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Preface
Preface
The Wrtsil RT-flex system represents a major step forward in the technology of large diesel engines: Common rail injection - fully suitable for heavy fuel oil operation. The Marine Installation Manual is for use by project and design personnel. Each chapter contains detailed information for design engineers and naval architects, enabling them to optimize plant items and machinery space, and to carry out installation design work. This manual is only designed for persons dealing with this engine.
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Preface
This manual provides the information required for the layout of marine propulsion plants. It is not to be considered as a specification. The build specification is subject to the laws of the legislative body of the country of registration and the rules of the classification society selected by the owners. Its content is subject to the understanding that any data and information herein have been prepared with care and to the best of our knowledge. We do not, however, assume any liability with regard to unforeseen variations in accuracy thereof or for any consequences arising therefrom. Attention is drawn to the following: All data are related to engines compliant with IMO-2000 regulations Tier II. The engine performance data (rating R1+) refer to winGTD and netGTD. The engine performance data (BSFC, BSEF and tEaT) and other data can be obtained from the winGTD and netGTD. The winGTD can be downloaded from our Licensee Portal. The netGTD is accessible on internet using the following address: http://www.wartsila.com/en/marine-solutions/products/netGTD
Wrtsil Switzerland Ltd. Product Information Zrcherstrasse 12 PO Box 414 CH-8401 Winterthur Switzerland Tel: +41 52 262 07 14 Fax: +41 52 262 07 18 http://www.wartsila.com WCH.MIM@wartsila.com
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Preface List of updated text in this version See section 1.2 1.3.1 1.4.1 Information in section "Tuning options" has been updated. Information in section "Design features:" has been updated.
Page 1.-3 1.-7 1.-9 2.-3 2.-6 5.-6 5.-9 5.-9 8.-1 9.-7 9.-11 18.-5 18.-174 19.-3 19.-3 19.-4 19.-5 22.-1 22.-1 22.-3 22.-5
Information in section "The major benefits of the RT-flex system are:" has been updated. Information in section "SAC parameters and turbocharger weights" has been updated. Information in section "Electrical power requirement" has been updated. Information in section "Reduction of torsional vibration" has been updated. Information in section "External mass moments" has been updated. Information in section "Lateral and longitudinal rocking" has been updated. Information in section "Cooling Water System" has been updated. Information in section "Lubricating oil drain tank" has been updated. Information in section "Dimensioning guide-lines and filling process" has been updated. Information in section "Contents of fluid in the engine" has been added. Information in section "Extinguishing agents" has been updated. Information in section "Engine noise" has been added. Information in section "Engine surface sound pressure level" has been added. Information in section "Engine exhaust sound pressure level at funnel top" has been added. Information in section "Engine structure borne noise" has been added. Information in section "Appendix" has been added. Information in section "Abbreviations" has been added. Information in section "SI dimensions for internal combustion engines" has been added. Information in section "Approximate conversion factors" has been added.
2.7 5.5.1 5.8.1 5.8.2 8. 9.7 9.7.3 18.1.3 18.7.1 19.2 19.2.1 19.2.2 19.2.3 22. 22.1 22.2 22.3
List of updated drawings in this version Drawing number DAAD023066 a Connection Crank/Propeller Shaft, 4-8 Cyl. Updates revised from - to a Page 18.-115
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Table of contents
Table of contents
1. Engine Characteristics ............................................................................................................................... 1.1 Primary engine data ......................................................................................................................... 1.2 Tuning options ................................................................................................................................. 1.3 Main features and parameters: ........................................................................................................ 1.4 The RT-flex system ......................................................................................................................... Engine Data ................................................................................................................................................ 2.1 Reference conditions ....................................................................................................................... 2.2 Design conditions ............................................................................................................................ 2.3 Ancillary system design parameters ................................................................................................ 2.4 Engine performance data ................................................................................................................ 2.5 Turbocharger and scavenge air cooler ............................................................................................ 2.6 Auxiliary blower ................................................................................................................................ 2.7 Electrical power requirement ........................................................................................................... 2.8 Pressure and temperatures ranges ................................................................................................. Engine Rating and Load Range ................................................................................................................. 3.1 Rating field ....................................................................................................................................... 3.2 Load range ....................................................................................................................................... winGTD and netGTD .................................................................................................................................. 1-1 1-2 1-3 1-7 1-9 2-1 2-1 2-1 2-2 2-2 2-2 2-5 2-6 2-7 3-1 3-1 3-3 4-1
2.
3.
4. 5.
Engine Dynamics ....................................................................................................................................... 5-1 5.1 External forces and moments .......................................................................................................... 5-1 5.2 Lateral engine vibration (rocking) ..................................................................................................... 5-5 5.3 Reduction of lateral vibration ........................................................................................................... 5-6 5.4 Longitudinal engine vibration (pitching) ........................................................................................... 5-6 5.5 Torsional vibration ............................................................................................................................ 5-6 5.6 Axial vibration .................................................................................................................................. 5-8 5.7 Hull vibration .................................................................................................................................... 5-9 5.8 Summary of countermeasures for dynamic effects ......................................................................... 5-9 5.9 System dynamics ............................................................................................................................ 5-11 5.10 Order forms for vibration calculations and simulation ..................................................................... 5-11 Auxiliary Power Generation ........................................................................................................................ 6.1 Waste heat recovery ........................................................................................................................ 6.2 Power take-off (PTO) ....................................................................................................................... Ancillary Systems ....................................................................................................................................... 7.1 Data for central freshwater cooling system (integrated HT) ............................................................ Cooling Water System ............................................................................................................................... 8.1 Central freshwater cooling system components ............................................................................. 8.2 General recommendations for design ............................................................................................. 8.3 Freshwater generator ....................................................................................................................... 8.4 Pre-heating ...................................................................................................................................... 8.5 Drawings .......................................................................................................................................... Lubricating Oil Systems ............................................................................................................................. 9.1 Lubricating oil systems for turbochargers ....................................................................................... 9.2 Main lubricating oil system .............................................................................................................. 9.3 Main lubricating oil system components ......................................................................................... 9.4 Cylinder lubricating oil system ......................................................................................................... 9.5 Lubricating oil maintenance and treatment ..................................................................................... 9.6 Lubricating oil requirements ............................................................................................................ 9.7 Lubricating oil drain tank ................................................................................................................. 6-1 6-2 6-2 7-1 7-2 8-1 8-2 8-10 8-11 8-15 8-15 9-1 9-1 9-1 9-2 9-3 9-3 9-4 9-7
6.
7. 8.
9.
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10. Fuel Oil System .......................................................................................................................................... 10-1 10.1 Fuel oil requirements ....................................................................................................................... 10-1 10.2 Fuel oil treatment ............................................................................................................................. 10-5 10.3 Pressurized fuel oil system .............................................................................................................. 10-6 10.4 Heavy fuel oil system components .................................................................................................. 10-7 10.5 Drawings .......................................................................................................................................... 10-14 11. Starting and Control Air Systems .............................................................................................................. 11.1 Capacities of air compressor and receiver ...................................................................................... 11.2 Starting and control air system specification .................................................................................. 11.3 General service and working air ...................................................................................................... 11.4 Drawings .......................................................................................................................................... 12. Leakage Collection System ....................................................................................................................... 12.1 Sludge oil trap .................................................................................................................................. 12.2 Air vents ........................................................................................................................................... 12.3 Drawings .......................................................................................................................................... 11-1 11-2 11-3 11-3 11-3 12-1 12-2 12-3 12-4
13. Exhaust Gas System .................................................................................................................................. 13-1 13.1 Recommended gas velocities: ........................................................................................................ 13-1 13.2 Exhaust gas pipe diameters ........................................................................................................... 13-1 14. Engine-room Ventilation ............................................................................................................................. 14-1 14.1 Engine air inlet - Operating temperatures of 45 to 5C ................................................................... 14-2 15. Pipe Sizes and Flow Details ....................................................................................................................... 15-1 15.1 Pipe velocities .................................................................................................................................. 15-1 15.2 Piping symbols ................................................................................................................................ 15-3 16. Pipe Connections ....................................................................................................................................... 16-1 16.1 Drawings .......................................................................................................................................... 16-1 17. Engine Automation ..................................................................................................................................... 17-1 17.1 UNIC - engine control system interface .......................................................................................... 17-1 18. General Installation Aspects ...................................................................................................................... 18-1 18.1 Engine Dimensions and masses ...................................................................................................... 18-2 18.2 Outlines ............................................................................................................................................ 18-6 18.3 Engine seating ................................................................................................................................. 18-18 18.4 Engine coupling ............................................................................................................................... 18-114 18.5 Engine earthing ................................................................................................................................18-116 18.6 Engine stays .................................................................................................................................... 18-119 18.7 Fire protection ..................................................................................................................................18-174 19. Engine Emissions ....................................................................................................................................... 19-1 19.1 Exhaust gas emissions .................................................................................................................... 19-1 19.2 Engine noise .................................................................................................................................... 19-3 20. Engine Dispatch and Installation ............................................................................................................... 20-1 20.1 Treatment against corrosion ............................................................................................................ 20-1 20.2 Engine dismantling .......................................................................................................................... 20-72 20.3 Removing rust preventing oils ......................................................................................................... 20-72 20.4 Engine installation ............................................................................................................................ 20-73 21. Engine and Shaft alignment ....................................................................................................................... 21-1 21.1 Procedure ........................................................................................................................................ 21-1 21.2 Tools ................................................................................................................................................. 21-1
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22. Appendix .................................................................................................................................................... 22.1 Abbreviations ................................................................................................................................... 22.2 SI dimensions for internal combustion engines .............................................................................. 22.3 Approximate conversion factors ......................................................................................................
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List of tables
List of tables
1.1 1.2 2.1 2.2 2.3 2.4 2.5 2.6 5.1 5.2 5.3 5.4 6.1 7.1 8.1 8.2 9.1 9.2 9.3 9.4 9.5 11.1 15.1 17.1 17.2 17.3 17.4 17.5 17.6 18.1 18.2 22.1 22.2 22.3 Primary engine data ............................................................................................................................... Overall sizes of engine ........................................................................................................................... Scavenge air cooler parameters ............................................................................................................ Turbocharger weights ............................................................................................................................ Guidance for air filtration ....................................................................................................................... Number of auxiliary blowers .................................................................................................................. Electrical power requirement ................................................................................................................. Pressure and temperature ranges ......................................................................................................... Mass moments and forces .................................................................................................................... Countermeasures for external mass moments ...................................................................................... Countermeasures for lateral and longitudinal rocking ........................................................................... 1-2 1-8 2-3 2-3 2-4 2-5 2-6 2-7 5-2 5-9 5-9
Countermeasures for torsional and axial vibration ................................................................................ 5-11 PTO power and speed ........................................................................................................................... Data for central freshwater cooling system ........................................................................................... Low-temperature circuit ......................................................................................................................... High-temperature circuit ........................................................................................................................ Global brands of lubricating oils ............................................................................................................ Local brands of lubricating oils .............................................................................................................. Minimum inclination angles at which the engine is to remain fully operational (1) ................................ Minimum inclination angles at which the engine is to remain fully operational (2) ................................ Vertical lubricating oil drains to drain tank ............................................................................................. 6-2 7-2 8-2 8-3 9-5 9-6 9-8 9-8 9-9
Air receiver and air compressor capacities ............................................................................................ 11-2 Recommended fluid velocities and flow rates for pipework .................................................................. 15-1 Suppliers of remote control systems ..................................................................................................... 17-3 Table of alarm sensors and safety functions (part 1) ............................................................................. 17-6 Table of alarm sensors and safety functions (part 2) ............................................................................. 17-10 Classification societies .......................................................................................................................... 17-13 Request of classification societies ........................................................................................................ 17-14 Functions and level ................................................................................................................................ 17-14 Dimensions and masses of main components ...................................................................................... 18-3 Recommended total number of fire extinguishing bottles .....................................................................18-174 Abbreviations ......................................................................................................................................... 22-1 SI dimensions for internal combustion engines ..................................................................................... 22-3 Approximate conversion factors ............................................................................................................ 22-5
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List of figures
List of figures
1.1 1.2 1.3 1.4 1.5 2.1 2.2 3.1 3.2 3.3 3.4 3.5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6.1 7.1 8.1 8.2 8.3 8.4 8.5 9.1 9.2 9.3 9.4 10.1 10.2 10.3 11.1 12.1 12.2 13.1 Cross section ......................................................................................................................................... Schematic functional principle of Low-Load Tuning ............................................................................. Delta Tuning and Low-load Tuning area ................................................................................................ Typical BSFC curves to illustrate Standard Tuning, Delta Tuning and Low-Load Tuning ...................... RT-flex key parts .................................................................................................................................... Scavenge air cooler ............................................................................................................................... Air filter size (example for 8-cyl. engine) ................................................................................................ Rating field ............................................................................................................................................. Load range limits of an engine corresponding to a specific rating point Rx ......................................... Load diagram for a specific engine, showing the corresponding power and speed margins ............... Load range limits with load diagram of an engine corresponding to a specific rating point Rx ........... Load range diagram of an engine equipped with a main-engine driven generator ............................... External forces and moments ................................................................................................................ Locating electrically driven compensator .............................................................................................. Power related unbalance (PRU) ............................................................................................................. External forces and moments ................................................................................................................ Vibration damper (viscous type) ............................................................................................................ Vibration damper (Geislinger spring type) ............................................................................................. Example of an axial damper (detuner) ................................................................................................... Heat recovery, typical system layout ..................................................................................................... Central freshwater cooling system with integrated HT circuit ............................................................... Central cooling water system, expansion tank ...................................................................................... Central cooling water system, expansion tank (HT circuit) ................................................................... Central cooling water system, expansion tank (LT circuit) .................................................................... 1-1 1-4 1-5 1-5 1-9 2-2 2-4 3-1 3-4 3-5 3-7 3-8 5-1 5-3 5-4 5-5 5-7 5-7 5-8 6-1 7-2 8-4 8-6 8-8
Freshwater generator installation, alternative 'A' .................................................................................. 8-12 Freshwater generator installation, alternative 'B' .................................................................................. 8-13 Arrangement of vertical lubricating oil drains for the 6 cylinders .......................................................... Minimum inclination angles at which the engine is to remain fully operational ..................................... 9-7 9-9
Example of an accepted vertical drain connection ............................................................................... 9-10 Filling process of lubricating oil tank ..................................................................................................... 9-11 Typical viscosity / temperature diagram ................................................................................................ 10-2 Fuel oil system mixing unit ..................................................................................................................... 10-9 Filter arrangements ................................................................................................................................ 10-13 Starting and control air system .............................................................................................................. 11-1 Sludge oil trap ........................................................................................................................................ 12-2 Arrangement of automatic water drain .................................................................................................. 12-3 Determination of exhaust pipe diameter ................................................................................................ 13-1
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List of figures 14.1 14.2 14.3 14.4 15.1 15.2 15.3 18.1 18.2 18.3 18.4 19.1 19.2 19.3 19.4
Direct suction of combustion air - main and auxiliary engine ................................................................ 14-1 Direct suction of combustion air - main and auxiliary engine ................................................................ 14-2 Scavenge air system for arctic conditions ............................................................................................. 14-3 Blow-off effect under arctic conditions .................................................................................................. 14-3 Piping symbols 1/3 ................................................................................................................................ 15-3 Piping symbols 2/3 ................................................................................................................................ 15-4 Piping symbols 3/3 ................................................................................................................................ 15-5 Engine dimensions ................................................................................................................................. 18-2 Thermal expansion, dim. X, Y, Z ............................................................................................................ 18-4 Shaft earthing arrangement ................................................................................................................... 18-117 Shaft earthing with condition monitoring facility ................................................................................... 18-118 Speed dependent maximum average NOx emissions by engines ........................................................ 19-1 Compliance with IMO regulations .......................................................................................................... 19-2 Engine sound pressure level at 1 m distance ........................................................................................ 19-3 Sound pressure level at funnel top of engine exhaust gas system ....................................................... 19-4
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1. Engine Characteristics
1. Engine Characteristics
The Wrtsil X62 (W-X62) engine is a camshaftless low-speed, direct-reversible, two-stroke engine, fully electronically controlled, featuring common rail injection. The W-X62 is designed for running on a wide range of fuels from marine diesel oil (MDO) to heavy fuel oils (HFO) of different qualities.
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1. Engine Characteristics
1 2 3 4 5 Bedplate Column Crankshaft Main bearing elastic studs Bottom-end bearings 6 7 8 9 Crosshead Cylinder liner Cylinder cover Piston
10 Turbocharging system
Brake specific fuel consumption (BSFC) [g/kWh] Load 100% All cyl 167 / 166 160 / 160 mep [bar] All cyl 20.5 / 19.3 15.4 / 14.5 20.5 15.4 167 160
Lubricating oil consumption (for fully run-in engines under normal operating conditions) System oil Cylinder oil
1)
This data is for guidance only, it may have to be adjusted as the actual cylinder lubricating oil consumption in service is dependent on operational factors. All brake specific fuel consumption (BSFC) data are quoted for fuel of lower calorific value 42.7 MJ/kg [10,200 kcal/kg]. All other reference conditions refer to ISO standard (ISO 3046-1). The figures for BSFC are given with a tolerance of +5%. The values of power in kilowatt [kW] and fuel consumption in g/kWh are standard figures.. To determine the power and BSFC figures accurately in bhp and g/bhph respectively, the standard kW-based figures have to be converted by factor 1.36 (see also winGTD and netGTD).
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1. Engine Characteristics
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1. Engine Characteristics
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1. Engine Characteristics
Figure 1.4: Typical BSFC curves to illustrate Standard Tuning, Delta Tuning and Low-Load Tuning
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The application of Delta Tuning or Low-Load Tuning has an influence on the harmonic gas excitations and, as a consequence, the torsional and axial vibrations of the installation. Hence, the corresponding calculations have to be carried out with the correct data to be able to apply appropriate countermeasures, if necessary. Project specification for RT-flex engines: Although Delta Tuning is realised in such a way that it could almost be considered a pushbutton option, its selection as well as the selection of LLT also have an effect on other aspects of engine and system design. Therefore the tuning option to be applied on RT-flex engines needs to be specified at a very early stage in the project: The calculations of the torsional and axial vibrations of the installation have to be performed using the correct data. The layout of the ancillary systems has to be based on the correct specifications. To prepare the software for the RT-flex system control, the parameters also have to be known in due time before commissioning of the engine. Data for brake specific fuel consumption (BSFC) in section Primary engine data refer to Standard Tuning. Data for Delta Tuning and Low-Load Tuning can be obtained from the winGTD and netGTD.
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1. Engine Characteristics
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1. Engine Characteristics
Overall sizes of engines No. cyl. 4 5 6 7 8 Length [mm] 6,825 7,931 9,037 10,143 11,249 11,950 Piston dismantling height (crank center crane hook) [mm] Dry weight [t] 270 325 377 435 482
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1. Engine Characteristics
All key engine functions such as fuel injection, exhaust valve drives, engine starting and cylinder lubrication are fully under electronic control. The timing of the fuel injection, its volumetric and various injection patterns are regulated and controlled by the UNIC control system.
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2. Engine Data
2. Engine Data
The engine can be operated in the ambient condition range between reference conditions and design (tropical) conditions.
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2. Engine Data
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2. Engine Data
Fresh water cooled / single-stage SAC 4 5 6 7 8 SACA2-SF SACA9-SF SACA9-SF SACA10-SF SACA2-SF 1 1 1 1 2 70.3 74.7 74.7 83.6 70.3 23.7 35.5 35.5 47.3 23.7 1.6 1.6 1.6 1.6 1.6 3,000 3,000 3,000 3,000 3,000 tbd tbd tbd tbd tbd tbd tbd tbd tbd tbd tbd tbd tbd tbd tbd
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2. Engine Data
Atmospheric dust concentration Normal Most frequent particle sizes > 5 m < 5 m Valid for Normal shipboard requirement Short period < 5% of running time, < 0.5 mg/m3 Standard TC filter sufficient Standard TC filter sufficient Alternatives necessary in very special circumstances frequently to permanently > 0.5 mg/m3 Oil wetted or roller screen filter Oil wetted or panel filter permanently > 0.5 mg/m3 Inertial separator and oil wetted filter Inertial separator and oil wetted filter
These may apply in only very few, extreme cases. the vast majority of installations E.g.: ships carrying bauxite or similar dusty cargoes, or ships routinely trading along desert coasts.
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2. Engine Data
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2. Engine Data
Supply voltage
6 7 8 4 5
440 V
Turning gear
6 7 8
440 V
Propulsion control system Additional monitoring devices (e.g. oil mist detector, etc.)
24 VDC UPS
on the size, type and voltage/frequency of the installed electric motor. Direct starting or Star-Delta starting to be specified when ordering.
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2. Engine Data
System
SAC LT circuit (single-stage SAC) Fuel oil Booster (injection pump) After pressure retaining valve Scavenge air Intake from engine room (pressure drop, max) Intake from outside (pressure drop, max) Cooling (pressure drop) Lubricating oil Servo oil Main bearing oil
*1)
Inlet Return
150 -
Air filter / silencer Ducting and filter New SAC Fouled SAC
Servo oil pump inlet Supply Outlet Inlet Outlet Pads AHEAD Supply Inlet casing Supply Damp. chamber Inlet Outlet Inlet Outlet Inlet Outlet
4.0 4.0 4.0 4.0 1.0 4.0 1.7 1.0 1.3 0.7 -
40 40 -
50 50 80 75 110 85 130 85
max. 30 -
Piston cooling oil Thrust bearing pads Torsional vibration damper (in case of steel spring damper) Integrated axial vibration damper (detuner) TC bearing oil (on engine lub. oil system), ABB A100-L TC bearing oil (with separate lub. oil system), ABB A100-L TC bearing oil MHI MB
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2. Engine Data
Location of measurement
Engine inlet Engine inlet (engine internal) Main distributor (engine internal)
12 6.0
25/30 7.5
normal 6.5
30 mbar 50 mbar
515 515 -
stand-by condition; during commissioning of the fuel oil system the fuel oil pressure is adjusted to 10 bar.
*4) Maximum
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Selecting a suitable main engine to meet the power demands of a given project involves proper tuning in respect of load range and influence of operating conditions which are likely to prevail throughout the entire life of the ship. This chapter explains the main principles in selecting a Wrtsil 2-stroke marine diesel engine. Every engine has a rating field within which the combination of power and speed (= rating) can be selected. Contrary to the rating field, the load range is the admissible area of operation once the contract maximum continuous rating (CMCR) has been determined. To define the CMCR, various parameters need to be considered, such as propulsive power, propeller efficiency, operational flexibility, power and speed margins, possibility of a main-engine driven generator, and the ships trading patterns. Selecting the most suitable engine is vital to achieving an efficient cost/benefit response to a specific transport requirement.
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The rating field shown in fig. 3.1 is the area of power and engine speed. In this area the contract maximum continuous rating of an engine can be positioned individually to give the wanted combination of propulsive power and rotational speed. Engines within this rating field will be tuned for maximum firing pressure and best efficiency. Experience over the last years has shown that engines are ordered with CMCR-points in the upper part of the rating field only. The engine speed is given on the horizontal axis and the engine power on the vertical axis of the rating field. Both are expressed as a percentage [%] of the respective engines nominal R1+ parameters. Percentage values are being used so that the same diagram can be applied to various engine models. The scales are logarithmic so that exponential curves, such as propeller characteristics (cubic power) and mean effective pressure (mep) curves (first power), are straight lines. The rating field serves to determine the specific fuel oil consumption, exhaust gas flow and temperature, fuel injection parameters, turbocharger and scavenge air cooler specifications for a given engine. Calculations for specific fuel consumption, exhaust gas flow and temperature after turbine are explained in further chapters. The rating points (R1, R1+, R2, R2+, R3 and R4) are the corner points of the engine rating field. The point R1+ represents the nominal maximum continuous rating (MCR). It is the maximum
power/speed combination which is available for a particular engine.
The point R2+ defines 100% speed and 75% power of R1+. The point R3 defines 78% speed and 82% power of R1+. The connection R1 - R3 is the nominal 100% line of the constant mean effective pressure of
R1.
The point R4 defines 78% speed and 62% power of R1+. The connection line R2 - R2+ is the line of 75% power between 94% and 100% speed of R1+. Rating points Rx can be selected within the entire rating field to meet the requirements of each
particular project. Such rating points require specific engine adaptations.
This relation is used in the engine selection procedure to compare different engine alternatives and to select optimum propeller revolutions within the chosen engine rating field. Usually, the selected revolution depends on the maximum permissible propeller diameter.
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The maximum propeller diameter is often determined by operational requirements such as: Design draught and ballast draught limitations Class recommendations concerning propeller/hull clearance (pressure impulse induced on the hull by the propeller) The selection of a main engine in combination with the optimum propeller (efficiency) is an iterative procedure where also commercial considerations (engine and propeller prices) play a great role. According to the above approximation, when a required power/speed combination is known for example point Rx1 - a CMCR-line can be drawn which fulfils the ships power requirement for a constant speed. The slope of this line depends on the ships characteristics (coefficient ). Any other point on this line represents a new power/speed combination, for example Rx2, and requires a specific propeller adaptation.
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Figure 3.2: Load range limits of an engine corresponding to a specific rating point Rx
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Figure 3.3: Load diagram for a specific engine, showing the corresponding power and speed margins
Assuming, for example, the following: Dry-docking intervals of the ship: 5 years Time between overhauls of the engine: 2 years or more Full service speed must be attainable, without surpassing the torque limit, under less favorable conditions and without exceeding 100% mep Therefore the required light running margin will be between 5 and 6%.
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3. Engine Rating and Load Range This is the sum of the following factors:
1.5-2% influence of wind and weather with adverse effect on the intake water flow of the propeller. Difference between Beaufort 2, sea trial condition, and Beaufort 4-5, average service condition. For vessels with a pronounced wind sensitivity, i.e. containerships or car carriers, this value will be exceeded. 1.5-2% increase of ships resistance and mean effective wake brought about by: Rippling of hull (frame to frame) Fouling of local, damaged areas, i.e. boot top and bottom of the hull Formation of roughness under paint Influence on wake formation due to small changes in trim and immersion of bulbous bow, particularly in ballast condition
1% frictional losses due to increase in propeller blade roughness and consequent drop in efficiency, e.g. aluminium bronze propellers: New: surface roughness = 12 micron Aged: rough surface but no fouling = 40 micron
1% deterioration in engine efficiency such as: Fouling of scavenge air coolers Fouling of turbochargers Condition of piston rings Fuel injection system (condition and timing) Increase of back pressure due to fouling of the exhaust gas boiler, etc.
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Figure 3.4: Load range limits with load diagram of an engine corresponding to a specific rating point Rx Line 1 Line 2 is a constant mep or torque line through CMCR from 100% speed and power down to 95% power and speed. is the overload limit. It is a constant mep line reaching from 100% power and 93.8% speed to 110% power and 103.2% speed. The latter one is the point of intersection between the nominal propeller characteristic and 110% power. is the 104% speed limit where an engine can run continuously. For Rx with reduced speed (NCMCR < 0.98 NMCR) this limit can be extended to 106%, however, the specified torsional vibration limits must not be exceeded. is the overspeed limit. The overspeed range between 104 (106) and 108% speed is only permissible during sea trials if needed to demonstrate, in the presence of authorised representatives of the engine builder, the ships speed at CMCR power with a light running propeller. However, the specified torsional vibration limits must not be exceeded. represents the admissible torque limit and reaches from 95% power and speed to 45% power and 70% speed. This represents a curve defined by the equation: P2/P1 = (N2/N1)2.45. When approaching line 5, the engine will increasingly suffer from lack of scavenge air and its consequences. The area formed by lines 1, 3 and 5 represents the range within which the engine should be operated. The area limited by the nominal propeller characteristic, 100% power and line 3 is recommended for continuous operation. The area between the nominal propeller characteristic and line 5 has to be reserved for acceleration, shallow water and normal operational flexibility.
Line 3
Line 4
Line 5
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is defined by the equation: P2/P1 = (N2/N1)2.45 through 100% power and 93.8% speed and is the maximum torque limit in transient conditions. The area above line 1 is the overload range. It is only allowed to operate engines in that range for a maximum duration of one hour during sea trials in the presence of authorized representatives of the engine builder. The area between lines 5 and 6 and constant torque line (dark area of Fig. 3.4) should only be used for transient conditions, i.e. during fast acceleration. This range is called service range with operational time limit.
Figure 3.5: Load range diagram of an engine equipped with a main-engine driven generator
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The purpose of these programs is to calculate the heat balance of a Wrtsil two-stroke diesel engine for a given project. Various cooling circuits can be taken in account, temperatures and flow rates can be manipulated online for finding the most suitable cooling system. This these programs provide the information required for the project work of marine propulsion plants. Its content is subject to the understanding that any data and information herein have been prepared with care and to the best of our knowledge. We do not, however, assume any liability with regard to unforeseen variations in accuracy thereof or for any consequences arising therefrom. The winGTD is available as download from our Licensee Portal. 1 Open the Licensee Portal and go to: - 'Project Tools & Documents' - 'winGTD' 2 Click on the link and follow the instructions The netGTD is accessible on internet using the following address: http://www.wartsila.com/en/marine-solutions/products/netGTD
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5. Engine Dynamics
5. Engine Dynamics
As a leading designer and licensor we are concerned that vibrations are minimised with our engine installations. The assessment and reduction of vibration is subject to continuing research. Therefore, we have developed extensive computer software, analytical procedures and measuring techniques to deal with this subject. For successful design, the vibration behaviour needs to be calculated over the whole operating range of the engine and propulsion system. The following vibration types and their causes are to be considered: External mass forces and moments Lateral engine vibration Longitudinal engine vibration Torsional vibration of the shafting Axial vibration of the shafting
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NOTICE
*1)
No engine-fitted 2nd order balancer available. If reduction on M2v is needed, an external 2nd order compensator has to be applied. - The resulting lateral guide force can be calculated as follows: FL = MLH x 0.25 [kN]. - The values for other engine ratings and engine tunings are available on request. - Crankshaft type: FCV1 / full crank pin.
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to be in accordance with the recommendations of the damper manufacturer and our design department. For high energy vibrations, e.g. for higher additional torque levels that can occur with 5 and 6-cylinder engines, a spring damper with its higher damping effect may have to be considered; refer to Fig. 5.6. This damper has to be supplied with oil from the engines lubricating oil system. Depending on the torsional vibration energy to be absorbed, it can dissipate up to 110 kW energy (depends on number of cylinders). The oil flow to the damper should be 11 m3/h, but an accurate value will be given after the results of the torsional vibration calculation are known.
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Table 5.2: Countermeasures for external mass moments NOTICE *1) No engine-fitted 2nd order balancer available. If reduction on M2v is needed, an external 2nd order compensator has to be applied.
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5. Engine Dynamics
NOTICE
*2) *3)
for standard rating fields (ncmcr < 97 rpm) for extended rating fields (ncmcr > 97 rpm)
A: The countermeasure indicated is needed. B: The countermeasure indicated may be needed and provision for the corresponding countermeasure is recommended. C: The countermeasure indicated is not needed.
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4 to 8
If you have no access to the Licensee Portal, order these forms from Wrtsil Switzerland Ltd. Send a PDF or fax a copy of the completed relevant forms to the following address:
Wrtsil Switzerland Ltd. Dept. 10189 Engine and System Dynamics Zrcherstrasse 12 PO Box 414 CH-8401 Winterthur eMail: dynamics.ch@wartsila.com Fax: +41-52-262 07 25
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This chapter covers a number of auxiliary power arrangements for consideration. However, if your requirements are not fulfilled, contact our representative or consult Wrtsil Switzerland Ltd. directly. Our aim is to provide flexibility in power management, reduce overall fuel consumption and maintain uni-fuel operation. The sea load demand for refrigeration compressors, engine and deck ancillaries, machinery space auxiliaries and hotel load can be met by using a main-engine-driven generator, a steamturbine driven generator using waste heat from the engine exhaust gas, or simply by applying auxiliary generator sets. The waste heat option is a practical proposition for high-powered engines employed on long voyages. The electrical power required when loading and discharging cannot be met with a main-engine driven generator or with the waste heat recovery system, and for vessels employed on comparatively short voyages the waste heat system is not viable. Stand-by diesel generator sets (Wrtsil GenSets) burning heavy fuel oil or marine diesel oil, available for use in port, when manoeuvring or at anchor, provide the required flexibility when the main-engine power cannot be used.
Although initial installation costs for a heat recovery plant are relatively high, these are recovered by fuel savings if maximum use is made of the steam output, i.e. electrical power and domestics, space heating, heating of tank, fuel and water.
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Table 6.1: PTO power and speed NOTICE *1) Higher powers on request. Free end PTO is available on request. An alternative is a shaft generator.
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7. Ancillary Systems
7. Ancillary Systems
Sizing engine ancillary systems, i.e. freshwater cooling, lubricating oil, fuel oil, etc., depends on the contract maximum engine power. If the expected system design is out of the scope of this manual, contact our representative or Wrtsil Switzerland Ltd. directly. The winGTD and netGTD enable all engine and system data at any Rx rating within the engine rating field to be obtained. However, for convenience or final confirmation when optimizing the plant, Wrtsil Switzerland Ltd. provide a computerized calculation service. All pipework systems and fittings are to conform to the requirements laid down by the legislative council of the vessels country of registration and the classification society selected by the owners. They are to be designed and installed to accommodate the quantities, velocities, flow rates and contents identified in this manual, set to work in accordance with the build specification as approved by the classification society and protected at all times from ingress of foreign bodies. All pipework systems are to be flushed and proved clean before commissioning. The data given in section 7.1 are applicable to the nominal maximum continuous rating R1+ of the 4 to 8-cylinder engines and suitable for estimating the size of ancillary equipment. These data refer to engines with the following conditions/features: At design (tropical) conditions Standard Tuning Central freshwater cooling system with single-stage scavenge air cooler (SAC) and integrated HT circuit ABB A100-L turbochargers Turbochargers lubricated from the engines lubricating system Furthermore the following data are obtainable from the winGTD and netGTD or on request from Wrtsil Switzerland Ltd.: Data for engines fitted with MHI MET MB turbochargers Derating and part-load performance data Data for Delta Tuning Data for Low-Load Tuning
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7. Ancillary Systems
Freshwater flow m3/h Freshwater temp. engine in / out Scavenge air cooler (LT) Heat dissipation kW C
4,225 229 36 / 52 78
5,274 204 36 / 58 98
Freshwater flow m3/h Freshwater temp. cooler in / out Scavenge air mass flow Lubricating oil cooler Heat dissipation Oil flow *1) Oil temp. cooler in / out kW m3/h C C t/h
971 155 58 / 45 84 36 / 46 10
Water flow m3/h Water temp. cooler in / out Mean log temp. difference Central cooler Heat dissipation Freshwater flow Freshwater temp. cooler in / out kW m3/h C C C
Seawater flow m3/h Seawater temp. cooler in / out Mean log temp. difference C C
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7. Ancillary Systems
Number of cylinders Exhaust gas Heat dissipation *2) Mass flow Temp. after turbine Engine radiation Radiation Starting air *3) Bottles (2 units), pressure Bottles (2 units), capacity each bar m3 kW kW t/h C
117
136
156
176
195
30 5.5 165
30 5.5 165
30 5.5 165
30 6.0 180
30 6.0 180
Air compressors (2 units), cam3/h pacity each Pumps / delivery head *4)
m3/h Lubricating oil High-temp. circuit Low-temp. circuit Fuel oil booster Fuel oil feed Seawater 155 96 313 4.8 2.7 333
Table 7.1: Data for central freshwater cooling system NOTICE *1) Excluding heat and oil flow for damper and PTO gear. *2) Available heat for boiler with gas outlet temperature 170C and temperature drop of 5C from turbine to boiler. *3) For 12 starts and refilling time 1 hour, when Jrel = 2.0 (see section 11.2 Starting and control air system specification). *4) Pressure difference across pump (final delivery head must be according to the actual piping layout).
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The cooling system runs on the following standard layout: Central freshwater cooling system with single-stage scavenge air cooler and separate HT circuit. WARNING For all relevant and prevailing information consult the drawings in section 'Drawings' at the end of this chapter. As freshwater is the standard cooling medium of the scavenge air cooler(s), this involves the use of a central freshwater cooling system. The central freshwater cooling system comprises low-temperature (LT) and high-temperature (HT) circuits. Freshwater cooling systems reduce the amount of seawater pipework and its attendant problems and provide for improved cooling control. Optimizing central freshwater cooling results in lower overall running costs compared to the conventional seawater cooling system.
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Central cooler Cooler type: Cooling medium: Cooled medium: Heat dissipation: Margin for fouling: Freshwater flow: Seawater flow: Temperatures: Temperature control The central freshwater cooling system is to be capable of maintaining the inlet temperature to the scavenge air cooler between 25C and 36C. Freshwater pumps for LT circuit Pump type: Pump capacity: centrifugal refer to table 7.1 Data for central freshwater cooling system (integrated HT); the given capacity of freshwater flow covers the need of the engine only and is to be within a tolerance of 0 to +10% the final delivery head is determined by the layout of the system and is to ensure that the inlet pressure to the scavenge air coolers is within the range of the summarized data plate or tubular seawater freshwater refer to table 7.1 10-15% to be added refer to table 7.1 refer to table 7.1 refer to table 7.1
Delivery head:
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Pump type:
For a pressure increase from 100% to 107%, the pump capacity should not decrease
by more than 10%. refer to section 7.1 The flow capacity is to be within a tolerance of -10 to +20%. determined by system layout 95C
Pump capacity: Delivery head: Working temperature: Pump delivery head (pp)
> system pressure losses (p) > required pressure at engine inlet (p0) + pressure drop between pump inlet and engine inlet (dp) - constant (h / 10.2) pp> p > p0- h / 10.2 + dp [bar].
The system pressure losses (p) are the pressure drop across the system components and pipework and the pressure drop across the engine. The pump delivery head (pp) depends on the height of the expansion tank, the pressure drop between pump outlet and engine inlet (dp), and the required pressure at engine inlet (p0). The constant is given as the difference in height between the expansion tank and the engine inlet (h) divided by 10.2. Expansion tank The expansion tank is to be fitted at least 3.5m above the highest engine air vent flange to ensure that the required static head is applied to the cylinder cooling water system. It is to be connected by a balance pipe, to replenish system losses, using the shortest route to the cylinder cooling water pump suction, making sure that pipe runs are as straight as possible without sharp bends. The cylinder cooling water system air vents are to be routed through the bottom of the expansion tank with the open end below the minimum water level. Automatic temp. control valve Electrically or electro-pneumatically actuated three-way type (butterfly valves are not adequate) having a linear characteristic Design pressure: Test pressure: Press. drop across valve: Controller: Temp. sensor: 5 bar refer to the specification laid down by the classification society max. 0.5 bar proportional plus integral (PI); also known as proportional plus reset for steady state error of max. 2C and transient condition error of max. 4C according to the control valve manufacturer's specification, fitted in the engine outlet pipe
Table 8.2: High-temperature circuit WARNING The illustrations below do not necessarily represent the actual configuration or the stage of development, nor the type of your engine. For all relevant and prevailing information consult the drawings in section 'Drawings' at the end of this chapter.
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NOTICE *1) Level indicator can be omitted if an alternative is fitted. *2) Other designs (like hinged covers, etc.) are possible. *3) Depending on actual ancillary plants. LT tank capacity to be increased accordingly.
Total capacity *3) (m3) 1.0 1.5 2.0 2.5 3.0 3.5 4.0
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Figure 8.2: Central cooling water system, expansion tank (HT circuit)
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NOTICE *1) Level indicator can be omitted if an alternative is fitted. *2) Other designs (like hinged covers, etc.) are possible.
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Figure 8.3: Central cooling water system, expansion tank (LT circuit)
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NOTICE *1) Level indicator can be omitted if an alternative is fitted. *2) Other designs (like hinged covers, etc.) are possible.
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Figure 8.4: Freshwater generator installation, alternative 'A' 1 2 3 4 Main engine Cylinder cooling water pump Cylinder cooling water cooler Automatic temperature control valve 5 6 7 8 Freshwater generator Throttling disc Freshwater valves Freshwater generator by-pass valve
Example 8-cyl. engine - R1+ specification with 21,280 kW at 103 rpm The available heat (from section 7.1.1 Data for central freshwater cooling system) is 3,295 kW. Alternative A uses up to 50% of the available heat, hence 1,647 kW of heat is available. Substitute this value in the equation: FW produced in t/day = constant x available heat FW produced in t/day = 32 x 10-3 x 1,647 FW produced in t/day = 53
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The quantity of freshwater produced by a single-effect vacuum (flash) evaporator can be estimated for guidance purposes as follows: FW produced in t/day = 32 x 10-3 x QFW where QFW is the heat in kW available from the cylinder cooling water, estimated from the derating table 7.1 Data for central freshwater cooling system (integrated HT) Example 8-cyl. engine - R1+ specification with 21,280 kW at 103 rpm fitted with central cooling system and single-stage scavenge air cooler The available heat (from table 7.1 Data for central freshwater cooling system (integrated HT)) is 3,295 kW. Alternative B uses up to 85% of the available heat, hence 2,801 kW of heat is available. Substitute this value in the equation: FW produced in t/day = constant x available heat FW produced in t/day = 32 x 10-3 x 2,801 FW produced in t/day = 90 NOTICE The indicated values for evaporator heat requirement and load in alternatives 'A' and 'B' (i.e. 50% and 85% respectively) are only applicable if there are no additional heat consumers installed (e.g. feed water pre-heater for waste heat recovery, etc.).
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8.4 Pre-heating
To prevent corrosive liner wear when not in service or during short stays in port, it is important that the main engine is kept warm. Warming-through can be provided by a dedicated heater, using boiler raised steam or hot water from the diesel auxiliaries, or by direct circulation from the diesel auxiliaries. If the main cylinder water pump is to be used to circulate water through the engine during warming-up, the heater is to be arranged parallel with the cylinder water system, and on/off control is to be provided by a dedicated temperature sensor at the cylinder water outlet of the engine. The flow through the heater is set by throttling discs, but not by valves, to assure flow through the heater. If the requirement is for a separate pre-heating pump, a small unit of 10% of the main pump capacity and an additional non-return valve between the cylinder cooling water pump and the heater are to be installed. In addition, the pumps are to be electrically interlocked to prevent two pumps running at the same time. Before starting and operating the engine, a temperature of 60C at the cylinder cooling water outlet of the main engine is recommended. If the engine has to be started below the recommended temperature, engine power is not to exceed 80% of CMCR until the water temperature has reached 60C. To estimate the heater power capacity required to achieve the target temperature of 60C, the engine ambient temperature and the heating-up time are the key parameters. If the requirement for warming-up is from the cooling water systems of the diesel auxiliaries, it is essential that the amount of heat available at normal load is sufficient to warm the main engine. If the main and auxiliary engines have a cooling water system which can be cross-connected, it has to be ensured that any pressure drop across the main engine, when the cross-connection is made, does not affect the cooling water pressure required by the auxiliaries. If the cooling water systems are separate, then a dedicated heat exchanger is required to transfer the heat to the main cylinder water system.
8.5 Drawings
DAAD031310 DAAD031234 107.245.626 c 107.245.419 c 107.429.532 Cooling Water Systems, Installation Drawings, 4-8 Cyl. .....................881 --6 _ Central Cooling Water System, 4-8 Cyl. ...........................................881 --8 _ Buffer, To Cyl.Cooling Water Sys, 4-8 Cyl. ........................................881 --9 _ Expansion Tank, Central Cooling Water Lt Circuit, 4-8 Cyl. .............882 --0 _ Concept Guidance, 4-8 Cyl. .............................................................883 --7
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7-77.309
17.12.09
RTA / RT-flex
Wrtsil Switzerland Ltd.
CONCEPT GUIDANCE
Group
9721
4-107.429.532
1/17
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Index:
Introduction.......................................................................................................................3 1 2 Safe engine operation .........................................................................................4 Single-stage fresh water generator ...................................................................5 2.1 Standard installation (single-stage FWG): up to about 2.2 x 10-3 x CMCR [m3/day] fresh water production. Installation alternative A ...................................6 2.2 Optimised installation (single-stage FWG): up to about 3.7 x 10-3 x CMCR [m3/day] fresh water production. Installation alternative B ...................................7 2.3 Installation, utilising main and auxiliary engine heat dissipation (single stage FWG): 3.7x10-3 x CMCR (ME) + 5.3x10-3 x base load (AE) [m3/day] fresh water production .............................................................................................................9 2.4 Installation with booster heater (single-stage FWG): maximum possible fresh water production depending on the additional booster heater capacity............... 10 3 Multi-effect and multi-stage FWG: a multiple of the single-stage FWG installations ....................................................................................................... 13 3.1 Multi-effect evaporation FWG installations: ......................................................... 13 3.2 Multi-stage flash FWG: a multiple of the single-stage FWG installations ............ 14 4 5 Heat-independent installations ........................................................................ 15 Abbreviations .................................................................................................... 17
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2/17
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Introduction Production of fresh water on board of sea going vessels is a well-established requirement. However, nowadays a trend to install fresh water generators (FWG) with larger capacities can be seen. Most fresh water generators work according to the operating principle of distillation by utilising part of the engine waste heat. For very high water production, heatindependent fresh water generators are also employed, as described in section 4 on page 15. This Concept Guidance assists in designing the installation which fits best to the fresh water demand while ensuring safe main engine operation. A simple formula in the following section titles allows calculating directly the possible fresh water production corresponding to the installed engine power in kilowatt [kW]. However, this simple formula is only applicable as a first estimation. The final possible water production depends on different factors, mainly on the available waste heat of the engines concerned and the heat demand of the chosen FWG type. The available heat from the high temperature (HT) cooling water circuit depends on the main engine load 1 and the ambient conditions. At lower engine load and in colder ambient conditions the available heat decreases. The fresh water generators heat requirement also depends on the ambient conditions, mainly on sea-water (SW) temperature: in colder ambient conditions the heat requirement increases. Therefore the FWG design has also to be determined in accordance with the vessels operational profile. In case of any doubt, please do not hesitate to contact Wrtsil Switzerland. If other high-temperature cooling water heat consumers are to be installed, the total heat requirement of all heat consumers has to be considered.
And auxiliary engine load for installations as described in sections 2.3 (p. 9) and 2.4 (p. 10).
Group
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CONCEPT GUIDANCE
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3/17
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The system drawings in this Concept Guidance show only installations with separated HT cooling water circuits, i.e. the HT and the LT cooling water circuits are separated by the HT cooling water cooler (HTC). However, this Guidance is also valid for installations with an integrated HT cooling water circuit. In integrated HT cooling water systems, LT cooling water is mixed to the HT circuit to maintain the required temperature at the engine inlet.
separated HT cooling water circuit integrated HT cooling water circuit part of HT out to central cooler
HTC
HT circuit
LT circuit
HT circuit
Fig. 1: The two principal types of cooling water systems 1 Safe engine operation
To avoid any negative impact of FWG operation on the engine, a few basic principles have to be observed: Avoid thermal shock to the engine. The fresh water generator inlet and outlet butterfly valves for the HT water are to be opened and closed slowly and progressively. They should be actuated manually with a large reduction ratio or preferably by a progressive servomotor with timer control. If the valves are manually operated, a conspicuous warning notice has to be positioned next to them. Please keep in mind that 50% to 100% of the cooling function may be taken over by the FWG, depending on the FWG design and the main engine load. Keep the water flow to the main engine always constant. Therefore do not install any stop valve in the main water flow to control the water flow.
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4/17
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On board cargo vessels the fresh water is usually produced by evaporating sea water under vacuum conditions. The most common installation is a single-stage FWG. Different designs are possible, basically divided between those with tube or plate heat exchangers. However, the working principles are the same. Sea water is pre-heated by condensing the vapour in the FWG and heated by HT cooling water. About one third of the sea water evaporates. The vapour flows through the so-called demister which separates water droplets from the vapour. In the sea-water cooled condenser the vapour condensates as so-called distillate. The distillate is pumped to the storage tank. The non-evaporated two thirds of the sea water are removed as brine and pumped overboard. To obtain the vacuum in the FWG, the air has to be removed by an ejector.
air
brine
HT CW out
HT CW in
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2.1
Standard installation (single-stage FWG): up to about 2.2 x 10-3 x CMCR [m3/day] fresh water production. Installation alternative A
The standard installation integrates the fresh water generator directly into the HT circuit. The FWG works as an additional cooler, but without any control valve, i.e. at a constant water flow and heat requirement. Therefore the FWG can only be operated at engine loads with sufficient heat dissipation from the HT cooling water to avoid cooling down the engine. The FWG can be designed to utilise up to 40% of the maximum available HT cooling water heat dissipation at 100% CMCR for the RTA52U-B, RTA62U-B, RTA72U-B and RTA84C engines and up to 50% for the other RTA and RT-flex engines. To ensure that still sufficient heat is available to cover the FWG need, the FWG must not be operated at engine loads lower than 50% CMCR. However, in cold environments the FWG heat demand increases, but the engine heat dissipation decreases, i.e. the FWG has then to be operated at higher engine loads. The possible fresh water production depending on the available heat can be calculated with the following formula: FW produced in m3/day = 32 x 10-3 x QFW. QFW is the available heat in kW from the cylinder cooling water, i.e. 40% and 50% respectively of the cylinder cooling water heat dissipation at 100% CMCR.
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Wrtsil Switzerland Ltd.
CONCEPT GUIDANCE
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6/17
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throttling disc in the main CW pipe fresh water generator by-pass valve FWG heat exchanger HT - SW
HT pump
Fig. 3: Standard installation: MIM fresh water generator installation alternative A As described in section 1 (Safe engine operation) on page 4, the cooling water flow to the engine has always to be kept constant. For this purpose an FWG by-pass line has to be installed: when the FWG is running, the cooling water is distributed to the FWG and to the main cooling water pipe by the throttling disc; when the FWG is shut down, the water is distributed to the FWG by-pass pipe and to the main cooling water pipe. The water flow across the FWG during its operation is equal to that through the by-pass pipe when the FWG is shut down. The by-pass line has to be designed accordingly. The purpose of the throttling disc in the main cooling water pipe is to adjust the pressure loss through this pipe to the pressure loss across the FWG at its nominal heating water flow. 2.2 Optimised installation (single-stage FWG): up to about 3.7 x 10-3 x CMCR [m3/day] fresh water production. Installation alternative B
For higher fresh water demands, it is possible to install an FWG which is designed to utilise up to 85% of the maximum available heat dissipation at 100% CMCR. To protect the engine against excessive cooling in cases where insufficient heat is available, the water flow to the FWG is reduced by a temperature control valve (CVA). During FWG operation, the FWG operates as the main HT cooling water cooler (HTC). Only if the engine HT cooling water heat dissipation is higher than the heat demand of the FWG, does the HTC take the remaining heat.
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7/17
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The FWG installation, with the by-pass pipes, is similar to that of the standard installation (installation alternative A). The FWG is integrated between the additional control valve (CVA) and the HTC control valve (CVB).
controller throttling disc fresh water generator by-pass valve heat exchanger HT - SW
CVA
1 3
main engine
CVB
1
2 3
HT cooler (HTC)
FWG
HT pump
Fig. 4: Optimised installation: MIM fresh water generator installation alternative B Both temperature control valves CVA and CVB are either controlled by: One controller which detects the opening position of the main temperature control valve CVA. Control valve CVB opens only if control valve CVA is already fully open in order to take the remaining heat dissipation. Or: Two separate temperature controllers with different temperature set points to avoid both controllers acting at the same time. The set point of temperature control valve CVB is adjusted 3 C higher than the set point of temperature control valve CVA: control valve CVB will only open if the cooling capacity of the FWG is not sufficient.
RTA / RT-flex
Wrtsil Switzerland Ltd.
CONCEPT GUIDANCE
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2.3
Installation, utilising main and auxiliary engine heat dissipation (single stage FWG): 3.7x10-3 x CMCR (ME) + 5.3x10-3 x base load (AE) [m3/day] fresh water production
A newly-developed system integrating the heat dissipation of the auxiliary engines into the HT system of the main engine is described below. The FWG capacity can be specified by taking into account the additional continuous heat available from the auxiliary engines at base load.
(91C)
HT fr. AE outlet
85C/90C 85C/90C
circulation pump
2
heat exchanger HT - SW
CVA
1 3
HT fr. ME outlet
HT to ME inlet SW in HT to AE inlet
70C
FWG
3 1 2
CVB
HT cooler (HTC)
Fig. 5: Installation option utilising ME and AE cylinder cooling water waste heat A circulation pump ensures a constant water flow to the FWG, independent of main and auxiliary engines load, but at different temperature levels. Depending on the opening position of temperature control valve CVA, part of the flow recirculates through the by-pass line between the FWG inlet and outlet. Control valve CVA maintains the cooling water temperature constant (85C or 90C 2 ) at the main engine outlet. When the whole available heat cannot be dissipated by the FWG, the remaining heat is dissipated in the HT cooler.
2 -
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9/17
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Control valve CVB maintains the temperature of the cooled HT cooling water at 70C. If the cooling water temperature after the control valve CVB falls below 70C, the FWG circulation pump has to be stopped. The 70C warm cooling water can directly be used for pre-heating the stopped auxiliary engines respectively the stopped main engine. Applying of an integrated HT cooling water circuit is also possible. The HT cooler has to be replaced by adding LT cooling water at the connection No. 2 of temperature control valve CVB. Other advantages of this installation, besides the greater fresh water production potential, are: Pre-heating of the ME from the AE is possible when in port. Pre-heating of the AE from the running ME is possible. Only a small pre-heater for one AE is required (not shown in above schematic drawing). For further information on this installation please contact Wrtsil Switzerland. 2.4 Installation with booster heater (single-stage FWG): maximum possible fresh water production depending on the additional booster heater capacity
To increase the available heat for the FWG, also during lower part-load operation of the main engine and in colder ambient conditions, it is possible to install a booster heater. The heater may be operated with steam or thermal oil heated by the exhaust gas boiler, enabling another source of waste heat to be used for the fresh water production. The booster heater can be integrated in the systems as described in section 2.2 on page 7 and section 2.3 on page 9.
RTA / RT-flex
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10/17
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Booster heater integrated in the system of installation alternative B A circulation pump provides a constant water flow to the FWG according to the FWG demand. When the available waste heat from the main engine is not sufficient, control valve CVA provides less HT cooling water to the FWG. In this case the circulation pump recirculates part of the flow of the cooled water through the by-pass line between the FWG inlet and outlet. The booster heater ensures a constant FWG operating temperature.
heat exchanger HT - SW
SW in CVB
2 3 1
HT cooler (HTC)
FWG
HT to eng. inlet
RTA / RT-flex
Wrtsil Switzerland Ltd.
CONCEPT GUIDANCE
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11/17
Version a2
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Booster heater integrated in the system of section 2.3 In the system described in section 2.3 on page 9, a booster heater is integrated after the circulation pump. This ensures that the FWG is always operated at a constant temperature. For an optimum recovery of the HT cooling water heat it is recommended that the FWG outlet temperature be kept at about the same level as the outlet temperature after control valve CVB, i.e. 70C. Therefore the booster heater should be controlled by the FWG outlet temperature.
(91C)
HT fr. AE outlet
circulation pump
2
heat exchanger HT - SW
CVA
1 3
70C
HT fr. ME outlet
HT booster-heater
HT to ME inlet SW in HT to AE inlet
70C
FWG
3 1 2
CVB
HT cooler (HTC)
Fig. 7: Booster heater integrated in the ME and AE cylinder cooling water waste heat utilising system
RTA / RT-flex
Wrtsil Switzerland Ltd.
CONCEPT GUIDANCE
Group
9721
4-107.429.532
12/17
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To increase the possible water production with a given amount of (waste) heat, it is possible to install fresh water generators which utilise the available heat several times. The basic principal behind the higher water production of these FWG is a better reutilisation of the latent vapour condensation heat. 3.1 Multi-effect evaporation FWG installations:
The single-stage FWG installations as described in section 2.1 to 2.4 can be replaced by a multi-effect evaporation FWG. The multi-effect distillers (MED or MEP) utilise the latent vapour heat of the previous stage for evaporation in the following stage, i.e. the vapour condenser is cooled by heating up the sea water of the following stage. Depending on the number of stages, it is possible to produce a multiple amount of fresh water compared to a single-stage FWG installation with the same heat input. The figure below (Fig. 8) shows the working principle of a multi-effect evaporation FWG with five stages as an example. For further information on this FWG type, please contact your FWG maker.
stage 1 vapour demister stage 2 stage 3 stage 4 stage 5 non-condensable (air)
sea water in
distillate
brine out
HT CW out
HT CW in
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8-33
3.2
The multi-stage flash (MSF) FWG type also re-uses a significantly higher amount of the condensation heat compared to the single-stage FWG. The main difference compared to the multi-effect FWG is that the total heat transfer to the sea water takes place before the sea water enters the FWG. First the sea water is heated by the vapour condensation heat, beginning from the last stage up to the first one. Thus the sea water gets already 70-80% (depending on number of stages) of the total required heat. The remaining required heat is provided by the HT cooling water and/or by a booster heater. After the final heating-up, the sea water has got enough latent heat for the multi-evaporation stages, i.e. the sea water inlet temperature is on a higher level compared to the other FWG (nearly HT cooling water outlet temperature).
non-condensable gas sea water distillate
HT CW from engine
stage 1
stage 2
stage 3
stage 4
stage 5
stage 6
steam
brine
Fig. 9: Principal flow diagram of a multi-stage flash evaporator The heated sea water enters the evaporation chambers from one stage to the next. The absolute pressure from the first stage to the last one is steadily decreased in a way that the sea water enters the chambers at a temperature level which is about 7C higher than its boiling temperature. This leads to a spontaneous controlled evaporation of the superheated sea water. The sea water (brine) cools down due to the evaporation chill and flows to the next chamber with again a lower pressure inside. The process goes on until the sea water has passed the last chamber. For further information on this FWG type, please contact your FWG maker.
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Version a2
SW to evap. SW in
CVB
3 1
HT to eng. inlet
HT cooler
The following FWG types are normally only applied if the available heat is absolutely insufficient. They are mentioned here for information only. Reverse osmosis Sea water is forced at high pressure (about 60-70 bar) to pass through an extremely fine semi-permeable filter membrane known as the diaphragm. The filter membrane is permeable to water, but only very limited to salt. The pump therefore presses water without salt through the membrane. Owing to the different salt concentrations on both membrane sides, an osmotic pressure builds up, which tries to balance the salt concentrations on both sides of the membrane by pressing back the saltless water to the salty side. Therefore a pump pressure higher than the osmotic pressure is required. According to an FGW makers data, about 10 kWh of electrical energy is required for 1 m3 fresh water production. About 20% of the supplied sea water permeates saltless to the fresh water side of the membrane. For further information on this FWG type, please contact your FWG maker.
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Vacuum vapour compression The vacuum vapour compression (VVC) FWG consists of only one heat exchanger. The sea water on one side of the heat exchanger is heated by the heat of condensation of the mechanically compressed vapour, which is produced by partial evaporation of the sea water. This heat exchanger operation principle is comparable to the heat exchangers in the multi-effect FWG, except for its first stage.
Fig. 11: Principal flow diagram of a vacuum vapour compression FWG. A mechanical compressor extracts the water vapour from the evaporation chamber, creating a vacuum which is required for sea water evaporation at a low temperature level. The compressed vapour flows from the compressor to the heat exchanger and condenses. According to an FGW makers data, about 25 kWh of electrical energy is required for 1 m3 fresh water production. Another installation option is thermo compression instead of mechanical compression. Steam flows at high velocity through an ejector, creating the required vacuum for sea water evaporation, like the compressor in the mechanical installation, and draws through the created vapour. The steam-vapour mixture flows to the condenser side of the heat exchanger. The reduced steam velocity at this side increases the static pressure, and the steam condenses in the heat exchanger, heating the sea water in the evaporation chamber. The boiler feed water cannot be treated with the usual chemicals, owing to the mixing of vapour and steam. For further information on this FWG type, please contact your FWG maker.
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5 AE CCW
Abbreviations auxiliary engine cylinder cooling water contracted maximum continuous rating cooling water fresh water fresh water generator FWG types: MED MEP MSF RO VVC multi-effect distiller (tube type) multi-effect distiller (plate type) multi-stage flash reverse osmosis vacuum vapour compression
CMCR CW FW FWG
HT HTC LT ME MIM SW
high temperature high temperature cooling water cooler low temperature main engine marine installation manual sea water
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9-1
Delivery head: ............................ (See also table 7.1.) The final delivery head to be determined is subject
to the actual piping layout.
Working temperature: ................ 60C Oil type: ..................................... SAE30, 50 cSt at working temperature; maximum viscosity to be allowed for when sizing of pump motor is 400 cSt
Test pressure: ............................ specified by classification society Working pressure: ..................... 6 bar Working viscosity: ..................... 95 cSt, at working temperature Oil flow: ..................................... refer to table 7.1 Diff. pressure, clean filter: .......... max. 0.2 bar Diff. pressure, dirty filter: ........... max. 0.6 bar Diff. pressure, alarm: ................. max. 0.8 bar Filter inserts bursting press.: ..... min. 8 bar (= differential pressure across the filter inserts) Filter material: ............................ stainless steel mesh Mesh size: ................................. sphere passing max. 0.034 mm
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NOTICE * Alternatively: Automatic back-flushing filter with differential pressure gauge and high differential pressure alarm contacts. Designed to clean itself automatically using reverse flow or compressed air techniques. The drain from the filter is to be sized and fitted to allow free flow into the residue oil tank. The output required by the main lubricating oil pump to back-flush the filter without interrupting the flow is to be taken into account when estimating the pump capacity.
Rated separator capacity: ......... The rated or nominal capacity of the separator is to be according to
the recommendations of the separator manufacturer.
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Total Shell
Table 9.1: Global brands of lubricating oils NOTICE *a) With a sulphur content in the fuel between 1.5 and 2.0%, BN 40 can also be used. *b) With a sulphur content in the fuel between 1.0 and 1.5%, BN 70 can be used only for a short period with low feed rate. *c) This BN 50 cylinder lubricant can be used with up to 3.0% sulphur content in the fuel. *d) This BN 60 cylinder oil is approved for a sulphur content in the fuel between 1.5 and 4.0%. *e) This BN 57 cylinder lubricant can be used over the whole sulphur content range.
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Cylinder Oil *a) Recommended for fuel with sulphur content > 1.5%
Cylinder Oil *b) Recommended for fuel with sulphur content < 1.5%
GulfSea SuperBear 3008 GulfSea Cylcare DCA5070H Servo Marine 0530 Servo Marine 7050 Marine C705 Medripal 570 Marbrax CID-57 KunLun DCA 5070H Supermar Cyl 70 plus Marbrax CID-54-AP Marbrax CID-55 *c)
JX Nippon Oil & Energy Corporation Marine S30 (NOC) Pertamina Petrobras PetroChina SK Medripal 307 Marbrax CAD-308 KunLun DCC3008 Supermar AS
Table 9.2: Local brands of lubricating oils NOTICE The application must be in compliance with the Wrtsil general lubricating oil requirements and recommendations. The supplying oil company undertakes all responsibility for the performance of the oil in service to the exclusion of any liability of Wrtsil Switzerland Ltd.
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Figure 9.1: Arrangement of vertical lubricating oil drains for the 6 cylinders
NOTICE *1) Proposal to determine final position in accordance with shipyard. *2) Alternatively the oil drains may also be arranged symmetrically on port/fuel pump side. WARNING The illustration above does not necessarily represent the actual configuration or the stage of development, nor the type of your engine. For all relevant and prevailing information consult the drawings a the end of this chapter.
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9.7.2 Min. inclination angles at which the engine is to remain fully operational
Classification societies American Bureau of Shipping 2007 Main and aux. engine Abbreviation Heel to each side Rolling to each side Trim by the head *) Trim by the stern *) Pitching Emergency sets Abbreviation Heel to each side Rolling to each side Trim Pitching Electrical installation Abbreviation Heel to each side Rolling to each side Trim Pitching 4/1/1/7.9 22.5 22.5 10 10 C/1/1/2.4 22.5 22.5 10 10 15 22.5 5 7.5 4/8/3/B 100 15 22.5 5 7.5 2/1.1/C.1 22.5 22.5 10 10 4/1/1/7.9 22.5 22.5 10 10 C/1/1/2.4 22.5 22.5 10 10 22.5 22.5 10 10 4/1/3/B 200 22.5 22.5 10 10 2/1.1/C.1 22.5 22.5 10 10 4/1/1/7.9 15 22.5 5 5 7.5 C/1/1/2.4 15 22.5 5 5 7.5 15 22.5 5 5 7.5 4/1/3/B 200 15 22.5 5 5 7.5 2/1.1/C.1 15 22.5 5 5 7.5 Bureau Veritas 2006 China Classification Society 2002 Croatian Register of Shipping Det Norske Veritas 2005 Germanischer Lloyd 2006
Table 9.3: Minimum inclination angles at which the engine is to remain fully operational (1)
Classification societies Korean Register of Shipping 2007 Main and aux. engine Abbreviation Heel to each side Rolling to each side Trim by the head *) Trim by the stern *) Pitching 15 22.5 5 5 7.5 5/1/3.6 15 22.5 5 5 7.5 D/1.3 15 22.5 5 5 7.5 VI-1.6 15 22.5 5 5 7.5 C/1/1/2.4 15 22.5 5 5 7.5 VII-2.3 15 22.5 5 5 7.5 Lloyds Register of Shipping 2006 Nippon Kaiji Koykai 2005 Polski Rejestr Statkow 2004 Registro Italiano Navale 2007 Russian Maritime Register of Shipping 2003
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Classification societies Korean Register of Shipping 2007 Emergency sets Abbreviation Heel to each side Rolling to each side Trim Pitching Electrical installation Abbreviation Heel to each side Rolling to each side Trim Pitching 6/2/1.9 15 22.5 5 7.5 H/1.1.7 15 22.5 5 7.5 VIII-2.1.2.2 15 22.5 5 10 C/2/2/1.6 15 22.5 5 7.5 XI-2.1.2.2 15 22.5 5 10 22.5 22.5 10 10 5/1/3.6 22.5 22.5 10 10 D/1.3 22.5 22.5 10 10 VI-1.6 22.5 22.5 10 10 C/1/1/2.4 22.5 22.5 10 10 VII-2.3 22.5 22.5 10 10 Lloyds Register of Shipping 2006 Nippon Kaiji Koykai 2005 Polski Rejestr Statkow 2004 Registro Italiano Navale 2007 Russian Maritime Register of Shipping 2003
Table 9.4: Minimum inclination angles at which the engine is to remain fully operational (2)
Figure 9.2: Minimum inclination angles at which the engine is to remain fully operational Vertical lubricating oil drains to drain tank No Cyl. 4 6 7 8 Necessary drains 2 2 3 3
The arrangement of lubricating oil drains is to comply with the relevant classification society rules.
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Figure 9.3: Example of an accepted vertical drain connection 001 002 003 004 Rubber gasket Oil strainer Cover Ring 005 006 007 008 Welding flange Hexagon head screw Hexagon head screw Support ring
WARNING For all relevant and prevailing information consult the drawings in section 'Drawings' at the end of this chapter.
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WARNING Be aware that the figure above does not necessarily represent your engine type. For all relevant and prevailing information consult the drawing(s) in section 'Drawings' at the end of this chapter. NOTICE
1)
Level after filling of external system. Volume and level in the lub. oil drain tank depend on capacity of pipes, coolers, filters, etc. The oil volume in tank contains part of the oil quantity which drains back when the pumps are stopped.
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9.8 Drawings
DAAD031391 DAAD026622 DAAD031614 107.246.799 e DAAD033160 DAAD032919 DAAD032783 DAAD032819 DAAD032811 DAAD032975 DAAD032928 DAAD032933 DAAD032934 DAAD032827 107.341.455 a DAAD031671 Lubricating Oil System, Ith Horizontal And Vertical Drains, W4-8 Cyl. .991 --3 _ Lubricating Oil System, 4-8 Cyl. .......................................................991 --6 _ Lubricating Oil Drain Tank, 4-8 Cyl. ..................................................991 --7 _ _ Plate, To Hydraulic Jack, 4-8 Cyl. ..................................................991 --8 _ _ Vertical Oil Drain, 4-8 Cyl. ..............................................................991 --9 _ _ _ Welding Flange, Vertical Oil Drain, 4-8 Cyl. .................................992 --0 _ _ _ Ring, 4-8 Cyl. ...............................................................................992 --1 _ _ _ Cover, Vertical Oil Drain, 4-8 Cyl. ................................................992 --2 _ _ _ _ Plate, Oil Drain Vertical, 4-8 Cyl. ..............................................992 --3 _ _ _ Oil Strainer, For Oil Drain In Bedplate, 4-8 Cyl. ...........................992 --4 _ _ _ _ Ring, On Frame For Oil Straine, 4-8 Cyl. ..................................992 --5 _ _ _ _ Flat Bar, On Frame For Oil Straine, 4-8 Cyl. .............................992 --6 _ _ _ _ Holder, On Frame For Oil Straine, 4-8 Cyl. ...............................992 --7 _ _ _ Rubber Gasket, Vertical Oil Drain, 4-8 Cyl. .................................992 --8 _ Instruction For Flushing, Lubricating Oil System, 4-8 Cyl. ...............993 --1 _ Lubricating Oil Drain Tank, Filling Guidelines, 4-8 Cyl. .....................993 --2
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1 1.1
A correct manufacturing of the pipes avoids the presence of scales, slag and spelter. It is a fact that the expense for special welding methods, e.g. inert gas welding, is worthwhile when considering the costs of an extensive flushing procedure or the grinding and cleaning work if using normal electric arc welding or welding with electrodes. A thorough cleaning of the pipes before mounting is a must.
It is absolutely essential to ensure that the lubricating oil systems are clear of all foreign matter before circulating oil through to the engine. A systematic approach is to be adopted prior to commissioning when the engine, pipe work, filters, heat exchangers, pumps, valves and other components are flushed and are proved absolutely clear of any dirt by observation and physical inspection. The engine crankcase and lubricating oil drain tank are to be inspected and cleaned by hand to remove all residual build-debris; special attention is to be given to very small loose particles of welding matter such as spelter and slag.
The pipes of the entire lubricating oil system on the plant side are to be flushed separately.
1.2
1. Led the lubricating oil connections immediately before the engine straight back into the lubricating oil drain tank by means of hoses or pipes see the figure. 2. Immediately before the engine, in the discharge pipes from the low-pressure and high-pressure lubricating oil pumps, install temporary filters with a mesh size (sphere passing) of max. 0.03 mm and equipped with magnetic elements. The surface loading of the temporary filters should be 1-2 I/cm2h. Alternatively, the plant lubricating oil filters can be used under the condition that the filter inserts are of mesh size of max. 0.03 mm and magnetic elements are used during flushing. After flushing, the filter inserts are to be replaced by the original ones and the filter housing is to be cleaned. In the final step of flushing, it is advisable to fit filter bag made of cotton or synthetic fabric of mesh size 0.040 to 0.050 mm to the end of the hoses or pipes, in order to facilitate checking the cleanliness of the system. 3. If the engine is supplied to the ship in sub-assemblies proceed as follows: Blank off each of the main bearing lubricating oil supply pipes at the main bearings in such a way that absolutely no oil can enter the bearing but oil can escape between pipe and blank piece. Blank off each of the crosshead lubrication linkage in that way, that absolutely no oil can enter the bearing but oil can escape between linkage and blank piece. Blank off the oil supply of the axial damper in that way that absolutely no oil can enter the damper but oil can escape between pipe and blank piece. Disconnect respectively blank off all oil supply pipes to the supply unit, rail unit and the gear train.
1.3
1. Fill the lubricating oil drain tank with sufficient oil to cover the pump suction and heat it up using temporary immersion heaters or the heating coil of the drain tank to approximately 40-60 C. 2. Circulate the oil in the drain tank using the lubricating oil separators(s) and their pre-heater(s) to maintain the flushing temperature to improve oil cleanliness. Operate the separators(s) until all the flushing procedures are completed. 3. All system valves are to be fully open. 4. Good ventilation is to be provided to avoid condensation. At the exhaust side, the crankcase round covers are to be removed and on the fuel pump side the crankcase doors must be opened. 5. Flush the system by starting the low- and high- pressure lubricating oil pumps, the main and stand by pumps are to be alternatively operated. Before starting the pumps, the oil cooler(s) might be bypassed at the beginning of the flushing procedure. Circulate the oil through the pumps and hose connections back to the drain tank. Observe the suction and discharge pressures carefully. Do not let the pumps run hot. Observe the pressure drop through the filters, too.
a 7-67.959 RTFL
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PC
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341_455a__.doc 12.05.2009
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6. During the flushing procedure, the pipes are to be periodically tapped to help loosen any foreign matter that may be present. If available, vibrators are to be used. All pipes used during the engine operation must be flushed, including by-pass lines and the oil cooler(s). Drain the dirt of all equipments (oil cooler(s), suction filters, etc.) where dirt can accumulate. 7. Inspect and clean the filters in the lubricating oil system periodically. Flushing is to be continued until filter bags remain clean and no residues can be found in the filters and; no metallic particles adhere to the magnetic filter inserts and no residues are detected in the bottom of the filter housing. When the system proves clean, remove any filter bags and connect the low- and high-pressure oil supply pipes to the engine.
1.4
Only in the case of engines supplied to the ship in sub-assemblies. 1. Start up the low- and high- pressure lubricating oil pumps and flush through the engine for at least another 8 hours. 2. Inspect and clean the filter in the lubricating oil system periodically. 3. Flushing is to be continued until the filters are absolutely clean: No metallic particles adhere to the magnetic inserts and no residues are detected in the bottom of the filter housing. When the lubricating oil system proves clean, remove all blank pieces and temporary flushing filters. Any pipe-connecting piece, which was not flushed before, must be clean separately. Drain the oil from the distribution pipe to the main bearings. Inspect the inside of the pipes for eventual deposits. If clean, re-fit all oil pipes. Make sure that all screwed connections are tight and secured. Inspect the bottom of the crankcase and clean it if necessary.
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Bypass
NAS 1638 classes Contamination (particles per 100 ml) Particle size in micron 5-15 15-25 25-50 50-100 >100 14 4096000 729600 129600 23040 4096 13 2048000 364800 64800 11520 2048 12 32400 5760 1024 1024000 182400 11 512000 91200 16200 2880 512 10 256000 45600 8100 1440 256 9 128000 22800 4050 720 128 8 64000 11400 2025 360 64 7 32000 5700 1012 180 32 6 2850 506 90 16 16000 5 8000 1425 253 45 8 4 4000 712 126 22 4 3 2000 356 63 11 2 2 178 32 6 1 1000 1 500 89 16 3 1 0 250 44 8 2 0 00 22 4 1 0 125 NAS 1638 cleanliness classes
Recommended limits in NAS 1638 classes The lubricating oil can be considered as clean, if the oil contamination is within the following NAS classes:
Particle size in micron Class 5-15 13 15-25 11 25-50 10 50-100 8 >100 3
Classes
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A number of systems external to the engine are required to maintain heavy fuel oil and marine diesel oil in the quality required for efficient and reliable combustion.
** ISO 8217:2005, class F, RMK700 *1) ISO standards can be obtained from the ISO Central Secretariat, Geneva, Switzerland (www.iso.ch). *2) Limited to max. 991 kg/m3 (ISO-F-RMH700), if the fuel treatment plant (Alcap centrifuge) cannot remove water from high density fuel oil (excludes RMK grades). - The fuel shall be free from used lubricating oil, a homogeneous blend with no added substance or chemical waste (ISO8217:2005-5-1).
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Example: To obtain the recommended viscosity before the fuel engine inlet, fuel oil of 380 mm2/s (cSt) at 50C must be heated up to 120-140C.
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10.1.3 Sulphur
The alkalinity of the cylinder lubricating oil, i.e. the base number (BN), should be selected with regard to the sulphur level of the fuel oil. When using a heavy fuel oil containing less than 1% sulphur, a low BN cylinder lubricant has to be used.
10.1.6 Water
The water content of the fuel oil must be reduced by centrifuging and by the use of proper draining arrangements on the settling and service tanks. A thorough removal of water is strongly recommended to ensure homogenous injection and to reduce the content of hydrophilic cat fines and sodium in the fuel oil. Sodium is not a natural oil component, but marine fuel oil is often contaminated with seawater containing sodium. A content of 1.0% seawater in the fuel oil corresponds to 100 ppm sodium.
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Throughput capacity = ...... 1.2 x CMCR x BSFC / 1000 [litres/hour] Example: ............................ 8-cyl. engine with CMCR R1+: CMCR: 21,280 kW BSFC: 166 g/kWh Throughput = 1.2 x 21,280 x 166 (see table 1.1 Primary engine data) / 1000 = 4,239 litres/hour The marine diesel oil (MDO) separator capacity can be estimated using the same formula. Separator without gravity disc: One of the main features of the self-adjusting separators is that only a single unit is required. This unit operates as a combined purifier/clarifier. However, as it is usual to install a standby separator as a back-up, it is of advantage to use the separator to improve the separation result. For the arrangement of the separators, parallel or in series, refer to the manufacturers instructions.
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These types are running in series with the fuel being purified in one and clarified in the other; thus two separators are required. The clarifier improves the separation result and acts as a safety device in case the purifier is not properly adjusted. When processing heavy fuel oils it is indispensable to strictly adhere to the separator manufacturers instructions. If using these separators it will be advantageous to install an extra separator for marine diesel oil, only to avoid the changing of gravity discs when changing over from HFO to MDO separation. Separation efficiency The separation efficiency is a measure of the separator's capability to remove specified test particles. The separation efficiency is defined as follows: n = 100 (1 - Cout/Cin) where : n .......................... separation efficiency (%) C out ..................... number of test particles in cleaned test oil Cin ....................... number of test particles in test oil before separator The term Certified Flow Rate (CFR) has been introduced to express the performance of separators according to a common standard. CFR is defined as the flow rate in l/h 30 minutes after sludge discharge, at which the separation efficiency of the separator is 85%, when using defined test oils and test particles. CFR is defined for equivalent fuel oil viscosities of 380 cSt and 700 cSt at 50C. More information can be found in the CEN (European Committee for Standardisation) document CWA 15375:2005 (E).
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Pump capacity: ......................... refer to table 7.1; the given capacity is to be within a tolerance of 0
to +20%
Fuel type: ................................... marine diesel oil and heavy fuel oil, up to 730 cSt at 50C Working temperature: ................ ambient to 90C Delivery pressure: ...................... The delivery pressure is to take into account the system pressure
drop and prevent entrained water from flashing off into steam by ensuring that the pressure in the mixing unit is at least 1 bar above the water vapour pressure and no lower than 3 bar. The water vapour pressure is a result of the system temperature and pressure for a given fuel type. Heavier oils need more heat and higher temperatures to maintain them at the correct viscosity than lighter oils; refer to the following formula and example: Delivery gauge pressure = pv + 1 + p1 + p2 [bar]
NOTICE pv = ............................................ water vapour gauge pressure at the required system temperature
[bar] (see viscosity/ temperature diagram fig. 10.1)
p1 = ......................................... maximum pressure losses between the feed pumps and the mixing
unit [bar]
Example HFO of 730 cSt at 50C Required system temperature: ................................ approx. 145C Water vapour gauge pressure at 145C: ................. pv = 3.2 bar Press. losses betw. feed pump and mixing unit: ..... p1 = 0.5 bar Pressure change difference across the pressure regulating valve: ....................................................... p2 = 0.6 bar Substituting these values in the formula: ................ delivery pressure = 3.2 + 1 + 0.5 + 0.6 = 5.3 bar Electric motor The electric motor driving the fuel oil feed pumps shall be sized large enough for the power absorbed by the pump at maximum pressure head (difference between inlet and outlet pressure), maximum fuel oil viscosity (600 cSt) and the required flow.
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Fuel oil viscosity: ....................... 100 cSt, at working temp. (HFO 730 cSt at 50C) Maximum capacity: ................... refer to feed pump capacity in table 7.1 Minimum capacity: .................... approx. 20% of that of the feed pump Service pressure: ....................... max. 10 bar Pressure setting range: ............. 2-6 bar Inlet pressure change: ............... < 0.8 bar, between 20 and 100% flow (upstream pressure build-up
over the valve capacity; between the minimum and maximum flow capacity)
Pump capacity: ......................... refer to table 7.1 Data for central freshwater cooling system (integrated
HT); the given flow rate is to be within a tolerance of 0 to +20%
Inlet pressure ............................. up to 6 bar Delivery head: ............................ see also table 7.1 Data for central freshwater cooling system (integrated HT); final delivery pressure according to the actual piping layout
Working temperature: ................ ambient to 150C Electric motor (booster pump) Refer to the remarks for electric motor for the feed pumps.
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Working pressure: ..................... max. 12 bar, pulsating on fuel oil side Working temperature: ................ ambient to 150C, outlet temperature on fuel oil side Heating capacity [kW]: .............. = 0.75 x 10-6 x CMCR x BSFC x (T1 - T2) Consumption of saturated = 1.32 x 10-6 x CMCR x BSFC x (T1 - T2) (at 7 bar gauge pressure steam: ........................................ [kg/h])
where:
BSFC is the brake specific fuel consumption at the contract maximum continuous rating (CMCR).
The viscosimeter monitors the fuel viscosity before the supply unit and transmits signals to the heater controls to maintain the viscosity by regulating the fuel temperature after the end heater. WARNING For all relevant and prevailing information consult the drawings in section 'Drawings' at the end of this chapter.
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001 002
003 004
005 006
007 008
NOTICE Configuration and dimensioning of the mixing unit have to comply with the relevant classification society/rules. *1) Mounting brackets for fixation on floor plate. The mixing unit must not, under any circumstances, be fitted unsupported.
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Service press. at filter inlet, after feed pumps: .............................. 10 bar Test pressure: ............................ specified by classification society Permitted differential press. at 100 cSt: ..................................... clean filter: max. 0.2 bar dirty filter: 0.6 bar alarm setting: max. 0.8 bar Min. bursting press. of filter insert: ........................................... max. 8 bar differential across filter Working temperature: ................ ambient to 90C Mesh size: ................................. max. 10 micron, sphere passing mesh Filter insert material: .................. stainless steel mesh (CrNiMo) Duplex filter The installation of the automatic back-flushing filter on the low-temperature side does not replace the need for a duplex filter fitted immediately before the supply unit. The same technical data are applied as specified for the arrangement before the supply unit. The filter mesh size (sphere passing) in this case is max. 0.060 mm (60 m). NOTICE For various reasons cat fines may be present in the fuel entering the engine. They often cause excessive piston ring and cylinder liner wear. It is obvious that other exposed parts, e.g. fuel pumps, fuel injection valves, piston rod and piston rod stuffing boxes, will also be damaged if the fuel oil shows a high content of cat fines.
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10-11
As an alternative, the following arrangement is possible: Arrangement before engine inlet (B) Figure 10.3, B): High-temperature (booster circuit). This filter is most important to protect the supply unit and is to be installed as close as possible to the inlet of the supply unit. The absolute minimum requirements are met by using either of the following filters: duplex filter or automatic back-flushing filter. Filter type:
Change-over duplex (full flow) heatable, designed for in-service cleaning, fitted with differential pressure gauge and high differential pressure alarm contacts. or Automatic back-flushing filter heated, with differential pressure gauge and differential pressure alarm contacts. Designed for automatic in-service cleaning, continuous or discontinuous back-flushing, using filtered fuel oil or compressed air techniques.
Further specifications/properties of the filters: Working viscosity: ..................... 13-20 cSt Flow rate: ................................... Booster pump capacity, refer to table 7.1 Data for central freshwater
cooling system (integrated HT). The given capacities cover the needs of the engine only. If an automatic back-flushing filter type is installed, the feed and booster pump capacities must be increased by the quantity needed for back-flushing of the filter.
Service pressure: ....................... max. 12 bar at filter inlet Test pressure: ............................ specified by classification society Permitted differential press. at 20 cSt: .................................. clean filter: max. 0.2 bar dirty filter: 0.6 bar alarm setting: max. 0.8 bar Min. bursting press. of filter insert: ........................................... max. 8 bar differential across filter Working temperature: ................ ambient up to 150C Mesh size: ................................. max. 10 m, sphere passing mesh Filter insert material: .................. stainless steel mesh (CrNiMo)
10-12
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Version a2
10-13
10.5 Drawings
DAAD031642 DAAD026383 DAAD031429 107.341.454 107.428.377 Fuel Oil System, 4-8 Cyl. .....................................................................1-0 5 011 _ Fuel Oil System, 4-8 Cyl. ..................................................................1-0 7 011 _ Mixing Unit, 4-8 Cyl. .........................................................................1-0 8 011 _ Instruction For Flushing, The Fuel Oil System, 4-8 Cyl. ...................1-0 0 012 _ Distillate Fuels, Installation Aspects, 4-8 Cyl. ...................................1-0 5 013
10-14
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Version a2
10-15
10-16
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Version a2
10-17
10-18
Version a2
1 1.1
1.2
1. By-pass the fuel oil connections immediately before the supply unit by means of temporary hoses or pipes as shown in the figure. 2. Install in the by-pass line a temporary filter with a mesh size (sphere passing mesh) of max. 0.03 mm and equipped with magnetic elements. Alternatively, the plant fuel oil duplex filter, if available, can be used under the condition that the filter inserts are of mesh size (sphere passing mesh) of max. 0.03 mm. After flushing the filter, inserts are to be replaced by the original ones and the filter housing to be cleaned.
1.3
Flushing procedure
1. Fill the daily tank with sufficient marine diesel oil (MDO). 2. Circulate the MDO in the daily tank using the separator(s) and pre-heater(s) to maintain the cleanliness and the MDO temperature at approximately 30 Operate the separator(s) until the C. flushing procedure is completed. 3. Circulate the MDO through the whole fuel oil system back to the daily tank by running the feed and booster pump. Both pumps (feed and booster pump) must be in operation to ensure a correct fuel oil circulation through the whole fuel oil system. As the capacity of the booster pump(s) is higher than the one of the feed pump(s), part of the fuel returns, via the mixing tank, directly to the booster pump. The fuel must circulate freely in the return pipe to the daily tank and from the feed pump to the mixing unit. The main and stand-by pumps are to be alternatively operated. Observe the suction and discharge pressure carefully; do not let run the pumps hot. Observe the pressure drop through the filters too. 4. During the flushing procedure, the pipes are to be periodically tapped to help loosen any foreign matter that may be present. If available, vibrators are to be used. All pipes used during the engine operation must be flushed, including by-pass lines. Inspect and clean all filters in the fuel oil system periodically. Drain the dirt of all equipments (mixing unit, end heater, etc.) where dirt can accumulate.
Flushing is to be continued until absolutely no residues can be found in the filters: No metallic particles adhere to the magnetic inserts and no residues are detected in the bottom of the filter housing. When the fuel oil system proves clean, the temporary flushing equipment can be removed and the engine connected to the fuel oil system.
PC
RTFL
Wrtsil Switzerland Ltd.
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1 of 1
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341_454___.doc 14.04.2004
Version a2
10-19
To daily tank
31
F10.5290
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2/2
10-20
Version a2
Table of contents: 1. 2. 3. 3.1 3.1.1 3.1.2 3.1.3 4. 4.1 4.2 5. 6. 7. Introduction.....................................................................................................2 Fuel oil viscosity..............................................................................................2 Fuel oil system................................................................................................3 Pressurised fuel oil system .............................................................................4 Cooler position................................................................................................4 Cooler principle...............................................................................................4 Cooler heat dissipation ...................................................................................4 Fuel change-over procedure...........................................................................7 Change-over from DO to HFO ........................................................................7 Change-over from HFO to DO ........................................................................7 Cylinder oil lubrication.....................................................................................8 Cylinder oil lubricating system ........................................................................8 Enclosures ......................................................................................................9
Q-Code
X X X X X 08.01.10
Replaced by: Substitute for:
77-747
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1. Introduction Current and foreseen marine fuel legislation is limited to prescribing the maximum sulphur content of marine fuel oils or to reduce the sulphur in the exhaust gas with alternative methods equivalently. The availability of fuels with various sulphur levels is not yet fully clear. However, as the demand for sulphur content in the fuel is reduced below 0.5%, the possibility of distillate fuel increases. According to ISO 8217 standard, distillate fuels are categorised as DMX, DMA (also called MGO) and DMB (often called MDO). DMX is emergency fuel with a lower flashpoint, coming with additional storage precautions. Due to the low flash point, this fuel would not normally be used in marine diesel engines: DMA and DMB being the most common distillate fuels. Wrtsil Switzerland allows for its engines to be operated on all fuels supplied under the ISO 8217 standard. This guide line is to mainly give information about the impact on the installation side, when using distillate fuels according to ISO 8217 standard. It is valid for RT-flex and RTA engines.
2. Fuel oil viscosity The current recommendation for fuel viscosity at the fuel injector is 13 to 17cSt when operating on HFO. However, this viscosity level cannot be met with MDO and MGO unless the fuel is cooled down to very low temperatures. Experience has however shown that viscosities for grades DMA and DMB distillate fuels have no adverse affect on the operation of the fuel system components: a nominal lower viscosity level of 2 cSt at the fuel pump is recommended. To achieve this level a cooler may be required depending on the actual temperature of the distillate fuel delivered to the engine. Table 1, page 9, shows the ISO 8217 standard. As example, the viscosity of the DMA grade as a function of the temperature is shown in figure 2, page 10.
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3. Fuel oil system A complete fuel oil system including the fuel oil treatment with a tank arrangement for various fuel oil qualities and the pressurised system is shown in figure 3, page 11. The tank arrangement shown in this enclosure is one possibility among several others. Further possible tank arrangements, as example: 1) HFO LSHFO DO HFO LSHFO DO HFO & LSFO combined HFO LSHFO DO 1 settling tank 1 settling tank 1 settling tank 2 settling tanks 2 settling tanks 1 settling tank 2 settling tanks 1 service tank 1 service tank 1 settling tank + 1 service tank + 1 service tank + 1 service tank + 1 service tank + 1 service tank + 1 service tank
2)
3)
+ 1 service tank
Remark concerning the fuel oil pumps The feed and booster pump capacities should be specified for the lower fuel oil viscosity, which normally corresponds to the MDO grade (7 - 11 cSt at 40C). With lower fuel viscosities, the nominal pump capacities will decrease, therefore this has to be considered when determining the capacities of the feed and booster pumps. Furthermore, the lower lubricating capacity of distillate fuels with low viscosity compared to HFO may influence the lifetime of the feed and booster pumps, especially when operating long periods with these fuels. Therefore, the advice of the pump manufacturers should be sought regarding pump performance when operating with distillate fuels.
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3.1
The main difference to the standard pressurised fuel oil system is the adding of a cooler, as shown in figure 4, page 13, to cool down the DO depending on the used viscosity grade. 3.1.1 Cooler position The cooler-chiller unit should be located before the viscosimeter with the sensor to control the fuel temperature located close to the engine inlet. Other locations, as for example in the fuel engine return line, are not recommended. The advantage of locating the cooler close to the engine inlet is to reduce as far as possible the reaction time of the fuel temperature control as it is done with fuel end heater, which is also located in the fuel delivery line to the engine. 3.1.2 Cooler principle There are two possible cooling principles: - Direct cooling: where the heat exchange directly occurs between the distillate fuel and the refrigerant (refrigerant fuel). - The indirect-cooling: Where the refrigerant cools down fresh water (FW), which in turns cools down the distillate fuel (refrigerant FW / FW distillate fuel), as shown in figure 4. The double heat exchanger arrangement is favoured basically in the event of fuel or refrigerant leakages; therefore direct cooling seems to be not accepted by the classification societies. However, shipyards should approach class for their advice / rules regarding direct cooling systems. Seawater as coolant is, of course, not recommended at all.
3.1.3 Cooler heat dissipation The cooler heat dissipation (Q) is determined by the following formula: Q = m cp DT [kW ]
Where:
m cp cp DT T1 T2
mass of the distillate fuel passing the cooler [kg/s] specific heat capacity of the distillate fuel [kJ/kg C] 2.0 2.2 kJ/kg C T1 T2 temperature at the cooler inlet [C] temperature at the cooler outlet [C]
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The temperature (T1) results from the mixing of the fuel part returning from the engine (temperature Tr) and the distillate fuel supply to the engine (temperature T1); the distillate fuel amount corresponding to the actual fuel consumption, see below figure. The temperature difference (Tr T2) corresponds to the fuel temperature increase across the engine injection system.
From the engine
Tr
To the engine
T2
chiller unit
T1'
T1
Figure 1
The below formulae allow to determine the required heat dissipation at 100% engine load by taking into account the temperature increase across the engine.
BSFC P ( DT + 6) 1.42 10 6
Where:
Q BSFC P DT T1 T2
Cooler heat dissipation at 100% engine load Specific fuel consumption at design conditions and 100% engine load [g/kWh] Engine power at 100% CMCR [kW] T1 T2 Temperature of the distillate fuel supply [C] Distillate fuel temperature required at engine inlet [C]
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At 100% engine load, the temperature at the cooler inlet (= mixing temperature T1) can simply be determined by the following formulae: For RT-flex engines T1 = 0.455 T 1 + 0.545 T 2 + 2.73 [C] For RTA engines T1 = 0.455 T 1 + 0.545 T 2 + 5.46 [C]
Q=
Q=
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4. Fuel change-over procedure (Refer to figure 3) Changing over from diesel oil (DO) to heavy fuel oil (HFO) and vice versa
The change-over of the main engine operating mode HFO / DO or vice versa occurs through the three-way valve installed in the suction line from the HFO and DO tank (see figure 4, position 01). When changing from one fuel to another however, thermal shock to the engine fuel injection system (injection pumps, piping, etc.) has to be prevented. Sudden temperature changes may lead to seizing of the fuel pump plungers; this may affect the manoeuvrability of the ship, or result in fuel pipe leakage with the risk of fire. Not only the temperature increase when changing over from DO to HFO is important, but also the temperature decrease when changing over from HFO to DO. The experience gained so far shows that the use of change-over valves (01) with time delay (e.g.: 10 duration from 100% on HFO to 100% DO), and acting therefore as mixing valves, has not been very successful. This is due to the fact that to mix both fuels properly, the HFO and DO pressures at the valve inlet must be equal, which, in practice, is hardly feasible. A metering device gradually mixing DO and HFO to obtain the required temperature gradient could be foreseen. However, such a metering device will require additional components (pumps, mixing valve, etc.) to the existing fuel oil circuit and is considered as not necessary.
4.1
The fuel viscosity is controlled by the viscosimeter and the increase in the fuel temperature itself can be manually or automatically controlled. Depending on the viscosimeter type, a temperature ramp (gradient) can be set to automatically control the change in temperature. The maximum temperature gradient must not exceed 15 C/min. The engine load must not exceed 75% of CMCR until the change-over procedure is finalised and the required HFO viscosity (13 to 17 cSt) is reached. The trace heating on the engine and installation side must be turned on at the same time when changing over. The change-over procedure itself is detailed in the relevant engine operating manual.
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A large capacity of the mixing unit will be of advantage in further reducing the temperature gradient. This will however increase the period for which both fuels are present together, and consequently the risk of compatibility problems may increase. The pipe diameters are normally dictated by the fluid velocity, however, the use of larger pipe diameters as required for the fuel oil pressurised circuit will be of advantage too, e.g. DN80 instead of DN65 A suggested measure to reduce the temperature difference between both fuels before changing over is to increase the DO temperature in the service tank. Such a measure should be considered with caution: the flash point of distillate fuels being rather low, e.g. 60C for DMA grade. Further, this measure can be considered as a waste of energy: on one hand the DO is pre-heated and on the other hand is cooled down again to reach the required viscosity before entering the engine. Figure 5, page 14, shows, as example, the progression trend of the fuel temperature as a function of the time for various engine loads by switching the change-over valves (01) from HFO to DO without any time delay. The highest temperature drop resulting in the highest temperature gradient takes place just after the change-over as it can be seen on this enclosure. The engine load must be lower than 50% CMCR until the change-over procedure is finalised and until the required DO viscosity ( 2 cSt) is reached. After a short period following the change-over from HFO to DO, the trace heating on the engine and installation side must be shut off. The change-over procedure itself is detailed in the relevant engine operating manual.
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Parameter Density at 15 C Viscosity at 40 C Viscosity at 40 C Micro Carbon Residue at 10% Residue Micro Carbon Residue Water Sulphur c Total Sediment Existent Ash Vanadium Aluminium + Silicon Flash point Pour point, Summer Pour point, Winter Cloud point Calculated Cetane Index Appearance Zinc
d
Unit kg/m mm/s mm/s % m/m % m/m % V/V % (m/m) % m/m % m/m mg/kg mg/kg C C C C
Limit Max Max Min Max Max Max Max Max Max Max Max Min Max Max Max Min
Phosphorus d Calcium
d
A sulphur limit of 1.5% m/m will apply in SOx Emission Control Areas designated by the International Maritime Organization, when its relevant Protocol comes into force. There may be local variations. The Fuel shall be free of ULO. A Fuel is considered to be free of ULO if one or more of the elements are below the limits. All three elements shall exceed the limits before deemed to contain ULO. Source: ISO 8217 Third Edition 2005-11-01 Petroleum products - Fuels (class F) - Specifications of marine fuels
Table 1
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Example: DMA with a viscosity of 1.5 cSt at 40C, the fuel should be cooled down to 22C to reach 2cSt.
3.0 2.8 2.6 2.4 2.2 2.0 1.8 1.6 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
Figure 2
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10-30
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Fuel oil system
19
19
Drawn: Verif::
15 16 18 19 19
From MDO service tank
14
17
RTMOT
From HFO service tank
&
20.11.09 30.11.09
25 25 26 27 25 23 22
From MDO settling tank
19
01
D
20
03 24 28 12 02
21
4-107.428.377
13
06
05
04
*1)
A B C D
These 3 change-over valves should be interconnected Change-over LSHFO and HFO for fuel treatment Change-over LSHFO and HFO for ME operation Change-over LSHFO/HFO and MDO for ME operation
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10-31
Table 2 Remarks:
*1) The return pipe may also be led to the HFO service tank. *2) Pump may be omitted, if integrated in separator. *3) Separator capacity related to viscosity in accordance with the instructions of the separator manufacturer.
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14
15
16
HFO
HFO
Distillate fuel
01
12 13
03
02 10
11 08
09
06
05
04
07
Refrigerant
Figure 4
01 02 03 04 05 06 07 08 09 10 Three-way valve, manually or remotely operated Pressure regulating valve Low pressure feed pump Mixing unit High pressure booster pump Fuel end heater Chiller (cooler-chiller unit) Fresh water circulating pump (cooler-chiller unit) Temperature control valve (cooler-chiller unit) FW fuel oil cooler (cooler-chiller unit) 11 12 13 14 15 16 Temperature sensor Viscosimeter Fuel oil filter HFO settling tank HFO service tank Distillate fuel service tank
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10-33
Fuel oil temperature at the engine inlet as a function of the time when changing over at once from HFO to DO
HFO temperature 145C DO temperature 35 C
150.0 140.0 130.0 120.0 F u e l o il te m p e ra tu re [d e g r.C ] 110.0 100.0 90.0 80.0 70.0 60.0 50.0 40.0 30.0 20.0 0 5 10 15 Time [min] 20 25 30 35
DO
75%
Figure 5
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03
04
Figure 6
01 02 03 04
Cylinder lubricating oil storage tanks Deck connection Cylinder lubricating oil service tanks Three-way valve, manually or remotely operated
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Compressed air is required for engine starting, engine control, exhaust valve air springs, washing plant for the scavenge air coolers, and general services.The starting and control air system shown in figure 11.1 comprises two air compressors, two air receivers, and systems of pipework and valves connected to the engine starting air manifold. For all relevant and prevailing information consult the drawings in section 'Drawings' at the end of this chapter.
Version a2
11-1
Number of starts requested by the classification societies for reversible engines: 12 *1) Max. air pressure: 30 bar Number x volume
*3)
Free air delivery at: 30 bar Number x capacity *3) [Nm3/h] 2 x 165 2 x 165 2 x 165 2 x 180 2 x 180 [kgm2] 60,000 68,000 80,000 95,000 112,000
[m3]
4 5 6 7 8
12 consecutive starts of the main engine, alternating between ahead and astern.
*2) Data
given for engines without damper and front disc on crankshaft, but smallest flywheel included.
*3)
Data for air pressure of 25 bar are available on winGTD and netGTD.
11-2
Version a2
Capacity: ........................... refer to section 11.1.1 Delivery gauge pressure: .... 30 bar
Capacity: ........................... refer to section 11.1.1 Working gauge pressure: .... 30 bar
11.4 Drawings
DAAD026756 Starting Air System, 4-8 Cyl. ...............................................................1-15 11-
Version a2
11-3
11-4
Version a2
Version a2
11-5
Dirty oil collected from the piston underside is led under a pressure of approximately 2.8 bar to the sludge oil trap and then to the sludge oil tank. The purpose of the sludge oil trap is to retain the large amount of solid parts contained in the dirty oil and to reduce the pressure by means of an orifice or throttling disc fitted at its outlet, so that the sludge oil tank is under atmospheric pressure. The dirty oil from the piston rod stuffing box, which consists of waste system oil, cylinder oil, metallic particles and small amounts of combustion products, is led directly to the sludge tank. Condensate from scavenge air is formed when the vessel is operating in a humid climate and is to be continually drained from the scavenge air receiver to avoid excessive piston ring and liner wear. WARNING For all relevant and prevailing information consult the drawings in section 'Drawings' at the end of this chapter.
Version a2
12-1
12-2
Version a2
Engine exhaust uptakes can be drained automatically using a system as shown in figure 12.2.
WARNING For all relevant and prevailing information consult the drawings in section 'Drawings' at the end of this chapter.
Version a2
12-3
12.3 Drawings
DAAD030307 DAAD026757 107.425.369 Leakage Collection/Washing Sys., System Diagram, 4-8 Cyl. ............1-25 21_ Leakage Collection/Washing Sys., 4-8 Cyl. ......................................1-27 21_ Sludge Oil Trap, 4-8 Cyl. ...................................................................1-28 21-
12-4
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Version a2
12-5
12-6
Version a2
Version a2
12-7
12-8
Version a2
The following gas velocities are indicated as a guideline for an optimised exhaust gas system.
Version a2
13-1
The engine room ventilation is to conform to the requirements specified by the legislative council of the vessels country of registration and the classification society selected by the shipowners. Calculation methods for the air flows required for combustion and keeping the machinery spaces cool are given in the international standard ISO 8861 Shipbuilding - Engine-room ventilation in diesel engined ships; Design requirements and basis of calculations. Based on ISO 8861, the radiated heat, required air flow and power for the layout of the engine room ventilation can be obtained from the winGTD and netGTD on the Licensee Portal. The final layout of the engine room ventilation is, however, at the discretion of the shipyard.
Figure 14.1: Direct suction of combustion air - main and auxiliary engine
Version a2
14-1
Figure 14.2: Direct suction of combustion air - main and auxiliary engine
14-2
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14-3
There are up to three blow-off valves fitted on the scavenge air receiver. In the event that the air inlet temperature to the turbocharger is less than +5C the first blow-off valve vents. For each actuated blow-off valve, a higher suction air temperature is simulated by reducing the scavenge air pressure and thus the air density. The second blow-off valve vents automatically as required to maintain the wanted relationship between scavenge and firing pressures. Figure 14.4 shows the effect of the blow-off valves on the air flow, the exhaust gas temperature after turbine and the firing pressure. Control of the blow-off valves is effected by means of a signal generated by the temperature sensors in the inlet piping. Care is to be taken that no foreign particles in the form of ice gain access to the turbocharger compressor in any way, because they could lead to its destruction. Reduction of the pipes cross sectional area by snow is also to be prevented. NOTICE The scavenge air cooling water inlet temperature is to be maintained at min. 25C. This means that the scavenge air cooling water will have to be preheated in the case of low-power operation. The required heat is obtained from the lubricating oil cooler and the engine cylinder cooling.
14-4
Version a2
pumpside suction delivery suction delivery suction delivery suction delivery suction delivery 32 [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] 2.6 676 2.5 458 2.7 494 2.6 676 1.0 3.5 1.2 5.7 1.3 9.5 1.5 16.7 1.6 27.5 1.8 53 2.0 93 2.2 148 2.3 267 2.6 302 2.6 476 1.4 4.9 1.6 7.6 1.8 14.0 2.0 22.0 2.1 36.1 2.2 65 2.3 107 2.4 161 2.5 291 1.5 5.2 1.7 8.1 1.9 14.8 2.1 23.3 2.2 37.8 2.3 68 2.4 112 2.5 168 2.6 302 2.7 494 2.7 702 1.5 5.2 1.7 8.1 1.9 14.8 2.1 23.3 2.2 37.8 2.3 68 2.5 116 2.6 175 2.7 314 2.7 494 2.7 702 0.6 2.1 0.7 3.3 0.8 6.2 0.8 8.9 0.9 15.5 0.9 27 1.1 51 1.3 87 1.3 151 1.3 238 1.3 338 1.0 3.5 1.2 5.7 1.4 10.9 1.5 16.7 1.6 27.5 1.6 47 1.7 74 1.8 114 1.8 198 1.9 330 1.9 494 0.9 3.1 1.0 4.7 1.1 8.6 1.2 13.3 1.3 22.3 1.4 31 1.5 70 1.5 101 1.1 3.8 1.2 5.7 1.3 10.1 1.4 15.6 1.5 25.8 1.6 47 1.7 79 1.8 121 0.5 1.7 0.5 2.4 0.5 3.9 0.6 6.7 0.6 10.3 0.7 21 0.8 37 0.9 60 0.6 2.1 0.7 3.3 0.8 6.2 0.9 10.0 1.0 17.2 1.2 36 1.4 65 1.6 107 -
40
50
65
80
100
125
150
Version a2
15-1
Medium Nominal pipe diameter Aluminium brass 350 Aluminium brass 400 Aluminium brass 450 Aluminium brass 500 Aluminium brass Pipe material
pumpside suction delivery suction delivery suction delivery suction delivery suction delivery [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] [m/sec] [m3/h] 2.6 1,678 2.9 1,872 2.6 1,351 2.9 1,507 2.7 1,743 2.6 1,067 2.8 1,149 2.7 1,403 2.6 817 2.8 800 2.6 1,067 2.8 728 2.6 817 2.7 848 2.7 1,108 2.7 1,403 2.7 1,743 2.7 848 2.7 1,108 2.7 1,403 2.7 1,743 1.4 440 1.4 575 1.4 727 1.5 968 2 597 2 780 2 987 2.1 1,227 -
Table 15.1: Recommended fluid velocities and flow rates for pipework NOTICE The velocities given in the above table are guidance figures only. National standards can also be applied.
15-2
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15-3
15-4
Version a2
Version a2
15-5
16.1 Drawings
DAAD025574 Pipe Connection Plan, 6 Cyl. ...............................................................1-63 61-
Version a2
16-1
16-2
Version a2
Version a2
16-3
Developments in Automation & Controls at Wrtsil are focussed on the latest trends in ship automation that tend to still higher integration levels. The standard electrical interface, designated DENIS-UNIC (Diesel Engine CoNtrol and optImizing Specification), assures a perfect match with approved remote control systems, while the UNIC (Wrtsil Engine Control System) takes care of all RT-flex-specific control functions. All those systems provide data bus connection to the ship automation to facilitate installation and make specific data available wherever required. Complete ship automation systems provided by one of the leading suppliers approved by Wrtsil offer the degree of integration demanded in modern shipbuilding while being perfectly adapted to the engines requirements. Applying a single supplier strategy for the entire ship automation shows many other advantages in terms of full responsibility, ease in operation and maintenance. DENIS ................. The DENIS family contains specifications for the engine management systems of all
modern types of Wrtsil two-stroke marine diesel engines. The diesel engine interface specification applicable is DENIS-UNIC.
UNIC ................... Under the designation of UNIC, Wrtsil Switzerland Ltd. provides a fully embedded
engine control system. The UNIC system is handling e.g. tasks related to fuel injection, exhaust valve control, cylinder lubrication, engine crank angle measurement and speed/load control. The system uses modern bus technologies for safe transmission of sensor- and other signals.
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interface (HMI) of the vessels automation can therefore also handle the additional MMI functions attributed to the UNIC. Ship automation from one supplier - integrated solution Automation suppliers approved by Wrtsil can handle all ship board automation tasks. Complete automation systems from one supplier show advantages like easier engineering, standardisation, easier operation, less training, fewer spare parts, etc. The UNIC is well suited to support this integrated automation concept by providing redundant data bus lines that deliver all necessary information for propulsion control, alarm / monitoring system and man-machine interface. The HMI of the UNIC can provide additional features when using such an integrated solution. Ship automation from different suppliers - split solution In case the propulsion control and alarm / monitoring systems are from different suppliers, the UNIC also supports such a split solution by providing two separate redundant data bus lines, one each for the propulsion control and the alarm / monitoring system. In that case the MMI functions are also split within propulsion control and alarm / monitoring system. UNIC describes the signal interface between the RT-flex engine and the ship automation.. UNIC specification does not include any hardware. It summarises all the data. UNIC specification is presented in two sets of documents: UNIC engine specification This file contains the specification of the signal interface on the engine and is made available to engine builders and shipyards. It consists basically of the control diagram of the engine, the signal list including a minimum of functional requirements, and gives all information related to the electrical wiring on the engine It lists also the necessary alarm and display functions to be realised in the vessels alarm and monitoring system. The UNIC engine specification covers the engine-built components for control, alarm and indication. UNIC remote control specification This file contains the detailed functional specification of the remote control system. The intellectual property on this remote control specification remains with Wrtsil. Therefore this file is licensed to remote control partners of Wrtsil only. The companies offer systems which are built exactly according to the engine designers specifications, tested and approved by Wrtsil.
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engines. All approved propulsion control systems listed below comprise the same functionality specified by Wrtsil
Supplier / company Kongsberg Maritime Kongsberg Maritime AS P.O. Box 1009 N-3194 Horten Norway NABTESCO Corporation NABTESCO corp., Marine Control Systems Company Tel. +81 78 967 5361 1617-1, Fukuyoshi-dai 1-chome Fax +81 78 967 5362 Nishi-ku Kobe, 651-22413 Japan SAM Electronics GmbH / Lyngs Marine SAM Electronics GmbH Behringstrasse 120 D-22763 Hamburg Germany Lyngs Marine AS 2, Lyngs All DK-2970 Hrsholm Denmark Tel. +49 40 88 25 0000 Fax +49 40 88 25 4116 Tel. +45 45 16 62 00 Fax +45 45 16 62 62 M-800-III km.sales@kongsberg.com Tel. +47 81 57 37 00 Fax +47 85 02 80 28 AutoChief C20 Remote control system
DMS2100i
Table 17.1: Suppliers of remote control systems Modern remote control systems consist of electronic modules and operator panels for display and order input for engine control room and bridge. The different items normally communicate via bus connections. The engine signals described in the UNIC specification are connected via the terminal boxes on the engine to the electronic modules placed in the engine control room. These electronic modules are built to be located either inside the ECR console or in a separate cabinet to be located in the ECR. The operator panels are to be inserted in the ECR consoles surface.
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The classification societies require different alarm and safety functions, depending on the class of the vessel and its degree of automation. These requirements are listed together with a set of sensors defined by Wrtsil in the tables below. The time delays for the slow-down and shut-down functions given in tables below are maximum values. They may be reduced at any time according to operational requirements. When decreasing the values for the slow-down delay times, the delay times for the respective shut-down functions are to be adjusted accordingly. The delay values are not to be increased without written consent of Wrtsil. Included in the standard scope of supply are the minimum of safety sensors as required by Wrtsil for attended machinery space (AMS). If the option of unattended machinery space (UMS) was chosen, the respective sensors have to be added according to the requirements issued by Wrtsil. There are also some additional sensors defined for the monitoring of flex system-specific engine circuits. The extent of delivery of alarm and safety sensors has to cover the requirements of the respective classification society, Wrtsil, the shipyard and the owner. The sensors delivered with the engine are basically connected to terminal boxes mounted on the engine. Signal processing is performed in a separate alarm and monitoring system usually provided by the shipyard.
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Cylinder cooling water PT1101A PS1101S Engine Inlet Temperature Outlet each cyl. TE1111A TE1121-28A ALM SLD SHD ALM ALM SLD L L L L H H 4.5 bar 4.3 bar 4.0 bar 65 C 95 C 97 C 0 60 60 0 0 60
Pressure
Engine Inlet
Scavenge air cooling water Pressure Inlet cooler Fresh water singleInlet cooler stage Temperature Outlet cooler Main bearing oil PT2001A PS2002S Temperature Supply TE2011A ALM SLD SHD ALM SLD ALM SLD L L L H H H H 4.0 bar 3.8 bar 3.3 bar 50 C 55 C 65 C 70 C 0 60 10 0 60 0 60 PT1361A TE1371-72A TE1381-82A ALM ALM ALM L L H 2.0 bar 25 C 80 C 0 0 0
Pressure
Supply
Temperature Oultet Bearing 2-10 Servo oil Pressure Flow *1) leakage monitoring Level Thrust bearing oil Temperature Outlet Thrust rad. bearing Thrust bearing pads Injector cooling Pump inlet Servo oil pipes Rail unit
TE2102-10A
L L H H
30 0 0 0
TE2101A
ALM SLD
H H
65 C 70 C
0 60
TE4521A TS4521S
H H H
75 C 80 C 85 C
0 60 60
Crank bearing oil Temperature Outlet Bearing 1-8 Crosshead bearing oil Temperature Outlet Bearing 1-8 TE2301-08A ALM SLD H H 65 C 70 C 0 60 TE2201-08A ALM SLD H H 65 C 70 C 0 60
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Alarm and safety functions Medium Phys. Value Location Signal No. Function Level
Oil mist concentration Concentration Failure Piston cooling oil Temperature Outlet each cyl. TE2501-08A ALM SLD SHD SHD H H H L 80 C 85 C 190 l/min 80 l/min 0 60 15 15 Crankcase Detection unit AS2401A AS2401S XS2411A ALM SLD ALM H H F ---0 60 0
FS2521-28S
Pressure
Inlet each TC
ALM SLD SHD ALM SLD ALM SLD SHD ALM SLD ALM SLD SHD ALM
L L L H H L L L H H L L L H H H H H H
1.0 bar 0.8 bar 0.6 bar 110 C 120 C 0.7 bar 0.6 bar 0.4 bar 85 C 90 C 1.3 bar 1.1 bar 0.9 bar 130 C 140 C 85 C 90 C 60 C 65 C
5 60 5 0 60 5 60 5 0 60 5 60 5 0 60 0 60 0 60
Temperature Outlet TC
Pressure
Inlet each TC
TE2601-02A PT2611-12A
Inlet each TC
*2)
PS2611-12S TE2601-02A
Separate TC lub. oil supply Temperature Outlet TC ABB A100-L Inlet TC ABB A100-L Additional requirement when separate Temperature TC lub. oil supply Inlet TC MHI MET MB Turbocharger overspeed Speed Geislinger damper oil Pressure Axial damper (detuner) oil Pressure Cylinder lubricating oil Diff. pressure Oil filter Aft side Fore side Casing inlet TC casing
TE2621A
TE2621A
ST5201-02A
ALM
*7)
PT2711A
ALM
1.0 bar
PT2721A PT2722A
ALM ALM
L L
60 60
PS3121A
ALM
0.X bar
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Alarm and safety functions Medium Fuel oil Regulating Position Viscosity Fuel pumps Before supply unit TE3411A *3) PT3421A Fuel pumps and pipes Fuel pipe LS3426A LS3446A ALM ALM ALM ALM ALM ALM ALM ALM D H L H L L H H Phys. Value Location Signal No. Function Level
30 0 0 0 0 0 0 0
ALM Temperature After each cylinder TT3701-08A ALM SLD SLD Before each turbocharger Temperature After each turbocharger Scavenge air ALM After each cooler Temperature Each piston underside TE4081-88A *5) LS4071-72A TE4031-32A *4) ALM SLD ALM SLD ALM SLD ALM SLD TT3731-32A TT3721-22A ALM SLD ALM SLD
H D H D H H H H
0 0 60 60 0 60 0 60
L H H H H H H H H
0 0 60 0 60 0 60 0 60
Water separator Condensation water Level *6) Before water separator Starting air Pressure Air spring air Engine inlet
LS4075-76A
PT4301C
ALM
12.0 bar
ALM Pressure Distributor PT4341A ALM SLD PS4341S Leakage oil Control air Supply Stand-by supply Pressure Engine inlet PT4401A PT4411A PT4421A ALM ALM ALM Level Exh. Valve air LS4351A SHD ALM
H L L L H
0 0 60 0 0
L L L
0 0 0
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Alarm and safety functions Medium Engine ok Overspeed Speed Crankshaft ST5111-12S SHD H Phys. Value Location Signal No. Function Level
110%
*1) ALM has to be suppressed at low load. *2) The indicated alarm and slow-down values and the values indicated are minimum settings allowed by the TC maker. In order to achieve an earlier warning, the ALM and SLD values may be increased up to 0.4 bar below the minimum effective pressure measured within the entire engine operation range. The final ALM/SLD setting shall be determined during commisioning / sea trial of the vessel. *3) ALM vale depending on fuel viscosity. *4) For water separators made from plastic material the sensor must be placed right after the separator. *5) Acts as fire monitor *6) Alternatively, low temperature alarm or condensation water high level alarm. *7) ALM value depending on turbocharger type. Optional SLD for turbocharger available on customers request.
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Medium
Signal No.
add. add. to for flex Function AMS for IACS ABS BV CCS DNV GL KR LR MRS NK PRS RINA AMS sigUMS nals
Cylinder cooling wate PT1101A PS1101S TE1111A TE1121-28A Scavenge air cooling water PT1361A Fresh water single-stage TE1371-72A TE1381-82A Main bearing oil PT2001A PS2002S TE2011A ALM SLD SHD ALM SLD ALM SLD A A A A A A A A A A A A ALM ALM ALM ALM SLD SHD ALM ALM SLD
Thrust bearing oil TE2101A Thrust bearing pads TE4521A TS4521S Crank bearing oil TE2201-07A ALM SLD A A A A A A A A A A A A ALM SLD SHD ALM SLD A A A A A A A A A A A A
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Medium
Signal No.
add. add. to for flex Function AMS for IACS ABS BV CCS DNV GL KR LR MRS NK PRS RINA AMS sigUMS nals
Crosshead bearing oil TE2301-08A Oil mist concentration AS2401A AS2401S XS2411A Piston cooling oil TE2501-08A ALM SLD SHD SHD ALM SLD ALM B B B B B B B B B B B B B B B B B B B B B B ALM SLD A A A A A A A A A A A A
FS2521-28S Turbocharger oil PT2611-12A ME bearing oil supply ABB TPL-B PS2611-12S TE2601-02A
ALM SLD SHD ALM SLD ALM SLD SHD ALM SLD ALM SLD
PT2611-12A ME bearing oil supply MHI MET PS2611-12S TE2601-02A Sep. lub. oil supply Sep. lub. oil supply ABB A100-L Sep. lub. oil supply ABB A100-L Additional requirement when separate TC lub. oil supply
PT2611-12A
PS2611-12S TE2601-02A
TE2621A
TE2621A
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Medium
Signal No.
add. add. to for flex Function AMS for IACS ABS BV CCS DNV GL KR LR MRS NK PRS RINA AMS sigUMS nals
Axial damper (detuner) oil PT2721A PT2722A Cylinder lubricating oil PS3121A Fuel oil Position ALM ALM ALM TE3411A PT3421A Leakage Exhaust gas ALM TT3701-08A ALM SLD SLD TT3721-22A ALM SLD ALM SLD E F G H LS3426A LS3446A ALM ALM ALM ALM ALM C C C C C D D D D D D C C C C C C C C D D D D D D ALM ALM ALM
ALM TE4031-32A ALM SLD TE4081-88A ALM SLD ALM SLD ALM SLD
I I I
K K
ALM
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Signal No.
add. add. to for flex Function AMS for IACS ABS BV CCS DNV GL KR LR MRS NK PRS RINA AMS sigUMS nals
Air spring air ALM PT4341A ALM SLD PS4341S Leakage oil Control air Supply Stand-by supply Engine Overspeed ST5111-12S SHD PT4401A PT4411A PT4421A ALM ALM ALM LS4351A SHD ALM
Table 17.3: Table of alarm sensors and safety functions (part 2) Classification societies
IACS ABS BV CCS DNV GL KR LR MRS NK PRS RINA International Association of Classification Societies American Bureau of Shipping Bureau Veritas Chinese Classification Society Det Norske Veritas Germanischer Lloyd Korean Register Lloyds Register Maritime Register of Shipping (Russia) Nippon Kaiji Kyokai Polski Rejestr Statkow Registro Italiano Navale
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Special request for AMS: Request for AMS only Additional request to UMS for AMS
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The purpose of this chapter is to provide information to assist in planning and installation of the engine. It is for guidance only and does not supersede current instructions. WARNING The illustrations in this chapter do not necessarily represent the actual configuration or the stage of development, nor the type of your engine. For all relevant and prevailing information consult section 'drawings' of this chapter.
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Figure 18.1: Engine dimensions Number of cylinders A B C Dimensions in mm with a tolerance of approx. 10 mm D E F G Net engine mass (without oil/water) [tonnes] Minimum crane capacity [kg] 270 325 3,698 3,915 4 6,825 5 7,931 6 9,037 4,200 1,360 9,750 3,915 11,950 2,111 377 6,500 435 482 4,132 4,132 7 10,143 8 11,249
NOTICE F: Min. height to crane hook for vertical piston removal. Mass estimated according to nominal dimensions of drawings, including turbocharger and SAC, pipings and platforms (specified for R1 and ABB turbochargers).
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Crankshaft
Flywheel
Tie rod
Cylinder liner Cylinder cover, complete incl. starting and fuel valve and upper ring of water guide jacket Connecting rod, complete
Piston, complete with rod Scavenge air receiver, complete with valves and covers Exhaust valve, complete
Rail unit
Supply unit
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Transverse expansion (X): ........ crankshaft centerline to centre of gas outlet flange Vertical expansion (Y): .............. bottom edge of bedplate to centre of gas outlet flange Longitudinal expansion (Z): ...... engine bedplate aft edge to centre of gas outlet flange
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18.2 Outlines
18.2.1 Drawings
DAAD019094 c DAAD027102 b DAAD019097 c DAAD019095 c DAAD019096 c DAAD024665 c DAAD024731 c DAAD024736 c DAAD024739 c DAAD024791 c Engine Outline View, A180, 5 Cyl. ........................................................1-88 8 -117 _ Dismantling Dimensions, 5-8 Cyl. .....................................................1-88 8 -119 Engine Outline View, A170, 6 Cyl. ........................................................1-880 8 -111 Engine Outline View, A175, 7 Cyl. ........................................................1-881 8 -111 Engine Outline View, A175, 8 Cyl. ........................................................1-882 8 -111 Engine Outline View, A180, 6 Cyl. ........................................................1-883 8 -111 Engine Outline View, A185, 7 Cyl. ........................................................1-884 8 -111 Engine Outline View, A185, 8 Cyl. ........................................................1-885 8 -111 Engine Outline View, A180, 5 Cyl. ........................................................1-886 8 -111 Engine Outline View, A180, 6 Cyl. ........................................................1-887 8 -111
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18.3.1 Drawings
DAAD032658 DAAD032626 107.398.394 107.380.159 b DAAD031462 107.375.301 d DAAD031490 DAAD032274 DAAD031713 107.326.466 a 107.367.119 a DAAD032768 107.367.109 DAAD032973 107.395.701 a 107.395.699 a 107.345.444 b DAAD032972 DAAD032917 107.412.130 DAAD033032 DAAD033025 Engine Seating/Foundation, Vertical And Horizontal Drain, 6 Cyl. ......1-881 8 -112 _ Rib, 6 Cyl. ..........................................................................................1-882 8 -112 _ Epoxy Resin, 6 Cyl. ...........................................................................1-883 8 -112 _ Round Nut, 4-8 Cyl. ..........................................................................1-884 8 -112 _ Bush, 6 Cyl. .......................................................................................1-885 8 -112 _ Elastic Bolt, 6 Cyl. .............................................................................1-886 8 -112 _ Conical Socket, 6 Cyl. .......................................................................1-887 8 -112 _ Conical Socket, 6 Cyl. .......................................................................1-888 8 -112 _ Bush, 6 Cyl. .......................................................................................1-889 8 -112 _ Spherical Round Nut, 6 Cyl. .............................................................1-880 8 -113 _ Sealing Piece, For Chocking Fast, 6 Cyl. ..........................................1-881 8 -113 _ Joint Disc, 6 Cyl. ...............................................................................1-882 8 -113 _ Pin, For Chocking Fast, 6 Cyl. ..........................................................1-883 8 -113 _ Engine Side Stopper, Elded Type, W6 Cyl. .......................................1-884 8 -113 _ _ Flat Bar, To Engine Side Stopper, 6 Cyl. ........................................1-885 8 -113 _ _ Flat Bar, To Engine Side Stopper, 6 Cyl. ........................................1-886 8 -113 _ _ Welding Instructions, 6 Cyl. ...........................................................1-880 8--3 111 _ Engine Side Stopper, Elded Type, W6 Cyl. .......................................1-880 8--4 111 _ Wedge, To Engine Side Stopper, 6 Cyl. ............................................1-880 8--5 111 _ Fitting Instructions, To Eng. Seat. W. Epoxy Resin Chock, 6 Cyl. ....1-881 8--1 111 _ Engine Side Stopper, Execution "Flame Cut", 6 Cyl. ........................1-881 8--2 111 _ Engine Side Stopper, Execution "Flame Cut", 6 Cyl. ........................1-881 8--3 111
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RT - Engines
page 2 page 3
2. Production Specification
2.1 2.2 2.3 2.4 2.5 Preparations for welding Welding procedure Repair work Flame straightening Heat treatment page 21 page 23 page 27 page 30 page 32
APPENDIX 1) Recommendations for storage and handling of welding consumables 2) Welding shop equipment 3) Record sheets
A) B) C) Calibration Preliminary Welding Procedure Specification (pWPS) Implementation schedule page 56 page 61 page 63
Whenever Quality assurance or Quality control documentation is required to be approved by WCH, approval must be directed to Wrtsil site office or directly to: Wrtsil Switzerland Ltd., Quality & Manufacturing Support 10198, Zrcherstrasse 12, CH-8401 Winterthur a 7-45.105 05.07.2006 b EAAD080995 09.04.2010 Substitute for: 4-107.144.363
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Documentation (appendix 3) pWPS
(test piece configuration, run sequence and weld parameters)
WPQR WPQR *
(recorded weld process parameters, destructive and non-destructive test results) (weld process parameters inside approval range of the WPQR)
WPS
WPS *
Production
NDT *
VT / MT / UT record sheets
Evaluation
Weld process related systematic defects ** (chapter 4.3.3) Repairs general in accordance with chapter 2.3
Non-compliance of weld quality Repairs minor major* Weld repair procedure VT / MT / UT record sheets
Repair based on production WPS Generation of specific Weld Repair Procedure Specification (WRPS) for repair work (quality level C). Re-examination of weld repair according original quality requirements
NDT *
Requires approval prior to welding activities by: * Classification society and WCH ** WCH RTA-Engines
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Level C higher stressed area High influence restrictions are mandatory (correct applications increases safety margin) Yes (essential welding variables according chapter 1.7.3)
WPS based on qualified WPQR and / or WPS based on qualified WPQR manufacturers experience - Drying (moisture removal) of base material mandatory - Preheat to 80 on weld joint C where specified on WCH technical drawing VT / MT / UT : 100% Detailed documentation of location and extent of weld defect required Major weld repairs on weld joints with quality level C requirement must be performed in line with approved repair welding procedure
VT: 100% MT / UT: weld ends + spot tests (exception marked on drawing) Detailed documentation of location and extent of weld defect not required Rectification can be performed based on WPS applicable for the original weld
Overview of single bevel butt welds and single - J butt welds with quality requirement level C for bedplate and column:
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1. General
Content 1.1 Introduction
1.1.1 Purpose 1.1.2 Application range 1.1.3 Parts and components requiring Classification society approval 1.1.4 References
1.3 Requirements
1.3.1 Approval of materials, testing, qualification and related documentation 1.3.2 Welding personnel 1.3.3 Inspection personnel 1.3.4 Welding shop equipment 1.3.5 Handling and storage of welding consumables and ancillary materials
1.5 WCH specific application (single-bevel butt weld with quality level C) 1.6 Materials
1.6.1 Base metals 1.6.2 Base material delivery condition and properties 1.6.3 Base material certification and testing requirements 1.6.4 Welding filler and ancillary materials 1.6.5 Minimum requirement for mechanical properties of weld deposit 1.6.6 List of recommended filler metals
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1.1 Introduction
1.1.1 Purpose This welding instruction is designed to ensure that all weld quality requirements for the manufacturing of welded components of RT-Engines as specified in the relevant drawings are fully met. 1.1.2 Application range This instruction is valid for all welded components of RT-Engines made of rolled or cast structural steel excluding piping. It specifies the minimum quality requirements for welding processes, base material and filler materials, quality standard and testing of welded joints and materials. When requirements as specified on drawings conflict with this instruction, the drawing requirements must govern. 1.1.3 Parts and components requiring Classification society approval For all parts and components requiring Classification approval, the manufacturer must apply all relevant requirements of the Classification societies technical rules over and above to the requirements of this instruction. In particular all Classification requirements regarding base and welding materials, qualification and control of fabrication processes (including the special provisions for repair activities), fabrication- and inspection personnel and documentation must be strictly adhered to by the manufacturer. 1.1.4 References This instruction is based on the below mentioned EN and ISO standards. As an alternative, the manufacturer may apply other recognised national or international standards, provided they are accepted by the Classification Society and WCH and their technical requirements give reasonable equivalence to the EN and ISO standards in order to ensure the required minimum product quality. ISO Standard 4063 ISO Standard 6520-1 ISO Standard 6947 ISO Standard 13916 ISO Standard 2553 ISO Standard 5817 EN 287-1 EN 1418 EN 15613 EN 15609-1 ISO 15614-1 EN 473 EN 12062 EN 970 EN 1290 EN 1714 EN 571-1 EN 895 EN 910 Welding and allied processes / Nomenclature of processes and reference numbers Welding and allied processes / classification of geometric imperfections in metallic materials Welds / working positions / definitions of angles of sloop and rotation Welding / guidance on the measurement of preheating temperature, interpass temperature and preheat maintenance temperature Welded, brazed and soldered joints / symbolic representation on drawings Guidance on quality levels for imperfections Approval testing of welders Approval testing of operator Specification and qualification of welding procedures for metallic materials Qualification based on pre-production welding test Welding procedures specification (WPS) Specification and qualification of welding procedures for metallic materials welding procedures tests (WPQR) NDT-Personnel NDT-test scope Non-destructive examination of fusion welds / Visual examination Non-destructive examination of fusion welds / Magnetic particle examinations Non-destructive examination of fusion welds / Ultrasonic examination Non-destructive testing / penetrant inspection Destructive testing of welds / transverse tensile test Destructive testing of welds / Bend testing
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1. General
EN 875 EN 1043-1 EN 1321 EN 13920 EN 10204 EN 10160 EN 10029 EN 1291 EN 1011-1 Destructive testing of welds / Impact tests Destructive testing of welds / Hardness testing Destructive testing of welds / Macroscopic and Microscopic examination General tolerances for welding construction Inspection documents for metallic products Ultrasonic testing of steel flat products General tolerances for hot rolled steel plates Acceptance levels for Magnetic particle testing of welds Requirements for weldabillity of steel plates regarding preheating
PC
PC
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1.3 Requirements
1.3.1 Approval of materials, testing, qualification and related documentation Subject to approval by the Classification Societies are the following items (see also Parts Acceptance List, Drawing group No 0400): - Base metals employed (as specified on WCH drawings) - Consumables and ancillary materials employed for welding (as specified in manufacturers WPSs) - Welder, Operator and NDT-operator qualification certificates - Welding Procedure Specifications (WPS), Repair Welding Procedure Specifications and Welding Procedure Qualification Records (WPQR) - Non-destructive examination reports 1.3.2 Welding personnel Welder: A welder who holds and manipulates the electrode holder or welding gun, torch or blowpipe by hand. Operator: A welder who operates welding equipment with partly mechanised relative movement between the electrode holder, welding gun, torch or blowpipe and the work piece. Personnel performing work affecting product quality must be competent on the basis of appropriate education, training, skills and experience. The company must: - determine the necessary competence for personnel performing work affecting product quality - provide training or take other actions to satisfy these needs - evaluate the effectiveness of the actions taken - ensure that its personnel are aware of the relevance and importance of their activities and how they contribute to the achievement of the quality objectives - maintain appropriate records of education, training, skills and experience. All welding personnel must be qualified. The qualification level for welding personnel must be directly related to the type of production welding and documented with a valid Welder Performance Qualification Certificate based on EN 287 for welders and EN 1418 for operators including a picture to clearly identify the welder. Each welder/operator qualification certificate has to be approved by the Classification society and must be freely available for review on request by the Classification Society or WCH. Welders engaged in welding single sided root runs of butt welds should be exposed to special and regularly training on mock-ups, simulating the production welds as close as possible. The NonDestructive-Test (NDT) results from this training should be used to justify the extension of validity of welder qualification certificates according to the requirements of the EN 287. 1.3.3 Inspection personnel All testing, as specified on production drawings and other quality assurance & control documentation, must only be performed by inspection personnel with the minimum qualification level (specified in chapter 3.1.4) as required by EN 473. Only properly maintained and regularly calibrated test equipment must be used. Calibration records must be freely available for review on request by the Classification Society or WCH. 1.3.4 Welding shop equipment Welding shop equipment must be properly maintained and regularly calibrated in accordance with the recommendations of the equipment manufacturers and the WCH guidelines specified in APPENDIX 2. 1.3.5 Handling and storage of welding consumables and ancillary materials Lack of care during handling and storage of welding consumables can seriously affect the quality of welded joints. Minimum handling and storage requirements for consumables (electrodes and wire) and ancillary materials (fluxes and gases) are specified by the manufacturers on their packaging, on related material safety data sheets (MSDS) and by WCH in APPENDIX 1. It is essential that all welding personnel are fully aware of these requirements and that they put them into practice on the shop floor.
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1. General
1.4 Documents, drawings
1.4.1 Requirements The following documents are the basis for the manufacture and acceptance of the welded components: A) Welding drawings Identifying weld seams (type, size, length), weld joint fit-up requirements (e.g. air gap), quality level and extent and type of NDT. The base materials for plates etc, as well as weld edge preparation dimensions are specified on detail drawings accompanying the welding drawing. B) Welding sequence plan A welding sequence plan for complex welding structures, such as bedplate, column and air receiver has to be generated by the manufacturer. The plan needs to be submitted to WCH for review. C) Welding instruction 4-107.345.444 D) Welding Procedure Qualification Record (WPQR) According to ISO 15614-1 and the applicable Classification Society rules. E) Welding Procedure Specification (WPS) According to EN 15609-1 and the applicable Classification Society rules. 1.4.2 Handling of documents All quality documentations (WPQR, WPS, WRPS, NDT, base material) must be stored by the engine manufacturer for a minimum period of 10 years from the day of the shop-test. This documents must be readily available on request from WCH for the above mentioned time period. All documents must be directly traceable to a specific engine project. 1.4.3 Shrinkage dimension The amount of shrinkage depends on various factors e.g. welding sequence, welding parameters, welding process, free/restricted shrinkage, air gap etc. Shrinkage must be determined by the manufacturer of the welded components, taking their own fabrication methods into consideration. 1.4.4 General tolerances for welded components If not specified differently on a manufacturing drawing, tolerance class B and F according EN 13920 must be applicable for welded components.
1.5 WCH specific application (single-bevel butt weld with quality level C)
The double wall box design leads to single-bevel butt welds with the root welded from one side without backing. Compared to the double-bevel butt weld, the quality and the condition of the root is of utmost importance. Due to the welding process, tension on surface side and compression on root side is expected. This positive and necessary effect of compression on root side results in a higher fatigue strength. For the same reason WCH does not apply post weld heat treatment (PWHT) on welded structures. To achieve this essential quality condition and desired pre-stressing of root runs, the following requirements are mandatory: 1. Fit-up gap 2 - 4 mm to achieve full penetration. 2. Tack welding to achieve proper alignment of parts to be welded. 3. Drying of base material prior to welding (with the purpose removal of moisture), followed by the preheat as required by the WPS. 4. Welding process and parameters according qualified welding procedure (WPQR). WCH recommends the use of solid filler wire (GMAW) for welding of the root run. 5. Repair of root run defects must only be carried out on the basis of approved repair welding procedures. chapter 2.2.1 chapter 2.2.2 chapter 2.5.1 chapter 1.8.2
chapter 2.3
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1.6 Materials
1.6.1 Base metals Strict compliance with the material specification is necessary to ensure that the mechanical and chemical properties of material for welded components of RT-Engines, such as rolled or cast steel, satisfy all design requirements. The required types and grades of base materials are specified by the WCH design department on the parts list (or bill of materials) of the WCH technical drawings. If a specified base material is not available, an equivalent base material with equivalent mechanical and technological properties, proven weldability and the same heat treatment condition may only be employed by the manufacturer after the written approval by WCH design has been obtained. 1.6.2 Base material delivery condition and properties All rolled steel materials as specified on WCH technical drawings (e.g. SM400B or R-St 37-2 or S235JR or CL.B) must be ordered strictly in accordance with Classification society material grading system for normal strength steels Grade B including all additional requirements as specified in table 1.1. All cast steel materials as specified on WCH technical drawings (e.g. SCW410 or GS-38) must be ordered strictly in accordance with Classification society material grading system for normal strength steels Grade 410W.
Material type Classification society material grading system for normal strength steels Tolerance on dimensions, shape and mass according:
2
rolled steel
1
cast steel
1
Grade B
Grade 410 W
Condition of supply Unkilled steel is not acceptable for all material thicknesses t 50 mm: any t > 50 mm: normalized (N) or controlled rolled (CR) Killed
Desoxydation
Heat treatment
Normalized
Mechanical properties Yield stress ReH Tensile strength Rm Elongation A5 3 V-notch Impact Strength Chemical composition C (%) P (%) S (%) N (%) Mn (%) Si (%)
4
min. 235 N/mm2 400 - 520 N/mm2 min. 22% min. 27J (0 C)
min. 235 N/mm2 min. 410 N/mm2 min. 24% min. 35J (20 C)
max. 0,21 max. 0,035 max. 0,035 max. 0,009 min. 0,6 max. 0,35 0,35 (t 40 mm) 0,38 (t > 40 mm)
max. 0,23 max. 0,04 max. 0,035 0,5 1,6 max. 0,6 0,38
Table 1.1
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Notes: 1- In addition to the general technical delivery and order condition, all base material must be ordered in accordance with the special order conditions as required by the rules of classification society and chapter 1.6.3. 2- Condition of supply (deoxidation and heat treatment) must be indicated on the base material certificate. 3- Only required for plate thickness > 25 mm 4- The Carbon Equivalent is be calculated in accordance with the following formula:
CEV = C +
Mn Cr + Mo + V Ni + Cu [%] + + 6 5 15
5- The content of the trace elements Cr, Mo, V, Ni and Cu must be indicated on the base material certification in order to allow the calculation and verification of the CEV restriction and therefore ensure good weld ability. In addition to the CEV restriction, the trace elements must not exceed the following max. values: Cu max. 0,30%, Cr max. 0,20%, Ni max. 0,40%, Mo max. 0,08% and a total of Cr + Cu + Mo 0,45%.
1.6.3 Base material certification and testing requirements The type of required base material certification must be selected in accordance with table 1.2. Base material certificates must be freely available for review by the representatives of Classification societies or WCH. Steel mill delivering rolled plates should have an approval by classification society which is valid up to the delivered material thickness. Type of component Components requiring Classification approval (e.g. bedplate or column) Type of base material certification required Inspection certificate 3.2 (according EN 10204) based on specific (lot or heat) inspection. Document certified by the Classification society. Min. extent of testing certified on the material certificate - Chemical composition (heat analysis) - Tensile test (ReH) and V-Notch impact Testing and acceptance in accordance with the rules of classifications - Ultrasonic test for internal discontinuities according to EN 10160, Classes S0 and E0. - Chemical composition (heat analysis) - Tensile test (ReH) and V-Notch impact Testing and acceptance in accordance rules of classifications - Ultrasonic test for internal discontinuities according to EN 10160, Classes S0 and E0.
Inspection certificate 3.1 (according EN 10204) based on specific (lot or heat) inspection. Document validated by the manufacturers authorized inspection representative independent of the manufacturing department.
Table 1.2
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1.6.4 Welding Filler and ancillary materials The preferred filler metals in table 1.3 were chosen for optimum results when used with the mentioned base metals. The manufacturer of the welded components must determine the appropriate similar filler metals when using similar base metals. 1.6.5 Minimum requirement for mechanical properties of weld deposit In general all welding consumables selected for production welding must fully comply with the minimum technical requirements for Grade 2Y in accordance with IACS W17 (Approval of consumables for welding normal and higher strength hull structural steels). Filler make (brand name) and filler-shielding gas combination must always be approved by the Classification Society. Every manufacturer is free to choose their own brand and type of welding consumables provided that an approval by the classification society is available. Following mechanical properties of weld deposit must be verified: Tensile strength: Yield point: Elongation (5d) : V-notch Impact strength: 490 - 660 N/mm2 min. 375 N/mm2 min. 22% min. 47 J (0 C)
1.6.6 List of recommended filler metals The following filler metals have been tested by WCH and can be recommended: Welding process ISO 4063 (AWS) Preferred Applications 111 (SMAW) unalloyed, basic root pass / tack weld / repair work 136 (FCAW) flux-cored wire, basic CO2 or mixed gas root pass 136 (FCAW) flux-cored wire, rutile CO2 or mixed gas filling and final passes 135 (GMAW) solid wire CO2 or mixed gas root pass 141 (GTAW) unalloyed filler bar root pass for repair work 121 (SAW) Wire : unalloyed Flux : unalloyed, fused neutral filling and final passes Filler classification
: E 42 5 B 4 2 H5 : E 7018-1
EN 1668 : W 42 5 W3Si1 AWS A5.18 : ER 70 S6 Wire: EN 756 AWS A5.17 Flux: EN 760 AWS A5.17
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1.7 Welding procedure qualification record (WPQR)
The general purpose of qualification of the WPQR is to prove the mechanical and technological welded joint properties. In addition the qualification of a root run without backing on designated single-bevel butt welds is necessary to ensure continuous full penetration during production welding. WPQR welding and testing must be general in accordance with ISO 15614-1 with the additional mandatory requirements of this instruction. The WPQR must be witnessed and approved by the Classification Society and on request by a designated WCH representative. It must be carried out under production-like conditions (e.g. welding position, welding consumable classification and brand, base material thickness, groove dimensions, welding process and parameters etc.). 1.7.1 Range of qualification for production welding Following range of qualification is to a large extent in accordance with ISO 15614-1. A) Related to the manufacturer The qualification of a welding procedure test by a manufacturer is only valid for welding in workshops or sites under the same technical and quality control of the manufacturer. Welding is under the same technical and quality control when the manufacturer who performed the welding procedure test retains complete responsibility for all welding carried out to it. B) Thickness The approval range for plate thickness is 0,5 t to 2 t. WCH recommends a test plate thickness of 25 mm, which qualifies the thickness range from 12.5 to 50 mm. C) Degree of mechanization Each degree of mechanization has to be qualified independently (manual, partly mechanised, fully mechanized and automatic). Multi-process procedures have to be done as a multi-process procedure test. manual: SMAW partly mechanised: GMAW fully mechanised: SAW automatic: robot welding D) Welding Process Process 135 and 136 (GMAW / FCAW) The Qualification given to the shielding gas is restricted to the symbol of the gas according to EN 439. However the content of CO2 must not exceed 10% of that used to qualified the procedure test. Shielding gases not covered by EN 439 are restricted to the nominal composition used in the test. The qualification given is restricted to the wire system used in the welding procedure test. Due to better welding characteristics and improved weld metal properties it is recommended to use mix-gases (75% Ar / 25% CO2) instead of 100% CO2 . For single sided root runs without backing the use of CO2 shielding gas in combination with process 135 (GMAW) is recommended by WCH. For solid metal wires, the qualification using short circuiting transfer qualifies only short circuiting transfer. Process 121 (SAW) The qualification given for the flux is restricted to the make and designation used in the welding procedure test. The quantity of recycled flux is restricted to max. 50%. Process 141 (GTAW) The Qualification given to the shielding gas and backing gas is restricted to the symbol of the gas according to EN 439. Shielding gases not covered by EN 439 are restricted to the nominal composition used in the test. A weld procedure test made without a backing gas qualifies a welding procedure with backing gas. E) Welding positions: root run PA, PC and PF are permitted welding positions for root run. Each of these 3 positions requires a separate qualification. F) Welding position: filling up It is strongly recommended that all welding work for filling up must be done in PA or PC position. If quality level C is required, other positions are permitted only in exceptional cases after approval by the WCH Engineering department.
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G) Filler material, designation Filler materials cover filler materials as long as they have equivalent mechanical properties, same type of covering core or flux, same nominal composition and the same or lower hydrogen content according to the designation in the appropriate EN standard for the filler material concerned. Welding consumables have to be type approved by the Classification Society. H) Filler material size It is permitted to change the size of filler material provided that the requirements of heat input (I) are satisfied. The size of filler material for root runs of single bevel butt welds must be identical for production welding as used during welding procedure qualification. I) Heat input Heat input for production welding (as specified in WPS) may only exceed the recorded maximum heat input from WPQR qualification by max. 25%. However each of the related parameters (voltage, current and travel speed) may only vary 10% as recorded during WPQR qualification.
U I KJ E = 0,006 mm v
E U I v
= = = =
Heat input (KJ/mm) Voltage (volts) Current (amps) Travel speed (cm/min)
K) Preheat temperature When preheating is required the lower limit of qualification is the nominal preheat temperature applied at the start of the welding procedure test. L) Interpass temperature The upper limit of the qualification is the highest interpass temperature reached in the welding procedure test. M) Weld bead width and layer thickness As an indication of travel speed and finally for heat input, the width of the bead and the thickness of the layer must be recorded during WPQR qualification. N) Type of joint / weld Butt welds qualify full and partial penetration butt welds and fillet welds. Welds made from one side without backing qualify welds made from both sides and welds with backing. To cover all welded structures of RT-Engines, two different weld joint types with requirement of quality level C must be qualified. Joint 1: Single-bevel butt weld quality level C Joint 2: Single-J butt weld quality level C
All welds with quality level D are covered by the welding procedure qualification for quality level C. 1.7.2 Weld repair A weld repair of the root-pass must be simulated as part of the WPQR qualification. Approximately in the middle of a test piece a root defect of 200 mm must be prepared and recorded. Afterwards the root defect must be repaired according to the specified repair procedure (chapter 2.3.2).
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1.7.3 Guideline for planning of welding procedure
Range of qualification
Example
Type
manual
automatic
partly mechanised
manual
partly mech.
fully mech.
automatic
partly mechanised
111
135
136
141
135
111
135
136
121
135
1,2
1,4
1,6
1,2
Shielding gas
CO2
Ar/CO2
Ar
CO2
PA
PC
PF
PA
PA
PC
PF**
PA
If any of the essential welding variables changes, re-qualification of WPQR is required. *) **) Tack welding is part of root run PF-position for quality level C must be approved by the WCH Engineering department
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1.7.4 WPQR test piece The joint geometry requirement is not represented by the standardized test pieces as shown in ISO 15614-1. Therefore the use of following production related test pieces is mandatory. Joint 1: Single-bevel butt weld, quality level C Figure 1.7 and 1.8 example
*** 60
Grade B
7 5 3 2 1 6 4
25
***
***) bevel angle and root gap intended for production welding Joint 2: Single-J butt weld, quality level C Figure 1.9 and 1.10
25 example
7 5 3 2 8
60
25
4 1
Grade B
25
23
The WPQR is qualified, if the imperfections in the test piece are within the limits of quality level B according ISO Standard 5817. If tack welds are incorporated into the production welds, they must also be applied during WPQR qualification (at least 2 tack welds with a length of approximately 75 mm). 1.7.5 Examination and testing of WPQR test pieces A) Non-destructive testing: VT acc. EN 970 UT acc. EN 1714 MT acc. EN 1290 B) Tensile tests (transverse) acc. EN 895 C) Side bend tests (transverse) acc. EN 910 D)* Charpy V notch bar impact tests acc. EN 875
100% 100% 100% 2 specimens 4 specimens 5 sets (Notch located in: fusion line 0 mm; + 2 mm; + 5 mm / centre of weld metal / root zone) 2 specimen (macro examination)
*) Additional examination required for the 200 mm root repair area Welding of the test piece and all mechanical and technological tests performed must be witnessed by the classification society and on request by a designated WCH representative. General test temperature for destructive testing 20 C
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1.7.5 Test specimen location plan and test results for WPQR test pieces 2 specimen transverse tensile tests (EN 895) LS
20
LC
Figure 1.11
20
LT LT : Length to suit particular testing machine LC > LS + 60 mm R > 25 mm Tensile strength Rm: min 400 N/mm2 4 specimen side bend tests (EN 910) LS Test result:
20
= 250
10
Figure 1.12
d 1,3 x LS 10 mm = 180 R : min. 2 mm (side in tension) Test result: During testing, the test specimen shall not reveal any one single flaw > 3 mm in any direction. Flaws appearing at the corners of a test specimen during testing shall be ignored in the evaluation. 40 Figure 1.13
Group: 1115,1118,1409 1411,6406,6409,6410
40 d + 30
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5 sets of charpy V notch bar impact tests at 20 ( EN 875) C centre line weld 1 10 (one set = 3 specimen)
VWT 0/1
VWT 0/14
10
fusion line ( 0 mm) VHT 0/1 Figure 1.14 fusion line (+2 mm) VHT 2/1 fusion line (+5 mm) VHT 5/1 1 10
25 Test result: min. 47J at 20 for manual and semi mechanized wel ding processes (111, 135 and 136) C min. 37J at 20 for fully mechanized welding proce sses (121) C min. 35J at 20 for weld joints between rolled ste el and cast steel C Hardness test (EN 1043) Two rows of indentations must be made at a depth of up to 2mm below the upper and the lower surface of the welded joint. For each row of indentation at least 3 individual indentations in each of the following areas: - the weld - both heat affected zones - both parent metals Figure 1.15 Test result: Permitted max. hardness value = 380 (HV 10)
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2 specimen macroscopic examination (EN 1321 The test specimen shall be prepared and etched in accordance with EN 1321 on one side to clearly reveal the fusion line, the HAZ and the build up of the runs. The macroscopic examination shall include unaffected parent metal and shall be recorded by at least one macro reproduction per procedure test.
Destructive examination required for the 200 mm repair area - 2 sets of charpy V notch impact tests at 20 fro m the root area: VWT 0/14 and VHT 2/14 C - Hardness test - 2 specimen macroscopic examination
1) 2)
Discard 20 mm one tensile and two side bend specimen Charpy V notch impact specimen Repair area (impact- , hardness- and macro test specimen) Charpy V notch impact specimen one tensile and two side bend specimen Macro and hardness specimen
2
3) 4)
3
5) 6) 7)
7 1
Figure 1.16
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1.8 Welding Procedure Specification (WPS)
In general all welding work on the engine structure must only be carried out in accordance with job specific WPSs. For all level C weld joints the WPSs must be based on qualified WPQRs. For all level D weld joints the WPSs must be based on qualified WPQRs (if available) or on previous productions experiences, qualified welding consumables or pre-production test pieces. The Welding Procedure Specification (WPS) must give details of how a welding operation is to be performed and must contain all relevant information as required in EN 15609-1 about the welding work. Ranges and tolerances of welding parameters according to the manufacturers experience must be specified where appropriate and must be in accordance with ISO 15614-1 and the additional requirements of this instructions. Example for specifying WPS welding parameters and heat input: Welding parameter pWPS Current Voltage Speed Current Voltage Speed Current Voltage Speed 240 320 A 28 35 V 25 35 cm/min 300 A 30 V 30 cm/min 270 330 A 27 - 33 V 29 - 33 cm/min E = 1,8 KJ/mm (100%) Heat input Range of proposed weld process parameters Table 1.4
WPQR
Recorded weld process parameters Weld process parameters inside approval range of the WPQR
WPS*
1.8.1 Proposed parameters for preliminary repair welding procedure specification (pRWPS) Following parameters tested by WCH are recommended: Table 1.5 Run no. 1 Process Polarity Current Amp 90 - 150 60 100 2-n 111 (SMAW) DC+ 100 140 120 - 180 Voltage Consumables Gas
141 (GTAW)
DC-
11 - 17 18 26 18 26 18 - 26
100 % Ar
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1.8.2 Run sequence of welding joints with proposed parameters (pWPS) Following parameters tested by WCH are recommended: Joint 1: Single-bevel butt weld, quality level C Figure 1.17 35 Run no. Welding Position Process EN (AWS) Consumables EN (AWS) Unalloyed 1,2 G 46 4 C G4Si1 (ER 70 S-6) Unalloyed 4 S 42 3 FB S 3 (F 7 A 3-EH10K) Unalloyed 1,6 G 46 4 C G4Si1 (ER 70 S-6) Table 1.6 Gas/flux
7 5 3 2 1
6 4
24 mm Table 1.7 Run Process Polarity no. 1 2 1 2 1 2 135 / PA 135 / PC 135 / PF DC+ DC+ DC+ DC+ DC+ Current Amp
PA
Wire speed cm/min 700 725 480 630 270 420 100 570
Stick-out Mm 22 - 27 22 - 27 22 - 27 22 - 27 22 - 27 22 - 27 29 - 31 22 - 27
Energy KJ/mm 0,6 1,0 0,7 1,2 0,6 1,2 1,1 2,0 0,5 1,2 0,7 1,3 1,3 2,4 2,1 3,6
135 165 180 220 125 155 180 220 90 110 115 145 400 500 360 - 400
3 - n 121 / PA 3 - n 135 / PA
Table 1.8 Process EN (AWS) 135 (GMAW) Consumables EN (AWS) Unalloyed 1,2 G 46 4 C G4Si1 (ER 70 S-6) Unalloyed 4 S 42 3 FB S 3 (F 7 A 3-EH10K) Unalloyed 1,6 G 46 4 C G4Si1 (ER 70 S-6) Gas/flux
6 4 2 1
CO2
PA 3-n min. 2 mm PA
121 (SAW)
BB25
135 (GMAW)
CO2
Table 1.9 Run Process Polarity no. 12 135 121 3-n 135 DC+ 360 - 400 570 22-27 27 - 33 25 - 35 1,7 3,2 DC+ DC+ Current Amp 180 - 220 400 - 500 Wire speed Stick-out cm/min Mm 700 100 22-27 29-31 Voltage Travel Speed cm/min 22 - 27 30 - 36 25 - 35 45 - 55 Energy KJ/mm 0,7 1,4 1,3 2,4
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2. Production Specification
Content 2.1 Preparations for welding
2.2.1 Edge preparation 2.2.2 Surface cleanliness and over-weldable shop primer
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2.1 Preparations for welding
2.1.1 Edge preparation Plate edges must be free of any foreign matter as rust, oil, residual slag or carbonised material and scale. The maximum acceptable depth of cutting notches is 1mm. All suitable cutting processes are accepted which have no negative influence on welding process. Possible cutting processes for weld edge preparation are for example: - Oxy acetylene cutting (oxide scales and any notches due to irregular cutting to be removed) - mechanical machining (planing, milling etc.) - gouging (only applicable for weld repairs) During production, the bevel angle of the edge preparation must be identical to the bevel angle qualified in the WPQR. To correct plate length (for fitting purpose) which have already bevelled edges, the entire edge profile must be cut back in order to assure proper weld penetration. It is recommended that a template should be produced and used in order to check the shape of the edge preparation. Figure 2.1
Edge preparation Quality level C Quality level D
= 35- 40 t
= 40- 45
c 1 mm
t 20 20 < t 40 t > 40
c 2 mm c 3 mm c 4 mm
t : Plate thickness
2.1.2 Surface cleanliness and over-weldable shop primer Plates which are shot blasted and correctly primed with a over-weldable shop primer have a sufficiently clean surface for welding. Over-weldable shop primer may not be removed from the weld edge preparation, if all of the following conditions are met: 1. The type and brand name of the primer must be approved by the Classification Society. 2. Approval is based on the typical pigment and binding agent base and classed according to the total pore area determined during testing. 3. Over-weldable shop primer must be included in the welding procedure qualification tests (WPQR). 4. The manufacturer must ensure, that the maximum applied primer thickness, as tested during the weld tests (WPQR) must not be exceeded. 5. The recommendations of the primer manufacturer regarding handling and application of the specific primer brand (e.g. application technique, application thickness, required drying time before welding and humidity and temperature limitations for correct application) must strictly be followed and regularly verified by quality control personnel. If base material is contaminated in the area of weld edge preparation by scale, corrosion, cutting fluid etc., it must be cleaned approximately 30 to 50 mm in all directions from the weld edge prior to any welding operation.
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2.2 Welding procedure
2.2.1 Fit up Bars, plates, etc, which are used for fixation must be of same specification as the base material. The recommended location of temporary position bars are shown on sequence drawings. Fit up gap : Depending on the required quality level, fit up gaps are recommended for quality level D and mandatory for quality level C to achieve the required weld quality. Double-bevel butt weld Single-bevel butt weld Single-J butt weld
Figure 2.2 Table 2.1 Quality Level D Double bevel butt weld / butt weld with back weld Single bevel butt weld Single-J butt weld x = 0 4 mm x = 0 4 mm not applicable Quality Level C x = 2 4 mm (0 4 mm with back gouging) x = 2 4 mm x = min. 2 mm
Proposal for weld preparation fit-up: To facilitate the weld fit-up, the manufacturer may use fit up bars (thickness 4 6 mm) for fixation and to keep the required conditions for the fit up gap. After tack welding in between the bars, the bars must be removed carefully by grinding without damaging the base material. All ground areas on the base material must be inspected by MT. Fit-up bars should be spaced at an interval of approximately 1000 mm in order to prevent sagging in between. In case of local excessive root gap, follow these instructions. As it is a minor weld repair, execution without NCR is allowed but a specific WPQR is mandatory! Restrictions for the root gap: Distance 412 mm, length: max. 500 mm Restrictions for build-up welding: GMAW or FCAW PA or PB position Max. 3 layers, max. 2 on top of each other Max. bead width 12 mm Max. layer thickness 4 mm 2/3 of the weld seam must be on the weld seam side of the joint Grind start and end points before welding the root run! Weld root run in PC position as specified in according WPQR.
20
Figure 2.3
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2.2.2 Tack-welding Tack welds are ideal for setting and maintaining the joint gap but can also be used to resist transverse shrinkage. The tack welding sequence is important to maintain a uniform root gap along the length of the joint. Two alternative tack welding sequences are recommended and shown in Figure 2.4:
Figure 2.4
1 6
2 5
3 3
4 1
5 2
6 4
7 7
The surface must be free from any foreign matter (e.g. scale, paint, rust, oil, moist, water, etc.) according chapter 2.5.1 according chapter 2.5.2 135 / 136 (GMAW / FCAW) Alternative process : 111 (SMAW) If tack welds are incorporated into the final weld, filler metal in accordance with the WPS requirements 4 5 mm min. 75 mm approx. 500 mm or approx. 1000 mm (without fit up gap requirements or using fit up bars) min. 1 Quality level equivalent to the drawing requirements for the specific weld joint Figure 2.5: Length and spacing of tack welds 75 500 (1000) 75
Recommended processes: Filler metal: Throat thickness: Length: Spacing: No. of runs in tack welds: Weld quality:
It is important that tacks welds, which are to be fused into the main weld, are produced to an approved procedure using appropriately qualified welders. The procedure may require preheat and an approved consumable as specified for the main weld. Removal of the tacks results in a larger root gap making it more difficult to achieve an acceptable root condition in this area and also needs careful control to avoid causing defects in the component surface. Tack welds must be visually inspected. Start and end point of the tack weld must be ground smoothly if tack welds are to be fused into the main weld. If back gouging is used, then tack welds must be positioned suitably to allow the appropriate access for their removal. Cracked or defective tack welds must be removed before the main weld is made. Where tack welds are incorporated into the final weld, it has to be simulated and qualified in the welding procedure (WPQR).
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2.2.3 Starting and run-off tabs Starting and run-off tabs are mandatory for all butt joints independent from welding process. The tabs must be readily available in the workshop. For process 121 (SAW) the tabs should have a length of 150 mm, a width of 100 mm and the same thickness as the work piece, or max. 25 mm.
max. 25
Figure 2.6
For processes 135 / 136 and 111 (FCAW / GMAW and SMAW) the tabs should have a length of 50 mm, a width of 50 mm and a thickness of app. 5 10 mm.
Figure 2.7
2.2.4 Slag removal For slag removal, air needle guns or air driven chisels should be used. Slag hammers and wire brushes may only be used if sufficient access to the weld is ensured. 2.2.5 Temporary welded devices In general, welding of temporary devices must comply with the requirements of chapter 2.2.8 and carried out according to the WPS applicable to the specific component. This includes drying and preheating (if required) prior to tacking and welding and the use of qualified consumables, welding processes and welding personnel. All temporary devices (e.g. fixation bars, plates, lifting lugs, starting and run-off tabs etc.) must be removed by suitable means (gouging, oxy-acetylene cutting and/or grinding) in order to prevent damage to base material. The entire surface must be ground smoothly after removal. Maximum acceptable undercut in base material of 1 mm is permitted and smooth transitions are required. Thereafter the area of removed welding must be inspected visually and by MT. 2.2.6 Welding process Close adherence to the qualified welding process is one precondition to ensure the required weld quality. All weld parameters used in production and specified in the job specific production WPS must be inside the approval ranges for parameters qualified during welding of the WPQR. These approval ranges are specified in ISO 15614-1 with additional restrictions as specified in this instruction. Production parameter ranges for the WPSs are based on qualified WPQRs (chapter 1.7) and must be specified by the manufacturer in accordance chapter 1.7.1. The following processes for production welding are recommended: For root runs: 135 (GMAW) with solid wire (Alternative processes are acceptable if qualified with WPQR and fatigue test on request) For filling up: 121 (SAW) / 135 (GMAW) / 136 (FCAW) qualified with WPQR
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2.2.7 Welding bead width and layer thickness In order to obtain the required weld metal mechanical properties by controlling welding heat input and to avoid weld imperfections, the bead width and appropriate layer thickness must be restricted. For all welding processes maximum bead width and appropriate layer thickness, as recorded during WPQR, must be specified in the WPS and is applicable for production welding. The bead with and appropriate layer thickness can even exceed the values in table 2.2 and 2.3, whereas the required mechanical properties must be confirmed during WPQR. If bead width and / or layer thickness where not recorded during WPQR, the maximum values specified in table 2.2 and 2.3 are mandatory for production welding. Processes 131, 135, 136 and 137 (GMAW and FCAW) Welding wire 1.6 1.4 1.2 Process 111 (SMAW) max. bead width max. layer thickness 3 x core welding wire diameter 1 x core welding wire diameter Table 2.3 bead width max. 20 mm max. 15 mm max. 12 mm layer thickness max. 6 mm max. 5 mm max. 4 mm Table 2.2
This restriction does not apply to fully mechanised and automatic welding processes (e.g. submerged arc welding (SAW) or robot welding), where the travel speed is adjusted and can be verified by the operator. Figure 2.8 2.2.8 Attachment welds The minimum distance between any temporary (e.g. lifting lugs, fit-up brackets) and / or permanent attachment welds (e.g. clips and brackets for attachment of piping, isolation etc.) not originally specified on WCH drawings and existing weld seams must always be greater than 50 mm. Attachment welds crossing existing weld seams are not allowable. In this context, no arc strike must be performed on and close to existing weld seams. Arc strikes and additional weld joints crossing existing joints are introducing uncontrolled additional residual stresses and notches, and are therefore detrimental to the fatigue strength of the welded component. min. 50 mm bracket
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2.3 Repair work
In general only 2 repair attempts must be allowed on any one defective area. No further attempts to repair must be carried out without the written approval of WCH and the classification society. All repair welding must only be carried out by welders or operators qualified according Chapter 1.1.5 2.3.1 Base material repair Quality requirements of base materials intended for welding are specified in chapter 1.6. The repaired items must be tested by suitable NDT methods. A detailed report for every repair, containing information on size, location, welding procedure including heat treatment must be generated and handed over to the classification society as well as form part of the manufacturers final quality assurance documentation. Rolled steel Materials with surface defects exceeding the limits specified in the relevant material manufacturing specifications must be removed by grinding, provided the depth of material ground away does not exceed 3 mm and provided also that at least 90% of the nominal thickness remains. In addition, the depression caused by grinding must have a smooth transition to the surrounding surface of the product. The affected surface must not exceed 2% of the total plate area. Defects which cannot be removed by grinding may be repaired by gouging and / or grinding with subsequent welding, provided that the following requirements are met: - After defect removal the remaining base material thickness must be at least 80 %. - All welds must be performed in accordance with approved WPS and electrodes with a controlled hydrogen content. At least one layer of weld metal is to be welded in excess (temper bead) and must afterwards be ground even to the original base material surface level. - Prior to re-welding, the excavation must be tested by MT to ensure that the imperfection has been removed completely. - If a weld repair on previously heat treated base material (e.g. normalized) is required, an additional heat treatment after repair welding may be requested. For the repair of defects requiring base material excavation of more than 20% of the nominal plate thickness the following procedure is mandatory: - generation of a specific repair procedure by the licensee (based on qualified WPQR and qualified welding personnel) - approval of the specific repair procedure by the classification society - after approval of the classification society approval by WCH design department - start of repair operations only after approval by classification society and WCH Cast steel Fabrication repairs on cast steel by the foundry must be strictly in accordance with the technical rules of classification societys and WCH quality and test specification 4-107.143.790. In exceptional cases cast steel repairs may be required after machining or even after the casting has been already welded into structural assembly. Surface breaking defects must be removed by grinding, provided the depth of material ground away does not exceed 5 mm and provided that at least 90% of the nominal thickness remains. In addition, the depression caused by grinding must have a smooth transition to the surrounding surface of the product. Repairs of surface breaking defects by grinding do not require prior approval from WCH, but reporting to the classification society by the licensees. For the repair of defects requiring base material excavation of more than 5 mm or more than 10% of the nominal thickness the following procedure is mandatory: - generation of a specific repair procedure by the licensee (based on qualified WPQR and qualified welding personnel) - approval of the specific repair procedure by the classification society - after approval of the classification society approval by WCH design department - start of repair operations only after approval by classification society and WCH
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2.3.2 Repair of welded seams Weld quality levels (e.g. Quality level B, C , D), classification of imperfections and the acceptance criteria in arc welded joints are defined in Chapter 4 of this specification. Welds containing imperfections exceeding the limits of the specified weld quality level as given in the relevant welding drawing, must be repaired. Depending on the extent and location, the imperfection must be completely removed by arc-air gouging or grinding. If arc-air gouging is used the following must be applied: - on weld joints which require pre-heating according to the applicable WPS, the same pre-heating must be applied to the repair area prior to gouging. - residual material not removed by gouging and a further 1 mm of base material is to be removed by grinding to be sure that any carbonised material is removed. Prior to re-welding, the excavation must be tested by MT to ensure that the imperfection has been removed completely. After completion of the weld repair, the repair area is to be at least subjected to the same NDT procedure or sequence of procedures as specified for the original weld in the manufacturing drawing. In the context of this instruction repairs are classified into minor and major repairs:
Minor weld repairs Rectification of internal or external weld defects with weld metal excavation of 70% of nominal weld metal thickness can be performed without the generation of a specific Weld Repair Procedure, only based on the WPS applicable for the original weld. This implies however, that the selected welding process for production welding is also used for the repair welding. Small imperfections in the capping/final weld passes can be repaired by grinding smoothly with max. 1 mm under-thickness for quality level C and max. 2 mm for quality level D. Repair weld run-in and run-out To avoid imperfections caused by starting points, following procedure is recommended:
Figure 2.10
Excess weld material must be ground even to the original weld surface level.
defect
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Major weld repair Weld metal excavation of > 70% of nominal weld metal thickness or root weld repairs (incomplete root penetration or imperfections which impact on the root condition) must be repaired according following procedure: A Removal of existing weld metal in the vicinity of the Extent of remaining area root defect
A-A
rd (root defect) t max. 30 rd + t Figure 2.12 Welding process: Major weld repairs on weld joints with quality level D requirement can be performed without the generation of a specific Weld Repair Procedure, only based on the WPS applicable for the original weld. Major weld repairs on weld joints with quality level C requirement must be performed in line with approved repair welding procedure. This repair welding procedure must be based on a WPQR which includes a simulated root weld repair. The following procedure for major weld repair are recommended. Proposed parameters are listed in chapter 1.8. For root runs: 141 (GTAW) with low alloyed filler bar (AWS: ER70S-6) Preheat: The areas of repair welding must be locally preheated to min. 120 (max. 250 due to C ) restricted shrinkage. The minimum pre-heating temperature must continuously be maintained throughout the whole repair. Should the repair process be interrupted, minimum pre-heating temperature must be applied prior to any further repair welding. Max. interpass temperature of 250 must not be ex ceeded. C For filling up: 111 (SMAW) with unalloyed basic electrodes (AWS: E 7018-1) If the root gap after removing of weld metal is basically equivalent to the original weld fit-up and the length of the excavation is more than 100 mm, the repair may be performed based on the applicable WPS for the original weld. Report: The location and extent of major weld repair activities for quality level C requirements must be recorded in the repair welding procedure. The repair welding procedure and all associated NDT reports must be approved at final welding inspection by the Classification Society and copies must be submitted without request to a representative of WCH. 2.3.3 Build-up repairs prior to machining In exceptional cases a locally restricted build-up by arc-welding of parts and components may be required to provide the minimum allowance for machining. If no minimal plate thickness is marked on the drawing, the nominal plate thickness which is given in the drawing (and increased by the manufacturers addition) may be under run by 10% before build-up welding is necessary! If all of the following preconditions are met, the manufacturer can handle this build-up as a Minor weld repair (in accordance with chapter 2.3.2) and neither a specific weld repair procedure nor the generation of a NCR is required: 1) The selected welding technology (e.g. welding process, consumable type, pre-heat etc.) for the build-up is the same as used for production welding and based on a qualified WPQR. 2) The area is at least 50 mm away from quality level C or B weld joints. 3) Build-up on rolled steel (build-up on cast steel or wrought steel is excluded). If one of the above listed conditions are not met, the manufacturer is required to generate a specific Weld Repair Procedure and obtain approval prior to commencement of the build-up.
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2.4 Flame straightening
Flame straightening is a common work shop practise for components (e.g. plates, angles, other shapes and build-up members) distorted by welding. Anyway it must only be applied for RT-Engine Bedplates, Columns and Charge air receivers in exceptional cases after approval by the WCH Engineering department. The reason for this restriction is the importance to preserve the residual stress distribution after welding for the structural integrity of this components, especially residual stresses in the weld root area. Additional residual stresses, as generated during flame straightening, cause strength reductions in compression members and must therefore be avoided. If the manufacturer decides to utilise flame straightening, he must prepare a detailed work instruction for approval by WCH prior to commencement of any straightening activities. Straightening work must only be performed by experienced personnel having a thorough understanding of the behaviour of plates during the heating and cooling process. 2.4.1 General There are two basic types of distortion generally associated with plates: A) Bends about the strong axis -> usually straightened with vee-heats, and B) Bends or bulges about the week axis -> usually straightened with line or spot heats The most serious damage encountered in practise usually consists of plate elements and structures bent about their strong axis. Thus, the vee heat can be considered the fundamental heat pattern associated with heat-straightening. 2.4.2 Heating pattern Stages of plate deformation as a vee heat is applied to an initially straight plate. Figure 2.13 (deformations are magnified for illustration purposes) initial position
C D
As shown in Figure 2.13, the heat is applied with a torch to a vee shape area starting at the apex and progressing across the vee in a serpentine motion. By alternating the direction of the vees and varying the spacing, practically any type of curvature can be removed. Since each heat produces small changes in curvature, a number of heating/cooling cycles are usually required to completely straighten a damaged member. In a similar manner, line and /or spot heats can be used to remove weak axis damage such as bulges and buckles.
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2.4.3 Theoretical heating temperature limits The ideal temperature for heat straightening depends on the grade and type of heat. For carbon- and low alloy steels, the theoretical upper limit is the phase transition temperature of around 721 For C. constructional alloy steel the limiting value is the tempering temperature of 621 C. Heating above transition temperature does not increase the amount of straightening, but has an inclination to produce the following results: a) out-of plane distortion b) plate buckling c) pitting and surface damage to steel 2.4.4 Temperature control In order to minimise the heat-input and possible side effects of overheating, temperature control during flame straightening is of utmost importance. Factors effecting the temperature include: a) size of heating torch orifice b) intensity of the flame c) speed of torch movement d) plate thickness Temperature has to be controlled by: a) Temperature indicating crayons (flame tends to distort the results by blackening the crayon marks) b) Contact pyrometers (tend to give erroneous results and must therefore be calibrated for use in heat straightening applications) The procedure to determine temperature by the colour of the material adjacent to the tip of the torch, also very common with so called heat treatment practitioners, is not acceptable for flame straightening applications of components listed in Chapter 2.4. 2.4.5 Flame straightening restrictions Any flame straightening work instruction must be based on the following restrictions: 1) In no case must the maximum temperature, of material to be straightened, exceed 610 (a dull C red). A cherry red colour during heating or a black colour after cooling indicates that the applied temperature was too high. This restriction provides a safety factor to account for operator errors and also produces relatively large movements as a result of the flame straightening process. Heat must not be applied directly on weld metal or within 30 mm from weld joints. No mechanical forces (e.g. hammering, jacking etc.) must be applied during flame straightening. If required, jacking forces must be applied already prior to heating and be self relieving (they should not prohibit contraction during the cooling phase), as contraction occurs. The maximum force of any jacking must be based on a structural analysis. Cooling and contraction after heating must in no case be accelerated by any means (e.g. Water etc.), as this could lead to brittleness and other material property changes. Following straightening, the metal surface must be carefully inspected for evidence of damage (e.g. fracture etc). Non-destructive testing may be required, as specified by the work instruction for the specific straightening operation.
2) 3)
4) 5)
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2.5 Heat treatment
2.5.1 Moisture removal prior to welding by pre-warming In order to avoid hydrogen induced cracking due to water condensation and subsequent weld defects, drying of base materials prior to welding is mandatory. This happens normally by preheating of base material in the vicinity of weld joints. This procedure must be applied regardless of weather condition. It is important to pay attention to correctly adjusted flames, otherwise the welding zone will be covered with carbon (black surface). Such carbon will cause a hardening of the weld seam. The preheat on all base material thicknesses must be applied at a minimum distance of a = 50 mm in all directions from the weld seam, as seen in Figure 2.14.
Figure 2.14
a a
2.5.2 Preheating temperature requirements Major reason to utilize preheat is to slow down the cooling rate in the weld metal and base metal. A slower cooling rate produces a more ductile metallurgical structure with greater resistance to cracking and provides an opportunity for hydrogen that may be present to diffuse out harmlessly, also reducing the potential for cracking. Additionally the slower cooling rate reduces the shrinkage stresses and improve the distribution of residual stress in the weld and adjacent base material. Preheat required
Preheat to 80 on weld joint where C specified on WCH technical drawing * Hydrogen scales C,D,E acc. EN 1011-2 ** Hydrogen scales A,B acc. EN 1011-2
Preheat on weld joint where specified on WCH technical drawing and preheat requirement on all other weld joints calculated according EN 1011-2
Preheating involves heating the base metal, either in its entirety or just the region surrounding the joint, to a specific desired temperature prior to welding. Independent of the preheating to remove moisture on base material, each weld joint has to be preheated as specified in the applicable WPS if required. The preheat temperature indicated on WCH drawings must be continuously maintained until the welding is complete. If welding on a joint is interrupted, welding may only commence after the required minimum preheating temperature was re applied. The preheat on all base material thicknesses must be applied at a minimum distance of a = 100 mm in all directions from the weld seam, as seen in Figure 2.14.
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Hydrogen cracking (cold cracking) Hydrogen cracking normally occurs in the heat affected zone where hard microstructure is found. The risk of cold cracking must always be considered. Damages which can result from hydrogen diffusion occur from few hours up to 24 hours. It is therefore necessary to carry out NDT at least 16 hours after completion of the final welding. Shrinkage stresses (residual stress) Welded components of welded structure are not stress relieved. Due to the welding process of a multi layer weld in combination with existing boundaries, resulting residual stresses have high influence on fatigue. Therefore it is of importance to apply some restriction for welded components regarding preheating to utilise the positive effect and minimise the negative effect of non heat treatment. Longitudinal joints with high joint restraint * Less deformation after welding in longitudinal direction Elongation of plate by reason of preheating Circular welds Elongation of inner part by reason of preheating restraint outer part (prevents free transverse shrinkage)
thick plate
inner part
Preheating reduces longitudinal shrinkage stresses Preheating required transverse shrinkage longitudinal shrinkage
The requirement regarding preheating of longitudinal welds refers in particular to weld joints on bearing girders and weld joints on guide rails. Preheating reduces shrinkage stresses and has therefore positive influence on fatigue. The restriction regarding preheating of circular welds refers in particular to weld joints on gear boss of gear column (single wall column). Preheating increases shrinkage stresses and must therefore be prevented. Nevertheless it must be sure that the welds meet the required quality. * Definition: High joint restraint is a function of section thicknesses and joint geometry. All joints (for plate thicknesses > 12 mm) with a plate thickness ratio of t2 > 3 x t1 are highly restraint. Figures 2.15
t2 t2 > 3 x t1
Group: 1115,1118,1409 1411,6406,6409,6410
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2.5.3 Interpass temperature The observance of the maximum interpass temperature, as specified in the WPS, is of great importance to the properties of the welded joint. Interpass temperature must be measured on the weld metal or the immediately adjacent parent metal shortly before passage of the arc. Normally, the interpass temperature should not exceed 250C. 2.5.4 Heat treatment of base material All the materials must be delivered in the specified heat treatment condition. Plate material above 50 mm thickness and steel casting must be purchased in the normalised condition. If specified on the relevant drawings, base material must be subjected to a normalizing heat treatment after bending in order to reduce residual stresses from the bending process. 2.5.5 Post Weld Heat Treatment (PWHT) Application of PWHT depends on the major design features: Double wall design: Bedplate and column must not be stress relieved by applying PWHT. If PWHT is required for particular welded parts or components, details of this PWHT are specified on the relevant drawing. All welding procedures for such parts or components must also be qualified with an equivalent PWHT. Single wall design: Bedplate and column must be stress relieved by applying PWHT in accordance with the relevant instruction listed up on the welding drawing.
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Step within production progress Parts to be examined Failures to be detected, production details to set high value on
NDT method
Specification No. Scope of inspection Additives Document-No. of detailed instruction referring to NDT method Description of NDT examination and extent Additives like necessary tools or special procedures
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Fit-up inspection, Production surveillance Weld seam area Correct gap, grinded tack welds, weld seam geometry
Defects
VT 107.301.003
Complete extent Gage for gap inspection
UT 107.301.019
See ISM Testing with 45 , 60, 70angle of incidence
Production surveillance Weld seams in general Lack of penetration, lack of fusion, inclusions, hot / cold cracks in non accessible areas
Lamination
UT 107.301.014
See ISM Perpendicular testing with SE probe
UT 107.301.015
See ISM Testing with 45 , 60, 70 angle of incidence
MT 107.301.020
See ISM
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Figure 3.3: WRTSIL calibration block III with side drill holes All these indications allow a classification into spherical or planar discontinuities. Together with the measurement of indication length, adequate reporting and / or repair work can be appointed. For acceptance criteria see chapter 4 of this instruction or the relevant UT instruction. 3.5.2 Root run examination on level C weld seams Root run examination aims at detecting incomplete penetration in region of 12 mm level C single bevel butt welds. Therefore WRTSIL calibration block II (step wedge with 1mm notch on each step) was invented to simulate incomplete penetration for adequate plate thickness as good as possible.
Figure 3.4: WRTSIL calibration block II Setting the ultrasonic test equipment, a DAC-curve based on this calibration block is generated. Advanced investigations with 2 mm deep notches on a similar calibration block delivered a DAC-curve with approximately 10 dB lower values. Notches with bigger depth are not reasonable any more because the probe runs into repletion or the echo can no longer be caught by the receiver. For the analysis of the examination only the echo height is important to draw the correct conclusions i.e. make the correct classification! Indication length is used later to define the reporting and/ or repair work. If the evaluation curve (with 1 mm notches) is exceeded by an echo, the recording gain is decreased by 10dB which is equal to an incomplete penetration of 2 mm. So, indications are always compared to a notch size between 1mm and 2mm. For acceptance criteria see the corresponding UT examination instruction. Experience shows that this calibration method behaves as sensible as the method described in 3.5.1. Therefore it is permitted to pre-scan the weld volume with these DAC curve settings. If any indications appear, a detailed examination with an aligned setting (see 3.5.1) has to be done.
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Table 4.1
D: Represents the minimum weld quality which can be obtained from normal qualified welders without problems. Welds that do not fulfil quality level D are not acceptable. C: Represents normal good workmanship, which should be obtainable without problems. Minor grinding work may be necessary. B: Represents the best practical obtainable quality. The welder must be extra careful, and some repair work might be necessary. The choice of quality level for any application must take account of design considerations, subsequent processing, (e.g. surfacing), mode of stressing (e.g. static, dynamic), service conditions (e.g. temperature, environment) and consequences of failure. Economic factors are also important and should include not only the cost of welding but also inspection, test and repair costs. Normally all the dimensional limits for imperfections are covered by specifying one quality level. In some cases, it may be necessary to specify different quality levels for different imperfections in the same welded joint, or to include additional requirements.
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=> All areas with unacceptable indications must be repaired according Repair Work (Chapter 2.3). => If less than 25% of specific weld length has recordable indications, the required weld quality is satisfactory and no further action is needed. => If more than 25% of specific weld length has recordable indications, the required weld quality is not satisfactory. This situation indicates an error in the welding process. Since local or overall weld repairs can even worsen the actual situation (residual stress, lack of fusion, deformations), a decision by WCH Design Department has to be made whether the weld in question has to be repaired or not. However before welding a next series or part, the welding shop is responsible that the welding process will be optimised in order to achieve the required quality level. Following action may be necessary: - monitoring of parameters or adjustments within allowable tolerances - check welders qualification - check the welding shop equipment If no clear reasons are obvious, WCH strongly requires a new welding procedure qualification.
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t z s z *
Fit up gap 2 4 mm
t/s
D (partial penetration)
C (full penetration) Limits for imperfections are based on the evaluation curve which corresponds to a 1 mm groove in the relevant plate thickness of the calibration block II
Example: RT96C (t = 32mm) Incorrect transitions profile (item 28) Example: RT96C (t = 32mm) 0.15 t z 0.4 t 5 . 13 mm
0.15 t z 0.3 t 5 . 10 mm
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1 2
Surface pore 2017 Maximum dimension of a single pore for - butt welds - fillet welds Gas pore Uniformly distributed porosity 2011 The following conditions and limits for imperfections must be fulfilled: 2012 a) Maximum dimension of the summations of the projected area of the imperfection (for multi layer) b) Maximum dimension of the cross section area of the imperfection (inclusive of systematic imperfection) related to the fracture area c) Maximum dimension of a single pore for - butt welds - fillet welds
Not permitted
5%
3%
2%
2,5%
1,5%
1%
2013 The following conditions and limits for imperfections must be fulfilled: 2014 a) Maximum dimension of the summations of the projected area of the imperfection (for multi layer) b) Maximum dimension of the cross section area of the imperfection (inclusive of systematic imperfection) related to the fracture area c) Maximum dimension of a single pore for - butt welds - fillet welds 16% 8% 4%
8%
4%
2%
d 0,4 s d 0,3 s d 0,2 s d 0,4 a d 0,3 a d 0,2 a max. 4 mm max. 3 mm max. 2 mm h 0,4 s h 0,3 s h 0,2 s max. 4 mm max. 3 mm max. 2 mm ls ls ls max. 75 mm max. 50 mm max. 25 mm h 0,4 a h 0,3 a h 0,2 a max. 4 mm max. 3 mm max. 2 mm la la la max. 75 mm max. 50 mm max. 25 mm
Group: 1115,1118,1409 1411,6406,6409,6410
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Solid inclusions Slag inclusions Flux inclusions Oxide inclusions Metallic inclusions (other than copper) Copper inclusions
h 0,4 s h 0,3 s h 0,2 s max. 4 mm max. 3 mm max. 2 mm ls ls ls max. 75 mm max. 50 mm max. 25 mm h 0,4 a h 0,3 a h 0,2 a max. 4 mm max. 3 mm max. 2 mm la la la max. 75 mm max. 50 mm max. 25 mm h 0,4 s max. 4 mm h 0,4 a max. 4 mm Not permitted Not permitted h 0,3 s max. 3 mm h 0,3 a max. 3 mm Not permitted Not permitted h 0,2 s max. 2 mm h 0,2 a max. 2 mm Not permitted Not permitted
401
Lack of side 4011 wall fusion Lack of inter 4012 run fusion Lack of root fusion 4013
Short imperfections permitted, but not breaking of the surface Butt welds h 0,4 s max. 4 mm Fillet welds h 0,4 a max. 4 mm
Not permitted
Not permitted
2025
h 0,2 t max. 2 mm
h 0,1 t max. 1 mm
Not permitted
Crater pipe
2024
l h
h 0,2 t max. 2 mm
Not permitted
Not permitted
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90
90
110
110
one-sided access
t/s
Fit up gap 2 4 mm
Limits for imperfections are based on the evaluation curve which corresponds to a 1 mm groove in the relevant plate thickness Short imperfections of the calibration block II
h = 2 mm
h
Figure C: single-J butt weld (level C)
Evaluation of UT indications shall in general be carried out in accordance with the requirements of the UT testing procedures
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s1 s2
double-sided access
Full penetration
h1
h2
h = h1 + h2
s = s1 + s2
s1 s2
Partial penetration
Not permitted
h1
h2
Full penetration
h s
h
Butt joint correlates with T-joint
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13 Undercut
5011 5012
h 1 mm
h 0,5 mm h 0,5 mm
502
b h
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Actual weld
5214
For many applications a throat thickness bigger than the nominal one may not be a reason for rejection. Nominal weld Actual weld
unlimited
5213
A fillet weld with an apparent throat thickness smaller than that prescribed should not be regarded as being imperfect if the actual throat thickness with a compensating bigger depth of penetration complies with the nominal value. Nominal weld Actual weld
Short imperfections
18 Excessive penetration
504
b
19 Local protrusion 5041 Individual excessive root deviation
Permitted
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20 Linear misalignment
Fig.A h t
Fig.A h t
Figure B Circumferential welds h 0,5 t h 0,5 t h 0,5 t max. 4 mm max. 3 mm max. 2 mm Figure C J-welds on cast steel girders h max. 2 mm
Fig.B
512 In cases where a symmetric fillet weld has not been prescribed.
h 2 mm + 0,2 a
h 2 mm + 0,15 a
h 1,5 mm 0,15 a
z1 h z2
Actual weld
Nominal weld
h = z1 z2
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b h
h 0,25 t h 0,1 t h 0,05 t max. 2 mm max. 1 mm max.0,5mm
24 Root porosity
516
Spongy formation at the root of a weld to bubbling of the weld metal at the moment of solidification (e.g. lack of gas backing) Level D: Short imperfections permitted, but not breaking of the surfaces
locally permitted
Not permitted
Not permitted
25 Shrinkage cavity
202
butt welds Not h 0,4 s permitted max. 4 mm fillet welds h 0,4 a max. 4 mm
Not permitted
515 5013
h 2 mm
h 1 mm
h 0,5 mm
27 Overlap
506
h 0,2 b
Not permitted
Not permitted
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t z
Valid for all butt welds 29 Burn through 30 Poor restart 510 Not permitted Level D: The limit depends on the type of imperfection occurred due to restart. Permitted Not permitted Not permitted
517
601
Permitted, if the properties of the parent metal are not affected Example: column section
32 Weld Spatter
602
A C B
A) Spatter are to be removed at internal welds (crank casing, exhaust receiver, air cooler etc). B) Spatter on root side of single bevel butt welds should be removed if accessible. C) Visible spatter on outer side of engine structure must be removed because of unaesthetic reason.
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h4
Overall size of short imperfections h 0,4 t or 0,3 t or 0,2 t or 0,25 a 0,2 a 0,15 a max.10 mm max.10 mm max.10 mm
h5
h1 h2 h3
h1 + h2 + h3 + h4 +h5 = h
h1
h3
h1 + h2 + h3 + h4 + h5 = h Projected or cross-section area in longitudinal direction (see annex A) Case 1 (D > l3) lp x wp = 100% hxl 16% hxl 8% hxl 4%
l1 h1 wp
l2 h2
l3 h3 l3 h3
D lp
h1 x l1 + h2 x l2 + h3 x l3 = h x l Case 2 (D < l3) lp x wp = 100%
l1 wp h1
l2
h2
D lp
h1 x l1 + h2 x l2 + (h2+h3) x 0,5 + D +h3 x l3 = hxl
h2
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4.5.2 Surface defects For examination of incorrect shape and other surface defects, NDT methods with a better resolution than listed above are to be used.
Annex A
Additional information and guidelines for the use of this quality standard Imperfections are quoted in terms of their actual dimensions, and their detection and evaluation may require the use of one or more methods of non-destructive testing. The detection and sizing of imperfection is dependent on the inspection methods and the extent of testing specified by WCH in supplementary documents. It should be noted that methods of non-destructive examination may not be able to give the detection, characterization and sizing necessary for use within certain types of imperfections shown in table 4.3. This standard specifies requirement for three levels of acceptance for imperfections in welded joints of steel for arc welding processes according to the scope and for weld thickness 0,5 mm. It may be used where applicable for other fusion welding processes or weld thicknesses. Different parts are very often produced for different applications but to similar requirements. The same requirements should , however, apply to identical parts produced in different workshops to ensure that work is carried out using the same criteria. The consistent application of this standard is one of the fundamental cornerstones of a quality assurance system for use in the production of welded structures. In table 4.3, figures for multiple imperfections (item 33), show a theoretical possibility of superimposed individual imperfections. In such a case the total summation of all permitted deviations should be restricted by the stipulated values for the different quality levels. However, the values of a single imperfection may exceed h, example for a single pore. This standard may be used in conjunction with a catalogue of realistic illustrations showing the size of the permissible imperfections for the various acceptance level by means of photographs showing the face and root and/or reproductions of radiographs and of photo macrographs showing the cross-section of the welds. This catalogue may be used with reference cards and replicas to assess the various imperfections and may be employed when opinions differ as to the permissible size of imperfections.
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Appendix 1
Content 1. Scope 2. Introduction 3. Reference documents 4. Covered welding electrodes
4.1 4.2 4.3 4.4 4.4.1 4.4.2
Electrode types Guidelines for storage Guidelines for baking Guidelines for handling Non-conforming covered electrodes Workshop procedure for guaranteeing dry electrodes
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Appendix 1
1. Scope
This recommendation covers the basic principles to be observed in the handling and storage of welding consumables in order to ensure the deposit of quality welds.
2. Introduction
Handling and storage of covered welding electrodes, solid- and cored welding wire and welding fluxes have a significant influence on the weld quality. It is therefore of utmost importance, that all welders and operators are familiar with these requirements and first of all put these requirements into action on the shop floor. The manufacturers recommendations for handling and storage of a specific type and brand of consumable or flux, as detailed on the packaging or materials data sheet, takes always precedence over the following general recommendations.
3. Reference documents
a) Welding consumable Handbook from Thyssen Schweisstechnik 1999 Edition b) Welding consumable Handbook from Bhler Schweisstechnik 2003 Edition c) Recommendation for storage, re-drying and handling of ESAB consumables d) FILARC product catalog international edition 1999/2000
4.1 Electrode types a) Low hydrogen basic electrodes (excluding vacuum packed electrodes) must be re-baked before use to ensure low weld metal hydrogen content. b) Acid rutile or basic stainless/nickel electrodes (excluding vacuum packed electrodes) must be rebaked before use to avoid porosity. c) Mild steel rutile and acid electrodes normally needs no re-baking. Over baking can damage the flux coating and impair welding characteristics. d) Cellulose electrodes must not be baked. These electrodes need a defined amount of moisture in the flux coating in order to function properly.
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Appendix 1
4.2 Guidelines for storage Coated electrodes should principally be kept in their original packaging until use. The withdrawal of electrode packages from store should be based on the first-in/first-out principle. The electrode storage room has to fulfil the following requirements: - the room must be protected against atmospheric conditions and adequate ventilation must be ensured, ceiling, floor and walls must be dry, there must not be any open water areas in the room. Coated electrodes must not be stored in direct contact with either the floor or the walls. - open electrode packages have to be stored in a dry and, if necessary, heated rooms in order to prevent the temperature from dropping below the dew point. Covered electrodes of any type will pick up moisture only very slowly if they are stored under the following climatic conditions as detailed in table 2: At temperature ( C) 5 - 15 5 - 25 > 25 Max. relative humidity (%) 60 50
40 During winter, it is possible to maintain low relative humidity by keeping the temperature in the store room at least 10C above the outdoor temperature. During certain periods in the summer and in tropical climate, sufficiently low relative humidity may be maintained by air dehumidification. 4.3 Guidelines for baking and holding Baking and re-baking must only be carried out in special electrode baking ovens.. For baking and re-baking, the oven must be preheated to 80-100 before placing the electrodes in it. C Electrodes must not be stacked higher than 3-4 layers in the oven. After baking temperature is reached, it must be maintained for approximately 2 hours. For baking temperatures from 250 , heating rate of C the oven should not exceed 150 C/h. Basic coated e lectrodes may be baked or re-baked only up to 3 times, whereby they total baking or re-baking time should not exceed 10 hours. Vacuum packed electrodes dont require baking , if they are taken from there original packaging directly prior to welding. General recommendations for baking and re-baking subject to storage condition, flux coating type, packaging and cold-crack sensitivity of the base material welded are listed in table 3: Electrode application Unalloyed and low alloy steel Type of coating*** A, AR, C**, RC R, RR, RB B High strength fine grained constructional steel High temperature steels B R RB, B Stainless and heat resistant steels Soft-martensitic steels Duplex steels Nickel-base alloys * R RB, B B RB all Re-backing generally Baking recommended temperature ( C) No* yes yes No* yes yes No* yes yes if required* -* 300-350 300-350 300-350 120-200 -* 300-350 250-300 120-300 Re-backing time (h) 2-10 2-10 2-10 2-10 2-10 2-10 2-10
- In certain cases it may be reasonable to re-bake even electrodes for which table 3 does not recommend re-baking. Should the coating exhibit an excessively high water content as the result of improper storage or other adverse influences, which is reflected, among others, by the welding behaviour and by increased spattering or formation of pores, the electrodes may- in the absence of specifications by the manufacturer to the contrary- be re-baked at 100-120 for one hour. C ** - Cellulose coated electrodes must principally not be re-baked. *** - Abbreviations of electrode coating types: A acid covering / B - basic covering / C cellulosic covering / R rutile covering / RA rutile-acid covering / RB rutile-basic covering / RC rutilecellulosic covering / RR rutile-thick covering / S other types
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Appendix 1
4.4 Guidelines for handling
4.4.1 Non-conforming covered electrodes Non-conforming covered electrodes must be treated as per table 4: Electrode condition Cracked or chipped off flux coating Possible Causes Mishandling during transport, excessive bending, stepping on electrode or incorrect arc striking technique Damaged packaging or excessive exposure to humidity Effects Porosity, Unstable arc, Lack of fusion Appropriate remedies Electrode must not be used for welding and scrapped
Porosity, Electrode must not be Excessive spatter used for welding and scrapped
Excessively damp, discoloured and / or contaminated flux coating Electrodes from sealed packages or before any use (excluding vacuum packed, cellulose- and mild steel rutile and acid electrodes)
Direct exposure to water, oil, Hydrogen Electrode must not be grease induced cracking, used for welding and Porosity scrapped Moisture pick up through original shrink- film paper boxes or in the workshop Hydrogen Re-baking according to induced cracking, the consumable Porosity manufacturers recommendations as printed on the consumable package
4.4.2 Workshop procedure for guaranteeing dry electrodes Each welder should only fetch a quantity of covered electrodes for no more than a work shift. Low hydrogen electrodes either from the baking or holding oven or vacuum packed and electrodes with other coating from the original package must immediately be transferred into electrically heated quivers. These quivers keep the electrodes dry at a minimum temperature of 70-120C. After work, remaining electrodes must be returned to the holding oven. The holding oven is used for intermediate storage to avoid moisture pick up in the coating. Holding oven temperature should be between 120-150 with a C maximum storage period of 30 days. The following flow diagram summarizes the procedure for low hydrogen electrodes: Store room for electrode (< 60% relative humidity) electrode in sealed original packaging Baking / Re-baking oven (350 for 2 hours) C Holding oven (120 150 C C for 30 days) Remaining electrodes from the Quiver to be returned for re-baking (max. 3 times for 10 hours)
Quiver (70 120 for C C work shift) Welding electrodes for max. 10 min consumption can be taken out of the quiver
Welding
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Appendix 1
Suitable flux quantities depend on the design and ventilation of the drying oven, but the height of the flux layer should not exceed 50 mm. 6.3 Guideline for handling Re-baked flux should be stored at 150 25C until use for a period of no longer than 30 days.
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Appendix 2
1. References documents
EN ISO 9001/9002 EN 729-2 EN ISO 17662 Quality management system
Quality requirements for welding - fusion welding of metallic materials Part 2, comprehensive quality requirements Welding-Calibration, verification and validation of equipment used for welding, including ancillary activities
DVS techn. Bulletin 3009 Calibration of welding power sources DVS techn. Bulletin 0714 Manufacturer requirements for the calibration of welding equipment manufacturers
Heat treatment equipment Annealing furnaces Induction- and Resistance heat treatment equipment Stationary Baking and Holding ovens for welding consumables (electrodes and fluxes) Mobile Holding equipment for welding electrodes (Quivers) Motor driven ancillary welding equipment Measuring devices Welding turntables Temperature measuring instruments (for verification of pre-heat and interpasstemperature)
24 12 24 12 12 12
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Appendix 2
2.2 Typical weld parameter tolerances
Table 2 lists typical weld parameter tolerances to be considered for calibration of welding equipment: Welding process SMAW (111)* GTAW (141)* manual 10% 10% *** 15% 510% N/A 10% *** 110% 110% 110% 110% GTAW (141)* mechanized 110% 15% 15% 10% *** 110% 2,55% 2,55% 110% 15% GMAW / FCAW active / inert gas (135,131 / 136,137)* manual 10% 2,510% 510% 10% *** **** **** **** **** GMAW / FCAW active / inert gas (135,131 / 136,137)* mechanized 10% 2,510% 2,510% 10% *** **** **** **** **** 15%
Weld parameter Current Voltage Wire feed speed Shielding gas flow Open circuit voltage Peak current** Pulse width** Pulse frequency** Background current** Travel speed
* - Weld process numbers as defined in ISO 4063 ** - Parameters only for pulse arc welding relevant *** - Testing in accordance with equipment manufacturer requirements **** - Calibration based on equipment manufacturer recommendations (e.g. by means of an oszillogramm) 2.3. Calibration procedure and documentation Calibration of welding equipment must only be carried out by qualified personal, using measuring devices calibrated to national or international standards and specifications. This measuring devices must be autonomous from the equipment to be calibrated. Calibration must be carried out only in accordance with a written calibration procedure. This procedure specifies the relevant details of the calibration process as listed below: - Purpose - Terms and abbreviations - Sequence of operations - Employed measuring and calibration devices - Measuring setup - Calibration process - Evaluation of calibration results Calibration of welding equipment is to be done by checking at least 3 to 5 measuring points in between the operating range of the equipment (e.g. 10%, 50% and 90% of the nominal parameter to be tested). The calibration process must be documented by means of a calibration record (or calibration certificate). A sample calibration record/certificate is attached in Appendix 3 (Record sheets). This calibration record must contain the details as recorded during the calibration process, as well as information on the calibrated equipment (e.g. type and equipment identification number, date of calibration and period of validity). The calibration records must be retained at least until the next scheduled calibration is completed. Calibration records must be readily available for verification by the Classification Society or by designated WCH personal. Prove of calibration for welding equipment is done either by applying calibration stickers directly on the relevant equipment or by presentation of the calibration record itself. Calibration stickers must carry the following information as a minimum: - Period of validity or month and year of the next scheduled calibration. - Identification of calibrated equipment.
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record sheet
Content A) Calibration B) Preliminary Welding Procedure Specification (pWPS) C) Implementation schedule
No. Page
Record sheets for Visual Testing, Ultrasonic Testing and Magnetic Particle Testing are attached to the relevant work instruction.
Version a2
18-99
No. Page
Remarks
18-100
Version a2
record sheet
Preliminary Welding Procedure Specification (pWPS)
Location Manufacturer Joint Design 60 Related WPS No. Related WPQR No. Welding Sequences A
No. Page
G
* simulated root repair
Welding details
Run Process Position no. 1-2 3-n Filler metal AWS Brand Size Polarity Current Voltage Speed Amp V cm/min Gas
Method of preparation and cleaning Parent material designation Preheat temperature ( C) Post-weld heat treatment Repair procedure
Run Process Position no. 1-2 3-n Filler metal AWS Brand Size Polarity Current Voltage Speed Amp V cm/min Gas
A-A
200 mm
~30
A
Manufacturer Name: Date: Classification Society Name: Date: Accepted by Wrtsil Switzerland Ltd. Name: Date:
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record sheet
Preliminary Welding Procedure Specification (pWPS)
Location Manufacturer Joint Design 60
Grade 410W Grade B
No. Page
Related WPS No. Related WPQR No. Welding Sequences A T (mm) G (mm) T T R (mm) 0 mm A ( )
Welding details
Run Process Position no. 1-2 3-n Filler metal AWS Brand Size Polarity Current Voltage Speed Amp V cm/min Gas
Method of preparation and cleaning Parent material designation Preheat temperature ( C) Post-weld heat treatment Repair procedure
Run Process Position no. 1-2 3-n Filler metal AWS Brand Size Polarity Current Voltage Speed Amp V cm/min Gas
A-A
~30
200 mm
A
Manufacturer Name: Date: Classification Society Name: Date: Accepted by Wrtsil Switzerland Ltd. Name: Date:
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record sheet
Implementation schedule for WPQR qualification
*) At first pre-definition of welding processes and related welding positions for all quality level B & C joints necessary to define the required number of pWPS.
No. Page
pWPS
*Generation of pWPS Ordering and preparation of test materials and equipment Execution of test welds for fine tuning of weld parameters
WPQR**
**) The presence of CS is mandatory. WCH must be invited and reserves the right to attend.
WPS
Training and qualification of welders / operators as required (Qualification of welders / operators must be done in the presence of CS, welders involved in welding the WPQR are automatically qualified) Welding of test piece NDT of test piece Destructive testing of test piece Generation of job specific WPS, based on the approval range of the qualified WPQR Start of production welding Approval of WPQR by CS Approval of pWPS by CS and WCH *** Start of WPQR Submit all WPQR documents to CS Name: Date: Submit pWPS to WCH
Note: The licensee/manufacturer must appoint at least one of the Classification societies, which have previously approved the WCH Welding Instruction, to witness and formally approve welding and testing of the PQR/WPQR. The other Classification societies, relevant to this licensee/manufacturer, must also be invited to witness welding and testing in order to ensure their general acceptance. CS: Classification society WCH Name: Date: WCH: Wrtsil Switzerland Ltd Licensee Name: Date: Manufacturer
Version a2
Start
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Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these rights. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made accessible to third parties without the previous written consent of Wrtsil.
Introduction
Apart from the normal conventional engine holding down stud used to fasten the engine to the tank top plate, a different design is to be applied for the propeller thrust transmission. The propeller thrust is transmitted from the engine thrust bearing to the bedplate and to the tank top plate which is part of the ships structure by means of thrust sleeves located adjacent to the engine thrust bearing.
Substitute for:
Modif
PC
Q-Code X
Number
Number
Drawn Date
Number
Drawn Date
Number
Drawn Date
W-X35
Made Chkd Appd
Fitting Instruction
to engine seating with epoxy resin chocks
Main Drw. Design Group Page Material ID
1/6
Drawing ID
107.412.130.500
Rev -
9710
107.412.130
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
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Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these rights. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made accessible to third parties without the previous written consent of Wrtsil.
2
2.1
Thrust sleeve
Fitting
The thrust sleeve is fitted in the bottom plate of the engine bedplate and cast in the tank top plate. The diameter of the flame-cut or drilled hole for the thrust sleeve in the tank top plate is larger than the diameter of the sleeve to allow engine alignment without remachining of the hole. The sleeve in the tank top plate hole is then fixed with epoxy resin material as used for the chocks. The engine holding down stud is inserted in the sleeve and tightened in the same way as the normal holding down studs. This hydraulically tightened holding down stud is of the same design, as the normal holding down stud used to fasten the engine to the tank top plate. Drilling and reaming of the holes in the engine bedplate is carried out by the engine manufacturer. The thrust sleeves with the final tolerance and the holding down studs are supplied by the shipyard.
2.2
2.3
Chock thickness
Since the chock thickness cannot be precisely determined before engine alignment is finalized, the standard design of the holding down stud, thrust sleeve and conical socket, allows for the application of chock thicknesses from 25 up to 60 mm. To avoid additional machining of the sleeve to adjust its length, the conical socket is provided with a larger bore compared to the sleeve's external diameter. The sleeve can protrude beyond the top plate more or less, the space in the conical socket allows for this variability. If chock thickness needs to be more than 60 or less than 25 mm, the length of the thrust sleeve and its corresponding holding down stud as well as the length of the normal holding down stud must be in- or decreased accordingly. Please note: In any case, if the minimum thickness is less than 25 mm, the epoxy resin supplier must be consulted.
Substitute for:
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PC
Q-Code X
Number
Number
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Drawn Date
Number
Drawn Date
W-X35
Made Chkd Appd
Fitting Instruction
to engine seating with epoxy resin chocks
Main Drw. Design Group Page Material ID
2/6
Drawing ID
107.412.130.500
Rev -
9710
107.412.130
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
Version a2
18-107
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these rights. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made accessible to third parties without the previous written consent of Wrtsil.
3
3.1
3.2
Pouring
Pouring of the epoxy resin chocks together with its preparatory work must be carried out either by experts of the epoxy resin manufacturers or by their representatives. Their instructions must be strictly observed. In particular, no yard work on the engine foundation may proceed before completion of the curing period of the epoxy resin chocks. Epoxy resin material for the thrust sleeve holes is identical to that used for the chocks. The epoxy resin material applied for the chocking of the engine has to fulfill the following requirements: Approved by the major classification societies The following materials properties are met:
Properties Ultimate compression strength Compression yield point Compressive modulus of elasticity Deformation under load: Load 550 N / 70C Load 1100 N / 70C Curing shrinkage Coefficient of thermal expansion (0-60 K) Coefficient of friction normal Standard ASTM D695 ASTM D695 ASTM D695 ASTM D621 max. 0.10 % max. 0.15 % ASTM D2566 ASTM D696 max. 0.15 % max. 50 10 1/K min. 0.3
-6
Values min. 130 MPa min. 100 MPa min. 3100 MPa
Table 1:
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PC
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W-X35
Made Chkd Appd
Fitting Instruction
to engine seating with epoxy resin chocks
Main Drw. Design Group Page Material ID
3/6
Drawing ID
107.412.130.500
Rev -
9710
107.412.130
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
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Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these rights. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made accessible to third parties without the previous written consent of Wrtsil.
Substitute for:
Modif
PC
Q-Code X
Number
Number
Drawn Date
Number
Drawn Date
Number
Drawn Date
W-X35
Made Chkd Appd
Fitting Instruction
to engine seating with epoxy resin chocks
Main Drw. Design Group Page Material ID
4/6
Drawing ID
107.412.130.500
Rev -
9710
107.412.130
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
Version a2
18-109
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these rights. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made accessible to third parties without the previous written consent of Wrtsil.
5
5.1
Table 2:
Remarks: *1) Including an efficiency loss during tightening process *2) The hydraulic pre-tensioning jack is part of the engine builders tool kit
5.2
Figures
thrust sleeve
conical socket
spong rubber sealing to be compressed when assembled prior to assembly smear gasket sealant (Loctite 574/orange or similar)
Figure 1: Arrangement of thrust sleeve with stud prior pouring the epoxy resin chocks
Substitute for:
Modif
PC
Q-Code X
Number
Number
Drawn Date
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W-X35
Made Chkd Appd
Fitting Instruction
to engine seating with epoxy resin chocks
Main Drw. Design Group Page Material ID
5/6
Drawing ID
107.412.130.500
Rev -
9710
107.412.130
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
18-110
Version a2
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these rights. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made accessible to third parties without the previous written consent of Wrtsil.
Figure 2: Arrangement prior pouring the epoxy resin chocks for normal stud (proposal)
Substitute for:
Modif
PC
Q-Code X
Number
Number
Drawn Date
Number
Drawn Date
Number
Drawn Date
W-X35
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Fitting Instruction
to engine seating with epoxy resin chocks
Main Drw. Design Group Page Material ID
6/6
Drawing ID
107.412.130.500
Rev -
9710
107.412.130
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
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18-116
Version a2
Figure 18.3: Shaft earthing arrangement View on A - Brush gear omitted 1 2 3 4 5 6 Slip ring Tension bands Twin holder Brushes Connection to the ships hull Steel spindle 7 8 9 10 11 12 Connection to the voltmeter Mounting bracket Insulated spindle Single holder Monitoring brush Clamps
Version a2
18-117
18-118
Version a2
18.6.1 Drawings
DAAD026720 107.429.043 107.429.068 107.246.515 107.246.522 107.246.513 a 107.246.651 107.246.439 b 107.246.516 107.246.650 a 107.380.159 b 107.246.429 e DAAD026712 107.165.800 g 107.165.801 f 107.165.802 a 107.165.803 d 107.165.804 b 107.165.808 a 107.165.806 a 107.165.809 107.165.810 a 107.165.815 107.165.821 a 107.245.489 107.165.811 107.165.812 107.329.413 a 107.165.814 107.165.820 b 107.165.818 b 107.165.817 a DAAD006100 107.165.822 107.165.813 b DAAD026719 Engine Stays, 4-8 Cyl. .........................................................................1-882 8--0 111 _ Engine Stays/ Friction Type, 4-8 Cyl. ................................................1-882 8--1 111 _ _ Support, To Engine Stays, Friction Type, 4-8 Cyl. .........................1-882 8--2 111 _ _ Clamping Part, To Engine Stays, Frictio, 4-8 Cyl. ..........................1-882 8--3 111 _ _ Support, Engine Stays, Friction T, 4-8 Cyl. ....................................1-882 8--4 111 _ _ Stay, To Engine Stays, Frictio, 4-8 Cyl. ..........................................1-882 8--5 111 _ _ Friction Shim, Ordering Drawing, 4-8 Cyl. .....................................1-882 8--6 111 _ _ Bolt, To Engine Stays, Frictio, 4-8 Cyl. ...........................................1-882 8--7 111 _ _ Disc Spring, To Engine Stays, Frictio, 4-8 Cyl. ..............................1-882 8--8 111 _ _ Centring Sleeve, To Engine Stays, Friction, 4-8 Cyl. .....................1-882 8--9 111 _ _ Round Nut, 4-8 Cyl. .......................................................................1-883 8--0 111 _ Assembly Instructions, To Engine Stays Friction, 4-8 Cyl. ...............1-883 8--8 111 Engine Stays, Hydraulic Type, 4-8 Cyl. ................................................1-883 8--9 111 _ Hydraulic Cylinder, To Engine Stays, 4-8 Cyl. ...................................1-884 8--0 111 _ _ Cylinder, 4-8 Cyl. ............................................................................1-884 8--1 111 _ _ Piston, 4-8 Cyl. ...............................................................................1-884 8--2 111 _ _ Cover, 4-8 Cyl. ................................................................................1-884 8--3 111 _ _ Valve Spindle, 4-8 Cyl. ...................................................................1-884 8--4 111 _ _ Connecting Piece (Sw41), 4-8 Cyl. ................................................1-884 8--5 111 _ _ Pointer, 4-8 Cyl. ..............................................................................1-884 8--6 111 _ _ Bearer, 4-8 Cyl. ...............................................................................1-884 8--7 111 _ _ Treaded Sleeve, Engine Stays, 4-8 Cyl. .........................................1-884 8--8 111 _ _ Support, 4-8 Cyl. ............................................................................1-884 8--9 111 _ _ Ring, 4-8 Cyl. .................................................................................1-885 8--0 111 _ _ Ball Valve, Order Drawing, 4-8 Cyl. ................................................1-885 8--1 111 _ _ Piston Guide, Order Drwg., 4-8 Cyl. ..............................................1-885 8--2 111 _ _ Pressure Gauge, Order Dr., 4-8 Cyl. ..............................................1-885 8--3 111 _ _ Bladder Accumulator, Order Drawing, 4-8 Cyl. ..............................1-885 8--4 111 _ _ Plug, Order Drwg., 4-8 Cyl. ............................................................1-885 8--5 111 _ _ Hydraulic Lateral Device, For Main Engine, 4-8 Cyl. .....................1-886 8--7 111 _ _ Testing And Filling Device, Order Drwg., 4-8 Cyl. ..........................1-886 8--8 111 _ _ Instruction For Pressure Test, 250 Bar, 4-8 Cyl. ............................1-886 8--9 111 _ Round Bar, 4-8 Cyl. ...........................................................................1-887 8--0 111 _ _ Male Union, Order Drwg., 4-8 Cyl. .................................................1-887 8--1 111 _ _ Prec. Seamless Pipe, Order Drwg., 4-8 Cyl. ..................................1-887 8--2 111 Engine Stays, 4-8 Cyl. .........................................................................1-887 8--3 111
Version a2
18-119
18-120
Version a2
Version a2
18-121
18-122
Version a2
Version a2
18-123
18-124
Version a2
Version a2
18-125
18-126
Version a2
Version a2
18-127
18-128
Version a2
Version a2
18-129
18-130
Version a2
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these right s. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made a ccessible to third parties without the previous written consent of Wrtsil.
Introduction
Lateral and longitudinal stays are installed where countermeasures against dynamic effects are necessary (for indications refer to Marine Installation Manual, chapter Engine Dynamics). For stay arrangement and details refer also to the relevant installation drawings of the corresponding design group 9715. It is vital that the stays are fitted correctly to ensure proper operation and to prolong the lifetime of the components.
Support
Support
E ngine S ide
D riv ing E nd
H ing e P in
D is c S pring s
H ing e P in
Substitute for:
Modif
PC 19.11.2008 Drawn Date Product C EAAD082173 Number 04.08.2010 Drawn Date D EAAD082947 Number 13.05.2011 Drawn Date
Q-Code X
S hip S ide
X X
B EAAD067959 Number
E EAAD083505 Number
RTMOT
Made Chkd Appd
Assembly Instruction
for engine stays, friction type
Main Drw. Design Group Page Material ID
27.01.1998
1/8
Drawing ID
107.246.429
Rev
9715
107.246.429
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
Version a2
18-131
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these right s. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made a ccessible to third parties without the previous written consent of Wrtsil.
For lateral application the stays are fixed on the engines exhaust side or fuel side, according to the arrangement shown on the main drawing of design group 9715. For longitudinal application the stays are fixed on engines free end. Examples of stay arrangements are provided in figure 2, figure 3 and figure 4. Which stay arrangement is applicable depends on the engine type and is specified by the corresponding drawing of design group 9715. As the design of the clamping bolts is similar to that applied for the engine holding down studs, the same hydraulic tool (design group 9411-06) can be used for pre-tensioning.
Lateral arrangement with attachment on scavenge air receiver box Lateral arrangement with attachment on platform support Longitudinal arrangement with attachment on platform support
Figure 2
Figure 3
Figure 4
3
3.1
Substitute for:
Modif
PC 19.11.2008 Drawn Date Product C EAAD082173 Number 04.08.2010 Drawn Date D EAAD082947 Number 13.05.2011 Drawn Date
Q-Code X
B EAAD067959 Number
E EAAD083505 Number
RTMOT
Made Chkd Appd
Assembly Instruction
for engine stays, friction type
Main Drw. Design Group Page Material ID
27.01.1998
2/8
Drawing ID
107.246.429
Rev
9715
107.246.429
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
18-132
Version a2
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these right s. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made a ccessible to third parties without the previous written consent of Wrtsil.
Note:
The attachment points of the stays on engine and ship hull side are marked in the final position according to the relevant main drawing of design group 9715 Hydraulic tensioning device is ready for use (engine builders tool kit, code-No. 94145)
When fitting the stays it is very important that the engine is preheated to starting condition. This is necessary to reduce any possible misalignment of the stay due to engine thermal expansion between fitting and service condition. Excessive horizontal and vertical misalignment of the stay between the engines and the ships attachment points may restrict the stays function. It may even lead to buckling or cracking of the stay. For admissible tolerances refer to table 2. During positioning and fitting use a crane to avoid overstress to the stay.
3.2
Installation steps
1. Prepare all parts and installation tools. 2. Make sure that all starting conditions according to section 3.1 are fulfilled. 3. Assemble the stay according to the relevant assembly drawing of design group 9715 and tighten the clamping bolts slightly by hand. 4. Shift the stay until the nominal position (defined by the distance M in table 1) is achieved. Then tighten the clamping bolts with 100 bar pressure. 5. Check at the marked attachment points on ship hull and engine side that there is no platform support, piping or something else which could collide with the stay. In particular pay attention to the space requirements of the hydraulic tensioning device in order to allow proper tightening of the clamping bolts. 6. Put the stay in the final position between ship hull and engine and align the stays support without fixing on engine side. Check whether the stay is longer, shorter or equal in relation to the clear width between engine and ship hull. - In case the stay is longer than the clear width between ship hull and engine, measure its overall length X. Then measure the clear width between ship hull and engine and calculate the difference to the overall stay length X. If the difference exceeds the maximum allowed value limited by the tolerances in table 1, the support on the engine side has to be shortened and the edges must be prepared for welding. - In case the stay is shorter than the clear width between ship hull and engine, measure the gap between stay end and ship hull directly. If the gap exceeds the maximum allowed value limited by the tolerances in table 1, a steel plate has to be added as spacer under the support to compensate the undersize.
Substitute for:
Modif
PC 19.11.2008 Drawn Date Product C EAAD082173 Number 04.08.2010 Drawn Date D EAAD082947 Number 13.05.2011 Drawn Date
Q-Code X
B EAAD067959 Number
E EAAD083505 Number
RTMOT
Made Chkd Appd
Assembly Instruction
for engine stays, friction type
Main Drw. Design Group Page Material ID
27.01.1998
3/8
Drawing ID
107.246.429
Rev
9715
107.246.429
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
Version a2
18-133
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these right s. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made a ccessible to third parties without the previous written consent of Wrtsil.
- In case stays length is equal to the clear width between ship hull and engine, no modifications are necessary. Note: During loading, the ships hull tends to deform towards the ships centre line, respectively to engine side. Therefore it is suggested to fit a stay of a length just correct or rather too short than with overlength, in order to allow an extra stroke in longitudinal direction (see table 1). 7. Make sure that the surfaces of the receiver box/platform support and the ship side attachment points are clean. 8. Attach the stay on engine side in the final position and fix the support by spot welding. 9. Align the stay horizontally and vertically (observe the tolerances given in table 2) and fix the support on ship hull side by spot welding. 10. Before accomplishing the final welding, loosen the clamping bolts in order to avoid material stress due to thermal expansion. 11. Perform final welding at the supports on engine and ship hull side. 12. After all parts have cooled down, tighten the clamping bolts with the final pressure according to table 4. 13. Measure the height of each pre-tensioned disc spring pack and check with the relevant assembly drawing of design group 9715 whether the height is according to Wrtsils specifications. If the height deviates from the given value the following need to be checked: Was the correct tensioning device used for tensioning the clamping bolts? - In case a too small tensioning devise was used, re-tighten the clamping bolts with the correct devise and given pressure. - In case a too big tensioning devise was used, calculate whether the maximum permissible yield strength of the clamping bolts, nuts, friction shims and disc springs was already exceeded and the elements need to be replaced due to damage by plastic deformation. Even if the calculation result indicates that the maximum permissible yield strength was not exceeded, make finally a visual check to ensure that no element was damaged due to the wrong tensioning. Were the clamping bolts, nuts, friction shims and disc springs correctly assembled according to the relevant assembly drawing? - In case one or more elements were wrong assembled, re-arrange those accordingly.
Substitute for:
Modif
PC 19.11.2008 Drawn Date Product C EAAD082173 Number 04.08.2010 Drawn Date D EAAD082947 Number 13.05.2011 Drawn Date
Q-Code X
B EAAD067959 Number
E EAAD083505 Number
RTMOT
Made Chkd Appd
Assembly Instruction
for engine stays, friction type
Main Drw. Design Group Page Material ID
27.01.1998
4/8
Drawing ID
107.246.429
Rev
9715
107.246.429
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
18-134
Version a2
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these right s. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made a ccessible to third parties without the previous written consent of Wrtsil.
Are the material and dimensions of all elements in compliance with Wrtsils specifications? - In case the material or dimensions of one or more elements are not according to Wrtsils specifications replace those accordingly.
Substitute for:
Modif
PC 19.11.2008 Drawn Date Product C EAAD082173 Number 04.08.2010 Drawn Date D EAAD082947 Number 13.05.2011 Drawn Date
Q-Code X
B EAAD067959 Number
E EAAD083505 Number
RTMOT
Made Chkd Appd
Assembly Instruction
for engine stays, friction type
Main Drw. Design Group Page Material ID
27.01.1998
5/8
Drawing ID
107.246.429
Rev
9715
107.246.429
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
Version a2
18-135
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these right s. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made a ccessible to third parties without the previous written consent of Wrtsil.
no
A djus t
A s se m bly the stay a cc . to th e as se m bly d raw ing an d tig hten the c la m p in g bo lts by h an d.
S h ift the s ta y u ntil the n om in al po sitio n (de fin ed by th e d is ta nc e M in tab le 1) is ac h iev e d. T he n tig hte n th e c la m ping bo lts w ith 10 0 b ar pre ss ure .
P u t th e sta y in th e fina l po sitio n b etw ee n s hip hu ll an d en gine a nd alig n the stay s up po rt w itho ut fix in g on en gine s id e. C h ec k w he th er the s tay is lon ge r, s ho rte r or eq ua l in re latio n to th e ga p b etw ee n e ng in e a nd s hip h ull.
no
s ho rter
S ta y le ng th in re la tio n to th e g ap ?
lo ng er
M ea su re the s tay len gth X . M ea su re the c le ar w id th be tw e en sh ip hu ll a nd en gine . C a lc ula te th e de v ia tio n b etw ee n the m ea su red d is tan ce X an d the c le ar w idth.
y es
eq ua l
no
y es
P o sitio n the s tay s up po rt o n en gin e side in th e fin al po sitio n and fix it by s po t w elding .
A lign th e sta y ho riz on ta lly a nd v ertica lly (m a in tain the to le ran ce s giv e n in tab le 2) an d fix th e su pp ort on s hip h ull s id e b y sp ot w elding .
P e rfor m fin al w eldin g at the s up po rts on e ng ine a nd sh ip h ull s id e. C o rrec t th e de term ined dis cre pe nc ie s ac co rding ly . A fter a ll pa rts h av e c o ole d do w n tigh te n the clam p ing b olts w ith th e fin al pre ss ur e a cc . tab le 4. C h ec k the fo llo w in g po ints: - W as th e c o rrec t tigh te nin g d ev is e us ed ? - W ere th e c la m pin g bo lts , n uts, fric tion s him s an d disc s p rin gs c orre ctly as se m bled ? - A r e th e m ate ria ls a nd d im e ns io ns of all e le m e nts in co m p lian ce w ith W rtsil s s pe cific atio ns ?
no
H e igh ts of pr e-te ns io ne d dis c s pring pa ck s in c om plia nc e w ith th e v alue in th e relev an t as s em bly dra w in g?
PC 19.11.2008 Drawn Date Product C EAAD082173 Number 04.08.2010 Drawn Date D EAAD082947 Number 13.05.2011 Drawn Date
Q-Code X
B EAAD067959 Number
E EAAD083505 Number
RTMOT
Made Chkd Appd
Assembly Instruction
for engine stays, friction type
Main Drw. Design Group Page Material ID
27.01.1998
6/8
Drawing ID
107.246.429
Rev
9715
107.246.429
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
18-136
Version a2
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these right s. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made a ccessible to third parties without the previous written consent of Wrtsil.
14.
X
E ngine S ide
m ax. 5m m overlength
M D riving E nd
-S
+S
Figure 6
Deviation of stay length X related to clear width 0 +5 -10 Reference M 25 30 15 Resulting stroke -S 24.5 29.5 14.5 +S 24.5 19.5 34.5
Nominal position Stay too long (max. over length) Stay too short (max. gap)
+V 2 2 4 4
-H 0 0 0 0
+V 2 2 4 4
-H 1.5 2 3 4
Substitute for:
Modif
PC 19.11.2008 Drawn Date Product C EAAD082173 Number 04.08.2010 Drawn Date D EAAD082947 Number 13.05.2011 Drawn Date
Q-Code X
-H
X
+H
-V
S hip S ide
X X
+V
B EAAD067959 Number
E EAAD083505 Number
RTMOT
Made Chkd Appd
Assembly Instruction
for engine stays, friction type
Main Drw. Design Group Page Material ID
27.01.1998
7/8
Drawing ID
107.246.429
Rev
9715
107.246.429
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
Version a2
18-137
Copyright Wrtsil. All rights reserved. By taking possession of the drawing, the recipient recognizes and honors these right s. Neither the whole nor any part of this drawing may be used in any way for construction, fabrication, marketing or any other purpose nor copied in any way nor made a ccessible to third parties without the previous written consent of Wrtsil.
4
4.1
4.2
Loaded state
Engine type
Substitute for:
Modif
PC 19.11.2008 Drawn Date Product C EAAD082173 Number 04.08.2010 Drawn Date D EAAD082947 Number 13.05.2011 Drawn Date
Q-Code X
B EAAD067959 Number
E EAAD083505 Number
RTMOT
Made Chkd Appd
Assembly Instruction
for engine stays, friction type
Main Drw. Design Group Page Material ID
27.01.1998
8/8
Drawing ID
107.246.429
Rev
9715
107.246.429
T_PC-Drawing_portrait | Author: Y. Keel, S. Knecht | Released by: K. Moor | First released: 29.07.2010 | Release: 1.2 (06.09.2010)
18-138
Version a2
Version a2
18-139
18-140
Version a2
Version a2
18-141
18-142
Version a2
Version a2
18-143
18-144
Version a2
Version a2
18-145
18-146
Version a2
Version a2
18-147
18-148
Version a2
Version a2
18-149
18-150
Version a2
Version a2
18-151
18-152
Version a2
Version a2
18-153
18-154
Version a2
Version a2
18-155
1.
General
Installation drawing Sectional view drawing see page 2 see page 3
Hydraulic transverse stays are used to shift the natural frequency when resonance can be expected in the normal operating range of the engine. The applied arrangement enables: - The adjustability of the pretension force. - The adaptability to the slow movement of the ship's hull when loading or unloading the ship.
2.
Description
The hydraulic lateral fixation device consists of: - Hydraulic cylinder with differential piston, fitted with hydro accumulator and pressure gauge. - Stays for lateral fixation of the engine to the ship's structure. - Adjusting screw, fixed to the engine. Accessories per ship for single main engine installation (for multiple main engine installation the engine supplier is to be consulted) - Hydraulic cylinders either to design 200 or 201 with adjusting screw (stays are yard delivery) Design 200: Compact execution Design 201: Hydro accumulator detached for separate installation (Fittings included, but connection steel pipe 10 x 2 is yard delivery) - Tester and pressurizer VGU - 250 - TS3 for nitrogen (for details see page 9) - Hand pump for hydraulic oil (contained in the standard engine tool set)
Replaced by:
Substitute for:
1
Design group
RTA-Engines
Wrtsil Switzerland Ltd.
9715
Page
Created: 23.8.1984
4-107.165.820
1/12
18-156
Version a2
Replaced by:
Substitute for:
2
Design group
RTA-Engines
Wrtsil Switzerland Ltd.
9715
Page
Created: 23.8.1984
4-107.165.820
2/12
Version a2
18-157
I II III IV V VI VII
Set bolt Plug Throttling valve Filling valve Vent screw Vent screw Adjusting screw
Replaced by:
Substitute for:
3
Design group
RTA-Engines
Wrtsil Switzerland Ltd.
9715
Page
Created: 23.8.1984
4-107.165.820
3/12
18-158
Version a2
Free end
Cyl. No.1
Driving end
For details see drawing "Engine stays, hydraulic type" of the relevant engine.
3.
Function
Transverse vibrations of the engine cause rapid pressure fluctuations in the hydraulic cylinder. Thereby the unit behaves like a strong spring. By using the throttling valve III (page 3), the spring rate can be adjusted such that the rapid pressure fluctuations are practically filtered off and do not continue into the hydro accumulator. The hydraulic cylinder nevertheless adjusts itself to the slow deformations of the ship's hull.
4.
Installation
The hydraulic cylinders are to be bolted to the reinforced attachment points on the ship structure. The adjustments screws are welded on the engine at position shown on the relevant arrangement drawing from the engine builder. Stay length "L" shown on page 2 is to be determined and the diameter "D" taken from the table or from the arrangement drawing.
5.
Commissioning
Commissioning of the hydraulic cylinders should be carried out shortly before the sea trial as follows:
5.1.
The stay is to be fitted between the hydraulic cylinder and the adjusting screw on engine side and secured against dropping. The adjusting screw is to be set as shown on page 2 (axially: piston face and indicator pin to be on same plane; radially: pin and holes in line). Set bolt pos. I to be secured. The hydro accumulator will be delivered pre-pressurised to 10 bar. The pressure is to be raised to the figure shown on page 7 with the help of the tester pressurizer (see page 9).
5.2.
5.3.
Plug pos. II is to be removed for filling of the hydraulic oil and the flexible hose connected to the hand pump. Throttling valve pos. III and filling valve pos. IV must be open (throttling valve switched to mark "1") as well as vent screws pos. V on the hydro accumulator and pos. IV on the hydraulic cylinder. Hydraulic oil to be pumped slowly into the hydr. cylinder (oil to be warmed when engine room is cold). After perfect venting, first close vent screw pos. IV on the hydr. cylinder and then vent screw pos. V on the hydro accumulator. The 4 hydr. cylinders must then be pumped up to service pressure as follows:
5.4.
Replaced by:
Substitute for:
4
Design group
RTA-Engines
Wrtsil Switzerland Ltd.
9715
Page
Created: 23.8.1984
4-107.165.820
4/12
Version a2
18-159
(Attention: Check that pump is always full and the filling hose completely filled before connecting up).
B
Cyl. No. 1
Driving end
Free end
5.4.1.
On cylinder A the oil pressure is to be raised to half the nominal pressure shown on page 7. (Pressure to be checked at the built on pressure gauge below the hydro accumulator). Filling valve pos. IV is to be closed and the hand pump disconnected. On cylinder B the same preparatory work can be carried out, however, the pressure can be raised to 10 bar above the nominal pressure. Filling valve pos. IV is to be closed and the plug (II) fitted. The hand pump is to be reconnected to cylinder A and the pressure increased to 10 bar above the nominal pressure. Filling valve pos. IV is to be closed and the plug (II) fitted. The procedure for cylinders C and D is the same as for cylinders A and B. After several hours, all hydraulic cylinders must be vented carefully at valves V and VI so as not to loose too much pressure. It must not sink below the nominal value.
5.4.2.
5.4.3.
5.4.4. 5.4.5.
5.5.
The throttling valve pos. III is to be adjusted to mark "A" and secured on all cylinders. Mark "B" is used for reduced stiffness. At Mark "1" the function is practically ineffective. Attention The throttling valve pos. III must never be closed (Mark "0") in service because in this position the hydraulic piston cannot adjust itself to the movement of the ship's hull.
Replaced by:
Substitute for:
5
Design group
RTA-Engines
Wrtsil Switzerland Ltd.
9715
Page
Created: 23.8.1984
4-107.165.820
5/12
18-160
Version a2
6.
Sea trial
The hydraulic cylinders must be checked frequently for oil pressure and general soundness.
6.1.
At the end of the sea trial the following must be checked: - "0" position of the piston according to page 2 - pressure to be the nominal value as shown on page 7. If the pressure is too high it can be corrected with careful opening of the vent screw pos. V. Where the pressure is too low, it has to raised with the hand pump.
7.
Check when loading the ship fully for the first time
The position of the piston relative to the cylinder is to be checked when the ship is fully laden. Should it occur that the piston is almost touching the bottom of the cylinder (this situation must not be allowed to occur, but it will happen when the piston is 15 mm on the inside of the "0" position) then the hydraulic lateral fixation device is to be shortened by about 7 mm with the adjusting screw pos. VII.
8.
Regular checks
The oil pressures on the pressure gauges of the hydraulic cylinders are to be compared with each other at regular intervals. (The shown oil pressure may not be identical with the nominal pressure, because it varies according to the loading of the ship). If one of the cylinders shows a considerably lower pressure, which could be caused by a leaking seal, the opposite hydraulic cylinder must be released of its pressure until the leaking seal has been replaced. Afterwards both cylinders are to be put into service as mentioned under commissioning.
9.
Spares
For spares see the following pages: Pneumatic accumulator Tester pressurizer Hydraulic cylinder page 8 page 11 page 12
Replaced by:
Substitute for:
6
Design group
RTA-Engines
Wrtsil Switzerland Ltd.
9715
Page
Created: 23.8.1984
4-107.165.820
6/12
Version a2
18-161
Technical data
Hydraulic cylinder 200/160 Mass: Piston stroke: Oil Content: Oil Type: Viscosity grade: Hydropneumatic accumulator type: Engine type about 138 kg 15 mm about 2,5 l Hydraulic oil HL or HLP ISO VG 32/46 (20 - 30 mm/s at 50 C) IHV 2,5 - 330/05 with bladder ref.: 105644-01120 RTA 68T-B, RTA72U/-B, RTA84T/-B/-D, RTA84C, RTA96C 40 bar 80 bar 160 kN about 320 kN/mm Throttl.valve pos."A" about 60 bar when piston is protruding 15 mm in cylinder about 115 bar when piston is recessed 15 mm in cylinder. Pomax = Po + 10 bar Po = above given nominal pressure RTA52U/-B, RTA62U/-B, RTA48T/-B, RTA58T/-B RTA60C 20 bar 50 bar 100 kN about 270 kN/mm
Pre-pressurising pressure (gas) Nominal oil pressure 1) Nominal pre-tensioning force Fvo Dynamic spring rate
about 37 bar
about 80 bar
1)
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Hydropneumatic accumulator
P0 = nitrogen pressurising pressure P1 = minimum working pressure P2 = maximum working pressure V0 = total nitrogen volume in the accumulator V1 = nitrogen volume at P1 V2 = nitrogen volume at P2 V = volume absorbed and/or returned beween P1 and P2
(1)
P0V0 state
(2)
P1V1 state
(3)
P2V2 state
The bladder, enclosed in the accumulator body is pre-pressurised by means of an inert gas (nitrogen), capable of great compression, to a pressure determined by the needs of the work to be done. During this pressurising operation, the bladder expands, progressively approaches the lower part of the accumulator, and presses against its sides, so occupying the entire volume of the chamber (1). When the circuit pressure generator causes the liquid to penetrate into the shell of the accumulator (2) the gas enclosed in the bladder is compressed and increases the pressure. The process comes to an end when the pressure of the liquid and of the gas reach equilibrium (3). In the reverse process, the return commences when the resisting pressure of the liquids is less than the pressure of the gas in the bladder. The lateral deformation of the latter in three lobes, forming a shamrock shape with three promontories excludes rubbing and inertia, and enables an efficiency of nearly 100% to be attained.
Spare Parts
1. Valve cap and gasket 2. Nut 3. Bladder 4. Bladder assembly 5. Anti-extrusion ring 6. Washer 7. Gland-ring 8. Ring nut 9. Venting screw and gasket 10. Fluid port sub-assembly 11. Fluid port assembly complete 12. Set of gaskets
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Model Tester and Pressurizer Manometer 6, 10, 25, 60, 100, 250, 400 bar
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x x
x x x
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18-167
Charging hose TS 3: for Ch, D, N, S, Manometer A, FL, NL, DK, GUS 6, 10, 25, 60, 100, 250, 400 bar Connector W24,32 x 1,814 245 bar
SUPPLIER:
a b
Pipa 7-14.418
Design group
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No. cyl.
4 5 6 7 8
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The International Maritime Organisation (IMO) is a specialized agency of the United Nations (UN), dealing with technical aspects of shipping. For more information see http://www.imo.org.
Version a2
19-1
The rules and procedures for demonstrating and verifying compliance with this regulation are laid down in the NOx Technical Code, which is part of Annex VI and is largely based on the latest revision of ISO 8178.
19-2
Version a2
Average values Lp in dB in comparison with the ISO NR-curves and overall average values LpA in dB(A), at nominal MCR under free field conditions.
Version a2
19-3
Figure 19.4: Sound pressure level at funnel top of engine exhaust gas system
Average values Lp in dB in comparison with the ISO NR-curves and overall average values LpA in dB(A), at nominal MCR; at 1 m distance from the edge of the exhaust gas pipe opening at an angle of 30 to the gas flow. Exhaust gas system without boiler and silencer.
19-4
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Version a2
19-5
Engines are transported as complete or part assemblies and protected against corrosion by rust preventing oils, vapour phase inhibitor papers (VPI) and wooden crates lined with jute reinforced bituminous paper.
20.1.1 Drawings
107.426.585 Treatment against corrosion ................................................................2-001 0 -227
Version a2
20-1
Table of Contents
Introduction. Responsibility. Reason for proper corrosion protection Consequences for fully assembled engines on store side Range of application: Engine delivery condition.. Engine delivered in fully assembled condition.. Engine delivered in 3 pre-assembled major parts. Engine delivered in 3 pre-assembled major parts & crankshaft delivered separately. Engine delivered fully disassembled Climatic conditions for: Cleaning Coating Storage.. For cleaning of machined surfaces - before coating For application of corrosion protection For storage of engine or engine parts..
1- 3 4 4-5 5 6 7 7 8 9 9 9 10 10 10
5.0.0
5.0.1 5.0.2 5.0.3 5.0.4
6.0.0
6.0.1 6.0.2 6.0.3
7.0.0
7.0.1 7.0.2 7.0.3.0 7.0.3.1 7.0.3.2 7.0.3.3 7.0.4 7.0.5.0 7.0.5.1 7.0.6 7.0.7 7.0.8 7.0.9 7.1.0 7.1.1 7.1.2 7.1.3
7-77.252
Draining & cleaning of engine parts after shop test 10 General preparations.... 11 Tools & materials to be used for cleaning.. 12 Crankcase drying & cleaning 12 Engine fully assembled12 - 13 Engine dismantled in 3 major parts (bedplate with crankshaft).. 14 Engine dismantled in 3 major parts (bedplate without crankshaft). 14 Main bearings & thrust bearing pads dismantled. 15 Crankshaft delivered as single part.. 15 Crankshaft cleaning. 15 Cylinder liner & scavenge air cooler: cooling water system.... 16 Consequences.... 17 Cylinder liner & piston. 18 Cylinder cover 19 Starting- & control air system 19 RTA Engine. 19 RT-flex Engine... 20 Fuel injection system.. 21
27.10.09 Replaced by: Substitude for:
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Fuel injection valve RTA & RT-flex engines.. 21 RTA Engine Fuel pump 21 RTA Engine Camshaft housing. 21 - 22 RT-flex Engine.. 22 RT-flex Engine ICU, IFA , Fuel Rail 23 - 24 Supply Unit. 24 Corrosion protection of machined surfaces / engine parts.. 24 Overview of the general application range 25 Application of the corrosion protectors / coating 25 Checking the quality of the coating. 25 Coating & corrosion protection of the components General information. 25 Crankshaft corrosion protection at engine shop 26 Preservation for indoor and temporary storage.. 26 Preservation of crankshafts for land and sea transport 26 - 27 Additional mechanical protection of the crankshaft pins for open transport. 27 Additional mechanical protection of the axial surfaces of the thrust bearing flange 27 Mechanical protection of crankshafts for transport in boxes.. 27 Packaging 28 Removal of the preservation material prior to fitting and for inspection purposes 28 Corrosion protection of cooling water circuits 28 - 29 Electrical equipment 29 RTA Engine 29 RT-flex Engine 29 Overview concerning the components to be corrosion protected. 30 Quick overview of engine parts and the corrosion protection liquids.. 31 Detailed overview of parts & spaces to be corrosion protected. 32 - 38 Corrosion protection of piping. 39 Overview over flange connections to be sealed air tight 39 Dehumidifier installation..40 - 41 Turbocharger. 42 Final delivery Inspection (at engine maker).. Sample sheet : Final delivery Inspection (at engine maker) Protection condition during transport to shipyard Inspection upon arrival (at shipyard).. Sample sheet: Inspection of engine upon arrival at the destination Storage conditions at shipyard Installation and/or maintaining of dehumidifier operation... Installation of turning gear power supply. 43 43 44 44 45 46 46 46
8.0.0
8.0.1 8.0.2 8.0.3 8.0.4 8.0.5.0 8.0.5.1 8.0.5.2 8.0.5.3 8.0.5.4 8.0.5.5 8.0.5.6 8.0.5.7 8.0.6.0 8.0.6.1 8.0.6.2 8.0.6.3 8.0.7.0 8.0.7.1 8.0.8 8.0.9 8.1.0 8.1.1 8.1.2
9.0.0
9.0.1
10.0 11.0.0
11.0.1
12.0.0
12.0.1 12.0.2
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13.0.0
13.0.1 13.0.2 13.0.3 13.0.4
Regular re-inspection & re-coating of machined surfaces / engine parts at yard condition Once a week Every two weeks Every month Overview inspection time-table Recovery of corroded parts...
47 47 - 48 48 - 49 49 50 51
14.0 15.0.0
15.0.1 15.0.2 15.0.3 15.1.0 15.1.1 15.1.2 15.1.3 15.2.0 15.2.1 15.2.2 15.2.3
Tools needed for storage... 51 Dehumidifier.. 51 Introduction 51 Engine volume overview 51 - 52 Tools for dehumidification & corrosion protector application 52 Munters M120 52 Munters ML420. 53 Munters ML690. 53 Accessories... 54 Humidity and temperature control.. 54 HygroLog NT3 54 Equipment for preservation oil spraying 55 Overview of liquids & application properties 55 Cleaning and degreasing agents.. 56 Corrosion Inhibitors for Wrtsil 2-stroke diesel engines 57-58 Overview of some corrosion protection product specifications. 59 Dewatering Fluid WA 59 Tectyl 506 60 Tectyl 5006W. 61 Tectyl 5805W.. 62 Tectyl 910 / Tectyl 930. 63 Tectyl 175GW ; Tectyl 185 GW ; Tectyl 132 64 Overview of regular inspection lists during engine storage. 65 Inspection List for general parts purpose.. 65 Inspection List for daily dehumidifier inspection 66 Inspection List for time-dependant inspections or moving of parts 67 Inspection List for final delivery inspection / inspection upon arrival 68 - 69 Engine tools.. Spare parts. Health protection and safety at work. Disposal.. 69 70 70 70
16.0.0
16.0.1 16.0.2 16.0.3 16.0.4 16.0.5 16.0.6 16.0.7 16.0.8 16.0.9
17.0.0
17.0.1 17.0.2 17.0.3 17.0.4.
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2.0
Introduction
This document is an overview guide line for the application of corrosion protection coating after shop test of RTA and RT-flex engines as also for temporally undetermined storage at shipyard / final destination. For the corrosion protection of the engine and its parts, as well as for the treatment of the cooling water circuits during engine assembling and shop test, the specification 107.215.543i and its amendments are still valid. The way of application might differ and depend on the expected or agreed engine storage period and the conditions at final destination. There are normally 3 different timeframes to which the coating thickness as also the regular main inspection intervals are referring. - normal period storage (up to 6 months) - long period storage (6 12 months) - undefined period of storage due to unpredictable postponement of ship project (over 12 months)
This guide line covers re-coating after the shop test, as during final assembly of the engine parts and even more during engine running, most of the protective coating will have been flushed away. Therefore a proper re-coating after shop test is crucial.
It was chosen to divide this document in various chapters and sub-chapters in order to have separate steps, thus not losing the principal information by overloading the chapters.
3.0
Responsibility
The orderer specifies the duration of protection and the special requirements for transport and storage. The engine manufacturer will be responsible that the specified corrosion protection is executed with care and that packaging is carried out in a professional manner. Reliable preservation is assured if the drying time of the applied coating is observed and the processes and products described in the following are properly applied. As transition area of taking over the responsibility for further proper storage and corrosion preservation of the engine, the chapters 9.0 - Final inspection before delivery (at engine maker) & 11.0 - Inspection upon arrival (at shipyard) and their sub-chapters have been written.
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The manufacturers' specifications and safety sheets for these cleaning and coating products must be strictly observed. Other processes and products may be applied if they meet the specified requirements. Wrtsil Switzerland Ltd. will not accept any liability or responsibility for damage to the engine and its parts which is or has been sustained due to the none-observance of these preserving instructions, e.g. due to insufficient preservation, unsuitable storage or damaged preservation material. Moreover, Wrtsil Switzerland Ltd will not accept any liability for preservation measures that are carried out by the manufacturer or a third party. It is in any case the responsibility of the orderer to check the engine and its parts for any corrosive damage promptly upon arrival. Unless agreed differently in the purchase contract, any claim due to corrosion damage of the engine and its parts has to be made in writing to Wrtsil Switzerland Ltd. within two weeks from the arrival of the engine and its parts to the final destination defined in the purchase contract. Any claim made after the two weeks' notice period shall not be taken into account. The orderer shall be responsible for the preservation of the engine and its parts for further transport and final storage.
4.0.0
To give you an impression of corroded parts, respectively the possible or impossible access for repairing or replacing of them, the following short extract of pictures will illustrate the reasons for proper corrosion protection. Without access by crane, available normally just in engine room condition, or proper storage warehouse, no proper repair or replacement work of heavy parts can be done!
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As e.g. the pistons and cylinder liners can be checked only through the scavenge air ports, a cleaning and possible recovery of the parts at time will not be possible. Further corrosion leads to such kind of material pitting that the parts must be exchanged at a later stage.
Heavily corroded: Cylinder liner and piston crown. At last the parts could be pulled or reached to be cleaned and judged for further procedure (replacement).
Repaired (cleaned of upper rust layer) cylinder liner (above) and piston crown (below) surface revealed that the pitting had been so heavy that the parts had to be replaced.
Situation of cyl.liner & piston crown in fully assembled condition. Situation of parts access without crane available Be aware: These are just samples !
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5.0.0
The intention of this chapter is to give an overview of different ways and engine stages the corrosion protection, the transport and the storage will be done, as this will affect either the way of corrosion protection application and even more the storage capabilities and additional re-coating work, which are required for long-term storage and unpredictable engine storage-time respectively. Mainly for reasons of different crane capacities as also engine sizes either at engine maker or at shipyard, there are three different conditions of engine delivery: See 5.0.1 : Engine delivered in fully assembled condition. See 5.0.2 : Engine delivered in 3 major components (bedplate with crankshaft, column, cylinder jackets with cylinder liner installed).
- See 5.0.3. : Engine fully dismantled after shop test. 5.0.1 Engine delivered in fully assembled condition
It is recommended to install dehumidifiers for transportation already. It has to be assured that they are connected electrically at board side.
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5.0.2 Engine delivered in 3 pre-assembled major parts In general it has to be mentioned that the storage of single parts, even major parts like bedplate with crankshaft, column with platforms as well as the cylinder jackets and all additional parts like pistons, connecting rods, etc. can be done with less expense of time and work if the protection and packing of the parts was properly done beforehand. Dehumidifiers have to be placed at each single major part.
Cylinder jackets with scavenge air receivers Bedplates (2 parts) with crankshaft (in front) and column with fuel pumps (behind)
Main pistons and cylinder covers (still Turbocharger prepared ( openings closed by covered and exhaust cage closed by plate) wooden plates)
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5.0.3
It might occur quite often that the crankshaft has to be dismantled after shop test. This is mostly the case with bigger bore engines RTA/RT-flex 82; RTA/RT-flex 84; RTA/RTflex96, but it might also be required for small bore engines. The principal reason is the crane load capacity either at engine maker or at the shipyard. 5.0.4 Engine delivered fully disassembled
Engine fully dismantled after shop test: All parts have been cleaned, protected and covered properly (bedplate, crankshaft, column, cylinder jacket as single components); all platforms and pipes are dismantled, all other parts like cylinder covers and exhaust valves, pistons, cylinder liners, connecting rods, crossheads and so on are packed and protected in wooden boxes.
Example of connecting rod with crosshead at transport packaging stage. Stored outside just after arrival at shipyard.
6.0.0
As the many different climatic conditions are one of the major impacts in relation to the applicable corrosion protection work, this issue has to be clarified more closely. High humidity conditions with humidity values as high as 80-85% over nearly the whole year on the one hand, and the corrosion protection liquid properties on the other hand, implicate the recommendation of preferably low humidity values, as otherwise the fast accretion of moisture on the blank surfaces will complicate any proper procedure. Therefore Wrtsil Switzerland Ltd. recommends the a relative humidity value below 50% in general.
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6.0.1 For cleaning of machined surfaces parts in general; before coating The cleaning work has to be carried out in a well-ventilated room at a temperature between 15 C (min) and 35 C (max.). The relative humidity should be less than 50%. 6.0.2 For application of corrosion protection The cleaning work has to be carried out in a well-ventilated room at a temperature between 15 C (min) and 35 C (max.). The relative humidity should be less than 50%. 6.0.3 For storage of engine or engine parts The engine and its parts must be stored in well-ventilated rooms at a temperature between 15 C (min) and 35 C (max.). The relative humidity should be less than 50%.
7.0.0
The procedure described in this chapter has to be carried out hand in hand with chapter 8, taking into account that all painting work (coating of primer & top layer) has been done properly before engine assembly. The application of corrosion protection has to be checked and renewed on all machined/blank surfaces, as the corrosion protection may be flushed due to the temperatures reached during engine running for shop test, or has melted away during the shop test itself or scraped away during assembly. As general summary of this chapter 7, the following rule has to be considered stringently: The clean and dry condition of the machined/blank surfaces is of outmost importance for a proper application of corrosion protection, as the adhesion of all applicants will be as good as cleaning and drying work was performed!
To accelerate the drying time, heaters with dry air fans for heating up the engine interior can be considered. A heat venting system is probably even more useful in connection with drying of all water pipes and/or water cooling spaces. Connection flanges at the transition between the venting system and the piping/ cooling spaces might be especially useful, as flange connections are easily adaptable to different engine sizes by the mere use of additional adaptors. All parts which have been affected by carbon deposits during engine running have to be cleaned carefully, otherwise the carbon deposits will harm the parts, as there remains sulphuric acid which corrodes the material very much in connection with the long period of standstill.
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7.0.1
General preparations
- Heaters with dry air fans for heating up the engine internal can be considered due to the amounts of solvents as well as of the corrosion protectors used during a production year, and also to accelerate the drying time, in order to obtain a beneficial economical and environmental effect (one work carried out once) for the engine preservation work. - A heat venting system is probably even more useful in connection with drying of all water pipes and/or water cooling spaces (see also 7.0.6). - Connection flanges at the transition between the venting system and the piping/ cooling spaces might be especially useful, as flange connections are easily adaptable to different engine sizes by the mere use of additional adaptors. The engine maker and probably also the shipyard(*) should take the following into account: (*)= For the shipyards this might be interesting by reason of unpredictable anchoring of ships after sea-trails due to re-arranged final ship-delivery or other force majeure reasons. As the cleaning-, and much more, the drying work after a shop test can be of a dangerously annoying stimulus due to the fact that especially the oil will flow time and again over already cleaned surfaces, or, as in our case, over machined/blank surfaces, a fast heating and drying-up of the crankcase as well as of the piston underside by a heating fan system should be considered just after shop test. A thickened oil film is much easier and faster cleaned with much less solvent. Likewise the thickened oil will not flow quickly again over the surfaces cleaned/prepared for corrosion protection.
Heating fan with multi-connectable hose system & adaptable flange connectors.
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7.0.2
The following tools and products are to be used for cleaning work in general: Acid-free cotton cloth Paper towels Wooden or plastic spatula/scraper Airgun or airless spray unit (see chapter 15..2.3) White spirit (e.g. Shellsol : see chapter 16.0.1) Petroleum Kerosene NOT to be used under any circumstances: Metallic scraper
7.0.3.0
The crankcase can be cleaned and dried in usually three different engine stages: 7.0.3.1 7.0.3.2 7.0.3.3 Engine fully assembled Engine dismantled in 3 major parts (bedplate with crankshaft) Engine dismantled in 3 major parts (bedplate without crankshaft)
7.0.3.1
The engine will not be dismantled for transport and installation at shipyard. All engine internal parts have to be dried and cleaned after shop test.
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The cylinder covers and the pistons have been removed for their cleaning and corrosion protection work! All engine internal parts have to be dried and cleaned after shop test. Either of system oil, like piston cooling oil crosshead lubrication main bearing lubrication servo oil rail servo oil pumps (Supply Unit) Turbocharger lubrication all pipe circuits belonging either to the ingoing or outgoing of fluid flow,
or of water residues/deposits of the cooling water system, like cylinder liner cooling space cylinder cover & exhaust valve cage scavenge air receiver/cooler spaces all pipe circuits belonging either to the ingoing or outgoing of fluid flow,
or of air of the starting air- or control air system, like starting air shut-off valve starting air distributor starting air valve at cylinder cover all pipe circuits belonging either to the ingoing or outgoing of fluid flow,
or of fuel, like Injection Control Unit (ICU) - RT-flex engines fuel rail fuel pumps all pipe circuits belonging either to the ingoing or outgoing of fluid flow.
All engine external machined surfaces and/or parts have to be cleaned and dried. For all machined surfaces a cleaning solvent/white spirit should be used. See 16.1.2.
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7.0.3.2
7.0.3.3
Crankshaft delivered as single part. Already cleaned of corrosion protector by solvent and ready for bedplate assembling. Crank-throw journals protected with rubber and steel plates (8mm thick).
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7.0.4
If the crankshaft is delivered as single part, also the main bearing shells and bearing covers as well as the thrust bearing pads are to be removed from the bedplate. Carefully clean them with Shellsol / white spirit.
7.0.5.0
7.0.5.1
Crankshaft cleaning
Thorough manual cleaning of the entire crankshaft surface with acid-free cotton cloth (no rags), paper towels and clean solvent, e.g. white spirit, Shellsol or a similar product. Flushing of all bores with clean solvent. Important: From this moment the crankshaft must not be touched with bare hands anymore! Allow the crankshaft to dry completely. Check whether clean and free of rust. Do not touch the cleaned surfaces with bare hands. If there are signs of rust, the quality assurance department will decide whether additional work is necessary. If the traces of rust are only slight, they can be removed with emery cloth No. 220 (or finer) and petroleum. Repeat cleaning!
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7.0.6
Cylinder liner & scavenge air cooler: cooling water system (Cylinder liner scavenge air cooler piping for water circulation on engine)
- Make sure that the cooling water circuits have been treated properly by adding a water inhibitor during engine running. (water inhibitors see chapter 16.0.2)
- The cooling water must be drained and dried. It is recommended to blow warm, pre-dried air through the pipes. The cooler has to be sufficiently vented. or: - Drain the water from cylinder liner & scavenge (charge) air cooler when the engine is still warm after shop test (around 60 C).
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7.0.7
Consequences
The non-use of proper water inhibitors and soluble oil for proper corrosion protection will lead to severe corrosion, mostly in water cooling spaces which are not traced without additional inspection regulations/requirements. The pictures/sketches below are for reference only.
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7.0.8
If the engine is not dismantled, make sure that also the piston inner parts, like spraying plate with nozzles, as well as the piston inside itself are protected in a practicable way. This could be achieved by using either the piston cooling pipe system or the flange connections for lever. - Piston dismantling after shop test: After shop test, mainly the piston crowns, the piston rings and probably the piston ring grooves are to be cleaned of combustion residues. - Gland box piston rod: To be opened and properly cleaned of carbon and dirt oil deposits.
- Cylinder liner dismantling after shop test: It has to be determined whether the cylinder liners will be dismantled after shop test. The cylinder liners can be cleaned still assembled to the cylinder jacket, as also the pistons will have to be dismantled.
If the engine is not dismantled, make sure that also the piston inner parts, like spraying plate with nozzles, as well as the piston inside itself are protected in a practicable way. This could be achieved by using either the piston cooling pipe system or the flange connections for lever.
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7.0.9
Cylinder cover
After shop test, the cylinder covers will have to be dismantled to clean the combustion residues in the combustion chamber as well as the exhaust cage. Drain the cooling water carefully (check exhaust cooling water space) and use warm/heated-up air if necessary.
7.1.0 7.1.1
Starting- & control air system RTA Engine Drain the complete starting air system including air spring. Drain the complete control air system. Remove all starting air valves, open them, clean all parts, oil the parts slightly with rust protection oil and reassemble them. Option 1 The starting air valves can be refitted in the engine after overhaul. Option 2 (recommended) The starting air valves can also be kept separate from the engine. In this case the starting air valves should be stored in a dry place, well preserved and packed in VCI (Vapour, Corrosion, Inhibitor) paper. Note that the openings in the cylinder covers need to be closed air-tight with steel flange covers (draft prevention). Dismantle the shut-off valve for starting air, clean all parts and oil them with rust protection oil. Afterwards the valve can be refitted in closed position. Remove the end cover of the main starting air pipe and place silica gel desiccant bags inside. Afterwards refit the cover (as a precaution a marking must be applied outside to indicate that a silica gel desiccant bag has been stored inside).
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Overhaul the starting air distributor, extract the bushes and sleeves. All parts need to be cleaned and oiled before refitting. When extracting the valves, the air spaces of the housing can be cleaned and spray protected. The distributor control cam should be checked and spray coated as well.
7.1.2
RT-flex Engine Drain the complete starting air system including air spring. Remove all starting air valves, open them, clean all parts, oil the parts slightly with rust protection oil and reassemble them. Option 1 The starting air valves can be refitted in the engine after overhaul. Option 2 (recommended) The starting air valves can also be kept separate from the engine. In this case the starting air valves should be stored in a dry place, well preserved and packed in VCI paper. Note that the openings in the cylinder covers need to be closed air-tight with steel flange covers (draft prevention).
Dismantle the shut-off valve for starting air, clean all parts and oil them with rust protection oil. Afterwards the valve can be refitted in closed position. Remove the end cover of the main starting air pipe and place silica gel desiccant bags inside. Afterwards refit the cover (as a precaution a marking must be applied outside to indicate that a silica gel desiccant bag has been stored inside).
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7.1.3 7.1.4
Fuel injection system Fuel injection valve RTA & RT-flex engines
All fuel injection valves are to be overhauled according to the instructions given in the Maintenance Manual. It is recommended to flush the overhauled fuel injection valves on a test bench using a special calibration fluid (for corrosion protection reasons no MDO should be used). After flushing the injection valves the tension of the springs should be released. The openings at the cylinder cover are to be sealed air-tight.
7.1.5
To achieve the highest level of corrosion protection for the RTA fuel injection components, it is recommended to drain the MDO from the fuel system. The fuel inlet and outlet lines need to be closed. After dismantling the delivery valve, the fuel pump block can be filled with rust-preventing engine oil. Note that during filling up of the fuel pump block the spill and suction valves should be manually lifted in order to fill the complete fuel pump block. The oil level needs to be checked from time to time and if necessary oil has to be replenished. After the engine has been shut down on MDO, drain the complete fuel system. Overhaul the fuel cocks in the inlet and outlet lines. Afterwards reassemble them in closed position. Remove the delivery valve and fill the fuel pump block manually with rustpreventing engine oil. All open ports, adapters, pipes, etc. need to be preserved against corrosion and sealed in order to prevent ingress of foreign particles. Clean and then spray coat the fuel pump blocks and moving parts (springs, pushrods, etc.) with rust-preventing engine oil. Lubricate the fuel linkage including the spring link on the eccentric shaft.
7.1.6
RTA Engine Camshaft housing Clean and then spray coat the camshaft, bearing cover rollers, roller guides, etc. with rust-preventing engine oil.
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For transport and storage of the engine, the fuel pumps as well as the exhaust valve actuators have to be cut out under any circumstances. Not doing so will harm the rollers and cams.
7.1.7
RT-flex Engine
To achieve the highest level of corrosion protection for the RT-flex fuel injection components it is recommended to drain the MDO from the fuel system and to remove the ICUs from the engine. Afterwards the fuel rail and the intermediate accumulator including the fuel pumps need to be filled with system oil or special rust-preventing engine oil. Fuel pump In general the fuel pumps can be left in place during the transport / storage. However, some special measures are required to protect them against corrosion. To guarantee lubrication and preservation of the internal parts, the non return valve bodies including compression springs inside the fuel pump need to be removed. Note that the non return valves bodies should not be interchanged; therefore they have to be marked for correct positioning during re-installation. After the engine has been shut down on MDO, drain the complete fuel system including low pressure circuit, intermediate fuel accumulator and fuel rail. Close the valves in the fuel inlet and return lines (low pressure circuit). Clean the fuel pump from outside and protect all blank parts. Lubricate the fuel regulating linkage including regulating rack. All open ports, adapters, pipes, etc. need to be preserved against corrosion and sealed in order to prevent ingress of foreign particles.
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7.1.8
All ICUs need to be removed from the engine; depending on the number of running hours it should be considered to send them to a Wrtsil reconditioning workshop for overhaul. If the ICUs are not due they must be stored in an oil bath during the lay-up period. The openings on the fuel rail need to be sealed with blind flanges so that the fuel system can be completely filled with system oil or special rust-preventing engine oil. 1. After the engine has been shut down on MDO, make sure that the whole fuel system including low pressure circuit, intermediate fuel accumulator and fuel rail is completely drained. 2. Clean all ICUs as well as possible from outside. 3. Remove all rail valves and fuel quantity sensors from the ICUs. Preserve the fuel quantity sensors and rail valves and store them in a dry place. 4. Remove all ICUs from the engine and store them in an oil bath for corrosion protection. As soon as the ICU is in the oil bath, it is recommended to move the fuel quantity piston by manually carrying out a few strokes. 5. Blank off all openings on the fuel rail with blind flanges, except the one on the forward side. There a flange with a connection needs to be installed to supply oil into the fuel rail. 6. Blank off the control oil supply to the ICU to allow operating the control oil pumps. 7. Fill the fuel rail including rising pipes, intermediate accumulator and fuel pumps with system oil or special rust-preventing engine oil. As soon as the fuel system is completely air-free filled with oil, a small tank (oil barrel) can be connected to compensate slight leakages during the storage.
Additional lubrication oil tank connected to the fuel rail to keep it under constant static pressure.
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8. Check if the fuel pumps are filled with oil. Drain them if necessary.
7.1.9
Supply Unit Clean and then spray coat the camshaft, bearing covers rollers, roller guides, etc. with rust-preventing engine oil.
Open
Apply corrosion lubrication oil for camshaft bearing protection as also as bearing lubrication for during engine turning.
8.0.0
The application of corrosion protection has to be checked and renewed on all machined/blank surfaces, as the corrosion protection may be flushed due to the temperatures reached during engine running for shop test, or has melted away during the shop test itself or scraped away during assembly.
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8.0.1
For exposed parts (engine external), the following description of layer application might be used as general guidance regarding corrosion protection application. (e.g. starting air distributor, manoeuvring linkage, camshafts for RTA engines, RTA fuel pump block, etc.) Apply a first layer of Tectyl 506 to all surfaces using an airless spray unit. Allow to dry for at least 5 hours at 10-20C (3 hrs at 20-25C; 2 hrs at >25C). A second coating of Tectyl 506 must be applied to all surfaces, with the exception of the webs, using an airgun . Do not touch this coating. Allow to dry for at least 36 hours at 10-20C (24 hrs at >20C). A coating of Tectyl 132 must be applied to all crankshaft surfaces by means of an airless spray unit. Allow to dry for at least 36 hours at 10-20C (24 hrs at >20C).
8.0.2
The climatic properties have been described under 6.1.2. To avoid the accretion of moisture on blank surfaces, the components must show room temperature during the work. The coating must be applied straight after cleaning to the dried surfaces. For the recommended coating materials with details of their application see pages 10 to 12. The supplementary product specifications for the coating materials must be strictly observed.
8.0.3
The inspection of the dry coating is made non destructively according to the magneticinduction method, e.g. with the measuring device "Minitest". The adhesion of the coating is to be checked with a cross-cut test according to DIN 53 151 (Code GT 1). The damaged coating resulting from this inspection is to be ground over and applied anew. In case of non-fulfilment of the quality standard, the manufacturer's quality assurance department will decide whether further inspections are necessary and if the coating should be renewed.
8.0.4
The different surface protection measures are listed in the table "Coatings and corrosion protection general". The components and surfaces are shown in groups, thus allowing to be treated by the manufacturers in a corresponding manner.
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8.0.5.0 8.0.5.1
Crankshaft corrosion protection at engine shop Preservation for indoor and temporary storage The crankshaft must be free of rust, cleaned thoroughly as instructed in para. 7.0-5.1, and not have been touched since. If this is not fulfilled, repeat cleaning according to 7.0.5.1. Flush oil bores, threaded holes etc. with Dewatering Fluid WA or "Anticorit DFW" and allow to dry completely (min. 5 hrs at 10 to 20C; min. 3 hrs at 20 to 25C; 2 hrs at >25C). Close the bores, threaded holes, etc. with plastic protective plugs (do not use wooden pegs). These protective plugs are not to be removed until just before the crankshaft is fitted in the engine. Using an airgun, dewater and neutralize all surfaces with Dewatering Fluid WA or "Anticorit DFW". Do not touch the surface. Allow the waxy protective film to dry for at least 5 hours at 10-20C (3 hrs at 20-25C; 2 hrs at >25C) prior to further treatment. It is mandatory to keep to the drying time! The protective film must be touch proof (however, not to be touched with bare hands!). In case of insufficient drying, the adhesion of the subsequent coatings is not assured. Apply a first layer of Tectyl 506 to all surfaces with an airless spray unit. Allow to dry for at least 5 hours at 10-20C (3 hrs at 20-25C; 2 hrs at >25C). A second coating of Tectyl 506 must be applied to all surfaces, with the exception of the webs, using an airgun. Do not touch this coating. Allow to dry for at least 36 hours at 10-20C (24 hrs at >20C).
Duration of protection: indoor storage max. 12 months. Insulation protection must be guaranteed. Before the storage time expires, the preservation must be removed and the crankshaft checked for signs of rust. Afterwards the preservation is to be applied again.
8.0.5.2
After corrosion treatment, the crankshaft is to be preserved further prior to shipment. Any dust or layers of dirt are to be removed with dry compressed air or with clean cloths. Apply a first layer of Tectyl 506 to all surfaces with an airless spray unit. Allow to dry for at least 5 hours at 10-20C (3 hrs at 20-25C; 2 hrs at >25C). A second coating of Tectyl 506 must be applied to all surfaces, with the exception of the webs, using an airgun. Do not touch this coating. Allow to dry for at least 36 hours at 10-20C (24 hrs at >20C). A coating of Tectyl 132 must be applied to all crankshaft surfaces by means of an airless spray unit. Allow to dry for at least 36 hours at 10-20C (24 hrs at >20C).
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Duration of protection: indoor storage max. 12 months, outdoor storage max. 6 months Insulation protection must be guaranteed.
8.0.5.3
The journals and pins must be wrapped with the following materials: one layer of VCI paper (Volatile Corrosion Inhibitor) two layers of polyethylene foil one layer of Ethafoam foil, 5 mm thick (must not absorb water) three layers of Lamiflex laminae All layers are to be fixed with chlorine-free adhesive tape. To avoid damage to the mechanical protection and the preservation material during lifting, the journals are to be protected as follows: steel shells with a thickness of at least 8 mm are to be fitted. Instructions to the effect "Do not lift here" are to be posted on all other pins and journals. Supplier information : Lamiflex lamellae Lamiflex AB Gasverksvgen 4-6 611 35 Nykping - Sweden www.lamiflex.se
8.0.5.4
Additional mechanical protection of the axial surfaces of the thrust bearing flange one layer of VCI paper two layers of polyethylene foil one layer of Ethafoam foil, 5 mm thick plywood, 20 mm thick
8.0.5.5
The crankshaft is to rest on the webs .To avoid damage to the preservation material during lifting, the corresponding journals are to be protected with thick and reinforced rubber.
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8.0.5.6
Packaging
The engine maker is responsible for proper packaging. The crankshaft must rest on the webs, whatever the kind of transport. The surfaces of wooden supports must be treated in advance with a neutralising preservation product.
8.0.5.7
Removal of the preservation material prior to fitting and for inspection purposes
The corrosion protective products can be removed manually with acid-free cotton cloth soaked with petroleum or aromatic-free white spirit. A proven method is to wrap the bearing journals concerned in acid-free cotton cloths, which are then dowsed with a solvent, such as white spirit or Shellsol (for lack of solvents use diesel oil). After a sufficient application time (min. 1 hour), the cloths may be removed. The preservation layers can now been scraped off by means of a wooden spatula. Attention: metallic scrapers or other means, such as steam- or hot water cleaners, must not be used! The preservation must be checked before the expiration of the duration of protection and, if necessary, renewed.
8.0.6.0
Corrosion protection of cooling water circuits (Cylinder liner scavenge air cooler piping for water circulation at engine)
As the cooling water will be drained off after shop test, further treatment against corrosive attack is absolutely essential, i.e. the admixture of a so-called soluble oil to the cooling water in order to protect the engine cooling water system. The concentration must be maintained at levels between 0.5 and 0.8 per cent by volume. Prior to the complete shutdown of the system, the circulating cooling water through the engine cooling water system is to be maintained at a pH value between 7 and 9 and the soluble oil inhibitor level increased to 1 per cent by volume. The cylinder temperature is not to exceed 90C and circulation is to continue for at least three hours, allowing time for the soluble oil inhibitor to coat the internal surfaces. Attention: The application of soluble oil might be just of helpful use, if the storage period is predicted as being very long (over 12 months). The reason is that the water circuits would have to be flushed at shipside after installation, before being finally connected to board circuit. If the water circuits - especially the one for cylinder liners and cylinder cover cooling spaces with the cooling bores in the cylinder liner as well as the one in the cylinder cover - and exhaust valve cooling circuit are not flushed, the soluble oil foam, in connection with dust, will lead to clogging of the beforehand described cooling bores.
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To carry out corrosion protection of water cooling pipes and spaces properly, 8.0.6.1 8.0.6.2 Electrical equipment RTA Engine
the application of soluble oil has to be done right after shop test with still connected water circuit.
Make sure that the power supply for the heating of the electric motors is assured (if applicable). Place desiccant bags to all electrical connection boxes fitted on engine. In case RPLS/PLS is installed: Place desiccant bags in control boxes E40 and E41.N for Pulse Lubrication; make sure that all cable glands are tight. Open holes should be sealed. 8.0.6.3 RT-flex Engine Place desiccant bags in control boxes E85, E90, E95.N, E87 (for Bosch servo oil pumps) and/or E40, E41.N for Pulse Lubrication; make sure that all cable glands are tight. Open holes should be sealed. Place desiccant bags in control safety system boxes E10, E20, E25, E28. Place desiccant bags in alarm system boxes E110, E15.1, E120.n, E130, etc. Place desiccant bags in Boll & Kirch automatic oil filter control box. Make sure that the power supply for the heating of the electric motors is assured (if applicable).
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8.0.7.0
The next page gives a preliminary overview of corrosion protection liquids which can be used. For a proper evaluation of the correct corrosion protection application and the liquids used, refer to the components given in the chapters overview on page 32-38. (Attention : valid only for fully assembled engines in storage condition with fully operational dehumidifier.) - Tectyl 506 & 132: - Engine external: - Engine internal: First layer with Tectyl 506. Drying. Second layer with Tectyl 132. Generally all surfaces not painted with Tectyl 506 & Tectyl 132. Generally all machined (movable) parts with Tectyl 930.
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8.0.7.1
Quick overview of engine parts and the corresponding corrosion protection liquids - Refer (please compare) to chapter 16.0.0! Engine location Internal Internal Internal Internal Internal Internal Internal Internal Internal Internal Internal Internal Internal Internal External External Internal Internal Internal Internal Internal External Internal Internal External External External External External External External External External External External External Internal External External Protector type B or F B or F B or F B or F B or F B or F B or F B or F B or F B or F B or F B or F B or F B or F C C B or F B or F B or F B or F B or F C B or F B or F ---Turn elect. motor C&D ----C&D C C C C C C C B or F Silica Gel C
Group 0345
Pos. Part 1. Crankshaft Crank web Crankpin: web journal & main journal Gear wheels Thrust bearing pads Bottom end bearing Connecting rod Crosshead bearing Crosshead guide shoes Piston rod Piston Exhaust valve Bedplate Column (Guide rails) Cylinder block Tie rods Diaphragm Piston rod gland Cylinder liner Scavenge ports Anti-Polishing ring Cylinder cover Combustion space Exhaust valve cage Exhaust manifold Auxiliary scavenge air blower Flywheel Turning gear Electric motor Wheel pin RT-flex Supply Unit all flanged units High-pressure fuel pumps Servo oil pumps Rail Unit Fuel oil rail with injection units Servo oil rail with exhaust valve exhaust valve control units High-pressure pipes to fuel injectors Exhaust valve drive Electronic cabinets Scavenge air receiver all relief valves
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
24. 25. 26. 27. 28. 29. 30. 31. 32. 33.
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8.0.8
- Refer (please compare) to chapter 16.0.0! - All corrosion protectors given under C are to be removed from engine internal spaces parts before starting the engine. Group
1 1 1
Component
Bedplate arrangement Bedplate oil drain Bedplate free end
Comments
All exposed machined surfaces to be coated Seal drains with a suitably sized steel flange and airtight gasket Where applicable seal the crankcase vent Coat all machined surfaces, in particular the thrust area; remove the thrust bearing saddle drain to prevent any potential clogging and moisture accretion, refit before engine use All exposed surfaces to be coated Coat all machined surfaces, pay attention to the stud threads where applicable Coat all exposed machined surfaces Coat all machined surfaces, prevent excessive dry turning
Preserving actions
C ; 2 layers C ; 1 layer C ; 2 layers
C ; 2 layers
B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) C ; 2 layers
Main bearing cover Thrust bearing arrangement Thrust bearing pads Engine frame assembly parts Column doors Casing free end End casing driving end
1 2 2 2 2
Seal all crankcase relief valves, ensure that the valves are corrosion-free Coat all machined surfaces Coat all machined surfaces
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Group
2 2 2 2
Component
Oil baffle two-parts driving end Tie rod Cylinder jacket grouping Supporting ring
Comments
Seal the end baffle, be mindful of any turning and potential damage to this Ensure that drain bores are clear, fill with oil at each inspection in order to flush Clean after shop trial to remove any corrosive combustion by products Ensure that water is drained completely, in particular in the area of the lower O-rings Ensure that water is drained completely and machined running surface coated If engine is fully assembled: - Layer application through bore of dismantled starting air valve and from piston underside or scavenge ports (piston at BDC bottom dead centre) Ensure that water is drained completely Ensure that water is drained completely Fill with cylinder oil and top up for inspection or removal, and store by one layer of C, packed in VCI paper. Openings at water supporting ring to be closed / flanged air-tight. Fill with cylinder oil and top up for inspection or removal and store by one layer of C, packed in VCI paper. Openings at water supporting ring to be closed / flanged air-tight. Ensure that all machined surfaces are coated, pay attention to garter springs Be sure to coat all machined surfaces. If engine is fully assembled: - Layer application through bore of dismantled starting air valve Ensure that all water spaces are drained. All fuel injection and starting air valves dismantled for storage. All openings sealed by flange air-tight. Cyl. cover external surface: C ; 2 layers Cyl. cover internal: B / F Fuel injectors removed from cyl. cover and cleaned on test bench with A; packed in VCI after protection application Remove, clean, and apply protector, then store, packed in VCI paper; flange bore in cylinder cover air-tight
Preserving actions
C ; 2 layers B (ValvolineTectyl 930) or F (Shell Valvata 1000) C ; 2 layers C (external) or Water inhibitor (internal)
Cylinder liner
2 2
Cylinder liner holder Water guide jacket Lubricating quill with accumulator for cylinder lubrication
C ; 1 layer VCI paper B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) C ; 2 layers B (ValvolineTectyl 930) or F (Shell Valvata 1000) A ; B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000)
Cylinder cover
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Group
2
Component
Relief valve
Comments
Remove, clean, and apply protector, then store, packed in VCI paper; flange bore in cylinder cover air-tight Remove and store, close the bore in cyl. cover air-tight by flange. Apply B or F and store packed in VCI paper. Remove the valve and ensure that cooling spaces are completely drained. Seal off all openings (exhaust chamber to funnel) air-tight. Apply protection to valve seat. Nymonic valve spindles should not corrode; ensure no damage occurs during transportation. Apply protection. Coat all exposed machined surfaces. Grease the flywheel teeth. Viscous fluid dampers are sealed and no access is possible. Spring type dampers can be flushed with system oil; carry out when inspecting the engine at regular intervals. Flush when inspecting periodically Ensure that the gearbox is filled and all components are coated All machined and uncoated surfaces to be coated as well as the central oil bore Coat all exposed surfaces
Preserving actions
B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) See chapter 8.0.5.1
Indicator valve
Valve spindle for exhaust valve Complete crankshaft assembly Vibration damper crankshaft
C ; 2 layers
3 3 3
Axial detuner Turning gear Connecting rod assembly Bearing shell crankpin Upper bearing half of connecting rod top end bearing Bearing shell for top end bearing Screwed connection piston rod - crosshead Crosshead and guide shoe Piston assembly parts
B (ValvolineTectyl 930) or F (Shell Valvata 1000) C ; 2 layers Grease gear pinion B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000)
Ensure that the threads are coated, see notes on screw threads Coat all machined and other uncoated surfaces Internal parts to be coated; system oil is used but may not adhere as specific products would
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Group
3
Component
Piston cooling and crosshead lubrication Pneumatic manoeuvring units Camshaft drive
Comments
All pipes to be coated. Operate pump with 3-4bar pressure force and connect to flange at column-exhaust entering. Remove all control valves and store them separately; apply protector and then pack in VCI paper See specific instructions on the following list See specific instructions on the following list Coat all teeth and other machined surfaces; coat all uncoated surfaces. Fill bearings when rotating. This item is sensitive to corrosion. Coat all teeth and other machined surfaces; coat all uncoated surfaces. Fill bearings when rotating. This item is sensitive to corrosion. Coat all teeth and other machined surfaces; coat all uncoated surfaces. Fill bearings when rotating. This item is sensitive to corrosion. Coat all teeth and other machined surfaces; coat all uncoated surfaces. Fill bearings when rotating. This item is sensitive to corrosion. Coat all uncoated surfaces, internal components to be filled with system oil; this will not be as effective as a dedicated preserving oil Coat all surfaces, this item is sensitive to corrosion. Coat all surfaces, this item is sensitive to corrosion. Only viscous fluid dampers are used, no internal access; coat all external surfaces Remove for damper access, coat all surfaces Apply protector C to all external machined surfaces. All internal parts & surfaces: apply B/F Apply protector C to all external machined surfaces All internal parts & surfaces: apply B/F
Preserving actions
B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) C ; 2 layers --C ; 2 layers B (ValvolineTectyl 930) or F (Shell Valvata 1000) C ; 2 layers B (ValvolineTectyl 930) or F (Shell Valvata 1000)
Camshaft/reversing servomotor
Fuel cam
Actuator cam Vibration damper camshaft Damper casing camshaft Bearing housing(s)
4 4
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Group
4
Component
Gearing for auxiliary drives Starting air distributor Valve unit for starting air distributor Shut-off valve starting air
Comments
Coat all gears, sensitive to corrosion External surface: C ; 2 layers Internal surfaces: B / F Internal pilot valves to be coated, sensitive to corrosion Remove pneumatic valves and blank all ports/holes air-tight. Apply B / F. Store separately, packed in VCI. Coat all internal parts, removal is required for access. Apply silica gel, but mark outside. Internal parts coated with system oil, not effective in the long term. To be packed in VCI paper and then stored. Apply B / F beforehand. Blank openings air-tight. Internal parts coated with system oil, not effective in the long term. To be packed in VCI paper and then stored. Apply B / F beforehand. Blank openings air-tight. Disconnect supply and seal pipes. Control air usually contains humidity, ensure that all pipes are dry after shop trial. All control valves to be removed. Apply B / F, pack in VCI paper and store. Blank all openings. Remove pneumatic valves and blank all ports/holes. Apply B / F, pack in VCI paper and store separately. Remove all valves and store them. Apply B / F and pack in VCI paper. Blank all ports/connecting points. Remove all valves and store them, packed in VCI paper. Blank all ports/connecting points. Apply B / F. Sensitive to corrosion, seal or remove; if removed, pack in VCI paper and seal the cable ends Remove all valves and store them; blank all ports/connecting points Remove and seal pipe/ports/connections. Store separately. All surfaces to be coated Remove and seal pipe/ports/connections. Store separately.
Preserving actions
B (ValvolineTectyl 930) or F (Shell Valvata 1000) C ; 2 layers B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000)
Reversing valve
B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) C ; 2 layers
Valve unit reversing interlock Valve group B by gearing for auxiliary drive Control box local manoeuvring. stand Pick-up engine speed/TDC Control elements unit Fuel interlock override device Local manoeuvring stand Reversing interlock
4 4
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Group
Component
Rod for local manoeuvring stand and pneumatic logic unit Speed indication Speed indication drive Rotation counter Governor and booster arrangement Safety cut-out device Fuel pump block Eccentric shaft injection pump Plunger with bush Valves injection pump Roller guide fuel pump Gear wheel supply unit Pump servo oil
Comments
Coat and seal to exclude moisture. All surfaces must be adequately protected. Remove and store in VCI paper Ensure that all surfaces are coated Remove and store separately in VCI paper. Blank off bore air-tight. For mechanical and electrical governors remove and store as per makers' instructions Critical component sensitive to corrosion, ensure that no moisture remains Flush with calibrating fluid and seal; top up when inspecting Sensitive to corrosion, to be lubricated with system oil, but ineffective in the length of time Seal lower area to prevent air entry. Ensure that fuel pump is cut out. No touching of roller and cam. See above actions for fuel pump Assembly to be coated with system oil, not effective in the length of time
Preserving actions
B (ValvolineTectyl 930) or F (Shell Valvata 1000) ---------B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) ------B (ValvolineTectyl 930) or F (Shell Valvata 1000) External surface C ; 2 layers B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) B (ValvolineTectyl 930) or F (Shell Valvata 1000) C ; 2 layers
4 4
5 5 5
Remove and store separately; seal all ports/pipes and access points All internal parts to be coated with system oil, not effective in the length of time. Coat all external surfaces. All internal parts to be coated with system oil. Coat all external surfaces. Seal lower area to prevent air entry. Ensure that fuel pump is cut out. No touching of roller and cam. Coat all surfaces. Cabling and sensors are sensitive to corrosion. Coat all surfaces. Cabling and sensors are sensitive to corrosion (as for rail unit).
Supply unit
Fuel pump
5 5
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5 5 5 5
Component
Injection control unit Actuator (RTA only) Roller guide actuator pump Servo oil rail Exhaust Valve Drive / Partition Device / Assembly Regulating linkage arrangement Regulating linkage air cylinder Positioning unit VIT/FQS Scavenge air receiver Underslung separator Turbocharger
Comments
See Instructions 107.378.493. To be dismantled and stored in wooden box. Internal parts to be coated with system oil; coat all external surfaces. To be cut off. No contact of roller & cam. Assembly to be coated with system oil, not effective over longer periods. Coat all surfaces. Cabling and sensors are sensitive to corrosion. Coat all parts and inspect regularly. Or: to be dismantled and stored in wooden box. Coat all parts and inspect regularly
Preserving actions
--C ; 2 layers B (ValvolineTectyl 930) or F (Shell Valvata 1000) C ; 2 layers
C ; 2 layers
C ; 2 layers
5 5 6 6 6
Sensitive to internal corrosion Coat all surfaces. Cabling and sensors are sensitive to corrosion (as for rail unit). The internal and external surfaces should be coated; this is a large area which should be kept dry, use a dehumidifier Ensure that water is drained completely Store as per manufacturers' instructions. The motor and bearings are sensitive to corrosion. Electric motors should be covered and heated where possible. Check winding resistance when inspecting. Keep sealed and internal spaces warm, use silica gel Ensure that the water side is completely drained. This component is less sensitive to corrosion, but care should be taken when transporting. Ensure that the water side is completely drained The internal components should be free of corrosive combustion residue. Coat all parts. Clean and seal See manufacturer's Operation Manual. Drain the system and place silica gel bags to each candle tube.
Auxiliary blower
------
Auxiliary blower switch box Scavenge air cooler Water separator scavenge air Scavenge air waste gate Exhaust gas manifold Automatic oil filter
6 6 8 8
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8.0.9 Corrosion protection of piping See chapter 7.0.6. 8.1.0 Overview of flange connections to be sealed air-tight
To provide an overview of the flange connection options, some sketches of the Pipe Connection Plan are given below for your reference. The drawings of each corresponding engine type are available at the Licensees. The flange geometry can be used to produce proper steel flanges for air-tight sealing after the application of final corrosion preservation. For checking the positions, see the parts list. This Pipe Connection Plan differs with every engine type; therefore check carefully.
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8.1.1
Dehumidifier installation Install a dehumidifier system to crankcase, piston underside and supply unit or camshaft housing (RTA). Install a real-humidity monitoring system to crankcase and piston underside to record real humidity and temperature during the lay-up period. The dehumidifier needs to be connected with flexible hoses to the engine as described below. A real humidity of 40% - 50% inside the engine needs to be reached to keep the risk of corrosion low. The execution of the connection may vary depending on the dehumidifier system used and engine type. It is recommended to use a booster fan within the dehumidifier circuit to obtain a constant slight overpressure inside the engine. 1. Connect the dehumidifier to the piston underside, inlet on the AFT side and outlet on the FWD side of the engine (opposite direction is also possible). 2. Connect all camshaft housings together with the dehumidifier to one loop. 3. Connect the dehumidifier to the crankcase, inlet on the AFT side and outlet on the FWD side of the engine (opposite direction is also possible). The flexible hoses can either be connected to the crankcase door openings with a dummy plate, or two relief valves can be removed for the connection. 4. Record humidity values daily of each engine space given on the Inspection List for Dehumidifier see chapter 17.0.2.
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E1
E1
E1
E2
E3
E3 E3
Note that the dehumidifier's wet air outlet must be led outside the engine room.
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8.1.2
Turbocharger
Generally the turbocharger manufacturer operation manual has to be consulted to carry out any kind of work. It has to be assumed that all cast- or flange-contact surfaces have been corrosion protected properly with Tectyl 506 as first layer and Tectyl 132 as second layer. It is of outmost importance that the turbochargers be sealed against moisture penetration, and also the sealing of the exhaust silencer by proper application of socalled VCI (Volatile Corrosion Inhibitor) foil has to be assured. It is strongly recommended that reliable re-commissioning of the turbocharger be carried out by an authorised service branch the manufacturers. This is mostly by reason of detecting the proper condition (e.g. VTR 4: concentricity of rotor, condition of bearing space and bearing, as also the proper measuring of the clearances thereof), if necessary carrying out further action and finally, assuring readiness for operation.
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9.0.0 Final Delivery Inspection (at engine maker) Sample of a cover sheet of the Final Delivery Inspection The cover sheet is accompanied by the checking list given in chapter 17.0.4.
9.0.1
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10.0
As the engine and/or its parts have been checked at engine maker, see 9.0, and therefore the engine and/or its parts and the packaging are assumed to be in proper condition, the engine with connected dehumidifiers has to be checked on a daily basis for proper operation. As transportation can take even several weeks and/or the discharge at arrival port may be postponed due to unexpected occurrences, the further inspection procedure has to be guaranteed.
11.0.0
The inspection is to be carried out within two weeks after the engine/engine parts have arrived to the final destination. Any shortcomings because of an improper preservation are to be reported in writing to Wrtsil Switzerland Ltd within this time limit. After this time limit, no claims about corrosion damage of the engine and the engine parts respectively shall be taken into account. See also para. 9.0 .
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Sample of a cover sheet of the Final Delivery Inspection. The cover sheet is accompanied by the checking list given in chapter 17.0.4.
Inspection carried out on (Date YYYY-MM-DD : )____-__-__: Engine / engine parts are checked according to the detailed parts list as attached. See inspection parts list in chapter 17.0.4. The complete preservation is to be inspected for damage. Copy of the Final Delivery Inspection with the filled-out recording sheets is available. Yes / No
Removal of the preservation material prior to fitting and for inspection purposes after the period of protection has expired
The corrosion-protective products can be removed manually with acid-free cotton cloth soaked with petroleum or aromatic-free white spirit. Mechanical means, steam or hot water cleaners are not to be used. The following products are recommended: white spirit, Shellsol
If necessary, the preservation must be renewed. Manufacturer's information Date of preservation: Date of shipment: Name of manufacturer: Stamp of quality department and name of inspector:
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12.0.0
12.0.1
The dehumidifier should have been installed already since final corrosion protector application has been carried out, if the climatic conditions (humidity) required this. If not done so, install according to chapter 8.1.1. Check the dehumidifier and record the humidity values daily.
12.0.2
The main power source required for generally all turning gear types is AC 440V 60Hz. Please check beforehand on type plate of turning gear or verify with engine maker. If the engine has been delivered fully assembled or part-wise (bedplate with crankshaft installed), it is necessary to turn the crankshaft once a week by minimum of 3-4 turns. If so, check if the main bearings, connecting rod bottom end bearing, crosshead bearing, guide rails; the 4 guide shoes respectively of each cylinder, cylinder liners, pistons (either through the starting air valve bores at the cylinder covers, or through the scavenge ports), gear wheel drive, RTA engines: camshaft bearings (assure that guide pistons for fuel delivery as well as exhaust actuator have been cut out), RT-flex engines: camshaft bearings
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13.0.0
Regular Re-inspection & re-coating of machined surfaces / engine parts at yard condition
13.0.1
Once a week
(if possible at yard stage!) Operate the main engine system oil pump for 20 minutes while turning the engine. During this time the cylinder lubrication should be operated manually. The engine should be stopped each time in another position. Note that the dehumidifying system needs to be turned off prior to starting the lube oil pumps. Two hours after stopping the lube oil pumps the dehumidifier may be turned on again. Important! The number of pulses / turns required to keep the cylinder liner surface properly lubricated must be verified by visual inspections of the liner surface and piston ring package from the piston underside space. CLU-3 type lubricating system (if possible at yard stage!) Operate the manual/emergency cylinder lubrication for 10 15 minutes. During this time, keep the engine turning with the turning gear.
Retrofit Pulse and Pulse Lubricating System (RPLS & PLS) (if possible at yard stage!) Start the main lube oil pump and rotate the engine with the turning gear. Start the oil supply pump and set the delivery pressure to 12-14 bar by means of the oil supply units pressure regulating valve. Actuate manual cylinder lubrication. At such low pressure (normally 50 bar), the cylinder oil will not be injected but will flow along the liner wall. Give each cylinder approx. 100 pulses. During this time, keep the engine turning with the turning gear.
Pulse Feed Lubricating System (if possible at yard stage!) Start the main lube oil pump and rotate the engine with the turning gear. Start the control oil pump, or the Servo Oil Service pump on engines without control oil pumps, in order to provide hydraulic pressure for driving the dosage pumps. The lubricating system servo oil pressure has to be adjusted to 12 to 14 bar by means of the pressure regulating valves which are, depending on the execution, either located inside or just outside the rail unit. Start manual lubrication to individual cylinders. At such low pressure (normally 50 bar), the cylinder oil will not be injected but will flow along the liner wall. Give each cylinder approx. 100 pulses. During this time keep the engine turning with the turning gear.
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Pulse Jet Lubrication System (if possible at yard stage!) Start the main lube oil pump and rotate the engine with the turning gear. Start the control oil pump, or the so-called service pump on engines without control oil pumps, in order to provide hydraulic pressure for driving the dosage pumps. The servo oil pressure needs not be reduced. Start manual lubrication to individual cylinders. Give each cylinder approx. 100 pulses.
In case the cooling water system has not been drained, the cooling water pumps need to be operated for around 20 minutes to get some circulation in the cooling system. Check the level of the corrosion-protective oil which has been filled into the fuel system (if required refill). The fuel linkage needs to be moved by hand; re-lubricate it if required. Check the recorded relative humidity and temperature inside the engine on the data logger. Open the drain cock of the turbocharger gas outlet casing for one minute (water check). Re-spray rust-preventive coating on piston rods if required. Please note: Always use pumps alternately, a long standstill could lead to detriments (if there is no power supply to some pumps, they should be turned by hand on a weekly basis): o o o o LO pumps X head pumps booster pumps water pumps
13.0.2
Open the crankcase (on one side) and piston underside doors and check for condensation and rust traces, particularly on: thrust bearings gear wheels guide rails camshaft (RTA - & RT-flex engines) cams and rollers (RTA - & RT-flex engines) pistons
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piston rods cylinder liners fuel rail- & servo oil rail units If necessary re-spray coating on blank parts in the crankcase that are not covered with system oil when the engine is turned over. Open and close the main starting shut-off valve from time to time. Make sure that the supply from the starting air bottles is depressurised. Check the dehumidifying system and clean/replace the filter(s). Inspect the exhaust manifold for any moisture deposits or corrosion. Turn the rotor of the turbocharger(s) at an angle of 90 to avoid bending of the shaft. Turn the auxiliary scavenge air blower(s) by hand a few revolutions to avoid detriments.
13.0.3.
Every month
Lift a crosshead pin and check for signs of corrosion. Spray-coat again all mentioned parts with rust-preventing engine oil. For re-assembling use steam engine cylinder oil. Remove a main bearing cover and check the journal pin for signs of corrosion. Spray-coat again all mentioned parts with rust-preventing engine oil. For reassembling use steam engine cylinder oil. Replace the silica gel desiccant bags inside the control boxes. Replace the silica gel desiccant bags inside the main starting air pipe. Replace the silica gel desiccant in the automatic filter candles. If the fuel injectors, the starting air valves, the indicator cocks, the injection control units (ICU) have not been removed after shop test for single part storage, they must be removed and checked Check by analysis the following liquid media (if possible at yard stage!) : - cooling water - system oil - MDO in the fuel system of the engine
-
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13.0.4.
Main inspection parts De-Humidifier Bedplate Column Guide Rails Column Crankshaft Main Bearings Connecting Rod Bottom End Bearing Cross-Head Bearing Piston Head Piston Rod Gland Box Springs Cams & Camshaft Fuel pump block (RTA) Cyl. Liner Inside Cyl. Liner Outside Fuel rail pipe Servo rail pipe Exhaust Valve drive Injection Control Unit Starting Air Distributor Rotation Direction Safeguard Engine turning Ancillary Parts (*) installed at engine Ancillary Parts (*) stored in VCI paper & closed woodenbox (*) = Fuel Injection valves; Starting Air valves ; Indicator cock valve ; Injection Control Unit (ICU)
Daily
Every week
Every 4-6 month (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4)
Remark
(1)
(1) = Max. humidity 75% & dry condition at storage place (2) = Max. humidity 50% & dry condition at storage place (3) = Max. humidity 75% - dry condition - single part (4) = Max. humidity 50% - dry condition - single part (5) = To be opened for inspection
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14.0
If there are signs of rust, the quality assurance department will decide whether additional work is necessary. If the traces of rust are only slight, they can be removed with emery cloth No. 220 (or finer) and petroleum. Repeat cleaning! If the parts are too heavily corroded, contact your next Wrtsil Ltd. Service Branch for further decision.
15.0.0 15.0.1
It is up to the engine maker or shipyard to decide which tools are used, as long as the technical properties/specifications are complying with the samples attached.
15.0.2
Introduction
The requirements on a dehumidifier system always depend on the engine type/size (volume to be dried) and the storage location (temperature and real humidity). On the following pages three recommended dehumidifier products are shown which are able to cover the Wrtsil 2-stroke engine portfolio, even in subtropical areas. The main task of a dehumidifier system is to maintain the real humidity inside the engine between 40% and 50%, in order to keep the level of corrosion as low as possible.
15.0.3
The list below can be used as a rough reference for the volume (crankcase, piston underside and camshaft housing) which needs to be dried in the engine. ~ Volume per cylinder in m (crankcase & scavenge air space & camshaft housings) RTA 48T/T-B RTA 52U/U-B RTA 58 RTA 58T/T-B RTA 62U/U-B RTA 68 RTA 68T-B RTA 72U/U-B RTA 76 RTA 84
-
16 m 17 m 23 m 30 m 24 m 36 m 40 m 39 m 48 m 63 m 12 x 60 m = 720 m total air volume inside the engine Example for the definition of the air volume to be dried in a 12RTA96C engine
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75 m 60 m 68 m 60 m
Depending on the lay-up location, temperature, humidity and engine type, the capacity of the dehumidifier system needs to be defined case by case.
15.1.0
Below is a recommendation for three types of absorption dehumidifiers made by the Munters company. The marine industry has already had positive experience with these dehumidifiers.
15.1.1.
Munters M120
Process air Rated airflow (m/h) Available static pressure 50Hz (Pa) Available static pressure 60Hz (Pa) 120 200 360
Miscellaneous Operating temperature (C) -40/+40 Available for different voltage supplies from 115V to 240V
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15.1.2
Munters ML420
Process air Rated airflow (m/h) Available static pressure (Pa) 420 200
Miscellaneous Operating temperature (C) -20/+40 Available for different voltage supplies from 220V to 500V
15.1.3
Munters ML690
Process air Rated airflow (m/h) Available static pressure (Pa) 690 300
Miscellaneous Operating temperature (C) -20/+40 Available for different voltage supplies from 220V to 500V
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15.2.0
Accessories - Booster fan - Oil filter elements (to assure the efficiency of the dehumidifier) - Controller - Pipe distributor with flaps - Flexible hose 80 mm - Flexible hose 125 mm - Flexible hose 160 mm - Flexible hose 200 mm - Connecting T-pieces - Transport frame
15.2.1
During the lay-up a humidity and temperature data logger must be fitted to the crankcase, piston underside and camshaft housing/supply unit, in order to monitor the conditions inside the engine and check proper working of the dehumidifier system. Below is a recommendation for a tool which can be used for this purpose. 15.2.2 HygroLog NT3 Relative humidity, temperature, dew point or other calculated parameter Multi-probe capability, wide selection of probes to satisfy every application Measurements from 0 to 100%RH and -50..200C /-58..392F (with external probe) Optional internal humiditytemperature probe, protected against unauthorized removal Monitoring of up to two external contacts (door, relay contact, etc.) Optional LC display and multifunction keypad Large recording capacity with removable flash memory card Operates with a 9 VDC standard or rechargeable battery Data download without interrupting the measurements
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15.2.3
To spray coat engine components and blank metal parts, a portable oil sprayer may be used. There are different types and executions of oil sprayers. Below two examples are shown for reference only.
Below a sample list has been compiled of fluids to be used for various applications, which have been summarized. Note that the fluids have been divided in various categories; they are referred to in the subsequent component tables. Where applicable the application method is referred to. The list is not complete: where the products referred to are not available locally, a suitable replacement can be used; however, the basic properties should remain the same. In all cases where cabling and sensors are concerned the compatibility of the preserving agent with the relevant cabling should be confirmed. Please contact Wrtsil Switzerland Ltd. or any other Wrtsil Branch next to you, if any doubt remains. Product*
Shell calibration fluid S9365 Shell Ensis Engine Oil 30 Valvoline Tectyl 930 Mobilarma 524
-
Description
Calibrating fluid for testing fuel injectors and pumps Mineral oils with excellent rust prevention properties Used for coating engine parts including cylinder liners, piston
Class
A
Application method
Used in conjunction with a test pump/bench Spray coating or brush. Where spraying is used, a manual pump is
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Tectyl 502 EH Tectyl 506 H Tectyl 132 Chevron Rustproof Compound L Shell Ensis DW2462 Mobilarma 798 Castrol Safecoat DW33 Pyroshield LE 5182 Klberfluid CF Ultra Mobilcut 200 Shell Dromus B / BX Total Lactuca MS 5000 Castrol Cresta SHS Chevron Cylinder oil 1000 Shell Valvata Oil 1000 Mobil 600 W Super Cylinder Oil Total Cyl 1000 High-viscosity steam engine cylinder oils with excellent corrosion protection and resistance to wiping. Used for bearing shells High-pressure grease which can be used for lubricating flywheel teeth. Soluble oil inhibitors which are used to protect emptied cooling water spaces. D Brush. Solvent cutback, soft-wax based, corrosion-preventive compound. Can be used to protect external blank metal parts, for example fuel pump blocks, rails, cylinder covers, etc.
Brush.
Brush.
16.0.1
(inodorous aliphatic hydrocarbons, free of aromatics) White spirit is the generic term for the following Shell products: - Shellsol TD - Shellsol T Valvoline product: Solvent FP68
Properties Boiling range, at 760 mm Hg beginning at C ending at C Density at 20C in kg/m3 Colour SAYBOLT Aromatic content vol. % Sulphur content weight % Copper corrosion
-
Shellsol TD
Shellsol T
Solvent FP68
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Aniline point C Viscosity at 20C in cst. Relative evaporation time (ether = 1) Flash point Abel C Drop ignition temperatureC Danger class BVD Transport danger class RID/ADR Poison class Max. permissible concentration ppm mg/m3 Toxicology:
Only at very high vapour concentrations: will have narcotic effects and may cause dizziness. Solvents, thinning, cleaning and degreasing agents for lacquers and paints. Non-fluorescent dielectric material for non-destructive testing. Royal Dutch Shell plc Shellsol TD and T Carel van Bylandtlaan 30 NL 2596 HR DEN HAAG www.shell.com Valvoline Europe, Solvent FP68 Pesetastraat 5 NL 2991 XT, Barendrecht www.valvolineeurope.com
Application:
Manufacturers:
16.0.2
For closed cooling water circuits Approved and recommended for use in Wrtsil 2-stroke diesel engines
Supplier
Main reagent
Liquidewt Maxigard CorrShield OR4411 Q8 Corrosion Inhibitor Long-Life D.C.W.T. Non Chromate Marisol CW Nalfleet EWT 9-108
-
Ashland Drew Marine Ashland Drew Marine GE Betz Kuwait Petroleum Marichem Marigases Maritech Nalco / Nalfleet
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RD 25 Complex Havoline XLI WT Supra Colorcooling Anticorr NCLT Cooltreat AL Dieselguard NB Rocor NB Liquid
Rohm and Haas Texaco Total Uniservice Uniservice Uniservice Unitor Chemicals Unitor Chemicals Unitor Chemicals
Molybdate/phosphate Organic compounds Organic compounds Nitrite Phosphonate Nitrite Organic compounds Nitrite/borate Nitrite/borate
The condition of the cooling water before treatment should be as follows: min. pH 6.5 max. 10 dH (corresponds to 180 mg/l CaCO3) max. 80 mg/l chloride max. 150 mg/l sulphate
The dosage of the corrosion inhibitor and the maintenance of its concentration in service should be carried out according to the supplier's instructions. The supplier company undertakes all responsibility for the performance of the water treatment in service to the exclusion of any liability of Wrtsil Switzerland Ltd.
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16.0.3 16.0.4
Fluid WA
15C to 35C
Thinner %
Viscosity
Nozzle mm
k/ Oh
Airless
Electrostatic Drying: Air
A-II free BAG T Nr. 611 500 40C in closed pot ADR/SDR Cl. 3 Pt. 31 c 12 months cool/dry
2)
20
Oven Forced
1h
Time no Time
no
Temperature of component: Temperature of component:
no
Technical data: Cross-cut test DIN 53151 Hardness acc. to: Steel ball jet: DIN 53154 Mandrel bend test: DIN 53152 Ericcson cupping index IE: DIN 53156 Salt-spray test: DIN 50021 Kesternich test: DIN 50018 Condensed water climate: ASTM-D-148, DIN 51359
180 m /l 0.8
microns 3)
- 20C to + 60C
Highly water displacing, liquid repellent films on metal surfaces, displaces liquids and moisture out of pocket holes Duration of protection: Indoor storage 9 - 12 months / shed storage 4 - 8 months Removal, cleaning: Normally not necessary. Considered as coat structure for further preservation. Removal with white spirit or petroleum.
Supplier:
Valvoline Oil Co. Ltd., Hardturmstr. 175, P.O. Box, CH-8005 Zurich, Switzerland Tel. +41 (0) 1/446 50 50
The data given are mean values based on practical experience. Application according to the suppliers specification and at users risk with regard to climatic and specific conditions.
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16.0.5
Tectyl 506
Waxy, dry, grip-dry protective film for long-term preservation and external protection
Article No: Specification No: Substitute for Spec. No: Protection against:
506
Atmospheric influences incl. rain, snow, etc., aggressive industrial atmosphere and gases such as SO2
Applicationmethod Brush Yes Roller Dipping
Spraying: low press. high press.
10C to 35C
Thinner %
Viscosity
Nozzle mm
k/ Oh
Airless
Electrostatic Drying: Air
A-II free BAG T Nr. 16889 41C in closed pot ADR/SDR Cl. 3 Pt. 31 c 12 months cool/dry
2)
20C
Oven Forced
2hrs 3 hrs
Time Time
4 hrs
Temperature of component: Temperature of component:
Technical data: Cross-cut test DIN 53151 Hardness acc. to: Steel ball jet: DIN 53154 Mandrel bend test: DIN 53152 Ericcson cupping index IE: DIN 53156 Salt-spray test: DIN 50021 Kesternich test: DIN 50018 Condensed water climate: ASTM-D-148, DIN 51359
16 m /l 35
microns 3)
- 40C to + 120C
5 % 80 days
Dry, dust-free, oil- and grease-free surface; surface treated with Dewatering Fluid WA Non water displacing Indoor storage up to 4 years / outdoor storage up to 2 years With petroleum, aromatic-free white spirit, alkaline soaker; steam or hot-water cleaner with corrosion protection additive Valvoline Oil Co. Ltd., Hardturmstr. 175, P.O. Box, CH-8005 Zurich, Switzerland Tel. +41 (0) 1/446 50 50
Supplier:
The data given are mean values based on practical experience. Application according to the suppliers specification and at users risk with regard to climatic and specific conditions.
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16.0.6
Tectyl 5006W
Waxy, dry, grip-dry protective film for long-term preservation and external protection
Article No: Specification No: Substitute for Spec. No: Protection against:
5006W
In dry state resistant to atmospheric influences such as rain, snow and aggressive industrial atmosphere and gases such as SO2
Applicationmethod Brush Yes Roller Dipping
Spraying: low press. high press.
10C to 35C
Thinner %
Viscosity
Nozzle mm
k/ Oh
1090 kg/m at 20C 40 % DIN 4 - 20C - 30 sec. none none none (emulsion) no cool/dry + 5C to + 35C
2)
Airless
Electrostatic Drying: Air
20
Oven Forced
1,5h 2 hrs h
3 hrs
no
1h
Technical data: Cross-cut test DIN 53151 Hardness acc. to: Steel ball jet: DIN 53154 Mandrel bend test: DIN 53152 Ericcson cupping index IE: DIN 53156 Salt-spray test: DIN 50021 Kesternich test: DIN 50018 Condensed water climate: ASTM-D-148, DIN 51359
10 m /l 40
microns 3)
- 30C to + 120 C
Surface preparation:
Dust-free, oil- and grease-free surface. May be applied to moist surface. Surface treated with Dewatering Fluid WA.
Storage: protect against frost. Treated parts should only be taken outside when completely dry. Duration of protection: Indoor storage up to 4 years / outdoor storage up to 2 years
Features: Removal, cleaning: Supplier:
With petroleum, aromatic-free white spirit, alkaline soaker, steam or hot-water cleaner with corrosion protection additive Valvoline Oil Co. Ltd., Hardturmstr. 175, P.O. Box, CH-8005 Zurich, Switzerland Tel. +41 (0) 1/446 50 50
The data given are mean values based on practical experience. Application according to the suppliers specification and at users risk with regard to climatic and specific conditions.
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16.0.7
Tectyl 5805W
5805 W
Article No: Specification No: Substitute for Spec. No: Protection against:
Oil-based corrosion preventive emulsifiable with water Application Temperature: 10C to 35C
Humidity: Colour: Degree of gloss: Covering power: Density: Content of solids: Viscosity: Danger class: Poison class: Flash point: Identification duty: Shelf life: Mixing ratio: 1) With hardener: Pot life: Coverage:
Industrial atmosphere in case of indoor storage. Not resistant against atmospheric influences such as rain, etc.
Applicationmethod Brush No Roller Dipping
Spraying: low press. high press.
Thinner %
Viscosity
Nozzle mm
k/ Oh
yellowish oily
3
900 kg/m at 20C none 17 mm /s at 40C none none 140C none 12 months cool/dry 1:4
2)
2
Airless
Electrostatic Drying: Air
20C
Oven Forced
2 hrs h
Temperature of component: Temperature of component:
Technical data: Cross-cut test DIN 53151 Hardness acc. to: Steel ball jet: DIN 53154 Mandrel bend test: DIN 53152 Ericcson cupping index IE: DIN 53156 Salt-spray test: DIN 50021 Kesternich test: DIN 50018 Condensed water climate: ASTM-D-148, DIN 51359
1:10
- 10C to + 50C
Storage: protect against frost. Mixable in every ratio with water, results in milky emulsion Duration of protection: Indoor storage up to 6 months, depending on mixture ratio
Removal, cleaning: Supplier:
If required, with petroleum, aromatic-free white spirit, alkaline soaker, steam or hot-water cleaner with corrosion protection additive Valvoline Oil Co. Ltd. Hardturmstr. 175, P.O. Box, CH-8005 Zurich, Switzerland Tel. +41 (0) 1/446 50 50
The data given are mean values based on practical experience. Application according to the suppliers specification and at users risk with regard to climatic and specific conditions.
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16.0.8
Oil-based corrosion preventive. Stays oil, does not become gummy. MIL-L-21260 B+C, API SF/CD
Application Temperature: Humidity: Colour: Degree of gloss: Covering power: Density: Content of solids: Viscosity: Danger class: Poison class: Flash point: Identification duty: Shelf life: Mixing ratio: 1) With hardener: Pot life: Coverage:
Atmospheric influences such as aggressive air, etc. Not resistant to mechanical loads and rain, etc.
Applicationmethod Brush Yes Roller Dipping
Spraying: low press. high press.
0C to 50C
Thinner %
Viscosity
Nozzle mm
k/ Oh
yellow-brown wet gloss 880 - 890 kg/m3 at 15C none 910: VG46 930: VG100 none free BAG T No. 611 500 218-230C in closed pot
Airless
Electrostatic Drying: Air
Oven Forced
Time Time
24 months cool/dry
2)
Technical data: Cross-cut test DIN 53151 Hardness acc. to: Steel ball jet: DIN 53154 Mandrel bend test: DIN 53152 Ericcson cupping index IE: DIN 53156 Salt-spray test: DIN 50021 Kesternich test: DIN 50018 Condensed water climate: ASTM-D-148, DIN 51359
- 20C to + 50C
passed 20 hrs
Indoor storage 6 - 24 months, depending on climatic conditions Normally not necessary. If required, with white spirit. Valvoline Oil Co. Ltd. Hardturmstr. 175, P.O. Box, CH-8005 Zurich, Switzerland Tel. +41 (0) 1/446 50 50
The data given are mean values based on practical experience. Application according to the suppliers specification and at users risk with regard to climatic and specific conditions.
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16.0.9
Extreme atmospheric influences, aggressive industrial atmosphere and gases such as SO2 and acid vapours. Absolutely resistant in water.
Applicationmethod Brush yes Roller Dipping
Spraying: low press. high press.
Application Temperature: Humidity: Colour: Degree of gloss: Covering power: Density: Content of solids: Viscosity: Danger class: Poison class: Flash point: Identification duty: Shelf life: Mixing ratio: 1) With hardener: Pot life: Coverage:
10C to 35C
Thinner %
Viscosity
Nozzle mm
k/ Oh
yellow waxy
3
no no no no yes yes
dustfree
set to touch completely dry Re-coatable after: spraying brush
Airless
Electrostatic Drying: Air
A-II free BAGT No. 611 500 43C in closed pot ADR/SDR cl. 3 zif. 31c 12 months cool/dry storage
2)
20C
Oven Forced
2h
Time Time
5h
10 h
Temperature of component: Temperature of component:
Technical data: Cross-cut test DIN 53151 Hardness acc. to: Steel ball jet: DIN 53154 Mandrel bend test: DIN 53152 Ericcson cupping index IE: DIN 53156 Salt-spray test: DIN 50021 Kesternich test: DIN 50018 Condensed water climate: ASTM-D-148, DIN 51359
5 m /l 100
microns 3)
- 23C to + 175C
5 % at 75 microns, 1500 h
Surface preparation:
Dry, dust-free, oil- and grease-free surface; surface treated with Dewatering Fluid WA and TECTYL 506 or 5006W Non water displacing. Indoor storage up to 5 years / outdoor storage up to 3 years. Immersion-resistant in water. With petroleum, aromatic-free white spirit, alkaline soaker; steam or hot-water cleaner with corrosion protection additive
Valvoline Oil Co. Ltd., Hardturmstr. 175, P.O. Box, 8005 Zurich, Switzerland Tel. +41 (0) 1/446 50 50 The data given are mean values based on practical experience. Application according to the suppliers specification and at users risk with regard to climatic and specific conditions.
Supplier: -
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17.0.0
Mainly four lists have to be used during engine storage: - 17.0.1 - 17.0.2 - 17.0.3 - 17.0.4 Inspection List for general parts purpose Inspection List for dehumidifier Inspection List for time-dependant inspections or moving of parts Inspection List for final delivery inspection (carried out at engine maker / see chapter 9.0) Same list to be used for Inspection upon arrival (carried out at shipyard / see chapter 11.0)
17.0.1
The below-mentioned inspection record list for the inspection of engine and/or parts is for reference only, as every person responsible for storage may create his/her own list, as long as the 7 items given in the list below are mentioned in a way or other and clearly identified respectively.
If possible the temperature and humidity should be recorded in the same daytime period
Part inspected
Recoated Yes/No
Date
Remark
(e.g. rust visible)
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17.0.2
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17.0.3
Repeated treatment record sheet Date Treatment Engine turned with main lube oil pump running Lubrication of the cylinder liners Check oil level in the fuel system Once a week Operation of the cooling water pumps Move the fuel regulating linkage Temperature and humidity recording Inspection/re-coating of blank metal parts Comments
Inspection of the crankcase Inspection of the piston underside Once a month Inspection of the exhaust manifold Open/close main starting shut-off valve Check dehumidifying system (filter, hoses, etc.) Turn the rotor of the turbocharger(s) by 90 Turn the auxiliary blower(s) by hand
Inspection of a cross head bearing pin After three months Inspection of a main bearing journal pin Replacement of the silica gel desiccant bags Analysis of the cooling water Analysis of the system oil
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17.0.4.
- Final delivery inspection (carried out at engine maker / see chapter 9.0) - Inspection upon arrival (carried out at shipyard / see chapter 11.0)
This parts list can/should be used for: Final delivery inspection (at engine maker) & Inspection upon arrival (at shipyard) No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
-
Part - Designation
Crankshaft Main bearing shell Main bearing cover Jacking bolt main bearing (For RTA52U ; RTA62U-B ; RTA72U-B ; RTA84T-D only) Crank web Crankpin : web journal & main journal Gear wheels Thrust bearing Thrust bearing pads Bottom end bearing Connecting rod Crosshead bearing Crosshead guide shoes Piston rod Piston Exhaust valve Bedplate: machined surfaces Column: machined surfaces Column (guide rails) Cylinder block Tie rods At cyl. block top At bedplate bottom Diaphragm Piston rod gland Cylinder liner Scavenge ports Anti-Polishing ring SAC cooler
Inspected Yes/No
Recoated Yes/No
Signature
Date
Remar k
(e.g. rust visible)
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30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
Cylinder cover Fuel injectors Combustion space Starting air valve Starting air shut-off valve Exhaust valve cage Exhaust manifold Scavenge air receiver Auxiliary scavenge air blower Flywheel Turning gear Electric motor RTA fuel pump block Starting air distributor Camshaft/reversing servomotor Linkage local manoeuvring stand RT-flex Supply Unit All flanged SU parts High-pressure fuel pumps Servo oil pumps Rail unit box Fuel oil rail Injection Control Unit (ICU) Servo oil rail Exhaust valve drive High-pressure pipes to fuel injectors Electronic cabinets All relief valves Turbocharger
18.0
Engine tools
The engine tools should be stored in a clean, well ventilated and dry place; in addition they need to be protected against corrosion. It is advisable to check the condition and completeness of the engine tools to avoid any problems during commissioning and engine hand over.
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19.0
Spare parts
All spare parts must be firmly secured to prevent any movement. Metal-to-metal contact is to be avoided during storage of any components. All open ports, adapters, pipes, etc. are to be sealed in order to prevent ingress of foreign particles. All spare parts have to be protected against corrosion. Large components should be treated with Valvoline Tectyl 506 or a suitable equivalent. Smaller components, with the exception of electronic equipment, may be wrapped in a corrosion-protective VCI paper.
20.0
The official statutes and regulations for occupational hygiene and technical equipment measures are to be stringently observed, and the working conditions with cleaning agents and corrosion protective products have to be allowed for. Samples of safety mask & safety goggle which are to be used:
Safety mask with exchangeable filter system. Must be used during corrosion protection application or use of cleaning solvent inside closed spaces (inside the engine) 21.0 Disposal
Safety goggle with closed side frame. Must be used during corrosion protection application or use of cleaning solvent inside closed spaces (inside the engine)
The generation of waste should be avoided or minimized wherever possible. Avoid dispersal of spilled material, their contact with soil and further runoff, waterways, drains and sewers. Disposal of these products, solutions and any by-products should at all times comply with the requirements of environmental protection and waste disposal legislation and any regional or local authority requirements.
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21-2
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Version a2
22. Appendix
22. Appendix
22.1 Abbreviations
ABB ALM AMS BFO BN BSEF BSFC CCAI CCR CCW CMCR CPP CSR cSt DAH DENISUNIC EM EMA FCM FPP FQS FW GEA HFO HT IMO IND IPDLC ISO kW ASEA Brown Boveri Alarm Attended machinery space Bunker fuel oil Base Number Brake specific exhaust gas flow Brake specific fuel consumption Calculated Carbon Aromaticity Index Conradson carbon Cylinder cooling water Contract maximum continuous rating (Rx) Controllable pitch propeller Continuous service rating (also designated NOR and NCR) centi-Stoke (kinematic viscosity) Differential pressure alarm, high MAPEX MCR MDO mep Monitoring and maintenance performance enhancement with expert knowledge Maximum continuous rating (R1) Marine diesel oil Mean effective pressure
METxxMB Turbocharger (Mitsubishi manufacture) MHI MIM MMI N, n NAS NCR NOR OM OPI P Mitsubishi Heavy Industries Marine installation manual Man-machine interface Rotational speed National Aerospace Standard Nominal continuous rating Nominal operation rating Operational margin Operator interface Power Pressure alarm, low Pressure indicator Pulse Lubricating System (cylinder liner) Parts per million Power related unbalance Power take-off Remote control system Redwood seconds No. 1 (kinematic viscosity) Shaft generator Scavenge air cooler Society of Automotive Engineers Shut down Shipyard interface box Slow down Sea margin
Diesel engine control and optimizing specification PAL Engine margin Engine Management & Automation Flex control module Fixed pitch propeller Fuel quality setting Freshwater Scavenge air cooler (GEA manufacture) Heavy fuel oil High temperature International Maritime Organisation Indication Integrated power-dependent liner cooling International Standard Organisation Kilowatt PI PLS ppm PRU PTO RCS RW1 S/G SAC SAE SHD SIB SLD SM
Version a2
22-1
22. Appendix
kWe kWh LAH LAL LCV LI LLT LR LSL LT M M1H M1V M2V Kilowatt electrical Kilowatt hour Level alarm, high Level alarm, low Lower calorific value Level indicator Low-Load Tuning Light running margin Level switch, low Low temperature Torque External moment 1st order horizontal External moment 1st order vertical External moment 2nd order vertical SSU SW TBO TC tEaT TI A1xx-Lxx UMS VI WCH UNIC winGTD M
22-2
Version a2
22. Appendix
, , , , Angle t f, v v, c, w, u N, n a qm qv p L F p , E W, E, A, Q P M, T , T, , t, T, , ... C, S c K e Time Frequency Velocity Rotational frequency Acceleration Angular velocity Angular acceleration Mass flow rate Volume flow rate Momentum Angular momentum Force Pressure Stress Modulus of elasticity Energy, work, quantity of heat Power Torque moment of force Dynamic viscosity Kinematic viscosity Surface tension Temperature Temperature interval Linear expansion coefficient Heat capacity, entropy Specific heat capacity Thermal conductivity Coefficient of heat transfer Net calorific value
Version a2
22-3
22. Appendix
Definition Total LIN noise pressure level Total A noise pressure level Average spatial noise level over octave band Voltage Current Brake specific fuel consumption
Other units
22-4
Version a2
22. Appendix
Power
Area
Version a2
22-5
Tel: +41 52 262 07 14 Wrtsil Switzerland Ltd. PO Box 414 Fax: +41 52 262 07 18 CH-8401 Winterthur Switzerland www.wartsila.com