WDAAA116776 - B - 19 Installation of Auxiliary Units and Modules

Installation Manual
19 Installation of auxiliary units and

modules
Document ID WDAAA116776b
Date of issue 25.10.2013
Status Approved
INSTRUCTIONS
Classification Confidential
Installation Manual
Table of Contents
19. Installation of auxiliary units and modules............................................................................................ 19-1

19.1. About these instructions...................................................................................................................... 19-1
19.2. Safety notes......................................................................................................................................... 19-1
19.2.1. Safety instructions for installation work........................................................................................ 19-1
19.2.2. Welding precautions..................................................................................................................... 19-2
19.3. Product handling................................................................................................................................. 19-3
19.3.1. Unpacking and inspection............................................................................................................ 19-3
19.3.1.1. Inspecting the delivery............................................................................................................ 19-3
19.3.1.2. Inspecting the pipes............................................................................................................... 19-3
19.3.2. Storing the unit after the inspection.............................................................................................. 19-4
19.3.3. Lifting the unit............................................................................................................................... 19-4
19.3.3.1. Lifting with a crane................................................................................................................. 19-4
19.3.3.2. Lifting with a forklift truck....................................................................................................... 19-5
19.3.4. Performing a separate flushing..................................................................................................... 19-5
19.4. Installing units and modules (overall sequence).................................................................................. 19-6
19.5. Mounting the unit................................................................................................................................. 19-7
19.5.1. Installation environment................................................................................................................ 19-7
19.5.2. Levelling the unit........................................................................................................................... 19-7
19.5.3. Fastening the unit to the floor....................................................................................................... 19-8
19.6. Installation of pipes.............................................................................................................................. 19-9
19.6.1. Installing pipes to external systems.............................................................................................. 19-9
19.6.2. Performing the final flushing....................................................................................................... 19-10
19.6.3. Mounting flexible hoses.............................................................................................................. 19-10
19.7. Electrical installation.......................................................................................................................... 19-11
19.7.1. Earthing the unit.......................................................................................................................... 19-11
19.7.2. Connecting the power supply and control cables...................................................................... 19-11
19.8. Finalizing the installation.................................................................................................................... 19-12
19.8.1. Touch-up and repair painting...................................................................................................... 19-12
19.9. Commissioning.................................................................................................................................. 19-12
19.9.1. Inspecting the installation........................................................................................................... 19-12
19.9.2. Performing functional tests......................................................................................................... 19-13
19.9.2.1. Adjusting control parameters and setpoints........................................................................ 19-13
19.9.2.2. Making test runs................................................................................................................... 19-14
19.9.2.3. Troubleshooting pumps........................................................................................................ 19-14
19.10. Installation details for Wärtsilä-designed units................................................................................ 19-15
19.10.1. Fuel oil system units.................................................................................................................. 19-15
19.10.1.1. Fuel pump units.................................................................................................................. 19-15
19.10.1.2. Fuel oil unit......................................................................................................................... 19-16
19.10.1.3. Return fuel unit................................................................................................................... 19-17
19.10.1.4. Ventilation tank unit............................................................................................................ 19-17
19.10.1.5. Fuel feeder unit................................................................................................................... 19-18
19.10.1.6. Heater unit.......................................................................................................................... 19-19
19.10.2. Lubricating oil system units...................................................................................................... 19-19
19.10.2.1. Lubricating oil pump units.................................................................................................. 19-19
19.10.2.2. Oil mist separator unit........................................................................................................ 19-20
19.10.2.3. Oil mist coalescer unit........................................................................................................ 19-21
19.10.3. Cooling system units................................................................................................................. 19-22
19.10.3.1. Preheating unit................................................................................................................... 19-22
19.10.3.2. Expansion vessel................................................................................................................ 19-22
19.10.3.3. Maintenance water tank..................................................................................................... 19-23
19.10.4. Exhaust gas and intake air system units................................................................................... 19-24
19.10.4.1. Exhaust gas ventilation unit................................................................................................ 19-24
19.10.4.2. Charge air preheating unit.................................................................................................. 19-24
WDAAA116776b Confidential i
Installation Manual
19.10.4.3. Turbocharger washing unit................................................................................................. 19-25

19.10.5. Oily water system units............................................................................................................. 19-26
19.10.5.1. Oily water and sludge pump units...................................................................................... 19-26
ii Confidential WDAAA116776b
Installation Manual 19. Installation of auxiliary units and modules
19. Installation of auxiliary units and modules
19.1 About these instructions

These instructions describe the installation of the prefabricated auxiliary units and modules,
giving general information about the various stages of the installation and the
recommended installation methods. Some of the more complex modules have their own
installation manuals with more type-specific instructions. In such a case, the installation
shall primarily be performed in accordance with that document.
NOTE
These instructions cover only units that are designed by Wärtsilä. For
instructions on installing other units, refer to the manuals issued by the
manufacturer.
These installation instructions are intended as guidance only, and some procedures are
described on a quite general level. Detailed specifications and installation requirements are
given in the mechanical and electrical drawings of the specific unit, and must be considered
when applying the instructions.
19.2 Safety notes

For detailed information about plant safety, first aid and actions in emergency situations,
refer to the separate plant safety instruction documents. All personnel working in the plant
must read the safety instructions and be familiar with the safety routines.
19.2.1 Safety instructions for installation work

To prevent personal injury or equipment damage, it is important that the safety instructions
are always observed during the installation. All installation tasks must be performed by
adequately trained workers, and no unauthorized people must be allowed in the area. All
installation equipment must be in excellent condition and thoroughly inspected.
The following general safety precautions are to be followed during the installation work:
● Always use adequate personal protective equipment.
● Do not go under a unit that is being lifted.
● Electrical installations must always be done by certified electricians. Improperly
connected electrical wires may cause severe personal injury or equipment damage.
○ Before connecting power cables or starting any other electrical installation work,
check that the system is not energized. Also make sure that the power cannot be
connected during the installation work.
○ Be careful not to damage any cables or other electrical equipment during the
installation.
● All welding operations must be performed by qualified personnel.
○ Before starting the welding, check that there is no flammable material nearby. Also
make sure that there are no explosive gases and that the ventilation is sufficient.
○ Beware of hot surfaces during and after the welding.
WDAAA116776b Confidential 19-1

19. Installation of auxiliary units and modules Installation Manual
● The material safety data sheets (MSDS) provided with the chemicals must be thoroughly
studied before the chemicals are used.
○ When handling chemicals, contact with skin and eyes must be avoided. Therefore,
always use protective clothing, including safety glasses and impermeable gloves. A
respirator may also be required. Never eat or drink while handling chemicals.
○ The chemicals must be kept in a well ventilated place. Spills must be properly
collected and the chemicals disposed of in accordance with the regulations and the
material safety data sheet.
● Make sure that all units are properly supported during the installation work, so that they
cannot fall or tip over.
● Notify the other installation workers before starting an installation task that requires
special attention from co-workers.
19.2.2 Welding precautions

To reduce the risk of personal injury and equipment damage, proper precautions must be
taken before starting any welding work. All welding work must be performed by qualified
welders who have valid welding certificates.
● Take care to secure the personnel safety.
○ Always use adequate protective equipment, including eye protection and fireproof
clothing.
○ To improve the insulation, use dry rubber boots and leather gloves. If necessary,
perform the welding work on an insulating protective mat.
○ To avoid burn injuries, keep in mind that the work piece is hot during the welding.
Also beware of hot surfaces after the welding.
● Take the necessary fire protection precautions.
○ Before starting the welding, check that there is no flammable material nearby. Also
make sure that there are no explosive gases and that the ventilation is sufficient.
○ Keep a foam extinguisher near the welding location, as welding sparks and hot work
pieces always cause a risk of fire.
○ A fire watcher, who is trained to use the fire extinguisher, should be present
whenever welding is being performed. The fire watch should be maintained for at
least half an hour after completing the welding, to extinguish possible smouldering
fires.
● Take the necessary precautions to prevent equipment damage.
○ Do not place the welding devices close to power supplies or other electric devices.
○ Disconnect any sensitive electronic equipment.
CAUTION
The control cabinets must be disconnected before starting any welding work.
○ Protect bellows and flexible hoses against welding sparks, for instance using steel
sheets or leather.
● Make sure that the return current cable of the welding device is connected in a safe and
correct way. In addition to the risk of equipment damage, incorrect connection of the
cable constitutes a safety hazard.
19-2 Confidential WDAAA116776b

19.3 Product handling

To prevent accidents, appropriate safety precautions must always be taken when handling
the product. This includes the use of personal protective equipment, such as safety shoes
and hard hat.
WARNING
The transport and lifting must be done only by authorized persons who have
received adequate training.
19.3.1 Unpacking and inspection

The unit can be delivered in a container or a wooden crate.
The container or crate can be lifted and moved with a crane. The crate can also be
transported with a forklift truck, provided that a truck with sufficient capacity is available.
NOTE
If the unit will be stored outdoors, keep the container or crate unopened until it
is time for the installation or inspection of the delivery.
For information about the weight of the unit, refer to the dimensional drawing.
19.3.1.1 Inspecting the delivery

When the equipment has arrived to the site, it should be checked for transport damage or
missing parts.
Procedure
1 Check the delivery against the packing list, to make sure that all parts are included.
Make sure that all pipes and other components that were dismounted for the transport are
included in the delivery.
2 Make a visual inspection of the equipment for signs of transport damage.

Check that any temporary fastening and locking devices are intact, and that all protective
covers are in place and undamaged.
3 If transport damage is found or suspected, make a thorough inspection and

immediately issue a failure report.
Consider that the process of delivering replacement parts may be time-consuming.
Postrequisites
If the equipment will be stored outdoors before the installation, it must be repacked after
the inspection.
19.3.1.2 Inspecting the pipes

Before the installation, the pipe systems must be inspected for rust or impurities.
Procedure
1 Remove the counter flanges and the protection plates of the pipes.

2 Inspect the pipes visually to check that they are clean on the inside.
3 Put the counter flanges and the protection plates back in place.
Postrequisites
If heavy rust or large impurities are found, the pipes must be mechanically cleaned or, in
worst case, chemically pickled or sandblasted before the installation. A separate flushing is
also needed. Contact Wärtsilä for further advice.
19.3.2 Storing the unit after the inspection

During storage, the unit must be protected from rain, heavy dust and other unfavourable
conditions.
● If possible, store the unit indoors in the container or crate until it is time for the
installation.
● Keep the container or crate unopened if the unit must be stored outdoors for a
long period of time.
If the unit was delivered in a wooden crate, cover it by a tarpaulin.
● Make sure that the unit is not subjected to excessive vibration.
19.3.3 Lifting the unit

A safe lifting arrangement is essential to avoid a risk personal injury or equipment damage.
● Make sure that the capacity of the lifting device is sufficient before starting to lift
the unit.
For information about the weight and the centre of gravity, refer to the dimensional
drawing of the unit.
● Lift the unit carefully, avoiding rapid movements or jerks that may damage the
equipment.
○ Do not lift the unit higher than necessary.
WARNING
Always make sure that nobody is under the lifted unit.
○ The unit must always be well balanced during the lifting.

● Make sure that the unit is properly supported if it is necessary to work under the
unit.
19.3.3.1 Lifting with a crane

Lifting with a crane requires careful preparations, to secure the personnel safety and avoid
equipment damage. Always use the lifting lugs or other dedicated lifting points when lifting
and moving a unit with a crane.
Procedure
1 Inspect the lifting equipment.

a Inspect the lifting lugs on the unit.
Check that the lifting lugs are correctly attached and that there are no cracks in the
welds around the lugs.

b Inspect the lifting ropes or chains.

Check that the ropes or chains are in perfect condition, and make sure that they are
strong enough.
2 Attach the lifting tools to the lifting lugs on the unit.

All lifting lugs should be used.
● Make sure that the lifting hooks are securely fastened.
● Make sure that the lifting ropes are long enough to obtain a sufficient lifting angle. Use
spreaders if required.
NOTE
The lifting ropes must not press against any part of the unit.
● Adjust the lifting ropes so that they carry the load evenly and the unit is well balanced.
The ropes must not get twisted.
3 Test the lifting arrangement.
a Tighten the lifting ropes until the unit is lifted off the floor.
b Check that the lifting tools are securely fastened.
c Check that the unit is well balanced.
4 Lift the unit carefully in position, avoiding impact against any nearby structures or
equipment.
19.3.3.2 Lifting with a forklift truck

The unit can be lifted with a forklift truck, provided that a truck with sufficient capacity is
available.
● Make sure that the capacity of the truck is sufficient to lift the unit.
○ The forks must be at least as long as the width of the unit.
○ The truck must be able to carry the weight of the unit.
● Place the forks entirely under the bottom frame of the unit.
Position the forks symmetrically around the centre of gravity, so that the unit lies stably
on the forks.
● Be careful not to damage the painted surfaces when lifting the unit.
If the protective coating is damaged, it must be repaired immediately.
19.3.4 Performing a separate flushing

All pipes in the unit have been flushed by the manufacturer before the delivery. Therefore,
no separate flushing is normally needed at the site. It is enough to flush the pipes in the unit
along with the external pipe systems in the final stage of the pipe system flushing.
The pipe systems in the unit need to be flushed separately only if the pipes are dirty, or if
mechanical cleaning or chemical pickling has been performed after the delivery. In that
case, a separate flushing must be done before the unit is connected to the external
systems.

CAUTION
It is of utmost importance that the pipes are clean. Dirt or impurities in the pipes
may cause severe damage to the engine.
CAUTION
When cleaning the external pipe systems made at the site, do not circulate the
pickling liquid in the unit.
If necessary, contact Wärtsilä for flushing instructions and advice regarding the need for a
separate flushing.
19.4 Installing units and modules (overall sequence)

This procedure outlines the main steps when installing an auxiliary unit. For detailed
instructions on performing the individual installation tasks, refer to the corresponding
sections of this manual.
The following drawings are needed when installing the unit:
● Master layout drawings
● Location plan drawings
● System flow diagram
● Dimensional drawing of the unit.
Procedure
1 Lift the unit in position.

2 Level the unit.
3 Fasten the unit to the floor or the support structures.
4 If some equipment has been delivered loose for easier transport, mount it on the unit.
5 Install the pipes to the external systems.
Cut the pipes to the correct length (unless prefabricated pipes are used), weld the flanges
and mount the pipes.
NOTE
All pipes made at the site must be properly cleaned and flushed before they are
installed.
6 Perform the final flushing of the complete pipe system if applicable.

A final flushing of the piping and the auxiliary units is required for the fuel system and the
lubricating oil system before these are connected to the engine. The final flushing can be
performed when the pipe system has been completely assembled.
7 Perform the electrical installation.
a Connect the earthing cable.
b Connect the power supply and control cables.
Postrequisites
Before taking the unit into use, perform the appropriate commissioning inspections and
tests to ensure that the installation is complete and the unit is ready for operation.

19.5 Mounting the unit
19.5.1 Installation environment

The unit should be located so that unnecessary piping is avoided. All components must be
accessible for supervision, inspection and maintenance work without jeopardizing the
personnel safety.
● The service space around the unit must enable easy inspection and maintenance.
Consider that components may have to be dismounted for maintenance or replacing.
● The unit must be positioned so that there is enough space in front of the control cabinet
and the front panel can be opened.
● The location of the unit should allow easy access to manual valves and other
components that may require actions by the operator.
● All local gauges should be easily accessible for monitoring.
19.5.2 Levelling the unit

Proper levelling of the unit compensates for slight unevenness of the floor. Depending on
the design, the unit can be levelled either by means of dedicated levelling bolts or by
inserting shims below the frame.
Procedure
1 Check that the unit is placed in the correct position.
2 If the unit is equipped with levelling bolts, put the bolts in place.
a Mount the levelling bolts in the preassigned locations, close to the corners of the
unit frame.
If the bolts have already been mounted, check that they are in the uppermost position so
that the unit does not yet rest on them.
b Tighten the levelling bolts just until they start to lift the unit off the floor.
3 Check that the unit frame is straight in all directions.

Use a spirit level or some other suitable levelling device.
4 Adjust the height of the module as necessary and then recheck the levelling. Repeat
this procedure until the unit frame is completely level.
Any inclination is corrected by tightening the appropriate levelling bolts, or by inserting
shims of suitable thickness between the unit frame and the floor.

Example
Fig 19-1 Levelling bolts GUID-EA8E36D8-2536-43E6-8348-926051A2D92F v1
Postrequisites
When the unit has been correctly levelled, it shall be secured to the floor with anchor bolts.
For units equipped with a levelling bolt arrangement, this is usually done using special
frame feet, which are delivered loose and have to be welded to the unit frame after
fastening them to the floor.
19.5.3 Fastening the unit to the floor
Prerequisites
Before fastening the unit to the floor, make sure that it has been correctly positioned
according to the layout drawings and properly levelled.
The unit is fastened to the floor using anchor bolts. The holes for the anchor bolts are
located in the corners of the unit frame. Alternatively, the unit can be equipped with
separate frame feet that are delivered loose and have to be welded to the unit frame after
fastening them to the floor.
Procedure
1 If the unit has separate frame feet, put these in position.

Check the correct locations of the frame feet from the dimensional drawing.
2 Drill the holes for the anchor bolts in the concrete foundation.
Check the correct size of the anchor bolts from the dimensional drawing.
3 Fix the unit frame (or the separate frame feet) to the floor with anchor bolts.
Tighten the anchor bolts to the torque specified by the manufacturer.
4 If the unit has separate frame feet, weld them to the unit frame. After the welding,
remove the welding slag and repaint the area.

Example
(1) Unit frame (3) Shims

(2) Concrete foundation (4) Anchor bolt
Fig 19-2 Anchor arrangement GUID-74B69FFC-E87B-4061-9BD2-A213EB2097FF v1
19.6 Installation of pipes

The pipes can be installed when the units to be connected have been mounted in their final
positions. Before the auxiliary systems are connected to the engine, the fuel and lubricating
oil piping must be flushed to remove any dirt.
The external pipes conveying heavy fuel oil, sludge or other high-viscosity liquids may have
to be insulated and trace heated, to prevent heat losses and ensure that the liquid is always
kept at a temperature and viscosity enabling pumping. The need for insulation and trace
heating depends on the plant type and the overall system design.
WARNING
Do not connect any pipe or open any flanges in the external pipe systems
before ensuring that the piping is not pressurized.
Table 19-1 Plant installation instructions for external piping
Piping/ducting supports WDAAA116756

Installation of flexible bellows and hoses WDAAA116758
Pressure test of pipelines WDAAA116766
Cleaning and flushing of external piping WDAAA116767
Trace heating WDAAA116779
Insulation of piping WDAAA116783
19.6.1 Installing pipes to external systems
Prerequisites
Before the pipes are installed, the units to be connected must be mounted in their final
positions.

The pipe connections of the unit are supplied with the necessary counter flanges.
● Make sure that pipes of the correct size and material are used.
● Make sure that the pipes are properly supported and fitted without tension.
All possible piping loads – such as the weight of the filled pipe and the thermal
expansion – must be taken into account.
● Clean and flush the pipes properly before connecting them, to remove any dirt.
● Keep the protective covers of the pipe connections in place until the pipes are
connected.
NOTE
Be careful not to let any dirt into the pipes during the installation.
● Tack weld the pipes to the flanges when the pipes are in position.
Remove the pipes for the final welding.
● Make sure that the gaskets of the flange connections are properly mounted and
that the bolts are tightened to the correct torque.
19.6.2 Performing the final flushing

In connection with the installation, a final flushing of the fuel and lubricating oil pipe systems
up to the engine must be performed. The purpose of the final flushing is to remove any dirt
or impurities that may have entered the pipes during transport, storage or installation.
CAUTION
It is of utmost importance that the pipes are perfectly clean. Dirt or impurities in
the pipes may cause severe damage to the engine.
For detailed information about the pipe system flushing, refer to the plant installation
instructions. Also see the flow diagrams.
● Make sure that the external pipes are properly cleaned before starting the final
flushing of the complete system.
● Flush all fuel and lubricating oil pipes in the auxiliary modules and the upstream
pipe systems.
○ Remove the filter elements before starting the flushing. Clean the filters after the
flushing.
○ Flush the fuel oil pipes with light fuel oil.
WARNING
Light fuel oil is a flammable liquid. Remove any potential ignition sources.
● Check the tightness of the pipe connections during the flushing.
19.6.3 Mounting flexible hoses

When mounting the flexible hoses, follow the instructions in the plant installation manual.
Install O-rings, gaskets and fittings in accordance with the material list for the flexible
connections, if available. Make sure that the correct screws and nuts are used, and install
hose clamps on the pipes as mentioned in the material list.

CAUTION
Do not twist or bend the hoses improperly.
Fig 19-3 Installing flexible hoses GUID-6632C67B-5768-435E-AE0C-035B015F34A4 v1
19.7 Electrical installation

Electrically powered units are equipped with an electrical cabinet for power distribution and
control. Alternatively, the unit may be connected to the power supply and control systems
through the main control cabinet of the auxiliary modules or another common control
cabinet.
The electrical installation work at the site includes connecting the power supply to the unit,
as well as connecting the control cables from external instrumentation and remote control
systems. The internal cables of the unit are generally factory-installed.
CAUTION
Be careful not to damage any factory-installed cables when lifting and mounting
the unit.
The power supply and control cables must be connected in complete accordance with the
electrical drawings and lists provided.
WARNING - ELECTRICITY
All electrical installation work must be done by certified electricians.
19.7.1 Earthing the unit

Pull the earthing cable from the dedicated earthing point of the unit frame to the plant’s
earthing bar. Refer to the earthing layout drawings of the plant.
19.7.2 Connecting the power supply and control cables
Prerequisites
Make sure that the electrical cabinet is securely mounted before connecting any cables to
the cabinet. Also check that the earthing cables are properly connected.
When connecting the power supply and control cables, refer to the applicable electrical
drawings, cable lists and wiring diagrams.
WARNING - ELECTRICITY
Do not switch on the power until all electrical connections are ready and in
accordance with the electrical drawings.

● Connect the power supply cables to the unit.

○ If the unit is equipped with its own electrical cabinet for internal power distribution,
the power supply cable is usually connected directly from the plant switchgear to the
terminals at the main switch of the cabinet.
○ If the power distribution is handled by a remote cabinet, the power supply cables are
connected from that cabinet directly to the individual components in the unit.
● Connect the control cables to the input and output connectors in the electrical
cabinet.
a Connect the control cables from the individual components in the unit, if a
remote control cabinet is used.
For units with their own local control cabinet, these cables are usually factory-
installed.
b Connect the cables from any external instrumentation (such as tank level
switches) and cabinets involved in the control of the unit.
c Connect the cables to the central control system of the plant.

The connections to the central control system may be installed for alarm indications,
status information or remote control.
Postrequisites
After the installation, check the cable continuity and make sure that the insulation is not
damaged. Make sure that all cables are properly fastened and supported.
19.8 Finalizing the installation
19.8.1 Touch-up and repair painting

The steel structures are protected from corrosion by a protective coating. Any damaged
coating must be carefully repaired to maintain the level of corrosion protection.
Touch-up painting is generally used for repairing damaged paintwork. Repair painting
involving more surface treatment is used when damage is seen on a bare steel surface, for
instance at welding seams. The size of the damaged area shall also be considered when
determining which painting method is suitable.
Detailed instructions for touch-up and repair painting are given in a separate chapter in the
plant installation instructions.
19.9 Commissioning
The commissioning procedures are performed to validate and document that the system is
correctly designed and installed, and that the equipment operates correctly. The
commissioning process includes checks to be made during the installation of the
equipment, as well as inspections and function tests to be performed after the installation.
19.9.1 Inspecting the installation

The factory acceptance test (FAT) reports are prepared by the equipment supplier before
the delivery. To verify that the unit is correctly installed, additional inspections and tests
must be carried out during and after the installation.
After the installation, inspect the whole system to ensure that the installation is complete
and that all stages of the installation have been correctly performed.

● Check that the unit and all connections have been installed according to the flow
diagram.
● Check that the unit is correctly positioned and properly fastened.
● Check that the piping has been correctly installed.
a Check that all pipe connections are sealed and tight.
b Check that all pipes are properly supported.
c Check that there is no visible tension on the pipes.

● Check that all bolts are tightened to the correct torque.
● Check that any required touch-up painting has been performed.
● Check that all electrical cables are correctly installed and connected.
a Check that the cables are pulled and connected according to the electrical
drawings.
b Check that the cables are properly fastened and supported.
c Check the cable continuity and make sure that the insulation is not damaged.
19.9.2 Performing functional tests
Prerequisites
CAUTION
Before starting the function tests, make sure that any tools or temporary
protective covers that may inhibit proper operation have been removed. The
permanent covers and protective shields must be in place.
Function tests are performed to verify that the installed equipment is ready for operation
and check its technical performance. Before performing the test runs for the whole system,
test the function of all components individually to make sure that they operate correctly.
● Test the operation of the motors and pumps.
a Check that there is no abnormal noise or vibration.
b Check that the rotation direction is correct.

● Check that all filters are in working order and that the filter elements are correctly
installed.
● Test the operation of the pressure relief valves and check the opening pressure.
● Measure the resistance of the electric heaters and trace heating circuits.
● Check that the steam traps are in working order.
● Test the automatic valves to make sure that they operate correctly and do not jam.
● Check that all manual valves can be turned freely and do not leak.
● Check all pressure and temperature indicators.
● Test the operation of all instrumentation equipment and control devices.
19.9.2.1 Adjusting control parameters and setpoints

Before the unit is taken into operation, the control parameters must be carefully adjusted.

● Adjust the opening pressure of the overflow valves for pressure control or
overpressure prevention.
● Adjust the compressed air pressure for pneumatic components with the pressure
reducers.
● Adjust the temperature settings of the heater control thermostats.
● Adjust the settings of the pressure and temperature switches for alarm indications
and protection.
● Adjust the manual throttle valves for flow regulation.
● Adjust the PLC settings from the operator's workstation in the central control
system.
19.9.2.2 Making test runs

Test runs are made to check the overall performance of the system.
● Check that all components are functioning without disturbance.
● Check that the instrumentation equipment and the control system operate
correctly.
● Pay attention to signs of leakage from any pipe or component.
● Monitor the process values, such as pressure and temperature readings.
a Make sure that all adjustable setpoints are correct.
b Check that the readings of the local gauges correspond to the values shown at
the terminal of the control system.
19.9.2.3 Troubleshooting pumps

If a pump shows signs of malfunction – such as abnormal noise, vibration or leakage – shut
it down until the cause of the problem has been found and corrected. Refer to the
documentation issued by the pump manufacturer for accurate instructions on
troubleshooting a specific type of pump.
Table 19-2 General pump troubleshooting instructions
Problem Possible cause Remedy

Wrong rotation direction Incorrectly connected power supply Reverse the terminal connections on
cables the electric motor.
The pump cannot be primed Blockage in the suction line Check the suction line for clogged
strainers, partially closed valves or
other blockage.
Major air leakage into the suction line Check the suction line for open vent
valves, untight connections or other
leakage.
An excessive counter pressure Deaerate the discharge line manually.
prevents air evacuation through the
discharge line by the pump.
Continued on next page

Problem Possible cause Remedy

Too low flow or pressure The opening pressure of the pressure Readjust the pressure relief valve.
relief valve is set too low.
Blockage in the suction line Check the suction line for clogged
strainers, partially closed valves or
other blockage.
Reduced pump capacity Inspect the pump for worn or damaged
parts.
Too high pressure The opening pressure of the pressure Readjust the pressure relief valve.
relief valve is set too high.
Too viscous liquid due to insufficient Temporarily lower the opening
heating pressure of the pressure relief valve
until the liquid is at the normal
temperature.
Blockage in the discharge line Check the discharge line for partially
closed valves or other blockage.
The pump does not start, or the motor Excessive counter pressure See the information about too high
overload relay trips repeatedly pressure above.
Power supply failure Check the motor and the electrical
connections.
The motor overload relay is faulty or Readjust or replace the overload relay.
incorrectly adjusted.
19.10 Installation details for Wärtsilä-designed units

This section describes some special considerations that should be observed when installing
specific units. For detailed installation requirements and specifications, see the mechanical
and electrical drawings of the unit. The external pipes shall be connected in accordance
with the plant-specific system flow diagrams.
19.10.1 Fuel oil system units

A final flushing of the fuel oil piping up to the engine shall be performed when the
mechanical system installation is complete. The auxiliary units in the engine fuel supply
system and the upstream fuel transfer system shall be included in the flushing.
The external pipes conveying heavy fuel oil (HFO) or other high-viscosity fuels have to be
trace heated and insulated, to reduce the heat losses and keep the fuel at a viscosity
enabling pumping.
19.10.1.1 Fuel pump units

The fuel pump units can be used for unloading fuel to the storage system or for transferring
fuel between different tanks. Proper operation of the pumps requires that the unit is
installed close to the upstream tank, and at a low level relative to the tank.
The pump unit is fastened to the foundation with anchor bolts. The electrical installation
usually includes the connection of control cables for level signals from the related tanks.

Fig 19-4 HFO transfer pump unit GUID-BB5DC23F-A489-49D0-A6D3-D3EF849EA384 v1
19.10.1.2 Fuel oil unit

The fuel oil unit forms part of the engine fuel supply system and shall be installed in a
position close to the engine. The unit is fastened to the floor with anchor bolts.
A pipe support shall be installed between the engine and the fuel oil unit, and bolted to the
engine foundation block. The fuel oil unit and the pipe support have to be at the same
height but, as the foundation block may sink 1–5 mm, the pipe support should be levelled
about 2 mm higher when installing it. The fuel pipes are connected to the engine using
flexible hoses.

Fig 19-5 Fuel oil unit GUID-C1C7F551-929F-4E12-B63C-FE15FD4D6FC9 v1
19.10.1.3 Return fuel unit

The return fuel unit collects leak fuel from the engine. The tank and pump assembly is often
integrated in one of the auxiliary modules of the engine, in which case it is pre-installed at
the factory with all pipes connected. If the return fuel equipment is delivered as a separate
unit, the unit shall be fastened to the floor in a position close to the engine.
The leak fuel piping is connected to the engine using flexible hoses.
Fig 19-6 Return fuel unit GUID-455712FC-0201-430E-A514-DA84EBFBADCB v1
19.10.1.4 Ventilation tank unit

The ventilation tank unit for engines running on crude oil provides ventilation of the engine
hot box and collection of dirty leak fuel. The unit shall be fastened to the floor in a position
close to the engine.

The ventilation outlet pipe from the unit shall be routed to a safe outdoor area, in
accordance with the plant-specific risk analysis regarding hazardous areas.
Fig 19-7 Ventilation tank unit GUID-41C8822E-8F5B-4B38-9CFF-134FC19592FA v1
19.10.1.5 Fuel feeder unit

The fuel feeder unit transfers fuel from the storage system to the engine fuel supply system.
The unit shall be installed close to the upstream fuel tank, to enable proper operation of the
feeder pumps.
The feeder unit is fastened to the foundation with anchor bolts. The power to the frequency
converters of variable-speed pumps is usually supplied directly from the plant switchgear,
while the power to other components is distributed by the local control cabinet of the unit.
Fig 19-8 Fuel feeder unit GUID-4ECF4010-BD42-4C84-BFBD-2E2121B237E6 v1

19.10.1.6 Heater unit

The fuel oil heater unit forms part of the engine fuel supply system, and shall be installed
close to the engine and its other auxiliary modules. The heater unit is usually
complementary to the compact booster unit and is connected to the engine through that
module.
The heater unit is fastened to the floor with anchor bolts. The electrical cables to the unit
are usually connected through the main auxiliary control cabinet of the engine.
Fig 19-9 Fuel oil heater and cooler unit GUID-5EB13A97-78E7-4DFF-A6EC-C96D22FCD0E4 v1
19.10.2 Lubricating oil system units

A final flushing of the lubricating oil piping up to the engine shall be performed when the
mechanical system installation is complete. The auxiliary units in the lubricating oil transfer
system shall be included in the flushing.
19.10.2.1 Lubricating oil pump units

The lubricating oil pump units can be used for unloading oil to the storage system, for
pumping used oil for disposal, or for transferring oil between the storage tanks and the
engine. Proper operation of the pumps requires that the unit is installed close to the
upstream tank, and at a low level relative to the tank.
The pump unit is fastened to the foundation with anchor bolts. The electrical installation
usually includes the connection of control cables for level signals from the related tanks.

Fig 19-10 Lubricating oil transfer pump unit GUID-75D7D145-5636-43C3-A62D-0A322683BB60 v1
19.10.2.2 Oil mist separator unit

The oil mist separator unit is installed in the crankcase ventilation piping from the engine.
The unit can be mounted in a reserved location on the exhaust gas module or bolted to
some other appropriate support structures.
The electrical cabinet of the separator unit has to be mounted in a suitable location in
connection with the installation. Depending on the installation location of the separator unit,
the cabinet can be mounted on brackets on the unit frame, or installed remotely for better
protection and easier access. The installation of the control cabinet includes connecting the
electrical cables to the separator unit, the plant switchgear and the central control system.
Refer to the separator unit manual for detailed installation instructions. If the unit will be
installed on the exhaust gas module, consider also the instructions in the module
installation manual.

Fig 19-11 Oil mist separator unit GUID-972EDB4C-973B-4F9E-8A9C-171883EECFDF v1
19.10.2.3 Oil mist coalescer unit

The oil mist coalescer unit is installed in the crankcase ventilation piping from the engine.
The unit can be mounted in a reserved location on the exhaust gas module or bolted to
some other appropriate support structures.
Fig 19-12 Oil mist coalescer unit GUID-10B8AA20-9C80-449C-8739-B8FAB2C9D2EC v1

19.10.3 Cooling system units
19.10.3.1 Preheating unit

The preheating unit is usually integrated in the engine auxiliary module. It may be pre-
installed on the module at the factory, or it may have to be mounted in the reserved location
in connection with the module installation. If the unit will be installed on the engine auxiliary
module at the site, refer also to the instructions in the module installation manual. The unit
is fastened to the module or other support structures with bolts.
If the preheating unit has its own electrical cabinet for power distribution and control, the
power is usually supplied directly from the plant switchgear. Otherwise, the unit is
connected to the power supply and control systems through the main auxiliary control
cabinet of the engine.
Fig 19-13 Preheating unit GUID-B987499E-A437-4EED-8499-4560E8CB1C56 v1
19.10.3.2 Expansion vessel

The expansion vessel shall be installed in an elevated position relative to the engine cooling
circuit, to achieve a sufficient suction pressure for the circulation pump. If the required
suction pressure cannot otherwise be achieved, a pressure increasing pump can be
installed in the piping between the expansion vessel and the engine cooling circuit. The
pipes to the expansion vessel – including the deaeration pipes from the engine – must have
a continuous upward slope to avoid air pockets.
The expansion vessel can be mounted in a reserved location on the exhaust gas module or
bolted to some other appropriate support structures. If the vessel will be installed on the
exhaust gas module, refer also to the instructions in the module installation manual.
The instrumentation for level monitoring is usually connected to the plant control system
through the main auxiliary control cabinet of the engine.

Fig 19-14 Expansion vessel GUID-EB806961-6A7E-43A6-ABD6-6262670B8833 v1
19.10.3.3 Maintenance water tank

The installation of the maintenance water tank mainly consists of mounting the external
piping and connecting the power supply cable to the pump control box.
NOTE
The maintenance water tank shall not be fastened to the floor.
The fresh water supply piping and the piping to the engine cooling system can be
connected to either side of the maintenance water tank. Blind flanges shall be mounted on
pipe connections that will not be used.
Fig 19-15 Maintenance water tank GUID-5C63FE7D-4CB9-4444-A4A6-4D4E48606C52 v1

19.10.4 Exhaust gas and intake air system units
19.10.4.1 Exhaust gas ventilation unit

The exhaust gas ventilation unit is usually mounted in a reserved location on the exhaust
gas module, but it can also be bolted to some other appropriate support structures at the
level of the exhaust gas duct. If the unit will be installed on the exhaust gas module, refer
also to the instructions in the module installation manual.
The ventilation unit is usually connected to the power supply and control systems through
the main auxiliary control cabinet of the engine.
Fig 19-16 Exhaust gas ventilation unit GUID-0324E24A-20E4-47CB-8BD1-9883449E3A23 v1
19.10.4.2 Charge air preheating unit

The charge air preheating unit is fastened to the floor with anchor bolts. Unless the unit is
equipped with a separate control cabinet, it is usually connected to the power supply and
control systems through the main auxiliary control cabinet of the engine.

Fig 19-17 Charge air preheating unit GUID-5E09D5EF-233A-44A4-9D92-D27AF263AD7E v1
19.10.4.3 Turbocharger washing unit

The turbocharger washing unit shall be installed close to the engine and secured to the
support structures with bolts. The electrical cables to the unit are usually connected
through the main auxiliary control cabinet of the engine.
Fig 19-18 Turbocharger washing unit GUID-DB0AF0A2-0E82-4EF3-9C7C-C339A83C9DFB v1

19.10.5 Oily water system units

Proper operation of the units in the oily water system may require trace heating and
insulation of the external piping, to keep the liquid at a viscosity enabling pumping. This
depends on the overall system design and the type of fuel used.
19.10.5.1 Oily water and sludge pump units

The oily water and sludge pump units are typically used for emptying drain pits or tanks.
The unit shall be installed close to the drain pit or the upstream tank, and secured to the
foundation with anchor bolts.
Pump units that are designed for automatic control are equipped with an electrical cabinet,
in which case the installation includes the connection of control cables for level signals from
the associated tank or drain pit. The electrical cables of pump units functioning as a feed
pump for a treatment unit are often connected through the control system of the treatment
unit.
Fig 19-19 Oily water transfer pump unit GUID-50775767-8D3D-4D37-8F2E-29E54622E596 v1

Wärtsilä is a global leader in complete lifecycle power solutions for the marine and energy markets.
By emphasising technological innovation and total efficiency, Wärtsilä maximises the environmental
and economic performance of the vessels and power plants of its customers. Wärtsilä is listed on the
NASDAQ OMX Helsinki, Finland.
See also www.wartsila.com
WÄRTSILÄ® is a registered trademark. © 2013 Wärtsilä Corporation.
Wärtsilä Services Main Office Vaasa, Finland

24hrs Phone +358 10 709 080
Switchboard +358 10 709 0000
Fax +358 10 709 1380
Find local offices at www.wartsila.com/addresses

WDAAA116776 - B - 19 Installation of Auxiliary Units and Modules

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WDAAA116776 - B - 19 Installation of Auxiliary Units and Modules

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Installation Manual

19 Installation of auxiliary units and

Date of issue 25.10.2013

19. Installation of auxiliary units and modules............................................................................................ 19-1

19.10.4.3. Turbocharger washing unit................................................................................................. 19-25

19. Installation of auxiliary units and modules

19.1 About these instructions

19.2 Safety notes

19.2.1 Safety instructions for installation work

WDAAA116776b Confidential 19-1

19.2.2 Welding precautions

19-2 Confidential WDAAA116776b

19.3 Product handling

19.3.1 Unpacking and inspection

19.3.1.1 Inspecting the delivery

2 Make a visual inspection of the equipment for signs of transport damage.

3 If transport damage is found or suspected, make a thorough inspection and

19.3.1.2 Inspecting the pipes

WDAAA116776b Confidential 19-3

19.3.2 Storing the unit after the inspection

19.3.3 Lifting the unit

○ The unit must always be well balanced during the lifting.

19.3.3.1 Lifting with a crane

1 Inspect the lifting equipment.

19-4 Confidential WDAAA116776b

b Inspect the lifting ropes or chains.

2 Attach the lifting tools to the lifting lugs on the unit.

3 Test the lifting arrangement.

b Check that the lifting tools are securely fastened.

c Check that the unit is well balanced.

19.3.3.2 Lifting with a forklift truck

19.3.4 Performing a separate flushing

WDAAA116776b Confidential 19-5

19.4 Installing units and modules (overall sequence)

1 Lift the unit in position.

6 Perform the final flushing of the complete pipe system if applicable.

19-6 Confidential WDAAA116776b

19.5 Mounting the unit

19.5.1 Installation environment

19.5.2 Levelling the unit

1 Check that the unit is placed in the correct position.

3 Check that the unit frame is straight in all directions.

WDAAA116776b Confidential 19-7

Fig 19-1 Levelling bolts GUID-EA8E36D8-2536-43E6-8348-926051A2D92F v1

19.5.3 Fastening the unit to the floor

1 If the unit has separate frame feet, put these in position.

19-8 Confidential WDAAA116776b

(1) Unit frame (3) Shims

Fig 19-2 Anchor arrangement GUID-74B69FFC-E87B-4061-9BD2-A213EB2097FF v1

19.6 Installation of pipes

Table 19-1 Plant installation instructions for external piping

Piping/ducting supports WDAAA116756

19.6.1 Installing pipes to external systems

WDAAA116776b Confidential 19-9

19.6.2 Performing the final flushing

● Check the tightness of the pipe connections during the flushing.

19.6.3 Mounting flexible hoses

19-10 Confidential WDAAA116776b

Fig 19-3 Installing flexible hoses GUID-6632C67B-5768-435E-AE0C-035B015F34A4 v1

19.7 Electrical installation

19.7.1 Earthing the unit

19.7.2 Connecting the power supply and control cables

WDAAA116776b Confidential 19-11