LEBW0014-01 Proyecto Ejenplo

12_16_CM32C-Project-Guide_Petroleum_2013_Layout 1 20.01.
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CM32 Project Guide • Petroleum Applications

CM32
Project Guide
Generator Set for Petroleum Applications
12 • 16 Cylinder
Caterpillar Oil & Gas

Headquarters
Caterpillar Inc.
13105 N.W. Freeway
Suite 1100
Houston, Texas 77040 6321
Phone: (+1) 713 329 2207
Telefax: (+1) 713 895 4280
Europe, Africa, Middle East and CIS Asia Pacific
Caterpillar Commercial Caterpillar Motoren Caterpillar CIS LLC Caterpillar Caterpillar Asia Pte., Ltd
Northern Europe Ltd. GmbH & Co. KG 82 Sadovnicheskaya Str. Oil & Gas China 7 Tractor Road
Caterpillar Oil & Gas Caterpillar Oil & Gas Moscow 113035, RF Room 1601 Caterpillar Tower Singapore 627968
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United Kingdom, RG42 1 NG Telefax: (+49) 431 3995 5004 Telefax: (+86) 10 5921 0022
Phone: (+44) 1344 782 920
Telefax: (+44) 1344 782 930
For more information please visit our website: Subject to change without notice. © 2014 Caterpillar All Rights Reserved. Printed in Germany. CAT, CATERPILLAR, their
www.catoilandgasinfo.com Leaflet No. 706GP · 01.14 · e · L+S · VM3 respective logos, ACERT, ADEM, „Caterpillar Yellow“ and the POWER EDGE trade dress,
LEBW0014-01 as well as corporate identity used herein, are trademarks of Caterpillar and may not
be used without permission.
Caterpillar Oil & Gas is committed to sustainability. This document is printed on
Please check out the CM32 Specification Sheets
PEFC certificated paper.
TM
(12 + 16 cylinder) by scanning the QR code
® ®
Introduction
Information for the user of this project guide
The project information contained in the following is not binding, since technical data of products may
especially change due to product development and customer requests. Caterpillar Motoren reserves
the right to modify and amend data at any time. Any liability for accuracy of information provided
herein is excluded.
Binding determination of data is made by means of the Technical Specification and such other agree-
ments as may be entered into in connection with the order. We will supply further binding data, draw-
ings, diagrams, electrical drawings, etc. in connection with a corresponding order.
This edition supersedes the previous edition of this project guide.
All rights reserved. Reproduction or copying only with our prior written consent.
Caterpillar Motoren GmbH & Co. KG

P. O. Box, D-24157 Kiel
Germany
Phone +49 431 3995-01
Telefax +49 431 3995-2193
Issue January 2014
CM32 – Generator Set – Oil & Gas 01.2014 I
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Cat Financial – World-Class Financing Solutions
Global Resource from One Source

When you select Cat Global Petroleum Power
for your offshore units, look to Cat Financial
for world-class financial support. With offices in
Europe, Asia and the US supporting Caterpillar’s
worldwide distribution network, Cat Financial
Caterpillar Financing Guidelines is anchored in your homeport.
Power: Cat and MaK. We also have over 20 years of financing
Financial Products: Construction, term experience, so we understand your unique
and repower financing. commercial offshore, drilling, power production
Repayment: Loan terms up to industry business needs. Whether you’re in
10 years, with longer this business, you can count on
amortizations available. Cat Financial for the same high standard you
Financed Amount: Up to 80% of your expect from Caterpillar.
offshore unit cost.
Rates: Fixed or variable. www.finance.cat.com
Currency: US Dollars, Euros and Visit our web-site or see your local dealer
other widely traded to learn how our financing plans and
currencies. options can help your business succeed.
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Integrated Solutions – Product Support Portfolio
Commissioning
DICARE Training
Diagnostic Software
Global
Remanufactured Dealer Network Maintenance
Parts
Genuine
Spare Parts Overhauls
Engine Repairs
Upgrades
Customer Support
Agreements
(CSAs)
Providing integrated solutions for your power system means

much more than just supplying your engines. Beyond complete
auxiliary and propulsion power systems, we offer a broad port-
folio of customer support solutions and financing options. Our
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To find your nearest dealer, simply go to:

WWW.CATOILANDGASINFO.COM
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DET NORSKE VERITAS
TYPE APPROVAL CERTIFICATE
CERTIFICATE NO. M-12395
This is to certify that the

Diesel Engine
with type designation(s)

M32C LS/FCT/CR
Manufactured by
Caterpillar Motoren GmbH & Co. KG
Kiel GERMANY, Germany
is found to comply with

Det Norske Veritas' Rules for Classification of Ships
DNV's Offshore Standard DNV-OS-D101 "Marine and Machinery Systems and Equipment"
DNV's Offshore Service Specification DNV-OSS-201 "Verification for Compliance with Norwegian Shelf Legislation".
Application
The approval is valid for propulsion, auxiliary and emergency duty.
Rating see page two for ratings
This Certificate is valid until 2017-06-30.
Issued at Høvik on 2013-10-16

for Det Norske Veritas AS
DNV local station: Hamburg CMC Northern & Eastern Germany 'LJLWDOO\6LJQHG%\1JX\HQ7LQ+XX
/RFDWLRQ'19+¡YLN1RUZD\
Approval Engineer: Dag Harald Williksen 6LJQLQJ'DWH RQEHKDOIRI
Torbjørn Lie
Head of Section
This Certificate is subject to terms and conditions overleaf. Any significant change in design or construction may render this Certificate invalid.
The validity date relates to the Type Approval Certificate and not to the approval of equipment/systems installed.
If any person suffers loss or damage which is proved to have been caused by any negligent act or omission of Det Norske Veritas, then Det Norske Veritas shall pay compensation to such
person for his proved direct loss or damage. However, the compensation shall not exceed an amount equal to ten times the fee charged for the service in question, provided that the maximum
compensation shall never exceed USD 2 million. In this provision "Det Norske Veritas" shall mean the Foundation Det Norske Veritas as well as all its subsidiaries, directors, officers,
employees, agents and any other acting on behalf of Det Norske Veritas.
DET NORSKE VERITAS AS, Veritasveien 1, NO-1322 Høvik, Norway, Tel.: +47 67 57 99 00, Org.No. NO 945 748 931 MVA. www.dnv.com
Form No.: TA 1411a Issue: December 2012 Page 1 of 5
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Contents
1.0 Engine description ......................................................................................... 1

1.1 Engine description .............................................................................................................. 1
1.2 Engine design features ...................................................................................................... 2
2.0 General data and outputs ............................................................................. 3

2.1 General data and outputs .................................................................................................. 3
2.1.1 Output definition .................................................................................................................. 3
2.1.2 Fuel consumption ................................................................................................................ 4
2.1.3 Lubricating oil consumption .............................................................................................. 4
2.1.4 Soot- and nitrogen emissions (IMO II NOx - values) ..................................................... 4
2.1.5 Technical data ...................................................................................................................... 5
2.2 Generator set dimensions and weights .......................................................................... 9
2.3 Restrictions for low load operation and stand-by mode ............................................. 10
2.4 Load application and recovery behaviour ..................................................................... 12

2.4.1 Speed control of auxiliary generating sets / DE-drive .................................................. 14
2.5 Flexible Camshaft Technology – FCT (option) ............................................................... 15
3.0 Installation and arrangement ...................................................................... 16

3.1 General installation aspect .............................................................................................. 16
3.2 25 degree tilt capability ..................................................................................................... 16
3.3 Rules of classification societies ...................................................................................... 17
3.4 Required dimensions of generator .................................................................................. 18
3.5 Space requirement for dismantling of turbocharger cartridge

and vibration damper, charge air cooler cleaning ....................................................... 19
3.5.1 12CM32C ............................................................................................................................... 19
3.5.2 16CM32C ............................................................................................................................... 20
3.6 Engine parts ......................................................................................................................... 21
3.7 System connections ........................................................................................................... 22
3.8 Lifting of generator set ....................................................................................................... 23
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4.0 Safety equipment ........................................................................................... 24
4.1 Hot-box ventilation .............................................................................................................. 24
4.2 Air shut-off valve ................................................................................................................. 25
5.0 Systems ............................................................................................................ 26
5.1 Fuel oil system, MGO/MDO operation ............................................................................ 26

5.1.1 Quality requirements .......................................................................................................... 26
5.1.2 MGO/MDO fuel components ............................................................................................. 26
5.1.2.a Day tank DT 1 ....................................................................................................................... 26
5.1.2.b Strainer (separate) DF 2 ..................................................................................................... 26
5.1.2.c Preheater (separate) DH 1 ................................................................................................. 26
5.1.2.d Feed pump (separate) DP 1/DP 2 ...................................................................................... 27
5.1.2.e Pressure regulating valve (separate) DR 2 ..................................................................... 27
5.1.2.f Fine filter (separate) DF 1 ................................................................................................... 27
5.1.2.g Separator DS 1 ..................................................................................................................... 27
5.1.3 MGO/MDO fuel oil diagram ............................................................................................... 28
5.2 Fuel oil system, HFO and crude oil operation ................................................................ 29
5.2.1 Heavy fuel oil specification – limit values ....................................................................... 29
5.2.2 Crude oil specification – limit values ............................................................................... 30
5.2.3 Minimum requirements for storage, treatment and supply systems ........................... 32
5.2.3.a Bunker tanks ........................................................................................................................ 32
5.2.3.b Settling tanks ....................................................................................................................... 32
5.2.3.c Day tank ................................................................................................................................ 32
5.2.3.d Separators ............................................................................................................................. 32
5.2.3.e Supply system (Separate components) ........................................................................... 33
5.2.4 HFO components ................................................................................................................. 33
5.2.4.a Strainer HF 2 ......................................................................................................................... 33
5.2.4.b Pressurizing pumps HP 1/HP 2 .......................................................................................... 33
5.2.4.c Pressure regulating valve HR 1 ......................................................................................... 34
5.2.4.d Self cleaning filter HF 4 ...................................................................................................... 34
5.2.4.e Mixing tank HT 2 .................................................................................................................. 35
5.2.4.f Circulating pumps HP 3/HP 4 ............................................................................................. 35
5.2.4.g Final preheater HH 1/HH 2 ................................................................................................. 35
5.2.4.h Viscosimeter HR 2 ............................................................................................................... 35
5.2.4.i Fine filter (fitted) HF 1 .......................................................................................................... 35
5.2.4.j Mixing receiver HT 4 ........................................................................................................... 36
5.2.4.k Diesel oil intermediate tank DT 2 ...................................................................................... 36
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5.2.4.l Diesel oil feed pump DP 1 .................................................................................................. 36
5.2.4.m Fuel Cooler DH 3 .................................................................................................................. 36
5.2.5 HFO fuel oil diagram ............................................................................................................ 37
5.2.6 Heavy fuel oil supply- and booster standard module .................................................... 38
5.2.6.a Primary filter ......................................................................................................................... 38
5.2.6.b Fuel pressure pumps, vertical installation ...................................................................... 38
5.2.6.c Pressure regulating system ............................................................................................... 38
5.2.6.d Self cleaning fine filter ........................................................................................................ 38
5.2.6.e Consumption measuring system ........................................................................................ 38
5.2.6.f Mixing tank with accessories ........................................................................................... 38
5.2.6.g Circulating pumps, vertical installation ........................................................................... 38
5.2.6.h Final preheater ..................................................................................................................... 38
5.2.6.i a) Heating medium control valve ...................................................................................... 38
5.2.6.j Viscosity control system .................................................................................................... 38
5.2.6.k Cooler .................................................................................................................................... 38
5.2.7 Heavy fuel oil supply- and booster standard module – diagram ................................. 40
5.3 Lubricating oil system ........................................................................................................ 41

5.3.1 Lubricating oil quality ......................................................................................................... 41
5.3.2 Lubricating oil quantities/-change intervals ................................................................... 42
5.3.3 Lubricating oil components ............................................................................................... 42
5.3.3.a Force pump (fitted) LP 1 ..................................................................................................... 42
5.3.3.b Strainer (fitted) LF 4 ............................................................................................................. 42
5.3.3.c Selfcleaning filter (separate) LF 2 ..................................................................................... 42
5.3.3.d Protection strainer (fitted) LF 3 ......................................................................................... 43
5.3.3.e Cooler (separate) LH 1 ......................................................................................................... 43
5.3.3.f Temperature controller (separate) LR 1............................................................................ 43
5.3.3.g Prelubricating pump (fitted) LP 5 ....................................................................................... 43
5.3.3.h Prelubricating pump ............................................................................................................ 44
5.3.3.i Circulating tank LT 1 ............................................................................................................. 44
5.3.3.j Crankcase ventilation .......................................................................................................... 44
5.3.3.k Treatment at MGO/MDO operation .................................................................................. 44
5.3.3.l Treatment at HFO operation................................................................................................ 44
5.3.4 Lubricating oil system diagram ......................................................................................... 45
5.3.5 Lubricating oil module (optional) ...................................................................................... 46
5.4 Cooling water system ........................................................................................................ 47

5.4.1 Cooling water system components .................................................................................. 47
5.4.1.a Two-circuit cooling ............................................................................................................. 47
5.4.1.b LT-cooling water pump FP 4/FP 6 ...................................................................................... 47
5.4.1.c HT-cooling water pump FP 3/FP 5 ...................................................................................... 47
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5.4.1.d HT-temperature controller (separate) FR 1 ..................................................................... 47
5.4.1.e LT-temperature controller (separate) FR 2 ....................................................................... 48
5.4.1.f Preheater (fitted on base frame) FH 5/FP 7 .................................................................... 48
5.4.1.g HT-cooler (separate) FH 1 ................................................................................................... 48
5.4.1.h LT-cooler (separate) FH 2 .................................................................................................... 48
5.4.1.i Header tank (separate) FT 1/FT 2 ....................................................................................... 49
5.4.1.j Drain tank with filling pump ................................................................................................ 49
5.4.1.k Electric motor driven pumps .............................................................................................. 49
5.4.2 Heat balance 12CM32C – 6,000 kW / 720 rpm ................................................................. 50
5.4.6 Heat balance 12CM32C – 6,720 kW / 720 rpm .................................................................. 52
5.4.10 HT- and LT- pump system ................................................................................................... 54
5.4.11 Central cooling system ....................................................................................................... 55
5.4.12 Central cooling module (optional) ..................................................................................... 56
5.5 Starting air system .............................................................................................................. 57

5.5.1 Quality requirements of starting air at engine inlet connection C86 ........................... 57
5.5.2 Requirement of classification societies (regarding design) ........................................ 58
5.5.3 Starting air components ...................................................................................................... 58
5.5.3.a Compressor AC 1/ AC 2 ...................................................................................................... 59
5.5.4 Starting air system diagram .............................................................................................. 59
5.6 Combustion air system ....................................................................................................... 60

5.6.1 General .................................................................................................................................. 60
5.6.2 Air intake from engine room (standard) ........................................................................... 60
5.6.3 Air intake from outside ....................................................................................................... 60
5.6.4 Radiated heat ....................................................................................................................... 60
5.7 Exhaust gas system ............................................................................................................ 61

5.7.1 Starting air components ..................................................................................................... 61
5.7.2 Exhaust sound level ............................................................................................................ 62
5.7.3 Exhaust gas data (preliminary) ......................................................................................... 63
5.7.4 Silencer ................................................................................................................................. 65
5.7.5 Turbo charger cleaning ...................................................................................................... 67
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6.0 Air borne sound power level ....................................................................... 68
6.1 Noise level for 12CM32C engines .................................................................................... 68
6.2 Noise level for 16CM32C engines .................................................................................... 68
7.0 Foundation ....................................................................................................... 69
7.1 Structure borne level Lv, expected (measured in the test cell) ................................. 69
7.2 Foundation plan ................................................................................................................... 70
8.0 Control and monitoring system .................................................................... 71
8.1 LESS cabinet ........................................................................................................................ 71
8.2 Blockdiagram LESS ........................................................................................................... 72
8.3 LESS control and monitoring system .............................................................................. 73
8.4 Speed control ...................................................................................................................... 74
8.5 Location of engine control panel ..................................................................................... 75
8.6 Measuring points ................................................................................................................ 76
8.7 Remote indication interfacing .......................................................................................... 81
9.0 Condition monitoring ..................................................................................... 82
10.0 Factory acceptance test (FAT) ..................................................................... 84
11.0 Engine international air pollution prevention certificate ...................... 85
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12.0 Painting/Preservation ................................................................................... 86
12.1 Inside preservation ............................................................................................................. 85

12.1.1 Works standard N 576-3.3 ................................................................................................... 85
12.2.2 Works standard clear varnish N 576-4.1 .......................................................................... 86
12.2.3 Works standard painting N 576-4.3 ................................................................................... 86
12.2.4 Works standard VCI packaging N 576-5.2 ........................................................................ 87
12.3 Works standard information panel ................................................................................... 88
12.4 Protection period, check, and represervation N 576-6.1 .............................................. 88

12.4.1 Protection period .................................................................................................................. 88
12.4.2 Protection check .................................................................................................................. 88
12.4.3 Represervation N 576-6.1 .................................................................................................... 88
13.0 Appendix ......................................................................................................... 89
13.1 Exhaust system .................................................................................................................... 89
13.2 Fuel oil system ...................................................................................................................... 90
13.3 Cooling water system ........................................................................................................ 91
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1 | Engine description
1.1. Engine description
The CM32 is a four stroke diesel engine, turbocharged and intercooled with direct fuel
injection.
V-engine CM32
A5 A6 A7 A8
A1 A2 A3 A4
8
B6 B7 B
B4 B5
B1 B2 B3
Free
end
Driving
end
Output/cyl.: 500 kW Output/cyl.: 560 kW*

Cylinder configuration 12, 16 12, 16
Bore 320 mm 320 mm
Stroke 460 mm 460 mm
Stroke/Bore-Ratio 1.44 1.44
Swept volume 37 l/Cyl. 37 l/Cyl.
BMEP 22.5/21.6 bar 25.2/24.2 bar
Revolutions 720/750 rpm 720/750 rpm
Mean piston speed 11.0/11.5 m/s 11.0/11.5 m/s
Turbocharging Single pipe Single pipe
Direction of rotation counter clockwise counter clockwise
* MDO operation only
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1 | Engine description
1.2 Engine design features
O Designed for heavy fuel operation up to 700 cSt/50 °C, fuel grade acc. to CIMAC
H55 K55, ISO 8217, 1996 (E), ISO-F-RMH55 RMK55 for 500 kW/cyl. only.
O 1-piece dry engine block made of nodular cast iron. It incorporates the
crankshaft bearings, camshaft bearings, charge air receiver, vibration damper
housing and gear drive housing.
O Underslung crankshaft with corrosion resistant main and big end bearing
shells.
O Natural hardened liners, centrifugally casted, with calibration insert.
O Composite type pistons with steel crown and nodular cast iron skirt or steel
skirt.
O Piston ring set consisting of 2 chromium plated compression rings, first ring
with chromium-ceramic plated running surfaces and 1 chromium plated oil
scraper ring. All ring grooves are located in the steel crown. The first ring
groove is chromium plated. The other ring grooves are hardened.
O 3-piece marine design connecting rod with the possibility to dismount the
piston without opening the big end bearing.
O Cylinder head made of nodular cast iron with 2 inlet and 2 exhaust valves with
valve rotators.
Directly cooled exhaust valve seats.
O Camshaft made of sections per cylinder allowing a removal of the pieces side-
ways.
O Turbocharger supplied with inboard plain bearings lubricated by engine lubri-
cating oil.
O 2-stage fresh water cooling system with 2-stage charge air cooler.
O Nozzle cooling for heavy fuel operation only with engine lubricating oil.
2 CM32 – Generator Set – Oil & Gas 01.2014

2 | General data and outputs
2.1 General data and outputs
12CM32C 16CM32C
Unit 500 kW/cyl. 560 kW/cyl. 500 kW/cyl. 560 kW/cyl.
Frequency Hz 50 60 50 60 50 60 50 60
Speed rpm 750 720 750 720 750 720 750 720
kW 6,000 6,000 6,720 6,720 8,000 8,000 8,960 8,960
Engine rating kWe 5,820 5,820 6,518 6,518 7,760 7,760 8,691 8,691
kVA 7,275 7,275 8,148 8,148 9,700 9,700 10,864 10,864
Mean eff. pressure bar 21.6 22.5 24.2 25.2 21.6 22.5 24.2 25.2
Mean piston speed m/s 11.5 11.0 11.5 11.5 11.5 11.5 11.5 11.5
Swept Volume l 444 444 444 444 592 592 592 592
Remark:
The generator outputs are based on 97 % efficiency and a power factor of 0.8.
2.1.1. Output definition
The maximum continuous rating (locked output) stated by Caterpillar Motoren refers
to the following reference conditions according to “IACS” (International Association
of Classification Societies) for main and auxiliary engines:
Reference conditions according to IACS (tropical conditions):

air pressure 100 kPa (1 bar)
air temperature 318 K (45 °C)
relative humidity 60 %
seawater temperature 305 K (32 °C)
An overload of 10 % is permitted for one hour within 12 hours of operation.

The blocking will be fixed to 10 % above the maximum continuous rating.

2.1.2 Fuel consumption
The fuel consumption data refer to the following reference conditions:

O intake temperature 298 K (25 °C)
O charge air temperature 318 K (45 °C)
O charge air coolant inlet temperature 298 K (25 °C)
O net heating value of the Diesel oil 42,700 kJ/kg
O tolerance of the stated consumption data 5%
O Specification of the fuel consumption data without built on pumps;
for each pump fitted on an additional consumption of 1 % has to be calculated.
2.1.3 Lubricating oil consumption
Actual data can be taken from the technical data sheet next page.
2.1.4 Soot- and nitrogen oxide emissions (IMO II NOx-values)

NOx-limit values according to MARPOL 73/78 Annex VI: 9.0 g/kWh (n = 720 rpm)
9.0 g/kWh (n = 750 rpm)
Generator according to cycle E2 and D2 will be fulfilled.
In combination with "Flex Cam Technology" (FCT) the soot emission will be lower than
0.5 FSN in the operation range between 10 and 100 % load.
For details see page 15.

2.1.5 Technical data for HFO, crude oil and MDO operation, 12/16 CM32C – 500 kW/cyl.
500 kW/cyl.
60 Hz 50 Hz 60 Hz 50 Hz
Performance Data Unit 12 12 16 16
Maximum continous rating acc. ISO 3046/1 kW 6,000 6,000 8,000 8,000
Speed 1/min 720 750 720 750
Brake mean effektive pressure bar 22.5 21.6 22.5 21.6
Charge air pressure bar 3.25 3.4 3.3 3.5
Firing pressure bar 200 200 200 200
Combustion air demand (ta = 20 °C) m3/h 34,400 35,005 46,135 47,050
Specific fuel oil consumption 100% g/kWh 178 179 178 179
2)
n = const 85% g/kWh 177 179 177 179
75% g/kWh 179 180 179 180
50% g/kWh 189 190 189 190
Lubricating oil consumption 3) g/kWh 0.6 0.6 0.6 0.6
NOx emission 7) g/kWh 9 9 9 9
ABB ABB ABB ABB
Turbocharger type TPL65 TPL65 TPL65 TPL65
Fuel
Stand-by booster pump m3/h 3.9/10 4.2/10 5.2/10 5.4/10

Mesh size MDO fine filter mm 0.025 0.025 0.025 0.025
Mesh size HFO automatic filter mm 0.010 0.010 0.010 0.010
Mesh size HFO fine filter mm 0.034 0.034 0.034 0.034
Nozzle cooling by lubricating oil system
Lubricating Oil
Engine driven pump m3/h/bar 161.3/10 168/10 161.3/10 168/10

Independent pump m3/h/bar 120/10 120/10 160/10 160/10
Working pressure on engine inlet bar 4-5 4-5 4-5 4-5
3
Priming pump m /h/bar 12/5 12/5 16/5 16/5
Sump tank content/dry sump content m3 7.6 8.0 10.0 10.8
Temperature at engine inlet °C 60 - 65 60 - 65 60 - 65 60 - 65
Temperature controller NB mm 125 125 150 150
Double filter NB mm 125 125 125 125
Mesh size double filter mm 0.08 0.08 0.08 0.08
Mesh size automatic filter mm 0.03 0.03 0.03 0.03
1) -
2) Reference conditions: LCV = 42,700 kJ/kg, ambient temperature 25 °C charge air coolant temperature 25 °C,
tolerance 5 %, + 1 % for engine driven pump
3) Standard value , tolerance + 0.3 g/kWh,related on full load
4) Charge air heat based on 45 °C ambient temperature
5) Preheated engine
6) Tolerance 10% , rel. humidity 60%
7) Marpol 73/78, annex VI, cycle E2,D2

2.1.5 Technical data for HFO, crude oil and MDO operation 12/16 CM32C – 500 kW/cyl.
500 kW/cyl.
60 Hz 50 Hz 60 Hz 50 Hz
Fresh water cooling Unit 12 12 16 16
Engine content m3 1.4 1.4 1.9 1.9

Pressure at engine inlet min/max bar 2.5/6.0 2.5/6.0 2.5/6.0 2.5/6.0
Header tank capacity m3 0.7 0.7 1 1
Temperature at engine outlet °C 80 - 90 80 - 90 80 - 90 80 - 90
Two circuit system

Engine driven pump HT m3/h/bar 100/4.6 100/4.6 130/4.5 130/4.5
Independent pump HT m3/h/bar 100/4.0 100/4.0 130/4.0 130/4.0
HT-Controller NB mm 125 125 150 150
Water demand LT-charge air cooler m3/h 80 80 100 100
Temperature at LT-charge air cooler inlet °C 38 38 38 38
Heat Dissipation
Specific jacket water heat kJ/kW 500 500 500 500

Specific lub. oil heat kJ/kW 525 525 525 525
Lub. oil cooler kW 875 875 1,167 1,167
Jacket water kW 835 835 1,115 1,115
Charge air cooler (HT-Stage) 4) kW 2,010 2,210 2,732 2,875
Charge air cooler (LT-Stage) 4) kW 384 450 501 650
(HT-Stage before engine)
Heat radiation engine kW 260 260 347 347
Exhaust gas
Silencer/spark arrester NB mm 900 900 1000 1000

Pipe diameter NB after turbine mm 2x600 2x600 2x700 2x700
Maximum exhaust gas pressure drop bar 0.03 0.03 0.03 0.03
Exhaust gas temp. after turbine °C 317 310 311 305
(intake air 25°C) 6)
Exhaust gas mass flow (intake air 25°C) 6) kg/h 42,520 43,266 57,020 58,160
Starting air
Starting air pressure max. bar 30 30 30 30

Minimum starting air pressure bar 10 10 10 10
Air consumption per start 5) Nm3 1.2 1.2 1.2 1.2
Max.allowed crank case pressure, mmWs/mm 15/125 15/125 15/125 15/125
ND ventilationspipe
1) -
5) Preheated engine

2.1.5 Technical data for MDO operation, 12/16 CM32C – 560 kW/cyl.
560 kW/cyl.
Preliminary Data 60 Hz 50 Hz 60 Hz 50 Hz
Performance Data Unit 12 12 16 16
Maximum continous rating acc. ISO 3046/1 kW 6720 6720 8960 8960
Speed 1/min 720 750 720 750
Brake mean effektive pressure bar 25,2 24,2 25,2 24,2
Charge air pressure bar 3,72 3,74 3,72 3,74
Firing pressure bar 215 215 215 215
Combustion air demand (ta = 20 °C) m3/h 36400 37520 48535 50050
Specific fuel oil consumption 100% g/kWh 178 179 181 182
2)
n = const 85% g/kWh 177 179 177 179
75% g/kWh 179 180 179 180
50% g/kWh 189 190 189 190
Lubricating oil consumption 3) g/kWh 0,6 0,6 0,6 0,6
NOx emission 7) g/kWh 9 9 9 9
Turbocharger type TPL65 TPL65 TPL65 TPL65
Fuel
Stand-by booster pump m3/h 3,9/10 4,2/10 5,2/10 5,4/10

Mesh size MDO fine filter mm 0,025 0,025 0,025 0,025
Mesh size HFO automatic filter mm 0,010 0,010 0,010 0,010
Mesh size HFO fine filter mm 0,034 0,034 0,034 0,034
Nozzle cooling by lubricating oil system No No No No
Lubricating Oil
Engine driven pumpe m3/h/bar 161,3/10 168/10 161,3/10 168/10

Working pressure on engine inlet bar 4-5 4-5 4-5 4-5
Pre lube pump m3/h/bar 12/5 12/5 16/5 16/5
Required lube tank content m3 7,6 8,0 10,0 10,8
with engine dry sump
Temperature at engine inlet °C 60 - 65 60 - 65 60 - 65 60 - 65
Temperature controller NB mm 125 125 150 150
Double filter NB mm 125 125 125 125
Mesh size double filter mm 0,08 0,08 0,08 0,08
Mesh size automatic filter mm 0,03 0,03 0,03 0,03
1) -
5) Preheated engine

2.1.5 Technical data for MDO operation, 12/16 CM32C – 560 kW/cyl.
560 kW/cyl.
Preliminary Data 60 Hz 50 Hz 60 Hz 50 Hz
Fresh water cooling Unit 12 12 16 16
Engine content m3 1,4 1,4 1,9 1,9

Pressure at engine inlet min/max bar 2,5/6,0 2,5/6,0 2,5/6,0 2,5/6,0
Header tank capacity m3 0,7 0,7 1 1
Temperature at engine outlet °C 80 - 90 80 - 90 80 - 90 80 - 90
Two circuit system

Engine driven pump HT m3/h/bar 100/4,6 100/4,6 130/4,5 130/4,5
Independent pump HT m3/h/bar 100/4,0 100/4,0 130/4,0 130/4,0
HT-Controller NB mm 125 125 150 150
Water demand LT-charge air cooler m3/h 80 80 100 100
Temperature at LT-charge air cooler inlet °C 38 38 38 38
Heat Dissipation
Specific jacket water heat kJ/kW 500 500 500 500

Specific lub. oil heat kJ/kW 525 525 525 525
Lub. oil cooler kW 980 980 1307 1307
Jacket water kW 933 933 1244 1244
Charge air cooler (HT-Stage) 4) kW 2087 2151 2783 2868
Charge air cooler (LT-Stage) 4) kW 596 625 795 833
(HT-Stage before engine)
Heat radiation engine kW 260 260 347 347
Exhaust gas
Silencer/spark arrester NB mm 900 900 1000 1000

Pipe diameter NB after turbine mm 2x600 2x600 2x700 2x700
Maximum exhaust gas pressure drop bar 0,03 0,03 0,03 0,03
Exhaust gas temp. after turbine °C 338 329 340 330
(intake air 25°C) 6)
Exhaust gas mass flow (intake air 25°C) 6) kg/h 44,990 46,375 59870 61,833
Starting air
Starting air pressure max. bar 30 30 30 30

Minimum starting air pressure bar 10 10 10 10
Air consumption per start 5) Nm3 1,2 1,2 1,2 1,2
Max.allowed crank case pressure, mmWs/mm 15/125 15/125 15/125 15/125
ND ventilationspipe
1) -
5) Preheated engine

2.2 Generator set dimensions and weights depend on generator type
and technical requirements
Dimensions [mm] 1) – example only Weight [t] 1)

Engine Type A B C D E F
12CM32C 10,980 9,160 3,395 2,320 3,142 2,450 127.1
16CM32C 12,420 10,510 3,351 2,310 3,750 2,450 149.9
1)
Dimensions and weights vary depending on generator type
Prime mover and generator are always flexibly coupled.

2.3 Restrictions for low load operation and stand-by mode
Low load operation
An unrestricted low load operation is permitted with diesel oil.
Below 25 % rated output diesel oil operation is neither efficient nor economical.
A change-over to diesel oil avoids disadvantages as e.g. increased wear and tear,
contamination of the air and exhaust gas systems and increased contamination
of lube oil.
Low load below 25 % rated output over prolonged periods usually occurs only during
laytime operation in the harbour. These duties are best carried out by means of
harbour gensets or the emergency diesel genset.
Thus, change-over to diesel oil is practically limited to "cleaning runs" of the injection
system for maintenance purposes.
Cleaning run of engine
3h 2 1h 30 min 15 min 0
PE %
100
Cleaning run after partial load operation
70
50 Load increase period

40 approx. 15 min.
30
20
HFO-operation
15
10
8
6 Restricted HFO-operation
1h 2 3 4 5 6 8 10 15 20 24 h

2.3 Restrictions for low load operation and stand-by mode
Stand-by mode
Start and stop with heavy fuel is generally permissible.
The following conditions have to be met for stand-by mode:
The HFO system of the engine remains in operation and keeps the HFO at injection
viscosity. The temperature of the engine injection system is maintained by the
circulating hot HFO and heat losses are compensated.
Prelubrication is to be continuous.
The lube oil treatment system (lube oil separator) remains in operation, the lube oil
is separated continuously.
The operating temperature of the engine cooling water is maintained by the cooling
water preheater.
Emergency operation in the event of a black-out (with gravity feed fuel)

Emergency operation with gravity feed fuel from the MDO day tank in the event of
a black-out is permissible under the following conditions inst for starting procedure
of the genset with MDO:
O Bottom edge of MDO day tank DT 1 is arranged at least 4 m above injection pump
level

2.4 Load application and recovery behaviour
The permissible load increase according to ISO 8528-5 and IACS must be carried
out in several steps, depending on the mean effective pressure. The vessel‘s
network must be designed so that this permissible load increase is kept. The
yard has to provide the approval of the responsible classification society in time
before classification acceptance of the engine.
Guide values for maximum possible sudden power increase as a function of brake
mean effective pressure, pme at declared power.
Recovery behaviour after a sudden load increase according to load steps depen-
ding on pme / unloading corresponding ISO 8528-5.

60Hz 720 rpm 50Hz 750 rpm
kW 6000 6720 8000 8960 6000 6720 8000 8960
kW/cyl. 500 560 500 560 500 560 500 560
cyl. 12 12 16 16 12 12 16 16
BMEP 22,5 25,2 22,5 25,2 21,6 24,2 21,6 24,2
Load steps Load Steps
1st 0–36% 0–31% 0–36% 0–31% 0–37% 0–32% 0–37% 0–32%
2nd 36–59% 31–52% 36–59% 31–52% 37–62% 32–55% 37–62% 32–55%
3rd 59–80% 52–72% 59–80% 52–72% 62–83% 55–75% 62–83% 55–75%
4th 80–100% 72–100% 80–100% 72–100% 83–100% 75–100% 83–100% 75–100%
Power steps Power application kW
1st 2160 2083 2880 2778 2220 2150 2960 2867
2nd 1380 1411 1840 1882 1500 1546 2000 2061
3rd 1260 1344 1680 1792 1260 1344 1680 1792
4th 1200 1882 1600 2509 1020 1680 1360 2240
110
oad increase referred to continous rating [%] ĺ
4. load step
100
90
3. load step
80
70
2. load step
60
50
1. load step
40
30
Load
20
10
0
4 6 8 10 12 14 16 18 20 22 24 26
28 30
BMEP at cont. rating of diesel engine [bar] ĺ
Example: For BMEP 21.6, 16CM32C, 8,000 kW, 750 rpm

1. max. load from 0% to 37% MCR 3. max. load from 63% to 83% MCR
2. max. load from 38% to 62% MCR 4. max. load from 84% to 100% MCR
Different load steps on request.

2.4 Load application and recovery behaviour
2.4.1 Speed control of auxiliary generating sets / DE - drive
Electronic governor system

Standard
Regulateurs Europe (RE)
Type: Actuator 2221
Governor Viking 35
Option
Woodward
Type: Actuator UG 40
Governor WW 723+
The engine is equipped with an actuator without mech. back-up governor.
The electronic governor is installed inside the protection system cabinet.
On request the governor can be delivered as a separate part for installation
by the shipyard at a suitable place.
The governor comprises the following functions:
O Speed setting range to be entered via parameters

O Adjustable acceleration and decelaration times
O Adjustable synchronizing ramp rates
O Starting fuel limiter
O Input for stop (not emergency stop)
O 18 - 32 V DC voltage supply
O Alarm output
O Isochronous load sharing by master / slave princip
O Droop operation selectable

2.5 Flexible Camshaft Technology - FCT (option)
Building upon the emission reduction system integration concept, FCT achieves
synergy between flexible fuel systems and advanced air systems with maximum
utilization of the current engine design. While maintaining high fuel injection
pressure over the whole operating range, fuel injection and inlet valve timing are
load controlled and influenced by a lever shaft which affects injection timing/pres-
sure and inlet valve events. Valve timing changes at part load to raise effective
compression and enhance complete combustion. In addition, shifting the relative
position of the lever to the fuel cam increases injection pressure, producing a finer
atomization of fuel in a load range where it would otherwise be difficult to control
smoke.
2,0
IMO II IMO I
max. Soot Emissions (FSN)
1,5
Baseline
Valve Lift
1,0
FCT
0,5
Low NOx
Invisible Smoke Low
Smoke 90 180 270 360 450 540 630
0
Crank Angle (°)
6 7 8 9 10 11 12 13
NOx Emissions Cycle Value (g/kWh)
Soot Emission of CM32 IMO II

Soot Emission (FSN)
IMO II with FCT

Plunger Speed
IMO II w/o FCT

IMO I
TDC
Crank Angle (°)
Power output
CM32 constant speed

3 | Installation and Arrangement
3.1 General installation aspect
Inclination angles of vessels at which engine running must be possible:
Rotation X-axis:
Static: heel to each side: 15°
Dynamic: rolling to each side: 22.5°
Rotation Y-axis:
Static: trim by head and stern: 5°
Dynamic: pitching: + 7.5°
3.2 25 degree tilt capability

The CM32 newest feature incorporates a 25 degree tilt capability in all
directions. This feature was especially developed for jackup platforms and
semi-submersibles used by the offshore industry.
The tilt capability is a requirement by ABS/DNV classification societies and the
Norwegian Marine Directorate.
For details see next page.

3.3 Rules of classification societies
Semi-submersible / Column-stabilized
Angle of Inclination
Classification Society Equipment Propulsion
Static Dynamic
For essential service 15° 22.5°
ABS Offshore Rules
For emergency purpose 15° 22.5°
self propelled 22.5° in any direction
For essential service 15° in any direction
not propelled No requirement
BV Offshore Rules
self propelled
For emergency purpose 25° in any direction No requirement
not propelled
Main and auxilliary machinery 15° 22.5°
DNV Offshore Rules
For emergency purpose 15° 25°
Self-elevating units
Static Dynamic
For essential service 10° 15°
ABS Offshore Rules
self propelled 15° in any direction
BV Offshore Rules
self propelled
not propelled
DNV Offshore Rules
Surface units / Ship-shaped types
Static Dynamic
For essential service 15° 22.5°
ABS Offshore Rules
For emergency purpose 15° 22.5°
self propelled 22.5° in any direction
BV Offshore Rules
self propelled
not propelled
DNV Offshore Rules

3.4 Required dimensions of generator.
Generators structural requirements for diesel generator sets CM32
O Mounting flap for anti-condensation heater above the mounts.

O With air cooling the air outlet above the mounts.
O CL height "H" max. permissable deviation and the parallelis tolerance acc. to DIN 747.
O The mounts are to be designed with 4 alignment screws (l = 200).
O Plain bearings must be removable without coupling removal.
Dimensions depend on generator type and technical requirements.

3.5 Space requirement for dismantling of turbocharger cartridge and
vibration damper, charge air cooler cleaning
3.5.1 12CM32C
Turbocharger dismantling Charge air cooler cleaning

Engine R [mm] Weight [kg] Dimension of cooler
12CM32C 1,866 160 Length: 2,010 mm
Width: 536 mm
Height: 716 mm
Weight: 1,100 kg
Cleaning is carried out with charge air cooler dismantled.
A container to receive the cooler and cleaning liquid is to be
supplied by the yard. Intensive cleaning is achieved by using
ultra sonic vibrators.
Removal of: Vibration damper dismantling

Piston and cylinder liner The vibration damper is arranged at the free end of the engine.
in transverse direction X = 5,155 mm
min. centre distance of 2 gensets: 3,500 mm
Engine Type Diam. [mm] Width [mm] Weight [kg]
12CM32C 800 90 273

3.5 Space requirement for dismantling of turbocharger cartridge and
vibration damper, charge air cooler cleaning
3.5.2 16CM32C
Turbocharger dismantling Charge air cooler cleaning

Engine R [mm] Weight [kg] Dimension of cooler
16CM32C 1,115 211 Length: 2,010 mm
Width: 536 mm
Height: 716 mm
Weight: 1,100 kg
Cleaning is carried out with charge air cooler dismantled.
A container to receive the cooler and cleaning liquid is to be
supplied by the yard. Intensive cleaning is achieved by using
ultra sonic vibrators.
Vibration damper dismantling

The vibration damper is arranged at the free end of the engine.
Engine Type Diam. [mm] Width [mm] Weight [kg]

16CM32C 800 114 335
Removal of piston and cylinder liner see previous page.


3.6 Engine parts
Cylinder head, Weight 345 kg Cylinder liner, Weight 266 kg
Connecting rod, Weight 241 kg Piston, Weight 150 kg
123
1353
573
496
120

3.7 System connections, Example for seawater cooled generator
C12 C13 C91 C91a
C14
C15
C25
C 12 Generator Cooler, Inlet n.n.

C 13 Generator Cooler, Outlet n.n.
C 14 Charge Air Cooler LT, Inlet DN 125
C 15 Charge Air Cooler LT, Outlet DN 125
C 21 HT Freshwater Pump HT, Inlet DN 125
C 25 Manifold, Outlet DN 125
C 55 Lube Oil Inlet Protective Filter DN 150
C 55c Connection Flushing Pipe Automatic Filter DN 50
C 58 Lube Oil Force Pump, Outlet DN 150
C 60 Separator Connection Suction Side DN 50
C 61 Separator Connection Delivery Side DN 50
C 65 Lube Oil Filling Socket DN 50
C 76 Fuel Inlet, Duplexfilter DN 50
C 78 Fuel Outlet DN 50
C 86 Starting Air DN 40
C 91 Crankcase Ventilation DN 125
C 91a Exhaust Gas Outlet 12/16CM32C DN 700

3.8 Lifting of generator set
For the purpose of transport the generator set is equipped with a lifting device
which shall remain the property of Caterpillar Motoren. It has to be returned in a
useable condition free of charge.
adjustable screw
max. adjustment range

min. adjustment range
Weights Assembly instruction

12 cyl. generator set 127.1 t* Mount the subassembly engine according to the rules.
Align lifting device (1, 2, 3) according to instruction
16 cyl. generator set 149.9 t*
and hang up on engine and base frame (7, 8).
Lifting device 9.5 t*
Caution!
* Weights vary depentding on When lifting up generator set minimize inclination by
generator type. adjusting of lifting device.

4 | Safety Equipment
4.1 Hot-box ventilation for crude oil operation only
When operating diesel engines with crude oil it is necessary to avoid the presence of
gas from crude oil leaks in the injection pump housing.
For this purpose the complete area of the injection pumps is covered with a protec-
tive casing. Mounted on these casings (bank A and B of V-engines) is the air intake
manifold that has flexible connections for the required pipes, which will be routed
into a common pipe out of the engine room.
The pipes after the flexible connection are to be provided by the customer.
In the common pipe after the flexible connections an electrically driven fan is in-
stalled that exhausts the air from the injection pump housing of the engine. Compa-
red to the engine room air pressure, a negative pressure will be inside the pipe. This
is necessary to exhaust the gas from the engine injection pump housing. Due to the
importance of this function, gas and negative pressure will be monitored in the con-
trol system by means of 2 separate sensors (1 x gas sensor, 1 x vacuum sensor).

4 | Safety Equipment
4.2 Air shut-off valve for crude oil operation only
The purpose of air shut-off valves is to stop the engine in case of overspeed. Over-
speed may occur when gaseous fuel is in the engine room and is sucked in by the air
inlet of the turbocharger.
In this case engine can only be stopped by shutting down the air supply with the air
shut-off valves.
Air shut-off valves are placed between the turbocharger and the air inlet housing
of the specific engine. The air shut-off valves are connected and actuated via the
engine air supply.

5 | Systems
5.1 Fuel oil system, MGO/MDO operation
5.1.1 Quality requirements
Two fuel product groups are permitted for Cat engines:
Pure distillates: Gas oil, marine gas oils, diesel fuel
Distillate/mixed fuels: Marine gas oil (MGO), marine diesel oil

(MDO). The difference between dis-
tillate/mixed fuels and pure distillates
are higher density, sulphur content and
viscosity.
MGO MDO
Designation Max. viscosity [cSt/40 °C] Designation Max. viscosity [cSt/40 °C]
ISO 8217: 1996 ISO-F-DMA 1.5 - 6.0 ISO-F-DMB 11
ISO-F-DMC 14
ASTM D 975-78 No. 1 D 2.4 No. 2 D 4.1
No. 2 D 4.1 No. 4 D 24.0
DIN DIN EN 590 8
Max. injection viscosity 12 cSt (2 °E)
5.1.2 MGO/MDO Fuel components
a) Day tank DT 1: To be layed out for heat dissipation from

injection pumps, approx. 1.8 kW/cylinder.
b) Strainer (separate) DF 2: Mesh size 0.32 mm, dimensions see

HFO-system
c) Preheater (separate) DH 1: Heating capacity

Peng. [kW]
Q [kW] =
166
Not required with:

O MGO < 7 cSt/40 °C
O Heated day tank

5 | Systems
5.1.2 MGO/MDO Fuel components
d) Feed pump (separate) DP 1/DP 2: Capacity see technical data

Screw type pump with mechanical seal.
Installation vertical or horizontal.
Delivery head 5 bar.
e) Pressure regulating valve (separate) DR 2: Dimensions see HFO-system/Pressure

regulating valve.
f) Fine filter (fitted) DF 1: Duplex filter, mesh size see technical

data.
g) Separator DS 1: Recommended for MGO

Required for MDO
Capacity
V [l/h] = 0.22 · Peng. [kW]

Marine gas oil / marine diesel oil operation
5 | Systems
5.1.3 MGO/MDO fuel oil diagram
* optional available as fuel oil booster skid General notes:

For location, dimensions and design
(e. g. flexible connection) of the connecting points
Accessories and fittings: see engine installation drawing.
DF1 Fine filter (duplex filter) KP1 Fuel injection pump DH1 not required with:
DF2 Primary filter (duplex filter) KT1 Drip fuel tank - Gas oil < 7 cSt/40°
DF3 Coarse filter - heated diesel oil day tank DT1
DH1 Preheater FQ1 Flow quantity indicator Notes:
DH2 Electrical preheater (separator) LI Level indicator p Free outlet required
DP1 Diesel oil feed pump LSH Level switch high s Please refer to the measuring point list regar-
DP2 Diesel oil standby feed pump LSL Level switch low ding design of the monitoring
DP3 Transfer pump (to day tank) PDI Diff. pressure indicator devices
DP5 Transfer pump (separator) PDSH Diff. pressure switch high Connecting points:
DR2 Pressure regulating valve PI Pressure indicator C76 Inlet, duplex filter
DS1 Separator PT Pressure transmitter C78 Fuel outlet
DT1 Day tank, min. 1 m above crankshaft level TI Temperature indicator C81 Drip fuel
DT4 Storage tank TT Temperature transmitter (PT 100) C81b Drip fuel

5
Requirements for residual fuels for diesel engines (as bunkered)
5.2
5.2.1
CAT_CM32C_Innenteil.indd 29
Designation: CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC
A 10 B 10 C 10 D 15 E 25 F 25 G 35 H 35 K 35 H 45 K 45 H 55 K 55
| Systems
Related to RMA30 RMB30 RMB30 RMD80 RME180 RMF180 RMG380 RMH380 RMK380 RMH500 RMK500 RMH700 RMK700
ISO8217 (2005):F-
Characteristic Dim. Limit
Density at 15 °C kg/m3 max 950 2) 975 3) 980 4) 991 991 1,010 991 1,010 991 1,010
Kin. viscosity max 10 15 25 35 45 55
at 100 °C 1) 5) 5)
cSt min 6 15
Flash point °C min 60 60 60 60 60 60
Pour point
(winter) 0
24 30 30 30 30 30
(summer) °C max 6
Carbon % (m/m) max 12 6) 14 14 15 20 18 22 22 22
Heavy Fuel Oil specification - limit values
residue
(Conradson)
Ash % (m/m) max 0.10 0.10 0.10 0.15 0.15 0.15 7) 0.15 7) 0.15 7)
Total sedim, % (m/m) max 0.10 0.10 0.10 0.10 0.10 0.10
after ageing
Water % (V/V) max 0.5 0.5 0.5 0.5 0.5 0.5
Sulphur % (m/m) max 3.5 4.0 4.5 4.5 4.5 4.5
Vanadium mg/kg max 150 300 350 200 500 300 600 600 600
Aluminium + mg/kg max 80 80 80 80 80 80
silicon
Fuel oil system, HFO and crude oil operation for 500 kW/cyl. only
Zinc mg/kg max 15 15 15 15 15 15

Phosphor mg/kg max 15 15 15 15 15 15
CM32 – Generator Set – Oil & Gas 01.2014

Calcium mg/kg max 30 30 30 30 30 30
1) 2)
An indication of the approximate equivalents in ISO: 975
3)
kinematic viscosity at 50 °C and Redw. I sec. ISO: 981
4)
100 °F is given below: ISO: 985
5)
ISO: not limited
Kinematic viscosity at 100 °C mm2/s (cSt) 7 10 15 25 35 45 55 6)
ISO: Carbon residue 10
Kinematic viscosity at 50 °C mm2/s (cSt) 30 40 80 180 380 500 700 7)
ISO: 0.20
Kinematic viscosity at 100 °F Redw. I sec. 200 300 600 1,500 3,000 5,000 7,000
29
Fuel shall be free of used lubricating oil (ulo)
05.02.14 13:30
5 | Systems
5.2 Fuel oil system, HFO and crude oil operation for 500 kW/cyl. only
5.2.2 Crude oil specification - limit values
Characteristic Dimension Limit Limit Value Notes
Density at 15°C kg/m³ max 1,010 Density is limited due to separator capabilities. Fuels
with higher carbon contents (higher asphaltenes and
carbon residue) are heavier than fuels with lower
carbon content.
Kinematic visco- max 55 Fuel viscosity information is important for the design
sity at 100°C of the fuel system. Fuel viscosity information is used
to size pumps and heating equipment for tanks, pre-
cSt heaters. Fuel viscosity is limited due to the high tempe-
Equivalent kine- max 700
ratures and pressures that are required to process fuel
matic viscosity above the limits indicated.
at 50°C
Flash point °C min 60 The flash point of a fuel is the temperature at which
vapor given off will ignite when an external flame.
A flash point is defined to minimize fire risk during
normal storage and handling.
Pour point °C max 30 The pour point is the lowest temperature at which a
(upper) fuel can be handled without excessive amounts of wax
crystals forming so preventing flow. If a fuel is below
the pour point, wax will begin to separate out which
will block the filters. The wax will also build up on tank
bottoms and on heating coils.
Carbon residue % (m/m) max 22 The carbon residue of a fuel is its tendency to form
(Conradson) carbon deposits under high temperature conditions in
an inert environment. A high carbon residue number
may cause excessive fouling of exhaust system inclu-
ding boilers and may result in increased maintenance.
Ash % (m/m) max 0.15 Ash is the residue after all combustible components
have been burned. Elevated levels of ash can cause
premature component wear.
Total sediment % (m/m) max 0.10
Water % (V/V) max 1.0 Water contamination sources include condensation,

leakage during transport or steam heating. This is ge-
nerally not an issue because water should be removed
by separator. Problems associated with water in the
fuel include:
O Retardation of the combustion
O Dilution of the cylinder liner oil film
O Corrosion of exhaust system components

5 | Systems
5.2 Fuel oil system, HFO and crude oil operation for 500 kW/cyl. only
5.2.2 Crude oil specification - limit values
Characteristic Dimension Limit Limit Value Notes
Sulphur % (m/m) max 5.0 The amount of sulphur in a fuel depends mainly on the
source of the crude. The corrosive effect of the sul-
phuric acid is controlled by the design of the cylinder
head and the use of lube oils as recommended by KEC.
Vanadium mg/kg max 600 Vanadium is present in fuels in soluble form; the level of
vanadium depends mainly on the source of the crude.
Vanadium cannot be removed from the fuel. Vanadium
deposits may cause damage to the turbocharger nozzle
ring and turbine wheel.
Aluminum and mg/kg max 80 Aluminum and Silicon are limited to reduce the level of
silicon catalytic fines (catfines). Catfines cause abrasion and
wear and should be removed. Catfines are removed
during separation and by the fine filter.
Sodium mg/kg NA Not Sodium is typically present in the fuel in the form of
specified seawater. Sodium is normally present at low levels
by CIMAC generally below 50 mg/kg, every additional percent of
seawater increases this by 100 mg/kg. Seawater and
the sodium contaminant is generally removed during
the separation process.
Sodium/vanadi- Not The level of sodium is not specified by CIMAC but the
um ratio specified ratio of Vanadium to Sodium is normally limited to 3/1.
by CIMAC At 600 mg/kg of Vanadium the maximum Sodium level
would be 200 mg/kg.
Reid vapor wPa max 1.0 Reid vapor pressure (RVP) is a common measure of the
pressure psi 0.14 volatility of gasoline. It is defined as the absolute vapor
pressure exerted by a liquid at 100 °F (37.8 °C) as
determined by the test method ASTM-D-323. The test
method applies to volatile crude oil and volatile non-
viscous petroleum liquids, except liquified petroleum
gases.
Total Acid mg KOH/g max 0.5 The Total Acid Number (TAN) is the amount of potassium
Number (TAN) hydroxide in milligrams that is needed to neutralize the
acids in one gram of oil. It is an important quality
measurement of crude oil.
Gum % max 0 The chemical nature of gum is difficult to determine.

A degumming process is required.

5 | Systems
5.2 Fuel oil system, HFO and crude oil operation
5.2.3 Minimum requirements for storage, treatment and supply systems

a) Bunker tanks: In order to avoid severe operational problems due to
incompatibility, each bunkering must be made in a
separate storage tank.
b) Settling tanks: In order to ensure a sufficient settling effect, the
following settling tank designs are permissible:
O 2 settling tanks, each with a capacity sufficient for
24 hours full load operation of all consumers
O 1 settling tank with a capacity sufficient for 36
hours full load operation of all consumers and
automatic filling
O Settling tank temperature 70 - 90 °C
c) Day tank: Two day tanks are required. The day tank capacity
must cover at least 4 hours/max. 24 hours full load
operation of all consumers. An overflow system into
the settling tanks and sufficient insulation are requi-
red.
Guide values for temperatures
Fuel viscosity Tank temperature

cSt/50 °C [°C]
30 - 80 70 - 80
80 - 180 80 - 90
> 180 - 700 max. 98
d) Separators: Caterpillar Motoren recommends to install two

self-cleaning separators. Design parameters as per
supplier recommendation. Separating temperature
98 °C! Maker and type are to be advised to Caterpil-
lar Motoren.

5 | Systems
5.2.3 Minimum requirements for storage, treatment and supply systems

e) Supply system A closed pressurized system between daytank and
(Separate components): engine is required as well as the installation of an auto-
matic back-flushing filter with a mesh size of
10 µm (absolute).
5.2.4 HFO/crude oil components:

a) Strainer HF 2: Mesh size 0.32 mm
DN H1 H2 W D
Output [kW] mm
<= 10,000 40 330 300 250 210
<= 20,000 65 523 480 260 355
> 20,000 80 690 700 370 430
b) Pressurizing pumps HP 1/HP 2: Screw type pump with mechanical seal.

Installation vertical or horizontal. Delivery head
5 bar.
Capacity
. Peng. [kW]
.
V [m3/h] = 0.40
1,000

5 | Systems

c) Pressure regulating valve HR 1: Controls the pressure at the engine inlet, approx. 4 bar.
Engine outputs
<= 8,000 kW > 8,000 kW
d) Self cleaning filter HF 4: Mesh size 10 µm sphere passing mesh, make Boll
& Kirch*, without by-pass filter.
* In case of Caterpillar Motoren supply.
<
= 8,000 kW, Type 6.60, DN 50 > 8,000 kW, Type 6.64, DN 100
Dismantling of sieve
600 mm
Dismantling of sieve
300 mm

5 | Systems

e) Mixing tank HT 2:
Vent
Engine output Volume Dimensions [mm] Weight

Inlet [kW] [l] A D E [kg]
from <= 10,000
pressure 100 1,700 323 1,500 120
pump From
engine > 10,000 200 1,700 406 1,500 175
Outlet
to engine
f) Circulating pumps HP 3/HP 4: Design see pressure pumps.
Capacity
. Peng. [kW]
.
V [m3/h] = 0.7 1,000
Design head: 5 bar.
g) Final preheater HH 1/HH 2: Heating media:

O Electric current (max. surface power density 1.1 W/cm2)
O Steam
O Thermal oil
Temperature at engine inlet max 150 °C.
h) Viscosimeter HR 2: Controls the injection viscosity to 10 - 12 cSt.
i) Fine filter (fitted) HF 1: O Mesh size 34 µm

O Without heating
O Differential pressure indication and alarm contact fitted

5 | Systems

j) Mixing receiver HT 4: Permits the individual change-over to MGO/
MDO. Reduces the temperature variation
during change over.
Capacity: approx. 30 l
Dimensions: Ø approx. 325 mm
height approx. 755 mm
without insulation
k) Diesel oil intermediate tank DT 2: Required for the individual change-over to

MGO/MDO.
Capacity: approx. 50 l
Dimensions: Ø approx. 325 mm
height approx. 850 mm
l) Diesel oil feed pump DP 1: Capacity and delivery head

see heavy fuel oil circulating pump HP 3/HP 4
m) Fuel cooler DH 3: Necessary for heat dissipation under diesel oil

operation with low viscosity (< 10 cSt/40 °C).
The injection pumps are supplying the fuel oil
with heat, which is not carried off sufficiently
by the recirculation. In MDO systems the
cooling can be carried out via the day tank.

5 | Systems
5.2.5 HFO Diagram
C76 C78
- Peak pressure max. 16 bar
Notes:
Accessories and fittings: ff Flow velocity in circuit system < 0.5 m/s
DH3 MGO/MDO cooler FQ1 Flow quantity indicator p Free outlet required
DT1 Diesel oil day tank LI Level indicator s Please refer to the measuring point list
HF1 Fine filter (duplex filter) LSH Level switch high regarding design of the monitoring devices
HF2 Primary filter LSL Level switch low tt Neither insulated nor heated pipe
HF3 Coarse filter PDI Diff. pressure indicator u From diesel oil separator or diesel oil transfer pump
HF4 Self cleaning filter PDSH Diff. pressure switch high
HH1 Heavy fuel final preheater PDSL Diff. pressure switch low All heavy fuel pipes have to be insulated.
HH2 Stand-by final preheater PI Pressure indicator ---- heated pipe
HH3 Heavy fuel preheater (separator) PT Pressure transmitter
HH4 Heating coil TI Temperature indicator Connecting points:
HP1/HP2 Pressure pump TT Temperatur transmitter (PT100) C76 Inlet duplex filter
HP3/HP4 Circulating pump VI Viscosity indicator C78 Fuel outlet
HP5/HP6 Heavy fuel transfer pump (separator) VSH Viscosity control switch high C81 Drip fuel
HR1 Pressure regulating valve VSL Viscosity control switch low C81b Drip fuel (filter pan)
HR2 Viscometer
HS1/HS2 Heavy fuel separator General notes:
HT1 Heavy fuel day tank For location, dimensions and design (e. g. flexible connection) of the connecting points see engine
HT2 Mixing tank installation drawing.
HT5/HT6 Settling tank If a "Fuel oil supply and booster module" is supplied by Caterpillar Motoren, arrangement and scope
KP1 Injection pump of the supply components are to be gathered from the module schema.
KT2 Sludge tank Valve fittings with loose cone are not accepted in the admission and return lines.

5 | Systems
5.2.6 Heavy fuel oil supply- and booster standard module

(Pressurized System), up to IFO 700 for steam and thermaloil heating, up to IFO 180
for electr. heating
Technical specification of the main components:
a) Primary filter
1 pc. Duplex strainer 540 microns
b) Fuel pressure pumps, vertical installation

2 pcs. Screw pumps with mechanical seal
c) Pressure regulating system

1 pc. Pressure regulating valve
d) Self cleaning fine filter

1 pc. Automatic self cleaning fine filter 10 microns absolut (without by-pass filter)
e) Consumption measuring system

1 pc. Flowmeter with local totalizer
f) Mixing tank with accessories

1 pc. Pressure mixing tank approx. 49 l volume up to 4,000 kW
approx. 99 l volume from 4,001 - 20,000 kW
(with quick-closing valve)
g) Circulating pumps, vertical installation
2 pcs. Screw pumps with mechanical seal
h) Final preheater
2 pcs. Shell and tube heat exchangers each 100 % (saturated 7 bar or thermal oil
180 °C)
each 100 % electrical
i) a) Heating medium control valve (steam/thermaloil)

b) Control cabinet (electrical)
1 pc. control valve with built-on positioning drive
1 pc. control cabinet for electr. preheater
j) Viscosity control system

1 pc. automatic viscosity measure and control system VAF
k) Cooler
1 pc. shell and tube heat exchanger for operating on MGO/MDO

5 | Systems
5.2.7 Heavy fuel oil supply- and booster standard module

Module controlled automatically with alarms and starters
Pressure pump starters with stand-by automatic
Circulating pump starters with stand-by automatic
PI-controller for viscosity controlling
Starter for the viscosimeter
Analog output signal 4 - 20 mA for viscosity
Alarms
Pressure pump stand-by start
Low level in the mixing tank
Circulating pump stand-by start
Self cleaning fine filter clogged
Viscosity alarm high/low
The alarms with potential free contacts
Alarm cabinet with alarms to engine control room and connection possibility for
remote start/stop and indicating lamp of fuel pressure and circulating pumps
Performance and materials:

The whole module is tubed and cabled up to the terminal strips in the electric switch
boxes which are installed on the module. All necessary components like valves,
pressure switches, thermometers, gauges etc. are included. The fuel oil pipes are
equipped with trace heating (steam, thermaloil or electrical) where necessary.
The module will be tested hydrostatical and functional in the workshop without
heating.
Steam Electric Steam Electric Steam Electric

Thermal oil Thermal oil Thermal oil
Total power in kW up to (50/60 Hz) 4,000 4,000 4,000/8,000 4,000/8,000 8,000/12,000 12,000/20,000
Length in mm 2,200 2,700 3,200 3,500 3,500 3,500
Width in mm 1,200 1,200 1,200 1,200 1,350 1,500
Height in mm 2,000 2,000 2,000 2,000 2,000 2,000

5 | Systems
5.2.7 Heavy fuel oil supply- and booster standard module - diagram
- Peak pressures max. 16 bar
Notes:
Accessories and fittings: ff Flow velocity in circuit system < 0.5 m/s
DH3 MGO/MDO cooler FQ1 Flow quantity indicator p Free outlet required
DT1 Diesel oil day tank LI Level indicator s Please refer to the measuring point list regarding de-
HF1 Fine filter (duplex filter) LSH Level switch high sign of the monitoring devices
HF2 Primary filter LSL Level switch low tt Neither insulated nor heated pipe
HF3 Coarse filter PDI Diff. pressure indicator u From diesel oil separator or diesel oil transfer pump
HF4 Self cleaning filter PDSH Diff. pressure switch high
HH1 Heavy fuel final preheater PDSL Diff. pressure switch low All heavy fuel pipes have to be insulated.
HH2 Stand-by final preheater PI Pressure indicator ---- heated pipe
HH3 Heavy fuel preheater (separator) PT Pressure transmitter
HH4 Heating coil TI Temperature indicator Connecting points:
HP1/HP2 Pressure pump TT Temperatur transmitter (PT100) C76 Inlet duplex filter
HP3/HP4 Circulating pump VI Viscosity indicator C78 Fuel outlet
HP5/HP6 Heavy fuel transfer pump (separator) VSH Viscosity control switch high C81 Drip fuel
HR1 Pressure regulating valve VSL Viscosity control switch low C81b Drip fuel (filter pan)
HR2 Viscometer
HS1/HS2 Heavy fuel separator General notes:
HT1 Heavy fuel day tank For location, dimensions and design (e. g. flexible connection) of the connecting points see engine installation
HT2 Mixing tank drawing.
HT5/HT6 Settling tank If a "Fuel oil supply and booster module" is supplied by Caterpillar Motoren, arrangement and scope of the supply
KP1 Injection pump components are to be gathered from the module schema.
KT2 Sludge tank Valve fittings with loose cone are not accepted in the admission and return lines.

5 | Systems
5.3 Lubrication oil system
5.3.1 Lubricating oil quality

The viscosity class SAE 40 is required.
Wear and tear and thus the service life of the engine depend on the lube oil quality. Therefore high requirements are
made for lubricants:
Constant uniform distribution of the additives at all operating conditions. Perfect cleaning (detergent effect) and disper-
sing power, prevention of deposits from the combustion process in the engine. Sufficient alkalinity in order to neutralize
acid combustion residues. The TBN (total base number) must be between 30 and 40 KOH/g at HFO operation. For MDO
operation the TBN is 12 - 20 depending on sulphur content.
Manufacturer Diesel oil/Marine-diesel I II HFO operation I II

oil operation
AGIP DIESEL SIGMA S X CLADIUM 300 S X
CLADIUM 120 X CLADIUM 400 S X
BP ENERGOL HPDX 40 X ENERGOL IC-HFX 304 X
ENERGOL DS 3-154 X ENERGOL IC-HFX 404 X
ENERGOL IC-HFX 204 X
VANELLUS C3 X
CHEVRON, CALTEX, TEXACO DELO 1000 MARINE X TARO 30 DP X
TARO 12 XD X TARO 40 XL X
TARO 16 XD X TARO 40 XLX X
TARO 20 DP X
TARO 20 DPX X
CASTROL MARINE MLC X TLX PLUS 304 X
MXD 154 X TLX PLUS 404 X
TLX PLUS 204 X
CEPSA KORAL 1540 X
ESSO EXXMAR 12 TP X EXXMAR 30 TP X
EXXMAR CM+ X EXXMAR 40 TP X
ESSOLUBE X 301 X EXXMAR 30 TP PLUS X
EXXMAR 40 TP PLUS X
MOBIL MOBILGARD 412 X MOBILGARD M 430 X
MOBILGARD ADL X MOBILGARD M 440 X
MOBILGARD M 430 X MOBILGARD M 50 X
MOBILGARD 1-SHC 1) X
DELVAC 1640 X
SHELL GADINIA X ARGINA T X
GADINIA AL X ARGINA X X
ARGINA S X
ARGINA T X
TOTAL LUBMARINE RUBIA FP X AURELIA TI 4030 X
DISOLA M 4015 X AURELIA TI 4040 X
AURELIA TI 4030 X
I Approved in operation
II Permitted for controlled use
When these lube oils are used, Caterpillar Motoren must be informed because at the moment there is insufficient experience
available for MaK engines. Otherwise the warranty is invalid.
1)
Synthetic oil with a high viscosity index (SAE 15 W/40). Only permitted if the oil inlet temperatures can be decreased by 5 - 10 °C.

5 | Systems
5.3.2 Lubricating oil quantities/-change intervals The circulating quantity is approx. 1.1 l/kW
engine output.
The change intervals depend on:
O fuel quality
O quality of lube oil treatment (filter,
separator)
O engine load
By continuous checks of lube oil samples
(decisive are the limit values as per
"MaK Operating Media") an optimum
condition can be reached.
5.3.3 Lubricating oil components

a) Force pump (fitted) LP 1: Gear type pump
b) Strainer (fitted) LF 4
c) Selfcleaning filter (separate) LF 2: Mesh size 30 µm sphere passing mesh,

type 6.46, make Boll & Kirch*. Without by-
pass filter. Without flushing oil treatment.
* In case of Caterpillar Motoren supply.
Engine DN A B C
12CM32C 125 440 580 260
16CM32C 150 490 655 300

5 | Systems

d) Protection strainer (fitted) LF 3: Mesh size 320 µm
e) Cooler (separate) LH 1: Plate type (plates made of stainless

steel)
f) Temperature controller (separate) LR 1: P-controller with manual emergency

adjustment
Dimensions [mm] Weight

Engine DN D F G H [kg]
12CM32C 125 250 241 489 200 67
16CM32C 150 285 254 489 200 80
g) Prelubricating pump (fitted) LP 5: Delivery head

Continuous lubrication is carried out
with stopped genset.
Starter to be supplied by the yard.
Engine Hz Capacity [m3/h] Electr. motor [kW]

50 10.4 3.7
12/16CM32C
60 12.7 4.9
h) Prelubricating pump: baseframe mounted
Engine Hz Flow Capacity [m3/h] Electr. motor [kW]

12 cyl. 50/60 12
16 cyl. 50/60 16

5 | Systems
Lube oil content in base frame to max level
12 cyl. 8,500 l
16 cyl. 12,000 l

h) Circulating tank LT 1: Located in the base frame, equipped with high/low
level switch and level control stick.
i) Crankcase ventilation: At engine 1 x DN 125. Approx. 1 m after the connec-
tion point has to be enlarged to DN 150.
Pipe has to run upwards. A continous drain has to be
installed appox. 2 m after the connection point.
j) Treatment at MGO/MDO operation

Separator LS 1: Recommended with the following design:
O Separating temperature 85 - 95 °C
O Quantity to be cleaned three times/day
O Self cleaning type
Capacity
Veff [l/h] = 0.18 · Peng [kW]
k) Treatment at HFO operation

Separator LS 1: Required with the following design:
O Separating temperature 95 °C
O Quantity to be cleaned five times/day
O Self cleaning type
Capacity
Veff [l/h] = 0.29 · Peng [kW]

5 | Systems
12 11
5.3.4 Lubricating oil diagram
DPA
TI TI
PDSH
PI TI TI
NC PDI
1 TI
C
f A
3
LUBE OIL COOLER
B
BACKFLUSHING
FILTER 9
13
DRAIN
C91 C58 C55
TI PI
h 1106.11105CM
TURBOCHARGER
1142 1203CM1202 290kPa 350kPa
PSL TSHH TT PSLL PT
PRELUB- LUBE OIL SAFETY STRAINER

RICATION PUMP
PUMP
TURBOCHARGER
ENGINE
LSH
C55c
C65
LI
C60
LSL
C61
General notes:
For location, dimensions and design (e. g. flexible connection) of the connecting points see engine installation drawing.
Notes:
f Drain
h Please refer to the measuring point list regarding design of the monitoring devices
o See "crankcase ventilation" installation instructions 4-A-9570
nc Normally closed LI Level indicator
Connecting points: LSH Level switch high
C55 Lube oil inlet, protective filter Accessories and fittings: LSL Level switch low
C55c Connection flushing pipe LF2 Lube oil automatic filter PDI Diff. pressure indicator
automatic filter LF3 Protective strainer PDSH Diff. pressure switch high
C58 Force pump, delivery side LF4 Suction strainer PI Pressure indicator
C60 Separator connection, LH1 Lube oil cooler PSL Pressure switch low
suction side LP1 Lube oil force pump PSLL Pressure switch low
C61 Separator connection, LP5 Prelubrication pump PT Pressure transmitter
delivery side LR1 Lube oil temperature control valve TI Temperature indicator
C65 Lube oil filling socket LR2 Oil pressure regulating valve TSHH Temperature switch high
C91 Crankcase ventilation to stack LT1 Lube oil sump tank TT Temperature transmitter (PT 100)

5 | Systems
5.3.5 Lubricating oil module (optional)
C
A B

Engine Type A B C [t]
12CM32C 2,000 1,375 2,080 1.8
16CM32C 2,200 1,400 2,100 2.0
Values may vary due to project specifics.

5 | Systems
5.4 Cooling water system
The heat generated by the engine (cylinder, charge air and lube oil) is to be removed by
means of treated freshwater acc. to the MaK coolant regulations.
The inlet temperature in the LT-circuit is max. 38 °C.
5.4.1 Cooling water system components
a) Two-circuit cooling: with two-stage charge air cooler.
b) LT-cooling water pump FP 4/FP 6
c) HT-cooling water pump FP 3/FP 5 Option: fitted (FP 1)
d) HT-temperature controller (separate) FR 1: P-controller with manual emergency

adjustment. Option: PI-controller with
electric drive.
See charge air thermostat.

Engine DN D F G H [kg]
12/16CM32C HT 125 250 241 489 200 67
12CM32C LT 125* 250 241 489 200 67
16CM32C LT 150* 285 254 489 200 80
* Minimum, depending on total cooling water flow

5 | Systems
e) LT-temperature controller (separate) FR 2: P-controller with manual emergency

adjustment
(basis). Option: PI-controller with elec-
tric drive.
See charge air thermostat.
f) Preheater (fitted on base frame) FH 5/FP 7: Consisting of circulating pump 1), elec-
tric preheater 2) and control cabinet
1)
Capacity 5 m3/h
2)
Output 48 kW
g) HT-cooler (separate) FH 1: Plate type (plates made of titanium),

size depending on the total heat to be
dissipated.
h) LT-cooler (separate) FH 2: Plate type (plates made of titanium),

size depending on the total heat to be
dissipated.

5 | Systems
i) Header tank (separate) FT 1/FT 2: O Arrangement: min. 4 m above crank-

shaft.
O Size acc. to technical engine data, in
case of several engines
+ 25 % volume per engine.
O All continuous vents from engine are
to be connected.
j) Drain tank with filling pump: Is recommended to collect the treated

water when carrying out maintenance
work (to be installed by the yard).
k) Electric motor driven pumps: Option for freshwater and seawater,

vertical design.
Rough calculation of power demand for
the electric balance.
.
ρ·H·V
P= [kW]
367 · η
P - Power [kW]
P. M - Power of electr. motor [kW] PM = 1.5 · P < 1.5 kW
V - Flow rate [m3/h] PM = 1.25 · P 1.5 - 4 kW
H - Delivery head [m] PM = 1.2 · P 4 - 7.5 kW
ρ - Density [kg/dm3] PM = 1.15 · P > 7.5 - 40 kW
η - Pump efficiency PM = 1.1 · P > 40 kW
0.70 for centrifugal pumps

5 | Systems
5.4.2 Heat balance 12CM32C - 6,000 kW / 720 rpm

5 | Systems

5 | Systems
5.4.6 Heat balance 12CM32C - 6,720 kW / 720 rpm 48,4°C
90°C
V = 100 cbm/h
FW-COOLER HT
Q = 3020 kW
90°C
55°C 51,9°C
V = 110 cbm/h
LUB. OIL COOLER
V = 80 cbm/h
Q = 980 kW
64°C 38,1°C
ENGINE
FW-COOLER LT
Q = 1778 kW
12 M32C IMOII
P = 6720 KW 44,4°C 43,8°C
n = 720 1/min
GENERATOR COOLER
Q = 933 kW
(V = 30 cbm/h)
(Q = 202 kW)
M
CHARGE AIR COOLER 2
82,0°C 32°C
Q = 596 kW
V = 80 cbm/h
CHARGE AIR COOLER 1

Q = 2087 kW
38°C 38°C 38°C
V = 100 cbm/h
64,0°C
FW PUMP HT FW PUMP LT SW PUMP
V = 100 cbm/h V = 110 cbm/h V = 270 cbm/h
p = 4,7 bar p = 3,0 bar p = 2,5 bar
V = 100 cbm/h SEA CHEST
48,7°C

90°C
V = 100 cbm/h
FW-COOLER HT
Q = 3084 kW
90°C 55,3°C 52,15°C

V = 110 cbm/h
LUB. OIL COOLER
V = 80 cbm/h
Q = 980 kW
63,4°C 38,2°C
ENGINE
FW-COOLER LT
Q = 1807 kW
12 M32C IMOII
P = 6720 KW 44,7°C 43,8°C
n = 750 1/min
GENERATOR COOLER
Q = 933 kW
(V = 30 cbm/h)
(Q = 202 kW)
M
CHARGE AIR COOLER 2
82°C 32°C
Q = 625 kW
V = 80 cbm/h
CHARGE AIR COOLER 1

Q = 2151 kW
38°C 38°C 38°C
V = 100 cbm/h
63,4°C
p = 4,7 bar p = 3,0 bar p = 2,5 bar

5 | Systems
48,9°C
90°C
V = 130 cbm/h
FW-COOLER HT
Q = 4027 kW
90°C
56,1°C 52,6°C
V = 140 cbm/h
LUB. OIL COOLER
V = 100 cbm/h
Q = 1307 kW
63,3°C 38,3°C
ENGINE
FW-COOLER LT
Q = 2371 kW
16 M32C IMOII
P = 8960 KW 44,8°C 43,8°C
n = 720 1/min
GENERATOR COOLER
Q = 1244 kW
(V = 40 cbm/h)
(Q = 269 kW)
M
CHARGE AIR COOLER 2
81,8°C 32°C
795
V = 100 cbm/h
CHARGE AIR COOLER 1

Q = 2783 kW
38°C 38°C 38°C
V = 130 cbm/h
63,3°C
p = 4,5 bar p = 3,0 bar p = 2,5 bar
49,2°C

90°C
V = 130 cbm/h
FW-COOLER HT
Q = 4112 kW
90°C
56,4°C 52,8°C
V = 140 cbm/h
LUB. OIL COOLER
V = 100 cbm/h
Q = 1307 kW
62,8°C 38,4°C
ENGINE
FW-COOLER LT
Q = 2409 kW
16 M32C IMOII
P = 8960 KW 45,2°C 43,8°C
n = 750 1/min
GENERATOR COOLER
Q = 1244 kW
(V = 40 cbm/h)
(Q = 269 kW)
M
CHARGE AIR COOLER 2
81,8°C 32°C
Q = 833 kW
V = 100 cbm/h
CHARGE AIR COOLER 1

Q = 2868 kW
38°C 38°C 38°C
V = 130 cbm/h
62,8°C
p = 4,5 bar p = 3,0 bar p = 2,5 bar

5 | Systems
5.4.10 HT- and LT-pump system
Notes:
f Drain
h Please refer to the measuring
point list regarding design of the
Accessories and fittings: monitoring devices
CH1 Charge air cooler HT LH1 Lube oil cooler General notes:
CH2 Charge air cooler LT SF1 Seawater filter For location, dimensions and design (e. g. flexible
FH1 Freshwater cooler HT SP1 Seawater pump connection) of the connecting points see engine
FH2 Freshwater cooler LT SP2 Seawater stand-by pump installation drawing.
FH5 Freshwater preheater ST1 Sea chest With skin cooler not required: Seawater system
FP3 Freshwater pump (separate) HT XH1 Generator cooler (SP1, SP2, SF1, ST1)
FP4 Freshwater pump (separate) LT LI Level indicator Temp.-control valve FR3 with heat recovery < 30 %
FP6 Freshwater stand-by pump LT LSL Level switch low not required.
FP7 Preheating pump PI Pressure indicator Connecting points:
FR1 Temperature control valve HT PSL Pressure switch low C14 Charge air cooler LT, inlet
FR2 Temperature control valve LT PSLL Pressure switch low C15 Charge air cooler LT, outlet
FR3 Temperature control valve HT PT Pressure transmitter C16 Charge air cooler HT, inlet
FR6 Sensor for temperature control valve LT TI Temperature indicator C25 Cooling water, engine outlet
FT1 Compensation tank HT TSHH Temperature switch high C37 Vent
FT2 Compensation tank LT TT Temperature transmitter (PT 100)

5
5.4
DRAWING SYMBOLS 3
5.4.11
2 3
FILLING
TEMPERATURE CONTROL VALVE
CAT_CM32C_Innenteil.indd 55
SUPPLY II SUPPLY I
NON-RETURN VALVE
PREHEATING CONTROL TREATMENT
BUTTERFLY VALVE CABINET CABINET PI
TI
BALL VALVE Vent
11
STOP VALVE FR1 TI TI
LSH
| Systems
REGULATING VALVE CENTRAL
B C COOLER LI
A
PI LSL
CR1 PI M PI
TI
OVER FLOW
M TI FR2
1 3 12
TI TI TI
2
LT-FRESH WATER
PUMP
EXPANSION TANK
TI TI
TI
DRAIN 1 10 4
GS
COV1 CENTRAL COOLING UNIT

Central cooling system
Cooling water system
4 1 2 6 5 7 15 8 14 16 13
LUB. OIL COOLING UNIT
COMPRESSED AIR
TI TI
12 11 ACCESSORIES AND FITTINGS

LUBOIL
LI LEVEL INDICATOR
COOLER LSL LEVEL SWITCH LOW
PI PRESSURE INDICATOR
MDO BOOSTER UNIT
PSL PRESSURE SWITCH LOW
TI TI TI
PSLL PRESSURE SWITCH LOW
11 12
PT PRESSURE TRANSMITTER
TI TEMPERATURE INDICATOR
C37 C25 C13 FUEL OIL TSHH TEMPERATURE SWITCH HIGH
COOLER
TT TEMPERATURE TRANSMITTER (PT100)
CM2211 2212
TT TSHH TI
GENERATOR SET Gen.
DISCONNECTING POINTS
COOLER C 12 GENERATOR COLLER, INLET
PSLL PT PI TT CM2201 C12 C 13 GENERATOR COLLER, OUTLET
2103 CM2102 C 14 CHARGE AIR COOLER LT, INLET
CHARGE AIR
COOLER C 15 CHARGE AIR COOLER LT, OUTLET
Cat-Engine C15 C 21 FRESHWATER PUMP HT, INLET
16CM32C 2229 2112
C 25 COOLING WATER, ENGINE OUTLET
TT PI PT C 36 DRAIN, TURBOCHARGER WASHING
C 37 VENT
PREHEATER C 42 TURBINE CLEANING CONNECTION
HT FW-PUMP C14
PREHEATING
PUMP
C21 ACCESSORIES AND FITTINGS
CM32 – Generator Set – Oil & Gas 01.2014

FR1 TEMPERATURE CONTROL VALVE HT
FR2 TEMPERATURE CONTROL VALVE LT
CR1 CHARGE AIR TEMPERATURE CONTROL VALVE
55
05.02.14 13:30
5 | Systems
5.4.12 Central cooling module (optional)

Engine Type A B C [t]
12CM32C 3,500 1,875 2,050 4.1
16CM32C 3,500 1,800 2,100 4.5
Values may vary due to project specifics.

5 | Systems
5.5 Starting air system
As required by the classification societies, two air compressors compress the starting air to
a nominal pressure of 30 bar. The starting air has to have a certain quality, be free from solid
particles, oil, and water.
5.5.1 Quality requirements of starting air at engine inlet connection C86

For the faultness operation of engine a staring air quality of class 4 according ISO 8573-1 is
required.
Class Particle size Particle density Pressure Water Oil

dew point Residual oil
max. in µm max. in mg/m³ in °C mg/m³ content in mg/m³
1 0.1 0.1 -70 3 0.01
2 1 1 -40 120 0.1
3 5 5 -20 880 1
4 15 8 3* 6,000 5
5 40 10 7 7,800 25
6 10 9,400
* recommended for auxiliary equipment. For starting air as minimum the compressed air must be always above
dew point to avoid free water in the air system.
The standard DIN ISO 8573-1 define the quality cases of compressed air as follows:
Oil content
Specification of the remnant of aerosols and hydrocarbons which may be contained in the compressed
air.
Particle size and density

Specification of size and concentration of particles which still may be contained in the compressed air.
Pressure dew point

Specification of the temperature on which the compressed air can cool down without the steam con-
tained in it condensing. The pressure dewpoint changes with the air pressure.

5 | Systems
5.5.2 Requirement of classification societies (regarding design)

- No. of starts: 6
- No. of receivers: min. 2
at max. 30 bar
Number of Number of Receiver capacity L DØ Valve head Weight

gensets receivers available mm mm approx. kg
[l]
2 2 500 3,355 480 DN 50 320
3, 4 2 1,000 3,670 650 DN 50 620
6, 8 4 1,500 3,753 800 DN 50 1,150
5.5.3 Starting air components

1 Filling valve DN 18
2 Pressure gauge G 1/4
3* Relief valve DN 7
4 Drain valve DN 8
5 Drain valve DN 8 (for vertical position)
6 Connection aux. air valve G1/2
7 To starting valve at engine
8 Typhon valve DN 16
Option:
* with pipe connection G 1/2
When CO2 fire extinguishing plants are arranged in the engine room, the blow-off
connection of the safety valve is to be piped to the outside.

5 | Systems

Compressor AC 1/AC 2: 2 compressors with a total output of 50 % each are required.
The filling time for one hour from 0 to 30 bar.
Compressor Selection
Receiver volume Compressor
filling capacity
2 x 250 l 2 x 7,5 m3 /h
2 x 500 l 2 x 15 m3/h
2 x 1000 l 2 x 30 m3/h
2 x 1500 l 2 x 45 m3/h
5.5.4 Starting air system diagram
PI
6106
AT1 AR1 PSH
AC1 h
AR5 C86
d 6101
d PT PI
6105
AC2 PSL
AR5 AR4
a
PI
AT2 e ENGINE
d j
General notes:
For location, dimensions and design (e. g. flexible con-
nection) of the connecting points see engine installation
AR2
drawing.
Auxillary Air
Clean and dry starting air is required. A starting air filter Accessories and fittings:
has to be installed before engine, if required. AC1 Compressor
AC2 Stand-by compressor
Notes: AR1 Starting valve
a Control air AR2 Pressure reduction aux. air
d Water drain (to be mounted at the lowest point) AR4 Pressure reducing valve
e To engine no. 2 AR5 Oil and water separator
h Please refer to the measuring point list regarding AT1 Starting air receiver (air bottle)
design of the monitoring devices AT2 Starting air receiver (air bottle)
PI Pressure indicator
Connecting points: PSL Pressure switch low, only for main engine
C86 Connection, starting air PT Pressure transmitter

5 | Systems
5.6 Combustion air system
5.6.1 General: To obtain good working conditions in the engine room

and to ensure trouble free operation of all equipment
attention shall be paid to the engine room ventilation
and the supply of combustion air.
The combustion air required and the heat radiation
of all consumers/heat producers must be taken into
account.
5.6.2 Air intake from engine room O Fans are to be designed for a slight overpressure
(standard): in the engine room.
O On system side the penetration of water, sand,
dust, and exhaust gas must be avoided.
O When operating under tropical conditions the air
flow must be conveyed directly to the turbochar-
ger.
O The temperature at turbocharger filter should not
fall below + 10 °C.
O In cold areas warming up of the air in the engine
room must be ensured.
5.6.3 Air intake from outside: O The intake air duct is to be provided with a filter.
Penetration of water, sand, dust and exhaust gas
must be avoided.
O Connection to the turbocharger is to be establis-
hed via an expansion joint (to be supplied by the
yard). For this purpose the turbocharger will be
equipped with a connection socket.
O At temperatures below + 10 °C Caterpillar Moto-

ren/Application Engineering must be consulted.
5.6.4 Radiated heat: see technical data

To dissipate the radiated heat a slight and evenly
distributed air current is to be led along the engine
exhaust gas manifold starting from the turbocharger.

5 | Systems
5.7 Exhaust gas system
Position of exhaust gas nozzle: Standard nozzle position is 0°.
Exhaust compensator:
Engine Diameter DN Length [mm]
12CM32C 2 x 600 450
16CM32C 2 x 700 520
Design of the pipe cross-section: The pressure loss is to be minimized in order

to optimize fuel consumption and thermal load
of the engine.
Max. flow velocity: 40 m/s (guide value).
Max pressure loss (incl. silencer and exhaust
gas boiler): 30 mbar
(lower values will reduce thermal load of the
engine).
Notes regarding installation: O Arrangement of the first expansion joint

directly on the exhaust gas transition piece
O Arrangement of the first fixed point in the
conduit directly after the expansion joint
O Drain opening to be provided (protection
of turbocharger and engine against water)
O Each engine requires an exhaust gas pipe
(one common pipe for several engines is
not permissible).
If it should be impossible to use the stan-

dard transition piece supplied by Caterpillar
Motoren, the weight of the transition piece
manufactured by the yard must not exceed
the weight of the standard transition piece.
A drawing including the weight will then have
to be submitted approval.

5 | Systems
5.7.2 Exhaust sound level
Exhaust sound power level Lw, not attenuated [1 x 1 m from open pipe] (to be expected)
The noise measurements are made with a probe inside the exhaust pipe.
12/16CM32C
160
152
150 146
Lw Oct [dB] 145
(reference 139 139
140 136 137
10-12 W)
130
130 127
120
110
100
0.031 0.063 0.125 0.25 0.5 1 2 4 8
Tolerance + 2 dB Frequency [kHz]

5 | Systems
5.7.3 Exhaust gas data (preliminary) CM32 500 kW/cyl

12 cyl. 6,000 kW 720/750 rpm
16 cyl. 8,000 kW 720/750 rpm
Tolerance: 5%
Atmospheric pressure: 1 bar
Relative humidity: 60 %
Constant speed
Charge air temperature 25 °C

Output % [kg/h] [°C]
Engine Output % 100 90 80 70 60 50
12CM32C 6,000 kW kg/h 42,800 35,962 35,125 31,046 26,738 22,426
720 rpm °C 304 308 312 323 340 358
12CM32C 6,000 kW kg/h 42,768 39,366 35,680 31,693 27,504 23,193
750 rpm °C 297 298 300 312 326 342
16CM32C 8,000 kW kg/h 59,116 54,512 49,584 44,038 38,198 32,358
720 rpm °C 294 288 286 293 308 323
16CM32C 8,000 kW kg/h 58,492 54,244 49,524 44,114 38,488 32,862
750 rpm °C 291 288 287 300 310 323

Engine Output % 100 90 80 70 60 50
12CM32C 6,000 kW kg/h 40,250 36,625 33,017 29,180 25,150 21,080
720 rpm °C 322 326 331 342 360 397
12CM32C 6,000 kW kg/h 40,200 37,000 33,539 29,790 25,855 21,800
750 rpm °C 315 316 318 331 345 362
16CM32C 8,000 kW kg/h 55,570 51,240 46,610 41,396 35,910 30,415
720 rpm °C 312 305 303 311 326 342
16CM32C 8,000 kW kg/h 54,980 50,990 46,550 41,470 36,180 30,890
750 rpm °C 308 305 304 318 329 342

5 | Systems
5.7.3 Exhaust gas data (preliminary) CM32 MDO 560 kW/cyl
12 cyl. 6,720 kW 720/750 rpm
16 cyl. 8,960 kW 720/750 rpm
Tolerance: 5%
Atmospheric pressure: 1 bar
Relative humidity: 60 %
Constant speed

Engine Output % 100 90 80 70 60 50
12CM32C 6,720 kW kg/h 46,650 42,485 38,318 33,675 29,040 24,400
720 rpm °C 335 334 336 345 365 385
12CM32C 6,720 kW kg/h 48,590 44,310 40,035 35,370 30,610 25,850
750 rpm °C 332 331 332 338 357 376
16CM32C 8,960 kW kg/h 62,185 56,630 51,080 44,890 38,710 32,450
720 rpm °C 332 331 333 340 363 383
16CM32C 8,960 kW kg/h 64,790 58,935 53,247 47,040 40,710 34,380
750 rpm °C 330 327 327 333 355 375

Engine Output % 100 90 80 70 60 50
12CM32C 6,720 kW kg/h 43852 39,935 36,020 31,655 27,300 22,940
720 rpm °C 355 354 356 366 387 408
12CM32C 6,720 kW kg/h 45675 41,652 37,633 33,249 28,773 24,300
750 rpm °C 352 351 352 358 378 399
16CM32C 8,960 kW kg/h 58455 53,232 48,015 42,197 36,390 30,505
720 rpm °C 352 351 353 360 385 406
16CM32C 8,960 kW kg/h 60905 55,400 50,050 44,220 38,270 32,318
750 rpm °C 350 347 347 353 376 397

5 | Systems
5.7.4 Silencer
Silencer: Design according to the absorbtion principle with
wideband attenuation over a great frequency range
and low pressure loss due to straight direction of
flow. Sound absorbing filling consisting of resistant
mineral wool.
Sound level reduction 35 dB(A) (standard).
Max. permissible flow velocity 40 m/s.
Silencer with spark arrester: Soot separation by means of a swirl device (par-
ticles are spun towards the outside and separated
in the collecting chamber). Sound level reduction
35 dB(A). Max. permissible flow velocity 40 m/s.
Silencers are to be insulated by the yard.
Foundation brackets are to be provided as an
option.

5 | Systems
5.7.4 Silencer
Silencer/Spark arrestor and silencer: Installation: vertical/horizontal
Flange according to DIN 86044
Counterflanges, screws and gaskets
are included, without supports and
insulation
Silencer
Spark arrestor and silencer
Attenuation 35 dB (A)
Engine DN D A B L kg
12CM32C 900 1,680 650 1,100 5,620 3,000
16CM32C 1,000 1,780 650 1,160 6,120 3,750
Exhaust gas boiler: Each engine should have a separate

exhaust gas boiler. Alternatively, a com-
mon boiler with separate gas sections
for each engine is acceptable.
Particularly when exhaust gas boilers
are installed attention must be paid not
to exceed the maximum recommended
back pressure.

5 | Systems
5.7.5 Turbo charger cleaning

Cleaning the turbocharger compressor: The components for cleaning (dosing
vessel, pipes, shut-off valve) are engine
mounted.
Water is fed before compressor wheel
via injection pipes during full load ope-
ration every 24 hours.
Cleaning the turbine blade and The cleaning is carried out with clean
nozzle ring: fresh water "wet cleaning" during low
load operation at regular intervals, de-
pending on the fuel quality, 150 hours.
Duration of the cleaning period is ap-
prox. 15 minutes (2 intervals for
12CM32C). Fresh water of 2 - 2.5 bar is
required.
During cleaning the water drain should
be checked. Therefore the yard has to
install a funnel after connection point
C36.
Engine Water flow Injection time

[l/min] [min]
12CM32C 25 - 30 2x5
16CM32C 20 - 25 10
C42 Fresh water supply, DN 12

(one connection for 16CM32C only)
C36 Drain, DN 30
for each turbocharger
Connection of C42 with quick coupling device

6 | Air borne sound power level
6.0 Air borne sound power level
The noise level is measured in a test cell with a turbocharger air filter in a distance
of 1 m from the engine. The measuring points are at camshaft level respective above
cylinder head cover.
6.1 Noise level for 12CM32C engines

130
125 123
121 120
120 119
Lw Oct [dB] 120
(reference
115 115
115
10-12 W)
110
105
100
95
90
0.063 0.125 0.25 0.5 1 2 4
6.2 Noise level for 16CM32C engines

130
125 122 122

120 121
119
Lw Oct [dB] 120 118 118
(reference
10-12 W) 115
110
105
100
95
90
0.063 0.125 0.25 0.5 1 2 4

7 | Foundation
Gensets have to be resiliently mounted.
This provides an activ insulation against forces generated by the engine as well as
protection against vibration from rigidly mounted main engines.
The ship's foundation does not require machining. Unevenness is to be compensated
by welding plates and shims (to be provided by the yard).
Major components:
O Bonded rubber rails for active insulation of dynamic engine forces
O Flexible pipe connection for all media
O Side stoppers, see foundation plan
O Axial stoppers, see foundation plan
O Shims and welding plates, see foundation plan
Details are shown on binding installation drawings.
7.1 Structure borne sound level Lv, expected (measured in the test cell)
12CM32C (6,000 kW/750 min-1) 16CM32C (8,000 kW/750 min-1)
LvOkt [dB re 5 x 10-8 m/s] LvOkt [dB re 5 x 10-8 m/s]
above above
below below

7 | Foundation
7.2 Foundation plan
12CM32C
16CM32C

8 | Control and monitoring system
8.1 LESS cabinet
LESS cabinet can also be delivered on a plate for an external cabinet
LESS Display LESS SAP
Governor terminal board

X55/X68

8.2 Blockdiagram LESS
Protection Emergency Automatic Override Reset

System Stop ( 4x ) Stop ( 4x ) ( 2x )
RPM
4...20mA
Pick-Up 1
direction cw
Main Engine Main Engine Main Engine POWER

Emergency Stop 1 Autostop 1 Oil Mist Pick-Up 1/Oversp.
DATA DISPLAY
Pick-Up 2 Emergency Stop 2 Autostop 2 Pick-Up 2/Oversp.
CANCEL
INTERLOCK 02431 Exhaustgas temp. Cyl.1 455.8 DEG
Emergency Stop 3 Autostop 3 Engine Run 02432 Exhaustgas temp. Cyl.2 445.2 DEG
TEST 02433 Exhaustgas temp. Cyl.3 459.4 DEG
Emergency Stop 4 Autostop 4 Pick-Ups Discrep. WIRE 02434 Exhaustgas temp. Cyl.4 451.1 DEG
BREAK
Emerg. Stop Local Autostop 5 RESET Remote 02435 Exhaustgas temp. Cyl.5 439.6 DEG ESC
02436 Exhaustgas temp. Cyl.6 452.5 DEG
Shut Down Channel 1 Override 1 Oil Mist Battery 1 02437 Main Bearing temp.1 77.68 DEG
Shut Down Channel 2 Override 2 AS2-AS5 Battery 2 EMERG. 02438 Main Bearing temp.2 81.14 DEG
STOP
Shut Down Emerg. System Autostop System Speed System
1 PD-N3000 N3000-DSP
2
Alarm ( 7x )
System Shut Down Over
Fail (3x) ( 6x ) ride
Frequency A05 A01.3
System
Power Supply 1
Power Supply 2
iBus 1
Power Supply 2
Power Supply 2 Auto A03.3
Load
Stop Option S1
4...20mA 1 2 3 4 5 6 7 8 X40 S1
1 2 3 4 5 6 7 8 X40 S1
X2 X1 X2 X1 Sensor
X30
24V
X30
24V Contacts
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Sensor X6 X6 Current
Contacts X20 X20
Sensors
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Pt100
X10 X10
Pt100
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
N3000-ISC X7 N3000-ISC X7
RPM A01.2 iBus 2

A03.2
4...20mA
A01.1 A03.1 Sensor
X40 S2 S1 X5 X40 S2 S1 X5 Contacts
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
X2 X1 X2 X1
Start
24V 24V Pt100
Stop 1 2 3 4 5 6 7 8 X30 1 2 3 4 5 6 7 8 X30
Reduce X3 CAN1 X6 X3 CAN1 X6 Current
Reset 1 2 3 4 5 6 7 8 X20 1 2 3 4 5 6 7 8 X20 Sensors
Sensor X4 CAN2 X4 CAN2
Contacts 1 2 3 4 5 6 7 8 X10 1 2 3 4 5 6 7 8 X10 NiCr-Ni
N3000-IMC X7 N3000-IMC X7
System Fail
Alarm
CAN-Bus 1 Alarm
System Fail - Start Interlock CAN-Bus 2
- Reduce
- Stop Engine
Start-Stop System Monitoring
Mod-Bus 1 Mod-Bus 2
to the Alarm System To Alarm System or Data from Big End Bearings

8.3 LESS control and monitoring system
LESS – Large Engine Safety System...

...is a compact engine control, monitoring and protection system. Included functions
are control of the engine (start, stop), monitoring of the actual status of sensors and
the protection system (emergency stops, interlocks, i.e.).
Engine control boxes include:

O Engine protection system
O Speed switch control
O Start-/Stop-control
O Alarm display (LED)
O Graphic display (settings)
O Engine monitoring
O Modbus output to alarm system
(Modbus RTU protocol RS 485/422)
O Data transfer via CAN-Bus to DICARE PC (option)
O Exhaust gas mean value system (option)
System designed for:

O Automatic shut down
O Manual stop inputs
O Configurable inputs
(shutdown, reduction, start interlock)
O Override
O Remote reset
O All inputs are wire break and short circuit monitored
O Free adjustable speed contact
O Fuel setting signals
O Overload contact
O RPM signal
Advantages:
O Complete equipped/tested engine
O Less installation space, no separate components,
installation friendly engine
O Less wiring
O Less commissioning time
O Data transfer via Modbus RTU protocol to alarm system

8.4 Speed control
Main engines are equipped with a mech./hydr. speed governor (milliampere speed
setting). With the following equipment:
O Stepper motor in the top part of the governor for remote speed control
O Separate stepper motor control with adjustable speed range and speed ramp.
Voltage supply = 24 V DC
The control is fitted easily accessible on the engine in the terminal board box (X3)
especially provided for control components.
The set speed value of
nmin = 4 mA
nmax = 20 mA
is converted into a current required by the stepper motor.
O Raise/lower push buttons (emergency speed setting)

O Shut-down solenoid (24 V DC/100 % duty cycle) for remote stop (not for automatic
engine stop).
O Steplessly adjustable droop on the governor from 0 - 10 %
O Standard setting: 0 %
O Device for optimization of the governor characteristic
O Serrated drive shaft (for easy service)

8.5 Location of engine control panel

8.6 Measuring points
Measur.-point Sensor
Monitoring point Abbrev. Action Remarks
MODBus Address Fitted Separate
CM 1105
Lube oil pressure PAL 0A A
30009
1106 PALL 0A
Lube oil pressure B
10113 MS
1111 Lube oil differential pressure duplex Only if autom. Filter
PDAH 0A B
filter is not mounted on engine
1112 Lube oil differential pressure duplex
PDAH 0A B External
filter
1142
Pre lube oil pressure PAL *) B *) Starting interlock
10116
CM 1202
Lube oil temperature at engine inlet TAH 0A A
30010
1203 0A
Lube oil temperature at engine inlet TAHH B
30119 MS
1251
Oil mist concentration in crankcase QAH 0A B# 1 device f. 1251+1253
10046
1251 .1
Oil mist concentration in crankcase QAH 0A B Prealarm
10001
1251 .2
Opacity QI I A
1253 0A
Oil mist concentration in crankcase QAHH B 1 device f. 1251+1253
10112 MS
1311 Lube oil level/lube oil collecting tank,
LAL 0A B
10037 base frame
1312 Lube oil level/lube oil collecting tank,
LAH 0A B
10038 base frame
CM 2102
Fresh water pressure HT at engine inlet PAL 0A A
30011
2103 0A
Fresh water pressure HT at engine inlet PALL B
10114 MS
2112
Fresh water pressure LT at engine inlet PAL 0A A
30012
CM 2201 Fresh water temperature HT A 2211
TAL 0A
30013 at water inlet 30014
CM 2211 Fresh water temperature HT
TAH 0A A
30014 at water outlet
2213 0A
Fresh water pressure LT at engine inlet TAHH B
30120 MS
2229 Fresh water temperature LT
TAH (0A) A
30015 at engine inlet
2321 Oil ingress in fresh water LT Option
QAH 0A B1
inlet cooler for DE-drive only

5102
Fuel oil pressure at engine inlet PAL 0A A
30021
5105 Starting stand-by pump
Fuel oil pressure at booster pump outlet PAL 0A B*
from pump control (extern)
5111
Fuel differential pressure at double filter PDAH 0A B
10036
5112 Fuel oil differential pressure
PDAH 0A B* External
at automatic filter
5115 Fuel oil differential pressure Starting stand-by pump
PDAL 0A B*
at circulating pump from pump control (extern)
5116 Fuel oil differential pressure
PDAL 0A B* External
at circulating pump
CM 5201
Fuel oil temperature at engine inlet TAL 0A A 1 Sensor for 5201+5202
30022
5202 1 Sensor for 5201+5202
Fuel oil temperature at engine inlet TAH 0A A
30022 not in use with HFO
CM 5206
Fuel oil temperature at viscosity outlet TI A Only crude oil
30090
CM 5253 1 Sensor f. 5251,
Fuel oil viscosity at engine inlet V
30089 5252+5253
5301 A/B
Leakage oil niveau at engine LAH 0A B 2 Sensors for 5301
10003
5302 A/B
Leakage oil niveau at engine LAH 2 Sensors for 5302
10092
6101
Starting air pressure at engine inlet PAL 0A A
30032
6105
Stopping air pressure at engine PAL 0A B
10048
CM 6181
Intake air pressure in engine room P
30019
6182 A Vaccum pressure in injection pump
PDAL A Only crude oil
space, stage A
6182 B Vaccum pressure in injection pump
PDAL A Only crude oil
space, stage B
6183 A
Gas detection injection pump space A S A Only crude oil
6183 B
Gas detection injection pump space B S A Only crude oil
CM 7109
Charge air pressure at engine inlet PI A
30017
* located in the HFO fuel pressure system

CM 7201
Charge air temperature at engine inlet TAH 0A B
30016
CM 7206 Intake air temperature at turbocharger
TI A
30020 inlet
7301
Condense water in charge air canal QAH 0A B
10004
CM 7307 Charge air differential pressure
PDI A
30018 at charge air cooler
CM 7309 A Charge air temperature at charge air
TI
30087 cooler inlet A
CM 7309 B Charge air temperature at charge air
TI
30065 cooler inlet B
CM 8211 .1A Exhaust gas temperature TAH
0A A
30073 after cylinder 1A TAHH
0A A
0A A
0A A
0A A
0A A
0A A
0A A
CM 8211 .1B Exhaust gas temperature TAH
0A A
30081 after cylinder 1B TAHH
0A A
0A A
0A A
0A A
0A A
0A A

0A A
8221 A Exhaust gas temperature
TAHH 0A A
30082 at turbocharger outlet
8221 B Exhaust gas temperature
TAHH 0A A
30083 at turbocharger outlet
8224 A Exhaust gas temperature 0A
TAHH A
at turbocharger outlet A AD
8224 B Exhaust gas temperature 0A
TAHH A
at turbocharger outlet B AD
CM 8231 A Exhaust gas temperature
TAH 0A A
30084 at turbocharger inlet A
CM 8231 B Exhaust gas temperature
TAH 0A A
30085 at turbocharger inlet B
9404 .1 0A
Engine overspeed SA B
MS
CM 9419
Engine speed NI A
30104
CM 9429 A
Turbocharger A speed NI A Start interlock
30024
CM 9429 B
Turbocharger B speed NI A Start interlock
30052
9503
Limit switch fuel rack, 100% fuel release SI B Start release
10222
CM 9509
Fuel pump setting GI A
30031
9561
Turning gear engaged SI B Start interlock
10117
9562 A Start blocking
Knife valve A not open SI B
10223 Only crude oil
9562 B Start blocking
Knife valve B not open SI B
10224 Only crude oil
9601 Voltage failure at terminal X1
SA 0A B
(alarm circuit)
9602
CAN bus failure SA
10005
9615 Electronic speed governor
SA 0A B
minor alarm
9616 Electronic speed governor 0A
SA B
major alarm MS
9631
Oil mist detector failure QA 0A B
10047

9675
Manual emergency stop SA B
9717
Voltage fail at terminal X3 engine control SA B
9836 .2
Sensor / Isolation fault A02 SA
10007
9836 .3
Sensor / Isolation fault A03 SA
10237
9961 Shutdown all engines,
Gas concentration ER >= 50% SA B Stop crude oil supply,
Only crude oil
9962 .2
Common alarm A02 SA
30008
9962 .3
Common alarm A03 SA
30238
9980 Stop crude oil supply
Engine ventilation failure SA B
Only crude oil
9981 Crude oil gas detection engine room Stop crude oil supply
SA B
>= 20% Only crude oil
Abbreviations
B = Binary sensor AD = Autom. speed/load reduction
A = Analogue sensor MS = Autom. engine stop
OA = Visual and audible alarm
Alarm function abbreviation

1. Letter Designation 2. Letter Function 3. Letter Value
P Pressure A Alarm H High
PD Diff. pressure I Indication HH High High
T Temperature L Low
Q Volume LL Low Low
S Switch
V Viscosity
G Position
L Level
N Speed

8.7 Remote indication interfacing
Turbocharger Remote indicator

Remote indicator speed engine speed
Monitor
option option option
*
n n
Signal type
4 - 20 mA
0 - 10 V
0 - 10 V
(mA)
Display
Monitoring
equipment
Modbus RTU Modbus
RTU W Ω, mA, mV
Noris N 3000 monitoring system Signals from the engine

for genset

9 | Condition monitoring
New diagnostic system for on-line engine data transmission
Based on several years of Caterpillar experience, Caterpillar Motoren will launch a new diag-
nostic system in early 2015.
The new system will be based on data transfer via internet to a central Caterpillar warehouse
and offers intensive diagnostics by Caterpillar engine specialists and use of a common data
base. The DICARE system has been discontinued and will not be offered due to lack of ability to
support the software platform in the future.
For detailed information please contact Caterpillar Motoren, application and installation de-
partment, + (49) 431-39 95 01.

10 | Factory acceptance test (FAT)
The acceptance test run of the complete genset is carried out on the testbed with
customary equipment and auxiliaries using exclusively MDO and under the respecti-
ve ambient conditions of the testbed. During this test run the fuel rack will be blocked
at the contractual output value. In case of deviations from the contractual ambient
conditions the fuel consumption will be converted to standard reference conditions.
The engine will be run at the following load stages acc. to the rules of the classifica-
tion societies. After reaching steady state condition of pressures and temperatures
these will be recorded and registered acc. to the form sheet of the acceptance test
certificate:
Load [%] Duration [min]

25 30 O with puric ohmic load (cos φ = 1)
50 30
O load application acc. to ISO 3046
85 30
100 60 O without parallel operation
110 30
In addition to that the following functional tests will be carried out:

O governor test
O overspeed test
O emergency shut-down via minimum oil pressure
O start/stop via central engine control
O starting trials up to a minimum air pressure of 10 bar
O measurement of crank web deflection (cold/warm condition)
After the acceptance main running gear, camshaft drive and timing gear train will be
inspected through the opened covers. Individual inspection of special engine com-
ponents such as piston or bearings is not intended, because such inspections are
carried out by the classification societies at intervals on series engines.
Engine movement due to vibration referred to the global vibration characteristics of
the engine:
The basis for assessing vibration severity are the guidelines ISO 10816-6.
According to these guidline the MaK engine will be assigned to vibration severity
grade 28, class 5. On the engine block the following values will not be exceeded:
Displacement Seff < 0.448 mm f> 2 Hz < 10 Hz

Vibration velocity Veff < 28.2 mm/s f > 10 Hz < 250 Hz
Vibration acceleration aeff < 44.2 m/s2 f > 250 Hz < 1,000 Hz

11 | Engine International Air Pollution
Prevention Certificate
The MARPOL Diplomatic Conference has agreed about a limitation of NOx emissions,
referred to as Annex VI to Marpol 73/78.
When testing the engine for NOx emissions, the reference fuel is Marine Diesel Oil
(Distillate) and the test is performed according to ISO 8178 test cycles:
D2: Auxiliary genset
E2: Diesel electric or controlable pitch propeller
Output [%] 100 75 50 25 10

E2 weighting factor 0.20 0.50 0.15 0.15 -
D2 weighting factor 0.05 0.25 0.30 0.30 0.10
Subsequently, the NOx value has to be calculated using different weighting factors
for different loads that have been corrected to ISO 8178 conditions.
NOx emission evidence for the engine about IMO-Marpol 73/78 Annex VI compliance
through EIAPP Certificate or EAPP Document of Compliance or EAPP Statement of
Compliance according to the authorisation by the flag state and related technical file
will be issued for the engine showing that the engine complies with the regulation.
The EAPP Document of Compliance shall be transformed into the EIAPP Certificate
if the flag state has ratified the Convention (MARPOL Annex VI). The EAPP Statement
of Compliance shall be transformed into a certificate issued on behalf of a flag state
if necessary for the vessel.
According to the IMO regulations, a technical file shall be made for each engine.
This technical file contains information about the components affecting NOx emis-
sions, and each critical component is marked with a special IMO number. Such
critical components are injection nozzle, injection pump, camshaft sections, cylinder
head, piston, charge air cooler, and turbocharger. The allowable setting values and
parameters for running the engine are also specified in the technical file.
The marked components can later, on-board the platform, be identified by the survey-
or.

12 | Painting/Preservation
12.1 Inside preservation
12.1.1 Works standard N 576-3.3
Components
O Main running gear and internal mechanics
Application
O Max. 2 years
NOTE:
Inside preservation does not have to be removed when the engine is commissioned
12.2 Outside preservation

12.2.1 Works standard VCI 368 N 576
Conditions
O Europe and overseas
O Sea and land transportation
O Storage in the open, protected from moisture
O Max. 2 years with additional VCI packaging
Appearance of the engine
O Castings with red oxide antirust paint
O Pipes and machined surfaces left as bare metal
O Attached components with colours of the manufacturers
NOTE:
Outside preservation must be removed before commissioning of the engines.
Environmentally compatible disposal is to be ensured.
Durability and effect depend on proper packaging, transportation, and storage (i.e. protected
from moisture, stored at a dry place and suffi ciently ventilated). Inspections are to be carried
out at regular intervals.

12.2.2 Works standard clear varnish N 576-4.1
Conditions
O Europe
O Land transportation
O Storage in a dry and tempered atmosphere, protected from moisture
O Max. 1 year with additional VCI packaging
NOTE:
Works standard clear carnish N 576-4.1 is not permissible for:
O sea transportation of engines and
O storage of engines in the open, even if they are covered with tarpaulin.
O Castings with red oxide antirust paint
O Pipes and machined surfaces left as bare metal
O Attached components with colours of the manufacturers
O Surfaces sealed with clear varnish
O Bare metal surfaces provided with VCI 368 preservation
NOTE:
VCI packaging as per N 576-5.2 is generally required!
Durability and effect depend on proper packaging, transportation, and storage (i.e. the engine is
to be protected from moisture, VCI fi lm not ripped or destroyed).
Inspections are to be carried out at regular intervals.
If the above requirements are not met, all warranty claims in connection with corrosion damage
shall be excluded.
12.2.3 Works standard painting N 576-4.3

Conditions
O Sea and land transportation
O Short-term storage in the open, protected from moisture
O Up to max. 4 weeks
O Longer than 4 weeks VCI packaging as per N 576-5.2 is required
O Max. 2 years with additional VCI packaging
O Surfaces mostly painted with varnish
O Bare metal surfaces provided with VCI 368 preservation
NOTE:

12.2.4 Works standard VCI packaging N 576-5.2
Conditions
O Engines with outside preservation VCI 368 as per N 576-3.2
O Engines with clear varnish according to application group N 576-4.1
NOTE:
These engines are always to be delivered with VCI packaging!
Nevertheless, they are not suitable for storage in the open!
O Engine or engine generator sets with painting according to application group N 576-4.3
O Storage in the open, protected from moisture
NOTE:
Apperance of the engine
O Bare metal surfaces provided with VCI 368 or VCI oil
O Cortec VCI impregnated fl exible PU foam mats attached to the engine using tie wraps.
Kind and scope depending on engine type.
The attached mats should not come into contact with the painted surface.
O Cover the engine completely with air cushion fi lm VCI 126 LP. Air cushions are to face
inwards! The air cushion fi lm is fastened to the transportation skid (wooden frame) by
means of wooden laths. Overlaps at the face ends and openings for the lifting gear are to be
closed by means of PVC scotch tape.
In case of engines delivered without oil pan, the overhanging VCI fi lm between engine and
transport frame is to be folded back upwards before fastening the air cushion fi lm.
ATTENTION:
The corrosion protection is only effective if the engine is completely wrapped in VCI fi lm. The
protective space thus formed around the component can be openend for a short time by slitting
the fi lm, but afterwards it must be closed again with adhesive tape.

12.3 Works standard information panel
A works standard information panel for VCI preservation and inspection N 576-5.2 suppl. 1 will be
supplied.
Application
O Engines with VCI packaging as per application group N 576-5.2
Description
O This panel provides information on initial preservation and instructions for inspection.
O Arranged on the transport frame on each side so as to be easily visible.
12.4 Protection period, check, and represervation N 576-6.1

12.4.1 Protection period
There will only be an effective corrosion protection of the engine if the defi nitions and required
work according to factory standard N 576-6.1 are duly complied with.
Normally, the applied corrosion protection is effective for a period of max. 2 years, if the engine
or engine generator set is protected from moisture.
After two years represervation must be carried out.
However, depending on the execution of the preservation or local conditions shorter periods
may be recommended.
12.4.2 Protection check

Every 3 month specific inspections of the engine or engine generator set are to be carried out at
defined inspection points.
Any corrosion and existing condensation water are to be removed immediately.
12.4.3 Represervation N 576-6.1

After 2 years represervation must be carried out.

13 | Appendix
13.1 Exhaust system
Resistance in exhaust gas piping
Example (based on diagram data A to E):

t = 335 °C, G = 25.000 kg/h
l = 15 m straight pipelength, d = 700 mm t = Exhaust gas temperature (°C)
3 off 90° bend R/d = 1.5 G = Exhaust gas massflow (kg/h)
1 off 45° bend R/d = 1.5 Δp = Resistance/m pipe length (mm WC/m)
ΔPg = ? d = Inner pipe diameter (mm)
w = Gas velocity (m/s)
Δp = 0.83 mm WC/m l = Straight pipe length (m)
L' = 3 · 11 m + 5.5 m L' = Spare pipe length of 90° bent pipe (m)
L = l + L' = 15 m + 38.5 m = 53.5 m L = Effective substitute pipe length (m)
ΔPg = Δp · L = 0.83 mm WC/m · 53.5 m = 44.4 mm WC ΔPg = Total resistance (mm WC)

13 | Appendix
13.2 Fuel oil system
Viscosity/temperature diagram

13 | Appendix
Flow velocities
Example: di = 100 mm, V = 60 m3/h

Velocity in the pipe 2.1 m/s

12_16_CM32C-Project-Guide_Petroleum_2013_Layout 1 20.01.14 16:11 Seite 1
CM32 Project Guide • Petroleum Applications

CM32
Project Guide
Generator Set for Petroleum Applications
12 • 16 Cylinder

Headquarters
Caterpillar Inc.
13105 N.W. Freeway
Suite 1100
Houston, Texas 77040 6321
Phone: (+1) 713 329 2207
Telefax: (+1) 713 895 4280
Europe, Africa, Middle East and CIS Asia Pacific
Caterpillar Commercial Caterpillar Motoren Caterpillar CIS LLC Caterpillar Caterpillar Asia Pte., Ltd
Northern Europe Ltd. GmbH & Co. KG 82 Sadovnicheskaya Str. Oil & Gas China 7 Tractor Road
Caterpillar Oil & Gas Caterpillar Oil & Gas Moscow 113035, RF Room 1601 Caterpillar Tower Singapore 627968
OTV House Falckensteiner Str. 2 Phone: (+7) 495 755 6811 No. 8 Wangjing Street Republic of Singapore
Wokingham Road, Rounds Hill D-24159 Kiel, Germany Telefax: (+7) 495 785 5688 Beijing 100102, P.R. China Phone: (+65) 6828 7333
Bracknell, Berkshire Phone: (+49) 431 3995 3004 Phone: (+86) 10 5921 0521 Telefax: (+65) 6828 7414
United Kingdom, RG42 1 NG Telefax: (+49) 431 3995 5004 Telefax: (+86) 10 5921 0022
Phone: (+44) 1344 782 920
Telefax: (+44) 1344 782 930
For more information please visit our website: Subject to change without notice. © 2014 Caterpillar All Rights Reserved. Printed in Germany. CAT, CATERPILLAR, their
www.catoilandgasinfo.com Leaflet No. 706GP · 01.14 · e · L+S · VM3 respective logos, ACERT, ADEM, „Caterpillar Yellow“ and the POWER EDGE trade dress,
LEBW0014-01 as well as corporate identity used herein, are trademarks of Caterpillar and may not
be used without permission.
Caterpillar Oil & Gas is committed to sustainability. This document is printed on
Please check out the CM32 Specification Sheets
PEFC certificated paper.
TM
(12 + 16 cylinder) by scanning the QR code
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12_16_CM32C-Project-Guide_Petroleum_2013_Layout 1 20.01.

CM32 Project Guide • Petroleum Applications

Caterpillar Oil & Gas

Europe, Africa, Middle East and CIS Asia Pacific

(12 + 16 cylinder) by scanning the QR code

Information for the user of this project guide

This edition supersedes the previous edition of this project guide.

Caterpillar Motoren GmbH & Co. KG

Issue January 2014

CM32 – Generator Set – Oil & Gas 01.2014 I

CAT_CM32C_Vorspann.indd I 05.02.14 13:35

Global Resource from One Source

II CM32 – Generator Set – Oil & Gas 01.2014

CAT_CM32C_Vorspann.indd II 05.02.14 13:35

Providing integrated solutions for your power system means

To find your nearest dealer, simply go to:

CM32 – Generator Set – Oil & Gas 01.2014 III

CAT_CM32C_Vorspann.indd III 05.02.14 13:36

CERTIFICATE NO. M-12395

This is to certify that the

with type designation(s)

is found to comply with

Rating see page two for ratings

This Certificate is valid until 2017-06-30.

Issued at Høvik on 2013-10-16

IV CM32 – Generator Set – Oil & Gas 01.2014

CAT_CM32C_Vorspann.indd IV 05.02.14 13:36

CAT_CM32C_Vorspann.indd V 05.02.14 13:36

CAT_CM32C_Vorspann.indd VI 05.02.14 13:36

1.0 Engine description ......................................................................................... 1

1.2 Engine design features ...................................................................................................... 2

2.0 General data and outputs ............................................................................. 3

2.2 Generator set dimensions and weights .......................................................................... 9

2.4 Load application and recovery behaviour ..................................................................... 12

2.5 Flexible Camshaft Technology – FCT (option) ............................................................... 15

3.0 Installation and arrangement ...................................................................... 16

3.2 25 degree tilt capability ..................................................................................................... 16

3.3 Rules of classification societies ...................................................................................... 17

3.4 Required dimensions of generator .................................................................................. 18

3.5 Space requirement for dismantling of turbocharger cartridge

3.6 Engine parts ......................................................................................................................... 21

3.7 System connections ........................................................................................................... 22

3.8 Lifting of generator set ....................................................................................................... 23

CM32 – Generator Set – Oil & Gas 01.2014 VII

CAT_CM32C_Vorspann.indd VII 05.02.14 13:36

4.1 Hot-box ventilation .............................................................................................................. 24

4.2 Air shut-off valve ................................................................................................................. 25

5.0 Systems ............................................................................................................ 26

5.1 Fuel oil system, MGO/MDO operation ............................................................................ 26

VIII CM32 – Generator Set – Oil & Gas 01.2014

CAT_CM32C_Vorspann.indd VIII 05.02.14 13:36

5.3 Lubricating oil system ........................................................................................................ 41

5.4 Cooling water system ........................................................................................................ 47

CM32 – Generator Set – Oil & Gas 01.2014 IX

CAT_CM32C_Vorspann.indd IX 05.02.14 13:36

5.5 Starting air system .............................................................................................................. 57

5.6 Combustion air system ....................................................................................................... 60

5.7 Exhaust gas system ............................................................................................................ 61

X CM32 – Generator Set – Oil & Gas 01.2014

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6.1 Noise level for 12CM32C engines .................................................................................... 68

6.2 Noise level for 16CM32C engines .................................................................................... 68

7.0 Foundation ....................................................................................................... 69