Project Guide - MaK M 25 C Propulsion
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M25C Project Guide • Propulsion
m
Introduction
Information for the user of this project guide The project information contained in the following is not binding, since technical data of products may especially change due to product development and customer requests. Caterpillar Motoren reserves the right to modify and amend data at any time. Any liability for accuracy of information provided herein is excluded. Binding determination of data is made by means of the Technical Technical Specification and such other agreements as may be entered into in connection with the order. order. We will supply further binding data, drawings, diagrams, electrical drawings, etc. in connection with a corresponding order. order. This edition supersedes the previous edition of this project guide.
All rights reserved. Reproduction or copying only with our prior written consent.
Caterpillar Motoren GmbH & Co. KG P. O. Box, D-24157 Kiel Germany Phone +49 431 3995-01 Telefax +49 431 3995-2193
Issue
M 25 C Propulsion
Juli 2008
m
Marine Financing Guidelines Power : Cat and MaK. Financial Financ ial Products: Products: Constr Construction uction,, term and repow repower er financing. financing. Repayment: Loan terms up to 10 years, with longer amortizations available. Financed Amount: Up to 80 80% % of your vessel ves sel cos cost. t. Rates: Currency:
Fixed or variable. US Dollars, Euros and other widely traded currencies.
Global Resource from One Source When you select Cat Marine Power for your vessel, look to Cat Financial for world-class financial support. With marine lending offices in Europe, Asia and the US supporting Caterpillar’ Caterpillar’ss worldwide marine distribution network, network, Cat Financial is anchored in your homeport. We also have over 20 years of marine lending experience, so we understand your unique commercial marine business needs. Whether you’re in the offshore support, cargo, ship assist, towing, fishing or passenger vessel industry, industry, you can count on Cat Financial for the same high standard you expect from Caterpillar Caterpillar.. www.CAT.com/CatMarineFinance Visit our web-site or or see your local Cat dealer to learn how our marine financing plans and options can help your business succeed.
Ocean-Going Vessels Pleasur Ple asuree Cra Craft ft Commercial Vessels
M 25 C Propulsion
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Commissioning Training
DICARE Diagnostic Diagno stic Softw Software are
Global Dealer Network
Remanufactured Parts
Genuine Spare Parts
Engine Upgrades
Overhauls
Repairs Customer Support Agreements (CSAs)
Providing integrated solutions for your power system means much more than just supplying your engines. Beyond complete auxiliary and propulsion power systems, we offer a broad portfolio of customer support solutions and financing options. Our global dealer network takes care of you wherever you are – worldwide. Localized dealers offer on-site technical expertise through marine specialists and an extensive inventory of all the spare parts you might need.
To find your nearest dealer, simply go to: www.cat-marine.com or www.cat-marine.com or www.mak-global.com www.mak-global.com
M 25 C Propulsion
Maintenance
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M 25 C Propulsion
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Contents
Page 1.
Engine description
1-2
2.
General data and outputs
3-4
3.
Restrictions for low load operation
4.
Propeller operation
6-8
5.
Technical data
9 - 10
6.
Engine dimensions
11 - 18
7.
Spac Sp ace e re requ quir irem emen entt fo forr di dism sman antl tlin ing g of ch char arge ge ai airr co cool oler er
5
and turbocharger cartridge
19
8.
Maintenance platform
20
9. 10.
System connections Fuel oil system
21 22 - 33
11.
Lubricating oil system
34 - 41
12.
Cooling water system
42 - 48
13.
Flow velocities in pipes
14.
Starting air system
15.
Combustion air system
16.
Exhaust system
17.
Air borne sound power level
18.
Foundation
61 - 67
19. 20.
Power transmission Data for torsional vibration calculation
68 - 71 72
21.
Control and monitoring system
73 - 91
22.
Diagnostic system DICARE
92 - 93
23.
Diesel engine management system DIMOS
94
24.
Standard acceptance test run
95
25.
EIAPP certificate
96
26.
Painting/Preservation
27.
Lifting of engines
99
28.
Engine parts
100
M 25 C Propulsion
49 50 - 51 52 53 - 59 60
97 - 98
m
1. Engine de description
The M 25 C is a four stroke diesel engine, non-reversible, turbocharged turbocharged and intercooled with direct fuel injection.
In-line engine M 25 C
Cylinder configuration: Bore:
6, 8, 9 in-line 255 mm
Stroke: Stroke/Bore-Ratio:
400 mm 1.57
Swept volume: Output/cyl.:
20.4 l/Cyl. 317 - 333 kW
BMEP: Revolutions:
25.8 bar 720/750 rpm
Mean piston speed: Turbocharging:
9.6/10.0 m/s pulse pressure
Direction of rotation:
clockwise, option: counter-clockwise
M 25 C Propulsion
1
m
1. Engine de description
Engine design - Designed Designed for heavy heavy fuel fuel operation operation up up to 700 cSt/50 cSt/50 °C, fuel fuel grade acc. acc. to CIMAC CIMAC H55 K55, K55, ISO 8217, 8217, 1996 (E), ISO-F-RMH55 RMK55. - 1-piece 1-piece dry engine engine block block made of nodular nodular cast cast iron. It incorpora incorporates tes the cranksh crankshaft aft bearing, bearing, camcamshaft bearing, charge air receiver, vibration damper housing and gear drive housing. - Unde Underslu rslung ng cranksha crankshaft ft with corrosion corrosion resis resistant tant main and and big end bearing bearing shells shells.. - Natur Natural al hardened hardened liners liners,, centrifuga centrifugally lly casted, casted, with with calibratio calibration n insert. insert. - Comp Composite osite type type piston pistonss with steel steel crown crown and and nodular nodular cast cast iron iron skirt. skirt. - Piston Piston ring set consistin consisting g of 2 chromium plated plated compress compression ion rings, rings, first ring with with chrom-cer chrom-ceramic amic layer and 1 chromium plated oil scraper ring. All ring grooves are hardened and located in the steel crown. - 2-pi 2-piece ece connec connecting ting rod, rod, fully machin machined, ed, oblique obliquely ly split with with serrated serrated joint. joint. - Cylinder Cylinder head head made of nodular nodular cast cast iron with 2 inlet inlet and 2 exhaust exhaust valves valves with valve valve rotators rotators.. Direct cooled exhaust valve seats. - Cams Camshaft haft made made of sections sections per per cylinder cylinder allowi allowing ng a removal removal of the piece piecess sideways. sideways. - Turbo urbochar charger ger supplied supplied with inboar inboard d plain bearings bearings lubricate lubricated d by engine lubrica lubricating ting oil. - 2-st 2-stage age fresh fresh water water cooling cooling system system with with 2-stage 2-stage charge charge air air cooler cooler.. - Nozz Nozzle le cooling cooling for for heavy heavy fuel fuel operation operation with with engine engine lubrica lubricating ting oil. oil.
2
M 25 C Propulsion
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2. General data and outputs
Engine
720/750 rpm
6 M 25 C
kW 1800/2000
8 M 25 C
2320/2640
9 M 25 C
2610/3000
i tion is mechanically The maximum fuel rack pos t limi ted ted to 100 % output for CPP and FPP applications. L imi tat tation of 110 % for gensets and DE applications.
Output defini t tion The maximum continuous rating (locked output) stated by Caterpillar Motoren refers to the following reference cond t i tions according to "IACS" (International Association of Classification Societies) for main and auxiliary engines: Reference cond t i tions according to IACS (tropical cond t i tions): air pressure 100 kPa (1 bar) air temperature 318 K (45 °C) relative humidi ty ty 60 % seawater temperature 305 K (32 °C)
Fuel consumption The fuel consumption data refer to the follow ing reference cond t i tions: intake temperature 298 K (25 °C) charge air temperature charge air coolant inlet temperature net heating value of the Diesel oil tolerance
318 K (45 °C) 298 K (25 °C) 42700 kJ/kg 5%
Specification of the fuel consumption data w thout i thout f tted-on i tted-on pumps; for each each pump pump f tted i tted on an add addi t tional consumption of 1 % has to be calculated.
Lubricating oil consumption Actual data can be taken from the techn ical data.
M 25 C Propulsion
3
m
2. Gen ene era rall da datta an and d ou outtpu puts ts
Nitrogen oxide emissions (NOx-values) NOx-l -lim imit it va valu lues es ac acco cord rdin ing g to to MAR MARPO POLL 73/ 73/78 78 An Anne nexx VI: VI:
12.0 12 .0 g/ g/kW kWh h (n (n = 75 7500 rpm rpm))
CPP and DE propulsion acc. to cycle E2: FPP propulsion acc. to cycle E3:
9.9 g/kWh (n = 750 rpm) 10.6 g/kWh (n = 750 rpm)
An engine version which keeps the requirements of "Blauer Engel" (20 % less NOx than MARPOL 73/78) is also available.
Emergency operation without turbocharger Emergency operation operation is permissible only with MDO and up to approx. 20 % of the MCR.
General installation aspect: Inclination angles of ships at which engine running must be possible: Heel to each side: Rolling to each side: Trim by head and stern: Pitching:
4
15° + 22.5° 5° + 7.5°
M 25 C Propulsion
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3. Re Rest stri rict ctio ions ns fo forr low low lo load ad ope opera rati tion on
The engine can be started, stopped and run on heavy fuel oil under all operating conditions. The HFO system of the engine remains in operation and keeps the HFO at injection viscosity. The temperature of the engine injection system is maintained by circulating hot HFO and heat losses are compensated. The lube oil treatment system (lube oil separator) remains in operation, the lube oil is separated con tinuously.. tinuously The operating temperature of the engine cooling water is maintained by the cooling water preheater. preheater. Below 25 % output heavy fuel operation is neither efficient nor economical. A change-over to diesel oil is recommended to avoid disadvantages as e.g. increased wear and tear tear,, contamination of the air and exhaust gas systems and increased contamination of lube oil.
Cleaning run of engine
3h
2
1h
30 min
15 min
0
PE % 100 Cleaning run after partial load operation 70 Load increase period approx. 15 min.
50 40 30 20 15
HFO-operation
10 8 Restricted HFO-operation
6 1h
M 25 C Propulsion
2
3
4
5 6
8 10
15 20 20 24 h
5
m
4. Propeller operation Required fixed pitch propeller layout
n/no [%] Speed
I. Speed range for continuous operation This speed range must not be exceeded for long-term operating conditions. II. Speed range range for short-time short-time operation Permitted for a short time t ime only, e.g. during acceleration and manoeuvring (torque limitation) Fixed-pitch propeller design Sea going vessel (fully loaded) Inland Inlan d water waterway way vess vessels els (fully loade loaded) d) Speed increase (grey area)
Max. output at 100 % rated speed: max. 85 % for seaships max. 100 % for towing ships at bollard pull max. 95 % for inlan inland d water waterway way vess vessels els max. 90 % for push boats The speed is blocked always at 10 100 % of rated speed. If required 103 % of rated speed is permissible at continuous operation. During the yard trial trip the engine speed may be increased to max. 106 % of the rated rated speed for max. 1 h, if required. required.
6
M 25 C Propulsion
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4. Propeller operation Recommendation for control pitch propeller
The design area for the combinator has to be on the right-hand side of the theoretical propeller curve and may coincide with the theoretical propeller curve in the upper speed range. A load above the output limit l imit curve is to be avoided by the use of the load control device or overload protection device. Binding data (depending on the type of vessel, rated output, speed and the turbocharging system) system) will be established upon order processing.
Normal acceleration time
110%
MCR 100 %
I : Normal operation II: Short time operation allowed
100%
70 %
n = const 100 % rpm
90% Power lim it curve for overload protection
80%
t
10 % MCR 100 %
] % [ t u p t u 60% o e n i g n E
B
A
70%
70 %
MCR 100 %
50%
70 %
10 %
n=
Combinator curve
i
40%
comb nator 10 %
t
30%
C
n= 70 % rpm
20%
II
I
D
n= 97 % rpm
n= 100 % rpm
10%
Droop
0% 50%
60%
70%
80%
90%
Engine speed [%]
6, 8, 9 M 25 C M 25 C Propulsion
100%
110%
103%
A (sec)
B (sec)
C (sec)
D (sec)
35
180
40
180
7
m
4. Propeller ope operation Acceleration time propulsion, standard engine
n o i t a r e p o l a m r o N
R n R o C C i t m M c o M u r % % d f e 0 0 R 0 1 o t
s s s 0 2 0 2 0 2
e k o m S
e l b i s i v n i
e l b i s i v n i
e l b i s i v n i
t n n o R i C % a t t s a R 0 m M n r C 0 e o o l r 1 M c e f % o = c c 0 7 t n a
n i m 3
n i m 3
n i m 3
t n n o R R i C C a t t M s a m M n r e o o l r % c e f % 0 7 = c c 0 1 o n a t
s s s 5 3 5 3 5 3
t t o n a t a d % R e o t R e C 0 i a C d e M p 7 r m s e o p M s l f = r % n i e % % m c 0 0 n c 0 % 0 0 a 7 7 9 1 1 m o o t t t r a f a d % n R d e R e 0 i o C e p 7 t C e M s M p a s = r n i e % % % % m l n e 0 0 0 7 c 1 7 7 9 c a
n o i t a r e p o y c n e g r e m e r o f e m i t m u m i n i M
R n R o C C i t m M c o M u r % % d f e 0 0 R 0 o 1 t e k o m S t n n o R i C % a t t s a R 0 m M n r C 0 e o o l r 1 c e f % o M = c c 0 1 t n a
m t o t o t a d r a f % n R d R e e 0 i o e C p 7 t C e M s M p a = s r n i e % % % m l 0 0 n e 0 % 0 0 1 c 1 0 c 7 1 a
8
n i n i m m ) r 3 3 e k l u B d n a r e d e s s e f 0 r 0 e 4 4 n i a t n o C , r e k n s s a T ( 8 8 n o i t a c e e i l l p l b i b p i s i s a i v v d r a d n a t S s s 5 r 0 o 2 2 f s t e s n e G d n a s s P 5 P 2 0 3 C / g n i g r h a C C C - 5 2 5 2 e s l M M u P 6 8
s s 0 2 2 0
s 0 2
. a . n
s s 5 4 3 0
s s 0 3 2 0
. a . n
s s 5 4 3 0
% 0 1 R s C o t M 0 4 % 0 5
s 0 4
s s 0 3 2 0
R C M % 0 5 o t % 0 1
s 8
s s 8 8
s 8
e l b i s i v
e e l l b b i i s s i i v v
e l b i s i v
s 5 2
e v o b a e e S
n i m 3
s s 0 e 3 i r r e F d n s C a g 5 u 2 T r M o 9 F
g u T r o f C 5 2 M
e v o b a e e S
y r r e F r o f C 5 2 M
h t i o V d n a P P F / g n i g r h a C e s l u P
s 0 3
. a . n
% 0 0 1 R s C o t M 0 4 % 0 1
C 5 2 M
r e t i m l i e u f d e l l o r t n o . c e e r l b i u s s s i v e e r p b r i l l i a w e e g r k a o h c m s a e s d i . o e r d m r e e d y f c d n e n a e n m g m r s o e g u m t c e r e r o i n F s I
. l y c / W k 0 3 3 / 7 1 3 / 0 0 3 / 0 9 2 C 5 2 M 9 , 8 , 6 : ) R C M ( s i n g t a r s i s a B
s n o i t i d n P o P c C g n h i t t i a w r t e n p i o o p n i m o n i r t a a r w e p e o n i t g s n e e , . s w o c e l t , e s u R n C i 5 ± m M : . 0 l % o 1 T 0 e , 1 m s i t d t s n g a o i e n l c t t e a a s r C C ° ° n n e i p 0 5 o t e o 5 6 i a > > m m l r i t u i t e l n n i e O a m . l c o i s : a t i o f n b a c u C r L k e M r l o a e t r m c a e c t R A S
. s t n e n o p m o c e n i g n e f o s e s s e r t s l a m r e h t r e . h s g e i m h i t o e t f i l e u t d n , n e d e o p d m n o e c m t s m e o g c r n e o t l o e n t d i u v b o , r e p l l l i i b w s s e o m p i t n o n i t o i t a r e a r l e l e e c c c c a a y d c r n a e d g n r e a t m S E
M 25 C Propulsion
m
5. Technical data
Cylinder
6
8
9
Performance data
Maximum continous rating acc. ISO 3046/1 Speed Minimum speed Brake mean effektive pressure Charge air pressure Compression pressure Firing pressure Combustion air demand (ta = 20 °C) Delivery/injection timing Exhaust gas temperature after cylinder/turbine
1/min 1/min bar bar bar bar 3 m /h ° v. OT
Specific fuel oil consumption 1) Propeller/n = const 100 % 85 % 75 % 50 % 2) Lubricating oil consumption Turbocharger type
g/kWh g/kWh g/kWh g/kWh g/kWh
Fuel Engine driven booster pump Stand-by booster pump Mesh size MDO fine filter Mesh size HFO automatic filter Mesh size HFO fine filter Nozzle cooling by lubricating oil system
kW
°C
1900
2000
720 750 240 250 25.8 26.1 3.1 3.2 172 175 204 208 11100 12850 11.0/8
2534
2660
720 750 240 250 25.8 26.1 3 3.2 172 175 204 208 14515 15665 11.0/8
360/305 360/290 370/325 370/320
2850
3000
720 750 240 250 25.8 26.1 3.2 3.2 172 175 200 204 16550 17020 11.0/8 380/320
184 182/183 180/185 187/193 0.6 HPR6000
184 182/183 180/185 187/193 0.6 HPR6000
184 182/183 180/185 187/193 0.6 HPR6000
1.5/5 2.3/6 0.025 0.010 0.034
1.5/5 2.7/5 0.025 0.010 0.034
1.5/5 2.7/5 2.8/5 0.025 0.010 0.034
m /h/bar 3 m /h/bar bar 3 m /h/bar 3 m /h/bar 3 m /h/bar 3 m °C mm
89/10 93/10 40/10 4-5 107/3 112/3 57/3 6.6/8/5 2.6 2.7 60-65 80
89/10 93/10 55/10 4-5 107/3 112/3 70/3 10/13/5 3.4 3.6 60-65 100
89/10 93/10 60/10 4-5 107/3 112/3 70/3 10/13/5 3.9 4.0 60-65 100
mm mm mm
80 0.08 0.03
80 0.08 0.03
80 0.08 0.03
m /h/bar 3 m /h/bar mm mm mm 3
Lubricating Oil Engine driven pump Independent pump Working pressure on engine inlet Engine driven suction pump Independent suction pump Priming pump pressure Sump tank content Temperature at engine inlet Temperature controller NB Doublesize filter NB filter Mesh double Mesh size automatic filter M 25 C Propulsion
3
9
m
5. Technical data
Cylinder
6
8
9
m bar 3 m °C
0,4 2.5/6.0 0.2 80 - 90
0,5 2.5/6.0 0.25 80 - 90
0,6 2.5/6.0 0.3 80 - 90
m /h/b /h/bar ar 3 m /h/b /h/bar ar mm 3 m /h
40/3.7 40/3 .7 40/3.0 40/3 .0 80 40
55/3.5 55/3 .5 55/3.0 55/3 .0 100 45
60/3.7 60/3.0 100 50
°C
38
38
38
kJ/kWh kJ/kWh MJ/h MJ/h MJ/h MJ/h
500 490
500 490
500 490
Fresh water cooling
3
Engine content Pressure at engine inlet min/max Header tank capacity Temperature at engine outlet
Two circuit system Engine driven pump HT Independent pump HT HT-Controller NB Water demand LT-charge air cooler Temperature at LT-charge air cooler inlet
3
Heat Dissipation Specific jacket water heat Specific lub. oil heat Lub. oil cooler Jacket water 3) Charge air cooler (HT-Stage) 3) Charge air cooler (LT-Stage) (HT-Stage after engine) Heat radiation engine
931 950 2160 828
970 990 2255 884
1242 1267 2808 1116
1294 1320 2934 1116
1396 1425 3096 1260
1455 1485 3240 1260
MJ/h
306
408
460
mm mm mm
500 500 500
600 600 600
600 600 600
bar
0.03
0.03
0.03
bar bar 3 Nm
30 10 0.8
30 10 0.8
30 10 0.8
Exhaust gas Silencer/spark arrester NB 25 dBA NB 35 dBA Pipe diameter NB after turbine Maximum exhaust gas pressure drop
Starting air Starting air pressure max. Minimum starting air pressure 4) Air consumption per Start 1)
Reference conditions: LCV = 42700 kJ/kg, ambient temperature 25 °C charge air temperature 45 °C, tolerance tole rance 5 %, + 1 % for each e ach e engine ngine drive driven n pump pu mp 2) Standard value, tolerance + 0,3 g/kWh, related on full load 3) Charge air heat based on 45 °C ambient temperature 4) Preheated engine
10
M 25 C Propulsion
m
6. Engine dimensions
Turbocharger at driving end
Engine type
Dimensions [mm]
Weight with flywheel [t]
A
B
C
D
E
F
G
H
6 M 25 C
1191
5345
1151
672
2260
861
460
2906
21.0
8 M 25 C
1191
6289
1151
672
2315
861
460
3052
28.0
9 M 25 C
1191
6719
1151
672
2315
861
460
3052
29.6
Removal of: in transverse direction in longitudinal direction
X1 X2
= 2420 mm = 3000 mm
Cylinder Liner in transverse direction in longitudinal direction
Y1 Y2
= 2510 mm = 2735 mm
Piston
Reduced removal height Piston and Liner: 2300 mm Special tool for liner removal in transverse direction necessary and according to lifting device arrangement.
Engine centre distance 6, 8, 9 Cyl. (2 engines side by side) M 25 C Propulsion
2500 mm 11
m
6. Engine dimensions
Turbocharger at free end
12
Engine type
Dimensions [mm] B
H
6 M 25 C
4917
2951
8 M 25 C
5777
3097
9 M 25 C
6207
3097
M 25 C Propulsion
m
6. Engine dimensions
6 M 25 C, Turbocharger Turbocharger at driving end
0 5 : 1 e l a c S
M 25 C Propulsion
13
m
6. Engine dimensions
8 M 25 C, Turbocharger Turbocharger at driving end
0 5 : 1 e l a c S
14
M 25 C Propulsion
m
6. Engine dimensions
9 M 25 C, Turbocharger Turbocharger at driving end
0 5 : 1 e l a c S
M 25 C Propulsion
15
m
6. Engine dimensions
6 M 25 C, Turbocharger Turbocharger at free end
0 5 : 1 e l a c S
16
M 25 C Propulsion
m
6. Engine dimensions
8 M 25 C, Turbocharger Turbocharger at free end 0 5 : 1 e l a c S
M 25 C Propulsion
17
m
6. Engine dimensions
9 M 25 C, Turbocharger Turbocharger at free end
0 5 : 1 e l a c S
18
M 25 C Propulsion
m
7. Space Space req requir uireme ement nt for dis disman mantli tling ng of cha charge rge air coo cooler ler and turbocharger cartridge
Dimensions [mm]
Weight
X
Y
A
B
C
kg
6 M 25 C
1900
1225
475
1155
552
270
8/9 M 25 C
2130
1225
475
1155
552
295
Charge air cooler cleaning Cleaning is carried out with charge air cooler dismantled. A container to receive the cooler and cleaning liquid is to be supplied by the yard. Intensive cleaning is achieved by using ultra sonic vibrators.
Not Caterpillar Motoren supply
Maintenance Space P = min. 1300 R = min. 750
Turbocharger Removal/Maintenance Caterpillar Motoren recommends providing right above the center of the turbocharger a lifting rail with a travelling trolley to which a lifting gear can be at tached in order to carry out the work on the turbocharger according to the maintenance schedule.
Weights M 25 C Turbocharger Turbocharger, compl. 563 kg
Si-
Compres-
lencer
sor housing
inlet housing
63 kg
136 kg
125 kg
M 25 C Propulsion
Turbine Exhaust-
Car-
Bearing
gas elbow
tridge
housing
68 kg
150 kg
100 kg
Rotor
32 kg
19
m
8. Maintenance platform
The platform, located at the control side of the engine including stairs and ladder ladder,, is normally designed and manufactured by the shipyard. As an option Caterpillar Motoren can supply a platform for rigidly mounted engines. For resiliently mounted engines a separate platform, that has to be adapted to local conditions, is strongly recommended recommended..
20
M 25 C Propulsion
m
9. System co connections
C14 C15 C17 C21 C22 C233 C2
Charge Air Cooler LT, Inlet Charge Air Cooler LT, Outlet Charge Air Cooler HT, Outlet Freshwater Pump HT, Inlet Freshwater Pump LT, Inlet Fres Fr eshw hwat ater er St Stan andd-by by Pu Pump mp HT HT,, Inlet C28 Freshwater Pump LT, Outlet C46a Luboil Stand-by Pump, Suction Side C51 Luboil Force Pump, Inlet
M 25 C Propulsion
DN DN DN DN DN DN
65 65 65 80 80 65
DN 65 DN 125 DN 125
C55c Connection Flushing Pipe Automatic Filter C58 Luboil Force Pump, Outlet C59 Luboil Inlet, Duplex Filter C600 Se C6 Sepa para rato torr Co Conn nnec ecti tion on,, Su Suct ctio ion n Si Side de C611 Se C6 Sepa para rato torr Con Conne nect ctio ion, n, De Deli live very ry Si Side de C76 Inlet, Duplex Filter C78 Fuel, Outlet C86 Crankcase Ventilation C91 Crankcase Ventilation C91a Exhaust Gas Outlet 6 M 25 C 8/9 M 25 C
DN 50 DN 100 DN 80 G 1 1/ 1/22" G 1 1/ 1/22" DN 32 DN 32 DN 40 40 DN 80 80 DN 500 DN 600 21
m
10.. Fu 10 Fuel el oi oill sys syste tem m Marine gas oil / marine diesel oil operation
Two fuel product groups are permitted for MaK engines:
Pure distillates:
Gas oil, marine gas oils, diesel fuel
Distillate/mixed fuels:
Marine gas oil (MGO), marine diesel oil (MDO). The difference between distillate/mixed fuels and pure distillates are higher density, sulphur content and viscosity.
MGO
MDO
Designation
Max. viscosity
ISO 8217: 1996
ISO-F-DMA
[cSt/40 °C] 1.5 - 6.0
ASTM D 975-78
No. 1 D No. 2 D
2.4 4.1
DIN EN 590
8
DIN
Designation
Max. viscosity
ISO-F-DMB ISO-F-DMC
[cSt/40 °C] 11 14
No. 2 D No. 4 D
4.1 24.0
Max. injection viscosity 12 cSt (2 °E)
Day tank DT 1:
To be layed out for heat dissipation from injection pumps, approx. 1.5 kW/cylinder.
Strainer (separate) DF 2:
Mesh size 0.32 mm, dimensions see HFO-system
Preheater (separate) DH 1:
Heating capacity Q [kW] =
Peng. [kW] 166
Not required with: - MGO < 7 cSt/40 °C - Heated day tank 22
M 25 C Propulsion
m
10.. Fu 10 Fuel el oi oill sys syste tem m Marine gas oil / marine diesel oil operation
Feed pump (fitted) DP 1:
Capacity see technical data
Feed pump (separate) DP 2:
Capacity see technical data Screw type pump with mechanical seal. Installation vertical or horizontal. Delivery head 5 bar.
Pressure regulating valve (fitted) DR 2 Fine filter (fitted) DF 1:
Duplex filter, filter, mesh size see technical data.
Separator DS 1:
Recommended for MGO Required for MDO
Capacity V [l/h] = 0.22 · Peng. [kW]
M 25 C Propulsion
23
m
10.. Fu 10 Fuel el oi oill sys syste tem m Marine gas oil / marine diesel oil operation
Notes: p Fr Free ee ou outl tlet et re requ quir ired ed s Pl Plea ease se re refe ferr to to the the mea measu suri ring ng point list regarding design of the monitoring devices General notes: For location, dimensions and design (e. g. flexible connection) of the connecting points see engine installation drawing. DH1 not required with:
Accessories and fittings: DF1 Fuel fine filter (duplex filter) DF2 Fuel primary filter (duplex filter) DF3 Fuel coarse filter DH1 Diesel oil preheater DH2 Electrical preheater for diesel oil (separator) DP1 Diesel oil feed pump DP2 Diesel oil stand-by feed pump DP3 Diesel oil transfer pump (to day tank) DP5 Diesel oil transfer pump (separator) DR2 Fuel pressure regulating valve DS1 Diesel oil separator DT1 Diesel oil day tank DT4 Diesel oil storage tank Connecting points: C73 Fuel inlet, to engine fitted pump C75 Connection, stand-by pump C78 Fuel outlet
24
- MGO < 7 cSt/40° - heated diesel oil day tank DT1
KP1 KT1 FQI LI LSH LSL PDI PDSH PI PSL PT TI TT
Fuel injection pump Drip fuel tank Flow quantity indicator Level indicator Level switch high Level switch low Diff. pressure indicator Diff. pressure switch high Pressure indicator Pressure switch low Pressure transmitter Temperature indicator Temperature transmitter (PT 100)
C80 C81b
Drip fuel Drip fuel
M 25 C Propulsion
m
10.. Fu 10 Fuel el oi oill sys syste tem m Heavy fuel operation
0 0 7 K M R
0 1 0 1
C 5 A 5 M I H C
0 0 7 H M R
1 9 9
C A 5 4 M I K C
0 0 5 K M R
0 1 0 1
C 5 A 4 M I H C
0 0 5 H M R
1 9 9
C A 5 3 M I K C
0 8 3 K M R
0 1 0 1
C A 5 5 M I K C
) d e r e k n u b s a ( s e n i g n e l e s e i d r o f s l e u f l a u d i s e r r f o s t n e m e r i u q e R
0 8 3 H M R 0 C 8 5 A 3 3 G M I G M C R C 5 A 3 M I H C
C A 5 2 M I F C
C A 0 1 M I C C
0 3 B M R
C 0 A 1 M I B C
0 3 B M R
C 0 A 1 M I A C
0 3 A M R
: n o i t a n g i s e D
F : ) 5 0 0 2 ( 7 1 2 8 O S I o t d e t a l e R
0 3
2 2
) 7 0 5 5 0 0 5 . 5 0 . 5 1 . 0 4 0 6 8 1 1 3 1 . 0 0
5 4
0 6
0 3
2 2
) 7 0 5 5 0 5 5 0 . 0 0 . 4 1 . 0 5 6 8 1 1 3 1 . 0 0
2 2
) 7 5 1 . 0
0 6
0 3
0 0 6 0 1 . . 5 . 5 4 0 0
0 8 5 1 5 3 1 0
1 9 9 8 1
5 1 . 0
0 0 3
0 1 e u d i s d e e t R i n m i l t b r 0 o 5 1 5 o a 2 7 8 8 . 9 : 9 : 9 : n : C : 0 : O O O O O O S I S I S I S I S I S I ) 2 ) 3 ) 4 ) 5 ) 6 ) 7
0 2
1 9 5 9 2
0 C 8 A 5 2 1 E M I E M C R 0 8 D M R
0 6
5 3
0 8 1 F M R
C 5 A 1 M I D C
5 5
0 6
0 6
) 3 5 7 9
) 2 0 5 9
c i t s i r e t c a r a h C
C ° 5 1 t a y t i s n e D
0 1 . 0
0 3
4 1
0 5 0 5 5 0 . 0 0 . 0 1 . 0 . 1 4 5 3 8 1 1 3 0 0
4 2
4 1
0 0 3
0 6
5 5 0 0 0 0 0 7 7 5 4 0 0 0 0 0 5 5 5 3 0 8 0 0 3 0 3 5 2 0 8 0 0 1 5 1
0 5 0 8 5 1 1 3 0 5 1
) 6 2 1
5 1 0 8 0 0 6 0 1 0 4 0 0 3
) 1 t C S ° c
C ° 0 0 1 t a y t i s o c s i v . n i K
0 0 2
0 5 5 0 . . 3 1 . 0 . 1 0 0
) 5 6
t x x n n i m a a i i i L m m m m
. 3 m m / i g D k
0 0 8 5 1 5 1 3
5 1
0 6
0 1
0 0 5 0 . 1 . 5 . 5 4 0 0
0 3
) 5 5 1
) 4 5 0 1 8 9
5 1 . 0
t n i o p h s a l F
x a m
C °
) r ) r e e t m n m i u s w ( ( t n i o p r u o P
x a m
) m / m ( %
7 0 0 3 0 2
x x x x x x x x x a a a a a a a a a m m m m m m m m m
) m / m ( %
) m / m ( %
g n i e g a r e t f a , m i d e s
V / V ( %
) m / m ( %
e u d i ) s n e o R s r n d r u a h p t e l a r n b o l r o h t a C s o a u C ( A T W S
g k / g m
g k / g m
m u i d a n a V
n o c i l i S + r m o u i h m n c i m i c u s p l o u i n h l a A Z P C
g k / g m
g k / g m
g k / g m
n i . s t c n e . e s ) l t ) t c I a S S e . s v c ( c I i w ( u d s s . q e / 2 / 2 w e R m m d e d e t m m R a n F C C m a i ° ° ° x C 0 0 0 o 0 0 r ° 1 5 1 p 0 5 p t : t t t a a w a a a e y y y o i t i t t y t l h t i e s i s s f s b o o o o o c c c c s i s i s n i s n e i o v i v v v i t c g c c v c a i t i t i t s i c t i a a a a i i d n m F ° m e m e m e e n i n i n n n 0 i A i k 0 1 K K K
) o l u ( l i o g n i t a c i r b u l d e s u f o e e r f e b l l a h l s e u F
) 1
M 25 C Propulsion
25
m
10.. Fu 10 Fuel el oi oill sys syste tem m Heavy fuel operation
m a r g a i d e r u t a r e p m e t / y t i s o c s i V
26
M 25 C Propulsion
m
10.. Fu 10 Fuel el oi oill sys syste tem m Heavy fuel operation
Minimum requirements for storage, treatment and supply systems Bunker tanks:
In order to avoid severe operational problems due to incompatibility, each bunkering must be made in a separate storage tank.
Settling tanks:
In order to ensure a sufficient settling effect, the following settling tank designs are permissible: - 2 settling settling tanks, tanks, each each with a capa capacity city sufficie sufficient nt for 24 hours full load operation of all consumers - 1 settling settling tank tank with a capaci capacity ty sufficien sufficientt for 36 hours hours full full load operation of all consumers and automatic filling - Settling Settling tank tank tempe temperatu rature re 70 70 - 80 °C °C
Two day tanks are required. The day tank capacity must cover at least 4 hours/max. 24 hours full load operation of all consumers. An overflow system into the settling tanks and sufficient insulation are required.
Day tank:
Guide values for temperatures
Separators:
M 25 C Propulsion
Fuel viscosity cSt/50 °C
Tank temperature [°C]
30 - 80
70 - 80
80 - 180
80 - 90
> 180 - 700
max. 98
Caterpillar Motoren recommends to install two self-cleaning separators. Design parameters as per supplier recommendation. Separation temperature 98 °C! Maker and type are to be advised to Caterpillar Motoren.
27
m
10.. Fu 10 Fuel el oi oill sys syste tem m Heavy fuel operation
Supply system (Separate components): A closed pressurized system between daytank and engine is required as well as the installation of an automatic backflushing filter with a mesh size of 10 µm (absolute).
Strainer HF 2:
Mesh size 0.32 mm
Output
Booster pumps HP 1/HP 2:
DN
H1
H2
W
D
[kW] < 5000
mm 32
249
220
206
180
< 10000
40
330
300
250
210
< 20000
65
523
480
260
355
> 20000
80
690
700
370
430
Screw type pump with mechanical seal. Installation vertical or horizontal. Delivery head 5 bar.
Capacity . V [m3 /h] = 0.4 .
28
Peng. [kW] 1000
M 25 C Propulsion
m
10.. Fu 10 Fuel el oi oill sys syste tem m Heavy fuel operation
Pressure regulating valve HR 1:
Controls the pressure at the engine inlet, approx. 4 bar.
Engine outputs < = 3000 kW
Self cleaning filter HF 4:
> 3000 kW
Mesh size 10 µm sphere passing mesh, type t ype 6.60, make Boll & Kirch*, DN 50, without by-pass filter. * In case of Caterpillar Motoren supply.
Dismantling of sieve 300 mm
M 25 C Propulsion
29
m
10.. Fu 10 Fuel el oi oill sys syste tem m Heavy fuel operation
Mixing tank (without insulation) HT 2: Vent
Inlet from pressure pump Outlet to engine
Circulating pumps HP 3/HP 4:
From engine
Engine output
Volume
Dimensions [mm]
Weight
[kW]
[l]
A
D
E
[kg]
< 4000
50
950
323
750
70
< 10000
100
1700
323
1500
120
> 10000
200
1700
406
1500
175
Design see pressure pumps.
Capacity . V [m3 /h] = 0.7 .
Final preheater HH 1/HH 2:
Peng. [kW] 1000
Heating media: - Elect Electric ric current current (max. (max. surface surface power power densit densityy 1.1 W/cm W/cm2) - Steam - Th The erm rmal al oil Temperature at engine inlet max 150 °C.
Viscosimeter HR 2:
Controls the injection viscosity to 10 - 12 cSt.
Fine filter (fitted) HF 1:
- Mesh Mesh si size ze 34 µm - Without heating - Differ Differentia entiall pressure pressure indicatio indication n and alarm alarm contact contact fitted
Fuel Cooler DH 3:
Required for heat dissipation with MGO/MDO operation.
30
M 25 C Propulsion
m
10.. Fu 10 Fuel el oi oill sys syste tem m Heavy fuel operation
- Pe Peak ak pr press essur ures es max max.. 16 16 bar bar
General notes: For location, dimensions and design (e. g. flexible connection) of the connecting points see engine installation drawing. Valve fittings with loose cone are not accepted in the admission and return lines. Accessories and fittings: DH3 MGO/MDO cooler DT1 Diesel oil day tank HF1 Fuel fine filter (duplex filter) HF2 Fuel primary filter HF3 Fuel coarse filter HF4 Self cleaning fuel filter HH1 Heavy fuel final preheater HH2 Stand-by final preheater HH3 Heavy fuel preheater HH4 Heating coil HP1 Fuel pressure pump HP2 Fuel stand-by pressure pump HP3 Fuel circulating Pump HP4 Fuel stand-by circulating Pump HP5 Heavy fu fuel tr transfer pu pump (s (separator)
HT1 HT2 HT5 HT6 KP1 KT2 FQI LI LSH LSL PDI PDSH PDSL PI PT
Heavy fuel day tank Mixing tank Settling tank I Settling tank II Fuel injection pump Sludge tank Flow quantity indicator Level indicator Level switch high Level switch low Diff. pressure indicator Diff. pressure switch high Diff. pressure switch low Pressure indicator Pressure tr transmitter
Notes: ff Flo Flow w verlo verloci city ty in cir circu cuit it syst system em < 0.5 m/s p Fr Free ee ou outl tlet et re requ quir ired ed s Pl Plea ease se re refe ferr to to the the me measu asuri ring ng point list regarding design of the monitoring devices u Fr From om dies diesel el oil oil separ separat ator or or or diese diesell oil transfer pump
HR P16 H HR2 HS1 HS2
TIT T VI VSH VSL
Te em mp pe erra attu urre e tin irnadnicsamtiottrer (PT 100) T Viscosity indicator Viscosity Control switch high Viscosity Control switch low
C7786 C C81 C81b
tu rare nsrfeegrupu pla utminpg (s (vsa elpvaerator) FSutaenl dp-rbeysstr Viscometer Heavy fuel separator I Heavy fuel separator II
M 25 C Propulsion
All heavy fuel pipes have to be insulated. ---- heated pipe
Connecting points: FInuleelt oduutplelet x filter Drip fuel Drip fuel
31
m
10.. Fu 10 Fuel el oi oill sys syste tem m Heavy fuel operation
Heavy fuel oil supply- and booster standard module (Pressurized System), up to IFO 700 for f or steam and thermaloil heating, up to IFO 180 for f or electr. electr. heating
Technical specification of the main components: 1. Pr Prim imar aryy fi filt lter er 1 pc. Duplex strainer 540 microns
2. Fuel pres pressure sure pump pumps, s, vertic vertical al insta installatio llation n 2 pcs. Screw pumps with mechanical seal
3. Pre Pressu ssure re reg regula ulatin ting g sys system tem 1 pc. Pressure regulating valve
4. Sel Selff cle cleani aning ng fin fine e filt filter er 1 pc. Automatic self cleaning fine filter 10 microns absolut (without by-pass filter)
5. Con Consum sumpti ption on mea measur suring ing sy syste stem m 1 pc. Flowmeter with local totalizer
6. Mix Mixing ing tan tank k with with ac acces cesso sorie riess 1 pc. Pressure mixing tank
approx. 49 l vo v olume up to 4000 kW approx. 99 l volume from 4001 - 20000 20000 kW (with quick-closing valve)
7. Circu Circulatin lating g pump pumps, s, vertic vertical al insta installatio llation n 2 pcs. Screw pumps with mechanical seal
8. Fi Fina nall pr preh ehea eate terr 2 pcs pcs.. She Shellll an and d tub tube e hea heatt exc excha hang nger erss
32
each 10 each 1000 % (s (sat atur urat ated ed 7 bar bar or th ther erma mall oil oil 18 1800 °C) °C) each 100 % electrical M 25 C Propulsion
m
10.. Fu 10 Fuel el oi oill sys syste tem m Heavy fuel operation
9. a) Heating Heating mediu medium m control control valve valve
(steam/thermaloil) (electrical)
b) Control cabinet
1 pc. control valve with built-on positioning positioning drive 1 pc. control cabinet for electr electr.. preheater
10. Vi Visco scosit sityy control control syst system em 1 pc. automatic viscosity measure and control system VAF
Module controlled automatically with alarms and starters Pressure pump starters with stand-by automatic Circulating pump starters with stand-by automatic PI-controller for viscosity controlling Starter for the viscosimeter Analog output signal 4 - 20 mA for viscosity
Alarms Pressure pump stand-by start Low level in the mixing tank Circulating pump stand-by start Self cleaning fine filter pollution Viscosity alarm high/low The alarms with potential free contacts Alarm cabinet with alarms to engine control room and connection possibility for remote start/stop and indicating lamp of fuel pressure and circulating pumps
Performance and materials: The whole module is tubed and cabled up to the terminal strips in the electric switch boxes which are installed on the module. All necessary components like valves, pressure switches, thermometers, gauges etc. are included. The fuel oil pipes are equipped with trace heating (steam, thermaloil or electrical) where necessary. The module will be tested hydrostatical and functional in the workshop without heating. Steam Thermal oil
Electric
Steam Thermal oil
Electric
Steam Thermal oil
Electric
2400/2900
2400/2900
4000/4800
4000/4800
8000/9600
8000/9600
Length in mm
2200
2300
2200
2700
3200
3500
Width in mm
1000
1000
1200
1200
1200
1200
Height in mm
2100
2100
2000
2000
2000
2000
Weight (approx.) in kg
1700
2500
2300
2400
2500
2700
For power in kW up to (50/60 Hz)
M 25 C Propulsion
33
m
11.. Lu 11 Lubri brica cati ting ng oil oil syst system em Lube oil quality The viscosity class SAE 40 is required. Wear and tear and thus the service life of the engine depend on the lube oil quality. Therefore high requirements are made for lubricants: Constant uniform distribution of the additives at all operating conditions. Perfect cleaning (detergent effect) and dispersing power, power, prevention of deposits from the combustion process in the engine. Sufficient alkalinity in order to neutralize acid combustion residues. The TBN (total base number) must be between 30 and 40 KOH/g at HFO operation. For MDO operation the TBN is 12 - 20 depending on sulphur content. Manufacturer
Diesel oil/Marine-diesel oil operation
I
AGIP
DIESEL SIGMA S CLADIUM 120
BP
ENERGOL DS 3-154 VANELLUS C 3
X
CALTEX
DELO 1000 MARINE DELO 2000 MARINE
X X
CASTROL
MARINE MLC MXD 154 TLX PLUS 204
X
34
I
CLADIUM 300 S CLADIUM 400 S
X X
X
ENERGOL IC-HFX 304 ENERGOL IC-HFX 404
X X
DELO 3000 MARINE DELO 3400 MARINE
X X
TLX PLUS 304 TLX PLUS 404
X X
II
X
CEPSA
KORAL 1540
CHEVRON
DELO 1000 MARINE OIL DELO 2000 MARINE OIL
X X
DELO 3000 MARINE OIL DELO 3400 MARINE OIL
X X
TOTAL LUBMARINE
DISOLA M 4015 AURELIA 4030
X X
AURELIA XL 4030 AURELIA XT 4040
X X
ESSO
EXXMAR 12 TP EXXMAR CM+
X
EXXMAR 30 TP EXXMAR 40 TP
X
EXXMAR 30 TP PLUS EXXMAR 40 TP PLUS
X X
X
MOBILGARD M 430 MOBILGARD M 440
X X
X X
X
MOBILGARD 412 MOBILGARD ADL MOBILGARD M 430 1) MOBILGARD 1-SHC
X X X
SHELL
GADINIA GADINIA AL ARGINA S ARGINA T
X X X X
ARGINA T ARGINA X
X X
TEXACO
TARO 16 XD TARO 12 XD TARO 20 DP
X X X
TARO 30 DP TARO 40 XL
X X
MOBIL
1)
HFO operation
X X
X
ESSOLUBE X 301
III
II
X
Ap Appr prov oved ed in op oper erat atio ion n d use Perm Pe rmit itte ted d for contr con trol olle led When these lube oils are used, Caterpillar Motoren must be b e informed because at the moment there is insufficient insufficie nt experience available for MaK-engines. Otherwise the warranty is invalid. Synthetic oil with a high viscosity index (SAE 15 W/40). Only permitted if the oil inlet temperatures can be decreased by 5 - 10 °C. M 25 C Propulsion
m
11.. Lu 11 Lubri brica cati ting ng oil oil syst system em
Lube oil quantities/- change intervals:
Circulating quantity: approx. 0.8 l/kW output with wet sump design approx. 1.3 l/kW output with separate tank The change intervals depend on: - the quantity - fuel quality - quality of lube oil treatment (filter, (filter, separator) separator) - engine load By continuous checks of lube oil samples (decisive are the limit values as per "MaK Operating Media") an optimum condition can be reached.
Force pump (fitted) LP 1:
Gear type pump
principle per engi engine ne Lub oil stand-by force pump (separate) LP 2: - principle - in case of Caterpillar Motoren supply supply vertical vertical design only - Prelubrication pressure pump only only for inland water way vessel and multi engines plants
Suction pump (fitted) LP 3: Lub oil stand by suction pump (separate) LP 4:
Strainer LF 4:
M 25 C Propulsion
Option for the operation with high level tank
- Option Option for the operatio operation n with high level level tank - prin principle ciple per engi engine ne - in case of Caterpillar Motoren supply supply vertical vertical design only - Prelubrication suction pump pump only for inland water way vessel and multi engine plants
Mesh size 2 - 3 mm to be supplied by the the yard
35
m
11.. Lu 11 Lubr bric icat atin ing g oil oil syst system em
Mesh size 30 µm sphere passing mesh, type 6.46, make Boll
Self cleaning filter LF 2:
& Kirch*. Without by-pass filter. Without flushing oil treatment. * In case of Caterpillar Motoren supply.
Dismantling of sieve 300 mm
Engine
Type 6.46
A mm
B mm
C mm
E mm
F mm
S mm
X mm
Y mm
Weight kg
6 M 25 C
DN 80
435
170
615
205
255
400
160
160
77
8/9 M 25 C
DN 100
485
200
615
245
295
400
180
180
112
Self cleaning filter (fitted) LF 2:
(Option)
Duplex filter (fitted) LF 1:
Mesh size 80 µm Differential pressure indication and alarm contact fitted. Omitted if LF 2 is fitted
36
M 25 C Propulsion
m
11.. Lu 11 Lubri brica cati ting ng oil oil syst system em
Plate type (plates made of stainless steel)
Cooler (separate) LH 1:
Temperature controller (separate) LR 1: P-controller with manual emergency adjustment
Dimensions [mm]
Weight
DN
D
F
G
H
[kg]
6 M 25 C
80
200
171
267
151
27
8/9 M 25 C
100
220
217
400
167
47
Discharge to circulating tank:
DN 200 at flywheel or counter flywheel side. Compensator to be supplied by the yard.
Circulation tank:
Volume V [m3] =
1.7 · Peng. [kW] 1000
In case of a high level tank max. 2.5 m height above crankshaft. Oil filling approx. 80 % of tank volume. M 25 C Propulsion
37
m
11.. Lu 11 Lubri brica cati ting ng oil oil syst system em
Recommendation of pipe location in the circulating tank Flushing oil from automatic filter Separator suction pipe
Separator return pipe
Suction pipe force pump Suction pipe stand-by force pump
Discharge from engine
Option (for MGO and MDO only):
Deep oil pan (wet sump)
Crankcase ventilation:
The location of the ventilation is on top of the engine block near to the turbocharger (see system connections C 91). The vent pipe DN 80 must be equipped with a condensate trap and drain. It has to be arranged arranged separately separately for for each engine. Crankcase pressure pressure max. 150 Pa (15 mm WC).
38
M 25 C Propulsion
m
11.. Lu 11 Lubri brica cati ting ng oil oil syst system em
Treatment at MGO/MDO operation The service life of the lube oil will be extended by by-pass treatment.
Centrifuge (Option, fitted on the engine) LS 2: Minimum requirement
Separator LS 1:
Recommended Design: - Separating temperature 85 - 95 °C - Quantity to be cleaned three times/day - Self cleaning type
Separation capacity Veff [l/h] = 0.18 · Peng [kW]
Treatment at heavy fuel operation Separator LS 1:
Required with the following design: - Separating temperature 95 °C - Quantity to be cleaned five times/day - Self cleaning type
Separation capacity Veff [l/h] = 0.29 · Peng [kW]
M 25 C Propulsion
39
m
11.. Lu 11 Lubri brica cati ting ng oil oil syst system em MGO/MDO operation (wet sump)
General notes: For location, dimensions and design (e. g. flexible connec tion) of o f the connecting points see engine installation drawing. The separator (LS1) can be omitted for engine with fitted centrifuge (LS2). Notes: f Drain h Pl Plea ease se ref refer er to to the the meas meas-uring point list regarding design of the monitoring devices See "crankcase ventila tion installation instruc tions" 4-A-9570 p Fr Free ee ou outl tlet et re requ quir ired ed * Option o
Accessories and fittings: LF1 Duplex luboil filter LF2 Self cleaning luboil filter LF4 Suction strainer LH1 Luboil cooler LH2 Luboil preheater LP1 Luboil force pump LP2 Luboil stand-by force pump LP9 Transfer pump (separator) LR1 Luboil te temperature co control va valve LR2 Oil pr pressure re regulating va valve LS1 Luboil separator LS2 Luboil c en entrifuge LT2 Oil pan
40
LI LSL PDI PDSH PI PSL PSLL PT TI TSHH TT
Level indicator Level switch low Diff. pressure indicator Diff. pressure switch high Pressure indicator Pressure switch low Pressure switch low Pressure transmitter Temperature in indicator Temperature sw switch hi high Temperature transmitter (PT 100)
Connecting points: C46a C46 a Stand St and-b -byy for force ce pu pump, mp, su suct ction ion si side de C55c C55 c Conn Co nnec ecti tion on fl flush ushin ing g pipe pipe au auto toma mati tic c filter C58 Force pu pump mp,, de delive verry si side C599 C5 Lubo Lu boil il in inle let, t, lu lubo boil il co cool oler er C600 C6 Sepa Se para rato torr con conne nect ctio ion, n, su suct ctio ion n sid side e or or drain or filling pipe C611 C6 Sepa Se para rato torr co conn nnec ecti tion on,, de deli live very ry si side de or from bypass filter C61b C6 1b Inle In lett lu lubo boil il ce cent ntri rifu fuge ge C62 Drip oil, dupl ple ex filter C911 C9 Cran Cr ankc kcas ase e ven venti tila lati tion on to st stac ackk
M 25 C Propulsion
m
11.. Lu 11 Lubri brica cati ting ng oil oil syst system em
General notes: For location, dimensions and design (e. g. flexible connection) of the connecting points see engine installation drawing.
Notes: h Ple Please ase ref refer er to to the the measu measurin ring g point point lis listt regarding design of the monitoring devices l A separ separat ator or is is requ requir ired ed for for hea heavy vy fue fuell operation o See "crankcase ventilation installation instructions" 4-A-9570 p Fr Free ee ou outl tlet et re requ quir ired ed y Pr Prov ovid ide e an an exp expan ansat satio ion n joi joint nt z Ma Max. x. suc sucti tion on pr press essur ure e 0.4 0.4 ba barr
Accessories and fittings: LF1 Duplex luboil filter LF22 LF Self Se lf cl clea eani ning ng lu lubo boil il fi filt lter er LF4 Suction strainer LH1 Luboil cooler LH2 Luboil pr preheater LP1 Luboil force pump LP22 LP Lubo Lu boil il st stan andd-by by fo forc rce e pum pump p LP55 LP Prelubrication pu pum mp
LI LSL LSH LS H PDII PD PDSH PDS H PI PSL
Level indicator Level switch low Leve vell switch hi hig gh Diff Di ff.. pr pres essu sure re in indi dica cato torr Diff. Dif f. pres pressure sure swi switch tch high Pressure indicator Pres esssure sw swit itc ch lo low
Connecting points: C51 Force pump, suction si sid de
LP9 LP9 LR11 LR LR22 LR LS1 LT1
PSLL PSLL PT TI TSHH TSH H TT
Pressu Pres sure re sw swit itch ch lo low w Pressure transmitter Temperature indicator Tempe emperat rature ure swi switch tch high Tem empe pera ratu ture re tra rans nsmi mitt tter er (P (PT T 100 100))
C53 C58 C599 C5 C62 C911 C9
Tra rans nsfe ferr pu pump mp (s (sep epar arat ator or)) Lubo Lu boil il te temp mper erat atur ure e con contr trol ol va valv lve e Oill pre Oi press ssur ure e re regu gula lati ting ng va valv lve e Luboil separator Luboil su sump tank
M 25 C Propulsion
Luboil discharge Force pu pump, delivery si side Lubo Lu boil il in inle let, t, lu lubo boil il co cool oler er Dripoil il,, duplex fil iltter Cran Cr ankc kcas ase e ven venti tila lati tion on to sta stack ck
41
m
12.. Co 12 Cool olin ing g wat water er sy syst stem em
The heat generated by the engine (cylinder, (cylinder, turbocharger, turbocharger, charge air and lube oil) is to be eliminated by means of treated freshwater acc. to the MaK coolant regulations. The inlet temperature in the LT-circuit is max. 38 °C.
Two-circuit cooling:
with two-stage charge air cooler.
HT-fresh water pump (fitted) HT-fresh (fi tted) FP 1: HT-fresh HT -fresh water pump (stand-by) FP 5
Capacity: acc. to heat balance
LT-fresh water pump (fitted) FP 2: LT-fresh LT-fresh water pump (stand-by) FP 6
Capacity: acc. to heat balance
HT-temperature HT -temperature controller (separate) FR 1: P-controller with manual emergency adjustment (basis). LT-temperature controller (separate) FR 2:
P-controller with manual emergency adjustment (basis). Option: PI-controller with electric drive.
Dimensions [mm]
Weight
DN
D
F
G
H
[kg]
6/8/9 M 2255 C HT 6 M 25 C LT*
80
200
171
267
151
27
8/9 M 25 C
100
220
217
403
167
47
LT*
* Minimum, depending on total cooling water flow
42
M 25 C Propulsion
m
12.. Co 12 Cool olin ing g wate waterr syst system em
Preheater (separate) FH 5/FP 7:
Consisting of circulating pump (5 m3 /h), electric heater (18 kW) and switch cabinet. Voltage 400 - 480, frequency 50/60 Hz. Weight 95 kg.
Charge air heating CR 4::
Control unit for charge air heating in part load condition with electric/pneumatic 2 position flap.
Option: Charge-air thermostat (separate) CR 1:
M 25 C Propulsion
PI-controller with electric drive
43
m
12.. Co 12 Cool olin ing g wat water er sy syst stem em
HT-cooler (separate) FH 1:
Plate type (plates made of titanium), size depending on the total heat to be dissipated. dissipated.
LT-cooler (separate) FH 2:
Plate type (plates made of titanium), size depending on the total heat to be dissipated. dissipated.
Header tank FT 1/FT 2:
- Arrangem Arrangement: ent: min. min. 4 m above crank crankshaft shaft centr centre e line. - Size acc. to techn technical ical engi engine ne data. data. - All continuo continuous us vents vents from engine engine are are to be connected connected..
Drain tank with filling pump:
Is recommended to collect the treated water when carrying out maintenance work (to be installed by the yard).
Electric motor driven pumps:
Option for fresh and seawater, vertical design. Rough calculation of power demand for the electric balance.
P=
P P. M V H ρ η -
44
Power [kW] Powe Po werr of of ele elect ctr. r. mo moto torr [kW [kW]] Flow rate [m3 /h] Delivery head [m] Densit ityy [k [kg/d /dm m3] Pump Pu mp ef effi fic cie ien ncy 0.70 for centrifugal pumps
. ρ · H · V 367 · η
[kW]
PM = 1.5 · P PM = 1.25 · P PM = 1.2 · P PM = 1.15 · P PM = 1.1 · P
< 1.5 1.5 - 4 4 - 7.5 > 7.5 - 40 > 40
kW kW kW kW kW
M 25 C Propulsion
m
12.. Co 12 Cool olin ing g wate waterr syst system em
Heat balance 6 M 25 C
M 25 C Propulsion
45
m
12.. Co 12 Cool olin ing g wat water er sy syst stem em
Heat balance 8 M 25 C
46
M 25 C Propulsion
m
12.. Co 12 Cool olin ing g wate waterr syst system em
Heat balance 9 M 25 C
M 25 C Propulsion
47
47
M 25 C Propulsion
m
12.. Co 12 Cool olin ing g wate waterr syst system em
General notes:
Notes:
For location, dimensions and design (e. g. flexible connection) of the connecting points see engine installation install ation drawing. drawing. With skin cooler not required: required: - Seawater Seawater system (SP1, (SP1, SP2, SF1, ST1) Temp. control valve FR3 required, if heat recovery installed.
b
Accessories and fittings: CH11 Ch CH Char arge ge air coo coole lerr HT HT CH22 Ch CH Char arge ge ai airr cool cooler er LT CR44 Fl CR Flap ap for for cha charg rge e preh preheat eating ing DH3 Fue Fuell oil coo cooler ler for for MDO MDO opera operation tion FH11 Fr FH Fresh eshwa wate terr co coole olerr HT * FH22 Fr FH Fresh eshwa wate terr coo cooler ler LT * FH33 He FH Heat at Co Cons nsum umer er FH55 Fr FH Fresh eshwa wate terr pr preh eheat eater er FP1 Fre Freshwa shwater ter pum pump p (fitt (fitted ed on on engin engine) e) HT HT FP2 Fre Freshwa shwater ter pum pump p (fitt (fitted ed on on engin engine) e) LT LT FP55 Fr FP Fresh eshwa wate terr stan standd-by by pump pump HT FP66 Fr FP Fresh eshwa wate terr stan standd-by by pum pump p LT LT FP77 Pr FP Preh ehea eati ting ng pum pump p FR11 Tem FR empe pera ratu ture re cont contro roll valve valve HT FR2 Temp empera eratur ture e cont control rol val valve ve LT FR3 Flow Flow.. tempe temperat rature ure cont control rol valv valve e HT HT
FT1 Co FT1 Comp mpen ensa sati tion on ta tank nk HT FT22 Co FT Comp mpen ensa sati tion on tan tankk LT LT LH11 Lu LH Lubo boil il co cool oler er LH33 Ge LH Gear ar lu lubo boil il co cool oler er SF11 Se SF Seaw awat ater er fil filte terr SP11 Se SP Seaw awat ater er pu pump mp SP22 Se SP Seaw awat ater er st stan andd-by by pu pump mp ST1 Sea chest LI Level indicator LSLL Le LS Leve vell swi switc tch h low low PI Pressu surre in ind dicator PSLL Pr PS Pres essu sure re swi switc tch h low low PSLLL Pre PSL Pressur ssure e switch switch low low PT Pr Pres essu surre tr tran ansm smit itte terr TI Tem empe pera ratu ture re in indi dica cato torr TSHH Temperat emperature ure switch high TT Tem empe pera ratu ture re tr trans ansmi mitt tter er (P (PT T 100 100))
* Classification society requirements have to be taken into account
Measu Me asure reme ment nt min 2.0 m dis dis- tance to C17 e Bypass DN 12 f Drain h Pl Pleas ease e refe referr to to the the measu measuri ring ng point list regarding design of the monitoring devices m Ai Airr sup suppl plyy 2 - 10 ba barr For temp. control valve P-type FR1, FR2, FR3 alternative PI-type possible
Connecting points: C14 Charge air air cooler LT LT, inlet C15 Charge air air cooler LT LT, outlet C17 Charge air air cooler cooler HT, HT, outlet C21 C22 C23 C28 C377 C3
Freshwater pump Freshwater pump HT, HT, inlet Freshwater Freshwa ter pump LT LT, inlet Stand-by Standby pump HT HT,, inlet Freshwater Freshwa ter pump, LT LT, outlet Ven entt
48
M 25 C Propulsion
m
13.. Fl 13 Flow ow vel veloc ocit itie iess in pipe pipess
Example:
di = 100 mm, V = 60 m3 /h Velocity in the pipe 2,1 m/s
49
M 25 C Propulsion
m
14.. St 14 Star arti ting ng ai airr sys syste tem m
Requirement of Classification Societies (regarding design) - No. of starts: - No. of receivers:
6 min. 2
Receiver capacity acc. to GL recommendation AT 1/AT 2 6/8/9 Cyl. Single-engine Single-engin e plant
2 x 250 l
Twin-engine plant
2 x 500 l
Receiver capacity [l]
L mm
DØ mm
Valve head
Weight approx. kg
250
2960
480
DN 38
230
500
3470
480
DN 50
320
1 Fill Fillin ing g va valv lve e DN 18 2 Pr Pres essu sure re ga gaug uge e G 1/ 1/44 3* Rel Relief ief val valve ve DN 7 4 5 6 7 8
Drain va Dra valv lve e DN 8 Drain Dra in valv valve e DN 8 (for (for verti vertical cal pos positi ition) on) Conn Co nnec ecti tion on aux aux.. air air valv valve e G1/2 G1/2 To st star arti ting ng va valv lve e at at eng engin ine e Typ Ty pho hon n val valve ve DN 16
Option: * with pipe connection G 1/2
When CO2 fire extinguishing plants are arranged in the engine room, the blow-off connection of the safety valve is to be piped to the outside.
50
M 25 C Propulsion
m
14.. St 14 Start artin ing g air air sy syst stem em
Compressor AC 1/AC 2:
2 compressors with a total output of 50 % each are required. The filling time from 0 to 30 bar must not exceed 1 hour.
Capacity . V [m3 /h] = Σ VRec. · 30 VRec. = Total receiver volume [m³]
General notes: For location, dimensions and design (e. g. flexible connection) of the connecting points see engine installation drawing. Clean and dry starting air is required. A starting air filter has to be installed before engine, if required. The air receivers are to be drained sufficiently at least once per day.
Notes: a Control air d Wate Wa terr drain drain (t (to o be mo moun unted ted at the the low lowest est poi point nt)) e To engine no. 2 h Please Ple ase ref refer er to the meas measuri uring ng poin pointt list list reg regard arding ing des design ign of *
the monitoring devices Auto Au toma mati tic c dr drai ain n req equi uirred
Connecting points: C86 Con Connec nectio tion, n, sta starti rting ng air
Accessories and fittings: AC1 Compressor AC2 Stand-by co compressor AR1 Starting valve AR4 Pressure reducing valve AR5 Oil an and wa water se separator AT1 Star St arti ting ng ai airr re rece ceiv iver er (a (air ir bo bott ttle le)) AT2 Star St arti ting ng ai airr re rece ceiv iver er (a (air ir bo bott ttle le)) PI Pressure indicator PSLL PS Pres Pr essu sure re sw swit itch ch lo low w, onl onlyy for for ma main in en engi gine ne PT
Pressure transmitter
AT1 T1/A /AT2 T2 Op Opti tion on:: - Typhon valve - Relief valve with pipe connection
M 25 C Propulsion
51
m
15.. Co 15 Comb mbus usti tion on air air sys syste tem m
General:
To obtain good working conditions in the engine room 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 combustion air required and the heat radiation of all consumers/heat consumers/he at producers must be taken into account.
are to be desig designed ned for a slight slight overpres overpressure sure in in the Air intake from engine room (standard): - Fans are engine room. - On system system side the the penetratio penetration n of water, water, sand, dust, dust, and exhaust gas must be avoided. - When operati operating ng under under tropical tropical conditio conditions ns the air flow flow must be conveyed directly to the turbocharger. - The tempera temperature ture at turboc turbocharg harger er filter filter should should not fall bebelow + 10 °C. - In cold areas areas warmin warming g up of the the air in the the engine engine room room must be ensured.
Air intake from outside:
- The intake intake air duct is to be be provided provided with with a filter. filter. PenetraPenetra tion of water water,, sand, dust and exhaust gas must be avoided. - Conn Connectio ection n to the turboch turbocharge argerr is to be establis established hed via an an expansion joint (to be supplied by the yard). For this purpose the turbocharger will be equipped with a connection socket. - At temperatur temperatures es below below + 10 °C the Caterp Caterpillar illar Motore Motoren/ n/ Application Engineering must be consulted. - The max max pressure pressure loss loss (incl. (incl. silencer silencer and exhaus exhaustt gas boiler) of 30 mbar is applicable as value for the total flow resistance of plants with separate intake air filter!
Radiated heat:
see technical data To dissipate the radiated heat a slight and evenly distributed air to bethe ledturbocharger. along the engine exhaust gas manifoldcurrent startingisfrom
52
M 25 C Propulsion
m
16.. Ex 16 Exha haus ustt sys syste tem m
Position of exhaust gas nozzle:
A nozzle position of 0, 30, 45, 60 and 90° is possible.
The exhaust outlet of the turbocharger has a fixed position of 45°. Transition pieces for outlets of 0, 30, 60 and 90° are available.
Exhaust compensator:
Diameter DN
Length [mm]
Weight [kg]
6 M 25 C
500
360
42
8/9 M 25 C
600
450
76
Design of the pipe cross-section:
The pressure loss is to be minimized in order to optimize fuel consumption and thermal load of the engine. Max. flow velocity: 40 m/s (guide value). Max pressure loss (incl. silencer and exhaust gas boiler): 30 mbar (lower values will reduce thermal load of the engine). The aforesaid value is also applicable as value for the total flow resistance of plants with separate intake air filter!
Notes regarding installation:
- Arrangem Arrangement ent of the first expans expansion ion joint joint directly directly on the the exhaust gas nozzle - Arra Arrangem ngement ent of the first first fixed fixed point point in the conduit conduit directl directlyy after the expansion joint - Drain openin opening g to be provided provided (protect (protection ion of turbocha turbocharger rger and engine against water) - Each engine engine requi requires res an exhau exhaust st gas pipe pipe (one (one common common pipe for several engines is not permissible). If it should be impossible to use the standard transition piece supplied by Caterpillar Motoren, the weight of the transition piece manufactured manufactured by the shipyard must not exceed the weight of the standard transition piece. A drawing including the weight will then have to be submitted approval.
53
M 25 C Propulsion
m
16.. Ex 16 Exha haus ustt sys syste tem m Resistance in exhaust gas piping
Example (based on diagram data A to E): t = 335 °C, G = 25000 kg/h kg/h l = 15 m straight pipelength, d = 700 mm 3 off 90° bend R/d = 1.5 1 off 45° bend R/d = 1.5 ∆Pg = ? ∆p L' L ∆Pg
= = = =
0.83 mm WC/m 3 · 11 m + 5.5 m l + L' = 15 m + 38.5 m = 53.5 m ∆p · L = 0.83 mm WC/m · 53.5 m = 44.4 mm WC
t G ∆p d w l L' L ∆Pg
= = = = = = = = =
Exhaust gas temperature Exhaust gas massflow Ex Resistance/m pipe length Inner pipe diameter Gas velocity Straight pipe length Spare pipe length of 90° bent pipe Effective substitute pipe length Total resistance
(°C) (kg/h) (mm WC/m) (mm) (m/s) (m) (m) (m) (mm WC)
54
M 25 C Propulsion
m
16.. Ex 16 Exha haus ustt sys syste tem m
Exhaust sound power level not attenuated [1 x 1 m] 6 M 25 C (1900 kW/720 rpm, 1980 kW/750 rpm) 160 150 140
139
137
LwOct [dB] 130 (reference 10-12 W)
138 132
130
132
129
120
122
119
110 100 0.031
0.063
0.125
0.25
0.5
1
2
8 f [kHz]
4
8 M 25 C (2540 kW/720 rpm, 2640 kW/750 rpm) 160 150 140
140
LwOct [dB] (reference 10-12 W) 130
13 9
139 134 1 33
132
130 125
120
122
110 100 0.031
0.063
0.125
0.25
0.5
1
2
8 f [kHz]
4
9 M 25 C (2850 kW/720 rpm, 2970 kW/750 rpm) 160 150 140 LwOct [dB] (reference 10-12 W) 130
1 40
14 0
139 135 133
132
131 126
120
123
110 100
Tolerance + 2 dB
0.031
0.063
0.125
0.25
0.5
1
2
4
8
f [kHz]
55
M 25 C Propulsion
m
16.. Ex 16 Exha haus ustt sys syste tem m Exhaust data:
Tolerance: Atmospheric pressure: Relative humidity: Constant speed
Intake air temperature:
25 °C
100 1900 14845 312 1980 16120 290 2540 19100
90 1710 13570 313 1782 13540 285 2286 17940
• Output % • Output [kW] • [kg/h] • [°C] 80 70 1520 1330 12385 11200 313 315 1584 1386 12500 10833 285 285 2032 1778 16560 15000
335 2640 20070 316 2850 22030 338 2970 22000 320
323 2376 17710 312 2565 20442 324 2673 19375 317
320 2112 16050 309 2280 18650 320 2376 17920 309
Output [kW]
1900 6 M 25 C 1980 2540 8 M 25 C 2640 2850 9 M 25 C 2970
1980 2540 8 M 25 C 2640 2850 9 M 25 C 2970
50 950 7686 339 990 7850 318 1270 10100
315 1584 12500 308 1710 15825 318 1782 14060 312
335 1320 10800 313 1425 11925 329 1485 12170 316
60 1140 9700 338 1188 8960 323 1524 12900 336 1584 11875 327 1710 15192 337 1782 13333 332
50 950 7380 359 990 7590 337 1270 9700 355 1320 10171 332 1425 11448 349 1485 11480 335
• Output % • Output [kW] • [kg/h]
Output [kW]
6 M 25 C
315 1848 14270 303 1995 16850 315 2079 16460 309
60 1140 10100 319 1188 9375 305 1524 13415
45 °C
Intake air temperature:
1900
5% 1 bar 60 %
100 1900 14250 331 1980 14146 306 2540 18335 355 2640 18044 335 2850 21150 358 2970 19600 339
90 1710 13027 332 1782 12920 302 2286 17222 342 2376 16666 331 2565 19624 343 2673 18230 336
• [°C] 80
1520 11890 332 1584 11355 302 2032 15900 339 2112 15210 321 2280 17905 339 2376 16980 328
70 1330 10750 334 1386 10312 302 1778 14400 334 1848 13545 322 1995 16175 334 2079 15375 328
56
M 25 C Propulsion
m
16.. Ex 16 Exha haus ustt sys syste tem m
Silencer:
Design according to the absorbtion principle with wideband attenuation over a great frequency range and low pressure loss due to straight direction of flow. Sound absorbing filling consisting of resistant mineral wool. Sound level reduction 25 dB(A), alternatively 35 dB(A). Max. permissible flow velocity 40 m/s.
Silencer with spark arrester:
Soot separation by means of a swirl device (particles are spun towards the outside and separated in the collecting chamber). Sound level reduction 25 dB(A) or 35 dB(A). Max. permissible flow velocity 40 m/s. Silencers are to be insulated by the yard. yard. Foundation Foundation brackets are provided as an option.
57
M 25 C Propulsion
m
16.. Ex 16 Exha haus ustt sys syste tem m
Silencer/Spark arrestor and silencer:
Installation: vertical/horizontal Flange according to DIN 86044 Counterflanges, screws and gaskets are included, without supports and insulation
Silencer
Spark arrestor and silencer
Attenuation
25 dB (A)
35 dB (A)
DN
D
B
L
kg
L
kg
6 M 25 C
500
950
588
3185
710
3940
750
8/9 M 25 C
600
1100
659
3760
1100
4760
1300
Exhaust gas boiler:
Each engine should have a separate exhaust gas boiler. Al ternatively,, a common boiler with separate ternatively separate gas sections sections for each engine is acceptable. Particularly when exhaust gas boilers are installed attention must be paid not to exceed the maximum recommended back pressure.
58
M 25 C Propulsion
m
16.. Ex 16 Exha haus ustt sys syste tem m
Cleaning the turbocharger compressor: The components for cleaning (dosing vessel, pipes, shut-off valve) are engine mounted. Water is fed before compressor wheel via injection pipes during full load operation every 24 to 48 hours.
Cleaning the turbine blade and nozzle ring:
The cleaning is carried out with clean fresh water "wet cleaning" during low load operation at regular intervals, depending on the fuel quality, 250 to 500 hours. Duration of the cleaning period is approx. 20 minutes. Fresh water of 1.5 bar is i s required. During cleaning the water drain should be checked. Therefore the shipyard has to install a funnel after connection point C36.
6/8/9 M 25 C
Water flow [l/min]
Injection time [min]
6 - 18
15 - 20
C42 Fres C42 Fresh h wat water er su supp pply ly,, Ø 16 C36 Drain, Ø 25
Dirty water tank Connection of C42 with quick coupling device
59
M 25 C Propulsion
m
17. Air bor borne ne sou sound nd pow power er lev level el
The airborne noise of the engines is measured as a sound power level according to EN ISO 9614-2/ Accuracy class 3.
6 M 25 C (1900 kW/720 rpm, 1980 kW/750 rpm) 125 120
117 115
LwOct [dB] (reference 10-12 W)
112 110
111
111
111 105
108
105 100
95
0.063
0.125
0.25
0.5
1
2
4
[kHz]
8 M 25 C (2540 kW/720 rpm, 2640 kW/750 rpm) 125 120
117 115
LwOct [dB] (reference 10-12 W)
116
112
115
110
113
113
0.5
1
110
105 100 95 0.063
0.125
0.25
2
4
[kHz]
9 M 25 C (2850 kW/720 rpm, 2970 kW/750 rpm) 125 120
118
120
LwOct [dB] (reference 10-12 W)
114
115
116
111 113
113
110 105 100 95
Tolerance + 2 dB
0. 063
0. 125
0. 25
0.5
1
2
4
[kHz]
60
M 25 C Propulsion
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18.. Fou 18 ound ndat atio ion n
External foundation forces and frequencies: The following information is relevant to the foundation design and the aftship structure. The engine foundation is subjected to both static and dynamic loads.
The static load results from the engine weight which is dis tributed approximately evenly over the engine’ engine’ss foundation supports and the mean working torque TN resting on the foundation via the vertical reaction forces. TN increases the weight on one side and reduces it on the other side by the same amount.
1. Static load:
6 M 25 C
8 M 25 C
9 M 25 C
Output [kW]
Speed [1/min]
[kNm]
1900
720
25.3
1980
750
25.2
2540
720
33.7
2640
750
33.6
2850
720
38.0
2970
750
37.8
Support distance a = 1210 mm F = TN / a
2. Dynamic load:
The dynamic forces and moments are superimposed on the static forces. They result on the one hand from the firing forces causing a pulsating torque and on the other hand from the external mass forces and mass moments. The tables indicate the dynamic forces and moments as well as the related frequencies.
61
M 25 C Propulsion
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18.. Fo 18 Foun unda dati tion on
Output [kW]
Speed [rpm]
Order-No.
Frequency [Hz]
M x [kNm]
1900
720
3 6
36 72
20.7 10.4
1980
750
3 6
37.5 75
20.6 10.4
2540
720
4 8
48 96
36.1 4.7
2640
750
4 8
50 100
36.0 4.6
2850
720
4.5 9
54 108
33.9 3.0
750
4.5 9
56.25 112.5
33.8 3.0
6 M 25 C
8 M 25 C
9 M 25 C 2970
6 M 25 C 8 M 25 C
My [kNm]
Mz [kNm]
720
—
—
1980
750
—
—
2540
720
—
—
2640
750
—
—
2850
720
1 2
12 24
8.6 7.2
—
2970
750
1 2
12.5 25
9.3 7.8
—
Output [kW]
Speed [rpm]
1900
9 M 25 C
Order-No.
Frequency [Hz]
All forces and moments not indicated are irrelevant or do not occur. The effect of these forces and moments on the ship’s foundations depends on the type of engine mounting.
62
M 25 C Propulsion
m
18.. Fo 18 Foun unda dati tion on
2.1 Rigid mounting:
The vertical reaction forces resulting from the torque varia tion Mx are the most important disturbances to which the engine foundation is subjected. As regards dynamic load, the indicated moments Mx only represent the exciting values and can only be compared among each other. The ac tual forces to which the foundation is subjected depend on the mounting arrangemen arrangementt and the rigidity of the foundation itself. In order to make sure that there are no local resonant vibra tions in the ship’ ship’ss structure, the natural frequencies of important components and partial structures must be sufficiently far away (+ 30%) from the indicated main exciting frequencies.
2.2 Resilient mounting:
The dynamic foundation forces can be considerably reduced by means of resilient engine mounting.
General note:
The shipyard is solely responsible for the adequate design and quality of the foundation. Information on foundation bolts (required pretightening torques, elongation, yield point), steel chocks, side stoppers and alignment bolts is to be gathered from the foundation plans. Examples "for information only" for the design of the screw connections will be made available as required. If pourable resin is used it is recommendable to employ au thorized workshops of resin manufacturers approved by the classification societies for design and execution. It has to be taken into account that the permissible surface pressure for resin is lower than for steel chocks and therefore the tightening torques for the bolts are reduced correspondingly.
63
M 25 C Propulsion
m
18.. Fou 18 ound ndat atio ion n Rigid mounting
Side stoppers
6 M 25 C 1)
1 Pair
8/9 M 25 C 2 Pairs
1) 2)
2)
1 pair at end of bed plate 1 pair at end of cylinder housing and 1 pair between cyl. 4 and 5.
Side stopper to be with 1 wedge (see sketch). Wedge to be placed at operating temperature and secured by welding. Dimensioning according to classification society and cast resin suppliers requirements.
Number of Bolts
Fitted bolts
Foundation bolts
6 M 25 C
4
24
8 M 25 C
4
32
9 M 25 C
4
36
Jacking Bolts
- To be prote protected cted agai against nst conta contact/bo ct/bond nd with with resin resin - After setti setting ng of resi resin n dismantle dismantle the jacking jacking scre screws ws complet completely ely
To be supplied by yard:
Foundation fitted bolts, nuts and tension sleeves, side stoppers, steel chocks,bolts, cast resin
The shipyard is solely responsible for adequate design and quality of the foundation.
64
M 25 C Propulsion
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18.. Fo 18 Foun unda dati tion on Rigid mounting
Proposal for rigid mounting
Pre-tightening force Cast resin
Steel
Through bolts M 24 [N]
Fitted bolts M 24 [N]
Through bolts M 24 [N]
Fitted bolts M 24 [N]
100000
100000
170000
170000
Bolts and chocks are yard supply. Design responsibility is with the yard.
65
M 25 C Propulsion
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18.. Fou 18 ound ndat atio ion n Resilient mounting
Major components: - Conical Conical rubber rubber elements elements for active active isolation isolation of of dynamic dynamic engine forces forces and and structure structure born born noise are are combined horizontal, lateral and vertical stoppers to limit the engine movements. - Dyn Dynami amical cally ly balance balanced d highly highly flexibl flexible e couplin coupling. g. - Fle Flexib xible le con connec nectio tions ns for all med media. ia. - Spe Specia ciall desig designed ned exh exhau aust st gas gas belo below w. Details are shown on binding installation drawings. No. of elements:
Conical elements
6 M 25 C
6
8 M 25 C
8
9 M 25 C
8
Important note: - The resilien resilientt mounting mounting alone does does not provide provide garant garant for a quiet quiet ship. Other Other sources sources of noise noise like propeller, gearbox and aux. engines have to be considered as well. - Radi Radial al restoring restoring forces forces of the flexible flexible coupling coupling (due (due to seaway) seaway) may be of importan importance ce for the layout layout of the reduction gear.
66
M 25 C Propulsion
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18.. Fou 18 ound ndat atio ion n Structure borne
Structure borne sound level Lv, expected (measured in the test cell)
110 100
Lv Oct [dB] (reference 5*10-8 m/s)
90 80
above
70 60 50
below
40 30 20 0.031
0.063
0.125
0.25
0.5
1
2
4
8
Frequency [kHz]
67
M 25 C Propulsion
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19.. Po 19 Powe werr tra trans nsmi miss ssio ion n
Coupling between engine and gearbox For all types of plants the engines will be equipped with flexible flange couplings. The guards for the flexible couplings should be of perforated plate or gratings to ensure an optimum heat dissipation (yard supply).
Mass moments of inertia Speed [rpm] 6 M 25 C 8 M 25 C
Engine * 2 [kgm ]
Flywheel 2 [kgm ]
135 720/750
9 M 25 C
Total 2 [kgm ] 355
220
205 215
425 435
* Running gear with balance weights and vibration damper
Selection of flexible couplings The calculation of the coupling torque for main couplings is carried out acc. to the following formula.
T KN [kNm] > ·
Po no TKN
Po [kW] -1
no [min ]
· 9.55
Engine output Engine speed Nominal torque of the coupling in the catalog
For installations with a gearbox PTO it i t is recommended to oversize the PTO coupling by the factor 1.5 in order to have sufficient safety margin in i n the event of misfiring.
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19.. Po 19 Powe werr tra trans nsmi miss ssio ion n
Fly wheel and flexible coupling
1) 2) 3) 4)
Power
Speed
Nominal torque of coupling
without torsional limit device with torsional limit device length of hub Alignment control (recess depth 5 mm)
Type Vulkan Rato-R
4)
Weight
1)
2)
[mm]
[kg]
[kg]
309
333
352
Size
d
L1
L2
[mm]
[mm]
800
594
[kW]
[rpm]
[kNm]
Rato-R
6 M 25 C
2000
750
31.5
G 262 ZR
8 M 25 C
2640
750
40.0
G 262 TR
9 M 25 C
3000
750
45.0
G 262 YR
3)
Space for OD-Box to be considered! Couplings for twin rudder propeller have to be designed with a supplementary torque of 50 %.
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19.. Po 19 Powe werr tra trans nsmi miss ssio ion n
Power take-off The PTO output 6, 8 and 9 M 25 C in equal to the engine output. The connection requires a highly flexible coupling, type Vulkan (if supplied by Caterpillar Motoren). A combination (highly flexible coupling/clutch) will not be supplied by Caterpillar Motoren. The weight force of the clutch cannot be absorbed by the engine and must be borne by the succeeding machine. The coupling hub is to be adapted to suit the PTO shaft journal. The definite coupling type is subject to confirmation by the torsional vibration calculation.
X
Y
Z
< 1000 kW
100
170
1320
< 2700 kW
157
240
1320
70
M 25 C Propulsion
m
19.. Po 19 Powe werr tra trans nsmi miss ssio ion n
Voith propeller drive, rudder-propeller-drive
All components after flex. coupling are not supplied by Caterpillar Motoren!
All components after flex. coupling are not supplied by Caterpillar Motoren!
P/n [kW/rpm]
A [mm]
B [mm]
6 M 25 C
2.7
1823
1261
8 M 25 C 9 M 25 C
3.5 4.0
1823 1823
1261 1261
B Is valid valid for Vul Vulkan kan RatoRato-coup couplings lings
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20. Dat Data a for torsion torsional al vibrat vibration ion calcul calculati ation on
Details to be submitted for the torsional vibration calculation A torsional vibration calculation is made for each installation. For this purpose exact data of all components are required. See table below: 1. Ma Main in pro propu puls lsio ion n Clutch existing ?
yes
no
Moments of Inertia:
Engaged .............
kgm²
Disengaged: .............. kgm²
Flexible Coupling:
Make ..................
Type: .......
Size
Gearbox:
Make ...................
Type: .......
Gear ratio .........
Moments of Inertia and dyn. torsional rigidity (Mass elastic system) Shaft drawings with all dimensions CPP
D = ............
mm mm
Blade No. ........
Moments of Inertia: in air ............. kgm² / in water = ............. Exciting Excit ing moment moment in in percent percent of nomina nominall moment moment = .......... ............. ... % Operation mode CPP:
const. speed
Speed range from:
................. – rp rpm
Normal speed range:
CPP =
0.6 Nominal speed
y es
no
2. PT PTO O from from gea gearb rbox ox::
kgm²
Combinator:
If yes, we need the following information: Clutch existing?
yes
no
Moments of Inertia:
Engaged: ............
kgm2
Disengaged: .............. kgm²
Flexible co coupling:
Make: ..............
type ....................
Size ..............
Gearbox:
..................
Make: ..............
type ....................
Moments of Inertia and dyn. torsional rigidity (Mass diagram) Kind of PTO driven machine: ............................ Powe Po werr charac characte teri rist stic ics, s, oper operat atio ion n speed speed rang range e
3. PT PTO O from from fre free e shaf shaftt end: end: yes
Gear ratio: .............
Rated output .. . ............. kW kW
.... .. .... .... .... .... .... .. rp rpm m no
If yes, we need the following information: Clutch existing?
yes
no
Moments of Inertia:
Engaged: ............
kgm2
Disengaged: .............. kgm²
Flexible coupling:
Make .............
type ....................
Size ..............
Make .............
type ....................
Gearbox:
..................
Gear ratio .............
Moments of Inertia and dyn. torsional rigidity (Mass diagram) Kind of PTO driven machine:
...........................
Power Pow er cha charac racter terist istics ics,, ope operat rating ing spe speed ed ran range ge
...... ... ...... ...... ....... rpm
Rated output ... ............. kW
4. Ex Expl plan anat atio ion: n: Moments of Inertia and dyn. torsional rigidity in absolut dimensions, i. e. not reduced.
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21. Con Contro troll and and monit monitori oring ng syst system em
Engine control panel
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21. Con Contro troll and and monit monitori oring ng sys system tem
Remote control for reversing gear plant
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21. Con Contro troll and and monit monitori oring ng sys system tem Remote control for reversing gear plant
75
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21. Con Contro troll and and monit monitori oring ng sys system tem Remote control for CP propeller plant
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21. Con Contro troll and and monit monitori oring ng syst system em Remote control for twin engine plant with one propeller
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21. Con Contro troll and and monit monitori oring ng syst system em Electric remote control/Fixed rudder propeller
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21. Con Contro troll and and monit monitori oring ng syst system em Electric remote control/Voi control/Voith-propeller th-propeller propulsion
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21. Con Contro troll and and monit monitori oring ng sys system tem
Speed control Main engines are equipped with a mech./hydr. mech./hydr. speed governor (milliampere speed setting). With the following equipment: - Stepper Stepper motor motor in the the top part part of the the governor governor for remote remote speed speed contr control ol - Sepa Separate rate stepper stepper motor motor control control with adjustable adjustable speed speed range range and speed speed ramp. Voltag Voltage e supply = 24 V DC The control is fitted easily accessible on the engine in the terminal board box (X3) especially provided for control components. The set speed value of nmin = 4 mA nmax = 20 mA is converted into a current required by the stepper motor. -
Speed settin Speed setting g knob knob (emerge (emergency ncy spee speed d setting setting)) Shut-down Shutdown solenoi solenoid d (24 V DC/100 DC/100 % duty cycle) cycle) for remot remote e stop (not (not for automatic automatic engine engine stop). stop). Steplessl Stepl esslyy adjustabl adjustable e droop droop on the gover governor nor from from 0 - 10 % Stan St anda dard rd se sett ttin ing: g: 0 % Device Devic e for optim optimizati ization on of the gove governor rnor char character acteristic istic Serrat Ser rated ed driv drive e shaft shaft (for (for easy easy ser servic vice) e)
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21. Con Contro troll and and monit monitori oring ng syst system em
Speed control
Twin engine plant with one CPP:
The engines are equipped with an actuator (optional with mech. back-up). Electronic governors are installed in a separate con trol cabinet. The governor comprises the following functions: -
Twin engine plant with one CPP
Speed setting Speed setting range range to be enter entered ed via param parameters eters Adjustabl Adju stable e accelera acceleration tion and and decelera deceleration tion times times Star St arti ting ng fue fuell limite limiterr Input Inp ut for stop stop (not (not emerg emergen ency cy stop) stop) 18 - 32 32 V DC DC volta voltage ge supp supply ly Ala larrm ou outp tpu ut Droop Droo p operatio operation n (primary (primary shaft gene generato rator) r) Isochron Isoc hronous ous load load distributio distribution n by master/slav master/slave e princip princip for twin engine propulsion plants via double-reduction gear
Single engine plant with CPP
Control cabinets electronic governor Woodward 723+ (standard) Regulateurs Europa Viking 35 (option) Cabinets with different dimentions
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21. Con Contro troll and and monit monitori oring ng sys system tem
Engine monitoring
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21. Con Contro troll and and monit monitori oring ng sys system tem
List of measuring point: Main engine M 25 C all classes Measur.point
Monitoring point
Abbrev.
Sensor
Action
Fitted
1104
Luboil pressure
PAL
OA
B
1105
Luboil pressure
PAL
OA
A1
1106
Luboil pressure
PALL
OA MS
B1
1111
Luboil differential pressure duplex filter
PDAH
OA
B1
1112
Luboil differential pressure selfcleaning filter
PDAH
OA
B1
TAH
OA OA AD
A1
1202 1203
Lubricating oil temperature engine inlet Lubricating oil temperature engine inlet
TAHH
Remarks
Separate Starting stand-by pump from pump control
Only if 1112 separate B1
B1
1251
Smoke concentration crankcase
QAH
OA
B1
Above 2200 kW 1 device f. 1251+1253
1253
Smoke concentration crankcase
QAH
OA MS
B1
Above 2200 kW 1 device f. 1251+1253
1301
Luboil level wet sump plan
LAL
OA
B1
Not provided with dry sump
1315
Niveau dry sump
LAH
OA
B1
Only at high tank Starting stand-by luboil suction pump
2101
FW pressure high temp. circuit engine inlet
PAL
OA
B
Starting stand-by pump from pump control
2102
FW pressure high temp. circuit engine inlet
PAL
OA
A1
2103
FW pressure high temp. circuit engine inlet
PALL
OA MS
B1
2111
FW pressure low temp. circuit cooler inlet
PAL
OA
B
2112
FW pressure low temp. circuit cooler inlet
PAL
OA
A
2211
FW temp. high temp. circuit engine outlet
TAH
OA
A1
2212
Fresh water temp. high temp. circuit engine outlet
TAHH
OA AD
B1
Starting stand-by pump from pump control
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21. Con Contro troll and and monit monitori oring ng sys system tem
List of measuring point: Main engine M 25 C all classes Measur.point
Monitoring point
Abbrev.
Sensor
Action
Fitted
Remarks
Separate
2229
Fresh water temp. low temp. circuit
2321
Oil ingress in fresh water cooler outlet
5101
Fuel oil pressure engine inlet
PAL
OA
B
5102
Fuel oil pressure engine inlet
PAL
OA
A
5105
Fuel oil pressure pressure pump
PAL
OA
5111
Fuel oil differential pressure before and after filter
PDAH
OA
5112
Fuel oil differential pressure before and after autom. filter
PDAH
OA
B*
5115
Fuel oil differential pressure circulating pump
PDAL
OA
B*
5116
Fuel oil differential pressure before and after circulating pump
PDAL
OA
B*
5201
Fuel oil temperature engine inlet
TAL
OA
A1
1 Sensor f. 5201+5202
5202
Fuel oil temperature engine inlet
TAH
OA
A
1 Sensor f. 5201+5202
5251
Fuel oil viscosity engine inlet
VAH
OA
A*
1 Sensor f. 5251, 5252 + (5253 DICARE if available)
5252
Fuel oil viscosity engine inlet
VAL
OA
A*
1 Sensor f. 5251, 5252 + (5253 DICARE if available)
Level of leak fuel
LAH
OA
Fuel level mixing tank
LAL
OA
6101
Starting air pressure engine inlet
PAL
OA
A1
6105
Shut down air pressure on engine
PAL
OA
B1
7201
Charge air temperature engine inlet
TAH
OA
A
5301 5333
* located in the fuel pressure system
TI QAH
A OA
B
Option Not provided with HFO Starting stand-by pump from pump control
B*
Starting stand-by pump from pump control
B1
B1 B*
Starting stand-by pump from pump control
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21. Con Contro troll and and monit monitori oring ng sys system tem
List of measuring point: Main engine M 25 C all classes Measur.point
Monitoring point
Abbrev.
Sensor
Action
Fitted
Remarks
Separate
7301
Water in charge air manifold
QAH
OA
B
8211
Exhaust gas temp. deviation from average each cylinder
TAH TAHH
OA AD
A
8221
Exhaust temperature after turbocharger
TAH TAHH
OA AD
A1
8231
Exhaust temperature before turbocharger
TAH TAHH
OA
A1
9401
Engine speed
S
B1
Alarm suppression
9402
Engine speed
S
B1
Start/stop luboil stand-by pump
9403
Engine speed n < 0,7 n nom
S
B1
Alarm suppression
9404
Engine overspeed
S
OA MS
B1 Start/stop of luboil gear box stand-by pump from pump control
9411
Engine speed
S
B
9419
Engine speed
NI
A1
9531
Load/>=Engine limit curve speed governor
GI
B1
Overload indication (CP-propeller)
9532
Load/>=Engine limit curve speed governor
GI
A1
Load control (CP-propeller)
9561
Barring gear engaged
S
B1
Start interlock
9601
Electronic units/terminal point X1/voltage failure
S
OA
9611
RPM switch/voltage failure/ wire break
S
OA
B1
9615
Failure electronic governor
S
OA
B
only with electronic governor
9616
Failure electronic governor
S
OA MS
B
only with electronic governor
9622
Exhaust gas temp. average equipment, voltage failure
S
OA
9631
Crankcase oil mist detector voltage, lens/lamp
QA
OA
9671
Safety system failure
OA
9717
Electrical start/stopfailure equipment/voltage
OA
B1
B1 B
If provided B1
B1
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M 25 C Propulsion
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21. Con Contro troll and and monit monitori oring ng syst system em
List of measuring point: Main engine M 25 C all classes Measur.point
Monitoring point
Abbrev.
Sensor
Action
Fitted
Remarks
Separate
9751
Temperature controller voltage failure
OA
B1
Dependent from system
9761
Viscosity control, voltage failure
OA
B
Dependent from system
9771
Freshwater preheater, voltage failure
OA
B1
Dependent from system
9775
Fuel oil preheater, voltage failure
OA
B1
Dependent from system
Option: Modbus connection to alarm system
Abbreviations 1 B A GI LAH LAL NI
= = = = = = =
Min. requirements for inland vessel MDO Binary sensor Analogue sensor Position indication Level alarm high Level alarm low Speed indication
OA AD MS QA QAH S TAH
= = = = = = =
Visual and audible alarm Autom. speed/load reduction Autom. engine stop Measurement alarm Measurement alarm high Speed Temperature alarm high
P PAL PALL PDAH PDAL PI
= = = = = =
Pressure Pressure alarm low Pressure alarm low low Pressure difference alarm high Pressure difference alarm low Pressure in indication
TAHH TAL TI VAH VAL
= = = = =
Temperature alarm high high Temperature alarm low Temperature indication Viscosity alarm high Viscosity alarm low
Sensors for DICARE see chapter 22
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21. Con Contro troll and and monit monitori oring ng sys system tem Local and remote indicators Remote indication interfacing r o t d a e c e i n d p o n s i t i e e n t i p o g o m n e e R
h c t i t w i V A m
V 0 1 - 0
r e g r d n a o h e i t c e p o p s o b r u T
V A m V m
V 0 1 - 0
Ω
r o t a c i d n o n i i t e t p o o m e R
e p A y t m l a 0 n 2 g 4 i S
) A m (
s u n M P R e h t m o r f s e l n a i n g g i n S e r o s n e S
g n i r * o t t i n n e o p m m - i g u o q l a e n A
y a l p s i D r o t i n * o M
e t 6 o 9 ⊗ ⊗ m x ⊗ 6 e R 9
s r o t a c e i n d i n g I n e e h t t A
E " R F e A F i n C I O " L
⊗
⊗ ⊗
y l p p u s n e r o t o M r a l l i p r e t a C t o n *
) 1 ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗
) 2
⊗
) 2
⊗
n o i t p O ⊗
E N I L N O E R A C I D h t i w
r r e r e g r ) T r g r e e r T H l r g e e a g t e a H t o r l h r e h r a e o l t l r r o c a a e t c o c h a e o e o h l o u o r p r c d b c n n o e c b c e i o i r i e n r o s g l r n t r t b e u l e e b o t r t e ( o u n i t r r n t e r i n i n i t o n y u t l t i e i e c t u n o c i e e t r e e r s i n e g g ) r r r l l r r n e e t n n o r o r o r o e e o r l e e f n e i i l t t t n f e e e f e n t p e o o f o f e f t t f a b a n l n o t e f e f c f T i e i i i i t g f k i e e t a a b a b a L r n g r o n i l b b c e e e a e n b e e e e e e e r r r e t e e T T r g e a t r r r r r r r e e u r u u u f u n e m n f L H r r l n i u t t u u t u u u u t a p o r t o e e p a e t t t t t t e u u a a a e e t t d a o o e a a a a a a s t r m r r r r r e r r r r r r r r a r d a r t e r e e e a u u e u u r d r r u u n e e e e e e e r o e e u s s e s t s e e e p p p t u e p u s s p r t s s r s p t s p p p p p p s e i a d n p m m c o s s p m f e m m m m m m e u n a ( c 4 n i r e r u r e t e s e r i r e r m e r m m r e t e t e e e t i e e e e o e e g d r u 4 t r t t t t t t p p s a e d d e e p t e p p r l p e g t s s s n u 1 t t n r r r r r r l t r r r r r e u s c p l s r a a i a e e i a e r r r r a o e e e e e e e e e a a a x s i i i i i e t t t t t t t e t t p g g g p p t j m t a a o s r h 4 n d t a a b e a a a a a a s a a a t t t t e r h n e e p n e m n i t n i e 4 u e s s s a , d w w w w w w e e c w e r w w a e l e 1 r c i e 4 u u u i g g g t e r n l r h p r o i h h h h n b r a a a a v y 4 n h h h r r i l e a o e s h s s s s s e r s g l o s s t l e p e e u a e e u e f i f i b u e t e r 1 x h x h x h a r u r e r e r h x e r e r n g h a t a e r u e r b u r e f i h a r e v a F D M L D F F F F F F D C F G F L F F S C E T C E E E S S i t 8 6 a 8 9 n r 2 y x e t l • • • • • • • • l • • • • • • • • • • • • n 2 8 A 1 O ) )
D
1
2
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21. Con Contro troll and and monit monitori oring ng sys system tem
Protection system
Version = unattended engine room seagoing vessel Operat Oper atin ing g vol volta tage ge:: 24 V DC DC Type of protect protection: ion: IP 55 for wallwall-moun mounting ting type hous housing ing IP 20 for 19" subrack type Protection against false polarity and transient protection provided. Designed for:
6 starting interlock inputs 6 automatic stop inputs 4 automatic reduction inputs 4 manual stop inputs
The input and output devices are monitored for wire break.
88
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21. Con Contro troll and and monit monitori oring ng sys system tem Protection system
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21. Con Contro troll and and monit monitori oring ng sys system tem
Rpm switch system
Operating voltage: 24 V DC Type of protection: IP 55 for wall-mounting type housing IP 20 for 19" subrack type Designed for: 8 rpm switching points Analogue outputs for speed: 2 x 0-10 V, 2 x 4-20 mA, 2 x frequency Analogue outputs for fuel rack position: 0 - 10 V, 2 x 4-20 mA plus 2 binary outputs
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21. Con Contro troll and and monit monitori oring ng sys system tem Rpm switch system
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M 25 C Propulsion
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22. Dia Diagno gnosti stic c sys system tem DI DICAR CARE E
DICARE is an efficient expert system which collects permanently the actual operating data of the t he engine, scales them to ISO condition, compares them with the nominal values and evaluates all detected deviations from these nominal values. Out of this comparison a printable diagnosis results which ease condition based maintenace considerably. considerably. The sensor equipment of the engine engine laid out for the "on-line operation" with analogue transmitters via a data converter feeds the PC with measured data on-line for evaluation and storing. Due to the automatically established history files trends can be made visible.
Benefits of DICARE: • • • • • •
Earlyy det Earl detec ectio tion n of of wea wearr. Optimum Optim um operating operating conditi condition on due to clearly clearly laid out out display display of deviating deviating engines engines parame parameters. ters. Reduction Redu ction of mainten maintenance ance cost due to to recogn recognition ition of trends trends.. Longer Long er service service life of compone components nts due to display display of compar comparison ison of actual actual vs. desired desired values values.. Informatio Infor mation n about about the engine engine condition condition by by means means of remote remote access access possibili possibilities. ties. Allows personnel personnel and material material planning planning by early, condition-bas condition-based ed recognition recognition of contamination or wear.
Option: Installed in junction box
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22. Dia Diagno gnosti stic c sys system tem DI DICAR CARE E
Transmitter for DICARE ON-LINE M 25 C Designation
Transmitter
Fuel viscosity
Signal
Meas. point no. CM
Location
4 - 20 mA
5253
L
Fuel temperature after viscomat
PT 100
5206
L
Fuel temperature at engine inlet
PT 100
5201
M
Injection pump rack position
4 - 20 mA
9509
DS
Lube oil pressure
4 - 20 mA
1105
M
1202
M
2102
M
Lube oil temperature at engine inlet
PT 100
Freshwater pressure HT
4 - 20 mA
Freshwater temperature at engine inlet HT
PT 100
2201
M
Freshwater temperature at engine outlet HT
PT 100
2211
M
Differential pressure charge air cooler
4 - 20 mA
7307
M
Intake air pressure
4 - 20 mA
6181
M
7206
M
4 - 20 mA
7109
M
mV
7309
M
7201
M
Intake air temperature before turbocharger
PT 100
Charge air pressure after intercooler Charge air temperature before intercooler
NiCrNi
Charge air temperature at engine inlet
PT 100
Exhaust gas temperature for each cylinder and after turbocharger
NiCrNi
mV
8211/8221
M
Exhaust gas temperature before turbocharger
NiCrNi
mV
8231
M
Engine speed
4 - 20 mA
9419
DS
Turbocharger speed
4 - 20 mA
9429
M
binary
9409
DS
Service hour counter (manual input)
Counter
= Tra Transm nsmitt itter er from from engin engine e monito monitorin ring g Location L = Separate M = Engine
DS = RPM sw switch sy system
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23. Dies Diesel el engin engine e managem management ent syst system em DIMO DIMOS S
DIMOS is a computer aided maintenance and spare part management system for Caterpillar Motoren diesel engines. The DIMOS-system will include a data base which is filled with information derived from the operating instructions and the spares catalogue of your respective engine type. This system enables to administration and check the following four f our major subjects: 1. Maintenance 2. Material management 3. Statistics 4. Budget control. These four major subjects are provided with many internal connections, so that no double inputs are required. All you need for running the DIMOS-system is commercial PC hardware. The advantages are evident: • Prec Precise ise follow-up follow-up regardin regarding g the maintenance maintenance interval intervalss as specified specified by Caterpillar Caterpillar Motoren. Motoren. No scheduled date will be forgotten and no history file will be missed. • Immed Immediate iate acces accesss to mainten maintenance ance and compo component nent infor informatio mation. n. • Quick and simple simple modif modificatio ication n of data data is possi possible ble at any time. time. • Exten Extensive sive and permane permanently ntly up-to-dat up-to-date e decision decision documents documents for maintenanc maintenance e with precise updating updating of terms. • A lot of paper paper work work can be omitted, omitted, and and this mean meanss a consider considerable able savin saving g of time. time. • This can can be taken taken from the the DIMOS databa databank nk as well well as from the the CD-Rom CD-Rom and the standa standard rd docudocumentation.
From various single information to an integrated system Engine operatin ope ratingg
Engine spare parts
Maintenance
Maintenance
instructions
catalogues
schedule
job cards
I
N
P
U
T
DIMOS
O
Maintenance planning
U Work orderT creation
PHistory and U statistics
T
Inventory and purchase
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24. Sta Standa ndard rd acce accepta ptance nce tes testt run run
The acceptance test run is carried out on the testbed with customary equipment equipment and auxiliaries using exclusively MDO and under the respective ambient conditions of the testbed. During this test t est run the fuel rack will be blocked at the contractual output value. In case of deviations from the contractual ambient conditions the fuel consumption will be converted to standard reference conditions. The engine will be run at the following load stages acc. to the rules of the classification societies. After reaching steady state condition of pressures and temperatures these will be recorded and registered acc. to the form sheet of the acceptance test certificate:
Load [%]
Duration [min]
50
30
85
30
100
60
110
30
In addition to that the following functional tests will be carried out: - governor test - overspeed test - emergency shut-down via minimum oil pressure - start/stop via central engine control - starting trials up to a minimum air pressure of 10 bar - measurement of crank web deflection (cold/warm condition) After the acceptance main running gear, camshaft drive and timing gear train will be inspected through the opened covers. Individual inspection of special engine components such as piston or bearings is not intended, because such inspections are carried out by the classification societies at intervals on series engines.
Engine movement due to vibration referred to the global vibration characteristics of the engine: The basis for assessing vibration severity severity are the guidelines ISO 10816-6. According to these guidline the MaK engine will be assigned to vibration severity grade 28, class 5. On the engine block the the following values will not not be exceeded: Displacement Vibration velocity
Seff Veff
< 0,448 mm < 28, 8,22 mm/ m/ss
f > 2 Hz < 10 Hz f > 10 Hz < 250 Hz
Vibration acceleration
aeff
< 44,2 m/s2
f > 250 Hz < 1000 Hz 95
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25.. En 25 Engi gine ne In Inte tern rnat atio iona nall Ai Airr Po Poll llut utio ion n Pr Prev even enti tion on Certi Certifi fica cate te
The MARPOL Diplomatic Conference has agreed about a limitation of NO emissions, referred to as x Annex VI to Marpol 73/78. When testing the engine for NOx emissions, the reference fuel is Marine Diesel Oil (Distillate) and the test is performed according according to ISO 8178 test cycles:
E2: Diesel-electric propulsion, controllable pitch propeller Speed [%]
100
100
100
100
Power [%]
100
75
50
25
Weighting factor
0.2
0.5
0.15
0.15
Subsequently, the NOx value has to be calculated using different weighting factors for different loads that have been corrected corrected to ISO 8178 conditions. An EIAPP (Engine International Air Pollution Prevention) certificate will be issued for each engine showing that the engine complies with the regulation. At the time of writing, only an interim certificate can be issued due to the regulation not yet in force. According to the IMO regulations, a Technical File shall be made for each engine. This Technical File contains information about the components affecting NO x emissions, and each critical component is marked with a special IMO number. Such critical components are injection nozzle, injection pump, camshaft, cylinder head, piston, connecting rod, charge air cooler and turbocharger. The allowable setting values and parameters for running the engine are also specified in the Technical File. The marked components can later, on-board the ship, be easily identified by the surveyor and thus an IAPP (International Air Pollution Prevention) certificate for the ship can be issued on basis of the EIAPP and the on-board inspection.
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26.. Pai 26 Painti nting/ ng/Pre Preser servat vation ion
Inside preservation N 576-3.3 Up to 1 year, engine protected from moisture. - Mai Main n runn running ing gea gearr and and int intern ernal al mec mechan hanics ics
Outside preservation N 576-3.1 - Tectyl light Europe Storage in the open, protected from moisture, up to 1 year
Appearance ofith the - Ca Cast stin ings gs wit w h red reengine: d oxid oxide e antir antirus ustt pain paintt - Pip Pipes es and and mach machine ined d surf surface acess left left as as bare bare met metal al - Att Attach ached ed comp compone onents nts wit with h colou colours rs of the the mak maker erss
N 576-3.2 - Tectyl heavy-duty Overseas Storage in the open, protected from moisture, up to 1 year Appearance of the engine: - Ca Cast stin ings gs wit with h red red oxid oxide e antir antirus ustt pain paintt - Pip Pipes es and and mach machine ined d surf surface acess left left as as bare bare met metal al - Att Attach ached ed comp compone onents nts wit with h colou colours rs of the the mak maker erss
N 576-4.1 - Clear Varnish Clear varnish painting is applicable within Europe for land transportation with protection from moisture. It is furthermore f urthermore applicable for storage in a dry and tempered atmosphere. Clear varnish painting is not permissible for: - Sea transportation of engines - Storage of engines in the open, even if they are covered with tarpaulin VCI packaging as per N 576-5.2 is always required! Durability and effectiveness are dependent on proper packing, transportation, and storage, i.e. the engine must be protected from moisture, the VCI foil must not be torn or destroyed. Checks are to be carried out at regular intervals. If the above requirements are not met, all warranty claims in connection with corrosion damages shall be excluded.
M 25 C Propulsion
97
m
26. Pai Painti nting/ ng/Pre Preser servat vation ion
Appearance of the engine: - Ca Cast stin ings gs wit with h red red oxid oxide e antir antirus ustt pain paintt - Pip Pipes es and and mach machine ined d surf surface acess left left as as bare bare met metal al - Att Attach ached ed comp compone onents nts wit with h colou colours rs of the the mak maker erss - Su Surf rfac aces es sea seale led d with with cle clear ar va varn rnis ish h - Bar Bare e meta metall surf surface acess with with lig light ht pre preser servat vation ion
N 576-4.3 - Painting - No VCI packaging: Short-term storage in the open, protected from moisture, max. 4 weeks - Wi With th VC VCII pack ckag agin ing g: Storage in the open, protected from moisture, up to 1 year Appearance of the engine: - Su Surf rfac aces es mos mostly tly pa pain inte ted d with with var varni nish sh - Bare metal surfa surfaces ces prov provided ided with light or heavy heavy-duty -duty pres preserva ervation tion
N 576-5.2 - VCI packaging Storage in the open, protected from moisture, up to 1 year. Applies for engines with painting as per application groups N 576-4.1 to -4.4 Does not apply for engines with Tectyl Tectyl outside preservation as per application groups N 576-3.1 and 3.2. Description: - Engi Engine ne complete completely ly wrapped wrapped in VCI air air cushion cushion foil, foil, with inser inserted ted VCI-imp VCI-impregn regnated ated flexib flexible le PU-foam mats.
N 576-5.2 Suppl. 1 - Information panel for VCI preservation and inspection Applies for all engines with VCI packaging as per application group N 576-5.2 Description: - This panel panel provides provides informa information tion on the kind kind of initial initial preserva preservation tion and and instruction instructionss for inspectio inspection. n. - Arra Arranged nged on the the transpo transport rt frame frame on each side so as to be easi easily ly visible. visible.
N 576-6.1 - Corrosion Protection Period, Check, and Represervation Applies to all engines with inside and outside storage Description: - Defin Definition itionss of corr corrosion osion prote protection ction peri period, od, check check,, and repr represer eservatio vation n
98
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27. Li Lift ftin ing g of en engi gine ness For the purpose of transport the engine is equipped with a lifting device which shall remain the property of Caterpillar Motoren. It has to be returned in a useable condition free of charge.
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28.. En 28 Engi gine ne pa part rtss
Cylinder head, Weight 240 kg
Cylinder liner, Weight 162 kg
Connecting rod, Weight 79 kg
Piston, Weight 46 kg
100
M 25 C Propulsion
Caterpillar Marine Power Systems Headquarters
Europe, Africa Africa,, Middle East
Americas
Asia Pacific
Caterpillar Marine Power Systems Neumühlen 9 22763 Hamburg/Germany
Caterpillar Marine Power Systems Neumühlen 9 22763 Hamburg/Germany
MaK Americas Inc.
Phone: +49 40 2380-3000 Telefax: +49 40 2380-3535
Phone: +49 40 2380-3000 Telefax: +49 40 2380-3535 2380-3535
Caterpillar Marine Trading (Shanghai) Co., Ltd. 25/F, Caterpillar Marine Center 1319, Yan’an West Road 200050 Shangha Shanghai/P i/P.. R.China Phone: +86 21 6226 2200 Telefax: Te lefax: +86 21 6226 6226 4500
For more information please visit our website: www.cat-marine.com or www.mak-global.com
3450 Executive Way Mirama Mir amarr Par Parkk of Com Commer merce ce Miramar, FL. 33025/USA Phone: +1 954 447 71 00 Telefax: +1 954 447 71 15 15
Subject to change without notice. Leafle Lea flett No. 229 229 · 07. 07.08 08 · e · L+S · VM3
Caterpillar Marine Asia Pacific Pte Ltd 14 Tractor Road Singapore 627973/ Singapore Phone: +65 68287-600 Telefax: +65 68287-62 68287-6244
© 2008 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, „Caterpillar Yellow“ Yellow“ and the POWER EDGE trade dress , as well as co rpora te id entit y used herein, are trademarks of Caterpillar and may not be used without permission
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