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WinGD X92DF User Manual

WinGD X92DF
608 pages
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Operation Manual
X92DF
Issue 002 2020-08
Winterthur Gas & Diesel Ltd.
Schützenstrasse 3 Tel. +41 (0)52 264 8844
Winterthur Gas & Diesel AG P.O. Box 414, 8401 Fax +41 (0)52 264 8866
Winterthur Gas & Diesel S.A. Winterthur, Switzerland www.wingd.com

Table of Contents

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WinGD X92DF Specifications

General IconGeneral
BrandWinGD
ModelX92DF
CategoryEngine
LanguageEnglish

Summary

Operation Manual Change Record

Preface

Technical Documentation Set

Operation Manual

Contains data about engine operation, operating media, component/system descriptions, and troubleshooting.

Maintenance Manual

Covers disassembly/assembly, maintenance schedules, component weights, and tool lists for engine upkeep.

Spare Parts Catalogue

Lists all spare parts with unique codes for ordering from designated suppliers.

Data Module Codes

Descriptive Data Module Codes

Explains the structure and components of data module codes used for descriptive engine information.

Procedural Data Module Codes

Details the structure and components of data module codes used for procedural engine information.

About This Book

Definitions for General Text

Defines terms, cross-references, instructions, notes, and decimal separator conventions used in the manual.

Warnings

Explains the structure of warnings, including signal words (WARNING, CAUTION) and their hazard levels.

About the Engine

Groups of Components

Divides engine components into nine groups based on their material number's first digit.

Engine Sides and Ends - Names

Defines the names and abbreviations for the engine's sides and ends (DE, FS, FE, ES).

Standard and LEFT Engine

Describes the two engine types: standard (exhaust on right) and LEFT (exhaust on left).

Numbering of Items

Explains the numbering convention for engine items, starting from the flywheel in axial and radial directions.

List of Abbreviations

Safety

Safety Precautions and Safety Rules

Details general safety precautions for lighting, cleanliness, fire prevention, tools, spare parts, and temperature hazards.

Safety Precautions and Safety Rules for Natural Gas

Outlines specific safety measures and definitions for hazardous zones when operating with natural gas.

Contamination and Fire in the Scavenge Air Spaces

Explains the causes of contamination and potential fires within the scavenge air spaces.

Fire-fighting in the Scavenge Air Space

Provides procedures for fire-fighting specifically within the scavenge air space.

Explosions in the Crankcase

Discusses the causes and frequency of crankcase explosions in diesel engines.

Prevent Explosions in the Crankcase

Details procedures to prevent explosions from occurring within the crankcase.

Prevention of Explosions in the Exhaust Gas System (Gas Mode)

Covers measures to prevent explosions in the exhaust gas system when operating in gas mode.

Access to Engine Spaces

Outlines the procedures and precautions for safely accessing engine spaces for maintenance.

Design and Function of the Engine

Short Description of the DF Engine

Provides a concise overview of the dual fuel (DF) engine's design, operation modes, and control system.

Use of the Engine

Defines the intended and incorrect uses of the engine, including operating ranges and tuning options.

The Relation Between Engine and Propeller

Explains the relationship between engine speed, power, and propeller characteristics for optimal operation.

Design and Function of Systems

General for Systems

Provides a general overview of the engine systems, including line codes and simplified descriptions.

Cooling Water System

Details the components and function of the engine's cooling water system, including connections and parts.

Wash-water System

Describes the wash-water system used for cleaning the scavenge air cooler (SAC).

System Oil System

Explains the components and function of the system oil system for engine lubrication.

Servo Oil System

Details the servo oil system's function, components, and connections for controlling engine parts.

Cylinder Oil System

Describes the cylinder oil system responsible for lubricating cylinder liners and its components.

Starting Air System

Explains the starting air system components and their function in starting the engine.

Scavenge Air System

Details the scavenge air system, its components, and how it supplies air to the cylinders.

Control Air System

Describes the control air system, its components, and its role in operating exhaust and starting air valves.

Exhaust Gas System

Explains the exhaust gas system, including its components and interface with the turbocharger.

Fuel System

Details the fuel system, its components, and how it supplies fuel to the injection valves.

Gas System

Describes the gas system, its components, and its monitoring for gas leaks and fire.

Pilot Fuel System

Explains the pilot fuel system's role in igniting the gas-air mixture in gas mode.

LP Selective Catalytic Reduction System

Details the Low Pressure Selective Catalytic Reduction (LP SCR) system for reducing nitrogen oxides.

HP Selective Catalytic Reduction System

Describes the High Pressure Selective Catalytic Reduction (HP SCR) system for reducing nitrogen oxides.

Steam Production Control System

Explains the Steam Production Control (SPC) system for managing steam production using exhaust gas.

Design and Function of Components

Group 1 - Engine Frame and Bearings

Details the design and function of the engine frame and its associated bearings.

Group 2 - Cylinder

Explains the design and function of the engine's cylinder components.

Group 3 - Crankshaft, Connecting Rod and Piston

Describes the design and function of the crankshaft, connecting rod, and piston assemblies.

Group 4 - Supply Unit Drive and Control Components

Details the components related to the supply unit drive and control systems.

Group 5 - Supply Unit, Pumps and Control Valves

Explains the design and function of the supply unit, pumps, and associated control valves.

Group 6 - Scavenge Air Components

Details the scavenge air components, including the receiver, turbocharger, and blowers.

Group 7 - Cylinder Lubrication

Describes the cylinder lubrication system, its components, and the automatic pre-lubrication sequence.

Group 8 - Pipes

Details the exhaust waste gate component, its valve, and its role in controlling exhaust gas flow.

Group 9 - Monitoring Instruments

Explains the monitoring instruments, including crank angle sensors, water in oil monitors, and oil mist detectors.

Control System

Engine Control System UNIC

Describes the UNIfied Controls Flex (UNIC-flex) engine control system, its modules, and functions.

Engine Control System WECS-9520

Provides a general description of the WECS-9520 system, its design for two-stroke engines, and its functions.

Engine Control System WiCE

Explains the WinGD integrated Control Electronics (WiCE) engine control system and its components.

Intelligent Combustion Control

Describes the Intelligent Combustion Control (ICC) system for monitoring and optimizing the combustion process.

Gas Valve Unit and External Gas Supply System

Details the Gas Valve Unit (GVU) and external gas supply system for controlling gas pressure.

Integrated Gas Pressure Regulation

Explains the Integrated Gas Pressure Regulation (iGPR) system for controlling gas pressure supplied to the engine.

Local Display Unit (LDU-20) - General

Provides a general overview of the Local Display Unit (LDU-20), its display, buttons, and functions.

LDU-20 Pages - General for DF Engine

Lists the LDU-20 pages that provide descriptions for the DF engine.

Operation

Prepare the Engine Before Start - General

Details the general preparation steps required before starting the engine, covering all auxiliary systems.

Prepare the Engine Before Start

Outlines the specific procedures for preparing the engine before starting, including checks and system readiness.

Start the Engine - General

Provides general guidance on usual start conditions, limits, and procedures for starting the engine.

Start the Engine

Details the step-by-step procedure for starting the engine, including clutch engagement and control panel operations.

Do Checks During Operation - General

Explains the importance of regular checks during engine operation to prevent malfunctions.

Do Checks During Operation

Lists daily and weekly checks required during engine operation to ensure performance and identify issues.

Do Regular Safety Checks

Details the procedures for performing regular safety checks on the engine, including pressure switches and oil mist detectors.

Maneuver the Ship - General

Provides general information on maneuvering the ship, including factors affecting speed and load changes.

Maneuver the Ship

Outlines the procedures for maneuvering the ship, covering speed changes and engine direction control.

Change-over the Diesel Fuel - General

Details the general procedures for changing over between HFO, MDO, and MGO fuels, emphasizing thermal stress management.

Change-over to and from Gas - General

Explains the procedures for changing over between liquid fuel and gas operation, including limits and requirements.

Change-over the Diesel Fuel Automatically

Describes the procedure for automatic change-over of diesel fuel, recommending its use when possible.

Change-over from HFO to MDO manually

Provides manual procedures for changing over from HFO to MDO, including temperature and viscosity control.

Change-over from MDO to HFO manually

Details the manual procedure for changing over from MDO to HFO, emphasizing safety and temperature management.

Change-over to and from Gas

Outlines the procedures for changing over fuel between liquid and gas modes, including manual and automatic sequences.

Stop the Engine - General

Provides general procedures for stopping the engine from various locations and handling shutdown signals.

Stop the Engine

Details the steps involved in stopping the engine, referring to the general procedure.

Emergency Stop the Engine - General

Explains how to stop the engine in an emergency, referring to the specific procedure.

Emergency Stop the Engine

Provides the specific procedure for executing an emergency stop of the engine.

Prepare the Engine After Stop - General

Details general procedures for preparing the engine after stopping, including post-lubrication.

Prepare the Engine for a Short Service Break

Outlines procedures for preparing the engine for a short service break, including keeping systems operational.

Prepare the Engine for Standstill Maintenance

Describes procedures for preparing the engine for longer standstill maintenance periods.

Service During Operation

Do an Analysis of the System Oil

Details the procedure for taking and analyzing system oil samples for monitoring engine health.

Do an Analysis of the Cylinder Oil

Explains the process for taking and analyzing cylinder oil samples for performance monitoring.

Replace the Filter Element of the Duplex Filter

Provides instructions for replacing the filter element in the duplex filter system.

Clean the Turbocharger During Operation

Details the procedure for cleaning the turbocharger during engine operation, with safety precautions.

Clean the Scavenge Air Cooler During Operation

Explains the procedure for cleaning the scavenge air cooler (SAC) during engine operation.

Do a Test of the Exhaust Waste Valve

Describes how to test the exhaust waste valve for proper function.

Running-in of New Components - General

Provides general recommendations for a running-in procedure after overhauling or installing new components.

Running-in of New Components

Details the specific steps and feed rate adjustments for running-in new engine components.

Troubleshooting

Troubleshooting - General Data

Provides general data and guidelines for troubleshooting engine malfunctions, including table structures.

Malfunctions of Systems and Components

Lists malfunctions across various engine systems, categorized by system type for easy diagnosis.

Examine the Supply Unit for Servo Oil Leakage

Details procedures for examining the supply unit for servo oil leaks and their causes.

Examine the Supply Unit for Fuel Leakage

Explains how to examine the supply unit for fuel leaks, including safety precautions.

Examine the Rail Unit for Leakage

Provides procedures for examining the rail unit for leaks and identifying defective items.

Examine the ICU or Fuel Pipes for Fuel Leakage

Details how to examine the ICU and fuel pipes for fuel leakage, including safety measures.

Temporary Cut Out a Defective Injection Valve

Describes how to temporarily cut out a defective injection valve to maintain engine operation.

Temporary Cut Out a Defective Exhaust Valve Drive

Explains how to temporarily cut out a defective exhaust valve drive to allow engine operation.

Temporary Isolate a Cylinder with Cooling Water Leakage

Details the procedure for temporarily isolating a cylinder with a cooling water leakage.

Disconnect the Fuel Pump

Provides procedures and parts list for disconnecting the fuel pump.

Connect the Fuel Pump

Details the procedure for connecting the fuel pump, including safety warnings.

Temporary Isolate a Defective Turbocharger

Explains how to temporarily isolate a defective turbocharger to allow engine operation at reduced load.

Temporary Isolate the Exhaust Waste Gate

Describes the procedure to temporarily isolate the exhaust waste gate for maintenance or troubleshooting.

Isolate a Defective Engine at Twin Engine Installation

Outlines the procedure for isolating a defective engine in a twin engine installation, including safety precautions.

Technical Data

Engine Data

Provides general engine data for the X92DF engine, including cylinder bore, stroke, and speed range.

List of Usual Values and Safeguard Settings - General

Lists usual operating values and trigger values for safeguard settings across various engine systems.

List of Usual Values and Safeguard Settings

Provides detailed usual operation values and safeguard trigger settings for engine systems.

Section Views (Generic Engine)

Presents section views of a generic engine for understanding its internal structure and layout.

Operating Media

General for Operating Media

Specifies the requirements for operating media such as fuel, lubricants, and water for the engine.

Compressed Air

Details the functions, requirements, and recommended procedures for compressed air systems.

Scavenge Air

Explains the scavenge air system, its purpose, and the importance of cleanliness for engine wear.

Gas Fuels

Provides specifications for gas fuels used by the engine in gas mode, including composition and temperature requirements.

Schematic Diagrams

Schematic Diagrams - General

Provides general information on schematic diagrams, including area codes, line codes, and signal codes.

Engine Control Diagram

Shows the engine control diagram, detailing control items, area codes, and line codes for system understanding.

Electric Connection Diagram

Illustrates the electric connection diagram, showing bus routing and color codes for connections.

Piping and Instrumentation Diagram

Details the piping and instrumentation diagrams for the auxiliary systems of the engine.

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