INS ABHAY

ENGINEERING
DEPARTMENT
 CONTENTS

MACHINERY LAYOUT

MAIN PROPULSION PLANT

POWER GENERATION PLANT

OMS
 MAIN ENGINEROOM LAYOUT
FIRE PP NO.1 AIR STATION

PORT ME STBD ME
MTU 1163 MTU 1163 FOXLE

TB93 TB93
DA NO.1

PWS 5 PWS 50
GEAR BOX GEAR BOX
FUEL
TRANSFER
TB PP TB
Q’DECK
HPAC
PORT GB LO NO.1 STBD GB LO
CIRCULATING CIRCULATING
TANK LOCAL CONTROL
TANK
PANEL
 AFT SWITCHBOARD
LO Storage LO Storage
Tank Tank

Tech Water AC COOLING

PUMP AFT ENGINEROOM
tank

RO
PLANT
DA NO. 02
NT 743 MG DA NO. 03
CENTRIFUGE
ESCAPE NTA 843 MG
HATCH

FOXLE

Dirty Water HPAC Dirty Fuel

tank Q’DECK
tank
FIRE PP 2 NO.2
 TILLER FLAT

STEERING
OIL RU
STEERING
TANK
PUMP
FEEDB
EM ACK
UNIT UNIT

RUDDER RAM RUDDER FOXLE

Q’DECK
 MAIN PROPULSION PLANT

MTU 1163 TB 93 SERIES ENGINES

PWS 50 GEARBOX

THRUST BEARING WITH TOOTH

COUPLING

MCS5 CONTROLS
 PROPULSION PLANT LAYOUT

GEAR BOX TB &

MTU 1163 TB 93 SERIES TC SHAFT
PWS 50

VULCAN COUPLING

GEAR BOX TB &

MTU 1163 TB93 SERIES TC
SHAFT
PWS 50 GB
MTU 1163 TB 93 SERIES ENGINES
SPECIFICATIONS
SPECIAL FEATURES
ENGINE MODEL DESIGNATION
 1163 - Engine Series – 100 Times Displacement Of
One Cylinder In Liters
 T - Exhaust turbocharging
 B - External charge air cooling
 9 - Marine engine
 3 - Design digit
 16 - Number of Cylinders
 V - Engine Vee
 Fuel stop power 5740 kW at 1350 RPM
 Intake air temperature 45 0C
 Raw water temperature 32 0C
 Air Pressure 1000 mbar
FUEL DELIVERY
PP DRIVE GEAR

CAMSHAFT
DRIVE GEAR

CAMSHAFT IDLER
GEAR

COOLANT PP
DRIVE GEAR

SMALL
REDUCTION
GEAR
LARGE
REDUCTION
GEAR

CRANKSHAFT
GEAR

ENGINE OIL PP
DRIVE GEAR

LARGE
REDUCTION
GEAR
ENGINE OIL PP
DRIVE GEAR
 FUEL SYSTEM
MTU 16V 1163 TB 93
 NOZZLE FOR VV
SEAT
LUBRICATION LUB OIL SYSTEM
L/O
SOLENOID
MTU 16V 1163 TB 93
PP.
VV.
L/O
FILLING
OIL FOR PISTON
COOLING

NRV
RUNNING GEAR
3 WAY
MECHANISM
COCK ACTUATOR FOR
CYL BANK SOLENOID VV.
CUTOUT
PRESSUR
PISTON
E REG VV.
COOLIN
G
THERMOSTAT FILTER
NRV
SUMP
HAN
D PP. GAP TYPE
L/O PP PAPER FILTER FILTER
EXHAUST TURBOCHARGER LEFT
SIDE

L/O BYPASS
EXHAUST TURBOCHARGER RIGHT FILTER PRIMING PP.
SIDE
 BREATHER
VALVE
CHARGE AIR
PREHEATER

EXHAUST
EXPANSION OVERFLOW
TURBOCHARGER
THERMOSTA TANK 85 ltr
HOUSING
T

FILLIN
G LINE
CYLINDER
HEAD

STRAINE
R

CYLINDER
HEAD COOLING WATER
HEAT EXCHANGER

COOLANT
PUMP

EXHAUST
TURBOCHARGER
HOUSING PREHEATING COOLANT SYSTEM
UNIT
MTU 16V 1163 TB 93
 CHARGE AIR
CONDENSAT
E VENT
PRIMING AIR
EDUCTOR

CYLINDER
HEAD

NR FLAP S/W PUMP

STRIP
MEASURING

S/W STRAINER
CHARGE AIR
COOLERS

G/B OIL HEAT

EXCHANGER

CYLINDER
HEAT
HEAD L/O HEAT
EXCHANGER
EXCHANGER

SUPPLY
EMERGENCY WATER
S

CHARGE AIR
COOLERS CHARGE AIR

OVERBOARD

OVERBOARD
VENT
CONDENSAT
E

SEA WATER SYSTEM

MTU 16V 1163 TB 93
 TO S/W PRIMING
TURBOCHARGER
SWITCHING
CONTROL BLOCK AIR TANK 3/2 WAY VALVE

A1 A2 A3 A4 A5 A6 AUTOMATIV
A7 A8 E DRAIN VV

PRESSURE
REDUCING
STATION 40 BAR
TO 6 BAR

STARTING VALVE

AIR SUPPLY

SHUT OFF
VALVE

BOOSTER FOR
B1 B2 B3 B4 B5 B6 B7 RACK ACTUATION
B8 STARTING AIR
DISTRBUTOR
STARTING AIR
VALVE CYL STARTING AIR SYSTEM
MTU 16V 1163 TB 93
PWS 50 GEARBOX
 TECHNICAL DATA

 GENERAL DESCRIPTION

 OPERATIONS

 ROUTINES

 POINTS TO REMEMBER
THRUST BEARING WITH TOOTH COUPLING

 TECHNICAL DATA

 DESCRIPTION OF THE
THRUST BEARING

 EQUIPMENTS

 DESCRIPTION OF THE
GEAR TYPE COUPLING
 TAIL AIR VENT
SHAFT AND OIL
END INPECTION
HOLE FILLING

TAPERED
ROLLER
BEARING

GREASE
NIPPLE

GEAR BOX
THRUST BEARING WITH TOOTH COUPING OUTPUT FLANGE
SIDE
TECHNICAL DATA

 NOMINAL SPEED - 552 RPM

 NOMINAL THRUST - 260 KN

 RADIAL BEARING LOAD - NOMINAL – 20 KN

MAX – 40 KN
 POWER LOSS - 6.5 KW

 LUBRICATING OIL - SAE 40 / 50 LTS

 GREASE TOOTH COUPLING - EP GREASE/20 KGS

 THRUST BEARING DESCRIPTION
 DESIGNED FOR BOTH SENSE OF ROTATION
 PORT IS SLIGHTLY LONGER THAN THE STBD\
(SPACER OF 14 MM)
 THRUST AS WELL AS RADIAL LOADS
IS TAKEN BY TAPERED ROLLER BEARING IN ‘O’
CONFIGURATION
 PROPER SHAFT ALIGNMENT TAKEN FOR GRANTED
UPTO 4 MM
 HOUSING IS OF FABRICATED STEEL WITH RUBBER
LIP SPLIT SEALS ON BOTH SIDES
 INTEGRATED SEA WATER COOLING FOR OIL IN SUMP
THRUST BEARING EQUIPMENTS
THRUST BEARING IS EQUIPPED WITH
 AIR VENT
 OIL FILLING PLUG
 OIL DRAIN PLUG
 OIL LEVEL SIGHT GLASS
 THERMOMETER FOR SUMP TEMPERATURE
 TEMPERATURE SENSOR PT 1000, CONNECTED TO
MCS CONTROL SYSTEM FOR HIGH TEMPERATURE
ALARM AND INPUT AT MCS
 GREASE NIPPLE GOR REGREASING
 PUGGED HOLE FOR ENDOSCOPIC INSPECTION
GEAR TYPE COUPLING
FUNCTIONAL DESCRIPTION
DESIGNED TO

 COMPENSATE FOR DISPLACEMENT OF THE INPUT

IN RELATION TO THE OUTPUT SHAFT DUE TO
 TAIL SHAFT WEARING TEAR
 THERMAL GROWTH
 SHIP DEFORMATION
 ALIGNMENT TOLERANCES

 COMPENSATE LENGTH OF INSTALLATION IN THE

RANGE OF +/- 4 MM
THRUST COUPLING DESCRIPTION
 TOOTH COUPLING IS THROUGH HARDENED WITH
NITRITED TEETH
 COUPLING SLEEVE IS SEALED WITH ‘O’ RINGS
 SEAL COVERS ARE OF SPLIT DESIGN TYPES FOR
EASY REPLACEMENT OF SEALS
 GEAR COUPLING I/P IS FLANGED ONTO TO THE
O/P FLANGE OF GEAR UNIT
 O/P SIDE IS COUPLED WITH TAIL SHAFT WITH
FITTED BOLTS
 IT IS EQUIPPED WITH
• GREASE FILLING PLUG
• GREASE DRAIN PLUG
MONITORING AND CONTROL
SYSTEM – MCS5 TYPE II
 CAN FIELD BUS LEVEL

Data acquisition and control in the ship

area with Peripheral Interface Modules –
PIM
Interface to monitor and control binary
signals (e.g. bilge, doors, hatches, limit
switches), pressure, temperature, etc.
Data communication via CAN bus, to
reduce cabling and maximize reliability.
 CAN PROCESS BUS LEVEL

DATA PROCESSING BY
PROGRAMMABLE PROCESS
STATIONS - PPS
GENERATING ALARMS IN CASE
OF LIMIT VIOLATION
PERFORMING TAILORED LOGIC
FUNCTIONS
 GRAPHIC OPERATOR STATION

 ONE COMMON PLATFORM

 INTUITIVE USER INTERFACE
 GRAPHICS
 COMMUNICATION TOOLS
BUS STRUCTURE FOR DATA
COMMUNICATION
OPERATOR
STATION

PPS PPS
RCS

PIM PIM

LOP
ETB2

ETB 2F

ENGINE
SENSORS
MAIN ECS BACKUP ECS ACTUATORS
ECS - SYSTEM OVERVIEW
PIM –PERIPHERAL INTERFACE MODULE
COMMUNICATION WITH HIGHER
LEVEL SYSTEMS

PROCESS CONTROL

DATA ACQUISITION

SLOT 1 IS RESERVED FOR MPU 23

ALL OTHER SLOTS MAY BE
POPULATED WITH PIM PRINTED
CIRCUIT BOARDS
ENGINE MOUNTING
ETB 2F
CCS
LOP
MCS5 CONTROLS
 BASIC LAYOUT OF ENGINES
 SPECIFICATIONS
 SPECIAL FEATURES
 MAIN TRANSMITTING UNIT
(MTU)
 EXPLOITATION FEATURES
 ORION CONTROL
 ENGINE ORDERS
 POINTS TO REMEMBER
 POWER GENERATION PLANT

ONE CUMMINS NT 743 MG DA

TWO CUMMINS NTA 855 MG DA

SYMTRONICS CONTROL PANEL

 SPECIFICATIONS

N - SERIES
T - TURBOCHARGED
743 - DISPLACEMENT (CU IN)
M - MARINE PURPOSE
G - GENERATOR

CAPACITY - 100KW
POWER O/P - 380V, 3 PHASE, 50 HZ
BORE & STROKE - 130 * 155 mm
SPECIFICATIONS

N - SERIES
T - TURBOCHARGED
A - AFTERCOOLED
855 - DISPLACEMENT (CU IN)
M - MARINE PURPOSE
G - GENERATOR

CAPACITY - 200KW
POWER O/P - 380V, 3 PHASE, 50 HZ
BORE & STROKE - 139.7 * 155 mm
SPECIFICATIONS

OIL USED : OMD 113

OIL SUMP CAPACITY : LOW 19 L
HIGH 26.5 L

ASPIRATION : TURBOCHARGED

FUEL USED : LSHFHSD

COOLANT USED : CAC

COOLANT CAPACITY : 18 L
SPECIAL FEATURES

• PTG FUEL SYSTEM

• CAM OPERATED INJECTORS
• ELECTROHYDRAULIC GOVERNOR
• VACUUM INDICATOR FOR AIR FILTER
CHOCKING INDICATION
• INDUCTION AIR AFTER COOLER
• INDIRECT AIR STARTING BY STARTING AIR
MOTOR/ BATTERY STARTING
BASIC LAYOUT OF ENGINE

• SIX CYLINDER IN INLINE CONFIGRATION

• BELT DRIVEN SEA WATER AND COOLANT

PUMP IN FREE END SIDE

• VIBRATION DAMPER IN FREE END SIDE

• ALTERNATER COUPLED WITH HOLESET

COUPLING
NORMAL WORKING PARAMETERS

COOLANT TEMPERATURE : 70 – 90 °c

LUB OIL TEMPERATURE : 82 – 107 °c

LUB OIL PRESSURE

IDLE : 0.68 – 1.38 KGF/CM²
RATED : 2.9 – 5.1 KGF/CM²
 MODES OF OPERATION OF AUTOMATIC WARNING &
PROTECTION SYSTEM

MODE A AUDIO VISUAL ALARM

MODE AT AUDIO VISUAL ALARM

+ BREAKER TRIP

MODE ATS AUDIO VISUAL ALARM

+ BREAKER TRIP
+ ENGINE SHUTDOWN
WARNING AND PROTECTION SYSTEM

A MODE (ALARM)

COOLING WATER HIGH

TEMPERATURE ALARM : 93°c

LUB OIL HIGH TEMPERATURE

ALARM : 120°c

LOW LUB OIL PRESSURE

ALARM : 1.2 KGF/CM²
WARNING AND PROTECTION SYSTEM

ATS MODE ( ALARM + BREAKER TRIP + ENGINE

SHUTDOWN)

VERY HIGH FRESH WATER

TEMPERATURE (°C) : 96 °c

VERY HIGH LUB OIL TEMPERATURE

ALARM (°C) : 125

VERY LOW LUB OIL PRESSURE : 0.8 (KGF/CM²)

OVER SPEED TRIP :1750 RPM

 SYMTRONICS CONTROL SYSTEM
SWITCHBOARD

MCR PANEL BUPS

SHIP’S DA
RECTIFIER

LOCAL
CONTROL CONTROL BOX JUNCTION BOX
PANEL
MCR PANEL

• FOR CONTROL ON AND

SELECTION OF SUPPLY FROM
RECTIFIER OR FROM UPS
• FOR STARTING AND STOPPING FROM REMOTE
• FOR REMOTE MONITORING OF SAFETIES LIKE
ALARMS AND TRIPS
• FOR LAMP AND HOOTER CHECK
• FOR ACKNOWLEDGE AND RESET OF ALARMS
AND TRIPS
LOCAL CONTROL PANEL

•FOR STARTING AND STOPPING

•FOR LOCAL PARAMETERS MONITORING

•FOR MAINTENANCE KEY ON

•FOR STARTING POSITION SELECTION

•FOR STARTING MODE SELECTION

 CONTROL BOX

• LOCATED IN RESPECTIVE
E/R

• CONTAINS CONTRACTORS,
RELAYS, ELECTRONIC
MODULES

• SEQUENCING AND LOGIC

CONTROL
BACKUP UPS

• LOCATED IN RESPECTIVE E/R

• TRICKLE CHARGES @ 2 AMPS AND BOOST

CHARGES @ 3-4 AMPS

• INPUT VOLTAGE 380 V AC

• CONTROLLED OUTPUT VOLTAGE 24 – 27 V

 JUNCTION BOX

• LOCATED IN E/R AND

MOUNTED ON THE ENGINE

• ALL SAFETY DEVICES AND

SENSORS ARE WIRED AND
TERMINATED AT THE
JUNCTION BOX