Man B&W S80ME-C7 - Turbocharger Choice & Exhaust Gas By-Pass

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MAN B&W

MAN Diesel

Turbocharger Choice &

Exhaust Gas By-pass

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Table of Contents3
Engine Design5
Index11
Calculation of Capacities11
Fuel Oil System11
Fuel Oils12
List of Capacities and Cooling Water Systems13
Space Requirements and Overhaul Heights14
Engine Design15
Concept of the ME Engine17
ME Advantages17
Differences between MC/MC-C and ME/ME-C Engines18
Engine Type Designation19
Power, Speed, Fuel and Lubricating Oil Consumption20
Engine Power Range and Fuel Oil Consumption21
Lubricating Oil Data21
Comparison of SFOC for ‘Fuel Economy Mode’ and ‘No Emission Mode’22
Performance Curves23
ME Engine Description24
Bedplate and Main Bearing24
Frame Box24
Cylinder Frame and Stuffing Box24
Cylinder Cover25
Crankshaft25
Thrust Bearing25
Turning Gear and Turning Wheel25
Connecting Rod26
Piston Rod26
Scavenge Air Cooler26
Auxiliary Blower26
Exhaust Turbocharger27
The Hydraulic Power Supply27
Hydraulic Cylinder Unit27
Fuel Valves and Starting Air Valve27
Exhaust Valve28
Man Diesel Alpha Cylinder Lubricator28
Gallery Arrangement28
Piping Arrangements28
Engine Cross Section of S80ME-C29
Engine Layout and Load Diagrams, SFOC31
Engine Layout and Load Diagrams Introduction33
Propulsion and Engine Running Points33
Propeller Curve33
Propeller Design Point33
Fouled Hull34
Engine Layout (Heavy Propeller)34
Engine Margin34
Constant Ship Speed Lines34
Propeller Diameter and Pitch, Influence on the Optimum Propeller Speed35
Layout Diagram and Constant Ship Speed Lines36
Layout Diagram Sizes37
Engine Layout and Load Diagram39
Specified Maximum Continuous Rating (M)39
Continuous Service Rating (S)39
Matching Point (O)39
Engine Load Diagram40
Operating Curves and Limits for Continuous Operation40
Limits for Low Load Running41
Recommendation41
Extended Load Diagram for Ships Operating in Extreme Heavy Running Conditions42
Examples of the Use of the Load Diagram43
Normal Running Conditions. Engine Coupled to Fixed Pitch Propeller (FPP) and Without Shaft Generator44
Special Running Conditions. Engine Coupled to Fixed Pitch Propeller (FPP) and Without Shaft Generator45
Normal Running Conditions. Engine Coupled to Fixed Pitch Propeller (FPP) and with Shaft Generator46
Special Running Conditions. Engine Coupled to Fixed Pitch Propeller (FPP) and with Shaft Generator47
Engine Coupled to Controllable Pitch Propeller (CPP) with or Without Shaft Generator48
Layout Diagram-Without Shaft Generator48
Layout Diagram-With Shaft Generator48
Load Diagram48
Engines Running at Constant Speed with Controllable Pitch Propeller (CPP)49
Position of Matching Point O for Engines Running at Constant Speed49
Diagram for Actual Project51
Construction of Layout Diagram51
Specific Fuel Oil Consumption, ME Versus MC Engines52
SFOC at Reference Conditions54
Recommended Cooling Water Temperature During Normal Operation54
Examples of Graphic Calculation of SFOC55
SFOC Calculations for S80ME-C56
SFOC for S80ME-C with Fixed Pitch Propeller57
SFOC for S80ME-C with Constant Speed57
SFOC Calculations, Example58
Example of Matching Point59
Fuel Consumption at an Arbitrary Load60
Emission Control61
IMO no Emission Limits61
30-50% no Reduction61
Up to 95-98% no Reduction61
Turbocharger Choice & Exhaust Gas By-Pass63
Turbocharger Choice65
Space Requirement65
Exhaust Gas By-Pass66
Extreme Ambient Conditions66
Exhaust Gas Receiver with Variable By-Pass66
Emergency Running Condition66
Total By-Pass of Exhaust for Emergency Running67
NO Reduction by SCR68
Engine with Selective Catalytic Reduction System68
Layout of SCR System69
Electricity Production71
Electricity Production73
Power Take off73
Types of PTO74
Designation of PTO75
Pto/Rcf76
Side Mounted Generator, BW III/RCF76
Power Take off with Renk Constant Frequency Gear: BW III/RCF76
Extent of Delivery for BW III/RCF Units77
Additional Capacities Required for BW III/RCF78
Space Requirement for Side Mounted Generator PTO/RCF Type Bwlll S80-C/RCF79
Engine Preparations for PTO80
Necessary Capacities for PTO/RCF, BW III/RCF System82
Lubricating Oil System for RCF Gear82
Standard Engine, with Direct Mounted Generator (DMG/CFE)83
Standard Engine, with Direct Mounted Generator and Tuning Wheel84
Diagram of DMG/CFE with Static Converter84
Static Converter85
Extent of Delivery for DMG/CFE Units85
SMG/CFE Generators85
Waste Heat Recovery Systems (WHR)87
Power Turbine Generator (PTG) Diagram88
The Size of a 1,500 Kw PTG System Depending on the Supplier89
Steam Turbine Generator (STG) Diagram90
Typical System Size for 2,000 Kw STG System91
Combined Turbines Diagram92
Typical System Size for 3,000 Kw Combined Turbines93
WHR Output94
Theoretically Calculated Outputs94
L16/24 Genset Data95
Power and Outline of L16/2495
List of Capacities for L16/24 1,000 Rpm96
List of Capacities for L16/24 1,200 Rpm97
L21/31 Genset Data98
Power and Outline of L21/3198
List of Capacities for L21/31, 900 Rpm99
List of Capacities for L21/31, 1,000 Rpm100
L23/30H Genset Data101
Power and Outline of L23/30H101
List of Capacities for L23/30H, 720/750 Rpm102
List of Capacities for L23/30H, 900 Rpm103
L27/38 Genset Data104
Power and Outline of L27/38104
List of Capacities for L27/38, 720 Rpm105
List of Capacities for L27/38, 750 Rpm106
L28/32H Genset Data107
Power and Outline of L28/32H107
List of Capacities for L28/32H108
Installation Aspects109
Space Requirements for the Engine111
Overhaul of Engine111
Crane Beam for Overhaul of Turbocharger113
Required Height and Distance and Weight113
Crane Beam for Turbochargers114
Crane Beam for Overhaul of Air Cooler115
Engine Room Crane116
Overhaul with man B & W Double-Jib Crane117
MAN B & W Double-Jib Crane118
Engine Outline, Galleries and Pipe Connections119
Engine Masses and Centre of Gravity119
Engine and Gallery Outline120
Engine Outline 7S80ME-C with Two Turbochargers120
Centre of Gravity123
For Engines with One Turbocharger123
Mass of Water and Oil124
Water and Oil in Engine124
Engine Pipe Connections125
Counterflanges126
Engine Seating and Arrangement of Holding down Bolts127
Epoxy Chocks Arrangement128
Arrangement of Epoxy Chocks and Holding down Bolts128
Profile of Engine Seating with Vertical Oil Outlet129
Profile of Engine Seating, End Chocks130
Engine Top Bracing131
Mechanical Top Bracing131
Mechanical Top Bracing Stiffener132
Hydraulic Top Bracing132
Outline of a Hydraulic Top Bracing Unit132
Hydraulic Top Bracing Data134
Components for Engine Control System135
Installation of ECS in the Engine Control Room135
Network and PC Components for the ME/ME-B Engine Control System135
MOP and Track Ball for the ME/ME-B Engine Control System136
The EICU Cabinet and MOP PC Unit for the ME/ME-B Engine Control System137
Pmi/Cocos PC Unit, Display and Printer for the ME/ME-B Engine Control System138
Scope and Field of Application139
Design Description of the Shaftline Earthing Device139
Connection of Cables as Shown on the Sketch140
MAN Diesel Controllable Pitch Propeller (CPP)142
List of Capacities: Pumps, Coolers & Exhaust Gas143
Calculation of List of Capacities and Exhaust Gas Data145
Nomenclature145
Engine Configurations Related to SFOC145
List of Capacities and Cooling Water Systems146
Heat Radiation and Air Consumption146
Flanges on Engine, Etc.146
List of Capacities, S80ME-C, High Efficiency T/C and Seawater Cooling System147
Fuel147
List of Capacities, S80ME-C, High Efficiency T/C and Central Cooling Water System148
Lubricating Oil148
Capacities of Starting Air Receivers and Compressors for S80ME-C149
Auxiliary Machinery Capacities150
Cooler Heat Dissipations150
Pump Capacities151
Pump Pressures151
Calculation of List of Capacities for Derated Engine152
Capacities of Derated 6S80ME-C with High Efficiency man B&W Turbocharger Type TCA and Central Cooling Water System153
Freshwater Generator154
Calculation Method154
Freshwater Generators. Jacket Cooling Water Heat Recovery Flow Diagram155
Jacket Cooling Water Temperature Control155
Calculation of Freshwater Production for Derated Engine156
Exhaust Gas Amount and Temperature157
Influencing Factors157
Summarising Equations for Exhaust Gas Amounts and Temperatures157
Correction for Choice of Specified MCR Point157
Correction of Exhaust Gas Data for Ambient Conditions and Exhaust Gas Back Pressure158
Correction for Actual Ambient Conditions and Back-Pressure158
Exhaust Gas Correction Formula for Ambient Conditions and Exhaust Gas Back Pressure159
Correction for Engine Load159
Calculation of Exhaust Data for Derated Engine160
Reference Conditions160
Final Calculation161
The Exhaust Gas Temperature161
Exhaust Gas Data at Specified MCR (ISO)161
Fuel163
Pressurised Fuel Oil System165
Fuel Considerations165
Constant Operation on Heavy Fuel165
Fuel Oil System166
Approximate Flow in HCU Leakage Drain167
Heating of Drain Pipe167
Fuel Oils168
Marine Diesel Oil168
Heavy Fuel Oil (HFO)168
Guiding Heavy Fuel Oil Specification168
Fuel Oil Pipes and Drain Pipes169
Fuel Oil Pipe Insulation170
Fuel Oil Pipes and Heating Pipes Together170
Flanges and Valves170
Mounting170
Heat Loss/Pipe Cover171
Fuel Oil Pipe Heat Tracing172
Fuel Oil and Lubricating Oil Pipe Spray Shields172
Components for Fuel Oil System173
Fuel Oil Centrifuges173
Fuel Oil Supply Pump173
Fuel Oil Circulating Pump173
Fuel Oil Heating Chart174
Fuel Oil Filter175
Fuel Oil Venting Box175
Flushing of the Fuel Oil System175
Water in Fuel Emulsification176
Temperature and Pressure176
Safety System176
Impact on the Auxiliary Systems176
System for Emulsification of Water into the Fuel Common to the Main Engine and man Diesel Gensets177
Lubricating Oil179
Lubricating and Cooling Oil System181
Lubrication of Turbochargers181
Hydraulic Power Supply Unit182
Hydraulic Power Supply Unit, Engine Driven183
Lubricating Oil Pipes for Turbochargers184
Man Diesel Turbocharger Type TCA184
ABB Turbocharger Type TPL184
Mitsubishi Turbocharger Type MET185
Lubricating Oil Centrifuges and List of Lubricating Oils186
Components for Lubricating Oil System187
Lubricating Oil Pump187
Lubricating Oil Cooler187
Lubricating Oil Temperature Control Valve187
Lubricating Oil Full Flow Filter188
Flushing of Lube Oil System188
Lubricating Oil Outlet189
Lubricating Oil Tank, with Cofferdam190
Lubricating Oil Tank Operating Conditions191
Crankcase Venting and Bedplate Drain Pipes192
Hydraulic Oil Back-Flushing193
Alternative Design for the Back-Flushing Servo Oil Drain Tank193
Separate System for Hydraulic Control Unit194
The Hydraulic Control Oil System Comprises194
Pressure Control Valve194
Hydraulic Control Oil Cooler194
Hydraulic Control Oil Filter195
Temperature Indicator195
The Pipes Can be Made of Mild Steel195
Piping195
Hydraulic Control Oil System, Manual Filter196
Hydraulic Control Oil System, S80ME-C197
Cylinder Lubrication199
Cylinder Lubricating Oil System201
Cylinder Oil Feed Rate (Dosage)201
MAN B & W Alpha Cylinder Lubrication System202
Alpha Adaptive Cylinder Oil Control (Alpha ACC)202
Working Principle202
Cylinder Lubricating Oil Dosage with Alpha ACC at All Loads (BN 70 Cylinder Oil)203
Cylinder Oil Pipe Heating204
El.heating Cylinder Oil Pipes205
Cylinder Lubricating Oil Pipes206
Suggestion for Small Heating Box with Filter207
Piston Rod Stuffing Box Drain Oil209
Stuffing Box Drain Oil System211
Central Cooling Water System213
Advantages of the Central Cooling System215
Disadvantages of the Central Cooling System215
Central Cooling Water System216
Components for Central Cooling Water System217
Seawater Cooling Pumps217
Central Cooling Water Pumps217
Central Cooling Water Thermostatic Valve217
Jacket Water System218
Jacket Water Cooling Pump218
Seawater Cooling219
Cooling System219
Seawater Systems221
Seawater Cooling System222
Seawater Cooling Pipes for Engines with One Turbochargers223
Seawater Cooling Pipes for Engines with Two Turbochargers223
Components for Seawater Cooling System224
Seawater Cooling Pump224
Jacket Water Cooler224
Seawater Thermostatic Valve224
Jacket Cooling Water System225
Jacket Cooling Water Pipes for Engines with man Diesel Turbochargers, Type TCA, ABB Turbochargers, Type TPL, Mitsubishi Turbochargers, Type MET226
Components for Jacket Cooling Water System227
Jacket Water Preheater227
Deaerating Tank227
Expansion Tank227
Deaerating Tank, Alarm Device228
Deaerating Tank Dimensions228
Temperature at Start of Engine229
Start of Cold Engine229
Preheating During Standstill Periods229
Preheating of Diesel Engine229
Starting and Control Air231
Starting and Control Air Systems233
Components for Starting Air System234
Starting Air Compressors234
Reduction Station for Control and Safety Air234
Reduction Valve for Turbocharger Cleaning Etc234
Starting and Control Air Pipes235
Exhaust Valve Air Spring Pipes236
Electric Motor for Turning Gear237
Scavenge Air239
Scavenge Air System241
Auxiliary Blowers242
Emergency Running242
Control of the Auxiliary Blowers242
Scavenge Air Space, Drain Pipes243
Electric Motor for Auxiliary Blower244
Scavenge Air Cooler Cleaning System245
Scavenge Air Box Drain System246
Drain from Water Mist Catcher246
Fire Extinguishing System for Scavenge Air Space247
Fire Extinguishing Pipes in Scavenge Air Space248
Exhaust Gas249
Exhaust Gas System on Engine251
Exhaust Gas Pipes252
Cleaning Systems253
MAN Diesel TCA Turbocharger, Water Washing of Turbine Side253
Water Washing of Turbine and Compressor Sides for ABB, TPL Turbochargers254
Soft Blast Cleaning of Turbine Side254
Exhaust Gas System for Main Engine255
Exhaust Gas Piping System for Main Engine255
Components of the Exhaust Gas System256
Exhaust Gas Compensator after Turbocharger256
Exhaust Gas Boiler256
Exhaust Gas Silencer257
Spark Arrester257
Calculation of Exhaust Gas Back-Pressure258
Exhaust Gas Data258
Measuring Back Pressure259
Pressure Losses and Coefficients of Resistance in Exhaust Pipes260
Forces and Moments at Turbocharger261
Vectors of Thermal Expansion at the Turbocharger Exhaust Gas Outlet Flange261
Max. Expected Movements of the Exhaust Gas Flange Resulting from Thermal Expansion261
Forces and Moments on the Turbochargers’ Exhaust Gas Outlet Flange262
The Max. Permissible Forces and Moments on the Turbocharger’s Gas Outlet Flanges262
Exhaust Pipe System, with Turbocharger Located on Exhaust Side of Engine263
Exhaust Gas Pipe Diameters and Exhaust Gas Mass Flow at Various Velocities263
Engine Control System265
Engine Control System ME267
Main Operating Panel (MOP)267
Cylinder Control Unit (CCU)267
Auxiliary Control Unit (ACU)267
Local Operating Panel (LOP)268
Control Network268
Hydraulic Power Supply (HPS)268
Engine Control System Layout269
Mechanical-Hydraulic System with Hydraulic Power Supply Unit on Engine270
Engine Control System Interface to Surrounding Systems272
Alarm System272
Telegraph System272
Power Management System272
Auxiliary Equipment System273
Monitoring Systems273
Instrumentation273
Pneumatic Manoeuvring Diagram274
Vibration Aspects275
Vibration Aspects277
External Unbalanced Moments and Guide Force Moments277
2Nd Order Moments on 6-Cylinder Engines278
Statistics of Vertical Hull Vibrations in Tankers and Bulk Carriers278
Preparation for Compensators279
Man Diesel 1St or 2Nd Order Electrically Driven Moment Compensator, Separately Mounted280
Compensation of 2Nd Order Vertical External Moments281
Power Related Unbalance282
Calculation of External Moments282
H-Type and X-Type Guide Force Moments283
Top Bracing283
Definition of Guide Force Moments283
Vibration Limits284
Axial Vibrations286
Torsional Vibrations286
Undercritical Running286
Critical Running287
Overcritical Running287
External Forces and Moments, S80ME-C, Layout Point L1-SFOC288
Monitoring Systems and Instrumentation289
Monitoring Systems and Instrumentation291
PMI System, Type PT/S Off-Line292
PMI System, Type On-Line293
Cocos Systems294
Cocos-EDS294
Cocos-EDS Sensor List295
Alarm–Slow down and Shut down System296
Attended Machinery Space (AMS)296
Unattended Machinery Space (UMS)296
Alarm, Slow down and Remote Indication Sensors296
General Outline of the Electrical System297
Panels and Sensors for Alarm and Safety Systems297
Alarms for Ums–Class and man Diesel Requirements298
Slow down for Ums–Class and man Diesel Requirements301
Shut down for AMS and Ums–Class and man Diesel Requirements302
International Association of Classification Societies302
Local Instruments303
Other Alarm Functions306
Drain Box for Fuel Oil Leakage Alarm306
Bearing Condition Monitoring306
Oil Mist Detector306
Oil Mist Detector Pipes on Engine, Type Graviner MK6 from Kidde Fire Protection307
Oil Mist Detector Pipes on Engine, Type Visatron VN215/93 from Schaller Automation307
Bearing Wear Monitoring System308
Water in Oil Monitoring System308
Bearing Temperature Monitoring System309
Control Devices310
Identification of Instruments311
Measured Variables311
Location of Measuring Point311
Repeated Signals311
Dispatch Pattern, Testing, Spares and Tools313
Painting of Main Engine315
Shop Trials/Delivery Test315
Spare Parts316
List of Spares, Unrestricted Service316
Additional Spare Parts Recommended by man Diesel316
List of Standard Tools316
Specification for Painting of Main Engine317
Dispatch Pattern, Engine with Turbocharger on Exhaust Side318
Shop Test322
EIAPP Certificate322
List of Spare Parts, Unrestricted Service323
Additional Spares324
Beyond Class Requirements324
Wearing Parts326
Large Spare Parts, Dimensions and Masses328
List of Standard Tools for Maintenance329
Dimensions and Masses of Tools331
Tool Panels337
Project Suppport and Documentation339
Project Support and Documentation341
Engine Selection Guides341
Project Guides341
Lubricating Oil341
Computerised Engine Application System342
Content of Extent of Delivery343
Installation Documentation345
Engine-Relevant Documentation345
Engine Room-Relevant Documentation346
Cylinder Lubrication346
Engine Production and Installation-Relevant Documentation348
Tools348
Auxiliary Equipment348
Appendix349
Symbols for Piping351

Man B&W S80ME-C7 - Turbocharger Choice & Exhaust Gas By-Pass

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