

Function I AL AL AH AH AL

Designation Fuel oil Inlet (after filter) Fuel oil before filter Fuel oil filter Fuel oil viscosity

Unit Bar Bar Bar cST

SLD

SHD

TE 8005 LS 8006 PT 8007

I AH I AH

PT 8001 PT 8002 PDT 8003 VT 8004 TE 8005

Fuel viscosity max. 700 cST. at 50 C measured at fuel pump level. Yard supply. Fuel viscosity max. 700 cST at 50 C. Yard supply. Yard supply. Viscosity to be monitored and alarm given off by sensor built into the Viscorator T = See chapter 705 Vol.1 Operation book.

Page 2 (17)


Guidance Value AutomationLubricating Oil SystemNormal Service Value 1.5 2.2 55 70 Set point 1.2 75 80 Thrust bearing segment Lubrication oil inlet L50MC S50MC, S50MC-C, L60MC S60MC-C, L60MC-C, S60MC, L70MC, L70MC-C, S70MC, K80MC-C S70MC-C, L80MC, S80MC-C, K90MC-C, L90MC-C, K98MC-C, K98MC S80MC, K90MC S90MC-C L50MC S50MC, S50MC-C, L60MC S60MC-C, L60MC-C, S60MC, L70MC, L70MC-C, S70MC, K80MC-C S70MC-C, L80MC, S80MC-C, K90MC-C, L90MC-C, K98MC-C, K98MC S80MC, K90MC S90MC-C Lubrication oil inlet L50MC S50MC, S50MC-C, L60MC S60MC-C, L60MC-C, S60MC, L70MC, L70MC-C, S70MC, K80MC-C S70MC-C, L80MC, S80MC-C, K90MC-C, L90MC-C, K98MC-C, K98MC S80MC, K90MC S90MC-C Lubrication oil inlet 40 47 55 70 1.9 2.2 2.0 2.3 2.1 2.4 90 1.5 1.6 1.7 C Bar

Chapter 701

701-02

Sensor Code PT 8103 TE 8106

Function I AL AH Y

Designation Lub. oil inlet to turbocharger Thrust bearing segment

Unit Bar C

SLD

SHD

H H

TE 8107 PT 8108

Z I AL

2.2 2.5

1.8

2.3 2.6 2.4 2.7

1.9 2.0 1.3 1.4 1.5 L

Y

1.6

1.7 1.8 Bar 1.1 1.2 1.3 L

PT 8109

Z

1.4

1.5 1.6 55 35 60 H C H L C

TE 8112

I AH AL Y

TE 8113

AH Y

Piston cooling outlet/cylinder

50 65

70 75

FS 8114

Y

Piston cooling outlet/cylinder

No flow


Page 3 (17)

Chapter 701

701-02

Guidance Value AutomationFunction I AH Designation Lub. oil outlet from turbocharger/TC MAN/TCA COM MAN/NA COM MHI/MET COM ABB/TPL COM/ABB/VTR COM Y 70 90 70 90 70 90 70 90 95 95 85 110 120 Lub. oil outlet from engine Main bearing metal temperature * 50 60 50 70 65 75 C C C C C C C 80 Crankpin bearing metal temperature * 50 70 75 C 80 Crosshead bearing metal temperature * 50 70 75 C 80 Main bearing oil outlet * 50 - 60 65 70 Deviation from average +/- 5 +/- 7 Crankpin bearing * 50 - 60 65 70 Deviation from average +/- 5 +/- 7 Crosshead bearing oil outlet, fore* 50 - 60 65 70 Deviation from average +/- 5 +/- 7 Lub. oil level in tank Low level H C H H C H H C H H Normal Service Value Set point Unit SLD SHD

Sensor Code TE 8117

TE 8118 TE 8120

I AH I AH Y

TE 8121

I AH Y

TE 8122

I AH Y

TE 8123

AH Y AH Y

TE 8124

AH Y AH Y

TE 8125

AH Y AH Y

LS 8130

AL Y

PT 8108, PT 8109.

Measured by pressure gauge placed 1.8 m above crankshaft centreline. For Lub. oil pumps of centrifugal type, the pressure at stopped engine will be about 0.2 bar lower. (The difference in pressure at stopped and running engine is mainly caused by influence of oscillation forces, especially in piston cooling space.). Inlet reference, see sensor TE 8112. * Please note that the Normal service value is to be stated at sea trial, but, in between the range stated. With regard to the Alarm, Slow down and Shut down levels they should be 5C, 10C and 20C above the sea trial finding respectively, however, maximum the value stated.

TE 8117 TE 8121 TE 8125

TE 8124 and TE 8125 Cut off at stopped engine. Cut off to remain until 3 minutes after start. LS 8130 For separate lubricating system of the turbochargers.

Page 4 (17)


Guidance Value AutomationCylinder Lubricating Oil System Sensor Code PT 8201 Function AH AL TE 8202 PDI 8206 XC 8220 XC 8221 XC 8222 XC 8223 XC 8224 XC 8226 XC 8227 LS 8250 PS 8251 AH AH A A A A A A Y AL AL Y Cylinder Lub. oil temperature Pressure drop across filter Alpha cylinder lubrication system MCU common alarm Alpha cylinder lubrication system BCU in control Alpha cylinder lubrication system MCU failure Alpha cylinder lubrication system BCU failure Alpha cylinder lubrication system MCU power failure Alpha cylinder lubrication system BCU power failure Alpha cylinder lubrication system slow down Cylinder lubricators build in switches (Hans Jensen) Cylinder lubricators build in switches (Hans Jensen) Low Level No Flow X 40 60 Designation Cylinder Lub.oil inlet pressure Normal Set point Service Value 40 50 60 35 70 high failure failure failure failure failure failure X C Unit Bar SLD

Chapter 701

701-02

SHD

XC 8227

The delay is between 50 to 120 seconds.


Page 5 (17)

Chapter 701

701-02Cooling Water System Sensor Code PT 8401 Function I AL Y PS 8402 PDT 8403 Z I AL Y TE 8407 TE 8408 I AL I AH


Designation Jacket cooling water inlet

Normal Set point Service Value 3.5 4.5 2.0 1.5

Unit Bar Bar Bar Bar Bar C C

SLD

SHD

L L

Jacket cooling water inlet Jacket cooling water pressure loss across engine

3.5 4.5 0.8 1.4

X X X 0.2

X 0.4

Jacket cooling water inlet Jacket cooling water outlet/cyl. L50MC, S50MC, S50MC-C S60MC-C, L60MC, L60MC-C, S60MC, L70MC, L70MC-C, S70MC, S70MC-C, K80MC-C, L80MC, S80MC, S80MC-C, K90MC-C, K90MC, L90MC-C, S90MC-C, K98MC-C, K98MC

65 70

57

75 80 80 85

85 90

Y

L50MC, S50MC, S50MC-C S60MC-C, L60MC, L60MC-C, S60MC, L70MC, L70MC-C, S70MC, S70MC-C, K80MC-C, L80MC, S80MC, S80MC-C, K90MC-C, K90MC, L90MC-C, S90MC-C, K98MC-C, K98MC Jacket cooling water outlet temp, at turbocharger L50MC, S50MC, S50MC-C S60MC-C, L60MC, L60MC-C, S60MC, L70MC, L70MC-C, S70MC, S70MC-C, K80MC-C, L80MC, S80MC, S80MC-C, K90MC-C, K90MC, L90MC-C, S90MC-C, K98MC-C, K98MC 75 80 80 85

90 95

C

H

TE 8409

I AH

C 85 90

TE 8411 LS 8412 PI 8413 PT 8421 I AH AL

Jacket cooling water outlet temp, exhaust valve Jacket cooling water de-aerating tank device Jacket cooling water outlet common pipe Cooling water inlet to air cooler(s) Sea water cooling system Central cooling water system AL

80 120 Low level 2.7 3.1

C

Bar

2.0 2.5 X 2.0 4.5 X

3.5 5.5 1.0

Bar

Bar

TE 8422

I AH

Cooling water inlet to air cooler(s) Sea water cooling system Central cooling water system >10 32 >10 36 40 40 C

Page 6 (17)


Guidance Value AutomationSensor Code TI 8423 I Function Designation Cooling water outlet from air cool. Sea water cooling system Central cooling water system PDT 8424 TE 8431 I I AL Pressure drop of cooling water across air cooler/air cooler Cooling water inlet to lub. oil cool. >10 50 >10 63 0.25 0.5 >10 32 10 Bar C C Normal Set point Service Value Unit SLD

Chapter 701

701-02SHD

PT 8401, PI 8413 PS 8402 PDT 8403 PT 8421

If the expansion tank is located more than 5 m above the engine outlet, the resulting increase in the static pressure must be added to the normal service value indicated here. X = With stopped cooling water pump, the set point for the sensor is the static pressure plus the stated value. X = To be stated on sea-trial. Set point 0.2 and 0.4 bar lower. X = To be stated on sea-trial.


Page 7 (17)

Chapter 701

701-02Compressed Air System Sensor Code PT 8501 PT 8503 Function I AL I-C-AH AL PT 8504 I-C-AH AL PT 8505 I AL


Designation Starting air inlet pressure Control air inlet

Normal Set point Service Value 30 6.5 7.5 15 0.5 X 5.5

Unit Bar Bar Bar Bar Bar Bar

SLD

SHD

Safety air inlet

6.5 7.5

0.5 X 5.5

Air inlet to air cylinder for exhaust valve

6.5 7.5

5.5

PT 8503, PT 8504.

X = AH at finished with engine.

Page 8 (17)


Guidance Value AutomationScavenge Air System Sensor Code PT 8601 I Function Designation Scavenge air receiver pressure L50MC, L60MC, L60MC-C, L70MC, L70MC-C, L80MC, L90MC-C, S90MC-C S50MC, S60MC, S70MC, S80MC, S80MC-C K80MC-C, K90MC-C, K90MC, K98MC-C, K98MC S50MC-C, S60MC-C, S70MC-C PS 8603 C Scavenge air receiver, auxiliary blower control L50MC, S50MC, S60MC-C, L60MC, L60MC-C, S60MC, L70MC, L70MC-C, S70MC, S70MC-C, K80MC-C, L80MC, S80MC, S80MC-C, K90MC-C, K90MC, L90MC-C, S90MC-C, K98MC-C, K98MC S50MC-C PS 8604 AH Scavenge air receiver, auxiliary blower control L50MC, S50MC, S60MC-C, L60MC, L60MC-C, S60MC, L70MC, L70MC-C, S70MC, S70MC-C, K80MC-C, L80MC, S80MC, S80MC-C, K90MC-C, K90MC, L90MC-C, S90MC-C, K98MC-C, K98MC S50MC-C AL L50MC, S50MC, S60MC-C, L60MC, L60MC-C, S60MC, L70MC, L70MC-C, S70MC, S70MC-C, K80MC-C, L80MC, S80MC, S80MC-C, K90MC-C, K90MC, L90MC-C, S90MC-C, K98MC-C, K98MC S50MC-C Scavenge air temp. before each cooler Scavenge air pressure drop across each air cooler Scavenge air pressure drop across filter Scavenge air temperature after each air cooler Scavenge air temperature in receiver Sea water cooling system Central cooling water system Y >25 47 >25 51 55 X 55 X C C C 65 X 170 210 X X X XX XX 0.56 0.55 0.7 X 3.50 Normal Set point Service Value Unit Bar SLD

Chapter 701

701-02

SHD

X 3.55 X 3.60 X 3.65 Bar

0.45 0.7 Bar

0.50 0.45

0.39 C Bar Bar C

TE 8605 PDT 8606 PDT 8607 TE 8608 TE 8609

I I AH I AH I I AH


Page 9 (17)

Chapter 701

701-02

Guidance Value AutomationFunction AH Y Designation Scavenge air box-fire alarm/cyl. Normal Set point Service Value 80 Unit C C Water mist catcher - water level Compressor inlet temperature/ turbocharger Compressor scroll housing, pressure at outlet for each turbocharger (NA type) Differential pressure across compressor scroll housing/each turbocharger (NA type) - 10 - + 45 0 3.0 0 0.3 High C Bar Bar 120 SLD SHD

Sensor Code TE 8610

LS 8611 TE 8612 PT 8613 PDT 8614

AH I I I

PT 8601 PS 8603 PS 8604 TE 8605 PDT 8606, PDT 8607 TE 8608 TE 8609

The set point of scavenge air pressure depends on the engine load and shall be set during sea trial. Makes at normal minimum. Breaks at normal maximum. Alarm contact brakes at alarm minimum. Alarm contact makes at alarm maximum. Value based on MCR, depending on engine load and ambient conditions. X = According to shop-trial results. XX = at 50 % increase. X = coolant inlet + 12 C. X = To be cut off during stop. To remain cut out until 3 5 minutes after start.

Page 10 (17)


Guidance Value AutomationExhaust Gas System Sensor Code TC 8701 Function I AH Designation Exhaust gas temperature before turbocharger L50MC, S50MC, S50MC-C, L60MC, S60MC-C, L60MC-C, S60MC, L70MC-C, S70MC, S70MC-C, S80MC, L70MC, K80MC-C, L80MC, S80MC-C, K90MC-C, K90MC, L90MC-C, S90MC-C, K98MC-C, K98MC Y TC 8702 I AH Exhaust gas temperature after valves. Average. L50MC, S50MC, S50MC-C, L60MC, S60MC-C, L60MC-C, S60MC, L70MC, L70MC-C, S70MC, S70MC-C, K80MC-C, L80MC, S80MC, S80MC-C, K90MC-C, K90MC, L90MC-C, S90MC-C, K98MC-C, K98MC Y Deviation from average TC 8704 PT 8706 I I Exhaust gas temperature in receiver Exhaust gas pressure in receiver L90MC-C, S90MC-C L50MC, L60MC, L60MC-C, L70MC, L70MC-C, L80MC, S50MC, S60MC, S70MC, S80MC, S80MC-C K80MC-C, K90MC-C, K90MC, K98MC-C, K98MC S50MC-C, S60MC-C, S70MC-C TC 8707 PT 8708 I AH I AH Exhaust gas temperature after each turbocharger Exhaust gas pressure after each T/C at MCR Exhaust gas pressure drop across boiler at MCR Exhaust gas by-pass valve angle position 3.25 3.30 3.35 3.40 3.45 220 300 300 350 450 C mm WC 150 mm WC 0 90 100 500 320 390 430 380 500 Normal Set point Service Value X Unit C SLD

Chapter 701

701-02

SHD

380 460

X C

H

450 +/-50 C Bar

H +/-60

PDI 8709

I

ZT 8721

I


Page 11 (17)

Chapter 701

701-02


Sensor Code

Function

Designation

Normal Set point Service Value

Unit

SLD

SHD

TC 8701

Normal exhaust gas temperatures depend on the actual engine load and ambient condition. X = turbocharger dependent.

TC 8702 PT 8706 TC 8707

Normal exhaust gas temperatures depend on the actual engine load and ambient condition. When operating below 200 C average temperature deviation alarm is cut off. Normal exhaust gas temperatures depend on the actual engine load and ambient condition. The service values apply under the following conditions: Ambient temperature in engine room 25 C. Scavenge air temperature in receiver 35 C.

Page 12 (17)


Guidance Value AutomationTacho / Crankshaft Position System Sensor Code ZT 4020 Function Z Designation Tacho for safety Normal Set point Service Value r/min Unit SLD

Chapter 701

701-02

SHD MCR x 1.09


Page 13 (17)

Chapter 701

701-02


Miscellaneous Sensor Code ZT 8801 PT 8802 PI 8803 PI 8804 WT 8805 PI 8806 XC 8807 XC 8808 XC 8809 XC 8810 XC 8811 WT 8812 I I I I I I AH AH Function I - AH I Designation Turbocharger speed, each unit Engine room pressure (bar abs.) Air inlet for dry cleaning, turbocharger Water for cleaning, inlet turbocharger Vibration of turbocharger, each unit (option) Speed setting to governor (air pressure) Pmax. control pressure Fuel injection pump index, each cylinder VIT index, each cylinder Governor index Engine torque Crankshaft longitudinal vibration Axial vibration monitor Peak to peak 6K98MC 7K98MC 8K98MC 9K98MC 10K98MC 11K98MC Monitoring equip. required 12K98MC 14K98MC Monitoring equip. required 6K98MC-C 7K98MC-C 8K98MC-C 9K98MC-C 10K98MC-C 11K98MC-C Monitoring equip. required 12K98MC-C 14K98MC-C 6S90MC-C Monitoring equip. required 7S90MC-C 8S90MC-C 9S90MC-C 0.0 2.28 0.0 2.66 0.0 3.03 0.0 3.41 0.0 3.78 0.0 4.16 0.0 4.54 0.0 5.30 0.0 1.88 0.0 2.19 0.0 2.49 0.0 2.80 0.0 3.11 0.0 3.42 0.0 3.72 0.0 4.34 0.0 3.24 0.0 3.78 0.0 4.32 0.0 4.86 3.05 3.55 4.05 4.55 5.05 5.55 6.06 7.06 2.51 2.92 3.33 3.74 4.15 4.56 4.97 5.79 4.33 5.04 5.76 6.48 mm 3.81 4.43 5.06 5.68 6.31 6.93 7.57 8.83 3.13 3.65 4.16 4.67 5.18 5.70 6.21 7.24 5.41 6.30 7.20 8.10 0.5 5.0 0.0 5.0 X X X X Nm Normal Set point Service Value X 0.95 1.05 4.5 10 min. 0.5 X high X Unit r/min Bar Bar Bar mm Bar Bar SLD SHD

Y

Page 14 (17)



Chapter 701

701-02

Sensor Code

Function

Designation 6L90MC-C Monitoring equip. required 7L90MC-C 8L90MC-C 9L90MC-C 10L90MC-C 11L90MC-C Monitoring equip. required 12L90MC-C 4K90MC 5K90MC 6K90MC 7K90MC 8K90MC 9K90MC 10K90MC 11K90MC Monitoring equip. required 12K90MC 6K90MC-C 7K90MC-C 8K90MC-C 9K90MC-C 10K90MC-C 11K90MC-C Monitoring equip. required 12K90MC-C 6S80MC-C Monitoring equip. required 7S80MC-C 8S80MC-C 4S80MC 5S80MC Monitoring equip. required 6S80MC 7S80MC 8S80MC 9S80MC 10S80MC 11S80MC Monitoring equip. required 12S80MC 4L80MC 5L80MC 6L80MC 7L80MC 8L80MC 9L80MC 10L80MC 11L80MC Monitoring equip. required 12L80MC

Normal Set point Service Value 0.0 2.45 0.0 2.85 0.0 3.26 0.0 3.86 0.0 4.08 0.0 4.49 0.0 4.89 0.0 1.44 0.0 1.80 0.0 2.16 0.0 2.54 0.0 2.90 0.0 3.26 0.0 3.62 0.0 3.98 0.0 4.34 0.0 1.95 0.0 2.28 0.0 2.61 0.0 2.94 0.0 3.26 0.0 3.59 0.0 3.92 0.0 2.99 0.0 3.45 0.0 4.06 0.0 1.95 0.0 2.45 0.0 2.93 0.0 3.42 0.0 3.90 0.0 4.40 0.0 4.88 0.0 5.37 0.0 5.87 0.0 1.44 0.0 1.80 0.0 2.16 0.0 2.52 0.0 2.90 0.0 3.26 0.0 3.62 0.0 3.98 0.0 4.34 3.26 3.80 4.34 4.90 5.44 5.98 6.52 1.92 2.40 2.88 3.38 3.86 4.34 4.82 5.30 5.78 2.60 3.04 3.48 3.92 4.34 4.78 5.22 3.98 4.59 5.40 2.60 3.26 3.90 4.56 5.20 5.86 6.50 7.16 7.82 1.92 2.40 2.88 3.36 3.86 4.34 4.82 5.30 5.78

Unit

SLD 4.08 4.75 5.43 6.13 6.80 7.48 8.15 2.40 3.00 3.60 4.23 4.83 5.43 6.03 6.63 7.23 3.25 3.80 4.35 4.90 5.43 5.98 6.53 4.98 5.74 6.75 3.25 4.08 4.88 5.70 6.50 7.33 8.13 8.95 9.78 2.40 3.00 3.60 4.20 4.83 5.43 6.03 6.63 7.23

SHD


Page 15 (17)

Chapter 701

701-02


Sensor Code

Function

Designation 6K80MC-C 7K80MC-C 8K80MC-C 9K80MC-C 10K80MC-C 11K80MC-C Monitoring equip. required 12K80MC-C 4S70MC-C 5S70MC-C Monitoring equip. required 6S70MC-C Monitoring equip. required 7S70MC-C 8S70MC-C 4S70MC 5S70MC Monitoring equip. required 6S70MC 7S70MC 8S70MC 4L70MC-C 5L70MC-C Monitoring equip. required 6L70MC-C Monitoring equip. required 7L70MC-C 8L70MC-C 4L70MC 5L70MC Monitoring equip. required 6L70MC Monitoring equip. required 7L70MC 8L70MC 4S60MC-C 5S60MC-C Monitoring equip. required 6S60MC-C Monitoring equip. required 7S60MC-C 8S60MC-C 4S60MC 5S60MC Monitoring equip. required 6S60MC 7S60MC 8S60MC

Normal Set point Service Value 0.0 1.73 0.0 2.03 0.0 2.31 0.0 2.61 0.0 2.90 0.0 3.18 0.0 3.47 0.0 1.77 0.0 2.19 0.0 2.62 0.0 3.05 0.0 3.58 0.0 1.71 0.0 2.15 0.0 2.57 0.0 3.00 0.0 3.42 0.0 1.41 0.0 1.74 0.0 2.08 0.0 2.42 0.0 2.76 0.0 1.28 0.0 1.59 0.0 1.91 0.0 2.22 0.0 2.54 0.0 1.52 0.0 1.88 0.0 2.25 0.0 2.61 0.0 3.07 0.0 1.47 0.0 1.85 0.0 2.21 0.0 2.58 0.0 2.94 2.30 2.70 3.08 3.48 3.86 4.24 4.62 2.36 2.92 3.50 4.07 4.78 2.28 2.86 3.42 4.00 4.56 1.88 2.32 2.78 3.23 3.68 1.70 2.12 2.54 2.96 3.38 2.03 2.51 3.00 3.49 4.10 1.96 2.46 2.94 3.44 3.92

Unit

SLD 2.88 3.38 3.85 4.35 4.83 5.30 5.78 2.95 3.65 4.37 5.08 5.97 2.85 3.58 4.28 5.00 5.70 2.35 2.90 3.47 4.03 4.60 2.13 2.65 3.18 3.70 4.23 2.53 3.13 3.75 4.36 5.12 2.45 3.08 3.68 4.30 4.90

SHD

Page 16 (17)



Chapter 701

701-02

Sensor Code

Function Y

Designation 4L60MC-C 5L60MC-C Monitoring equip. required 6L60MC-C Monitoring equip. required 7L60MC-C 8L60MC-C 4L60MC 5L60MC 6L60MC 7L60MC 8L60MC 4S50MC-C 5S50MC-C Monitoring equip. required 6S50MC-C Monitoring equip. required 7S50MC-C 8S50MC-C 4L50MC 5L50MC 6L50MC 7L50MC 8L50MC 4S50MC 5S50MC Monitoring equip. required 6S50MC 7S50MC 8S50MC

Normal Set point Service Value 0.0 1.20 0.0 1.49 0.0 1.77 0.0 2.07 0.0 2.36 0.0 1.08 0.0 1.35 0.0 1.62 0.0 1.89 0.0 2.16 0.0 1.26 0.0 1.56 0.0 1.87 0.0 2.17 0.0 2.55 0.0 0.92 0.0 1.14 0.0 1.37 0.0 1.59 0.0 1.82 0.0 1.23 0.0 1.55 0.0 1.85 0.0 2.16 0.0 2.46 1.60 1.99 2.37 2.76 3.15 1.44 1.80 2.16 2.52 2.88 1.69 2.09 2.50 2.90 3.41 1.22 1.52 1.82 2.12 2.42 1.64 2.06 2.46 2.88 3.28 high density or 0.5

Unit mm

SLD 2.00 2.48 2.96 3.45 3.93 1.80 2.25 2.70 3.15 3.60 2.11 2.61 3.12 3.62 4.26 1.53 1.90 2.28 2.65 3.03 2.05 2.58 3.08 3.60 4.10

SHD

XS 8813

AH Y

Oil mist in crankcase, each cyl.

mg/l

high density or 0.5

XS 8814

A

Oil mist detector failure (no value)

ZT 8801 PI 8804 XC 8808, 8809, 8810 and 8811

X = according to the manufacturer. X = higher than exhaust gas pressure. X = Engine and load dependent.


Page 17 (17)

Instrumentation

Chapter 701

701-03

701-031.

Instrumentation

Measuring Instruments, IdentificationRemote Indication Codes for identification of instruments and signal-related functions

PT

8108

AH

First letterMeasured or indicating variable (First letter(s))DS: Density switch DT: Density transmitter GT: Gauging transmitter (load/index transmitter) FT: Flow transmitter FS: Flow switch LS: Level switch LI: Level indication (local) LT: Level transmitter PDI: Pressure difference indication (local) PDS: Pressure difference switch PDT: Pressure difference transmitter PI: Pressure indication (local) PS: Pressure switch PT: Pressure transmitter ST: Speed transmitter TC: Thermo couple (NiCr-Ni) TE: Temperature element (Pt-100) TI: Temperature indication (local) TS: Temperature switch WS: Vibration switch WT: Vibration transmitter VS: Viscosity switch VT: Viscosity transmitter ZV: Position valve (solenoid valve) ZS: Position switch (limit switch) ZT: Position transmitter (e.g. proximity sensor) XC: Unclassified control XS: Unclassified switch XT: Unclassified transmitter

Ident. No.

Secondary letter(s)Function (Secondary letter(s))

Ident. number The first two digits indicate the point of measurement, the next two are serial numbers. Manoeuvring system Hydraulic power supply Combustion pressure supervision ECS to/from safety system ECS to/from remote control system ECS to/from alarm system ECS Miscellaneous input/output values 40. Tacho/crankshaft pos. system 41. Engine cylinder components 50. VOC: supply system 51. VOC: sealing oil system 52. VOC: control oil system 53. Other VOC related systems 54. VOC engine related components 80. Fuel oil system 81. Lubrication oil system 82. Cylinder lub. oil system 83. Stuffing box drain system 84. Cooling water system e.g. central cooling water e.g. sea cooling water e.g. jacket cooling water 85. Compressed air supply system e.g. control air e.g. starting air 86. Scavenge air 87. Exhaust gas system 88. Miscellaneous functions e.g. axial vibration 90. Project specific Note: ECS: Engine control system VOC: Volatile Organic Compound 11. 12. 14. 20. 21. 22. 30.

A: C: H: I: L: R: S: Y: X: Z:

Alarm Control High Indication (remote) Low Recording Switching Slow-down Unclassified function Shut-down


Page 1 (9)

Chapter 701

701-03

InstrumentationThe first link (first letter) indicates what is measured or the indicating variable. The second link is the Ident.No., in which the first two digits indicate the point of measurement or the indicating variable, followed by a serial number. The third link (secondary letter(s)) indicates the function of the measured value. Example

TE

8026

I AH YSlow down Alarm high Indicator Measurement No. 26 Fuel oil system Temperature Element

Repeated signals: Signals which are repeated, such as per cylinder measurement or per turbocharger measurement, etc. are provided with a suffix number. The suffix number is identical with the place of measurement, such as 1 for cylinder 1, etc. Where signals are redundant, suffix A or B may be used. Examples Cylinder or Turbocharger-Related Signals

ZV

1120-1

Ce.g. Cyl. No./TC No. Aux. Blower No.

Redundant Signals

PT

8603-A

I AH CSystem A

PT

8603-B

I AH CSystem B

Cylinder-Related Redundant Signals

ZT

8203-A-1

C e.g. Cyl. No./TC No. System A

Graphical presentation in PI-diagrams according to ISO 1219 I - II

Page 2 (9)


Instrumentation2. Lift of InstrumentsFuel Oil System PI PI PT TI TE LS 8001 8001 8001 8005 8005 8006

Chapter 701

701-03

Fuel oil, inlet engine (Setting of by-pass valve) Fuel oil, inlet engine (At local manoeuvring console) Fuel oil, inlet engine (After filter) (Alarm) Fuel oil, inlet engine (After filter) Fuel oil, inlet engine (After filter) Leakage from high pressure pipes (Alarm)

Lubrication Oil System PT PI TI TE TS PI PI PT PS TI TE TI TE FS TI TE 8103 8103 8106 8106 8107 8108 8108 8108 8109 8112 8112 8113 8113 8114 8117 8117 Lubricating oil inlet to Turbocharger/Turbocharger (Alarm) Lubricating oil inlet to Turbocharger/Turbocharger Thrust bearing segment Thrust bearing segment (Alarm + Slow down) Thrust bearing segment (Shut down) System lubricating oil inlet 1800 above cl. of crankshaft System lubricating oil inlet (At local manoeuvring console) Lubricating oil inlet to main bearing and thrust bearing (Alarm + Slow down) Lubricating oil inlet to main bearing and thrust bearing (Shut down) System lubricating oil inlet System lubricating oil inlet (Alarm + Slow down) Piston cooling oil outlet/cylinder Piston cooling oil outlet/cylinder (Alarm + Slow down) Piston cooling oil outlet/cylinder (Alarm + Slow down/ no flow) Lubricating oil outlet Turbocharger/Turbocharger Lubricating oil outlet Turbocharger/Turbocharger (Alarm)

Mechanical Cylinder Lub.Oil System (H.Jensen cylinder lubricators) LS FS ZV 8250 8251 8253 Hans Jensen cylinder lubricators Hans Jensen cylinder lubricators Load change dependent cylinder lubrication

Electronic Cylinder Lub.Oil System (Alpha cylinder lubricators) PT TE ZT ZV PDI 8201 8202 8203 8204 8206 Cylinder lubrication oil inlet pressure Cylinder lubrication oil temperature Confirm cylinder lubricator piston movement, cyl/cyl Activate cylinder lubricator, cyl/cyl Pressure drop across filter

Cooling Water System PT PI PDS TI 8401 8401 8403 8407 Jacket cooling water inlet Jacket cooling water inlet (At local manoeuvring console) Jacket cooling water across engine Jacket cooling water inlet


Page 3 (9)

Chapter 701

701-03

InstrumentationTE TI TE TI PI PT TI TE TI TE 8407 8408 8408 8409 8421 8421 8422 8422 8423 8423 Jacket cooling water inlet Jacket cooling water outlet/cylinder Jacket cooling water outlet/cylinder Jacket cooling water outlet/turbocharger Cooling water inlet air cooler Cooling water inlet air cooler (Alarm) Cooling water inlet air cooler Cooling water inlet air cooler (Alarm) Cooling water outlet air cooler/air cooler Cooling water outlet air cooler/air cooler

Compressed Air Supply System (Control, starting air) PI PT PI PT PI PI PT PS 8501 8501 8503 8503 8503 8504 8504 8505 Starting air to main starting valve (At local manoeuvring console) Starting air inlet (Alarm) Control air inlet (At inlet panel) Control air inlet (At inlet panel) Control air inlet (At local manoeuvring console) Safety air inlet (At inlet panel) Safety air inlet Air inlet to air cylinder for exhaust valve

Scavenge Air PT PI PI PS PS TI TE PDI TI TE TI TE TE LS 8601 8601 8601 8603 8604 8605 8605 8606 8608 8608 8609 8609 8610 8611 Scavenge air receiver Scavenge air receiver (at engine side) Scavenge air receiver (At local manoeuvring console) Scavenge air receiver auxiliary blower control Scavenge air auxiliary blower, failure Scavenge air before air cooler/air cooler Scavenge air before air cooler/air cooler Pressure drop across air cooler/air cooler Scavenge air after air cooler/air cooler Scavenge air after air cooler/air cooler Scavenge air receiver Scavenge air receiver (Alarm + slow down) Scavenge air box-fire alarm, cylinder/cylinder Water mist catcher water level

Exhaust Gas System TI TC TI TC PI 8701 8701 8702 8702 8706 Exhaust gas before turbocharger/turbocharger Exhaust gas before turbocharger/turbocharger (Alarm + slow down) Exhaust gas after valve, cylinder/cylinder Exhaust gas after exhaust valve, cylinder/cylinder Exhaust gas receiver

Page 4 (9)


InstrumentationManoeuvring System XC XS XC ZV PS PS ZV ZS ZS ZS ZV ZV ZV ZS PS ZS ZS ZV ZS ZS ZV ZV PI E E E 1103 1106 1126 1127 1133 1134 1137 1109 1110 1111 1112 1114 1116 1117 1118 1121 1122 1136 1138 1139 1141 1142 1149 1180 1181 1182

Chapter 701

701-03

Solenoid valve for engine emergency stop Reset shut down at emergency I/P Converter for V.I.T. control Solenoid valve for control of V.I.T. system in stop or astern function Cancel of tacho alarm from safety system, when stop is ordered Gives signal when on bridge control Remote start solenoid valve Turning gear disengaged Turning gear engaged Main starting valve blocked Main starting valve in service Slow turning valve Starting air distributor open Starting air distributor closed Manoeuvring system in emergency control Activate main starting valves open Gives signal when changes-over mechanism is in remote control Remote stop solenoid valve Reversing cylinder ahead position Reversing cylinder astern position Solenoid valve for reversing cylinder activation direction ahead during remote control Solenoid valve for reversing cylinder activation direction astern during remote control Pilot pressure to actuator for V.I.T. system Electric motor Auxiliary blower Electric motor Turning gear Actuator for electronic governor

Miscellaneous ST PI PI WT XC 8801 8803 8804 8812 8813 Turbocharger speed/turbocharger Air inlet for dry cleaning of turbocharger Cleaning water inlet to turbocharger Axial vibration monitor Oil mist in crankcase/cylinder

TACHO/CRANKSHAFT POS. SYSTEM ZT 4020 Tacho for safety Instrumentation on Engine


Page 5 (9)

Chapter 701

701-03

Instrumentation

3.

Instrumentation on Engine

Page 6 (9)


Instrumentation

Chapter 701

701-03


Page 7 (9)

Chapter 701

701-03

Instrumentation

Page 8 (9)


Instrumentation

Chapter 701

701-03


Page 9 (9)

Testbed Adjustments

Chapter 701

701-04

701-04TESTBED DATA Layout kW: Turbocharger(s) Make: Max. RPM: Compr. Slip Factor: TC specification:

TestbedAdjustmentsWater Brake: Engine No.: Layout RPM: No. of TC: Type: Max. Temp., C: Compr. Diam., m: 1 2 3 4 Internal Sign.: Serial No. No. of Cyl.: Cylinder Constant (kW,bar): Bore, m: No.: Yard: Test No.: Stroke, m: Mean Friction. Press., bar: Constant, K: kW/Kg.RPM

Engine Type: Engine Builder:

Lubrication Oil System (Tick box) External from M. E. System External from Gravity Tank

Observation No:Fuel Oil Viscosity: Bunker Station: Oil Brand: Density at 15 C: Test Date (yyyy-mm-dd) Test Hour (hh:mm) Heat value, kcal/kg: Sulphur, %: Load % Ambient Pressure mbar at: C Cylinder Oil Circulating Oil Turbo Oil Water Brake Load Kg Engine RPM Speed Setting bar VIT Control bar Brand Type

Governor index

Effective Power kW

Indicated Power kW

Eff. Fuel Consumption g/kWh

Indicated Fuel Consumption g/kWh

Cylinder No. Pi, bar Pmax, bar Ref. Pmax, bar Pcomp, bar Fuel Pump Index VIT index Exhaust Gas Temp., C Cooling Water Outlet Temp., C Piston Outlet Lub. Temp., C

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

Ave.

Cooling Water Temperature, C Air Cooler Inlet 1 Outlet 1 Seaw. Temp. Main Engine Inlet Turb. Outlet 1

Exhaust Gas Temp., C Turbine Inlet 1 Outlet 1

Exhaust Pressure Receiver bar Turb. Outl. mmWC 1 mmHg

Turbo Charger RPM 1

Aux. Blower On/Off

Scavenge Air Pressure p Filter mmWc 1 p Cooler mmWc 1 mmHg 2 2 Receiver bar

2

2

2

2

2

2

2

Axial Vibration mm

3

3

3

3

3

3

3

3

3

4

4

4

4

4

4

4

4

4

Ave.

Ave.

Ave.

Ave.

Ave.

Ave.

Ave.

Ave.

Ave.

Scavenge Air Temperature, C Inlet Blower Scavenge Air Temperature 1 Before Cooler 1 After Cooler 1 Pressure, bar System Oil

Lubricating Oil Temperature, C Inlet Engine Temperature, C TC Inlet / Blower end TC Outlet / Turb. end 1

Fuel Oil Pressure bar Before Filter

2

2

2

Cooling Oil

Inlet Cam

1

After Filter

3

3

3

Cam Shaft Oil

Outlet Cam

2

2

Temperature, C Before Pumps

4

4

4

Turbine Oil

Thrust Segment

3

3

Ave.

Ave.

Ave.

4

4

Ave. Remarks:

Ave.


Page 1 (1)

IMO NOx Components

Chapter 701

701-05

701-051.

IMO NOx Components and Technical File

Check of IMO-ID, Markings on ComponentsThe components described in Items 1.1 to 1.8 have been marked with unambiguous identification numbers to enable the relevant drawing and certificate to be traced. The schematic drawings show where to find the markings on the individual component types. Information on the important dimensions for each component type in respect to the NOx characteristic can be found in the engine instruction book, see references in footnotes **) to TF Chapter 1.4. The circled part of the number is the only part of the entire number that is to be defined as the IMO number. The component marking may include a revision reference nnnnnnn-n.n, however, that reference is not part of the defining marking and should be ignored. See also Drawing No. 0741260-8 regarding marks and stamps on components for MAN B&W two-stroke diesel engines.


Page 1 (23)

Chapter 701

701-05

IMO NOx Components

. 1.1 Fuel Valve Nozzle302 To be marked with Licensees name/ trademark or abbreviationXXX 1261573-1 x 150

Certified markings: Part No.

Marking instruction: No. 0742639-1

747

To be stamped:

Part No.

Checking the dimensions of the certified component: 1. 2. Remove the fuel valve, see instruction manual Vol.II, Procedure 901-2. Disassemble the fuel valve, see instruction manual Vol. II, Procedure 909-6.

Fig. 1 Fuel valve nozzle

Page 2 (23)


IMO NOx Components

Chapter 701

701-05

1.2

Fuel Pump Plunger302 To be marked with Licensees name/ trademark, Part No. and abbreviation



Checking the dimensions of the certified component: 1. 2. Remove the fuel pump top cover, see instruction manual Vol.II, Procedure 909-3. Remove the plunger/barrel assembly, see instruction manual Vol. II, Procedure 909-3.

Fig. 2 Fuel pump plunger


Page 3 (23)

Chapter 701

701-05

IMO NOx Components

1.3

Fuel Pump BarrelCertified markings:XXXXXXXXXXX 111111-1 SXXMC/MC-C

Part No.

Marking instruction:302 To be marked with Licensees name/ trademark, Part No. and engine type

No. 0742843-8

Checking the dimensions of the certified component: 1. 2. Remove the fuel pump top cover, see instruction manual Vol.II, Procedure 909-3. Remove the plunger/barrel assembly, see instruction manual Vol. II, Procedure 909-3.

Orifice

Orifice

Fig. 3 Fuel pump barrel

Page 4 (23)


IMO NOx Components

Chapter 701

701-05

1.4

Cylinder LinerCertified markings: Part No.307 4320920352 - 4

Marking scratch Camshaft side To be marked with Licensees name/trademark, Part No.


302

Checking the dimensions of the certified component: 1. 2. 3. Remove the cylinder cover, see instruction manual Vol.II, Procedure 901-1. Remove the piston, see instruction manual Vol. II, Procedure 902-2. Remove the liner and the cooling jacket, see instruction manual Vol. II, Procedure 903-3.

D

A

A

H

W

A-A

Liner diameter, D: _________________ Number of cooling water bores: ____________ Number of lubricating oil quills: ____________Fig. 4 Cylinder liner


Page 5 (23)

Chapter 701

701-05

IMO NOx Components

1.5

Cylinder CoverCertified markings:To be marked with Licensees name/ 302 trademark, Part No. Year and Week 309 To be marked with Charge and Serial No.

Part No.

Marking instruction: On camshaft side No. 0742634-2

Checking the dimensions of the certified component: 1. 2. Remove the cylinder cover, see instruction manual Vol.II, Procedure 901-1. Remove the cooling jacket, see instruction manual Vol. II, Procedure 901-3.

Fig. 5 Cylinder cover

Page 6 (23)


IMO NOx Components

Chapter 701

701-05

1.6

Piston CrownCertified markings:To be marked with Licensees name/ 302 trademark, Part No. Year and Week 309 To be marked with Charge and Serial No.

Part No.

Marking instruction: On camshaft side No. 0742392-0

Checking the dimensions of the certified component: 1. 2. 3. Remove the cylinder cover, see instruction manual Vol.II, Procedure 901-1. Measure the piston bowl, see instruction manual Vol. II, Procedure 902-3. Measure the heights (A and B) through the scavenge air ports.

A B

Fig. 6 Piston crown


Page 7 (23)

Chapter 701

701-05

IMO NOx Components

1.7

Exhaust CamAHEAD AHEAD

XXXXXXX-X.X5 0 0 5 10 15

XXXXX XXXXX

To be marked with Licensees 302 name/trademark or abbreviation 302 To be marked with Part No.25


25

201510

2025

Size: 3.5 mm Size: 5 mm

Marking instruction:0 510 15 20

No. 0742635-4

Checking the dimensions of the certified component: 1. Remove the cover for the exhaust roller guide, see instruction manual Vol.II, Procedure 908-4. 2. Locate the middle of the cam, see instruction manual Vol. II, Procedure 908-7. 3. Check the distance L according to the table below.155 150 140 AHEAD 130 230 180 205 210 220

120

240

110 100 90

250 260 270

0

Middle of Middle of cam

cam

Angle ( )Angle ( )

Angle ( ) 360.0Angle ( ) 360.0

L*) (mm)L *) (mm)

Angle ( )Angle ( )

Angle ( )Angle ( )

L*) (mm)L *) (mm)

Angle ( )Angle ( )

Angle ( )Angle ( )

L*) (mm)L *) (mm)

0.0

105.0105.0 110.0 110.0 115.0 115.0 120.0 125.0 120.0 130.0

255.0255.0 250.0 250.0 245.0 245.0 240.0 235.0 240.0 230.0

135.0

225.0

80.0 80.085.0 85.0 90.0 95.0 90.0 100.0

0.0

280.0 280.0275.0 275.0 270.0 265.0 270.0 260.0

135.0 140.0 140.0 145.0 145.0 150.0 155.0 150.0

225.0 220.0 220.0 215.0 215.0 210.0 205.0 210.0

95.0 100.0

265.0 260.0

125.0 130.0

235.0 230.0

155.0

205.0

*) Specific for an individual engine type

*) Specific for an individual engine type

Fig. 7 Exhaust cam

Page 8 (23)


IMO NOx Components

Chapter 701

701-05

1.8

Fuel CamTo be marked with Part No.xxxxx xxxxx

302 To be marked with Bearing side

302

Certified markings:To be marked with 302 Licensees name/trademark or abbreviation

Bearing side

Part No.

xxxxxxxxx

3075

Marking scratch


Checking the dimensions of the certified component: 1. Remove the covers for the fuel pump roller guide, see Vol.II, Procedure 909-2. 2. Locate the lowermost position of the cam, see instruction manual Vol. II, Procedure 909-1. 3. Check the distance L according to the table below.330 320 310 300 290 280 270 260 250 240 130 230 140 220 210 200 190 180 170 150 160 AHEAD 340 350 0 10 20 30 40 50 60 70 80 90 100 110 120

Angle ( )

L *) (mm)

Angle ( )0.0 0.0 5.0 5.0 10.0 10.0 15.0 15.0 20.0 20.0 25.0 25.0 30.0 30.0 35.0 35.0 40.0 40.0 45.0 45.0 50.0 50.0 55.0 55.0 60.0 60.0 65.0 65.0 70.0 70.0 75.0 75.0 80.0 80.0 85.0 85.0 90.0 90.0 95.0 95.0 100.0 100.0 105.0 105.0 110.0 110.0 115.0 115.0

L *) (mm)

Angle ( ) 120.0 125.0 130.0 135.0 140.0 145.0 150.0 155.0 160.0 165.0 170.0 175.0 180.0 185.0 190.0 195.0 200.0 205.0 210.0 215.0 220.0 225.0 230.0 235.0 240.0

L *) (mm)

Angle ( )

L *) (mm)

Angle ( )120.0 125.0 130.0 135.0 140.0 145.0 150.0 155.0 160.0 165.0 170.0 175.0 180.0 185.0 190.0 195.0 200.0 205.0 210.0 215.0 220.0 225.0 230.0 235.0 240.0

L *) (mm)245.0 250.0 255.0 260.0 265.0 270.0 275.0 280.0 285.0 290.0 295.0 300.0 305.0 310.0 315.0 320.0 325.0 330.0 335.0 340.0 345.0 350.0 355.0 360.0

Angle ( )245.0 250.0 255.0 260.0 265.0 270.0 275.0 280.0 285.0 290.0 295.0 300.0 305.0 310.0 315.0 320.0 325.0 330.0 335.0 340.0 345.0 350.0 355.0 360.0

L *) (mm)

*) Specific for the individual engine type

*) Specific for the individual engine type

Fig. 8 Fuel cam


Page 9 (23)

Chapter 701

701-05

IMO NOx Components

2.2.1 2.1.A

Checking Setting ValuesChecking the VIT-adjustments (Engines with VIT) Load the engine Loading to 75% MCR or 100% MCR: see Vol I, Chapter 706, Appendix 2 or 5.

Loading to the break-point:

Electronically controlled VIT: Follow the instructions from the supplier of the engine control system Mechanically controlled VIT: Load the engine until the steel bar touches the pivoting points (F1 and F2) simultaneously, see Fig. 2.1.A..

Fig. 2.1.A

2.1.B

Read the actual VIT-index Read the actual VIT-index on the scale of the fuel pump timing racks, see Fig. 2.1.B..

Fig. 2.1.B

Page 10 (23)


IMO NOx Components2.2 2.2.A Checking the Shims

Chapter 701

701-05

Number of shims in fuel pump (Injection timing) For engines without VIT, visually check the number of shims between the fuel pump top cover and the pump housing. See Fig. 2.2.A.

Fig. 2.2.A

2.2.B

Checking the shim thickness, t (Compression volume) Turn the crankthrow towards the exhaust side, to provide access for measuring the thickness of the shim which is inserted between piston rod and crosshead pin. See Fig. 2.2.B.

Fig. 2.2.B


Page 11 (23)

Chapter 701

701-05

IMO NOx Components

3.3.1

NameplatesTurbocharger Specifications (Nameplate) Manufacturer Type Serial number(s) Manufacturing date Specification Max. cont. speed Max. cont. gas temperature

3.2

Air Cooler Specifications (Nameplate) Manufacturer Type Contract Number Year build Water side Operational Gauge Pressure Test Gauge Pressure Operational Temperature Content Air side bar bar deg. C L

3.3

Auxiliary Blower Specifications (Nameplate) Manufacturer: Model: Capacity: Pressure: Temp.: Density: Serial number(s): Speed: Power: Elec. source: Mfg. date:

Page 12 (23)


IMO NOx Components4.4.1

Chapter 701

701-05

Survey methods including on-board verificationIMO surveys Figure B.1 shows a flow chart for all the survey methods used in connection with IMO certification of a MAN B&W two-stroke engine. a. b. c. test-bed survey (engine pre-certification survey) sea-trial survey (initial survey on board), and on-board surveys (intermediate and periodical surveys)

On test bed, parent and the member engines are surveyed by the same procedures, except for the important difference that emission measurements are performed and surveyed on the parent engine, only. (The emissions data measured on the parent engine are used to establish the emission simulation for the onboard survey code to verify compliance based on standard performance data.) On board, only the on-board survey method shall be used for future intermediate and periodical surveys. (Provided that the required IMO certificates have been issued based on the engine pre-certification and initial surveys.) The standard MAN B&W on-board survey method is defined as a combination of performance parameter checks, and component and setting verification. The extend of the component and setting verification depends on different conditions, but, in general, can be reduced to the fuel nozzle, if the performance data are within the specified tolerances given in TF Table 1.3 and no component changes have been made to the engine. The necessary performance parameters and corrections are specified in Chapter B.2. And a description with step-by-step procedures of the actual survey is presented in Section B.3. 4.2 4.2.1 4.2.2 Definitions and Corrections Definitions Standard MAN B&W performance check Table B.2.1 lists the parameters necessary as input for the survey code from a standard MAN B&W performance check.


Page 13 (23)

Chapter 701

701-05

IMO NOx ComponentsTable B.2.1: Input data for survey code *)Engine Number Vessel Name T/C inlet temperature ** Ambient temperature ** Ambient pressure ** Relative humidity of ambient air Scavenging-air temperature ** Scavenging-air pressure ** Sea-water (inlet) temperature ** Turbine back pressure ** Max. cylinder pressure ** Max. compression pressure Power **,*** Engine speed Turbocharger speed Fuel pump index VIT index (if applicable) * deg.C deg.C mbar rel.% deg.C bar deg.C mmWC bar bar kW r/min r/min -

See foot notes **) to TF Chapter 1.4 Comments on calibration of sensors and apparatus, and correction to ISO ambient conditions for these measurements. ** These items are required in order to calculate the NOx emission. *** See comment in text on power estimation (Section B.2.1.3.)

4.2.3

Tolerances for load points The actual load points are attached a certain tolerance (see NOx Technical Code, Appendix 4.) However, due to propeller lay out or vessel trim a light or heavy propeller may be experienced. In these cases MAN B&W recommend to select the load point according to the actual measured mean effective pressure corresponding to the specified load point. Power The power is usually derived from torque and speed. If the torque is difficult to measure directly through torsion measurements, the Charts added in Fig. B.2 or B.3, can be used to estimate the brake power. Alternatively the load could be derived from a MAN B&W PMI system. Back pressure The usual variations in turbine back pressure have been shown only to have a minor influence on the NOx emission and the measurement of the turbine back pressure, therefore, could be omitted during a NOx compliance survey. However, the

4.2.4

4.2.5

Page 14 (23)


IMO NOx Components

Chapter 701

701-05

influence has been included in the survey code as well as in the following example due to the influence on the ISO correction on Pmax. 4.3 Survey cases The different load points and cooling conditions lead to the following survey cases: 4.3.1 4.3.2 Load-point corrections Test-bed survey All engines Includes all four E3/E2-ISO cycle load points. On board Engine without VIT The actual NOx compliance is estimated from performance data at 75% load only, assuming that the NOx(test bed 75%) / NOx(estimated 75%) ratio is identical for the ratio of the remaining load points, also. On board Engine with VIT The actual NOx compliance assumes that the 25 to 75% load points contribute as without VIT, based on the 75% performance data. The 100% load point contribution is estimated from the actual performance at the measured load above the break point (from 85 to 100% loads), adjusting the NOx(test bed 100%) for the same Pmax difference as the measured load, but for a Tscav and Pturb.back reflecting the 100% load: 1. 2. 3. Pmax(100%) = Pmax(meas load%) Tscav(100%) = Tscav(meas load%) + (100 meas load%) x (Tscav.ref(100%) Tscav.ref(75%)) / 25 Pturb.back(100%) = Pt.back(meas load%) + (100 meas load%) x (Ptback.ref(100%) Ptback.ref(75%)) / 25

4.3.3

4.3.4

(If the VIT break point can not be reached, case B.2.2.1.3 is handled identical to case B.2.2.1.2.) 4.3.5 Scavenging-air temperature corrections on board The correction for cooling-water temperature depends on the actual cooling system. In all cases, TF Table 1.3 specifies the actual reference scavenging-air temperature. Sea-water cooling system (SW) 4. Relative scavenging-air temperature change = (Tmeas.scav.air Tref.scav. air) (Tmeas.sea-water inlet Tref.sea-water inlet)

4.3.6

4.3.7

Central cooling system Optimal cooling (CC-O) 5. Relative scavenging-air temperature change = (Tmeas.scav.air Tref.scav. air) (Tmeas.sea-water inlet Tref.sea-water inlet)


Page 15 (23)

Chapter 701

701-05

IMO NOx ComponentsCentral cooling system Fixed cooler out temperature (CC-F) 6. Relative scavenging-air temperature change = Tmeas.scav.air Tref.scav. air

4.3.8

4.3.9

Test-bed cooling system The scavenging-air temperature is on test bed always adjusted similar to a CC-F cooling system with the appropriate Tscav.ref., since the actual cooling system is not available and different cooling-water adjustment possibilities usually exists on a test bed. (The actual air-cooler performance can be evaluated based on a heat balance for the system.) All assumptions have been built into the MAN B&W survey code.

4.4 4.4.1

Correction to ISO ambient conditions Performance parameters correction to ISO ambient conditions Some of the measured performance parameters need to be corrected to ISO ambient conditions in order to perform a reliable evaluation and compare with reference conditions. These parameters are Pmax, Pcomp and Pscav. Correction equations: 7. 8. 9.CorrP max = P max, m (100 0.2198 Tinl + 0.081 Tsc + 0.022 Pamb 0.005278 Pback ) / 100CorrPcomp = Pcomp , m (100 0.2954 Tinl + 0.153 Tsc + 0.0301 Pamb 0.007021 Pback ) / 100

CorrPsc = Psc , m (100 0.2856 Tinl + 0.222 Tsc + 0.0293 Pamb 0.006788 Pback ) / 100

where: refers to (reference measured) subscript m measured Tinl T/C inlet temperature (deg.C) Tsc scavenging-air temperature (deg.C) Pamb ambient pressure (mmHg) Pmax maximum pressure (bar) Pcomp compression pressure (bar) Psc scavenging-air pressure (bar) Pback back pressure (mmWC) 4.4.2 NOx emission correction to ISO ambient conditions Based on simultaneous measurements of NOx emission and performance parameters from several different MAN B&W two-stroke engines, a special NOx function has been formulated to calculate NOx as a function of specific engine parameters. Together with the MAN B&W cycle simulation to predict dependent engine parameters (or simplified in the form of performance correction factors,) the NOx function can be used to calculate the tolerances on the most common performance parameters.

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IMO NOx Components

Chapter 701

701-05

The measured data have also been used to formulate an equation to correct emissions at the given ambient conditions to the specified ISO ambient conditions in order to compare emission values at the same conditions (see Equation (10).) 10.CorrNO x (H a ,Tamb , pamb ) = 1 1 + C 1 (H a 10.71) + C 2 (Tamb 298.15) + C 3 (pamb 1000 )

where: Ha Tamb pamb C1 to C3

water content in scavenging air (gH2O/kg dry air) ambient-air temperature (K) ambient pressure (mbar) coefficients depend on engine load (given in Table B.2.2)

Table B.2.2: ISO ambient correction coefficientsEngine load % 100 75, 50 and 25 C1 -0.00994 -0.00505 C2 0.00144 0.00145 C3 -0.00007 -0.00011

Ha can be calculated the following way:6.220 Ra pa pb pa Ra 10 2 6.220 psc 100 pc psc

11. 12. 13.

* Ha =

H sc =

If H*a Hsc then Ha = Hsc else Ha = H*a

where:

H*a Ra pa pb Hsc pc psc

water content at ambient-air condition (gH2O/kg dry air) relative humidity of intake air (rel.%) saturation vapour pressure at ambient-air condition (kPa) total barometric pressure (kPa) water content at scavenging-air condition (gH2O/kg dry air) scavenging-air pressure (kPa) saturation vapour pressure at scavenging-air condition (kPa)

The saturation vapour pressure is only a function of temperature and can be calculated the following way:

14.

p = 1.013 e

19.008

5325.35 T

where T is the temperature in Kelvin (K).


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Chapter 701

701-05

IMO NOx ComponentsThe ISO corrected NOx value is calculated using the equation for the average weighed NOx emission (IMONOx) given in the IMO-NOx Technical Code: 15.IMONOx =n ii =1 Specific _ emission (i ) Power (i ) WF (i ) = n ii =1 Power (i ) WF (i ) =

where n=4 represents the 4 load points of the E3/E2 cycle (please refer to the IMO-NOx Technical Code for definition of E3/E2.) Using the weight factor (WF), the power (in kW) and the specific NOx emission (in g/kWh) for the 4 load points, the equation can also be written as Equation (16). However, for Equation (16) to be valid, the load points of the E3/E2 cycle must correspond exactly to 100, 75, 50 and 25% of MCR. 16.IMONOx = 0.2909 NO x (100% ) + 0.5455 NO x (75% ) + 0.1091 NO x (50% ) + 0.0545 NO x (25% )

4.5

Correction to reference performance conditions The NOx function has also been used to derive a simplified method to calculate the variation in the ISO corrected NOx value as function of maximum cylinder pressure, scavenging-air temperature and turbine back pressure. The relative changes are shown in Table B.2.3 at the four specific cycle-load conditions. However, the simplified method will predict a slightly higher NOx emission than the NOx function. Table B.2.3: Relative changes in NOx for Pmax, Tscav and Pturb.backPower (%) NOx, Pmax 1) (gNOx/kWh pr. bar) 0.1816 0.1760 0.1760 0.1760 NOx, Tscav 2) (gNOx/kWh pr. deg.C) 0.0224 0.0209 0.0209 0.0209 NOx, Pturb.back (gNOx/kWh pr. mmWC) 0.0004 0.0006 0.0006 0.00063)

100 75 50 251. 2. 3.

Relative increase in NOx value (corrected to ISO ambient conditions) resulting from a one bar increase in the cylinder maximum pressure. Relative increase in NOx value (corrected to ISO ambient conditions) resulting from a one degree increase in the scavenging-air temperature. Relative increase in NO

MAN B & W Engine Automation

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