Man B&W L35MC6-TII - Starting and Control Air

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MAN B&W

MAN Diesel

Starting and Control Air

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Table of Contents3
Calculation of Capacities11
Engine Layout and Load Diagrams12
List of Capacities and Cooling Water Systems14
Propeller Diameter and Pitch, Influence on Optimum Propeller Speed15
The MC/MC-C Tier II Engine16
Engine Design19
The MC/MC-C Tier II Engine Design21
Concept of the MC/MC-C Engine21
Engine Design and IMO Regulation Compliance21
Engine Type Designation23
Power, Speed and Lubricating Oil24
Engine Power Range and Fuel Oil Consumption25
Lubricating Oil Data25
Specific Fuel Oil Consumption25
Layout Diagram for Engine Power and Speed25
Performance Curves26
MC Engine Description27
Bedplate and Main Bearing27
Frame Box27
Cylinder Frame and Stuffing Box27
Cylinder Liner/Cover28
Crankshaft28
Thrust Bearing28
Turning Gear and Turning Wheel28
Connecting Rod29
Piston29
Crosshead29
Scavenge Air System/Cooler29
Auxiliary Blower30
Exhaust Gas System/Turbocharger30
Camshaft and Cams30
Chain/Indicator Drive30
Governor31
Fuel Oil Pump and Fuel Oil High Pressure Pipes31
Fuel Valves and Starting Air Valve31
Starting Air System31
Exhaust Valve32
Cylinder Lubrication32
Manoeuvring System32
Reversing32
Piping Arrangements33
Engine Cross Section of L35MC634
Engine Layout and Load Diagrams, SFOC35
Engine Layout and Load Diagrams37
Introduction37
Propulsion and Engine Running Points37
Propeller Curve37
Fouled Hull38
Engine Layout38
Engine Margin38
Constant Ship Speed Lines38
Propeller Diameter and Pitch, Influence on the Optimum Propeller Speed39
Influence of Diameter and Pitch on Propeller Design39
Layout Diagram and Constant Ship Speed Lines40
Layout Diagram Sizes41
Engine Layout Diagram42
Specified Maximum Continuous Rating42
Continuous Service Rating42
Optimising Point42
Engine Load Diagram43
Definitions43
Operating Curves and Limits for Continuous Operation43
Standard Engine Load Diagram43
Limits for Overload Operation44
Limits for Low Load Operation44
Recommendation44
Load Diagram for Ships Operating in Extreme Heavy Running Conditions45
Examples of the Use of the Load Diagram46
Load Diagram for Speed Derated Engine with Increased Light Running46
Normal Running Conditions47
Layout Diagram47
Load Diagram47
Special Running Conditions48
Engine Coupled to a CPP with or Without a Shaft Generator51
Diagram for Actual Project53
Construction of Layout Diagram53
Specific Fuel Oil Consumption, ME Versus MC Engines54
SFOC for Conventional Turbochargers55
Example of Part Load SFOC Curves for Conventional Turbochargers55
SFOC Reference Conditions and Guarantee56
Recommended Cooling Water Temperature During Normal Operation56
Examples of Graphic Calculation of SFOC57
SFOC Calculations for L35MC658
SFOC for L35MC6 with Fixed Pitch Propeller59
SFOC for L35MC6 with Constant Speed59
SFOC Calculations, Example60
SFOC for Derated 6L35MC661
Fuel Consumption at an Arbitrary Load62
SFOC at an Arbitrary Load62
Emission Control63
Turbocharger Selection & Exhaust Gas By-Pass65
Turbocharger Selection67
Conventional Turbochargers67
Exhaust Gas By-Pass68
Extreme Ambient Conditions68
Arctic Running Condition68
Emergency Running Condition68
Total By-Pass of Exhaust for Emergency Running69
Nox Reduction by SCR70
Exhaust Gas Emission Control Today and Tomorrow70
Layout of SCR System71
Electricity Production73
Electricity Production75
Power Take off75
Types of PTO76
Designation of PTO77
Pto/Rcf78
Free Standing Generator, BW II/RCF78
PTO with RENK Constant Frequency Gear78
Extent of Delivery for BW II/RCF Units79
Engine Preparations for PTO BW II81
PTO Type: BW II/GCR82
PTO Type: BW IV/GCR82
Generic Outline of Power Take off (PTO) BW II/GCR82
Tunnel Gear with Hollow Flexible Coupling83
Generator Step-Up Gear83
Flexible Coupling Integrated in the Shaft Line83
Generic Outline of BW IV/GCR, Tunnel Gear83
Auxiliary Propulsion System/Take Home System84
Waste Heat Recovery Systems (WHR)85
L16/24 Genset Data86
List of Capacities for L16/24 1,000 Rpm, IMO Tier I87
List of Capacities for L16/24 1,200 Rpm, IMO Tier I88
L21/31 Genset Data89
Power and Outline of L21/3189
List of Capacities for L21/31, 1,000 Rpm, IMO Tier I91
L23/30H Genset Data92
Power and Outline of L23/30H92
List of Capacities for L23/30H, 720/750 Rpm, IMO Tier I93
List of Capacities for L23/30H, 900 Rpm, IMO Tier I94
Installation Aspects95
Installation Aspects97
Space Requirements and Overhaul Heights97
Overhaul of Engine97
Space Requirement98
Space Requirement for the Engine, Turbocharger on Aft End98
Space Requirement for the Engine99
Crane Beam for Overhaul of Turbocharger100
Required Height and Distance and Weight100
Crane Beam for Turbochargers101
Crane Beam for Overhaul of Air Cooler102
Engine Room Crane102
Engine Room Crane103
Overhaul with man B&W Double-Jib Crane104
MAN B&W Double-Jib Crane105
Gallery Outline106
Engine Outline, Galleries and Pipe Connections106
Engine and Gallery Outline107
Centre of Gravity111
Mass of Water and Oil112
Water and Oil in Engine112
Engine Pipe Connections113
Counterflanges114
Counterflanges116
Counterflanges, Connection D118
MAN Diesel Type TCA/TCR118
ABB Type TPL/A100119
MHI Type MET120
Counterflanges, Connection E121
MAN Diesel Type TCA121
ABB Type TPL122
Venting of Lubbricating Oil Discharge Pipe for Turbochargers123
Engine Seating and Holding down Bolts124
Epoxy Chocks Arrangement125
Arrangement of Epoxy Chocks and Holding down Bolts126
Engine Seating Profile127
Profile of Engine Seating with Vertical Oil Outlet127
Profile of Engine Seating with Horizontal Oil Outlet128
Profile of Engine Seating, End Chocks129
Engine Top Bracings130
Mechanical Top Bracing131
Hydraulic Top Bracing Arrangement133
Components for Engine Control System134
Shaftline Earthing Device135
Scope and Field of Application135
Design Description135
Shaftline Earthing Device Installations136
Connection of Cables for the Shaftline Earthing Device136
Installation of Shaftline Earthing Device in an Engine Plant136
MAN Diesel’s Alpha Controllable Pitch Propeller138
VBS Type CP Propeller Designation and Range138
Data Sheet for Propeller139
Dimension Sketch for Propeller Design Purposes139
Main Dimensions140
Propeller Clearance140
Propeller Design Purposes140
Servo Oil System for VBS Type CP Propeller141
Hydraulic Power Unit for Alpha CP Propeller142
Alphatronic 2000 Propulsion Control System143
Propulsion Control Station on the Main Bridge144
Main Bridge Station Standard Layout144
Renk KAZ Clutch for Auxilliary Propulsion Systems145
Further Information about Alpha CP Propeller145
List of Capacities: Pumps, Coolers & Exhaust Gas147
Calculation of List of Capacities and Exhaust Gas Data149
Nomenclature149
Engine Configurations Related to SFOC149
List of Capacities and Cooling Water Systems150
Heat Radiation and Air Consumption150
Flanges on Engine, Etc150
Diagram for Seawater Cooling System150
List of Capacities for 5L35MC6-TII at NMCR - IMO no151
Fuel151
List of Capacities for 6L35MC6-TII at NMCR - IMO no152
List of Capacities for 7L35MC6-TII at NMCR - IMO no153
List of Capacities for 8L35MC6-TII at NMCR - IMO no154
List of Capacities for 9L35MC6-TII at NMCR - IMO no155
List of Capacities for 10L35MC6-TII at NMCR - IMO no156
List of Capacities for 11L35MC6-TII at NMCR - IMO no157
List of Capacities for 12L35MC6-TII at NMCR - IMO no158
Auxiliary Machinery Capacities159
Cooler Heat Dissipations159
Scavenge Air Cooler159
Jacket Water Cooler159
Pump Capacities160
Seawater Cooling System160
Central Cooling Water System160
Pump Pressures160
Calculation of List of Capacities for Derated Engine161
Freshwater Generator163
Calculation Method163
Jacket Cooling Water Temperature Control164
Jacket Cooling Water Heat Recovery Flow Diagram164
Calculation of Freshwater Production for Derated Engine165
Exhaust Gas Amount and Temperature166
Influencing Factors166
Summarising Equations for Exhaust Gas Amounts and Temperatures166
Correction of Exhaust Gas Data for Ambient Conditions167
Exhaust Gas Correction Formula for Ambient Conditions168
Change of Specific Exhaust Gas Amount168
Change of Exhaust Gas Temperature168
Calculation of Exhaust Data for Derated Engine169
Fuel171
Pressurised Fuel Oil System173
Design Parameters173
Fuel Pumps and Drain173
Fuel Oil System174
Fuel Considerations175
Constant Operation on Heavy Fuel175
Heating of Fuel Drain Pipe175
Fuel Flow Velocity and Viscosity175
Fuel Oil System175
Fuel Oils176
Heavy Fuel Oil (HFO)176
Guiding Heavy Fuel Oil Specification176
Fuel Oil Pipes and Drain Pipes177
Fuel Oil Pipe Insulation178
Flanges and Valves178
Mounting178
Heat Loss in Piping179
Fuel Oil Pipe Heat Tracing180
Fuel Oil and Lubricating Oil Pipe Spray Shields180
Spray Shields by Anti-Splashing Tape180
Spray Shields by Clamping Bands180
Components for Fuel Oil System181
Fuel Oil Centrifuges181
Fuel Oil Supply Pump181
Fuel Oil Circulating Pump181
Fuel Oil Heater182
Fuel Oil Heating Chart182
Fuel Oil Filter183
Fuel Oil Venting Box183
Flushing of the Fuel Oil System183
Water in Fuel Emulsification184
Temperature and Pressure184
Safety System184
Impact on the Auxiliary Systems184
System for Emulsification of Water into the Fuel185
Lubricating Oil187
Lubricating and Cooling Oil System189
Lubrication of Turbochargers189
Lubricating and Cooling Oil Pipes190
Lubricating Oil Pipes for Turbochargers192
MAN Diesel Turbocharger Type TCA192
ABB Turbocharger Type TPL192
Mitsubishi Turbocharger Type MET193
Lubricating Oil Centrifuges and List of Lubricating Oils194
Components for Lubricating Oil System195
Lubricating Oil Pump195
Lubricating Oil Cooler195
Lubricating Oil Temperature Control Valve195
Lubricating Oil Full Flow Filter196
Flushing of Lube Oil System196
Lubricating Oil Outlet197
Lubricating Oil Tank198
Lubricating Oil Tank Operating Conditions199
Crankcase Venting and Bedplate Drain Pipes202
Cylinder Lubrication203
Cylinder Lubricating Oil System205
Cylinder Lubricators and Service Tank205
Cylinder Oils205
Cylinder Oil Feed Rate205
MAN B&W Alpha Cylinder Lubrication System206
System Control Units206
Alpha Adaptive Cylinder Oil Control207
Working Principle207
Basic and Minimum Setting with Alpha ACC207
Cylinder Lubricating Oil Dosage with Alpha ACC at All Loads207
Pump Station and man B&W Alpha Cylinder Lubricators on Engine208
Cylinder Lubricating Oil Supply System for Two Different BN Oils208
MAN B&W Alpha Cylinder Lubricators with Piping and Instrumentation208
Lubricator Control System209
Control of the man B&W Alpha Cylinder Lubrication System209
Wiring Diagram for man B&W Alpha Cylinder Lubrication System210
Mechanical Cylinder Lubricators211
Piping and Instrumentation for a Mechanical Cylinder Lubricator211
Load Change Dependent Mechanical Lubricator211
Cylinder Lubricating Oil Supply System212
Piston Rod Stuffing Box Drain Oil213
Stuffing Box Drain Oil System216
Central Cooling Water System217
Components for Central Cooling Water System221
Seawater Cooling Pumps221
Central Cooler221
Central Cooling Water Pumps221
Jacket Water System222
Jacket Water Cooling Pump222
Seawater Cooling223
Seawater Systems225
Seawater Cooling Pipes227
Components for Seawater Cooling System228
Seawater Cooling Pump228
Seawater Thermostatic Valve228
Jacket Cooling Water System229
Jacket Cooling Water Pipes230
Components for Jacket Cooling Water System231
Jacket Water Thermostatic Valve231
Jacket Water Preheater231
Deaerating Tank231
Temperature at Start of Engine233
Preheating of Diesel Engine233
Normal Start of Engine233
Start of Cold Engine233
Starting and Control Air235
Starting and Control Air Systems237
Components for Starting Air System238
Starting Air Compressors/Receivers238
Reduction Station for Control and Safety Air238
Turning Gear238
Starting and Control Air Pipes239
Exhaust Valve Air Spring Pipes240
Electric Motor for Turning Gear241
Scavenge Air243
Scavenge Air System245
Exhaust Gas245
Auxiliary Blowers246
Emergency Running246
Scavenge Air Cooler Requirements246
Influence of Ambient Temperature Conditions246
Control of the Auxiliary Blowers247
Diagram of Auxiliary Blower Control System247
Operation Panel for the Auxiliary Blowers248
Control Panel248
Scavenge Air Pipes249
Electric Motor for Auxiliary Blower250
Scavenge Air Cooler Cleaning System251
Drain from Water Mist Catcher251
Auto Pump Overboard System251
Air Cooler Cleaning Pipes251
Air Cooler Cleaning Unit252
Scavenge Air Box Drain System253
Fire Extinguishing System for Scavenge Air Space254
Fire Extinguishing Pipes in Scavenge Air Space255
Exhaust Gas257
Exhaust Gas System259
Exhaust Gas Pipes260
Cleaning Systems261
Exhaust Gas System for Main Engine262
Components of the Exhaust Gas System263
Exhaust Gas Compensator after Turbocharger263
Exhaust Gas Boiler263
Exhaust Gas Silencer264
Spark Arrester264
Calculation of Exhaust Gas Back-Pressure265
Exhaust Gas Data265
Exhaust Gas Velocity265
Pressure Losses Across Components265
Measuring Back Pressure266
Pressure Losses and Coefficients of Resistance in Exhaust Pipes267
Forces and Moments at Turbocharger268
Turbocharger Located on Aft End268
Vectors of Thermal Expansion268
Max. Expected Movements of the Exhaust Gas Flange268
Two Turbochargers Located on Exhaust Side269
Forces and Moments on the Turbochargers’ Exhaust Gas Outlet Flange270
The Max. Permissible Forces270
Diameter of Exhaust Gas Pipes271
Exhaust Pipe Systems271
Exhaust Gas Pipe Diameters and Exhaust Gas Mass Flow271
Engine Control System273
Engine Control System275
Manoeuvring Consoles275
Engine Control System Layout275
Diagram of Manoeuvring System276
Manoeuvring System on Engine277
Shut down System277
Slow Turning277
Control System for Plants with CPP277
Sequence Diagram278
Governor Parts and Mode of Operation280
Governor for ‘Conventional’ Plants280
Governor for ‘Advanced’ Plants280
Governor and Remote Control Components281
Electronic Governor281
Components for Remote Control of Reversible Engine with FPP281
Engine Side Control Console with Diagram282
Diagram of Engine Side Control Console282
Engine Side Control Console and Instrument Panel283
Engine Control Room Console284
Sequence Diagram for Engines with Fixed Pitch Propeller285
Engine Control System Interface to Surrounding Systems287
Alarm System287
Telegraph System287
Remote Control System287
Power Management System288
Auxiliary Equipment System288
Engine Monitoring288
Instrumentation288
Vibration Aspects289
Vibration Aspects291
External Unbalanced Moments291
2Nd Order Moments on 4, 5 and 6-Cylinder Engines292
Compensator Solutions292
Statistics of Vertical Hull Vibrations in Tankers and Bulk Carriers292
Preparation for Compensators293
Basic Design Regarding Compensators293
1St Order Moments on 4-Cylinder Engines294
Balancing 1St Order Moments294
1St Order Moment Compensators294
Electrically Driven Moment Compensator295
MAN Diesel 2Nd Order Electrically Driven Moment Compensator295
Compensation of 2Nd Order Vertical External Moments296
Power Related Unbalance297
Calculation of External Moments297
Guide Force Moments298
Top Bracing298
Definition of Guide Force Moments298
H-Type Guide Force Moment298
Vibration Limits Valid for Single Order Harmonics299
Axial Vibrations301
Torsional Vibrations301
Undercritical Running301
Critical Running302
Overcritical Running302
External Forces and Moments, L35MC6 Layout Point L303
Monitoring Systems and Instrumentation305
Monitoring Systems and Instrumentation307
PMI System308
Measurements308
PMI Type PT/S Off-Line308
PMI System, Off-Line and On-Line Versions309
Cocos-EDS Features310
Connectivity310
Cocos-EDS Sensor List311
Alarm – Slow down and Shut down System312
Basic Safety System Design and Supply312
Alarm and Slow down System Design and Supply312
Alarm, Slow down and Remote Indication Sensors312
General Outline of the Electrical System313
Panels and Sensors for Alarm and Safety Systems313
Alarms for UMS – Class and man Diesel Requirements314
Slow down for UMS – Class and man Diesel Requirements317
Shut down for AMS and UMS – Class and man Diesel Requirements318
Local Instruments319
Other Alarm Functions322
Drain Box for Fuel Oil Leakage Alarm322
Bearing Condition Monitoring322
Oil Mist Detector322
Oil Mist Detector Pipes323
Bearing Wear Monitoring System324
Bearing Temperature Monitoring System324
In the Extent of Delivery, There Are Three Options:324
Water in Oil Monitoring System325
Liner Wall Monitoring System325
Control Devices326
Identification of Instruments327
Dispatch Pattern, Testing, Spares and Tools329
Dispatch Pattern, Testing, Spares and Tools331
Painting of Main Engine331
Dispatch Pattern331
Shop Trials/Delivery Test331
Spare Parts332
Wearing Parts332
Tools332
Specification for Painting of Main Engine333
Dispatch Pattern, List of Masses and Dimensions336
Shop Test337
Minimum Delivery Test337
List of Spare Parts, Unrestricted Service338
Additional Spares339
Large Spare Parts, Dimensions and Masses348
List of Standard Tools for Maintenance349
Dimensions and Masses of Tools350
Tool Panels359
Project Support and Documentation363
Engine Selection Guides363
Project Guides363
Computerised Engine Application System (CEAS)364
Extent of Delivery365
Content of Extent of Delivery365
Description of the ‘Extent of Delivery’365
Copenhagen Standard Extent of Delivery366
Installation Documentation367
Engine-Relevant Documentation367
Engine Room-Relevant Documentation368
Engine Production and Installation-Relevant Documentation370
Appendix371
Appendix373
Symbols for Piping373

Man B&W L35MC6-TII - Starting and Control Air

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