Installation Planning Instructions for Aker Yards 728 Generating sets: 4 x Wärtsilä 9L20
Date: Version: Made by:
7 January 2008 a1 Wärtsilä Finland Oy
Lib Version: a1554
Installation Planning Instructions Preface
Preface Wärtsilä as supplier and the yard as contractor need to communicate installation specific information to build an installation that is both reliable and economical in use. During the years this information has evolved into what we today are calling the Installation Planning Instruction (IPI). Instructions included in this file are installation specific and based on the best of our experience and knowledge. The instructions shall be used as a recommendation with general guidelines. However, project specific deviations can be accepted based on special consideration. Alternative solutions and design should be separately agreed with Wärtsilä. The level of content maintained in the IPI is based on the assumption that the receiving contractor maintains the workmanship required to design and build high quality ship installations. The IPI is a living document that is updated according to the proceeding project and as far as technically possible reflect the actual situation. Each updated issue of the IPI is identified by its own unique version number ( e.g. "project xx" - a1) which should be referred to in any correspondence or discussion related to the specific projects. Issuing the first or any new version of IPI is proceeded by our internal quality assurance and approval by the Project Manager. To ensure further development in our common interest we appreciate your comments forwarded to us via the Project Manager. Wärtsilä, Ship Power 4 stroke business.
Aker Yards 728 - a1 7 January 2008
iii
Installation Planning Instructions
Version History Version a1
iv
Date
History
2008-01-07
Version 01
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions Table of Contents
Table of Contents 1.
Project Information ....................................................................................................................................... 1.1 Project administration .......................................................................................................................... 1.2 Project technical data ........................................................................................................................... 1.2.1 Ambient conditions ............................................................................................................. 1.2.2 Fuel oil specification ........................................................................................................... 1.2.3 Classification ...................................................................................................................... 1.2.4 Electric power supply ......................................................................................................... 1.2.5 Painting .............................................................................................................................. 1.2.6 Factory acceptance test ..................................................................................................... 1.3 Documents in this project ..................................................................................................................... 1.3.1 Comments to this document .............................................................................................. 1.3.2 Shipyard drawings .............................................................................................................. 1.4 Corrosion protection for the engines .................................................................................................... 1.4.1 Acceptance ........................................................................................................................ 1.4.2 Intermediate inspection ...................................................................................................... 1.4.3 Repeated inspection .......................................................................................................... 1.4.4 Long-term storing ............................................................................................................... 1.4.5 Subsequent work ............................................................................................................... 1.4.6 Recommended corrosion inhibitors ................................................................................... 1.5 Wärtsilä scope of supply for project Aker Yards 728 ............................................................................ 1.6 Drawings ..............................................................................................................................................
1-1 1-1 1-1 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-4 1-4
2.
Generating Set .............................................................................................................................................. 2.1 About the generating set ...................................................................................................................... 2.1.1 Recommendations for operation ........................................................................................ 2.1.2 Loading rate ....................................................................................................................... 2.1.3 Maximum instant load step ................................................................................................ 2.2 Technical information ........................................................................................................................... 2.2.1 Technical specification ....................................................................................................... 2.2.2 Technical data .................................................................................................................... 2.3 Design of the engine room ................................................................................................................... 2.3.1 Engine room arrangement ................................................................................................. 2.3.2 Noise levels ........................................................................................................................ 2.3.3 Foundation ......................................................................................................................... 2.4 Installation of the generating set .......................................................................................................... 2.4.1 Lifting the generating set .................................................................................................... 2.4.2 Installation procedure ......................................................................................................... 2.4.3 Installation of flexible pipe connections .............................................................................. 2.5 Component data, Wärtsilä scope of supply ......................................................................................... 2.5.1 Set of foundation bolts (6B04) ............................................................................................ 2.5.2 Flexible pipe connections (6H01) ....................................................................................... 2.5.3 Power transmission ............................................................................................................ 2.5.4 Packing and transportation ................................................................................................ 2.5.5 0Y02 - Tools (engine) ......................................................................................................... 2.5.6 0Y04 - Spare parts (engine) .............................................................................................. 2.5.7 Technical documentation ................................................................................................... 2.5.8 Start-up support ................................................................................................................. 2.6 Drawings ..............................................................................................................................................
2-1 2-1 2-1 2-1 2-1 2-1 2-1 2-2 2-4 2-4 2-5 2-5 2-6 2-6 2-6 2-7 2-13 2-13 2-13 2-13 2-14 2-14 2-14 2-14 2-14 2-14
3.
Fuel Oil System ............................................................................................................................................. 3.1 System overview .................................................................................................................................. 3.1.1 Engine internal system ....................................................................................................... 3.2 System design data ............................................................................................................................. 3.2.1 Fuel oil quality .................................................................................................................... 3.2.2 Calculation formulas .......................................................................................................... 3.3 Recommended functions ..................................................................................................................... 3.3.1 MDF separator unit (1N05) ................................................................................................
3-1 3-1 3-1 3-1 3-1 3-2 3-3 3-3
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Installation Planning Instructions Table of Contents 3.3.2 Sludge tank (1T05) ............................................................................................................ 3.3.3 MDF day tank (1T06) ......................................................................................................... 3.3.4 Collection leak fuel ............................................................................................................. Component data, Wärtsilä scope of supply ......................................................................................... 3.4.1 Cooler (MDF return line) (1E04) ........................................................................................ 3.4.2 Flow meter with pulse transmitter (MDF) (1I03) ................................................................. 3.4.3 Fuel circulation pump with el motor (1M01) ....................................................................... 3.4.4 Suction strainer (MDF) (1F07) ........................................................................................... Drawings ..............................................................................................................................................
3-4 3-4 3-4 3-4 3-4 3-5 3-5 3-5 3-5
4.
Lubricating Oil and Crankcase Ventilation Systems ................................................................................. 4.1 System overview .................................................................................................................................. 4.1.1 Engine internal system ....................................................................................................... 4.2 System design data ............................................................................................................................. 4.2.1 Lubricating oil quality ......................................................................................................... 4.3 Recommended functions ..................................................................................................................... 4.3.1 Lubricating oil system ........................................................................................................ 4.3.2 Crankcase ventilation system ............................................................................................ 4.4 Drawings ..............................................................................................................................................
4-1 4-1 4-1 4-1 4-1 4-3 4-3 4-5 4-5
5.
Compressed Air System .............................................................................................................................. 5.1 System overview .................................................................................................................................. 5.1.1 Engine internal system ....................................................................................................... 5.2 System design data ............................................................................................................................. 5.2.1 Starting air consumption .................................................................................................... 5.3 Recommended functions ..................................................................................................................... 5.3.1 Starting air vessel (3T01) ................................................................................................... 5.3.2 Starting air compressor unit (3N02) ................................................................................... 5.3.3 Air filter (3F02) ................................................................................................................... 5.4 Drawings ..............................................................................................................................................
5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-2 5-2 5-2
6.
Cooling Water System .................................................................................................................................. 6.1 System overview .................................................................................................................................. 6.1.1 Engine internal system ....................................................................................................... 6.2 System design data ............................................................................................................................. 6.2.1 Raw water quality ............................................................................................................... 6.2.2 Cooling water treatment ..................................................................................................... 6.3 Recommended functions ..................................................................................................................... 6.3.1 Central cooler (4E08) ......................................................................................................... 6.3.2 Expansion tank (4T05) ....................................................................................................... 6.3.3 Drain tank (4T04) ............................................................................................................... 6.3.4 Air venting (4S01) .............................................................................................................. 6.3.5 Orifices ............................................................................................................................... 6.4 Component data, Wärtsilä scope of supply ......................................................................................... 6.4.1 Temperature control valve (heat recovery) (4V02) ............................................................. 6.4.2 Preheating unit (4N01) ....................................................................................................... 6.4.3 Temperature control valve (LT) (4V03) ............................................................................... 6.5 Drawings ..............................................................................................................................................
6-1 6-1 6-1 6-1 6-1 6-1 6-3 6-3 6-4 6-4 6-4 6-4 6-4 6-4 6-5 6-5 6-5
7.
Combustion Air System ............................................................................................................................... 7.1 System overview .................................................................................................................................. 7.2 System design data ............................................................................................................................. 7.2.1 Combustion air quality ....................................................................................................... 7.3 Recommended functions ..................................................................................................................... 7.3.1 Engine room ventilation ...................................................................................................... 7.3.2 Combustion air for engines ................................................................................................ 7.3.3 Condensation of charge air coolers ...................................................................................
7-1 7-1 7-1 7-1 7-1 7-1 7-2 7-3
8.
Exhaust Gas System .................................................................................................................................... 8.1 System overview .................................................................................................................................. 8.1.1 Engine internal system .......................................................................................................
8-1 8-1 8-1
3.4
3.5
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Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions Table of Contents 8.2
Recommendations and design data .................................................................................................... 8.2.1 Exhaust gas piping ............................................................................................................. 8.2.2 Supporting ......................................................................................................................... 8.2.3 Back pressure .................................................................................................................... 8.2.4 Exhaust gas bellows (5H01) .............................................................................................. 8.2.5 Selective Catalytic Reduction (11N03) ............................................................................... 8.2.6 Exhaust gas silencer (5R02) .............................................................................................. 8.2.7 Exhaust gas boiler ............................................................................................................. Installation instructions ......................................................................................................................... Component data, Wärtsilä scope of supply ......................................................................................... 8.4.1 Turbocharger cleaning device (5Z03) ................................................................................. 8.4.2 Connection piece (5Z01) .................................................................................................... 8.4.3 Exhaust gas bellows (5H01) .............................................................................................. 8.4.4 Exhaust gas silencer with spark arrestor (5R02) ............................................................... Drawings ..............................................................................................................................................
8-1 8-1 8-1 8-2 8-2 8-2 8-2 8-2 8-3 8-4 8-4 8-4 8-4 8-4 8-5
Piping Arrangements ................................................................................................................................... 9.1 Recommendations regarding piping design ......................................................................................... 9.1.1 General .............................................................................................................................. 9.1.2 Pipe dimensions ................................................................................................................. 9.1.3 Trace heating ..................................................................................................................... 9.1.4 Pressure class ................................................................................................................... 9.1.5 Pipe class ........................................................................................................................... 9.1.6 Insulation ............................................................................................................................ 9.1.7 Local gauges ...................................................................................................................... 9.1.8 Cleaning procedures .......................................................................................................... 9.1.9 Flexible pipe connections ................................................................................................... 9.2 Installing flexible pipe connections ....................................................................................................... 9.2.1 General .............................................................................................................................. 9.2.2 Pipe supporting .................................................................................................................. 9.2.3 Fuel pipes .......................................................................................................................... 9.2.4 Pipe support nearby the diesel engine ............................................................................... 9.3 Flushing instructions ............................................................................................................................ 9.3.1 Fuel oil pipes ...................................................................................................................... 9.3.2 Lubricating oil pipes ...........................................................................................................
9-1 9-1 9-1 9-1 9-2 9-2 9-3 9-3 9-3 9-3 9-4 9-5 9-5 9-5 9-6 9-6 9-7 9-7 9-7
10. Automation System ...................................................................................................................................... 10.1 System overview .................................................................................................................................. 10.1.1 Internal el & automation system ......................................................................................... 10.2 Control signals ..................................................................................................................................... 10.2.1 Output signals .................................................................................................................... 10.2.2 Input signals ....................................................................................................................... 10.3 Bus communication .............................................................................................................................. 10.4 Functional description of start/stop ...................................................................................................... 10.4.1 Start function ...................................................................................................................... 10.4.2 Stop and shutdown function ............................................................................................... 10.5 Speed control functions & loadsharing ................................................................................................ 10.6 Power unit ............................................................................................................................................ 10.7 Precautions .......................................................................................................................................... 10.8 Component data, Wärtsilä scope of supply ......................................................................................... 10.8.1 Power Unit (9N36) .............................................................................................................. 10.9 Drawings ..............................................................................................................................................
10-1 10-1 10-1 10-3 10-3 10-5 10-7 10-7 10-7 10-7 10-7 10-8 10-8 10-9 10-9 10-9
11. ANNEX ........................................................................................................................................................... 11.1 List of symbols .....................................................................................................................................
11-1 11-1
8.3 8.4
8.5 9.
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Installation Planning Instructions Table of Contents
List of Drawings DBAA407004DBAA042536a tobeadded 2V69C0278e DAAE006367tobeadded DBAA388012a DBAA406985DBAA4069894V35A1591b 4V35A2939a 4V60B0093k 4V60B0095o 3V60D0025l 4V69L1585e DAAE002455a DAAE058154DAAE058155DAAE015263b DBAA406400DBAA406400Z102346DPI_4-36-2DBAA406434DBAA406434DBAA406434DAAE058156DAAE0581574V76E2522a DAAE058158DAAE058159DAAE058160DAAE0581614V60D0343DBAA396944DBAA39694410020-05 11472-03 DBAA396949DBAA396949DBAA396949DBAA396949DAAE0581623V37L0587a 3V60A49453V60B0020r 3ES0342C 4ES0061 DAAE061024DAAE061027tobeadded 4V50G1522h
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Order technical specification ................................................................................................. 1-5 Damage report form .............................................................................................................. 1-18 Generating set drawing, W 9L20 ........................................................................................... 2-15 Engine room arrangement ..................................................................................................... 2-16 Service space requirements .................................................................................................. 2-17 Location of sensors and el. components ............................................................................... 2-18 Generator technical data sheet ............................................................................................. 2-19 Tools for diesel engine ........................................................................................................... 2-20 Spare parts for diesel engine ................................................................................................. 2-22 Flexible pipe connection for fuel pipe ..................................................................................... 2-24 Flexible pipe connection for fuel pipe ..................................................................................... 2-25 Flexible hose .......................................................................................................................... 2-26 Flexible hose .......................................................................................................................... 2-27 Flexible rubber bellows for water pipe ................................................................................... 2-28 Installation of the generating sets .......................................................................................... 2-29 Factory acceptance test ........................................................................................................ 2-34 Internal fuel oil system ........................................................................................................... 3-6 Recommended fuel oil system .............................................................................................. 3-7 Recommended transfer and separating system .................................................................... 3-8 1E04 - Cooler (MDF return line), dimensional drawing ......................................................... 3-9 1E04 - Cooler (MDF return line), technical data .................................................................... 3-10 1F07 - Suction strainer (MDF) dimensional drawing ............................................................. 3-11 1F07 - Suction strainer (MDF) DPI ........................................................................................ 3-12 1P03 - Circulation pump (MDF) dimensional drawing ........................................................... 3-13 1P03 - Circulation pump (MDF) Driver specification ............................................................. 3-14 1P03 - Circulation pump (MDF) Pump calculation ................................................................ 3-15 Internal lubricating oil system ................................................................................................ 4-6 Recommended lubricating oil system .................................................................................... 4-7 Recommended crankcase ventilation .................................................................................... 4-8 Internal starting air system .................................................................................................... 5-3 Recommended starting air system ........................................................................................ 5-4 Internal cooling water system ................................................................................................ 6-6 Recommended cooling water system .................................................................................... 6-7 Recommended cooling water circuit deaerator ..................................................................... 6-8 4V02 - Temperature control valve (heat recovery), dimensional drawing .............................. 6-9 4V02 - Temperature control valve (heat recovery), installation instruction ............................ 6-10 4N01 - Preheating unit, dimensional drawing ........................................................................ 6-12 4N01 - Preheating unit, electrical drawing ............................................................................. 6-13 4V03 - Temperature control valve (LT), dimensional drawing ................................................ 6-15 4V03 - Temperature control valve (LT), el. PID valve controller ............................................. 6-16 4V03 - Temperature control valve (LT), temp sensor ............................................................. 6-17 4V03 - Temperature control valve (LT), installation instructions ............................................ 6-18 Internal charge air and exhaust gas system .......................................................................... 8-6 5Z03 - Turbocharger cleaning device, dimensional drawing .................................................. 8-7 5Z01 - Connection piece, dimensional drawing ..................................................................... 8-8 5H01 - Exhaust gas bellows, dimensional drawing ............................................................... 8-9 5R02 - Exhaust gas silencer with spark arrestor, dimensional drawing ................................ 8-10 5R02 - Exhaust gas silencer with spark arrestor, installation instruction ............................... 8-11 Block- / Interconnection diagram ...........................................................................................10-10 Power unit ..............................................................................................................................10-17 Modbus list ............................................................................................................................10-20 Pre-lubricating pump starter (recommended) ........................................................................10-21
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 1. Project Information
1.
Project Information
1.1
Project administration Wärtsilä internal order number:
M/03093
Wärtsilä project name:
Aker Yards 728
Wärtsilä project organisation: Project manager
Björn Nygård
Project engineer:
Tobias Knuts Tel:
+358 10 709 0000
Mobile: +359 50 589 2414
1.2
Fax:
+358 6 356 7188
E-mail:
[email protected]
Project technical data
1.2.1 Ambient conditions The equipment is designed for the following conditions: Maximum ambient air temperature
45 °C
Maximum LT cooling water temperature before engine
38 °C
Maximum sea water temperature
32 °C
Relative humidity
60 %
1.2.2 Fuel oil specification This installation is designed for MDF operation according to ISO 8217:2005 (E) with the viscosity of 14 cSt at 40°C. Table 1.1 ISO-F-DMC
Property
Limit
Unit
Density at 15°C, max.
920
kg/m3
Viscosity at 40°C, max.
14.0
cSt
Flash point, min
60
°C
Pour point (upper) - winter quality, max - summer quality, max
0 6
°C °C
Sulphur, max.
2.0
% mass
Carbon residue, max.
2.5
% mass
Ash, max.
0.05
% mass
Total sediment existent, max.
0.10
% mass
Water, max.
0.3
% mass
Vanadium, max.
100
mg/kg
Aluminium + silicon, max.
25
mg/kg
More detailed fuel oil requirements are specified in chapter "Fuel Oil System".
1.2.3 Classification The equipment meets the requirements of DNV for unrestricted service at the date of order.
Aker Yards 728 - a1 7 January 2008
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Installation Planning Instructions 1. Project Information
1.2.4 Electric power supply If not specially mentioned, all electrical equipment delivered with the engine is designed to operate with: Main voltage
3 x 690 V
Frequency
60 Hz
Control voltage
24 VDC
1.2.5 Painting The generating set(s) will be painted with acrylic-based paint in colour RAL 5019 Capri Blue.
1.2.6 Factory acceptance test A description of the procedure during factory acceptance test is enclosed in document "Factory acceptance test".
1.3
Documents in this project
1.3.1 Comments to this document Any comments to the material enclosed in this IPI-file have to be sent within one (1) month after receipt, if not stated differently in contract.
1.3.2 Shipyard drawings The following drawings are subject to review and should be forwarded as soon as available in 2 copies, one of which will be returned with comments:
1.4
•
Fuel oil piping diagram, including fuel treatment system and piping
•
Lubricating oil piping diagram, including separating system
•
Cooling water piping diagram, fresh and sea-water
•
Starting air piping diagram
•
Charge air and exhaust gas piping diagram showing the entire length of the pipes and details of the pipe supports
•
Main engine foundation
•
Crankcase vent piping diagram
Corrosion protection for the engines The engines are given corrosion protection at the factory according to our standard programme before delivery. Since storage and climatic conditions vary considerably around the world this protection must be checked regularly and, if necessary, be improved.
1.4.1 Acceptance When the engine arrives at its destination, the packing must be checked for possible damage during transport. If damage has occurred, please contact the insurance company concerned. The engines must be stored indoors or tightly secured under a tarpaulin.
1.4.2 Intermediate inspection Inspect the condition of the engines and their corrosion protection internally and externally no later than three months after delivery. To inspect internally, open the crankcase covers of the first and last cylinder, the corresponding covers of the camshaft and cylinder head, and the covers of the hot box. If the protection is sufficient, close the covers. If corrosion has begun, take appropriate measures to improve the protection. Note! See also turbocharger manufacturer’s specification.
1-2
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 1. Project Information
1.4.3 Repeated inspection Repeat this inspection every month.
1.4.4 Long-term storing If the engines have to be stored for several months before starting-up the following directions are to be followed: Pump Shell Argina T 40 or a corresponding lubricating oil into the crankcase in the following suggested quantities: •
Wärtsilä 9L20: 25 litre/cylinder
It is essential that oil reaches all parts of the engine, ensure this by opening the cylinder covers and inspect that all of the valve mechanism gets oil during the procedure. By aid of a pre-lubricating pump (manual or electrical) the oil should be circulated through the lubricating system (for about 15 minutes) at the same time as the flywheel is turned a few times. Repeat this procedure once a month in connection with the test mentioned in repeated control paragraph. Drain the crankcase of oil before starting up the engine and replace with fresh oil. The indicator valves have to be kept shut except in case of turning. The cover of the turbocharger air filter must not be removed before starting up the engine. The opening for the crankcase ventilation has to be shut until starting up the engine. For long time storing some turbocharger manufacturers require special arrangements e.g. supporting of the rotor or change of the bearings. For details see turbocharger manufacturer’s specification.
NOTE!
1.4.5 Subsequent work Refer to section "Recommended corrosion inhibitors" for the list of protective oils. •
Use protective oil ’A’, when checking or adjusting the opening pressure of the injection valves.
•
To protect the cylinder liners, spray about 3 cl of ‘B’ into the injection nozzle opening of each cylinder. NOTE!
To keep the protective film intact during transport, do not turn the crankshaft.
•
The valve mechanism, camshaft, crankshaft, connecting rods, cylinder liners, main bearings and gear wheels are sprayed with protective oil ‘B’.
•
The other unpainted surfaces in the camshaft and crankshaft space are also protected with ‘B’.
•
The injection pumps, control shaft, fuel pipes and other unpainted surfaces in the hot box are sprayed with protective oil ‘C’.
•
The indicating valves, screws and unpainted surfaces on the cylinder head are protected with ‘D’.
•
The edges of the crankcase and camshaft space openings and the side screws are protected with ‘E’.
•
The flywheel and the counter borings of its fastening bolts, the oil dipstick, governor levers and other unpainted surfaces are also protected with ‘E’.
1.4.6 Recommended corrosion inhibitors Protective oil
Name
Information For test pressure and protection of injection nozzles.
A
Shell Calibration Fluid B
B
Shell Ensis Fluid S, Shell Ensis Oil-based corrosion inhibitor which forms a thin transparent Fluid SX grease-like film. Dissolves into most lubricating oils.
C
Tectyl 502-C 1)
Aker Yards 728 - a1 7 January 2008
Wax-based corrosion inhibitor which forms a thick grease-like film. Dissolves into most lubricating and hydraulic oils.
1-3
Installation Planning Instructions 1. Project Information
Protective oil
1)
1.5
Name
Information
D
Mobiplex 47, Mobilux EP2
High-pressure general purpose greases which lubricate and protect parts from rust and corrosion.
E
Tectyl 506 EH
Wax-based corrosion inhibitor which forms a non-smudging hard brown transparent film.
Tectyl 502 EH, can alternatively be used in case of long-time outdoor storage.
Wärtsilä scope of supply for project Aker Yards 728 Below is the scope of supply listed for this installation. More details about the scope are found in each system chapter. Description
1.6
W20 - Wärtsilä 9L20
4
1E04 - Cooler (MDF return line)
4
1I03 - Flow meter with pulse transmitter (MDF)
4
1M01 - Fuel circulation pump with el motor
2
1F07 - Suction strainer 0.5mm (MDF)
2
4V02 - Temperature control valve (heat recovery)
4
4N01 - Preheating unit
4
4V03 - Temperature control valve (LT)
4
5Z03 - Turbocharger cleaning device
2
5Z01 - Connection piece
4
5H01 - Exhaust gas bellows
4
5R02 - Exhaust gas silencer with spark arrestor
4
9N36 - Power Unit
4
6H01 - Flexible pipe connections spare set
1
6H01 - Flexible pipe connections
4
6N01 - Common base frame
4
7C01 - Flexible coupling (flywheel)
4
9A03 - Generator 690V 60Hz IP44 sleeve
4
0Y02 - Tools (engine)
1
0Y04 - Spare parts (engine)
1
0Z12 - VCI-coating
4
0Z11 - Tarpaulin
4
0J10 - Engine manuals
1
0J13 - ELDOC
1
0J21 - Green Passport
1
0J17 - Start-up support 40 man-days in 4 trips
1
Drawings DBAA407004DBAA042536a
1-4
Qty/Set
Order technical specification ................................................................................ 1-5 Damage report form ............................................................................................. 1-18
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DBAA407004- - Order technical specification
Aker Yards 728 - a1 7 January 2008
1-5
Installation Planning Instructions DBAA407004- - Order technical specification
1-6
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Installation Planning Instructions DBAA407004- - Order technical specification
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1-7
Installation Planning Instructions DBAA407004- - Order technical specification
1-8
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Installation Planning Instructions DBAA407004- - Order technical specification
Aker Yards 728 - a1 7 January 2008
1-9
Installation Planning Instructions DBAA407004- - Order technical specification
1-10
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Installation Planning Instructions DBAA407004- - Order technical specification
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1-11
Installation Planning Instructions DBAA407004- - Order technical specification
1-12
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Aker Yards 728 - a1 7 January 2008
1-13
Installation Planning Instructions DBAA407004- - Order technical specification
1-14
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Installation Planning Instructions DBAA407004- - Order technical specification
Aker Yards 728 - a1 7 January 2008
1-15
Installation Planning Instructions DBAA407004- - Order technical specification
1-16
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DBAA407004- - Order technical specification
Aker Yards 728 - a1 7 January 2008
1-17
Installation Planning Instructions DBAA042536a - Damage report form
Damage Report Wärtsilä
Ship Power
Form Doc ID: DBAA042536
General information Name of installation:
Project number:
(Yard + NB no.)
(Wärtsilä ID)
Case no: Type of Equipment:
Report number:
Date when damage occurred: Reported by:
Description of damage
Probable cause
Witness statement and contact information
Use block letters for filling this form
Actions taken Damage photographed
Yes No N/A
Photographs enclosed Yes No
Insurance claim submitted
Yes No N/A
Claim enclosed
Yes No
Separate report submitted
Yes No N/A
Report enclosed
Yes No
Inspection performed by:
Date:
________________________________________________________________________________________________
(Signature)
1-18
Verified by:
Date:
_______________________________________________________________________________________________
(Signature)
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 2. Generating Set
2.
Generating Set
2.1
About the generating set The generating set comprises the diesel engine and the generator which are rigidly mounted on a common base frame. The common base frame is a welded steel structure. The complete generating set is installed on resilient mounts on the foundation in the ship. The main dimensions, locations of pipe connections, location of sensors, space required for maintenance, weight and centre of gravity are shown in enclosed drawings.
2.1.1 Recommendations for operation Starting and stopping The engine can be started and stopped provided that: •
The engine and the fuel system are pre-heated to operating temperature. The HT-water temperature must be min. 60°C and the lubricating oil temperature min. 40°C.
•
The pre-lubricating oil pump is running.
Recommendations for idling and low load operation Absolute idling (unloaded generator): •
Max. 5 minutes, if the engine is to be stopped after the idling. Recommended 1 minute.
Operations at loads lower than 20% on HFO or lower than 10% on MDF: •
Max. 100 hours continuous operation. At intervals of 100 operating hours the engine must be loaded to min. 70% of the rated load for at least 1 hour.
Operation at loads higher than 20% on HFO or higher than 10% on MDF: •
No restrictions.
2.1.2 Loading rate The loading rate of a highly turbocharged diesel engine must be controlled, because the turbocharger needs time to accelerate before it can deliver the required amount of air. Class rules regarding load acceptance capability stipulate what the generating set must be capable of in an unexpected situation, but in normal operation the loading rate should be slower, about 60 seconds from zero to full load. It is recommended to increase the load in small increments. The generating set can be loaded immediately after start, provided that the engine is pre-heated to a HTwater temperature of 60…70ºC, and the lubricating oil temperature is min. 40 ºC.
2.1.3 Maximum instant load step The automation system and the operation of the plant must prevent load steps exceeding the maximum load acceptance capability of the engine. The maximum permissible load step is 25% MCR. The resulting speed drop is less than 10% and the recovery time to within 1% of the steady state speed at the new load level is max. 5 seconds. When electrical power is restored after a black-out, fastest possible load increase is usually desired. The engine must be allowed to recover for at least 5 seconds before applying the following load step, if the load is applied in maximum steps.
2.2
Technical information
2.2.1 Technical specification The engine Wärtsilä 9L20 is a 4-stroke, non-reversible, turbocharged and intercooled diesel engine with direct injection of fuel.
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2-1
Installation Planning Instructions 2. Generating Set
Main particulars Type designation
Wärtsilä 9L20
Number of cylinders
9
Configuration
in-line engine
Max. continous rating
1665 kW
Overload capacity
10 % for 1h every 12h
Nominal speed
900 rpm
Direction of rotation
Clockwise
The generator is a two-bearing, brushless, 3-phase, synchronous alternator with built-on voltage regulator. Main particulars Maker
AvK
Type designation
DSG 99 L1-8 W
Rated output
2000
Power factor
0,80
Voltage
690V
Rated speed
900 rpm
Frequency
60 Hz
Overspeed capability
1,2 x nominal speed for 2 minutes
Bearing type
Sleeve
Cable outlet
Cable entry from the right side, 45° downwards Cable entry from the left side, 45° downwards Cable entry from the right side, 45° downwards Cable entry from the left side, 45° downwards
Anticondensation heater
Supply voltage 230V +-5% VAC 1-ph., Power required 500W
Cooling
IC 81W, water cooled
Temperature sensors
Yes
The generator is equipped with current transformers for differential protection. 3 pcs are mounted in neutral wires within the terminal box, 3 pcs are delivered loose for panel mounting. The generator is suitable for parallel operation, damper cage and droop transformers are built-in.
2.2.2 Technical data Wärtsilä 9L20 Engine output
1665 kW
Cylinder configuration
9L
Engine speed
900 rpm
Bore
200 mm
Stroke
280 mm
Mean effective pressure Mean piston speed
2.8 (28.0) MPa (bar) 8.4 m/s
Combustion air system (Note 1) Flow of air at 100% load
3.5 kg/s
Ambient air temperature, max
45 °C
Air temperature after air cooler, min
50 °C
Air temperature after air cooler, max
70 °C
Air temperature after air cooler, alarm
75 °C
Exhaust gas system (Note 2) Exhaust gas flow at 100% load
2-2
3,59 kg/s
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 2. Generating Set
Wärtsilä 9L20 Exhaust gas flow at 85% load
3,11 kg/s
Exhaust gas flow at 75% load
2,84 kg/s
Exhaust gas flow at 50% load
1,94 kg/s
Exhaust gas temperature after turbocharger at 100% load
320 °C
Exhaust gas temperature after turbocharger at 85% load
290 °C
Exhaust gas temperature after turbocharger at 75% load
285 °C
Exhaust gas temperature after turbocharger at 50% load
300 °C
Exhaust gas temperature after cylinder, alarm Exhaust gas backpressure, max
400 °C 3 (0.03) kPa (bar)
Turbocharger connection diameter
300 mm
Exhaust gas pipe diameter, min
450 mm
Calculated exhaust diameter for 35 m/s
462 mm
Heat balance (Note 3) Jacket water
367 kW
Charge air (LT-circuit)
550 kW
Lubrication oil
250 kW
Exhaust gases
1110 kW
Radiation etc.
68 kW
Fuel system (Note 4) Pressure before engine driven fuel feed pump, min Pressure before injection pumps Viscosity before engine (MDF), min
30 (0.3) kPa (bar) 700±50 (7±0.5) kPa (bar) 1.8 cSt
Pump capacity (MDF), engine driven
1.73 m3/h
Fuel consumption at 100% load
191 g/kWh
Fuel consumption at 85% load
190 g/kWh
Fuel consumption at 75% load
191 g/kWh
Fuel consumption 50% load
199 g/kWh
Leak fuel quantity (MDF), clean fuel at 100% load
6.0 kg/h
Lubricating oil system Pressure before engine, nom
450 (4.5) kPa (bar)
Pressure before engine, alarm
300 (3.0) kPa (bar)
Pressure before engine, stop
200 (2.0) kPa (bar)
Priming pressure, nom
80 (0.8) kPa (bar)
Priming pressure, alarm
30 (0.3) kPa (bar)
Temperature before engine, nom
63 °C
Temperature before engine, alarm
80 °C
Temperature after engine, about
78 °C
Pump capacity (main), engine driven
50 m3/h
Suction height of engine driven pump, max
4 m
Pump capacity (main), separate
30 m3/h
Priming pump capacity (60 Hz)
8.4 m3/h
Suction height of priming pump, max
3.5 m
Oil volume, nom Filter fineness Filter difference pressure alarm Oil consumption at 100% load, about
Aker Yards 728 - a1 7 January 2008
0.55 m3 25 microns 150 (1.5) kPa (bar) 0.5 g/kWh
2-3
Installation Planning Instructions 2. Generating Set
Wärtsilä 9L20 HT cooling water system Pressure at engine inlet, after pump, nom (+ static pressure)
200 (2.0) kPa (bar)
Pressure at engine inlet, after pump, alarm (+ static pressure)
100 (1.0) kPa (bar)
Pressure at engine inlet, after pump, max
500 (5.0) kPa (bar)
Temperature before engine, about
83 °C
Temperature at the engine outlet, nom
91 °C
Temperature after cylinders, alarm
105 °C
Temperature after cylinders, stop
110 °C
Pump capacity, nom Pressure drop over engine Water volume in engine Pressure from expansion tank Pressure drop over external system, max
44 m3/h 50 (0.5) kPa (bar) 0.16 m3 70...150 (0.7...1.5) kPa (bar) 120 (1.2) kPa (bar)
LT cooling water system Pressure at engine inlet, after pump, nom (+ static pressure)
200 (2.0) kPa (bar)
Pressure at engine inlet, after pump, alarm (+ static pressure)
100 (1.0) kPa (bar)
Pressure at engine inlet, after pump, max
500 (5.0) kPa (bar)
Temperature before engine, max
45 °C
Temperature before engine, min
25 °C
Pump capacity, nom
65 m3/h
Pressure drop over charge air cooler Pressure drop over oil cooler Pressure drop over external system, max Pressure from expansion tank
30 (0.3) kPa 30 (0.3) kPa (bar) 120 (1.2) kPa (bar) 70...150 (0.7...1.5) kPa (bar)
Starting air system Air pressure, nom Air pressure, alarm Air consumption per start at 20 °C
3000 (30) kPa (bar) 600(6) kPa (bar) 0.4 Nm3
Notes: Note 1
At ISO 3046-1 conditions (ambient air temperature 25°C, LT-water 25°C) and 100% load. Tolerance 5%.
Note 2
At ISO 3046-1 conditions (ambient air temperature 25°C, LT-water 25°C) and 100% load. Flow tolerance 5% and temperature tolerance 15°C.
Note 3
At ISO 3046-1 conditions (ambient air temperature 25°C, LT-water 25°C) and 100% load. Tolerance for cooling water heat 10%, tolerance for radiation heat 30%. Fouling factors and a margin to be taken into account when dimensioning heat exchangers.
Note 4
According to ISO 3046/1, lower calorific value 42 700 kJ/kg, with engine driven pumps. Tolerance 5%. Load according to propeller law for mechanical propulsion engines (ME).
The generator technical data sheet is enclosed, see section "Drawings".
2.3
Design of the engine room
2.3.1 Engine room arrangement Sufficient space for operation and maintenance has to be provided around the generating sets. For minimum centreline distance between the generating sets refer to the engine room arrangement drawing. The required service space around the generating set is stated in the service space drawing. No obstructive structures should be located close to the engine driven pumps nor crankcase or camshaft doors.
2-4
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Installation Planning Instructions 2. Generating Set
2.3.2 Noise levels The airborne noise level of the engine is measured as a sound power level acc. to ISO 9614-2. The diagram is based on measured noise levels. The lower figures represent the lowest levels found in the measurements, while 90 % of the measured values are below the higher figures. The airborne noise level of the engine is measured as a sound power level acc. to ISO 9614-2. The diagram is based on measured noise levels. The lower figures represent the lowest levels found in the measurements, while 90 % of the measured values are below the higher figures. Figure 2.1 Sound power levels according to ISO 9614-2
2.3.3 Foundation For more information about the foundation design refer to section "Installation of the generating set".
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Installation Planning Instructions 2. Generating Set
2.4
Installation of the generating set
2.4.1 Lifting the generating set Figure 2.2 Lifting the generating set
2.4.2 Installation procedure The following documents are enclosed to help you with the installation of the genset(s). Installation of the generating sets
2-6
4V69L1585
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Installation Planning Instructions 2. Generating Set
2.4.3 Installation of flexible pipe connections In this section you will find installation instructions for the flexible pipe connections included in the scope of supply. In chapter "Piping Arrangements" you will find additional instructions/recommendations about piping arrangements.
Installation of flexible pipe connections (with flanges) This instruction is valid for flexible pipe connections according to drawings 4V60B0007, 4V60B0008 & 4V60B0093. Figure 2.3 Flexible pipe connection
1. The generating set (or engine) should be installed in its final position before any external pipes are connected. 2. Fasten the flexible pipe connection to the connection on the engine according to the following procedure: •
If there is a counter flange, remove it.
•
Fasten the fixed flange of the flexible pipe connection to the engine side with a gasket between the flanges.
•
Oil the threads of the screws and nuts, fit all screws and tighten until finger tight.
•
Tighten screws in a crosswise sequence using a socket wrench. Increase the tightening torque gradually until the final torque is achieved.
3. Connect the free end of the flexible pipe connections to the external piping. •
The flange of the external pipe should be in line with the flange of the engine. No twisting, compression or elongation of the flexible pipe connection is allowed, i.e. it should fit between the flanges with the correct installation length (L). Align the external pipe and weld the counter flange to the pipe.
•
The flexible pipe connection can also be installed with a bending radius as stated in the flexible pipe connection drawing.
•
Bolt the swivel flange side of the flexible pipe connection to the flange of the external pipe as described in step 2.
4. Anchor the external pipe to the steel structure of the ship close to the flange. Observe that the pipe clamping must be very rigid in order to prevent vibration and movement of the flexible pipe connection. Most problems with bursting of the flexible connection originate from poor clamping. 5. The flexible pipe connection must be protected from external mechanical damage. There must be enough space around the flexible pipe connection for regular supervision and maintenance.
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Installation Planning Instructions 2. Generating Set
Installation of flexible pipe connections (with stud coupling) This instruction is valid for flexible pipe connections according to drawings 4V60B0009, 4V36G0055 & 4V60B0095. Figure 2.4 Flexible pipe connection.
1. The generating set (or engine) should be installed in its final position before any external pipes are connected. 2. Fasten the flexible pipe connection to the connection on the engine according to the following procedure. All stud coupling parts should be lubricated with engine oil. •
Remove the nut from the stud coupling of the engine and put it on the pipe end of flexible connection.
•
Remove the ring from the stud coupling of the engine and slip it over the pipe end of flexible connection with the thinner end outwards against the bottom of the stud coupling.
•
Screw the nut with flexible connection and ring manually to the stud coupling until finger tight.
•
Push the pipe of the flexible connection against the bottom of the internal cone of the fitting body.
•
Mark the position of the pipe as well as the nut with a marker pen.
•
Tighten the nut 1 1/2 turn while the pipe is prevented from turning.
3. When the flexible pipe connection is fitted to the engine, connect the external pipe to the end of the flexible pipe provided with the stud coupling. The stud coupling on the flexible pipe is similar to the stud coupling on the engine, i.e. a seamless steel pipe according to DIN 2391/c will fit directly to the stud. The tightening procedure is the same as outlined in step 2. If seamless steel pipe isn't available an adapter piece with a suitable outer diameter can be welded to shipyards pipe in order to fit the stud coupling of the flexible pipe connection. Mild steel (St 35) is recommended. The flexible pipe connection should be mounted in a straight position although some bending radius is allowed. The flexible pipe connection should be protected against external mechanical damage. The shipyards pipe should be fixed with suitable pipe clamps close to the flexible connection in order to prevent vibration and movements.
2-8
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Installation Planning Instructions 2. Generating Set
Installation of flexible rubber bellows connections This instruction is valid for flexible pipe connections according to drawing 3V60D0025. Figure 2.5 Flexible rubber bellow connection.
1. The generating set (or engine) should be installed in its final position before any external pipes are connected. 2. Remove the counter flange from the engine connection. Fit the flexible pipe connection temporarily. 3. The flexible pipe connection should not be exposed to axial , lateral or angular deflection. Align the external pipe in order to achieve this. •
The counter flange should have a smooth sealing surface against the rubber collar and the inner diameter of the flange should not be larger than the inner diameter of the rubber compensator.
•
Fix the flange by small tack weldings at three points around the pipe. Take care not to heat the flange. Protect the rubber against weld splash.
•
Remove the flexible pipe connection.
4. Weld the flange to the pipe and let it cool down before proceeding. 5. Fasten the flexible pipe connection to the connection to the engine according to the following procedure: •
Both flanges of the flexible pipe connection are swivel flanges which means it can be installed with either one of the flanges to the engine.
•
Oil the threads of the bolts and nuts, fit all bolts to the head on the compensator side and the nut on the pipe side and tighten until finger tight. No gaskets are needed between the flanges as the rubber collar is squeezed in between the flanges.
•
Tighten the nuts in a diagonal sequence with a wrench on the outside while the bolt head is held firmly on the inside. Take care not to damage the rubber bellows with the tool. The tightening torque is stated in drawing 3V60D0025.
6. Fasten the outer side of the flexible pipe connection in the same way as described in step 5. 7. Anchor the external pipe to the steel structure close to the flange. Observe that the pipe clamping must be very rigid in order to prevent vibration and movement of the flexible pipe connection. Most problems with bursting originate from poor clamping. 8. The flexible pipe connection must be protected from external mechanical damage. There must be enough space around the flexible pipe connection for regular supervision and maintenance. The rubber part must not be painted.
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2-9
Installation Planning Instructions 2. Generating Set
Installation of flexible fuel oil pipe connections This instruction is valid for flexible pipe connections according to drawing 4V35A0719. Figure 2.6 Flexible fuel oil pipe connection.
1. The generating set (or engine) should be installed in its final position before any external pipes are connected. 2. Fasten the flexible pipe connection to the engine according to the following procedure. All parts should be lubricated with engine oil. •
Remove the nut from the stud coupling on the engine and put it on the pipe end of flexible pipe connection.
•
Remove the ring from the stud coupling of the engine and slip it over the pipe end of flexible pipe connection with the thinner end outwards against the bottom of the stud coupling.
•
Screw the nut with flexible connection and ring manually to the stud coupling until finger tight.
•
Push the flexible connection against the bottom of the internal cone of the fitting body.
•
Mark the position of the pipe as well as the nut with a marker pen.
•
Tighten the nut 1 1/2 turn while the pipe is prevented from turning.
3. When the flexible pipe connection is fitted to the engine, connect the external pipe to the stud of the flexible pipe provided with the straight bulkhead fitting.
2-10
•
The flexible pipe connection must not be reshaped or welded. Enough space allowing maintenance must be provided.
•
The pipe clamp should have a diameter of 38 mm hole into which the bulkhead fitting is fixed. The pipe clamp bracket should be very rigid and welded to the steel structure of the foundation. Max. thickness of the clamp is 16 mm.
•
Tighten the bulkhead fitting to the flexible pipe as described in step 2.
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Installation Planning Instructions 2. Generating Set •
Align the external pipe to the bulkhead fitting. The external pipe should be seamless and have 28 mm. If suitable pipe is not available an adapter piece with 28 ± 0.1 mm outer diameter can be welded to the shipyards pipe in order to fit the bulkhead connection. Mild steel (St 35) is recommended.
•
Tighten the external pipe to the bulkhead connection the same way as outlined in step 2.
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2-11
Installation Planning Instructions 2. Generating Set
Installation of flexible fuel oil pipe connections This instruction is valid for flexible pipe connections according to drawings 4V35A1591 and 4V35A2939. Figure 2.7 Flexible fuel oil pipe connection.
1. The generating set (or engine) should be installed in its final position before any external pipes are connected. 2. Fasten the flexible pipe connection to the engine according to the following procedure. All stud coupling parts should be lubricated with engine oil. •
Remove the nut from the stud coupling of the engine. In case of flexible pipe connection of type 4V35A1591, put the nut on the pipe end of flexible connection.
•
Remove the ring from the stud coupling of the engine. In case of flexible pipe connection of type 4V35A1591, slip the ring over the pipe end of flexible connection with the thinner end outwards against the bottom of the stud coupling.
•
Screw the nut with flexible connection and ring manually to the stud coupling until finger tight.
•
Push the flexible pipe connection against the bottom of the internal cone of the fitting body.
•
Mark the position of the pipe as well as the nut with a marker pen. This will guide you to tighten the nut the correct number of turns.
•
Tighten the nut 1½ turn while the pipe is prevented from turning.
3. Connect the free end of the flexible pipe connection to the external piping.
2-12
•
The flange of the external pipe should be in line with the connection of the engine. No twisting, compression or elongation of the flexible pipe connection is allowed, i.e. it should fit between the connections in a straight position without reshaping. Align the external pipe and weld the counter flange to the pipe.
•
Fasten the fixed flange of the flexible pipe connection with a gasket between the flanges.
•
Oil the threads of the screws and nuts, fit all screws and tighten until finger tight.
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 2. Generating Set •
Tighten screws in a crosswise sequence using a socket wrench. Increase the tightening torque gradually until the final torque is achieved.
4. Anchor the external pipe to the steel structure of the ship close to the flange. Observe that the pipe clamping must be very rigid in order to prevent vibration and movement of the flexible pipe connection. Most problems with bursting of the flexible connection originate from poor clamping. 5. The flexible pipe connection must be protected from external mechanical damage. There must be enough space around the flexible pipe connection for regular supervision and maintenance.
2.5
Component data, Wärtsilä scope of supply
2.5.1 Set of foundation bolts (6B04) The jacking screws are not included in Wärtsilä scope of supply. Refer to section "Installation of the generating set" for instructions and recommendations.
2.5.2 Flexible pipe connections (6H01) Table 2.1 List of flexible pipe connections
Code
Pipe connection
Connection size
Qty / engine
Refer to drawing
101
Fuel inlet
OD28
1
4V35A1591
102
Fuel outlet
OD28
1
4V35A1591
103
Leak fuel drain, clean fuel
OD18
1
4V60B0095-5
105
Fuel stand-by connection
OD22
1
4V35A2939
213
Lube oil from separator and filling
DN32/PN40
1
4V60B0093-1
214
Lube oil to separator and drain
DN32/PN40
1
4V60B0093-1
301
Starting air inlet
OD28
1
4V60B0095-7
401
HT-water inlet
DN65/PN16
1
3V60D0025-2
402
HT-water outlet
DN65/PN16
1
3V60D0025-2
404
HT-water air vent
OD12
1
4V60B0095-3
406
Water from preheater to HT-circuit
OD28
1
4V60B0095-7
451
LT-water inlet
DN80/PN16
1
3V60D0025-3
452
LT-water outlet
DN80/PN16
1
3V60D0025-3
454
LT-water air vent from air cooler
OD12
1
4V60B0095-3
460
LT water to generator
DN40/PN16
1
3V60D0025-16
461
LT water from generator
DN40/PN16
1
3V60D0025-16
486
LT water outlet to generator cooler
DN80/PN16
1
3V60D0025-3
701
Crankcase air vent
DN65/PN16
1
4V60B0093-4
Spare set of flexible pipe connections The spare set include one flexible pipe connection of each kind listed in the table above.
2.5.3 Power transmission Component 7C01 - Flexible coupling (flywheel) 7B01 - Flexible coupling fitting materials
Aker Yards 728 - a1 7 January 2008
Qty
Installation documents
1 / engine 1 set / engine
2-13
Installation Planning Instructions 2. Generating Set
2.5.4 Packing and transportation Component
Qty
Description
0Z11 - Tarpaulin
1 / engine
For protection during transport
0Z12 - VCI-coating
1 / engine
For rust protection of the engine(s).
2.5.5 0Y02 - Tools (engine) Component
Qty
Description
0Y02 - Tools (engine)
1 set
According to enclosed drawing "tools list".
Component
Qty
Description
0Y04 - Spare parts (engine)
1 set
According to enclosed drawing "spare parts list".
2.5.6 0Y04 - Spare parts (engine)
2.5.7 Technical documentation Publication
Language
Media
Qty
Installation Planning Instructions
English
A4 binder
3 / vessel
O & M manual Spare parts catalogue
English English
A4 binder A4 binder
5 5
ELDOC 2i, Ship's CD
English
CD
1
Record Book of Engine Parameters
English
Paper
1 / vessel
Classification certificates for equipment subject to class approval
English
Paper
1 / vessel
2.5.8 Start-up support According to contract.
2.6
Drawings tobeadded 2V69C0278e DAAE006367tobeadded DBAA388012a DBAA406985DBAA4069894V35A1591b 4V35A2939a 4V60B0093k 4V60B0095o 3V60D0025l 4V69L1585e DAAE002455a
2-14
Generating set drawing, W 9L20 ......................................................................... 2-15 Engine room arrangement ................................................................................... 2-16 Service space requirements ................................................................................ 2-17 Location of sensors and el. components ............................................................. 2-18 Generator technical data sheet ............................................................................ 2-19 Tools for diesel engine ......................................................................................... 2-20 Spare parts for diesel engine ............................................................................... 2-22 Flexible pipe connection for fuel pipe ................................................................... 2-24 Flexible pipe connection for fuel pipe ................................................................... 2-25 Flexible hose ........................................................................................................ 2-26 Flexible hose ........................................................................................................ 2-27 Flexible rubber bellows for water pipe .................................................................. 2-28 Installation of the generating sets ........................................................................ 2-29 Factory acceptance test ....................................................................................... 2-34
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e h T
a r d
g n i w
b l l wi
p u e
d e t da
Installation Planning Instructions tobeadded - Generating set drawing, W 9L20
Aker Yards 728 - a1 7 January 2008
2-15
Installation Planning Instructions 2V69C0278e - Engine room arrangement
2-16
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Installation Planning Instructions DAAE006367- - Service space requirements
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2-17
e h T
a r d
g n i w
b l l wi
p u e
d e t da
Installation Planning Instructions tobeadded - Location of sensors and el. components
2-18
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Installation Planning Instructions DBAA388012a - Generator technical data sheet
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2-19
Installation Planning Instructions DBAA406985- - Tools for diesel engine
2-20
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Installation Planning Instructions DBAA406985- - Tools for diesel engine
Aker Yards 728 - a1 7 January 2008
2-21
Installation Planning Instructions DBAA406989- - Spare parts for diesel engine
2-22
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Installation Planning Instructions DBAA406989- - Spare parts for diesel engine
Aker Yards 728 - a1 7 January 2008
2-23
Installation Planning Instructions 4V35A1591b - Flexible pipe connection for fuel pipe
2-24
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Installation Planning Instructions 4V35A2939a - Flexible pipe connection for fuel pipe
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2-25
Installation Planning Instructions 4V60B0093k - Flexible hose
2-26
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Installation Planning Instructions 4V60B0095o - Flexible hose
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2-27
Installation Planning Instructions 3V60D0025l - Flexible rubber bellows for water pipe
2-28
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Installation Planning Instructions 4V69L1585e - Installation of the generating sets
INSTALLATION OF WÄRTSILÄ 20 GENERATING SETS
Wärtsilä Finland Oy Marine
This document is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
Subtitle
Product
Made
03.03.1998
LBd / Backlund
Page
Document No.
Rev.
W20
Apprvd
03.03.1998
LEl / Erroll
1 (5)
4V69L1585
e
Rev.
Date
Made
Approved
Memo No.
Explanation
e
29.11. 2007
OHA
JPW
139469
Way of measuring compression updated
1.
INTRODUCTION This instruction applies to installation of Wärtsilä 20 generating sets on RD 314 and RD 315 resilient mounts. Generating sets, comprising engine and generator mounted on a common base frame are usually installed on resilient mounts on the foundation in the ship. The resilient mounts reduce the structure borne noise transmitted to the ship and also serve to protect the generating set bearings from possible fretting caused by hull vibration. The number of mounts and their location is calculated to avoid resonance with excitations from the generating set engine, the main engine and the propeller. The exact positions of the mounts are indicated in the generating set drawing.
Note! To avoid induced oscillation of the generating set, the following data must be sent by the shipyard to Wärtsilä at the design stadium (not less than 16 weeks before delivery).
2.
Main engine:
Speed (rpm) and number of cylinders.
Propeller:
Shaft speed (rpm) and number of propeller blades.
FOUNDATION The foundation for the common base frame must be rigid enough to carry the load from the generating set. The recommended foundation design is shown in figure 1. The seating top plate is to be machined at the locations of the resilient mounts in order to provide an adequate load bearing surface and to ensure that the mounting surfaces are in parallel. The lateral distance between the mounts differs depending on the number of cylinders of the engine and the type of generator. Refer to the generating set drawing.
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Installation Planning Instructions 4V69L1585e - Installation of the generating sets
Page
Document No.
2 (5)
4V69L1585
Rev.
e
Figure 1 Recommended design of foundation for common base frame. (3V46L0720)
3.
RUBBER MOUNTS Conical resilient mounts, type RD 314 B or RD 315 HD from RUBBER DESIGN B.V. are used, see figure 2. The mounts are designed to withstand both compression and shear loads. Additional side or end buffers are not required to limit the movements of the generating set since the mounts are equipped with an internal, adjustable central limiter. The centre stud in the mounts is split in order to facilitate replacement of the mounts, if required. The rubber in the mounts is natural rubber and it must therefore be protected from oil, oily water and fuel.
2-30
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Installation Planning Instructions 4V69L1585e - Installation of the generating sets
Page
Document No.
3 (5)
4V69L1585
Rev.
e
Figure 2 Rubber Mounts. (4V46L0706-2)
4.
INSTALLATION WORK STEPS The generating set must be installed so that all rubber mounts are equally compressed; i.e. so that the load on each mount is equal.
Aker Yards 728 - a1 7 January 2008
1.
Drill the holes in the seating top plate for the M16 fastening screws according to the drilling scheme in the generating set drawing.
2.
Machine the seating top plate at the locations of the resilient mounts.
3.
Mount the flexible mounts to the common base frame, if not already mounted.
4.
Lift in the generating set and lower it onto the foundation. Use M16 screws to verify that the position of the drilled holes match the corresponding holes in the foot of each resilient mount. (Brackets with adjusting screws, temporarily welded to the ship foundation are useful for the alignment in horizontal direction during this work step).
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Installation Planning Instructions 4V69L1585e - Installation of the generating sets
Page
Document No.
4 (5)
4V69L1585
Rev.
e
Figure 3 Jacking screw and steel chock. (3V46L0720)
5.
Jacking screws are used for levelling the installation. The common base frame is provided with threaded holes for M20 jacking screws, see figure 3. Install M20 x 160 DIN933 8.8 jacking screws in the threaded holes. The jacking screws are to be supplied by the shipyard. Steel chocks should be used under the jacking screws in order to avoid bending of the screws and to increase the lift.
6.
It must be verified that the generating set is not resting on the internal limiters in the mounts. Hold the stud with a 19 mm spanner and loosen the M27 nut, which fastens the mount to the common base frame. Check that the stud can easily be turned with the 19 mm spanner. If this is not possible, release the load on the generating set by means of the jacking screws until the limiter can be easily turned. Turn the stud two turns in anti-clockwise direction. Release the jacking screws and check again that the stud can easily be turned. NOTE! The central limiter and the stud are divided in order to facilitate easy replacement of the mount. If the limiter is resting on the foundation due to foundation height variations, or if the limiter has been tightened down too hard against the foundation, then the stud will come out of the limiter, when the stud is turned in counter-clockwise direction. If this happens, turn the stud back into the limiter against the foundation. Then install four M12 screws in the threaded holes in the foot of the mount and elevate the mount about 1 mm so that the limiter no longer touches the foundation. Turn the stud two turns in counter-clockwise direction and remove the M12 screws.
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Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 4V69L1585e - Installation of the generating sets
Page
Document No.
5 (5)
4V69L1585
Rev.
e
In the normal case the limiter should be able to turn freely, when the mount is compressed by the weight of the generating set. It is in such case convenient to use a 4 mm feeler gauge to set the buffer clearance. There is a slot in the foot of the mount, where a feeler gauge can be inserted. Turn the limiter down against the feeler gauge (lightly) and pull out the feeler gauge. If the limiter is turned down carefully against the foundation, it is also possible to achieve the desired buffer clearance (4mm) by turning the stud two turns in counterclockwise direction. Repeat the above procedure until all limiters can be turned freely with the full installation load applied. 7.
Check that each mount is level. Measure and record the vertical distance from the machined surface on the foot of the mount to the top casting, on two sides of the mount, in longitudinal direction of the generating set. The difference between measured distances should not exceed 0.5 mm for the same mount. Calculate and record the average value for each individual mount.
8.
Check that all mounts are evenly compressed by comparing the average values obtained in previous step. The maximum permissible difference in compression between the mounts is 2 mm along one side of the generating set.
9.
If required, manufacture steel chocks or shims to compensate for local tolerances, or in order to achieve the desired alignment of the generating set. Chocks must be machined and the minimum thickness of shims is 0.5 mm. Only one shim is permitted under each mount. The chocks or shims must cover the complete mounting surface of the mount.
10. Fasten each mount to the seating top plate with four M16xL 8.8 DIN 931 screws and DIN 985-8 self locking nuts. Suitable flat washers (17/30 s3 DIN 125A) must be used. Lubricate the threads with engine oil and tighten to 200 Nm. 11. Set the internal buffer working clearance to 4 mm for each mount according to the procedure explained in workstep 6. 12. Tighten the M27 nut. Hold the spindle with a 19 mm spanner and tighten the M27 nut to a torque of 300 Nm. 13. The mounts should preferably be allowed to settle for a minimum of 48 hours, due to initial creeping, before lining up pipework, etc.
Aker Yards 728 - a1 7 January 2008
2-33
Installation Planning Instructions DAAE002455a - Factory acceptance test
¤ Wärtsilä Finland Oy Factory
FACTORY ACCEPTANCE TEST FOR WÄRTSILÄ 20 MARINE AUXILIARY ENGINES
This document is the property of Wärtsilä Finland Oy and shall not be copied, shown or communicated to a third party without the consent of the owner.
Subtitle
Product
Made
FAT
Wärtsilä 20
Revised date: 23.6.2004
Changed by: JPS/JHn
Apprvd
03.05.2004
JPS/Sundell
03.05.2004
KRk/Rönnbäck
Approved by: JPa
Page
Document No.
1(10) DAAE002455
Rev.
a
D-message No.: 51474
Factory Acceptance Test 1 Introduction The test is carried out as an overall check of the manufacturing quality and to establish that the contractual commitments have been fulfilled. The Factory Acceptance Test (FAT) comprises of a running-in part and an official FAT part. The test is carried out in accordance with ISO 15550. The function of built on ancillary systems and the performance of the engine is checked according to ISO 15550. Results are recorded in a test report signed by Wärtsilä, customer (if present) and a representative from a classification society. At the end of the factory acceptance test the engine is inspected by the same representatives mentioned above. After inspection, the engines are protected against corrosion, cleaned and painted before packing and shipment. 2 Test setup Auxiliary engines are tested as generating sets, i.e. mounted on a common base frame together with the alternator. The alternator is loaded with resistive load using water resistor. Auxliary engines without generator are tested as generating sets using in-house generator, but without any load acceptance tests because of not identical inertia. The alternator power cables are connected to the switchboard and Automatic Voltage Regulator (AVR) is connected if it is supplied as a loose item. The common base frame of the generating set is mounted on the same flexible mounts that will be delivered for installation on board if vibration measurements are needed. Necessary pipe connections between the engine and the test bed systems are made using in-house flexible hoses. The cold alignment of the crankshaft is checked in the main assembly line or in the alternator assembly cell. The measurement record is available at the test run department. If the engine is equipped with a mechanical governor and a speed setting motor, the motor is connected to a PC from which raise and lower commands can be given and the running speed selected. If the engine is fitted with an actuator and electronic governor, the running speed is controlled by a mA-signal from the in-house Woodward 721 Digital Controller. If the engine is equipped with Wärtsilä Engine Control System (WECS) the measurement logics and safety functions are located in the engine mounted control system. All engine mounted measurements are shown in the control room operator station and customer facility display.
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Installation Planning Instructions DAAE002455a - Factory acceptance test
Page
Document No.
2(10)
DAAE002455
Rev.
a
2.1 Checks before starting Check that measurements values in operator station are updated and that they are normal for standstill condition. Check that there is no leakage when lubricating oil, fuel oil and cooling water systems have been filled. Check that there is no leakage in starting- and control air systems and that the engine starts rotating when pressing the starting air solenoid valve. Blow the engine by rotating it with starting air while keeping indication cocks open. 2.2 Checks with running engine Check that there is no leakage in lubricating oil, fuel oil and cooling water systems. 2.3 Testing of instruments and functions (WECS engines) Check the function of the local control buttons (start, stop and shutdown reset) Verify that the engine speed (ST173 and ST174) are shown on the LDU Verify that the engine speed is shown on the Oil Mist detector display Verify that the backup meters are working and show correct values Verify that the hour counter is working Check the second lube oil pressure trip (at 2.0 bar, sensor PTZ201)
2.3 Testing of instruments and functions (Basic automation engines) Check the function of the local control buttons (Emergency stop, start, remote start, stop and shd. reset) Verify that the meters are working and show correct values Verify that the hour counter is working Verify that the engine speed is shown on the local gauge 2.4 Testing of safeties with running engine Check the first lube oil pressure trip (at 2.0 bar, sensor PT201) Check the first overspeed trip (1,15 x nominal speed, sensor ST173) by manually increasing the fuel rack Check the second overspeed trip (1,18 x nominal speed, sensor ST174) by disabling the first overspeed trip and manually increasing the fuel rack Notes: Set-points of pressure switches have factory settings and the switches are not recalibrated. It is a classification society requirement that all shutdown functions and alarm set-points are verified onboard when the ship is commissioned, regardless of any previous tests.
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Installation Planning Instructions DAAE002455a - Factory acceptance test
Page
Document No.
3(10)
DAAE002455
Rev.
a
2.5 Calibration of measuring equipment Measuring equipment related to calculation of fuel consumption are calibrated according to the manufacturer’s specifications and the certificates are available on request. 3 Test Run The test run is started with a running-in phase. The purpose of the running-in is to make sure that possible manufacturing defects and leakages are eliminated and that all bearing surfaces and piston rings are run in smoothly before the engine is delivered. During the running in process the engine loaded in steps. Between each step the engine is allowed to idle for five minutes, see Fig. 1. Marine Diesel Oil (MDO) is always used during the running in process.
Running in program for Wärtsilä 20 engines load 100% 75% 50% 25% 0% 0:00
0:30
1:00
1:30
2:00
2:30
3:00
3:30
4:00
time (h)
Fig. 1 Typical running in program.
After running-in the test run is followed by the official FAT phase according to the program stated in the contract. In addition to the running-in load-points auxiliary engines are tested at 100 and 110 % load. The duration of these is dependent on the requirements by the classification society concerned. If stated in the contract the fuel type used at 100 and 110 % can be Heavy Fuel (HF) with a viscosity of 180 cSt. If so an additional 20 min at 100 % load on MDO is run after completion of HF running to clean the heavy fuel from the engine. See examples of official FAT programs in Fig. 2 to 5 below.
Official FAT program for Wärtsilä 20 engines DNV, LR, CCS (MDO)
load 100% 75% 50% 25% 0% 2:30
2-36
3:00
3:30
4:00
4:30
5:00
5:30
6:00
6:30
time (h)
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Installation Planning Instructions DAAE002455a - Factory acceptance test
Page
Document No.
4(10)
DAAE002455
Rev.
a
Fig. 2 Official FAT program for Auxiliary engines for DNV, LR, CCS (MDO only)
Official FAT program for Wärtsilä 20 engines DNV, LR, CCS (HF + MDO)
load 100% 75% 50% 25% 0% 2:30
3:00
3:30
4:00
4:30
5:00
5:30
6:00
6:30
time (h)
6:30
time (h)
6:30
time (h)
Fig. 3 Official FAT program for Auxiliary engines for DNV, LR, CCS (HF+MDO)
Official FAT program for Wärtsilä 20 engines ABS, BV, RINA, KR, NK, MRS (MDO)
load 100% 75% 50% 25% 0% 2:30
3:00
3:30
4:00
4:30
5:00
5:30
6:00
Fig. 4 Official FAT program for Auxiliary engines for ABS, BV, RINA, MRS, KR, NK (MDO only)
Official FAT program for Wärtsilä 20 engines ABS, BV, RINA, KR, NK, MRS (HF+MDO)
load 100% 75% 50% 25% 0% 2:30
3:00
3:30
4:00
4:30
5:00
5:30
6:00
Fig. 5 Official FAT program for Auxiliary engines for ABS, BV, RINA, MRS, KR, NK (HF+MDO)
Aker Yards 728 - a1 7 January 2008
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Installation Planning Instructions DAAE002455a - Factory acceptance test
Page
Document No.
5(10)
DAAE002455
Rev.
a
Apart from these classification societies GL has same requirements as ABS, BV, RINA, MRS, KR and NK apart from 110 % load that needs to be run 45 min. Other durations than these can also be run depending on what has been agreed in the contract. 3.1 Engine Performance Parameters Performance data is recorded at 25, 50, 75, 100 and 110 % load. According to ISO 15550, the following parameters are recommended to be measured: List A - Test Measurements (ISO 15550) A1
Barometric pressure, humidity and ambient temperature
A2
Engine speed or cycle frequency
A3
Engine brake torque
A4
Fuel consumption
A5
Lubricating oil pressure
A6
Temperature and pressure of exhaust gas leaving the engine
A7
Air inlet pressure and temperature at the engine or pressure charger inlet
A8
Exhaust gas temperature at the turbine inlet
A9
Boost pressure in the air manifold
A10
Turbocharger speed
A11
Coolant mean temperature in and out of the cylinder block
A12
Lubricating oil temperature at the engine inlet and outlet
A13
Boost pressure drop through the charge air cooler
A14
Boost pressure after charge air cooler
A15
Charge air temperature after each charge air cooler
A16
Coolant mean temperature at the inlet and outlet of the charge air cooler
A17
Maximum cylinder pressure
A18
Exhaust-gas pressure at the turbine inlet
A19
Exhaust-gas temperature of each cylinder
A20
Individual coolant circuit temperatures and pressures
A21
Lubricating oil pressures in individual circuits, e.g. turbocharger, piston cooling, etc.
A22
Lubricating oil pressure before and after filters and coolers
A23
Secondary coolant and lubricating oil temperatures in and out of the heat exchangers
A24
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1)
1)
2)
2)
3) 1)
1)
1) 1)
Fuel supply pressure and temperature 1)
Not recorded
2)
Recorded on engines with WECS
3)
Recorded at 75 and 100 % load
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Installation Planning Instructions DAAE002455a - Factory acceptance test
Page
Document No.
6(10)
DAAE002455
Rev.
a
3.1.1 Firing pressure The firing pressure of each cylinder is measured by a pressure indicator. The acceptance criteria at 100% load are:
- The mean value of all cylinders is to be kept within the tolerances of +- 6 bar (HFO) and +- 7 bar MDO - The maximum deviation for any two cylinders to be within 10 bar - The maximum deviation from mean value for each cylinder is 6 bar and no cylinder is allowed to exceed: 200 bar for 900/1000rpm (C3 model) 190 bar for 900/1000rpm 180 bar for 720/750rpm Main reasons for deviations are: -
The fuel injection timing.
-
Variations of air receiver pressure.
-
Disturbances in injection pump or nozzle function.
3.1.2 Exhaust-gas temperature after cylinders The exhaust gas temperature is measured for each cylinder. The acceptance criteria at 100% load are:
Aker Yards 728 - a1 7 January 2008
4L20 6 - 9L20
720 & 750 rpm 400 ± 30°C 720 & 750 rpm 400 ± 30°C
4L20 5L20 6 & 9L20 8L20
900 rpm 900 rpm 900 rpm 900 rpm
400 ± 30°C 400 ± 30°C 400 ± 30°C 400 ± 30°C
4L20 5L20 6 & 9L20 8L20
1000 rpm 1000 rpm 1000 rpm 1000 rpm
400 ± 30°C 400 ± 30°C 400 ± 30°C 400 ± 30°C
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Installation Planning Instructions DAAE002455a - Factory acceptance test
Page
Document No.
7(10)
DAAE002455
Rev.
a
Maximum deviation between cylinders is 90°C. However, in 8L engines cylinder 7 for CW and cylinder 8 for CCW rotation can have temperature 80°C higher than the mean temperature of the other cylinders. This is due the configuration of the pulse turbo charging system and the cylinders firing sequence. Main reasons for deviations are: - changes in air receiver temperature 3.1.3 Charge air pressure The charge air pressure is measured using the engine mounted pressure gauge. - The readings at 100% load to be within: 720 & 750
2.60 bar ± 0.25
900 & 1000
3.00 bar ± 0.25
900 & 1000 (C3 model)
3.40 bar ± 0.25
3.2 Test results List B - Test Results, Parameters to be Calculated (ISO 15550) B1
Brake power
B2
Specific fuel consumption
3.2.1 Brake power The brake power for the engine is calculated from the measured electrical active power and the generator electrical efficiency. The efficiency of the generator is available from the manufacturer’s data sheet and is provided by the marine department. Data sheets for inhouse generators are available at the test run department. The electrical power can be read directly from the operator station. 3.2.2 Specific fuel oil consumption The fuel oil consumption is measured with a scale. The consumption measuring system will automatically measure the time the engine needs to consume a predetermined amount of fuel, usually 2,5 - 20 kg, depending on the size of the engine. The acceptance criteria for the engine fuel consumption are stated in the contract. Samples of the fuel are periodically sent to an independent authority for analysis. The latest analysis is available at the test run department on request. To correct for ambient conditions during test differing from ISO 15550 standard reference conditions, conversion formula as stated by ISO 3046-1, are used to obtain the specific fuel consumption. See formula below. In case the specific fuel consumption is presented as fuel consumption without engine driven pumps the following reductions from the SFOC will be made since the engine is equipped with following on-built engine driven pumps:
2-40
HT water pump
1.0 g/kWh
(at 100 % load)
LT water pump
1.0 g/kWh
(at 100 % load)
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DAAE002455a - Factory acceptance test
LO pump
2.0 g/kWh
(at 100 % load)
MDO pump
1.0 g/kWh
(at 100 % load)
Sea water pump
1.0 g/kWh
(at 100 % load)
Page
Document No.
8(10)
DAAE002455
Rev.
a
Conversion Formula
1 α = k − 0.7(1 − k ) − 1 ηm m
n
p T T k = x r cr pr Tx Tcx
Where:
s
BE =
M − S ⋅ MLS ⋅ 3600 P⋅S
[g/kWh]
BISO =
α Q ⋅ BE ⋅ x − EDP k Qr
[g/kWh]
k = ratio of indicated power α = power adjustment factor
px = barometric pressure during test
[kPa]
pr = standard reference barometric pressure
[100 kPa]
Tx = air temperature during test
[K]
Tr = reference air temperature
[298 K]
Tcx = charge air coolant temperature during test
[K]
Tcr = reference charge air coolant temperature
[298 K]
m = 0,7 n = 1,2
exponents to be used for 4-cycle diesel engines acc. to ISO 3046-1, table 3
s = 1,0 ηm = mechanical efficiency, 0.8
Aker Yards 728 - a1 7 January 2008
Qx = net calorific value of the fuel during test
[MJ/kg]
Qr = reference net calorific value of fuel
[42.7 MJ/kg]
BE = fuel oil consumption on test bed
[g/kWh]
BISO = fuel oil consumption according to ISO
[g/kWh]
M = measured fuel quantity
[g]
MLS = flow of clean leak fuel
[0.1 g/s cyl]
P = engine output
[kW]
S = time
[s]
EDP = engine driven pumps
[4 g/kWh]
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Installation Planning Instructions DAAE002455a - Factory acceptance test
Page
Document No.
9(10)
DAAE002455
Rev.
a
3.3 Functional checks [ISO 15550] “Functional checks which may additionally be carried out. Selection from list C shall be made by agreement between the manufacturer and customer.”
List C - Functional checks, Functions to be verified (ISO 15550) C1
The correct functioning of the overspeed limiting device in accordance with ISO 3046-6
C2
The correct functioning of the speed governing system in accordance with ISO 3046-4
C3
The ability of all malfunction protection and warning devices to respond correctly to the fault conditions in which they should operate (e.g., low lubricating oil pressure, high lubricating oil temperatures, high coolant temperatures, pressure rise in the crankcase, etc.)
C4
The correct functioning of all automatic pressure and temperature controls
C5
The ability of the starting system to perform prior to and/or after the acceptance test conditions of the engine are reached, subject to agreement between the customer and manufacturer
C6
The correct functioning of the reversing mechanism, built-in reverse reduction gear and couplings
C7
That the temperature of important components is satisfactory
C8
That the crank web deflection is within the given limits
C9
Stability of the engine on its support
C10
The condition after test of one or more piston chosen randomly for inspection
1)
1)
Piston is not inspected
2)
Cylinders inspected only from crankcase side
and cylinder
2)
assemblies and bearings,
Note: Points C1, C3 (low lube oil pressure shutdown), C8 and C10 are included in Wartsila standard FAT procedures. See note at section 2.4 in this document.
3.4 Load Application Test The speed governor and load acceptance of the generating set are tested by making rapid load changes. The load is applied in three steps, normally 0-33-66-100%, or 0-40-70-100%. According to the rules of the classification societies the instantaneous speed drop may not exceed 10 % of rated speed. The recovery time is 5 seconds, which means that the speed must be within 1% of the rated speed after 5 seconds. The minimum load steps recommended by the International Association of Classification Societies (IACS) are presented in Fig. 6. The individual classification societies may specify different a load application scheme, but three steps can normally be accepted by most classification societies if the load management system onboard will be built accordingly. The customer has to clarify this with the classification society concerned. Load application tests onboard must be performed with the contracted fuel in order to achieve the same performance as in the factory test run. The speed governor performance can be followed in the historical trends in the operator station where engine speed, generator voltage and output and turbocharger speed are graphically recorded.
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Installation Planning Instructions DAAE002455a - Factory acceptance test
Page
Document No.
10(10)
DAAE002455
Rev.
a
Fig. 6 IACS recommended load steps
3.5 Special tests Other tests or checks can be done in combination to the factory acceptance test if specifically stated in the contract, i.e. noise-, vibration- or emission measurement. 4. Crankshaft alignment check in hot condition For generating sets a hot crankshaft alignment is done when the test run is finished, the control is done to check the straightness of the crankshaft when it is in running (hot) condition and thereby verify correct installation on the common base frame. However, the alignment in hot condition is to be verified after final installation on board as well. 5. Inspection of engine After the test run, the customer and the representative of the classification society are invited to supervise the inspection of the engine. See instruction 4V59L0169 for details of the procedures. 6. Finishing After the inspection of the engine, there are a number of different items checked, just before delivery. A separate instruction 4V59L0171 describes the details and other routines after the test run, as well as the internal and external anticorrosion protection treatment and painting of the engine. 7. Health and safety during FAT The tests are made according to the factory internal health and safety instructions and way of working. These are governed by the ISO 18001 standard.
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Installation Planning Instructions
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Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 3. Fuel Oil System
3.
Fuel Oil System
3.1
System overview When running on MDF proper measures have to be taken to ensure that the fuel oil viscosity at the engine inlet does not fall below the minimum limit. Furthermore the inlet temperature shall not exceed 50°C. This may require an external MDF cooler to be installed. The lay-out of the fuel oil system is shown in drawing "recommended fuel oil system". If fuel oil system components are included in our scope of supply they are listed in section "Component data, Wärtsilä scope of supply".
3.1.1 Engine internal system The following equipment is built on the engine (Wärtsilä 9L20): •
fuel injection pumps
•
injection valves
•
engine driven fuel feed pump
•
duplex fine filter
•
pressure relief valve in the outlet pipe
Controlled leak fuel from the injection valves and the injection pumps is drained to atmospheric pressure (Clean leak fuel system). The clean leak fuel can be reconducted to the system without treatment. The quantity of leak fuel is given in the section "Technical data". Possible uncontrolled leak fuel and spilled water and oil is separately drained from the hot-box and shall be led to a sludge tank (“Dirty” leak fuel system). The arrangement of the built-on system is shown in the drawing "internal fuel system".
3.2
System design data
3.2.1 Fuel oil quality NOTE!
This installation is designed for the fuel specified in section "Fuel oil specification". The limits below are general for MDF operation.
Table 3.1 MDF Specifications
Property
Unit
Apperance
ISO-F-DMX
ISO-F-DMA
Clear and bright
ISO-F-DMB
ISO-F-DMC 1) Test method ref.
-
-
Visual inspection
Viscosity, min, before injection pumps 2)
cSt
1.8
1.8
1.8
1.8
Viscosity, max, before injection pumps 2)
cSt
24
24
24
24
cSt at 40°C
5.5
6
11
14
ISO 3104
Viscosity, max. Density, max.
kg/m³ at 15°C
Cetane index, min Water, max.
% volume
—
890
900
920
ISO 3675/12185
45
40
35
—
ISO 4264
—
—
0.3
0.3
ISO 3733
3)
3)
Sulphur, max.
% mass
1
1.5
2
Ash, max.
2
ISO 8754/14596
% mass
0.01
0.01
0.01
0.05
ISO 6245
Vanadium, max.
mg/kg
—
—
—
100
ISO 14597 or IP 501/470
Sodium before engine, max. 2)
mg/kg
—
—
—
30
ISO 10478
Aker Yards 728 - a1 7 January 2008
3-1
Installation Planning Instructions 3. Fuel Oil System
Property
ISO-F-DMC 1) Test method ref.
Unit
ISO-F-DMX
ISO-F-DMA
ISO-F-DMB
Aluminium + Silicon, max.
mg/kg
—
—
—
25
ISO 10478 or IP 501/470
Aluminium + Silicon before engine, max. 2)
mg/kg
—
—
—
15
ISO 10478 or IP 501/470
Carbon residue (micro method, 10 % vol dist. bottoms), max.
% mass
0.30
0.30
—
—
ISO 10370
Carbon residue, max.
% mass
—
—
0.30
2.50
ISO 10370
Flash point (PMCC), min.
°C
60 2)
60
60
60
ISO 2719
Pour point, max.
°C
—
-6...0
0...6
0...6
ISO 3016
Cloud point, max.
°C
-16
—
—
—
ISO 3015
% mass
—
—
0.1
0.1
ISO 10307-1
mg/kg mg/kg mg/kg
— — —
— — —
— — —
30 15 15
IP 501/470 IP 501/470 IP 501/470
Total sediment existent, max. Used lubricating oil 4) - calcium, max. - zinc, max. - phosphorus, max. 1)
Use of ISO-F-DMC category fuel is allowed provided that the fuel treatment system is equipped with a fuel oil separator.
2)
Additional properties specified by the engine manufacturer, which are not included in the ISO specification or differ from the ISO specification.
3)
A sulphur limit of 1,5 % m/m will apply in SOx emission controlled areas designated by International Maritime Organization. There may be also other local variations.
4)
A fuel shall be considered to be free of used lubricating oil (ULO), if one or more of the elements calcium, zinc and phosphorus are below or at the specified limits. All three elements shall exceed the same limits before a fuel shall be deemed to contain ULO.
3.2.2 Calculation formulas The total fuel oil consumption is calculated as follows. This formula shall be used when calculation the consumption for selecting sizes of pumps, valves, separators etc. related to the fuel oil system before the engines.
where: FE = Fuel oil consumption for the engine, site fuel [kg/h] FSH = Fuel oil consumption for the engine at ISO conditions [g/kWh]. See section "Technical data". Add a tolerance of 5%. Adjust the stated fuel consumption according to the following: •
Add 1 g/kWh since the fuel oil pump is built on the engine
QN = Site fuel caloric value [MJ/kg] PS = Shaft output for the engine [kW]
Minimum flow requirement for a fuel oil system component or unit is calculated as follows:
where: Q = Min. required capacity at injection temperature [m3/h] (for one engine) FE = Fuel consumption for the engine, site fuel [kg/h] CF = Circulation factor = 5:1 ρFUEL= Fuel oil density at injection temperature [kg/m3]
3-2
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 3. Fuel Oil System
3.3
Recommended functions The following functions are not included in Wärtsilä scope of supply. We recommend you to design these functions as follows.
3.3.1 MDF separator unit (1N05) General remarks The fuel treatment system should comprise a settling tank and separators to supply the engine(s) with sufficiently clean fuel. The recommendations for the design of the separator should be closely followed.
Settling of marine diesel fuel The settling tank (1T10) should normally be dimensioned to ensure fuel supply for min. 24 operating hours when filled to maximum. The tank should be designed to provide the most efficient sludge and water rejecting effect. The temperature in the settling tank should be between 20...40°C. The min. level in the settling tank should be kept as high as possible. In this way the temperature will not decrease too much when filling up with cold bunker.
Separator system Also marine diesel fuel must be cleaned in an efficient centrifugal separator before entering the day tank as fuel may be contaminated in the storage tanks.
Separator feed pump (1P02) The use of a screw pump is recommended. The pump should be separate from the separator and electrically driven. The pump should be dimensioned for the actual fuel quality and recommended throughput through the separator. Design data: Pressure, max
0.5 MPa (5 bar)
Temperature
40 °C
A suction filter should be fitted to protect the feed pump. The filter can be either a duplex filter with change over valves or two separate simplex filters. Fineness 0.5 mm.
Separator heater (1E01) The preheater is normally dimensioned according to the pump capacity and a given settling tank temperature. The heater surface temperature must not be too high in order to avoid cracking of the fuel. The heating should be thermostatically controlled for maintaining the fuel temperature within ±2°C. The recommended preheating temperature for MDF is 20-40°C depending on the viscosity. The required minimum capacity of the heater is:
where: P = heater capacity [kW] m = capacity of the separator feed pump [l/h] Δt = temperature rise in heater [°C]
Separator (1S01) The fuel oil separator should be sized according to the recommendations of the separator maker. The lower the flow rate, the better the efficiency. The required service throughput of the separator is:
Aker Yards 728 - a1 7 January 2008
3-3
Installation Planning Instructions 3. Fuel Oil System
where: QLFOS = Required capacity at 15°C [m3/h] (for one engine) FE = Fuel consumption for the engine, site fuel [kg/h] ρFUEL = Density of the fuel at 15°C [kg/m³] CS = Separator safety factor, e.g. 15%.
3.3.2 Sludge tank (1T05) The sludge tank shall be placed below the separators as close as possible. The sludge pipe shall be continuously falling without any horizontal parts. The principal lay-out of the transfer and separating system is shown in drawing "recommended transfer and separating system".
3.3.3 MDF day tank (1T06) Two marine diesel fuel day tanks should normally be dimensioned to ensure fuel supply for 8 operating hours each when filled to maximum. The design of the tanks should be such that water and dirt particles do not collect in the suction pipe. The day tanks must be placed at a sufficient height for positive head at the engine inlet. An overflow pipe should be installed from the day tank to the settling tank. The overflow pipe should be connected to the lower part of the day tank to recirculate water that may get into the fuel after the separators.
3.3.4 Collection leak fuel Leak fuel tank, clean fuel (1T04) Clean leak fuel draining from the injection equipment can, if desired, be re-used without repeated treatment. The fuel should then be drained to a separate leak fuel tank and, from there, be pumped to the day tank. Alternatively, the clean leak fuel tank can be drained to another tank for clean fuel, e.g. the bunker tank, the overflow tank etc. The pipes from the engine to the drain tank should be arranged continuously sloping.
Leak fuel tank, dirty fuel (1T06) Any leakage of fuel oil or water at the engine top is collected into the dirty leak fuel system. Normally no leakage occurs during operation.
3.4
Component data, Wärtsilä scope of supply
3.4.1 Cooler (MDF return line) (1E04) Quantity ................................................ 4 Type ...................................................... P10-3P-L=600 Flow (Fuel) (m³/h) .................................. 1,9 Pressure drop (Water) (bar) .................. 0,12 Pressure drop (Fuel) (bar) ..................... 0,03 Heat load (kW) ...................................... 9 Max. outlet temp (Fuel) (°C) .................. 45 Max. inlet temp (Fuel) (°C) .................... 55 Max. inlet temp (Water) (°C) ................. 38 Cooling media ...................................... Fresh water Dimensional drawing ............................ PS10-0-0005
3-4
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 3. Fuel Oil System
3.4.2 Flow meter with pulse transmitter (MDF) (1I03) Quantity ................................................ 4
3.4.3 Fuel circulation pump with el motor (1M01) Quantity ................................................ 2 Pump type ............................................ ACE 025N3 NTBP El motor type ........................................ WU-DA 80MJ-D-2 Frequenzy (Hz) ..................................... 60 Voltage (V) ............................................ 690 Nominal speed (rpm) ............................ 3496 Dimensional drawing ............................ U-ACE-981
3.4.4 Suction strainer (MDF) (1F07) Quantity ................................................ 2 Type ...................................................... 2.04.5 Brand .................................................... Boll&Kirch Max flow (m³/h) .................................... 4,5 Connection (DN) ................................... 40 Fineness absolute (micron) .................. 320 Dimensional drawing ............................ Z102346 DPI drawing .......................................... DPI_4-36-2
3.5
Drawings DAAE058154DAAE058155DAAE015263b DBAA406400DBAA406400Z102346DPI_4-36-2DBAA406434DBAA406434DBAA406434-
Aker Yards 728 - a1 7 January 2008
Internal fuel oil system ......................................................................................... 3-6 Recommended fuel oil system ............................................................................. 3-7 Recommended transfer and separating system .................................................. 3-8 1E04 - Cooler (MDF return line), dimensional drawing ........................................ 3-9 1E04 - Cooler (MDF return line), technical data .................................................. 3-10 1F07 - Suction strainer (MDF) dimensional drawing ............................................ 3-11 1F07 - Suction strainer (MDF) DPI ...................................................................... 3-12 1P03 - Circulation pump (MDF) dimensional drawing ......................................... 3-13 1P03 - Circulation pump (MDF) Driver specification ............................................ 3-14 1P03 - Circulation pump (MDF) Pump calculation ............................................... 3-15
3-5
Installation Planning Instructions DAAE058154- - Internal fuel oil system
3-6
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DAAE058155- - Recommended fuel oil system
Aker Yards 728 - a1 7 January 2008
3-7
Installation Planning Instructions DAAE015263b - Recommended transfer and separating system
3-8
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DBAA406400- - 1E04 - Cooler (MDF return line), dimensional drawing
Aker Yards 728 - a1 7 January 2008
3-9
Installation Planning Instructions DBAA406400- - 1E04 - Cooler (MDF return line), technical data
SPECIFICATION SHEET Service Client Coolertype Version
: : : :
Fuel oil cooler Wartsila Finland Ship Power P10-3P-L=600 PF/MV
Heat exchanged
Date : Your ref.: Our ref.: Drawing :
9.00
Shellside Oil MDO Inlet temperature 55.16 Outlet temperature 45.00 Fluid flow 1.90 Pressure drop 0.03 Operating pressure 16.00 External heat transfer surface 4.59 Connection 1½" BSP Content 2 Design temperature 120.00 Design pressure 16.00
26-apr-2007 Ulstein PX105-1/-2, P070709-01-0 PS10-0-0005
kW
°C °C m3/h bar bar m2 ltr °C barg
Tube side Non corrosive, circ.water Inlet temperature 38.00 °C Outlet temperature 41.26 °C Fluid flow 2.40 m3/h Pressure drop 0.12 bar Velocity 1.73 m/s Operating pressure 10.00 bar Internal heat transfer surface 0.38 m2 Connection 1½" BSP Content 1 ltr Design temperature 80.00 °C Design pressure 10.00 barg General Fouling (extra surface) Overall transfer rate (internal) Log mean temp diff. Number of tubepasses Nominal tube length Tube diameter Weight cooler empty (approx.) Materials Tubes: Tubeplates: Baffles: Fins: Shell: Bonnet/cover:
20.00 2440 9.66 3 600 8.30 14
% W/(m2K) °C mm mm kg
Mat.nr 2.0872 - CuNi10Fe1Mn Mat.nr 2.0540 - CuZn35Ni Aluminium Aluminium C.Steel / nod.cast iron Bronze (with anodes)
Remarks Design and Inspection: Bloksma
3-10
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions Z102346- - 1F07 - Suction strainer (MDF) dimensional drawing
Aker Yards 728 - a1 7 January 2008
3-11
Installation Planning Instructions DPI_4-36-2- - 1F07 - Suction strainer (MDF) DPI
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3-12
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DBAA406434- - 1P03 - Circulation pump (MDF) dimensional drawing
Aker Yards 728 - a1 7 January 2008
3-13
Installation Planning Instructions DBAA406434- - 1P03 - Circulation pump (MDF) Driver specification
Driver specification
Date of calculation
Signature
2007-12-17
R. Osterman
Inquiry from Our ref. No Cust. ref. No. Item No Selected pump
AKER Yards 728 MDF pumps ACE 025N3 NTBP
BC WU-DA 80MJ-D-2
Manufacturer Model Frequency Power Nominal speed Voltage Y/D Current Start current IEC size Weight Noise Efficiency cos(fi) Isol/prot Classification Mounting Cooling Cable Material Inertia Torque
BC WU-DA 80MJ-D-2 60 1.25 3440 690 Y 1,6 10.2 80 9.0 59.0 81.0 0.82 F/IP55 Marine/Industrial IM3001/B5 IC41 1xM20*1.5+M20*1.5 Aluminium 0.0019 9.99
Hz kW rpm V A A kg dB(A) %
kgm² Nm
Driver file V1.92
IMO AB P.O. Box 42090 S-126 14 Stockholm Visitors: Västberga allé 50
3-14
B108ABDC9C67C1F3
TELEPHONE: +46-(0)8-50622800
TELEX: 11548 IMO S
TELEFAX: +46-(0)8-199939
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DBAA406434- - 1P03 - Circulation pump (MDF) Pump calculation
Pump calculation
Date of calculation
Signature
2007-12-17
R. Osterman
Inquiry from Our ref. No Cust. ref. No. Item No Fluid type Driver Selected pump
AKER Yards 728 MDF pumps Marine Diesel Oil WU-DA 80MJ-D-2 / 3440 rpm / 1.25 kW ACE 025N3 NTBP
Duty case No.
1
2
Outlet press. Inlet press. Min. inlet pressure Differential pressure
bar bar bar bar
8.0 0.10 -0.85 7.9
8.0 0.10 -0.85 7.9
Speed Viscosity Inlet temp
rpm cSt °C
3496 13.0 20.0
3496 4.9 50.0
Calc'd flow Required flow Power
m³/h m³/h kW
2.25 1.80 0.81
2.07 1.80 0.81
Efficiency
tot
60.0
56.0
Calculations made by IMO pumpselection program WinPump 3.5.0 Pump file V5.15, Oil file V1.7, Driver file V1.92
IMO AB P.O. Box 42090 S-126 14 Stockholm Visitors: Västberga allé 50
Aker Yards 728 - a1 7 January 2008
TELEPHONE: +46-(0)8-50622800
B108ABDC9C67C1F3
TELEX: 11548 IMO S
TELEFAX: +46-(0)8-199939
3-15
Installation Planning Instructions
This page intentionally left blank
3-16
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 4. Lubricating Oil and Crankcase Ventilation Systems
4.
Lubricating Oil and Crankcase Ventilation Systems
4.1
System overview Each engine should have a lubricating oil system of its own. The lubricating oil must not be mixed between different systems. The lay-out of the lubricating oil system is shown in drawing "recommended lubricating oil system". If lubricating oil system components are included in our scope of supply they are listed in section "Component data, Wärtsilä scope of supply". Oil vapours formed in the crankcase of the engine have to be ventilated out of the engine room via the crankcase ventilation system. The outlet is to be equipped with a condensate trap.
4.1.1 Engine internal system The following equipment is built on the engine (Wärtsilä 9L20): •
engine driven lubricating oil pump
•
electric motor driven prelubricating pump
•
lubricating oil cooler
•
thermostat valve
•
automatic filter
•
centrifugal filter
•
pressure control valve
•
wet sump
The prelubricating oil pump is used for: •
filling of the lubricating oil system before starting
•
continuous prelubrication of a stopped engine in a multi-engine installation always when one of the engines is running
The arrangement of the built-on system is shown in the drawing "internal lubricating oil system".
4.2
System design data
4.2.1 Lubricating oil quality NOTE!
Contact Wärtsilä before using a non approved lubricating oil. Lubricating oils that are not approved have to be tested according to our procedures. Should unapproved lubricating oils be used during the engine warranty period, and there exist no agreement with the engine manufacturer about testing, the engine guarantee does not hold.
Approved lubricating oils for the engine The lubricating oil viscosity class is SAE 40 (ISO VG 150), minimum viscosity index is 95. The required lubricating oil alkalinity is tied to the fuel specified for the engine, see table below. Table 4.1 Fuel standards and lubricating oil requirements.
Category
Fuel standard
BN
A
ISO8217:2005(E)
ISO-F-DMA, ISO-F-DMX
10...30
B
ISO8217:2005(E)
ISO-F-DMB
15...30
Aker Yards 728 - a1 7 January 2008
4-1
Installation Planning Instructions 4. Lubricating Oil and Crankcase Ventilation Systems
Category C
Fuel standard ISO8217:2005(E)
BN
ISO-F-DMC ISO-F-RMA 30 to RMK 700 (HFO)
30...55
Fuel categories A and B, recommended in gas oil or marine diesel oil installations. If ISO-F-DMC is used as fuel, the recommended lubricating oils are according to fuel category C. Fuel category C, recommended in the first place when operating on HFO or an fuel with high sulphur content in order to reach full service intervals. BN50...55 lubricating oils are preferred in the first place. Table 4.2 Approved lubricating oils for fuel categories A and B.
Supplier
Brand name
Viscosity
BN
Fuel category
BP Castrol
Energol HPDX 40
SAE 40
12
A
HLX 40 MHP 154 Seamax Extra 40
SAE 40 SAE 40 SAE 40
12 15 15
A A, B A, B
ChevronTexaco (Caltex + FAMM)
Delo 1000 Marine 40 Delo 2000 Marine 40 Taro 12 XD 40 Taro 20 DP 40
SAE 40 SAE 40 SAE 40 SAE 40
12 20 12 20
A A, B A A, B
ExxonMobil
Mobilgard ADL 40 Mobilgard 412 Mobilgard 1 SHC
SAE 40 SAE 40 SAE 40
15 15 15
A, B A, B A, B
Indian Oil Corporation
Servo Marine 1040 Servo Marine 2040
SAE 40 SAE 40
10 20
A A, B
Petrobras
Marbrax CCD-410-AP Marbrax CCD-415 Marbrax CCD-420
SAE 40 SAE 40 SAE 40
12 15 20
A A, B A, B
Shell
Gadinia Oil 40
SAE 40
12
A
Statoil
MarWay 1040
SAE 40
10.6
A
Total / Lubmarine
Disola M 4015 Aurelia 4020
SAE 40 SAE 40
14 20
A A, B
Viscosity
BN
Fuel category
Table 4.3 Approved lubricating oils for fuel category C.
4-2
Supplier
Brand name
BP
Energol IC-HFX 404 Energol IC-HFX 504
SAE 40 SAE 40
40 50
C C
Castrol
TLX Plus 404 TLX Plus 504 TLX Plus 554
SAE 40 SAE 40 SAE 40
40 50 55
C C C
Cepsa
Troncoil 4040 PLUS Troncoil 4050 PLUS Ertoil Koral 4040 SHF Ertoil Koral 4050 SHF
SAE 40 SAE 40 SAE 40 SAE 40
40 50 40 50
C C C C
ChevronTexaco (Caltex + FAMM)
Taro 40 XL 40 Taro 50 XL 40 Delo 3400 Marine 40 Delo 3550 Marine 40
SAE 40 SAE 40 SAE 40 SAE 40
40 50 40 55
C C C C
Chinese Petroleum Corporation
Marilube Oil W 404 Marilube Oil W 504
SAE 40 SAE 40
40 50
C C
ENI S.p.A.
Cladium 400 S SAE 40 Cladium 500 S SAE 40 Cladium 550 S SAE 40
SAE 40 SAE 40 SAE 40
40 50 55
C C C
ExxonMobil
Exxmar 40 TP 40 Exxmar 50 TP 40 Mobilgard M 440 Mobilgard M50
SAE 40 SAE 40 SAE 40 SAE 40
40 50 40 50
C C C C
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 4. Lubricating Oil and Crankcase Ventilation Systems
Supplier
Brand name
Viscosity
BN
Fuel category
Fuchs
Titan PSW 40 SAE 40 Titan PSW 55 SAE 40
SAE 40 SAE 40
40 55
C C
Indian Oil Corporation
Servo Marine K-4040 Servo Marine K-5040 Servo Marine K-5540
SAE 40 SAE 40 SAE 40
40 50 55
C C C
Pertamina
Martron 440 Martron 450 Salyx 440 Salyx 450
SAE 40 SAE 40 SAE 40 SAE 40
40 50 40 50
C C C C
Petrobras
Marbrax CCD-440 Marbrax CCD-450
SAE 40 SAE 40
40 50
C C
Petron
Petromar XC 4040 Petromar XC 5540
SAE 40 SAE 40
40 55
C C
Repsol YPF
Neptuno W NT 4000 SAE 40 Neptuno W NT 5500 SAE 40
SAE 40 SAE 40
40 55
C C
Shell
Argina X 40 Argina XL 40
SAE 40 SAE 40
40 50
C C
Total / Lubmarine
Aurelia XL 4040 Aurelia XL 4055
SAE 40 SAE 40
40 55
C C
BN 30 lubricating oils should be used in HFO in installations with SCR (Selective Catalyctic Reduction), if better total economy can be achieved despite shorter oil change intervals. Lower BN may have a positive influence on the lifetime of the SCR catalyst.
Approved lubricating oil for engine turning device It is recommended to use EP-gear oils, viscosity 400-500 cSt at 40°C (ISO VG 460) as lubricating oils for the turning device.
Approved lubricating oils for governor An oil of viscosity class SAE 30 or SAE 40 is suitable and usually the same oil can be used as in the engine. Turbocharger oil can also be used in the governor. In low ambient conditions it may be necessary to use a multigrade oil (e.g. SAE 5W-40) to get a good control during start-up.
Approved lubricating oils for starting motor Table 4.4 Approved lubricating oils for starting motor.
4.3
Supplier
Brand name
NYE Lubricants
Rheolube 377AL
Recommended functions The following functions are not included in Wärtsilä scope of supply. We recommend you to follow these guidelines.
4.3.1 Lubricating oil system For engines with wet sump, the lubricating oil may be filled into the engine using a hose or an oil can, through the crankcase cover or through the separator pipe. The system should be arranged so that it is possible to measure the filled oil volume.
Separator unit (2N01) Each main engine operating on HFO shall have a dedicated separator. The separator shall be dimensioned for continuous operation.
Aker Yards 728 - a1 7 January 2008
4-3
Installation Planning Instructions 4. Lubricating Oil and Crankcase Ventilation Systems
Design data: Separating temperature
90…95 °C
Capacity according to the formula below:
where: Q = actual flow through the separator [l/h] P = total engine output [kW] n = number of through-flows of the oil volume/day (4 for engines operated on MDF) t = Separating time/day [h] 23h for separators with total discharge, 24h for separators with partial discharge
Separator pump (2P03) The separator pump may be directly driven by the separator or separately driven by an electric motor. The flow shall be adapted to achieve the above mentioned optimal flow.
Separator heater (2E02) The preheater may be a steam or an electric heater. The surface temperature of the heater coils must not exceed 150 °C in order to avoid coking of the oil.
Renovating oil tank (2T04) For engines with wet sump the oil sump content can be drained to this tank prior to separation.
Renovated oil tank (2T05) This tank contains renovated oil ready to be used as a replacement of the oil drained for separation.
New oil tank (2T03) For engines with wet sump the lubricating oil may be filled into the engine using the separator pipe or the filling connection on the engine. The system shall be arranged so that it is possible to measure the filled oil volume.
Sludge/waste oil tank (2T06) The sludge/waste oil tank can be used for the storage of used lubricating oil, in addition to the sludge coming from the LO separator unit.
4-4
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 4. Lubricating Oil and Crankcase Ventilation Systems
4.3.2 Crankcase ventilation system Figure 4.1 Crankcase ventilation overview
A crankcase vent pipe shall be provided for each engine. Vent pipes of several engines and vent pipes of engine crankcases and tanks shall not be joined together. The diameter of the pipe shall be large enough to avoid excessive back pressure considering the length of the pipe and number of bends. Flame arresters should not cause excessive flow resistance. The connection between engine and pipe is to be made flexible. The vent pipe should be led out of the engine room in such a way that the risk of water condensation in the pipe is minimized. A condensate trap shall be fitted on all vent pipes within 1...2 m from the engine. The design principle and connection sizes of the condensate trap is shown in the drawing "recommended crankcase ventilation system".
4.4
Drawings DAAE058156DAAE0581574V76E2522a
Aker Yards 728 - a1 7 January 2008
Internal lubricating oil system .............................................................................. Recommended lubricating oil system .................................................................. Recommended crankcase ventilation ..................................................................
4-6 4-7 4-8
4-5
Installation Planning Instructions DAAE058156- - Internal lubricating oil system
4-6
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DAAE058157- - Recommended lubricating oil system
Aker Yards 728 - a1 7 January 2008
4-7
Installation Planning Instructions 4V76E2522a - Recommended crankcase ventilation
4-8
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 5. Compressed Air System
5.
Compressed Air System
5.1
System overview Compressed air is used to start engines and to provide actuating energy for safety and control devices. Compressed air is used onboard also for other purposes with different pressures. The use of starting air supply for these other purposes is limited in the classification regulations. To ensure the functionality of the components in the compressed air system, the compressed air has to be free from solid particles and oil. The design of the starting air system is partly determined by the rules of the classification societies. Most classification societies require the total capacity to be divided over two roughly equally sized starting air receivers and starting air compressors. The rule requirements of some classification societies are not precise for multiple engine installations. The lay-out of the compressed air system is shown in the drawing "recommended starting air system". If compressed air system components are included in our scope of supply they are listed in section "Component data, Wärtsilä scope of supply".
5.1.1 Engine internal system The engine is equipped with a pneumatic starting motor driving the engine through a gear rim on the flywheel. The nominal starting air pressure of 3 MPa (30 bar) is reduced to 1 MPa (10 bar) with a pressure regulator mounted on the engine. The compressed air system of the electro-pneumatic overspeed trip is connected to the starting air system. For this reason, the air supply to the engine must not be closed during operation. The components built on the engine are shown in the drawing "internal starting air system".
5.2
System design data
5.2.1 Starting air consumption The starting air consumption stated in technical data is for a successful start. During a remote start the main starting valve is kept open until the engine starts, or until the max. time for the starting attempt has elapsed. A failed remote start can consume 2...3 times the air volume stated in technical data. If the ship has a class notation for unattended machinery spaces, then the starts may have to be demonstrated as remote starts, usually so that only the last starting attempt is successful. This must be checked, by the ship builder, with the classification society.
5.3
Recommended functions The following functions are not included in Wärtsilä scope of supply. We recommend you to design these functions as follows.
5.3.1 Starting air vessel (3T01) The starting air receiver should be dimensioned for a nominal pressure of 3 MPa (30 bar). The starting air receivers are to be equipped with at least a manual valve for condensate drainage. If the air receivers are mounted horizontally, there must be an inclination of 3...5° towards drain valve to ensure efficient draining The following formula shall be used to calculate the total air volume:
where: VAIR = Total air volume required [m3] nST = Number of starts [pcs] Δp
= Allowed pressure difference [bar], max start pressure (30 bar) - min air pressure (18 bar).
Aker Yards 728 - a1 7 January 2008
5-1
Installation Planning Instructions 5. Compressed Air System
where: QST, i = Consumption for one start for engine i [Nm3/h]
The number of starts is specified in the classification societies rules.
5.3.2 Starting air compressor unit (3N02) The recommended size of the starting air compressor is calculated according to the following formula:
where: QC = Recommended capacity [m3/h] VSAV = Starting air vessel volume [m3] nSAV = Number of starting air vessels of equal size [pcs] nC = Number of starting air compressors [pcs] pN = Nominal pressure [bar] t = Time for filling from atmospheric pressure to nominal pressure [h]
At least two starting air compressors must be installed. It is recommended that the compressors are capable of filling the starting air receiver from minimum to maximum pressure in 15...30 minutes. For exact determination of the minimum capacity, the rules of the classification societies must be followed.
Separator (3S01) An oil and water separator should always be installed in the pipe between the compressor and the air vessel. Depending on the operating conditions of the installation, an oil and water separator may be needed in the pipe between the air vessel and engine. The starting air pipes should always be drawn with slope and be arranged with manual or automatic draining at the lowest points.
5.3.3 Air filter (3F02) Condense formation after the water separator (between starting air compressor and starting air receivers) create and loosen abrasive rust from the piping, fittings and receivers. Therefore it is recommended to install a filter in the external starting air system just before the starting air inlet on the engine to prevent particles to enter the starting air equipment. An Y-type strainer can be used with a stainless steel screen with a 0.8 mm perforations. The pressure drop should not exceed 20 kPa (0.2 bar) for the engine specific starting air consumption under a time span of 4 seconds.
5.4
Drawings DAAE058158DAAE058159-
5-2
Internal starting air system .................................................................................. Recommended starting air system ......................................................................
5-3 5-4
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DAAE058158- - Internal starting air system
Aker Yards 728 - a1 7 January 2008
5-3
Installation Planning Instructions DAAE058159- - Recommended starting air system
5-4
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 6. Cooling Water System
6.
Cooling Water System
6.1
System overview Only treated fresh water may be used for cooling the engines. The lay-out of the cooling water system is shown in the drawing "recommended cooling water system". If cooling water components are included in our scope of supply they are listed in section "Component data, Wärtsilä scope of supply".
6.1.1 Engine internal system The cooling water system consists of a high temperature (HT) and a low temperature (LT) circuit, both cooled by treated fresh water. The HT-circuit is cooling the jackets and cylinder heads and the LT-circuit is cooling the charge air and lubricating oil. The following equipment is built on the engine (Wärtsilä 9L20): •
engine driven HT circulating pump with non-return valve
•
HT thermostatic valve of self actuating type for controlling the outlet temperature from the engine
•
charge air cooler
•
engine driven LT circulating pump with non-return valve
The arrangement of the built-on system is shown in the drawing "internal system".
6.2
System design data
6.2.1 Raw water quality Raw water quality to be used in the closed cooling water circuits of engines has to meet the following specification. Table 6.1 Raw water specification
Property
Limit
pH, min,
6.5
Hardness, max.
10 °dH
Chlorides, max
80 mg/l
Sulphates, max.
150 mg/l
For raw water, evaporated water and a good quality tap water are normally recommended. If a reverse osmosis process results in water quality specified above, that can be used as well. Untreated sea water and fresh water as well as rain water are unsuitable raw water qualities.
6.2.2 Cooling water treatment Table 6.2 Approved cooling water treatment products
Product
Supplier
CorrShield NT 4293 CorrShield NT 4200
GE Betz Europe Interleuvenlaan 25 B-3001 Heverlee, Belgium GE Betz 4636 Somerton Road Trevose PA 19053, United States
Cooltreat 651
Aker Yards 728 - a1 7 January 2008
Houseman Ltd The Priory, Burnham Slough SL1 7LS, UK
6-1
Installation Planning Instructions 6. Cooling Water System
Product
Supplier
DEWT-NC powder Liquidewt Maxigard
Ashland Specialty Chemical Drew Marine One Drew Plaza Boonton, NJ 07005, USA
Dieselguard NB Rocor NB liquid Cooltreat AL
Unitor ASA P.O. Box 300 Skøyen N-0212 Oslo, Norway
Drewgard 4109
Ashland Specialty Chemical Drew Industrial One Drew Plaza Boonton, NJ 07005, USA
Havoline XLi
S.A. Arteco N.V. Technologiepark-Zwijnaarde 2 B-9052 Ghent/Zwijnaarde, Belgium Chevron Global Lubricants 6101 Bollinger Canyon Road San Ramon, CA 94583
Korrostop KV
RRS-Yhtiöt Pieksämäentie 398A 77570 Jäppilä, Finland
Marisol CW
Maritech AB Box 143 S-29122 Kristianstad, Sweden
Nalco 39 L Nalcool 2000
Nalco Chemical Company One Nalco Centre Naperville, Illinois 60566-1024 USA
Nalcool 2000 Nalfleet EWT 9-108
Nalfleet Marine Chemicals PO Box 11 Winnington Avenue, Northwich Cheshire, CW8 4DX, UK
RD11 RD11M RD25
Rohm & Haas La Tour de Lyon 185, Rue de Bercy 75579 Paris, Cedex 12, France
Vecom CWT Diesel QC-2
Vecom Holding BV PO Box 27 3140 AA Maassluis, The Netherlands
W T Supra
Total Diamant B, 16, rue de la République 92922 Paris La Défense Cedex, France
Q8 Corrosion Inhibitor Long-Life
Kuwait Petroleum (Danmark) AS Hummetoftveij 49 DK-2830 Virum, Denmark
In order to prevent corrosion in the cooling water system, the instructions of right dosage and concentration of active corrosion inhibitors should always be followed. The information can be found in the table below. Table 6.3 Dosage instructions
Product designation Corrshield NT 4293 CorrShield NT 4200 Drewgard 4109
6-2
Dosage per 1 m³ of system capacity
Concentration of active corrosion inhibitor
10 litres
670...1000 ppm as NO2
16...30 litres
640...1200 ppm as NO2
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 6. Cooling Water System
Product designation
Dosage per 1 m³ of system capacity
DEWT-NC powder Liquidewt Maxigard
3...4.5 kg 8...12 litres 16...30 litres
Cooltreat 651
5 litres
Q8 Corrosion Inhibitor Long-Life
50...100 litres
Maricol CW Nalco 39 (L) Nalcool 2000 Nalfleet EWT 9 - 108
1500...2250 ppm as NO2 470...700 ppm as NO2 640...1200 ppm as NO2 800 ppm as NO2 1.8...3.7 Brix° of active compounds measured with a supplier’s refractometer
6...9 litres
1000...1500 ppm as NO2
16...36 litres 32...48 litres 2.25...3.4 litres
550...1200 ppm as NO2 1000...1500 ppm as NO2 670...1000 ppm as NO2
Korrostop KV
20...25 litres
RD11 (RD11M) RD25
5 kg 50 litres
120...150 ppm as Mo 1250 ppm as NO2 710 ppm as Mo
Havoline XLi
50...100 litres
1.8...3.7 Brix° of active compounds measured with a supplier’s refractometer
WT Supra
50...100 litres
1.8...3.7 Brix° of active compounds measured with a supplier’s refractometer
Dieselguard NB Rocor NB Liquid Cooltreat AL
2.0...4.8 kg 9.5...24 litres 50...100 litres
1000...2400 ppm as NO2 1000...2400 ppm as NO2 1.8...3.7 Brix° of active compounds measured with a supplier’s refractometer
Vecom CWT Diesel QC-2
6.3
Concentration of active corrosion inhibitor
6...10 litres
1500...2500 ppm as NO2
Note 1
For many products the recommended minimum and maximum limits are listed in the table above. Since the amount of active corrosion inhibitors, especially nitrites, is decreasing during the service of engines, the engine manufacturer recommends to start the dosage from the upper level of indicated range.
Note 2
The nitrite content of nitrite-based cooling water additives tends to decrease in use. The risk of local corrosion increases substantially when nitrite content goes below the recommended limit.
Note 3
Cooling water additive manufacturers can indicate the required nitrite content measured either as sodium nitrite, NaNO2 or as nitrite, NO2. 1 mg/l as NO2 equals to 1.5 mg/l as NaNO2.
Recommended functions The following functions are not included in Wärtsilä scope of supply. We recommend you to design these functions as follows.
6.3.1 Central cooler (4E08) The fresh water cooler can be of either tube or plate type. Due to the smaller dimensions the plate cooler is normally used. The fresh water cooler can be common for several engines, also one independent cooler per engine is used. Design data: Heat to be dissipated/engine
see "Technical data" and drawing "Recommended cooling water system"
Fresh water flow/engine
see "Technical data" and drawing "Recommended cooling water system"
Pressure drop on the FW side, max.
60 kPa (0.6 bar)
FW temp. after cooler, max
38 °C
Sea water flow
acc. to makers standard, normally 1.2...1.5 x FW flow
Pressure drop on the SW side, norm
80...140 kPa (0.8...1.4 bar)
Margin for fouling and safety, min
15%
Aker Yards 728 - a1 7 January 2008
6-3
Installation Planning Instructions 6. Cooling Water System
6.3.2 Expansion tank (4T05) The expansion tank compensates for thermal expansion of the coolant, serves for venting of the circuits and provides a sufficient static pressure for the circulating pumps. Design data: Pressure from the expansion tank at pump inlet 70 - 150 kPa (0.7...1.5 bar) Volume
min. 10% of the system, however min. 100 l.
Concerning the water volume in the engine, see Technical data. The expansion tank should be equipped with an inspection hatch, a level gauge, a low level alarm and necessary means for dosing of cooling water additives. The vent pipes should enter the tank below the water level. The vent pipes must be drawn separately to the tank (see air venting) and the pipes should be provided with labels at the expansion tank. The balance pipe down from the expansion tank must be dimensioned for a flow velocity not exceeding 1.0...1.5 m/s in order to ensure the required pressure at the pump inlet with engines running. The flow through the pipe depends on the number of vent pipes to the tank and the size of the orifices in the vent pipes. The table below can be used for guidance Table 6.4 Minimum diameter of balance pipe
Nominal pipe size
Max. flow velocity (m/s)
Max. number of vent pipes with ø5 mm orifice
DN 32
1.1
3
DN 40
1.2
6
DN 50
1.3
10
DN 65
1.4
17
DN 80
1.5
28
6.3.3 Drain tank (4T04) It is recommended to provide a drain tank to which the engines and coolers can be drained for maintenance so that the water and cooling water treatment can be collected and reused. For the water volume in the engine, see the section for Technical data (HT-circuit). Most of the cooling water in the engine can be recovered from the HT-circuit, whereas the amount of water on the LT side is small.
6.3.4 Air venting (4S01) Air and gas may be entrained in the piping after overhaul, centrifugal pump seals may leak, or air or gas may leak from any equipment connected the HT- or LT-circuit, such as diesel engine, water cooled starting air compressor etc. As presented in drawing "Recommended cooling water system", it is strongly recommended that air venting equipment is installed for venting of any entrained air.
6.3.5 Orifices An orifice must be mounted in each cooling water circuit branch to be able to correctly balance the flow. An orifice shall also be installed in each venting pipe directed to the expansion tank. When a thermostatic valve is used to bypass a cooler, an orifice should be mounted in the bypass line so that the valve "sees" equal back pressures in the cooler and the bypass line.
6.4
Component data, Wärtsilä scope of supply
6.4.1 Temperature control valve (heat recovery) (4V02) Quantity ................................................ 4
6-4
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 6. Cooling Water System
Type ...................................................... 3 GEF CBA 032 Model ................................................... Electric Setpoint (°C) ......................................... 38 Pressure drop (bar) ............................... 0.07 Connection (DN) ................................... 80 Dimensional drawing ............................ 3 GEF Electric PID valve controller ................. 8072D Temperature sensor ............................. 8060A
6.4.2 Preheating unit (4N01) Quantity ................................................ 4 Type ...................................................... KV-E 18 Heater power (kW) ................................ 18 Flow (m³/h) ........................................... 13.0 El. motor power (kW) ............................ 0.55 Frequency (Hz) ..................................... 60 Voltage (V) ............................................ 690 Connection (DN) ................................... 40 Max. temperature (°C) .......................... 95 Max. pressure (bar) .............................. 10 Heating media ...................................... Electric Dimensional drawing ............................ 10020-05 Electrical drawing ................................. 11472-03
6.4.3 Temperature control valve (LT) (4V03) Quantity ................................................ 4 Type ...................................................... 2 BRCB Model ................................................... Direct Setpoint (°C) ......................................... 77 Pressure drop (bar) ............................... 0,26 Connection .......................................... 50 (2") Dimensional drawing ............................ SK3258
6.5
Drawings DAAE058160DAAE0581614V60D0343DBAA396944DBAA39694410020-05 11472-03 DBAA396949DBAA396949DBAA396949DBAA396949-
Aker Yards 728 - a1 7 January 2008
Internal cooling water system .............................................................................. 6-6 Recommended cooling water system .................................................................. 6-7 Recommended cooling water circuit deaerator .................................................... 6-8 4V02 - Temperature control valve (heat recovery), dimensional drawing ............ 6-9 4V02 - Temperature control valve (heat recovery), installation instruction ........... 6-10 4N01 - Preheating unit, dimensional drawing ...................................................... 6-12 4N01 - Preheating unit, electrical drawing ........................................................... 6-13 4V03 - Temperature control valve (LT), dimensional drawing .............................. 6-15 4V03 - Temperature control valve (LT), el. PID valve controller ........................... 6-16 4V03 - Temperature control valve (LT), temp sensor ........................................... 6-17 4V03 - Temperature control valve (LT), installation instructions ........................... 6-18
6-5
Installation Planning Instructions DAAE058160- - Internal cooling water system
6-6
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DAAE058161- - Recommended cooling water system
Aker Yards 728 - a1 7 January 2008
6-7
Installation Planning Instructions 4V60D0343- - Recommended cooling water circuit deaerator
6-8
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DBAA396944- - 4V02 - Temperature control valve (heat recovery), dimensional drawing
Aker Yards 728 - a1 7 January 2008
6-9
Installation Planning Instructions DBAA396944- - 4V02 - Temperature control valve (heat recovery), installation instruction
AMOT CONTROLS Quality and reliability for over 50 years
Amot Thermostatic Valves are manufactured and tested to the highest possible standard. If the valve is correctly applied and installed, it will give many years of reliable, trouble-free service.
Internally Sensed Valves Installation & Operation Instructions (Model B, C, D, E, H, J) DIVERTING APPLICATIONS
C
AMOT THERMOSTAT
A B
This operating guide gives service information for most normal operating conditions, but for unusual situations, it may be necessary to consult your local Amot representative or the Amot factory.
HEAT LOAD
HEAT REMOVAL
PUMP
All Amot internally sensed thermostatic valves work on the “expanding wax” principle, the temperature elements are set to a pre-determined temperature under very strictly controlled conditions. They are not adjustable. If system temperatures need to be changed, then replacement elements must be fitted.
Inspection Upon receipt, the valve should be checked for damage sustained in shipping. All Amot valves have nameplates attached, which are stamped with the valve model number and serial number.
MIXING APPLICATIONS
HEAT REMOVAL
HEAT LOAD ’AMOT’ THERMOSTAT
B
C
A
PUMP
Installation Guidelines Installation Methods There are several ways of installing Amot thermostatic valves, but the two most common applications are “mixing” and “diverting”. When diverting the fluid, temperature into the valve is being controlled. When mixing the fluid, temperature from the valves is controlled. Experience has shown that in mixing mode the valve may run at 1-2˚C (1.8-3.6˚F) higher than the normal set temperature. All Amot internally sensed valves have the same port identification, ie, A,B and C.
Port Nomenclature “COLD” position: A-B connected, C closed. “HOT” position: A-C connected, B closed.
6-10
Electrolysis – If expected or encountered in the system, a zinc or magnesium waste plug should be fitted as close as possible to Port A. Salt Water – For direct sea water cooled applications, bronze valves with plated elements should be used. Venting – If the valve is mounted at the high point of the system, then care must be taken to ensure that the system is properly vented to prevent trapping air at the elements. A leak hole within the unit may be necessary. Environmental Conditions – Ensure protection against frost and direct sunlight.
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DBAA396944- - 4V02 - Temperature control valve (heat recovery), installation instruction
Overtemperature – Ensure maximum continuous temperatures of element assemblies are not exceeded; this can increase risk of premature failures. Pipe Alignment – Ensure good alignment of pipes prior to tightening of all connections. No pipe strain or loading should be applied to the valve body. Flange Gaskets – Use full face gaskets. Threaded Ports – Valves having threaded connections, use a thread sealant to prevent leakage rather than excessive tightening force.
Operation Upon installation and on start up of the system, all parts of the circuit should be closely monitored to ensure correct performance. A system in which the valves have been properly selected for the anticipated flows should operate very closely to the valve’s nominal temperature rating. Water cooling systems will usually operate at or slightly below the nominal temperature. Lubricating oils and most other higher viscosity fluids will operate at or slightly above the nominal temperature. In any system where the indicated temperatures are more than 2.7˚C (5˚F) from the nominal temperature, then an effort should be made to locate the cause. Any system operating at an indicated 5.5˚C (10˚F) or more from the nominal anticipated temperatures is probably malfunctioning and the cause should be located and rectified immediately. (See trouble-shooting guide for possible causes.)
CAN WE BE OF FURTHER HELP? Amot’s product portfolio does not stop at our extensive range of self-actuated internal sensing thermostatic valves. Complementing these are a complete range of control products, including: Remote sensing control valves with both electronic and/or pneumatic control loops, giving close temperature control in sizes from 2” to 16”. Switches and sensors for monitoring temperature, pressure, flow, level, speed and vibration, for industrial, marine and hazardous area applications. Mechanical safety controls, valves and indicators used for monitoring and controlling the operations of engines, compressors and other marine or industrial equipment and processes. Customised data acquisition systems for both intrinsically safe and standard industrial applications. In addition, Amot is an expert in the design and manufacture of instrumentation and control panels for a wide range of applications. With over 40 years’ experience providing specialised mechanical, hydraulic, pneumatic, electric, and electronic control components, from manufacturing and engineering facilities in the UK and US, technical centres in Switzerland and Singapore, plus more than 60 representatives appointed worldwide, Amot Controls has both the product range and infrastructure to maintain its obsession with customer service. If we can be of any further help to you, please contact us.
This sheet is distributed for information purposes only. It is not to be construed as becoming part of any contractual or warranty obligations of Amot Controls Limited, unless expressly so stated in a sales contract. Amot Controls Limited reserves the right to make product design changes at any time without notice.
AMOT Controls Limited AMOT Controls Corporation AMOT Controls Western Way 401 First Street 230 Orchard Road Bury St Edmunds, Suffolk Richmond, California #09-230 Faber House IP33 3SZ UK 94801-2906, USA Singapore 238854 Telephone: +44 (0)1284 762222 Telephone: (510) 236-8300 Telephone: (65) 235 8187 Telex: 81283 Telefax: (510) 234-9950 Telefax: (65) 235 8869 Telefax: +44 (0)1284 760256 E-mail
[email protected] AMOT Controls (UK) Ltd E-mail
[email protected] © Copyright Amot Controls Limited Amot UK factory approved to ISO 9001 Web: http://www.amot.com O&M VIB/rev 3/Mar 1998
Aker Yards 728 - a1 7 January 2008
6-11
6-12
750 800 800 800 840 840 840 840 940 940 1190 1190 1240
C
oD 190 240 240 240 290 290 290 290 350 350 400 400 450
500 500 500 700 500 700 500 700 700 700 700 700 700
E 310 310 310 310 310 310 310 310 350 350 360 360 360
F
zul.Betriebsüberdruck: max. 10 bar operating pressure
305 305 305 305 320 320 320 320 320 320 335 335 335
KVE-7,5 7,5 1050 155 KVE-12 12 1050 155 KVE-15 15 1050 155 KVE-18 18 1250 155 KVE-22,5 22,5 1050 160 KVE-27 27 1250 160 KVE-30 30 1050 160 KVE-36 36 1250 160 KVE-45 45 1250 190 KVE-54 54 1250 190 KVE-72 72 1260 215 KVE-81 81 1260 215 KVE-108 108 1260 240
A
B1
kW
B
TYPE oG 18 18 18 18 18 18 18 18 22 22 22 22 26 160 200 200 200 250 250 250 250 300 300 350 350 400
H 685 680 680 880 670 870 670 870 860 860 815 815 805
L 610 660 660 660 700 700 700 700 755 755 805 805 855
M 445 495 495 495 535 535 535 535 590 590 640 640 690
N 720 550 720 900 720 900 720 900 720 900 900 900 900
Z 8 17 17 20 24 29 24 29 46 46 66 66 91
75 93 93 95 100 103 105 125 145 150 187 190 215
Inhalt Gewicht Ltr. ca. kg
Pumpe 50 Hz
Pumpe 60 Hz
TP 40-160 ; 0.75kW 13m³/h ; 1,11bar
TP 40-180 ; 0.55kW 12m³/h ; 1,0bar
D-80687 München Landsberger Straße 367-369 Tel: (089) 546779-0 Fax:-10
TP 40-160 ; 0.75kW 13m³/h ; 1,11bar
TP 40-120 ; 0.37kW 12m³/h ; 0,7bar
TP 40-60/2 ; 0.25kW TP 40-80/2 ; 0.55kW 11m³/h ; 0,47bar 13m³/h ; 0,7bar
zul.Betriebstemperatur: max. 95°C operating temperature
235 240 240 240 240 240 240 240 240 240 265 265 265
K
WASSERVORWÄRME-AGGREGAT Type: KVE WATER PREHEATING SET type: KVE
RÜCKSCHLAGKLAPPE NON-RETURN FLAP
UMWÄLZPUMPE CIRCULATING PUMP
ELEKTRO-DURCHLAUFERHITZER ELECTRIC FLOW HEATER SCHALTSCHRANK Position der Schalter nicht verbindlich SWITCH CABINET Position of Lamps and switches could be different
Installation Planning Instructions 10020-05 - 4N01 - Preheating unit, dimensional drawing
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 11472-03 - 4N01 - Preheating unit, electrical drawing
Aker Yards 728 - a1 7 January 2008
6-13
Installation Planning Instructions 11472-03 - 4N01 - Preheating unit, electrical drawing
6-14
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DBAA396949- - 4V03 - Temperature control valve (LT), dimensional drawing
Aker Yards 728 - a1 7 January 2008
6-15
Installation Planning Instructions DBAA396949- - 4V03 - Temperature control valve (LT), el. PID valve controller
6-16
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DBAA396949- - 4V03 - Temperature control valve (LT), temp sensor
Aker Yards 728 - a1 7 January 2008
6-17
Installation Planning Instructions DBAA396949- - 4V03 - Temperature control valve (LT), installation instructions
79 Accessories Identification of Model Number
8072D
0
0
0
D
-AA
Inputs Input 1 = PT100
0
Input 1 = 4-20mA
2
Outputs Output 1 = SSR
0
Output 1 = 4-20mA
1
Direct/Reverse acting Direct
D
Reverse
R
Controls and Indications In addition to the 8071D controller described in Section 2, a power supply switch is mounted on the front panel. It switches all AC power to the controller and relays. 9.1.2
Installation Dimensions
Fig 18 8072D Dimensions
OMM807100043
6-18
Rev 2 – Dec 06
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions DBAA396949- - 4V03 - Temperature control valve (LT), installation instructions
80 Accessories Installation Guidance Notes The following notes provide a guide to deciding where a controller can be safely installed. Location and Climatic Requirements The instrument location should, as far as possible, be free from: x x x
Shock and vibration. Stray electromagnetic fields. e.g. from motors, transformers etc. The ambient temperature at the location must be between 0 and +50 °C at a relative humidity not exceeding 75 %. Electrical Requirements x The choice of cable, installation and electrical connection must conform with the requirements of the appropriate local regulations. x The electrical installation must only be carried out by suitably trained and qualified personnel. x If contact with live parts is possible when working on the instrument, it must be isolated on both poles from the supply. x The circuit must be fused for the maximum relay current in order to prevent welding of the output relay contacts in case of an external shortcircuit. x Run input, output and supply lines separately and not parallel to each other. x Do not connect additional loads to the supply terminals of the instrument. x The instrument is not suitable for installation in hazardous areas. x Apart from faulty installation, there is a possibility of interference or damage to controlled processes due to incorrect settings on the controller (setpoint, data of parameter and configuration levels, internal adjustments). Safety devices independent of the controller, such as overpressure valves or temperature limiters/monitors, should always be provided and should be capable of adjustment only by specialist personnel. Refer to the appropriate safety regulations. x The signal inputs of the controller must not exceed a maximum potential of 30 V ac or 50 V dc against the earth terminal. x All input and output lines that are not connected to the supply network must be laid out as shielded and twisted cables (do not run them in the vicinity of power cables or components). The shielding must be grounded to the earth potential on the instrument side. x Electromagnetic compatibility conforms to the standards and regulations detailed in Section 10 (Technical Data) of this Manual.
Rev 2 – Dec 06
Aker Yards 728 - a1 7 January 2008
OMM807100043
6-19
Installation Planning Instructions DBAA396949- - 4V03 - Temperature control valve (LT), installation instructions
81 Accessories Mounting the Controller
WARNING Two holes for the mounting of the controller are located under the flap that covers the terminal connections. The power supply to the controller must be isolated before the flap is lifted to prevent electric shock to personnel. Four mounting holes are provided in the case indicated by the arrows in Fig 19.
Fig 19 Mounting Holes Electrical Connections Electrical connections to the 8072D are made through terminal connections beneath the hinged flap as follows:
Fig 20 8072D External Connections
OMM807100043
6-20
Rev 2 – Dec 06
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 7. Combustion Air System
7.
Combustion Air System
7.1
System overview The engine draws the combustion air from the engine room through the inlet filter fitted on the turbocharger. The combustion air should be delivered through a dedicated duct close to the turbocharger(s), directed towards the air intake(s). For the required amount of combustion air, see the section for "Technical data".
7.2
System design data
7.2.1 Combustion air quality During normal operating conditions the air temperature at the turbocharger inlet should be kept between 15ºC and 35ºC. Max. 45ºC is allowed.
7.3
Recommended functions
7.3.1 Engine room ventilation Figure 7.1 Engine room ventilation.
To maintain acceptable operating conditions for the engines and to ensure trouble free operation of all equipment, attention shall be paid to the engine room ventilation and the supply of combustion air. The air intakes to the engine room must be located in a way that water spray, rain water, dust and exhaust gases cannot enter the ventilation ducts and the engine room. The dimensioning of blowers and extractors should ensure that an over pressure of about 5 mmWC is maintained in the engine room in all running conditions. For the minimum requirements concerning the engine room ventilation and more details, see applicable standards, such as ISO 8861. The amount of air required for ventilation is calculated from the total heat emission Φ to evacuate. To determine Φ, all heat sources shall be considered, e.g.:
Aker Yards 728 - a1 7 January 2008
7-1
Installation Planning Instructions 7. Combustion Air System •
main and auxiliary diesel engines
•
exhaust gas piping
•
generators
•
electric appliances and lighting
•
boilers
•
steam and condensate piping
•
tanks
•
other auxiliary equipment
It is recommended to consider an outside air temperature of not less than 35°C and a temperature rise of 11°C for the ventilation air. The amount of air required for ventilation is then calculated from the formula:
where: Qv = Amount of ventilation air [m3/s] Ф = total heat emission to be evacuated [kW] ρ = density of ventilation air 1.13 kg/m3 Δt = Temperature rise in engine room [°C] c = Specific heat capacity of the ventilation air 1.01 kJ/kgK
The engine room ventilation has to be provided by separate ventilation fans. These fans should preferably have two-speed electric motors (or variable speed). Thus flexible operation is possible, e.g. in port the capacity can be reduced during overhaul of the main engine when it is not preheated (and therefore not heating the room). The ventilation air is to be equally distributed in the engine room considering air flows from points of delivery towards the exits. This is usually done so that the funnel serves as an exit for the majority of the air. To avoid stagnant air, extractors can be used. It is good practice to provide areas with significant heat sources, such as separator rooms with their own air supply and extractors. For very cold conditions a preheater in the system should be considered. Suitable media could be thermal oil or water/glycol to avoid the risk for freezing. If steam is specified as a heating system for the ship the preheater should be in a secondary circuit.
7.3.2 Combustion air for engines The combustion air shall be supplied by separate combustion air fans, with a capacity slightly higher than the maximum air consumption. For the required amount of combustion air, see the section "Technical data". The fans should preferably have a two-speed electric motors (or variable speed) for enhanced flexibility. In multi-engine installations each main engine should preferably have its own combustion air fan. Thus the air flow can be adapted to the number of engines in operation. The air required for combustion is taken from the engine room through a filter fitted on the turbocharger. This reduces the risk for too low temperatures and contamination of the combustion air. It is imperative that the combustion air is free from sea water, dust, fumes, etc. With these arrangements the normally required minimum air temperature to the main engine, see section "Recommendations for operation", can typically be maintained. For lower temperatures special provisions are necessary.
7-2
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 7. Combustion Air System
7.3.3 Condensation of charge air coolers Condensed water from the charge air coolers is normally drained to the bilge. The condensation can be estimated according to the example below. Example, according to the diagram:
Figure 7.2 Condensation in charge air coolers
At an ambient air temperature of 35°C and a relative humidity of 80%, the content of water in the air is 0.029 kg water/ kg dry air. If the air manifold pressure (receiver pressure) under these conditions is 2.5 bar (= 3.5 bar absolute), the dew point will be 55°C. If the air temperature in the air manifold is only 45°C, the air can only contain 0.018 kg/kg. The difference, 0.011 kg/kg (0.029 - 0.018) will appear as condensed water.
Aker Yards 728 - a1 7 January 2008
7-3
Installation Planning Instructions
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7-4
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 8. Exhaust Gas System
8.
Exhaust Gas System
8.1
System overview Each engine should have its own exhaust pipe into open air.
8.1.1 Engine internal system The equipment built on the engine is shown in the drawing "internal charge air & exhaust gas system".
8.2
Recommendations and design data
8.2.1 Exhaust gas piping The piping should be as short and straight as possible. Pipe bends and expansions should be smooth to minimise the backpressure. The diameter of the exhaust pipe should be increased directly after the bellows on the turbocharger. Pipe bends should be made with the largest possible bending radius; the bending radius should not be smaller than 1.5 x D. The recommended flow velocity in the pipe is 35…40 m/s. If there are many resistance factors in the piping, or the pipe is very long, then the flow velocity needs to be lower. The exhaust gas mass flow given in the section for Technical data can be translated to velocity using the formula:
where: v = gas velocity [m/s] m = exhaust gas mass flow [kg/s] t = exhaust gas temperature [°C] D = exhaust gas pipe diameter [m]
Each exhaust pipe should be provided with a connection for measurement of the backpressure. The connection should be close to the engine, but not closer than 4..5 pipe diameters from the transition to larger pipe diameter after the bellows on the turbocharger. Neither should the connection be closer than 3..4 pipe diameters after a 90 degree pipe bend. The connection should be installed while the exhaust gas outlet on the turbocharger is protected with a cover. The exhaust gas pipe should be provided with water separating pockets and drainage. The exhaust pipe must be insulated all the way from the turbocharger and the insulation is to be protected by a covering plate or similar to keep the insulation intact. Closest to the turbocharger the insulation should consist of a hook on padding to facilitate maintenance. It is especially important to prevent the airstream to the turbocharger from detaching insulation, which will clog the filters.
8.2.2 Supporting It is very important that the exhaust pipe is properly fixed to a support rigid in all directions directly after the bellows on the turbocharger. The bellows on the turbocharger may not be used to absorb thermal expansion from the exhaust pipe. The first fixing point must direct the thermal expansion away from the engine and be located max. 3 diameters (bellows) away from the bellows on the turbocharger. There should be a fixing point on both sides of the pipe at the support. Absolutely rigid mounting between the pipe and the support is recommended at the first fixing point after the turbocharger. Resilient mounts can be accepted for resiliently mounted engines with long bellows, provided that the mounts are self-captive; maximum deflection at total failure being less than 2 mm radial and 4 mm axial with regards to the bellows. The natural frequencies of the mounting should be on a safe distance from the running speed, the firing frequency of the engine and the blade passing frequency of the propeller. The resilient mounts can be rubber mounts of conical type, or high damping stainless steel wire pads. Adequate thermal insulation must be provided
Aker Yards 728 - a1 7 January 2008
8-1
Installation Planning Instructions 8. Exhaust Gas System to protect rubber mounts from high temperatures. When using resilient mounting, the alignment of the exhaust bellows must be checked on a regular basis and corrected when necessary. After the first fixing point resilient mounts are recommended. The mounting supports should be positioned at stiffened locations within the ship’s structure, e.g. decklevels, framewebs or specially constructed supports. The supporting must allow thermal expansion and ship’s structural deflections.
8.2.3 Back pressure The maximum permissible exhaust gas back pressure is 3 kPa at full load. The back pressure in the system must be calculated by the shipyard based on the actual piping design and the resistance of the components in the exhaust system. The exhaust gas mass flow and temperature given in the section for Technical data may be used for the calculation. If there is an exhaust gas boiler in the system, then the temperature of the exhaust gas will be reduced in the exhaust gas boiler and the lower temperature will decrease the flow velocity after the boiler. The lower temperature will on the other hand result in a higher density, but the net effect is a slightly lower pressure loss than without temperature decrease. The back pressure should also be measured on the sea trial.
8.2.4 Exhaust gas bellows (5H01) Bellows must be used in the exhaust gas piping where thermal expansion or ship’s structural deflections have to be segregated. The flexible exhaust gas bellows mounted directly on the turbocharger outlet serves to minimise the external forces on the turbocharger and thus prevent vibrations and possible damage. All exhaust gas bellows must be of an approved type.
8.2.5 Selective Catalytic Reduction (11N03) If SCRs will be installed, the exhaust gas piping must be straight at least 3...5 meters in front of the SCR. If both an exhaust gas boiler and a SCR unit will be installed, then the exhaust gas boiler shall be installed after the SCR. Arrangements must be made so that when cleaning the exhaust gas boiler with water, the cleaning water cannot spill down into the SCR.
8.2.6 Exhaust gas silencer (5R02) Yard/designer should take into account that unfavorable layout of the exhaust system (length of straight parts in the exhaust system) might cause amplification of the exhaust noise between engine outlet and the silencer. Hence the attenuation of the silencer does not give any absolute guarantee for the noise level after the silencer.
8.2.7 Exhaust gas boiler If exhaust gas boilers will be installed, each engine should have a separate exhaust gas boiler. Alternatively, a common boiler with separate gas sections for each engine is acceptable. For dimensioning the boiler, the exhaust gas quantities and temperatures given in section "Technical data" may be used.
8-2
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 8. Exhaust Gas System
8.3
Installation instructions Figure 8.1 Overview of the exhaust gas pipe installation.
Refer to section "Technical data" for the dimensions A and B in the figure above. Installation procedure: 1. The engine or generating set should be installed in its final position before any external pipes are connected. 2. Remove the protective cover from the exhaust gas outlet on the turbocharger. Be careful that no dirt drops into the turbocharger. 3. Check the flow direction from the dimensional drawing of the bellows and install it on the turbocharger, using the correct gasket between the flanges. Lubricate the threads of the screws with heat resistant grease and tighten in a diagonal sequence. NOTE!
Do not remove the supports between the flanges of the bellows, until the installation procedure has been completed and the exhaust pipe has been rigidly fixed. Should the supports (for transport) have been removed, then prepare and install new supports so that the bellows is stretched about 3 mm during installation.
4. Make a temporary protection cover and place it between the bellows flange and the smaller flange of the connection piece. The thickness of the cover should be equal to the thickness of the gasket, which will be installed between the flanges later. Preferably make the cover slightly larger than the flange diameter. 5. Install the connection piece on the bellows with the protection cover between the flanges. Connect the flanges temporarily with a number of screws. Use a sufficient number of screws to ensure that the flanges are pulled together properly. If the bellows is aligned in a horizontal or tilted position, temporary supporting of the connection piece and the bellows is needed during the installation. 6. Mount the counter flange to the larger flange of the connection piece, using the correct gasket between the flanges. Use a sufficient number of screws to ensure that the flanges are pulled together properly. 7. Align the exhaust gas pipe to the counter flange. Do not force the connection piece in any direction. NOTE!
The exhaust gas outlet of a flexibly mounted engine will usually be displaced due to the torque reaction as the load increases. In some cases it is necessary to compensate for the torque reaction by installing the exhaust gas pipe with an initial lateral offset. Thus, if the engine is flexibly mounted, Wärtsilä should be contacted for further instructions. In the case of a flexibly mounted generating set, which has a common base plate, there is no lateral displacement due to the torque reaction.
Aker Yards 728 - a1 7 January 2008
8-3
Installation Planning Instructions 8. Exhaust Gas System 8. Anchor the exhaust gas pipe to the ship structure as close as possible to the flange of the connection piece. The supports must be made very rigid in order to prevent vibration and movement of the exhaust gas pipe. 9. Weld the counter flange to the exhaust gas pipe. 10. Remove the connection piece and clean the exhaust gas pipe from slag and particles developed during the welding. Remember to keep the entry into the turbocharger covered. 11. Remove the protection cover and install the connection piece with the appropriate gaskets. 12. Remove the temporary supports between the flanges of the flexible bellows. 13. Lubricate the threads of all screws with heat resistant grease and tighten in a diagonal sequence. Refer to the drawing "exhaust gas bellows" drawing for dimensions and flow direction.
8.4
Component data, Wärtsilä scope of supply
8.4.1 Turbocharger cleaning device (5Z03) Quantity ................................................ 2 Type ...................................................... Dosing unit Dimensional drawing ............................ 3V37L0587
8.4.2 Connection piece (5Z01) Quantity ................................................ 4 Type ...................................................... Adapter piece Exh.pipe dimension (DN) ...................... 450 TC outlet (DN) ....................................... 300 Turbo charger type ............................... TPS57 Dimensional drawing ............................ 3V60A4945
8.4.3 Exhaust gas bellows (5H01) Quantity ................................................ 4 Type ...................................................... Double Length (mm) ......................................... 420.0 Connection (DN) ................................... 300 Counter flanges .................................... Without Dimensional drawing ............................ 3V60B0020-5
8.4.4 Exhaust gas silencer with spark arrestor (5R02) Quantity ................................................ 4 Type ...................................................... MS-PAEXG-WSA NS 450 35dB(A) Connection (DN) ................................... 450 Attenuation (dB(A)) ............................... 35 Mounting bracket ................................. Without Dimensional drawing ............................ 3ES0342C Installation instruction .......................... 4ES0061
8-4
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 8. Exhaust Gas System
8.5
Drawings DAAE0581623V37L0587a 3V60A49453V60B0020r 3ES0342C 4ES0061
Aker Yards 728 - a1 7 January 2008
Internal charge air and exhaust gas system ........................................................ 8-6 5Z03 - Turbocharger cleaning device, dimensional drawing ................................ 8-7 5Z01 - Connection piece, dimensional drawing ................................................... 8-8 5H01 - Exhaust gas bellows, dimensional drawing .............................................. 8-9 5R02 - Exhaust gas silencer with spark arrestor, dimensional drawing ............... 8-10 5R02 - Exhaust gas silencer with spark arrestor, installation instruction ............. 8-11
8-5
Installation Planning Instructions DAAE058162- - Internal charge air and exhaust gas system
8-6
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 3V37L0587a - 5Z03 - Turbocharger cleaning device, dimensional drawing
Aker Yards 728 - a1 7 January 2008
8-7
Installation Planning Instructions 3V60A4945- - 5Z01 - Connection piece, dimensional drawing
8-8
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 3V60B0020r - 5H01 - Exhaust gas bellows, dimensional drawing
Aker Yards 728 - a1 7 January 2008
8-9
0.00
0.20
0.40
0.60
0.80
1.00
1.20
5 0
15 10
30 25 20
40 35
50 45
0
31.5
100
63
300
Exhaust gas temperature (°C)
200
400
250 500 1000 Frequency, Hz
Exhaust gas density
125
Estimated Transmission Loss
2000
500
4000
600
8000
30
v= m= NS= t=
v=
0
20
40
35
1,3 *
40
Δp = C *
1 * ρ *v2 2
flow velocity exhaust gas mass flow exhaust gas pipe diameter exhaust gas temperature
4*m 273 * π * NS 2 273 + t
Velocity, (m/s)
45
( m / s)
(m/s) ( kg / s ) (m) ( °C )
350
25
300 80
400
250 100 60
200 120
20
Temp. °C 140
160
180
200
C=2,23 Reactive and absorption model with spark arrestor 35 dB(A) Structure steel Fe37B (EN10025) (Cor-Ten B on request) DIN 2501 DIN 2986 D ( SFS-EN 25817 ) Vertical Ground painting, Primer thickness 25 µm Weatherproof steel, no painting Total Weight 855 kg (xxx) = auxiliary dimension
Transmission Loss, dB Exhaust gas density (kg/m³)
8-10 Pressure loss, (mmWc)
Technical data Pressure drop coeff. Silencer type Average attenuation Material: Flanges: Drains: Welding class: Mounting: Surface treatment:
Installation Planning Instructions 3ES0342C - 5R02 - Exhaust gas silencer with spark arrestor, dimensional drawing
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 4ES0061 - 5R02 - Exhaust gas silencer with spark arrestor, installation instruction
1/6 Rev. 09.03.2005 JH
12.7.2005
Date 20.8.1998 Author: T. Viitala Doc. 4ES0061
INSTRUCTIONS FOR ASSEMBLY, OPERATION, AND MAINTENANCE OF EXHAUST SILENCERS These instructions can be applied to exhaust silencers with or without spark arrestors. Our silencer models are suitable for attenuating noise generated by diesel engines, gas turbine engines, compressors, vacuum pumps or out-blow pipes. Silencers equipped with spark arrestors are suitable for shipbuilding and marine industry, and for environments, which are classified either as inflammable or where there is a danger of explosion. Weather conditions must be taken into account when choosing frame materials for silencers. In normal inland weather conditions steel for general structural purposes is used as the material for the frame structures. In corroding marine climate the most commonly used material is weatherproof Cor-Ten steel. If there are corrosive gasiform acids in the environment, it is advisable to choose acid proof stainless steel. The durability of a silencer can be maximized by paying attention to the environment where the silencer is to be operated.
OPERATING PRINCIPLE The operation of an exhaust silencer is based on absorptive and reactive attenuation, and on the combination of the two, depending on the requirements set for noise attenuation. The type designation on the dimensional drawing shows the silencer type.
ASSEMBLY When the silencer is being stripped of its packing crate, lifting points and lugs should be checked. Before assembly the silencer is checked visually. It is advisable to pay attention to possible damages caused during the transport and to check the cleanliness of the inlet and outlet ducts of the silencer. Note that there are plates at both ends of the silencer, which has to be removed before checking the cleanliness and the final assembly. Impurities or extra objects are to be removed. An exhaust silencer is equipped with a type plate that shows the type, model, manufacturer, date of manufacture, flow direction, and total weight of the silencer. WÄRTSILÄ made by JTK Power Oy Flow EXHAUST GAS SILENCERS Type: Tag n:o Manuf. no:
Manuf. year:
Max. Temp.
Weight:
JTK POWER OY Teollisuustie 6 FIN-66600 Vöyri
Tel. +358-6-281 2200 Telefax +358-6-361 0383
Figure 1. The type plate is placed at the in-flow end of the silencer. JTK
Drg no. 4ES0061
Metalli-Jokela Teollisuustie 6
Internet: www.jtk-power.fi
FIN-66600 Vöyri
E-mail:
[email protected]
Aker Yards 728 - a1 7 January 2008
Tel. +358-6-281 2200 Telefax +358-6-361 0383
8-11
Installation Planning Instructions 4ES0061 - 5R02 - Exhaust gas silencer with spark arrestor, installation instruction
2/6 Before connecting an engine to exhaust piping, it is switched off or its exhaust fumes are bypassed during the assembly of the silencer. The correct flow direction of the silencer is checked in the type plate. Warning ! A wrong flow direction may damage the interior of the silencer and decrease engine power due to increasing back pressure. In deliveries where counter-flanges for the connection to exhaust piping are included, counter-flanges have to be unscrewed from the flanges of the silencer. When the silencer has been fitted and it is being connected to the piping, the intactness of the seals should be checked. It is advisable to grease the sealing surfaces and hexagonal screws with heatproof graphite-based lubricating oil. The flange joints are tightened in two stages, i.e. pretightening and final torque tightening. The joints are tightened in turns from the opposite sides of the flange joint.
LOCATION The location of the silencer is important when choosing a suitable model. If the silencer is to be placed high up, e.g. on the roof of a building or outdoors, one must also take into account the wind loads on the silencer structures. If the silencer is placed in an environment likely to be exposed to storms, it is advisable to contact the manufacturer of the silencer for further advice.
SUPPORTS The silencer must be adequately supported. The perforation of the supports must accommodate the increase of the length of the silencer. Oblong holes on the supports leave room for termal expansion of the silencer structure during operation. In order to minimize vibration, flexible fasteneres must be used as the supports to the frame of the exhaust silencer. Flexible fasteners include the bellows compensator fitted between the piping and the silencer joint as well as the isolation of the support structures and the silencer frame with the help of a fastening method that damps vibrations.
Figure 2. Support of the silencer and use of a bellows compensator.
JTK
8-12
Drg no. 4ES0061
Metalli-Jokela Teollisuustie 6
Internet: www.jtk-power.fi
FIN-66600 Vöyri
E-mail:
[email protected]
Tel. +358-6-281 2200 Telefax +358-6-361 0383
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 4ES0061 - 5R02 - Exhaust gas silencer with spark arrestor, installation instruction
3/6
Figure 3. Examples of how to place the supports. If the silencer is equipped with sliding supports, the supports can be found from the silencer package. The sliding supports are marked with a corresponding silencer drawing number. The sliding supports are field welded to their right places during the assembly at the site. The following aspects of supporting the silencer should be taken into account when choosing the silencer type. • • •
Will there be a chimney after the outlet of the silencer? Will the silencer be supported with a framework or will it stand freely? Can an upright silencer be supported laterally from upside?
OPERATION A silencer is designed for round-the-year, periodical, or round-the-clock operation. The maximum temperature given in the type plate must not be exceeded during the operation. If the temperature of the exhaust fumes is higher than that allowed for the silencer, the absorptive material in the silencer may get damaged and the performance of the silencer deteriorate. MAINTENANCE The silencers in our standard range of products are designed maintenance-free. For silencers equipped with spark arrestors, the manufacturer advises to grease the threads of the discharge socket and cap with heatproof graphite lubricating oil when the spark box is being discharged. Manufacturer recommend to clean out the spark box after 4000 operating hours or inspection every half an year.
JTK
Drg no. 4ES0061
Metalli-Jokela Teollisuustie 6
Internet: www.jtk-power.fi
FIN-66600 Vöyri
E-mail:
[email protected]
Aker Yards 728 - a1 7 January 2008
Tel. +358-6-281 2200 Telefax +358-6-361 0383
8-13
Installation Planning Instructions 4ES0061 - 5R02 - Exhaust gas silencer with spark arrestor, installation instruction
4/6 Operation and Skeleton drawing of a Silencer Equipped with a Spark Arrestor.
Figure 4. Operation of a Silencer Equipped with a Spark Arrestor.
MODELS EQUIPPED WITH SPARK ARRESTOR Silencers equipped with spark arrestors are particularly well suited for marine industry and also for other industry in cases where there is a danger of explosion or fire. The efficient collecting capacity of the spark arrestor has been optimized with respect to back pressure and the nominal size of the piping. Its operation is based on an in-built flow separator that directs the exhaust gas flows towards the outer casing.
JTK
8-14
Drg no. 4ES0061
Metalli-Jokela Teollisuustie 6
Internet: www.jtk-power.fi
FIN-66600 Vöyri
E-mail:
[email protected]
Tel. +358-6-281 2200 Telefax +358-6-361 0383
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 4ES0061 - 5R02 - Exhaust gas silencer with spark arrestor, installation instruction
5/6
MAXIMUM LOAD ON THE TOP AND BOTTOM ENDS OF AN EXHAUST SILENCER The top and bottom ends of a silencer may be loaded during operation up to a specified limit. The maximum loads allowed are shown as static axial loads. Note! If there is a chimney pipe several metres long and the chimney is longer than 3 metres, wind loads must also be taken into account. When the total length of the silencer and the chimney pipe grows, the dynamic loads on the structure will also have to be given proper attention. In unclear cases we recommend you to contact the manufacturer.
Max Load F1
Max Load F2
Figure 5. Static load on the top and bottom ends of a silencer. Nominal Lenght of pipe size of pipe m (max) NS250 3 NS300 3 NS350 3 NS400 4 NS450 4 NS500 4 NS600 4 NS700 4 NS800 4 NS900 4 NS1000 4 NS1100 4 NS1200 4 NS1300 4 NS1400 4
Load, top Load, bottom flange F1, kg flange F2, kg 100 65 120 85 130 90 200 140 230 160 255 175 305 210 355 245 510 355 575 400 640 450 705 490 770 540 830 580 900 630
Table 1. Reference values for static loads on the top and bottom flanges of a silencer. JTK
Drg no. 4ES0061
Metalli-Jokela Teollisuustie 6
Internet: www.jtk-power.fi
FIN-66600 Vöyri
E-mail:
[email protected]
Aker Yards 728 - a1 7 January 2008
Tel. +358-6-281 2200 Telefax +358-6-361 0383
8-15
Installation Planning Instructions 4ES0061 - 5R02 - Exhaust gas silencer with spark arrestor, installation instruction
6/6
DIN 2501 DIMENSIONS OF FLANGES
Bolts
Weight
Pos
Osa
NS
Pipe
do
D
d5
Thickness
b
k
PCS
kpl
d2
Pultit
Paino/kg
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
250 300 350 400 450 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600
273 324 356 406 457 508 610 711 813 914 1016 1120 1220 1320 1420 1520 1620
375 440 490 540 595 645 755 860 975 1075 1175 1305 1375 1466 1575 1666 1790
276 327 359 409 460 511 613 714 816 917 1019 1124 1224 1326 1424 1526 1624
16 16 16 16 20 20 20 20 20 20 20 20 20 20 20 20 20
335 395 445 495 550 600 705 810 920 1020 1120 1240 1320 1410 1520 1610 1730
12 12 12 16 16 20 20 24 24 24 28 28 32 40 36 44 40
18 22 22 22 22 22 26 26 30 30 30 30 30 22 30 22 30
M16*50 M20*60 M20*60 M20*60 M20*60 M20*60 M24*70 M24*70 M27*70 M27*70 M27*70 M27*70 M27*70 M20*60 M27*70 M20*60 M27*70
6,0 7,9 10,5 11,5 13,3 14,3 22,3 26,3 32,4 36,1 39,1 51,1 44,8 45,8 51,8 52,5 65,4
NS1100, NS1300, NS1500, AND NS1600 DO NOT CONFORM TO STANDARD DIN2501.
JTK
8-16
Drg no. 4ES0061
Metalli-Jokela Teollisuustie 6
Internet: www.jtk-power.fi
FIN-66600 Vöyri
E-mail:
[email protected]
Tel. +358-6-281 2200 Telefax +358-6-361 0383
Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 9. Piping Arrangements
9.
Piping Arrangements
9.1
Recommendations regarding piping design
9.1.1 General Fuel, lubricating oil, fresh water and compressed air piping is usually made in seamless carbon steel (DIN 2448) and seamless precision tubes in carbon or stainless steel (DIN 2391), exhaust gas piping in welded pipes of corten or carbon steel (DIN 2458). Sea-water piping should be in Cunifer or hot dip galvanized steel. NOTE!
The pipes in the freshwater side of the cooling water system must not be galvanized!
Attention must be paid to fire risk aspects. Fuel supply and return lines shall be designed so that they can be fitted without tension. Flexible hoses must have an approval from the classification society. If flexible hoses are used in the compressed air system, a purge valve shall be fitted in front of the hose(s). It is recommended to make a fitting order plan prior to construction. The following aspects shall be taken into consideration: •
Pockets shall be avoided. When not possible, drain plugs and air vents shall be installed
•
Leak fuel drain pipes shall have continuous slope
•
Vent pipes shall be continuously rising
•
Flanged connections shall be used, cutting ring joints for precision tubes
Maintenance access and dismounting space of valves, coolers and other devices shall be taken into consideration. Flange connections and other joints shall be located so that dismounting of the equipment can be made with reasonable effort.
9.1.2 Pipe dimensions When selecting the pipe dimensions, take into account: •
The pipe material and its resistance to corrosion/erosion.
•
Allowed pressure loss in the circuit vs delivery head of the pump.
•
Required net positive suction head (NPSH) for pumps (suction lines).
•
In small pipe sizes the max acceptable velocity is usually somewhat lower than in large pipes of equal length.
•
The flow velocity should not be below 1 m/s in sea water piping due to increased risk of fouling and pitting.
•
In open circuits the velocity in the suction pipe is typically about 2/3 of the velocity in the delivery pipe.
Aker Yards 728 - a1 7 January 2008
9-1
Installation Planning Instructions 9. Piping Arrangements Table 9.1 Recommended maximum velocities on pump delivery side for guidance
Piping
Pipe material
Fuel piping (MDF and HFO)
Black steel
1.0
Lubricating oil piping
Black steel
1.5
Fresh water piping
Black steel
2.5
Sea water piping
Galvanized steel
2.5
Aluminum brass
2.5
10/90 copper-nickel-iron
3.0
70/30 copper-nickel
4.5
Rubber lined pipes
4.5
NOTE!
Max velocity [m/s]
The diameter of gas fuel and compressed air piping depends only on the allowed pressure loss in the piping, which has to be calculated project specifically.
9.1.3 Trace heating The following pipes shall be equipped with trace heating (steam, thermal oil or electrical). It shall be possible to shut off the trace heating. •
All heavy fuel pipes
•
All leak fuel and filter flushing pipes carrying heavy fuel
9.1.4 Pressure class The pressure class of the piping should be higher than or equal to the design pressure, which should be higher than or equal to the highest operating (working) pressure. The highest operating (working) pressure is equal to the setting of the safety valve in a system. The pressure in the system can: •
Originate from a positive displacement pump
•
Be a combination of the static pressure and the pressure on the highest point of the pump curve for a centrifugal pump
•
Rise in an isolated system if the liquid is heated
Within this publication there are tables attached to drawings, which specify pressure classes of connections. The pressure class of a connection can be higher than the pressure class required for the pipe. Example 1: The fuel pressure before the engine should be 0.7 MPa (7 bar). The safety filter in dirty condition may cause a pressure loss of 0.1 MPa (1.0 bar). The viscosimeter, automatic filter, preheater and piping may cause a pressure loss of 0.25 MPa (2.5 bar). Consequently the discharge pressure of the circulating pumps may rise to 1.05 MPa (10.5 bar), and the safety valve of the pump shall thus be adjusted e.g. to 1.2 MPa (12 bar). •
A design pressure of not less than 1.2 MPa (12 bar) has to be selected.
•
The nearest pipe class to be selected is PN16.
•
Piping test pressure is normally 1.5 x the design pressure = 1.8 MPa (18 bar).
Example 2: The pressure on the suction side of the cooling water pump is 0.1 MPa (1 bar). The delivery head of the pump is 0.3 MPa (3 bar), leading to a discharge pressure of 0.4 MPa (4 bar). The highest point of the pump curve (at or near zero flow) is 0.1 MPa (1 bar) higher than the nominal point, and consequently the discharge pressure may rise to 0.5 MPa (5 bar) (with closed or throttled valves).
9-2
•
Consequently a design pressure of not less than 0.5 MPa (5 bar) shall be selected.
•
The nearest pipe class to be selected is PN6.
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Installation Planning Instructions 9. Piping Arrangements •
Piping test pressure is normally 1.5 x the design pressure = 0.75 MPa (7.5 bar).
Standard pressure classes are PN4, PN6, PN10, PN16, PN25, PN40, etc.
9.1.5 Pipe class Classification societies categorize piping systems in different classes (DNV) or groups (ABS) depending on pressure, temperature and media. The pipe class can determine: •
Type of connections to be used
•
Heat treatment
•
Welding procedure
•
Test method
Systems with high design pressures and temperatures and hazardous media belong to class I (or group I), others to II or III as applicable. Quality requirements are highest on class I. Examples of classes of piping systems as per DNV rules are presented in the table below. Table 9.2 Classes of piping systems as per DNV rules
Media
Class I
Class II
Class III
MPa (bar)
°C
MPa (bar)
°C
MPa (bar)
°C
Steam
> 1.6 (16)
or > 300
< 1.6 (16)
and < 300
< 0.7 (7)
and < 170
Flammable fluid
> 1.6 (16)
or > 150
< 1.6 (16)
and < 150
< 0.7 (7)
and < 60
> 4 (40)
or > 300
< 4 (40)
and < 300
< 1.6 (16)
and < 200
Other media
9.1.6 Insulation The following pipes shall be insulated: •
All trace heated pipes
•
Exhaust gas pipes
•
Exposed parts of pipes with temperature > 60°C
Insulation is also recommended for: •
Pipes between engine or system oil tank and lubricating oil separator
•
Pipes between engine and jacket water preheater
9.1.7 Local gauges Local thermometers should be installed wherever a new temperature occurs, i.e. before and after heat exchangers, etc. Pressure gauges should be installed on the suction and discharge side of each pump.
9.1.8 Cleaning procedures Instructions shall be given to manufacturers and fitters of how different piping systems shall be treated, cleaned and protected before delivery and installation. All piping must be checked and cleaned from debris before installation. Before taking into service all piping must be cleaned according to the methods listed below. Table 9.3 Pipe cleaning
System
Methods
Fuel oil
A,B,C,D,F
Lubricating oil
A,B,C,D,F
Starting air
A,B,C
Cooling water
A,B,C
Exhaust gas
A,B,C
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Installation Planning Instructions 9. Piping Arrangements
System
Methods
Charge air
A,B,C
A = Washing with alkaline solution in hot water at 80°C for degreasing (only if pipes have been greased) B = Removal of rust and scale with steel brush (not required for seamless precision tubes) C = Purging with compressed air D = Pickling F = Flushing
Pickling Pipes are pickled in an acid solution of 10% hydrochloric acid and 10% formaline inhibitor for 4-5 hours, rinsed with hot water and blown dry with compressed air. After the acid treatment the pipes are treated with a neutralizing solution of 10% caustic soda and 50 grams of trisodiumphosphate per litre of water for 20 minutes at 40...50°C, rinsed with hot water and blown dry with compressed air.
9.1.9 Flexible pipe connections Pressurized flexible connections carrying flammable fluids or compressed air have to be type approved. Great care must be taken to ensure proper installation of flexible pipe connections between resiliently mounted engines and ship’s piping.
9-4
•
Flexible pipe connections must not be twisted
•
Installation length of flexible pipe connections must be correct
•
Minimum bending radius must respected
•
Piping must be concentrically aligned
•
When specified the flow direction must be observed
•
Mating flanges shall be clean from rust, burrs and anticorrosion coatings
•
Bolts are to be tightened crosswise in several stages
•
Flexible elements must not be painted
•
Rubber bellows must be kept clean from oil and fuel
•
The piping must be rigidly supported close to the flexible piping connections.
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Installation Planning Instructions 9. Piping Arrangements
Figure 9.1 Flexible hoses
9.2
Installing flexible pipe connections
9.2.1 General The generating set shall be installed in its final position before any external pipe is connected to the engine. Different types of loads that should be observed when designing pipes and pipe supports are: pressure inside pipe, own weight and fluid weight, thermal expansion, pressure shocks, vibrations, fluid flow rate and external forces.
9.2.2 Pipe supporting Never weld supports directly to the pipe. Supports shall be located so that different pipe loads do not cause too high tension to equipment or flexible bellows.
Fixed supports Fixed supports are used: •
Nearby equipment connections to protect equipment and flexible bellows from high tensions.
•
To direct thermal expansion in directions where it can be received.
•
To receive different forces acting on the pipeline.
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Installation Planning Instructions 9. Piping Arrangements
Sliding supports Sliding supports are used: •
Sliding supports should be located to protect the pipeline, equipment and flexible bellows from high tensions coming from thermal expansion.
•
To allow thermal expansion in directions where it can be received.
•
To receive different forces acting on the pipeline.
9.2.3 Fuel pipes Fuel pipes are exposed to fluctuating pressure disturbances from the injection pumps. These pressure pulses must be taken into account when pipe supporting for fuel pipes are designed. Fuel pipes should be rigidly supported not only nearby the engine, but also far away from the engine in the external fuel system. The distance between supports should be positioned with the shortest value mentioned in the section below.
9.2.4 Pipe support nearby the diesel engine The first three supports on the same pipeline next to the diesel engine are definitively exposed to vibration that comes from the engine oscillation. Therefore it is very important that they are positioned and fastened carefully and rigidly so that no resonant vibration can occur in any direction. Pipe supports should be made of steel, supports made of plastic or similar materials are not allowed. Rigid supporting of pipes will also prevent vibration and movement of the flexible pipe connection. Figure 9.2 Typical supports after bellows.
The first support after flexible bellows should be positioned as close as possible to the bellows. If the first support is to far away from the bellows then the bellows lifetime will be shortened considerably, the pipe is also exposed to increased forces that may injure the pipeline. The second support should be positioned about 0.3...0.5 meter from the first support, the reason why it should be so close to the first support is that this will reduce the vibrations of the pipe end. The third support can be positioned about 0.8...1.1 meter from the second support. Pipe supports further in the pipeline can be placed with the same distance from each other.
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Installation Planning Instructions 9. Piping Arrangements
Figure 9.3 The supports after flexible bellows.
9.3
Flushing instructions
9.3.1 Fuel oil pipes Before start up of the engines the external piping between the day tanks and the engines must be flushed in order to remove any foreign particles such as welding slag. The possibility to install a temporary flushing oil filter shall be considered in the piping design. Disconnect the fuel pipes at the engine inlet and outlet (connections 101 and 102). Install a temporary pipe or hose to connect the supply line to the return line, bypassing the engine. The piping should be flushed through a flushing filter with mesh size 34 microns or finer. The inserts of the filters should be removed. Heaters, automatic filters and the viscosimeter should be bypassed to prevent damage caused by debris in the piping. The automatic fuel filter must not be used as flushing filter. The pump used should be protected by a suction strainer. The recommended flushing time is min. 6 hours. During this time the welds in the fuel piping should be gently knocked at with a hammer to release slag and the filter inspected and carefully cleaned at regular intervals.
9.3.2 Lubricating oil pipes Flushing of the piping and equipment built on the engine is not required. The system oil tanks with piping and equipment should anyhow be carefully cleaned and the oil separated to remove dirt and welding slag. If an electric motor driven stand-by pump is installed this should be used for the flushing. In case only an engine driven main pump is installed, the ideal is to use for flushing a temporary pump of equal capacity as the main pump. The circuit is to be flushed drawing the oil from the sump tank pumping it through the off-engine lubricating oil system and a flushing oil filter with a mesh size of 34 microns or finer and returning the oil through a hose and a crankcase door to the engine sump. The flushing pump should be protected by a suction strainer. Automatic lubricating oil filters, if installed, must be bypassed during the first hours of flushing. The flushing is more effective if the lubricating oil is heated. Furthermore, lubricating oil separators should be in operation prior to and during the flushing.
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Installation Planning Instructions 9. Piping Arrangements
The minimum recommended flushing time is 24 hours. During this time the welds in the lubricating oil piping should be gently knocked at with a hammer to release slag and the flushing filter inspected and cleaned at regular intervals. Either a separate flushing oil or the approved engine oil can be used for flushing. NOTE!
9-8
If engine oil is used, it must not be re-used as lubricating oil!
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Installation Planning Instructions 10. Automation System
10. Automation System 10.1 System overview The engine automation system consist of control of the running parameters, monitoring of the sensors and automatic safety operations.
10.1.1 Internal el & automation system The engine is equipped with a distributed, built-on engine management system. It is an embedded system which handles all strategic functionality such as engine start, stop, speed control and engine safety. The system is totally distributed in terms of physical modules. The modules communicate with each other over an inter-module communication bus based on the CAN protocol. CAN is a communication bus specifically developed for compact local networks, where high speed data transfer and safety are of very high importance. The CAN-bus is physically doubled on the engine, resulting in redundant communication in case of a failure of the primary bus communication. In the same manner the power supply distribution is doubled on the engine. Figure 10.1 shows the overall architecture of the system built on the engine. Figure 10.1 System overall architecture
Short explanation of the modules used in the system: MCM
Main Control Module. Handles all strategic control functions (such as start/stop sequencing and speed/load control) of the engine.
IOM
Input/Output Module. Handles measurements and controls locally at its engine position.
ESM
Engine Safety Module. Handles fundamental engine safety, and is the interface to the engine’s shutdown devices and backup instruments.
LCP
Local Control Panel. Contains push buttons for local engine control, as well as a graphical panel with indication of the most important engine measurements.
LDU
Local Display Unit. Shows on a set of menus all measurements and calculations and provides various engine status indications as well as an event history. Contains also a communication port for a service tool.
PDM
Power Distribution Module. Handles the fusing, power distribution and EMC filtration in the system. Two fully redundant supplies are arranged for the module- and auxiliary supply (24 VDC) on the engine.
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10-1
Installation Planning Instructions 10. Automation System The system comprises the following major control/monitoring categories: •
Engine start- & stop management. -
starting of the engine
-
stopping of the engine
-
start blocking
-
automatic shutdown of the engine
-
load reduction request
-
local control through local command buttons
•
Speed and load control.
•
Measuring engine speed and turbocharger speed.
•
Measuring and signal processing of monitoring- and safety sensors.
•
Readout of engine measurements on a local graphical display.
•
Hardwired interface signals with external systems (e.g. with power management system, main switchboard and propulsion control system).
•
Modbus communication with ships alarm & monitoring system.
•
System diagnostics.
The system ingress protection class is IP54. The main connection box contains terminal strips for external interface connections. The yard cables shall enter the connection box through cable glands and be connected to terminals.
Local controls & indications The following operational functions are available in the LCP: •
Local start (HS721).
•
Local stop (HS722).
•
Local emergency stop (HS723).
•
Local shutdown reset (HS725).
•
Local mode selector switch (HS724) with positions blow, blocked, local and remote. Positions: -
Local: Engine start and stop can be done only at the local control panel.
-
Remote: Engine can be started and stopped only remotely.
-
Blow: In this position it is possible to perform a “blow” (an engine rotation check with indicator valves open and disabled fuel injection) by the start button.
-
Blocked: Normal start of the engine is not possible.
The following backup indications are available in the LCP: •
Engine speed.
•
Turbocharger speed.
•
Running hour counter.
•
Lubricating oil pressure.
•
HT cooling water temperature.
The graphical Local Display Unit shows on a set of menus all measurements and calculations and provides various engine status indications as well as an event history.
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Installation Planning Instructions 10. Automation System
Figure 10.2 Local controls and indications
10.2 Control signals The following chapter provides information of the signals between the engine with its related engine automation and other systems onboard the ship. The signals listed below may be in excess of what is needed for this installation. For more exact recommendation of typical use- and routing of the signals and yard cabling see drawing “Block/Interconnection diagram” included in this chapter. Digital input signals are powered from the engine (24 VDC), i.e. a potential free contact is required in the external system. Digital output signals are, unless otherwise specified below, potential free opto relay output signals with contact rating of 24 VDC / 0.2 A.
10.2.1 Output signals IS 872 Engine ready for start The signal is closed when the engine is ready for start and no internal or external start blockings are active.
IB 726 Remote control indication This is a potential free contact from the local/remote operation mode selection switch, closed contact = remote mode. In local mode all starting and stopping can only be done locally at the engine. In remote mode all starting and stopping can only be done from the remote control system.
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Installation Planning Instructions 10. Automation System
IS 181 Speed switch 1 (Engine running) The signal is closed when the engine is above 40% of rated speed.
IS 184 Speed switch 4 (Ready to synchronize) The signal is closed when the engine is above 95% of rated speed plus a delay of 2 seconds. The signal is typically used to initiate the synchronization of the generator breaker.
IS 875 Start failure indication The signal is activated (open contact) if the engine has not reached firing speed in abt. 10 sec. after the start signal has been activated. The output is automatically reset after the engine has come to standstill. This will set the engine “ready for start” again, and allow the power management system to initiate a new start attempt. However, in case of a start failure, if there is another generating set in standby ready for start, it is recommended to initiate a start on that generating set rather than a second start attempt on the one with a failed start.
OS 7315 Loadreduction request The signal is activated (closed contact) when a process value (e.g. temperature or pressure) is outside acceptable limits for normal operation. The power management system should reduce the load on this generating set and allow the other generating sets to take on more load or alternatively reduce the total load on the network. It is also recommended to start a standby generating set when this signal is activated. Once the new generating set is on line and the load has been ramped up, the failing generating set can be unloaded, disconnected and stopped.
XS 7323 Shutdown prewarning The signal is activated (open contact) when a shutdown limit has been exceeded and 3 seconds prior to the execution of the engine shutdown. The signal is typically used for tripping non-essential consumers in case the load step would exceed the acceptance limit of the remaining generating sets.
IS 7602 Stop / shutdown status 1 The signal is closed when the engine is being stopped (locally or remote) or shutdown by the safety system and remains on as long as the stop signal is active. I.e. in case of normal stop, until the stop timer has expired and the engine has come to complete standstill and in case of shutdown until the engine has come to complete standstill, the shutdown cause is cleared and manually reset. The signal is typically used for tripping the generator main breaker in the MSB.
OS 7602 Generator breaker open command The signal is closed when the engine, after having received an “unload command”, has been unloaded to a predefined level (abt 5% load). This signal is only applicable if isochronous loadsharing is used.
NS 881 Engine control system minor alarm The signal is activated when there is an internal fault in the engine control system. At a healthy condition the contact is closed. The signal is activated by: •
Failure in any of the electronic modules
•
Failure in Engine Safety Module
•
Failure in local control panel
•
Loss of power supply
NS 886 Engine control system major failure The signal is activated (open contact) when there is serious fault in the control system.
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Installation Planning Instructions 10. Automation System
When the major failure signal is activated, the engine will be shut down.
IB 7324 Engine shutdown status The signal is activated (open contact) when a shutdown function is activated. The signal can be used as a common shutdown alarm indication. (Individual shutdown reasons are identified via the modbus link and locally on the LDU.)
NS 885 Common engine alarm The signal is activated (open contact) when there is an abnormal process value (e.g. temperature or pressure). The individual alarm reason is transmitted over the modbus link. This hardwired signal can be used as a backup in case the modbus communication fails. To avoid duplicate alarm indication it is recommended that this signal is disabled while the modbus communication is healthy.
OS 441 Pre-lubrication pump control / Pre-heater control This signal is closed when the engine speed is below 40% speed, which is the limit below which the prelubricating pump and cooling water pre-heater pump shall continuously run. This output can ONLY be used for DC control voltage. I.e. this is typically connected to the ships automation system as reference signal in case the motor starters are controlled from the ships automation system.
CV 223 Pre-lubrication pump control / Pre-heater control This signal is closed when the engine speed is below 40% speed, which is the limit below which the prelubricating pump and cooling water pre-heater pump shall continuously run. This output can ONLY be used for AC control voltage. I.e. this is typically connected directly to the control circuit of the motor starter. The contact rating is 255 VAC / 0.6 A. However, in order to keep a safe voltage level in the main cabinet on the engine, the control voltage of the motor starter is required to be 24 VAC. For further details of wiring see drawing “pre-lubrication pump starter".
SI 196 Engine speed This is a galvanically isolated analogue output signal. The signal type is 4-20 mA and max external load is 500 Ω. Range 0 – 1200 rpm.
SI 518 TC A speed This is a galvanically isolated analogue output signal. The signal type is 4-20 mA and max external load is 500 Ω. Range 0 – 75000 rpm.
10.2.2 Input signals OS 7302 Remote start Activating this input (closed contact) will activate the engine starting sequence, if no start blockings are active and the local/remote switch is in remote mode. The input should be activated for min. 0.5s. for the engine to start.
OS 7304 Remote stop Activating this input (closed contact) will activate the engine stop sequence if the local/remote selector switch is in remote. The input should be activated for min. 0.5s for the engine to stop.
OS 7312 External start blocking 1 Opening the contact to this input will block the starting of the engine. This input is typically used for start blocking signals from the ships control system or switchboard.
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Installation Planning Instructions 10. Automation System
OS 7313 External start blocking 2 Opening the contact to this input will block the starting of the engine. This input is typically used for start blocking signals from the ships control system or switchboard.
OS 163 Speed increase Activating this input (closed contact) will increase the speed reference of the generating set. The speed increase rate is 0.05 Hz/sec when the input is active. This input is typically connected to power management systems, load-sharing systems, switchboards or synchronizers.
OS 164 Speed decrease Activating this input (closed contact) will decrease the speed reference of the generating set. The speed decrease rate is 0.05 Hz/sec when the input is active. This input is typically connected to power management systems, load-sharing systems, switchboards or synchronizers.
OS 7310 External shutdown 2 This shutdown input is activated by a closed contact. The external contact should be equipped with a 22 kΩ resistor for wire break monitoring. Any signal that requires a fast shutdown of the generating set should be connected to this input. Such signal could be e.g. generator protection. This shutdown does not include the delay explained under output signal XS 7323 Shutdown prewarning.
OS 7311 External shutdown 3 This shutdown input is activated by a closed contact. The external contact should be equipped with a 22 kΩ resistor for wire break monitoring. There is a shutdown delay as explained under output signal XS 7323 Shutdown prewarning. The signal is typically used in case shutdown from the ships automation system is needed.
OS 7305 External shutdown 4 (Emergency stop) This shutdown input is activated by a closed contact. The external contact should be equipped with a 22 kΩ resistor for wire break monitoring. This signal is typically used for e.g. emergency stop buttons or ships emergency shutdown (ESD) system.
OS 7308 Remote shutdown reset Activating this input (closed contact) will reset a shutdown and enable re-start of the engine. A shutdown can be reset only if the engine has come to full stop and the shutdown is not active anymore. Before restart the reason for the shutdown must be carefully checked and corrected.
GS 798 Generator breaker status This input shall be activated (closed contact) when the generator breaker is closed. The signal is used to optimise the engine dynamic response.
OS 7321 Engine unload Activating this input will cause the engine to unload to a predefined load level. This shall be done prior to opening the generator breaker. See also output OS 7602 Generator breaker open command. This signal is only applicable if isochronous loadsharing is used.
OS 7320 Blackout start mode Activating this input (closed contact) will override startblock functions which are “by default” activated in case of a blackout. E.g. the prelubricating oil pressure which is naturally lost when the prelubricating pump stops at a blackout. A closed contact will allow starting within 30 minutes after closure of the contact. This shall be seen as re-starting after blackout and the start sequence is initiated by the normal start command (OS7302 remote start). If blackout start is required, provisions for securing fuel supply and starting air in blackout situations must be made. Starting after an extended blackout period normally requires manual intervention for start-up of emergency generating sets for restoring the power.
10-6
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Installation Planning Instructions 10. Automation System
UT 793 Generator load This is an analogue 4-20 mA input signal. The signal shall be isolated external to the engine. The signal shall be from a kW transducer typically part of the main switchboard. The range of the signal 4-20 mA = ?? - ?? kW shall be informed to Wärtsila during the project stage, prior to FAT of the engine.
10.3 Bus communication The main interface with the ships alarm & monitoring system is a bus communication through which all measured values, alarm- and status indications are transmitted. For details, see drawing “Modbus list”.
10.4 Functional description of start/stop 10.4.1 Start function The engine is equipped with a pneumatic starting motor, which drives the engine through a gear rim on the flywheel. The engine can be started locally by the start button HS721, or remotely if applicable for the installation e.g. from the power management system. A generating set reaches the nominal speed typically in abt. 10 seconds after issuing the start command. For functions causing start blocking, see drawing “Modbus list”.
10.4.2 Stop and shutdown function A normal stop can be initiated locally by button HS722, or remotely if applicable for the installation. At normal stop the stop sequence is active by a timer function until the engine has come to standstill. Thereafter the system automatically returns to “ready for start” mode in case no start block functions are active, i.e. there is no need for manually resetting a normal stop. The safety of the engine is mainly handled by the Engine Safety Module (ESM). The ESM performs sensor failure detection on the shutdown sensors and solenoids. A safety shutdown must be manually reset (either locally by shutdown reset button HS725, or remotely if applicable). Reset is possible only when the engine has come to full stop and the shutdown is not active anymore. Before re-start the reason for the shutdown must be carefully checked and corrected. At a stop or shutdown the actuator/governor is driving the fuel rack control shaft to zero position. Additionally, pneumatic cylinders on each fuel injection pump are forcing the fuelracks to zero position by means of compressed air, thereby disabling the fuel injection. For functions causing safety shutdown, see drawing “Modbus list”.
10.5 Speed control functions & loadsharing The speed control is adjusted to 4 % speed droop to obtain basic load sharing. In systems with speed droop as the primary load sharing method it is necessary to actively transfer load to a recently connected generator from parallel generators in order to achieve even load on all generators. Before disconnecting a generator it must be correspondingly unloaded. Loading and unloading is normally performed automatically by a power management system. The power management system commonly also corrects the frequency to eliminate the speed droop offset, which is proportional to the system load. The power management system performs load balancing and frequency correction by adjusting the speed references of the individual engines. The controlling system (power management system) should not perform adjustments with shorter intervals than the controlled system (generating sets) responds. In order to achieve smooth load sharing it is important to implement suitable dead bands in the control. If the power management system performs continuous load balancing and frequency correction, it should include the following features: •
Pulse length and time between pulses shall be adjustable. If the same control system also handles automatic synchronization, then pulse length, time between pulses and dead band shall be separately adjustable for synchronisation.
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10-7
Installation Planning Instructions 10. Automation System •
The time between pulses shall be sufficiently long. After a correction it can take up to 30 seconds before the actual adjustment has reached 95% of the set point change. The control system should therefore wait at least 10 seconds before giving a new pulse.
•
The control system should preferably determine the length of the pulse based on the size of the desired correction and then wait for 30 seconds or more before performing a new correction.
•
A control dead band should be implemented, allowing for an uneven load of min ±2% of nominal power and a frequency drift of min ±1%.
•
The corrections should not be based on instantly sampled values. The corrections should be based on the average value over several seconds. 10 seconds is a suitable time span.
10.6 Power unit For each engine a power supply cabinet is delivered for providing the 24 VDC power supply required by the engine and for providing isolation from other DC systems on board. The cabinet is designed for bulkhead mounting, protection degree IP44, max ambient temp 50 °C. Main components: •
230 VAC / 24 VDC power supply converter
•
24 VDC / 24 VDC power supply converter
•
Miniature Circuit Breakers (MCBs) and terminals
Each converter is dimensioned for 100% load. Failure of one supply will cause automatic takeover by the second supply. Power supply, needed from shipyards system: •
Main: 230 VAC (100-240 VAC) / abt. 150 W
•
Backup: 24 VDC (18-32 VDC) / abt. 150 W.
At least one of these must be UPS or battery backed up at shipyards side.
10.7 Precautions The automation system contains circuit boards that are sensitive both to damage by electrostatic discharge (ESD) and mechanical damage. Therefore, the following precautions can significantly reduce the risk of system failure or malfunction:
10-8
•
Protect all modules against moisture and uncleanness by using moisture proof covering during storing at yard/site. If exposed to humidity during these stages, the components must be carefully dried. Otherwise wiring connections may become unreliable.
•
Avoid ESD to modules by not touching circuit boards and module connectors without ESD protection.
•
Locate the communication cables between engine and control panels as far away as possible, at least 300 mm, from power and high voltage cables. If this is not possible, pull the communication cables in grounded steel conduits.
•
Make sure the engine is well grounded, not connected to external systems and that the power is switched off before installation work is done near the engine. This is especially important during electrical welding in the engine room.
•
When welding ensure that welding earth is close to the welding point.
•
Power-on of the automation system must not be done until a Wärtsilä Service Engineer has checked and approved the cabling/connections.
•
Cabling/connections should be done according to Wärtsilä project specific drawings. Important is to use shields and cable-pairs accordingly.
•
Keep cabinets and modules closed at all time, as far as practically possible. If opened for some reason, avoid touching circuit boards and connector pins.
•
Avoid using RF-equipment near modules when covers are open or there are unconnected connectors or wires.
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Installation Planning Instructions 10. Automation System
WARNING! Arc welding on or close to the engine must be avoided if cables are connected to the automation system.
10.8 Component data, Wärtsilä scope of supply 10.8.1 Power Unit (9N36) Quantity ................................................ 4 Drawing ................................................ DAAE061027
10.9 Drawings DAAE061024DAAE061027tobeadded 4V50G1522h
Aker Yards 728 - a1 7 January 2008
Block- / Interconnection diagram ......................................................................... 10-10 Power unit ............................................................................................................ 10-17 Modbus list ........................................................................................................... 10-20 Pre-lubricating pump starter (recommended) ...................................................... 10-21
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Installation Planning Instructions DAAE061024- - Block- / Interconnection diagram
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Installation Planning Instructions DAAE061024- - Block- / Interconnection diagram
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Installation Planning Instructions DAAE061024- - Block- / Interconnection diagram
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Installation Planning Instructions DAAE061024- - Block- / Interconnection diagram
Aker Yards 728 - a1 7 January 2008
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Installation Planning Instructions DAAE061024- - Block- / Interconnection diagram
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Installation Planning Instructions DAAE061024- - Block- / Interconnection diagram
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Installation Planning Instructions DAAE061024- - Block- / Interconnection diagram
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Installation Planning Instructions DAAE061027- - Power unit
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Installation Planning Instructions DAAE061027- - Power unit
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Installation Planning Instructions DAAE061027- - Power unit
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e h T
a r d
g n i w
b l l wi
p u e
d e t da
Installation Planning Instructions tobeadded - Modbus list
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Installation Planning Instructions 4V50G1522h - Pre-lubricating pump starter (recommended)
Aker Yards 728 - a1 7 January 2008
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Installation Planning Instructions
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Aker Yards 728 - a1 7 January 2008
Installation Planning Instructions 11. ANNEX
11. ANNEX 11.1 List of symbols Figure 11.1 List of symbols (DAAE000806c).
Aker Yards 728 - a1 7 January 2008
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Installation Planning Instructions 11. ANNEX
Figure 11.2 Symbols for electrical components (4V92A0655).
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Aker Yards 728 - a1 7 January 2008
Wärtsilä Finland Oy Ship Power P.O. Box 252 65101 Vaasa, Finland
+358 10 709 0000 +358 6 356 7188 www.wartsila.com
