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L27/38-VBS Project Guide: Four-Stroke Propulsion Engine Compliant With IMO Tier II
L27/38-VBS Project Guide: Four-Stroke Propulsion Engine Compliant With IMO Tier II
Project Guide
Four-stroke Propulsion Engine
compliant with IMO Tier II
Introduction Contents
Complete manual
May 2015
MAN Diesel & Turbo
Introduction
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Page 1 (2) Project guide Index
L27/38
Dispatch condition of engine and reduction gear from MAN Diesel 912000 1699261-3.0
Storage of propeller equipment 912000 3700230-5.1
Storage of electronic equipment 912000 1699912-1.1
Lifting instruction 912000 3700398-3.0
Engine 14000
2015.05.07
MAN Diesel & Turbo
Plate
Index Project guide Page 2 (2)
L27/38
2015.05.07
General information
1000
MAN Diesel & Turbo
3700132-3.2
Page 1 (2) Introduction 100000
All data provided in this document is non-binding. This data serves informational purposes only and is especially not guar-
anteed in any way.
Depending on the subsequent specific individual projects, the relevant data may be subject to changes and will be
assessed and determined individually for each project. This will depend on the particular characteristics of each individual
project, especially specific site and operational conditions.
If this document is delivered in another language than English and doubts arise concerning the translation, the English
text shall prevail.
Original instructions
2015.03.09
MAN Diesel & Turbo
3700132-3.2
100000 Introduction Page 2 (2)
Propeller equipment
VBS 860
VBS CP propeller with monoblock hub
860 diameter of propeller hub
Propeller nozzle
FD 2930 x 0.5
FD or Fixed nozzle
RD Steering nozzle
2930 inside diameter in mm
0.5 lenght/diameter ratio
Control system
Alphatronic or Electronic control system with optimized automatic load control
SaCoSone and combined or separate pitch and rpm setting.
2015.03.09
MAN Diesel & Turbo
1689462-2.3
Page 1 (1) Engine Programme IMO Tier II - Propulsion 100000
L21/31, L23/30A
L27/38, L28/32A
Four-stroke diesel engine programme for marine
applications complies with IMO Tier II, Propulsion
application.
400-428 L58/64
1000-
V28/33D*
1032
1000-
V28/33D STC*
1032
775 L28/32A
L27/38
800
L27/38 (MGO)
900 L23/30A
1000 L21/31
12.05 - Tier II
MAN Diesel & Turbo
1696467-1.1
Page 1 (1) Project Service 109000
General
Prior to the final engineering stage we need con- Plant Specific Installation Manual
firmed documentation for the project in question
and with the following drawings in our possession: Once the contract documentation has been com-
pleted a Plant Specific Installation Manual will be
Ship lines plan available on the extranet.
Engine room arrangement
Instruction manual
General arrangement
Foundation (re-engining) As part of our technical documentation, an instruction
Exhaust gas system manual will be forwarded. The instruction manual
is tailor–made for each individual propulsion plant
Together with adequate information on the hull our and includes:
Project Engineers are able to carry out arrangement
drawings showing the most suitable location of the Descriptions and technical data
propulsion plant in the ship. Operation and maintenance guidelines
Spare parts plates
The optimum layout of propeller shaftline and bear-
ings, location of Power Take Off (PTO) and execution The manual can be supplied as a printed copy as
of exhaust pipe will be highly considered as well as well as an electronic book in English on CD–ROM.
securing sufficient space for daily maintenance and
major overhauls.
Customer information
Moreover, to assist the naval consultant or the
shipyard in accomplishing arrangement drawings, MAN Diesel & Turbo SE
drawings of our complete propulsion package can Niels Juels Vej 15
be forwarded on CD-ROM or by E−mail direct to you. DK-9900 Frederikshavn
The drawings will be forwarded in DXF− or DWG− Denmark
format in latest version, which can be imported by
most CAD−systems. Phone +45 96 20 41 00
Fax +45 96 20 40 30
Our Project Service from sales to order implementa- E-mail info-frh@mandieselturbo.com
tion comprises fields such as: www.mandieselturbo.com
10.39
MAN Diesel & Turbo 1 00 000
L27/38 Propulsion
L27/38 Propulsion
The concept
Many years of experience with the propulsion concept, together with cus-
tomers’ requirements for reliability, economy and technical advancement has
resulted in this attractive 800 rpm engine with a cylinder output of 340 kW.
The L27/38 engine can also be quoted with a higher cylinder output of 365
kW at 800 rpm. However, the elevated load is only possible for operation
with MGO and MDO (MDO viscosity must not exceed 6 mm2/s = @ 40° C)
according to MAN Diesel specification.
Combined with gearboxes, CP propellers and control systems, the L27/38 is
a fully integrated propulsion package for ferries, Ro–Ro vessels, container
feeder vessels, cargo ships, tugs, supply and fishing vessels requiring 2040–
3285 kW.
Installation aspects
The development target and design philosophy were to achieve the shortest
possible propulsion system by optimizing the combination of engine, flexible
coupling and gearbox.
2015-05-07 - en
Low dismantling height for cylinder head, piston and cylinder liner is ensured
thanks to the marine head connecting rod.
Description
3700112-0.1
TCR 1 (4)
L27/38 EN
1 00 000 MAN Diesel & Turbo
100% PTO is possible from either end of the engine and in addition a small
L27/38 Propulsion
2015-05-07 - en
Description
3700112-0.1
2 (4) TCR
L27/38 EN
MAN Diesel & Turbo 1 00 000
L27/38 Propulsion
Standard programme L27/38 – open propeller
Engine type Propeller Dimensions in mm
output MCR at Hub type Speed rpm Diameter B C G H L M W-min
800 rpm mm
6L27/38 VBS740 256 2650 3962 5070 1166 2225 569 655 1300
2040 kW VBS740 208 2950 3962 5070 1166 2225 569 655 1300
VBS860 177 3200 3962 5070 1166 2225 653 743 1400
VBS860 145 3500 3962 5070 1166 2225 653 743 1400
VBS860 133 3650 3962 5070 1166 2225 653 743 1400
7L27/38 VBS740 256 2800 4407 5515 1166 2357 569 655 1300
2380 kW VBS860 208 3100 4407 5515 1166 2357 653 743 1400
VBS860 177 3350 4407 5515 1166 2357 653 743 1400
VBS860 145 3650 4407 5515 1166 2357 653 743 1450
VBS980 133 3800 4407 5515 1166 2357 746 806 1500
8L27/38 VBS860 256 2900 4852 5960 1256 2357 653 743 1400
2720 kW VBS860 208 3200 4852 5960 1256 2357 653 743 1400
VBS860 177 3450 4852 5960 1256 2357 653 743 1450
VBS860 161 3600 4852 5960 1256 2357 653 743 1450
VBS980 133 3950 4852 5960 1256 2357 746 806 1500
9L27/38 VBS860 256 3000 5263 6405 1268 2357 653 743 1400
3060 kW VBS860 208 3300 5263 6405 1268 2357 653 743 1400
VBS860 177 3550 5263 6405 1268 2357 653 743 1400
VBS980 161 3700 5263 6405 1268 2357 746 806 1500
VBS980 133 4050 5263 6405 1268 2357 746 806 1550
The propeller diameter is optimized at 85% MCR, 98% rpm and 14.0 kn.
The strength calculation is made at 100% MCR, 100% rpm and 14.5 kn.
The propeller is calculated according to DnV, No ice with high skew.
VBS860 177 3300 4852 5960 1256 2357 653 743 1450
VBS860 161 3550 4852 5960 1256 2357 653 743 1450
Description
3700112-0.1
VBS980 133 3900 4852 5960 1256 2357 746 806 1500
TCR 3 (4)
L27/38 EN
1 00 000 MAN Diesel & Turbo
2015-05-07 - en
Description
3700112-0.1
4 (4) TCR
L27/38 EN
MAN Diesel & Turbo
1696433-5.1
Page 1 (2) Vibration levels 108054
L21/31, L27/38
2015.01.22
MAN Diesel & Turbo
1696433-5.1
108054 Vibration levels Page 2 (2)
L21/31, L27/38
2015.01.22
MAN Diesel & Turbo
3700395-8.0
Page 1 (3) Vibration limits and measurements 10 80 54
Crosswise (y)
100
Longitudinal (x)
100
2015.03.20
MAN Diesel & Turbo
3700395-8.0
10 80 54 Vibration limits and measurements Page 2 (3)
GenSet
Crosswise (y)
100
Longitudinal (x)
100
2015.03.20
MAN Diesel & Turbo
3700395-8.0
Page 3 (3) Vibration limits and measurements 10 80 54
Turbocharger
Vibration acceleration measuring point, see the project guide for turbocharger.
Crosswise (y)
100
Longitudinal (x)
100
2015.03.20
MAN Diesel & Turbo
1696436-0.1
Page 1 (1) NOx emission 108059
L27/38
11.04 - Tier II
Propeller equipment
2000
MAN Diesel & Turbo 2 00 010
Engine power % 85 85
Engine revolutions % 98 98
Ship speed knots 14 4
Description
1696402-4.2
1 (3)
L27/38 EN
2 00 010 MAN Diesel & Turbo
Project planning data
2 (3)
L27/38 EN
MAN Diesel & Turbo 2 00 010
3 (3)
L27/38 EN
MAN Diesel & Turbo
1690706-0.1
Page 1 (2) Propeller Layout Data 200010
L21/31
L27/38
Project : _______________________________________________________
S W I
D
D : ________ mm
5. Copies of complete set of reports from model tank test (resistance test, self-propulsion test and
wake measurement).
In case model test is not available section 10 must be filled in.
9. To obtain the highest propeller efficiency please identify the most common
service condition for the vessel:
Draft : __________ m
04.50
MAN Diesel & Turbo
1690706-0.1
200010 Propeller Layout Data Page 2 (2)
L21/31
L27/38
10. Vessel Main Dimensions (Please fill-in if model test is not available)
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
Date:_________________________ Signature:___________________________
04.50
MAN Diesel & Turbo
1696403-6.1
Page 1 (1) Propeller clearance 200010
L27/38
To reduce emitted pressure impulses and vibrations In twin-screw ships the blade tip may protrude below
from the propeller to the hull, MAN B&W Alpha the base line.
recommend a minimum tip clearance as shown in
fig 1.
X
2 P04-AMG28E
Baseline
VBS740 250
VBS860 265 15-20% of D 20-25% of D Mininum 50-100
VBS980 325
04.48
MAN Diesel & Turbo
1690708-4.1
Page 1 (1) Direction of rotation 200010
L21/31
L27/38
Definitions This solution will normally give the propellers the
highest efficiency, because the flow around the stern
The direction of rotation is defined seen from aft. The of most vessels will favour this direction of rotation.
normal direction is anticlockwise for the propeller.
Opposite rotating direction can also be supplied by However, it is not possible to give an opinion con-
changing direction of the engine. cerning this, unless model tests are carried out for
the specific vessel.
PS SB PS SB
port side starboard port side starboard
04.46
MAN Diesel & Turbo
3700068-8.1
Page 1 (7) Propeller Operation 200010
General
90
80
80
70
70
60
60
1 50
50
2
40
40
Range II
Range I 30
30
20
20
3
10 10
0
40 50 60 70 80 90 100 110
Engine speed [%]
11.07 - Tier II
MAN Diesel & Turbo
General
Maximum continuous rating (MCR) The engine speed has to be increased before in-
creasing the propeller pitch (see Fig 2, Example to
Range I: Operating range for continuous operation. illustrate the change from one load step to another).
Range II: Operating range which is temporarily ad- Or if increasing both synchronic the speed has to be
missible e.g. during acceleration and manoeuvring. increased faster than the propeller pitch. The area
above the combinator curve should not be reached.
The combinator curve must keep a sufficient distance
to the load limit curve. For overload protection, a load Deceleration/unloading the engine
control has to be provided.
The engine speed has to be reduced later than the
Transmission losses (e.g. by gearboxes and shaft propeller pitch (see Fig 2, Example to illustrate the
power) and additional power requirements (e.g. by change from one load step to another).
PTO) must be taken into account.
Or if decreasing both synchronic the propeller pitch
has to be decreased faster than the speed. The area
General requirements for propeller pitch above the combinator curve should not be reached.
control
Windmilling protection
Pitch control of the propeller plant
If a stopped engine (fuel admission at zero) is being
For mechanical speed governors turned by the propeller, this is called "windmilling".The
permissible period for windmilling is short, because
As a load indication a 4–20 mA signal from the en- windmilling can cause, due to poor lubrication at
gines admission teletransmitter is supplied to the low propeller speed, excessive wear of the engines
propeller control system. bearings.
As a load indication a 4–20 mA signal from the en- The propeller control has to ensure that the windmill-
gines electronic governor is supplied to the propeller ing time is less than 40 sec.
control system.
Multiple-screw ship
General
The propeller control has to ensure that the windmill-
A distinction between constant-speed operation and ing time is less than 40 sec. In case of plants without
combinator-curve operation has to be ensured. shifting clutch, it has to be ensured that a stopped
engine won't be turned by the propeller.
Combinator-curve operation:
The 4–20 mA signal has to be used for the assignment (Regarding maintenance work a shaft interlock has
of the propeller pitch to the respective engine speed. to be provided for each propeller shaft.)
The operation curve of engine speed and propeller
pitch (for power range, see Fig 1, Operating range
for controllable-pitch propeller) has to be observed
also during acceleration/load increase and unloading.
11.07 - Tier II
MAN Diesel & Turbo
3700068-8.1
Page 3 (7) Propeller Operation 200010
General
1 Load limit
2 Recommended combinator curve MCR
3 Zero thrust
Detail:
decreasing load
1st Pitch
1
(load)
2nd Speed
2
Detail:
increasing load
2nd Pitch
(load)
1st Speed
Load steps
Fig 2 Example to illustrate the change from one load step to another
11.07 - Tier II
MAN Diesel & Turbo
General
Propeller pitch reduction contact In case of a manned engine room, the engine room
personnel is responsible for the soft loading se-
This contact is activated when disturbances in engine quence, before control is handed over to the bridge.
operation occur, for example too high exhaust-gas
mean-value deviation. When the contact is activated, The lower time limits for normal and emergency ma-
the propeller control system has to reduce the propel- noeuvres are given in our diagrams for application
ler pitch to 60% of the rated engine output, without and shedding of load. We strongly recommend that
change in engine speed. the limits for normal manoeuvring will be observed
during normal operation, to achieve trouble-free
Distinction between normal manoeuvre and engine operation on a long-term basis. An automatic
emergency manoeuvre change-over to a shortened load programme is re-
quired for emergency manoeuvres.
The propeller control system has to be able to distin-
guish between normal manoeuvre and emergency The final design of the programme should be jointly
manoeuvre (i.e., two different acceleration curves determined by all the involved parties, considering
are necessary). the demands for manoeuvring and the actual service
capacity.
MAN Diesel & Turbo's guidelines concerning
acceleration times and power range, see page Please note that the time constants for the dynamic
4 and page 1. behaviour of the prime mover and the vessel are in
the ratio of about 1:100. It can be seen from this that
an extremely short load application time generally
don't lead to an improvement in ships manoeuvring
behaviour (except tugs and small, fast vessels).
11.07 - Tier II
Fig 3
11.07 - Tier II
Page 5 (7)
3700068-8.1
ASTERN AHEAD
MAN Diesel & Turbo
100
90
Emergency Manoeuvre
70
60
Normal Manoeuvre
50
40
20
10
0
1 0 2 1 0 0 1 2 3 4 5 6 7 8 9 10 0 1 2
Time in minutes Time in minutes
Time [min] with preheated engine (lube oil temperature minimum 40°C, cooling water temperature minimum 60°C)
Engine speed should generally rise more quickly than propeller pitch when loading and fall more slowly when unloading the engine.
200010
General
MAN Diesel & Turbo
General
100 90
70
4(FP) 60
3
2
60 1
50
50
Range II
40
40
30
30
Range I 20
20
10 10
106
103,5
0
30 40 50 60 70 80 90 100 110
Engine speed [%]
Fig 4 Operating range for fixed-pitch propeller
11.07 - Tier II
MAN Diesel & Turbo
3700068-8.1
Page 7 (7) Propeller Operation 200010
General
• Maximum continuous rating (MCR), fuel stop The propeller design depends on type and applica-
power tion of the vessel. Therefore the determination of the
installed propulsive power in the ship is always the
• Range I exclusive responsiblity of the yard.
Operating range for continuous service subject Determining the engine power: The energy demand
to a propeller light-running of 1.5–3%. It should or the energy losses from all at the engine additionally
be aimed at the lower value. attached aggregates has to be considered (e.g. shaft
alternators, gearboxes).That means, after deduction
• Range II (torque limit) of their energy demand from the engine power the
remaining engine power must be sufficient for the
Operating range which is temporarily admissible required propulsion power.
e.g. during acceleration, manoeuvring.
Note!
• Theoretical propeller curve
Type testing of the engines is carried out at 110%
Applies to a fully loaded vesel after a fairly long rated output and 103% rated engine speed.
operating time and to a possible works trial run
with zero-thrust propeller.
• FP
Attention!
11.07 - Tier II
MAN Diesel & Turbo 227000
Installation
The stern tube must be fitted with a tight fit. The propeller boss is measured
and the stern tube is finished with an interference of 0.02 - 0.05 mm.
If the bore in the boss is rough or out of round then the bore should be
lighter. The contact face of the boss for the stern tube flange has to be flat
and square to shaft line, so a leak-proof assembly is obtained. The bore
is chamfered.
The stern tube with gasket is pressed into position, the oil grooves of the
stern tube bearings being in horizontal position.
The alignment / welding ring and the sealing flange is fitted on the forward
end of the stern tube. The adapter ring is mounted on the forward end of
the stern tube, and the oilbox is mounted to.
The installation length for the stern tube is checked - it should not deviate
by more than S-dimension ± 5.0 mm
Molykote GN is applied to the bolts before tightening in to the required
torque.
Bearing temperature sensors may be required by more of the classification
societies, and fitted in the stern tube.
Description
The following formula can be used for calculating of the approx. force
required:
F=
(p × E × m)
2
( 2
× L 1 – (d/D) × U )
Stern Boss
1 2 3 4 5 6 7 8 9
1. Stern tube
2. Gasket
Alpha Fixed Pitch Propeller
4. Sealing ring
5. Sealing flange
6. Gasket
7. Adapter ring
2005-03-07
Description
8. Gasket
Epoxy chocks
Maintenance
The stern tube requires no maintenance, but care should be taken that the
lubricating oil is not contaminated by water or impurities. With good lubri-
cation the life of the white-metal bearings can be 100,000 hours or more.
The max permissible wear is 1.5 mm.
The clearance of a new stern tube bearing is indicated in the table below
where A = shaft diameter and D = inside diameter of stern tube bearing.
A = 100 – 200 mm
D = A + 0.5 –+ 00.05
A = 201 – 300 mm
D = A + 0.6 –+ 00.05
A = 301 – 400 mm
D = A + 0.7 –+ 00.05
A = 401 – 500 mm
D = A + 0.8 –+ 00.15
A = 501 – 600 mm
D = A + 0.9 –+ 00.15
Description
Installation
The stern tube must be fitted with a tight fit. The propeller boss is measured
and the stern tube is finished with an interference of 0.02 - 0.05 mm.
If the bore in the boss is rough or out of round then the bore should be
lighter. The contact face of the boss for the stern tube flange has to be flat
and square to shaft line, so a leak-proof assembly is obtained. The bore
is chamfered.
The stern tube with gasket is pressed into position, the oil grooves of the
stern tube bearings being in horizontal position.
The alignment / welding ring and the sealing flange is fitted on the forward
end of the stern tube. The adapter ring is mounted on the forward end of
the stern tube, and the oilbox is mounted to.
The installation length for the stern tube is checked - it should not deviate
by more than S-dimension ± 5.0 mm
Molykote GN is applied to the bolts before tightening in to the required
torque.
Bearing temperature sensors may be required by more of the classification
societies, and fitted in the stern tube.
Description
The following formula can be used for calculating of the approx. force
required:
F=
(p × E × m)
2
( 2
× L 1 – (d/D) × U )
Stern Boss
1 2 3 4 5 6 7 8 9
1. Stern tube
2. Gasket
Alpha Fixed Pitch Propeller
4. Sealing ring
5. Sealing flange
6. Gasket
7. Adapter ring
2005-03-07
Description
8. Gasket
Epoxy chocks
Maintenance
The stern tube requires no maintenance, but care should be taken that the
lubricating oil is not contaminated by water or impurities. With good lubri-
cation the life of the white-metal bearings can be 100,000 hours or more.
The max permissible wear is 1.5 mm.
The clearance of a new stern tube bearing is indicated in the table below
where A = shaft diameter and D = inside diameter of stern tube bearing.
A = 100 – 200 mm
D = A + 0.5 –+ 00.05
A = 201 – 300 mm
D = A + 0.6 –+ 00.05
A = 301 – 400 mm
D = A + 0.7 –+ 00.05
A = 401 – 500 mm
D = A + 0.8 –+ 00.15
A = 501 – 600 mm
D = A + 0.9 –+ 00.15
Description
Fig 1
Stern tube
Alignment
ring
Description
Fig 1
Stern tube
Alignment
ring
Description
1696404-8.1
Page 1 (1) Stern tube 227000
L27/38
Standard liners
The stern tube is provided with forward and aft white- A thermometer for the forward bearing is standard
metal liners, fig 1. delivery.
Lead-based
white metal
A
D
E
Cast iron
C F
2 P18
05.18
MAN Diesel & Turbo
1690713-1.0
Page 1 (1) Stern tube 227000
L21/31
L27/38
Optional liners These are used mostly when the stern tube is wa-
ter lubricated. Some types can also be used for oil
We have several years of experience in installing lubricated stern tubes.
other types of stern tube arrangements.
Cooling water
2 P10-AMG28E
03.30
MAN Diesel & Turbo
1690714-3.1
Page 1 (1) Stern tube 227000
L21/31
L27/38
Sensors in stern tube
The propulsion plant is equipped with a number The sensors are designed for replacement without
of sensors which via the alarm plant warn against redrawing of shaft.
abnormal operating conditions which may lead to
breakdown. On/off sensors are usually connected in such a way
that in case of alarm the switch will break, ie they are
The sensors can be either of the on/off type or analog, prepared for connection to a “closed circuit” alarm plant.
depending on the alarm plant.
Cable pipe
Support pipe for
View B-B cable pipe, located
between fore and
aft bearing
A
Cable pipe
TI3951-
View A-A Thermometer
B
2 P17
Pt 100 sensor-
B TE3951 (option)
05.46
MAN Diesel & Turbo
1690715-5.0
Page 1 (1) Stern tube 227000
L21/31
L27/38
Seals
As standard, the stern tube is provided with forward Optionally split seals, face seals and pollution free
and aft stern tube seals of the lip ring type with three seals can be supplied on request.
lip rings in the aft seal and two lip rings in the forward
seal, fig 2.11.
2032418-7.0
03.30
MAN Diesel & Turbo
1690716-7.0
Page 1 (1) Stern tube 227000
L21/31
L27/38
Net cutter and net pick−up
2 P14
and overlap the rotating part of the propeller.
12-15°
12-15°
2 P12
03.30
MAN Diesel & Turbo
1690717-9.0
Page 1 (1) Stern tube 227000
L21/31
L27/38
Cover tubes for twin-screw vessels
See detail
A-bracket
03.30
MAN Diesel & Turbo
1696406-1.1
Page 1 (2) Oil systems 227000
L27/38
Servo oil system
P2 PT PT
3253 2230
4
PT
3252
5
7
3 PT
2221
10
9
PSH
2222
LSL
2206
SERVO RETURN
SERVO FORWARD
SERVO ASTERN
CLUTCH OUT
CLUTCH IN
TE
2245
2
ALPHA REDUCTION GEAR
**
TO LUBRICATING
TE TE TE TE TE
2240 2241 2242 2243 2246
P1
TE
2244
1
E4
PSL 6
2231
TE E5
2231
PT
2231A
PT
2231B
09.27
MAN Diesel & Turbo
1696406-1.1
227000 Oil systems Page 2 (2)
L27/38
4 Non-return valve
09.27
MAN Diesel & Turbo
1690719-2.1
Page 1 (1) Oil systems 227000
L21/31
L27/38
Stern tube lub oil system
In order to prevent sea water penetration, the system piping connections, and a flange where a level alarm
is kept under static pressure by the gravity tank placed (LSL3954) can be mounted.
above normal load water line in accordance with the
stern tube seal manufacturer’s recommendations.
The gravity tank in fig 1 is equipped with level glass,
TANK
BWL
Overflow
To be closed
H
H
in dry-dock
Sectional view
of oil box
C.L. prop. shaft
Drain
05.17
MAN Diesel & Turbo
1690720-2.1
Page 1 (1) Oil systems 227000
L21/31
L27/38
Oil tank for forward seal
05.17
MAN Diesel & Turbo
1696464-6.0
Page 1 (1) Oil specification for Alpha CPP-systems 227000
L21/31
L27/38
General information Note II: In case of continuous operation in cold wa-
ters, it is recommended to use ISO VG100/SAE30
For both the servo oil system (only VBS-types) as oil for the system.
well as the stern tube/shaft seal system, only single
grade mineral oil is accepted. Note III: For the servo oil system, permitted con-
tamination class is 10 (NAS1638), 21/19/16
(ISO4406:1999), 11 (SAE AS4059:D) and recom-
Viscosity limits mended filtration rating is10-20 µm.
For both systems the maximum water content is
The kinematic viscosity @ 40°C of the oil used must 5%.
be in the range 80 - 200 cSt according to ISO.
Note IV: Normally it will be possible to choose an
oil,which fulfils the demands for both the CPP sys-
ISO & SAE classification tem, the engine and/or the gearbox.
09.28
MAN Diesel & Turbo
1690721-4.0
Page 1 (1) Oil systems 227000
L21/31
L27/38
Lubricating oil system All our propellers with seals of the lip ring type op-
erate on lub oil type SAE 30 or SAE 40 − usually
The stern tube and hub lubrication is a common the same type of lubricating oil as used in the main
system. The stern tube is therefore kept under static engine and reduction gear.
oil pressure by a stern tube oil tank placed above
sea level, see fig 1. In case of operating in cold waters it is recommended
to use SAE 30 lub oil.
03.31
MAN Diesel & Turbo
1690722-6.1
Page 1 (2) Propeller shaft and coupling 219000
L21/31
L27/38
Propeller shaft and coupling
The propeller hub and shaft are supplied assembled, L = 450 shaft diameter (mm)
with the aft seal fitted, fig 1.
L : maximum bearing distance
The propeller blades can be supplied fitted depending
on propeller size and transport facilities. For twin screw ships with open shaft line arrange-
ment supported by struts the distance between the
The tailshaft can only be installed from the aft end. aft and second aft bearing should not exeed 20 times
the shaft diameter.
Standard tailshafts can be supplied up to a length
of 14 m, longer on request. In plants with long shaft- For easy alignment of the propeller shaftline, align-
lines, the max distance between the intermediate ment calculations are made and a drawing with
journal bearings can be estimated by means of the instructions is supplied for all propulsion plants.
following formula provided the propeller speed is
below 350 r/min.
Wear-ring
O-ring
04.50
MAN Diesel & Turbo
1690722-6.1
219000 Propeller shaft and coupling Page 2 (2)
L21/31
L27/38
Hydraulic coupling flange For assembling or dismantling we recommend to use
SAE30 oil.To facititate mounting at low temperatures,
o
The flange diameter of the coupling matches the the coupling can be heated to approx 20 C.
counter part of the gearbox flange. This type of
coupling uses a special shrink fitted mounting. High
pressure oil of more than 2,000 bar is injected be- Special shaft arrangements
tween the muff and the coupling flange by means
of the injectors. By increasing the pressure in the We have several years of experience in special shaft
annular space C, with the hydraulic pump, the muff arrangements:
is gradually pushed up the cone.
Pendulum ferries
Longitudinal placing of the coupling flange as well Supply and anchor handling vessels
as final push−up of the muff is marked on the shaft Sailing ships
and muff. Ferries
Injectors
Venting
screw Muff
100 mm
A ....
A ....
Mark on shaft
04.50
MAN Diesel & Turbo
1696407-3.0
Page 1 (1) Intermediate shaft 223000
L27/38
Bulkhead seal
Journal bearing
VBS
propeller
Detail A Detail B
Intermediate shaft with servo
Hydraulic oil pipe for VBS propeller.
coupling To be specified by the customer
Servo pipe
2 P21-AMG28E
Detail A Detail B
04.04
MAN Diesel & Turbo
1690725-1.0
Page 1 (2) Propeller nozzle 1217000
L21/31
L27/38
General information Fixed nozzle
Nozzles offer many advantages for tugs and trawlers The nozzle and struts must be orientated relative
or whenever high thrust at low speed is required. We to the general water flow behind the hull in order to
have supplied hundreds of nozzles, both fixed and reduce drag and optimize propulsion. Furthermore
steering nozzles. A special propeller blade design the struts must be fitted to allow free flow around the
is supplied with the nozzle. whole surface of the nozzle.
A correctly mounted nozzle will have a favourable Behind a V−shaped afterbody, the nozzle should be
o
influence on propeller induced vibrations, as the tilted 2−3 relative to the baseline with the forward
nozzle has an equalizing effect on the wake field end downward to suit the flow to the nozzle, fig 1.
round the propeller. Furthermore ducted propellers
are lower loaded than open propellers contributing As the propeller shaft very often has an aft inclina-
to a lower vibration level. tion in proportion to the baseline, the relative tilting
between the nozzle and the propeller shaftline is
Design and classification approval of the nozzle increased. This has no negative influence on the
support structure is the responsibility of the yard, propulsion performance providing the angle does
o
but some general recommendations are given in not exceed 5−7 .
the following.
Pivot point
Engine
inclination
Max 5-7 °
2 P05 -AMG28E
2-3°
03.31
MAN Diesel & Turbo
1690725-1.0
1217000 Propeller nozzle Page 2 (2)
L21/31
L27/38
With the propeller blade in a vertical downward posi- Structurally, the side struts are cut through the shell
tion, and set at zero pitch, it is possible for the blade plating and connected to the hull framing. The shell
tip to be outside the stainless steel belt within the plating should be strengthened locally.
nozzle. This is acceptable because the tip moves
astern into the stainless steel zone, when “Ahead” The upper nozzle support might be constructed as
pitch is applied. a closed streamlined box as shown on fig 2 or with
sidestruts in V−form.
Cavitation in the lower part of the nozzle can normally
be disregarded, due to the improved water flow and During construction of the nozzle attachment, it
pressure head available in this area. is important to realize that not only strength and
reliability purposes have to be observed, but the
The position of the nozzle should have sufficient hydrodynamic performance as well. Providing ample
space for dismantling of the propeller blades and shaft. clearance between hull and nozzle reduces the thrust
deduction and improves the propulsion.
The nozzle is prepared for mounting with struts.
Pivot point
Space for d ismantling
CL Propeller shaft
Max
6-7°
CL Nozzle
2 P06 -AMG28E
03.31
MAN Diesel & Turbo
1696408-5.0
Page 1 (1) Propeller nozzle 1217000
L27/38
Standard dimensions Fixed nozzle L/D = 0.4
D max
FD
04.04
Packing and
preservation
9000
MAN Diesel & Turbo 9 12 000
Maintenance intervals
Protection maintenance must be carried out at the following intervals:
Storage conditions dry and indoor at 5°C above outside temperature or rela-
tive Humidity of 45-55% every 4 months
If the above conditions are not met every 1 month
Exhaust must be covered until installation, and Indicator valves closed.
Protection maintenance
Description
1699261-3.0
2015.05.08 1 (2)
L27/38; L21/31; L23/30A; L28/32A ; FPP; VBS ODG ODF EN
9 12 000 MAN Diesel & Turbo
e) Replace covers.
Packing and preservation
2 (2) 2015.05.08
L27/38; L21/31; L23/30A; L28/32A ; FPP; VBS ODG ODF EN
MAN Diesel & Turbo 9 12 000
Maintenance intervals
The preservation protects for until 1 year, provided that the preservation is
intact on receipt and that the consignment is kept in a dry and heated stor-
age room. Therefore the preservation of the propeller must be inspected
every 3rd month and if it is found necessary the preservation must be main-
tained and after 1 year the preservation must be renewed.
Description
3700230-5.1
2015.05.08 1 (1)
L27/38; L21/31; L23/30A; L28/32A ; FPP; VBS ODG ODF EN
MAN Diesel & Turbo 9 12 000
Protection maintenance
Provided the sealing has been properly maintained no additional measures
are needed for the entire period of protection. The electronic equipment can
be put into operation without degreasing, coating removal or cleaning.
Installation works
During the installation period the yard has to protect the cabinets and electri-
cal equipments against water, dust and fire.
It is not allowed to do any welding works near the cabinets. The cabinets
have to be fixed to the floor or to the walls by means of screws.
If it is necessary to do welding works near the cabinet the cabinets and pan-
els have to be protected against heat, electric current and electromagnetic
influences. For protection against current, all cabling has to be disconnected
from affected components.
Installation of additional components inside the cabinets is allowed upon
approval by the responsible project manager of MAN Diesel & Turbo only.
Description
1699912-1.1
2015.05.08 1 (1)
L27/38; L21/31; L23/30A; L28/32A ; FPP; VBS ODG ODF EN
MAN Diesel & Turbo 9 12 000
Lifting instruction
Lifting instruction
Lifting of engine
The engine should only be lifted in the two wire straps. Normally, the lifting
tools and the wire straps are mounted by the factory. If not, it must be
observed that the fixing points for the lifting tools are placed differently
depending on the number of cylinders.
The lifting tools are to be removed after the installation and the protective
caps should be fitted.
2015.04.27 1 (2)
L27/38; L21/31 EN
9 12 000 MAN Diesel & Turbo
Engine App. dry Lifting beam fastened to Lifting wires fastened with
Lifting instruction
2 (2) 2015.04.27
L27/38; L21/31 EN
Engine
14000
MAN Diesel & Turbo
1696416-8.2
Page 1 (2) Design features 1400000
L27/38
Design criteria for L27/38 In order to reduce the engine length, external pipe
connections are arranged on the sides of the front-
Decisive parameters for a propulsion engine are the end box
requirements for a compact engine design and long
term reliability in operation. The small optional PTO is located on the forward side.
Front-end box
10.40
MAN Diesel & Turbo
1696416-8.2
1400000 Design features Page 2 (2)
L27/38
Cylinder unit Lubricating oil system
The cylinder unit incorporating cylinder head, water The engine features an entirely closed lub oil system
jacket, piston and connecting rod can either be with- which ensures easy installation on board and no risk
drawn/installed as a complete unit or as individual of dirt entering the lub oil circuit.
components, depending on the available space
conditions. The helical gear type lub oil pump is mounted in the
The cylinder liner features a flame ring in the top. front-end box and draws the oil from the wet sump.
The purpose is to scrape away coke deposits on
the piston top land and thereby avoid bore polish- Via a pressure regulator, the oil flows through
ing of the cylinder liner. This will ensure optimal ring the lub oil plate cooler and the full-flow automatic
performance and low lub oil consumption. back-flushing lub oil filter. This solution eliminates
exchange of filter cartridges as well as the waste
The piston is a composite piston with steel crown and disposal problem.
a nodular cast iron body. A wear resistant chrome
layer on the piston rings ensures long TBOs. The back-flush oil is drained to the sump. A purifier
is to be connected to maintain proper condition of
The robust connecting rod is of the marine head the lub oil.
type with the joint above the marine head and fit-
ted with hydraulically tightened units. During piston An integrated thermostatic valve ensures a constant
withdrawal, the marine head remains on the journal, lub oil temperature to the engine.
saving dismantling space and at the same time pro-
tecting the journal.
Cooling water system
The “cross-flow” cylinder head in nodular cast iron
has 2 inlet and 2 exhaust valves – all rotating to The cooling water system is based on separate low
minimize wear and equalize temperatures. Together and high temperature systems.
with the direct cooled exhaust valve seat rings, a
reliable operation is ensured. Both circuits are cooled by fresh water.
The turbocharging system is based on the constant The water is circulated by the HT pump through the
pressure principle, using the newly developed radial- first stage of the charge air cooler, the jacket water
flow type MAN Diesel & Turbo turbochargers. collar, cylinder heads and thermostatic valve, through
the high temperature cooler, back to the HT pump.
Starting air system Nearly 100% of the heat removed from the high
temperature system can be utilized for heat recovery.
The engine is started by means of a built-on air
starter, controlled from the instrument panel on the
engine or from the remote control system. LT system
In case of electric power failure, an emergency start- The water is circulated by the LT pump through the
ing facility can be activated. second stage of the charge air cooler, the lub oil
coolers for engine and gearbox, the high tempera-
A cranking device is fitted on the engine. ture cooler, through the central cooler and back to
the LT pump.
10.40
MAN Diesel & Turbo
3700083-1.0
Page 1 (2) Main dimensions 1400000
L27/38
5070
2225
530
800
2108099-7.0
3962
5515
2357
530
800
4407
11.06 - Tier II
MAN Diesel & Turbo
3700083-1.0
1400000 Main dimensions Page 2 (2)
L27/38
5955
2357
530
800
2108115-4.0
4852
6405
5263
11.06 - Tier II
MAN Diesel & Turbo
1696451-4.2
Page 1 (1) Foundation for engine 1400000
L27/38
The details given in this chapter are important for We recommend the clearance between the tanktop
dimensioning the engine foundation and the aft and oil pan of the engine to be min 15 mm, when
structure of the vessel. the engine/reduction gear is placed on the top plates
without chocks.
The forces and torques, arising due to weight, and
operation of the engine must be taken into consid-
eration when designing the engine foundation. For
information on forces and torques, see fig 1.
1
2
3
4
5
6
08.45
MAN Diesel & Turbo
1696422-7.3
Page 1 (5) Foundation for Engine - Rigid Mounting 1482000
L27/38
DETAIL C
1130
2020
2465
2910
3338
1425
1575
1870
2315
2760
3205
FLYWHEEL
535
685
980
0
Scale 1:2.5
0
685
640
Front Foundation Bolt
5 Detail C
Front-end box
Flywheel
Aft-end box
1060
6 cyl
640
2
685
2x2xM30 Adjusting screws
5
3338
3777
3057.5
355
832.5
0
DETAIL C
FLYWHEEL
1130
1575
2465
2910
3355
3783
1425
1870
2020
2315
2760
3205
3650
980
535
685
Scale 1:2.5
0
0
685
5
640
Front Foundation Bolt
Detail C
Front-end box
Flywheel
Aft-end box
1060
2
685
4222
2167.5
3502.5
355
832.5
0
10 8 7
The wedges are to be lightly driven
into place, re-checked and tack-welded
at service temperature.
Engine seating - 7L27/38
10.47
MAN Diesel & Turbo
1696422-7.3
1482000 Foundation for Engine - Rigid Mounting Page 2 (5)
L27/38
DETAIL C
FLYWHEEL
1425
1575
1870
2315
2760
3205
3355
3650
1130
2020
2465
2910
3800
4095
4228
Scale 1:2.5
980
535
685
0
0
685
640
Front Foundation Bolt
Detail C
Front-end box
8 cyl
Aft-end box
1060
Flywheel
640
2
685
2x3xM30 Adjusting screws
5
4228
4667
832.5
2612.5
3947.5
355
0
10 11 8 7
The wedges are to be lightly driven
into place, re-checked and tack-welded
at service temperature.
Detail C
Flywheel
2281
1096
1391
1541
1836
1986
2431
2726
2876
3171
3321
3616
3766
4061
4211
4506
4639
Scale 1:2.5
501
651
946
0
0
21.7
Front Foundation Bolt
640
9 cyl Detail C
Front-end box
Aft-end box
Flywheel
2
2x3xM30 Adjusting screws
5
2578
4358
4639
321
798
0
10 8 7
The wedges item 8 are to be lightly
driven into place, re-checked and
tack-welded at service temperature.
10.47
MAN Diesel & Turbo
1696422-7.3
Page 3 (5) Foundation for Engine - Rigid Mounting 1482000
L27/38
ø1
530
23
2
40 *
165
1330
40 *
400 * 15 *
800
6
10
R
°
15
870
980
1060
1100
1280
1370
* GUIDANCE ONLY
DETAIL A, ENGINE
1 Scale 1:2.5
40
2
165
H1
S
40 *
Y
10.47
MAN Diesel & Turbo
1696422-7.3
1482000 Foundation for Engine - Rigid Mounting Page 4 (5)
L27/38
Ra 3.2
M24
ø24
M24
50 50
Ra 1.6
3x45° 3x45°
Ra 3.2
L=H1+85
6 29 10 24
80
10
45
175
35 100
135
30
WEDGE, ITEM 8
35
100
150
MATERIAL SPECIFICATION:
- Holding-down bolts item 2, nuts item 1 and 4
and endchock bolts item 12:
Tensile strenght min 700 N/mm .
Yield point min 640 N/mm .
ISO property class 8.8 or similar.
EPOXY CHOCKS:
25
10.47
MAN Diesel & Turbo
1696422-7.3
Page 5 (5) Foundation for Engine - Rigid Mounting 1482000
L27/38
Ra 3.2
item 10, must be adapted to the
foundation top plate, and full welded 10 40
both inside and outside.
** Height of epoxy chock "Y" + 50 mm
60
12
Tightening torque for
endchock bolts,item 12:
830 Nm
R 10
**
25
30°
10
14 13 11
110
80
33
15
.8x45°
41
R
3.6
11.2
19.2
56
3x45°
Ra 3.2
12
Max height
ITEM DESCRIPTION
40mm
50mm
1 M24 nut
2 M24 holding-down bolt
3 Plain washer. Min hardness 200HB
4 M24 nut with locking device
Adjustable 5 Adjusting screw (MAN Diesel & Turbo supply)
spherical washer 7 Side chocks
Item 11 8 Wedge
10 Engine end chocks
11 Adjustabel spherical washer
12 M30 bolt for engine end chocks
13 Spherical washer
14 M30 nut with locking device
10.47
MAN Diesel 6 Turbo
1699866-5.1
Page 1 (3) Foundation for Engine - Resilient Mounting 1482000
L27/38
A (The engine shown is 8L27/38)
A
16
View A-A
CL - Crankshaft 1 Hexagon screw
2 Washer
3 Hexagon screw
4 Support plate for bracket
700
10 Fastening plate
11 Alignment screw
12 Hexagon screw
13 Guide
14 Mounting template
870 15 Hexagon screw
1370 16 Distance ring
1630
1 2
Section B Section C 3 Section D 12
4
13
5
11 14
6
7 15
8
170
ø80
80
9
10
The engine is supplied without Brackets (item 5) and rubber mountings Mounting template (item 14) is to be
brackets and rubber mountings. (item 6) etc are supplied as loose parts used for installation of the cylindrical
and have to be installed according to distance pieces (item 9) and the
The engine is to be landed on the description "Installation of rubber fastening plates (item 10).
the adjusting screws (item 11), mountings".
and aligned in proportion to the
gearbox according to the
alignment instructions.
13.18
MAN Diesel & Turbo
1699866-5.1
1482000 Foundation for Engine - Resilient Mounting Page 2 (3)
L27/38
6L27/38
twin-bracket single-bracket
1430
2168
3058 3058
Position of adjusting screws
0
833
7L27/38
755
1335
2015
2765
3503
2168
0
833
3058
8L27/38
755
1430
3058
3948 3948
0
833
2613
9L27/38
721
1396
2578 2578
3468
4358 4358
0
798
13.18
MAN Diesel 6 Turbo
1699866-5.1
Page 3 (3) Foundation for Engine - Resilient Mounting 1482000
L27/38
26
21 Base casting
22 Central buffer
20
25
23 Synthetic bush
24 Rubber element
25 Top casting
26 Adjusting nut
27 Washer 24
28 Nut
29 Tapped hole M12 for jacking bolts
30 Protecting cap
23
22
21
29
13.18
MAN Diesel & Turbo
3700009-1.7
Page 1 (2) List of Capacities 1400000
L27/38
Volume flow (temperature turbocharger outlet) m3/h 7) 28921 33741 38562 43382
Mass flow t/h 15.3 17.9 20.4 23.0
Temperature at turbine outlet °C 385 385 385 385
Heat content (190°C) kW 896 1045 1194 1343
Permissible exhaust back pressure mbar < 30
12.29 - Tier II
MAN Diesel & Turbo
3700009-1.7
1400000 List of Capacities Page 2 (2)
L27/38
Number of Cylinders - 6 7 8 9
Pumps
External pumps 8)
For MGO/MDO-operation
Diesel oil pump (3.5 bar at fuel oil inlet B3) m3/h 1.57 1.83 2.10 2.36
For HFO-operation
Fuel oil supply pump (4 bar discharge pressure) m3/h 0.76 0.89 1.01 1.14
Fuel oil circulating pump (8 bar at fuel oil inlet B3) m3/h 1.59 1.86 2.12 2.39
Lube oil pump (4.5 bar) m3/h 60 60 60 75
LT cooling water pump (2.5 bar) m3/h 62 62 62 62
HT cooling water pump (2.5 bar) m3/h 62 62 62 62
Starting air data
Air consumption per start, incl. air for jet assist (IR/TDI) Nm3 2.9 3.3 3.8 4.3
7) Under below mentioned temperature at turbine outlet and pressure according above mentioned reference conditions.
8) Tolerance of the pumps delivery capacities must be considered by the manufactures.
12.29 - Tier II
MAN Diesel & Turbo
3700010-1.7
Page 1 (2) List of Capacities 1400000
L27/38
Volume flow (temperature turbocharger outlet) m3/h 7) 26658 31102 35545 39988
Mass flow t/h 14.7 17.1 19.6 22.0
Temperature at turbine outlet °C 360 360 360 360
Heat content (190°C) kW 748 873 997 1122
Permissible exhaust back pressure mbar < 30
1) HT cooling water flow first through HT stage charge air cooler, then through water jacket and cylinder head, water temperature outlet engine
regulated by mechanical thermostat.
2) LT cooling water flow first through LT stage charge air cooler, then through lube oil cooler, water temperature outlet engine regulated by mechani-
cal thermostat.
3) Tolerance: + 10% for rating coolers, - 15% for heat recovery.
4) Basic values for layout of the coolers.
5) Under above mentioned reference conditions.
6) Tolerance: quantity +/- 5%, temperature +/- 20°C.
7) Under below mentioned temperature at turbine outlet and pressure according above mentioned reference conditions.
12.29 - Tier II
MAN Diesel & Turbo
L27/38
Number of Cylinders - 6 7 8 9
Pumps
External pumps 8)
For MGO/MDO-operation
Diesel oil pump (3.5 bar at fuel oil inlet B3) m3/h 1.44 1.68 1.92 2.16
For HFO-operation
Fuel oil supply pump (4 bar discharge pressure) m3/h 0.70 0.81 0.93 1.04
Fuel oil circulating pump (8 bar at fuel oil inlet B3) m3/h 1.46 1.70 1.95 2.19
Lube oil pump (4.5 bar) m3/h 60 60 75 75
LT cooling water pump (2.5 bar) m3/h 62 62 62 62
HT cooling water pump (2.5 bar) m3/h 62 62 62 62
Starting air data
Air consumption per start, incl. air for jet assist (IR/TDI) Nm3 2.9 3.3 3.8 4.3
12.29 - Tier II
MAN Diesel & Turbo
1696424-0.1
Page 1 (4) List of Symbols 1400000
L21/31
L27/38
Pipe dimensions and piping signature
Pipe dimenesions
25 33.7 Piping
32 42.4
40 48.3 : Built-on engine/Gearbox
50 60.3
65 76.1 : Yard supply
80 88.9
90 101.6 Items connected by thick lines are built-on engine/
or other rules
04.27
MAN Diesel & Turbo
1696424-0.1
1400000 List of Symbols Page 2 (4)
L21/31
L27/38
Screw pump with electric motor DIN 2481 Spectacle flange, closed DIN 2481
04.27
MAN Diesel & Turbo
1696424-0.1
Page 3 (4) List of Symbols 1400000
L21/31
L27/38
Measuring device
PI Local reading
1.2 Pressure Indication Shut off cock
no 1.2 (refer to list of instruments) with test flange
Measuring device
PT Remote reading Before unit - pressure high
2231 Pressure Transmitter
ID-no 2231 (refer to list of alarms)
Measuring pressure difference
Plugged connection
for additional device
D : Density A : Alarm
E : Electric D : Difference
F : Flow E : Transducer
L : Level H : High
M ; Moisture I : Indicating
P : Pressure L : Low
S : Speed N : Closed
T : Temperature O : Open
V : Viscosity S : Switching, shut down
Z : Position T : Transmitter
2047948-0.1/2015716-6
X : Failure
C : Controlling
(ISO 3511/I-1977(E)) Z : Emergency/safety acting
The presence of a measuring device on a schematic diagram does not necessarily indicate that the device
is included in our scope of supply.
For each plant. The total extent of our supply will be stated formally.
04.27
MAN Diesel & Turbo
1696424-0.1
1400000 List of Symbols Page 4 (4)
L21/31
L27/38
Specification of ID-no code for measuring
signals/devices
Refers to the main system to which the signal is Refers to the auxillary system to which the signal
related. is related.
3xxx : Propeller equipment x2xx : Oil systems (lub. oil, cooling oil, clutch
oil, servo oil)
4xxx : Automation equipment
x3xx : Air systems (starting air, control air,
5xxx : Other equipment, not related to the charging air)
propulsion plant
x4xx : Fuel systems (fuel injection, fuel oil)
x5xx :
The last two digits are numeric ID for devices referring to the same main and aux. system.
Where dublicated measurements are carried out, i.e. multiple similar devices are measuring the same pa-
rameter, the ID specification is followed by a letter (A, B, ...etc.), in order to be able to separate the signals
from each other.
2047948-0.1/2015716-6
04.27
MAN Diesel & Turbo
1655210-7.3
Page 1 (2) Exhaust gas components 1400000
General
The exhaust gas is composed of numerous constit- For the typical exhaust gas composition of a MAN
uents which are formed either from the combustion Diesel & Turbo four-stroke engine without any ex-
air, the fuel and lube oil used or which are chemi- haust gas treatment devices, please see tab. 1.
cal reaction products formed during the combustion All engines produced currently fulfil IMO Tier II.
process. Only some of these are to be considered
as harmful substances.
1)
SOx according to ISO-8178 or US EPA method 6C, with a sulphur content in the fuel oil of 2.5% by weight.
2)
NOx according to ISO-8178 or US EPA method 7E, total NOx emission calculated as NO2.
3)
CO according to ISO-8178 or US EPA method 10.
4)
HC according to ISO-8178 or US EPA method 25A.
5)
PM according to VDI-2066, EN-13284, ISO-9096 or US EPA method 17; in-stack filtration.
6)
Marine gas oil DM-A grade with an ash content of the fuel oil of 0.01% and an ash content of the lube oil of 1.5%.
7)
Heavy fuel oil RM-B grade with an ash content of the fuel oil of 0.1% and an ash content of the lube oil of 4.0%.
8)
Pure soot, without ash or any other particle-borne constituents.
12.09
MAN Diesel & Turbo
1655210-7.3
1400000 Exhaust Gas Components Page 2 (2)
General
Carbon dioxide (CO2) is a product of combustion of Carbon monoxide (CO) is formed during incom-
all fossil fuels. plete combustion.
Among all internal combustion engines the diesel In MAN Diesel & Turbo four-stroke diesel engines,
engine has the lowest specific CO2 emission based optimisation of mixture formation and turbocharg-
on the same fuel quality, due to its superior effi- ing process successfully reduces the CO content
ciency. of the exhaust gas to a very low level.
Sulphur oxides (SOx) are formed by the combustion The hydrocarbons (HC) contained in the exhaust
of the sulphur contained in the fuel. gas are composed of a multitude of various organic
compounds as a result of incomplete combustion.
Among all propulsion systems the diesel process Due to the efficient combustion process, the HC
results in the lowest specific SOx emission based content of exhaust gas of MAN Diesel & Turbo four-
on the same fuel quality, due to its superior effi- stroke diesel engines is at a very low level.
ciency.
Particulate Matter PM
Nitrogen oxides NOx (NO + NO2)
Particulate matter (PM) consists of soot (elemental
The high temperatures prevailing in the combustion carbon) and ash.
chamber of an internal combustion engine causes
the chemical reaction of nitrogen (contained in the
combustion air as well as in some fuel grades) and
oxygen (contained in the combustion air) to nitro-
gen oxides (NOx).
12.09
MAN Diesel & Turbo
1696425-2.1
Page 1 (3) Space Requirements 1400000
L27/38
Dismantling Space
2255
2275
CL Crankshaft
CL Crankshaft
530
530
4 E08
Fig 4.20 Lifting height for Fig 4.21 Lifting height for cylinder
pistons heads
2540
CL Crankshaft
530
4 E08
04.46
MAN Diesel & Turbo
1696425-2.1
1400000 Space Requirements Page 2 (3)
L27/38
1186
966
1114
1670
Fig 4.23 Dismantling lub oil filter Fig 4.24 Dismantling lub oil pump
CL Crankshaft
530
CL Crankshaft
530
1757
Fig 4.25 Dismantling charging air cooler Fig 4.26 Dismantling complete cylinder unit
04.46
MAN Diesel & Turbo
1696425-2.1
Page 3 (3) Space Requirements 1400000
L27/38
4 E02-AMG28E
Min 2500
04.46
MAN Diesel & Turbo
1694925-0.4
Page 1 (9) Cooling Water System 1400000
L27/38
35
29 49 C B DN 100
34 A DN 32
DN 100
DN 100
M 39 M
DN 32 DN 100
DN 100
DN 100
38 33 31
F12 F10 F5 F6 F4 F8 F1 9
30 36 B
F7 PSL
1102
A C
TE
1104A
TE
1104B F13 37
PT
1102A
PT
1102B
TE
1102
32
13
TE
1002
TE
TE E2 18
E8 1005
17
Gearbox E7 E7 1103 16
A C
PT PSL B
1002 1002 M
15
E6 E6 14
4
M
12 E3 10 E1 3
DN 100
2
DN 100
4
M 3
DN 100
11 1
DN 32
Connections:
E1 LT cooling water - inlet
E2 LT cooling water - outlet (to cooler)
Item Description E3 LT cooling water stand-by pump - pressure
1 Seachest low E6 LT cooling water to gear cooler (on gear/engine)
2 Seachest high E7 LT cooling water from gear cooler (on gear/engine)
3 Sea water filter E8 LT cooling water to expansion tank (venting)
4 Sea water pump F1 HT cooling water - inlet
9 Overboard discharge valve F4 HT cooling water stand-by pump - pressure
10 LT pump F5 HT cooling water to heat recovery system
11 LT stand-by pump F6 HT cooling water from heat recovery system
12 Regulating valve (optional) F7 HT cooling water to expansion tank (venting)
13 Charging air cooler, LT section F8 HT cooling water from expansion tank
14 Orifice for cooling water to gearbox F10 Engine preheating - inlet
15 Gear oil cooler F12 Engine preheating - outlet
16 Engine lubricating oil cooler F13 HT cooling water - outlet (to cooler)
17 LT thermostatic valve
18 Central cooler Sea water filters (item 3):
29 LT expansion tank We recommend a filter with max 3 mm meshsize to
30 HT pump prevent clogging of the central cooler.
31 HT stand-by pump
32 Charging air cooler HT section
33 Adjustment valve for heat recovery Thermostatic valves (items 17, 34 and 36):
34 Thermostatic valve for heat recovery A, B and C refer to port position (diverting mode)
35 Heat recovery
2047914-3.4
36 HT thermostatic valve
37 HT fresh water cooler Expansion tank (items 29 and 49):
38 Circulating pump for preheater The lowest water level in the expansion tanks should be
39 Preheater min 6 meters above centerline of crankshaft.
49 HT expansion tank Inlet to expansion tank to be beneeth the lowest water
level.
12.31
MAN Diesel & Turbo
1694925-0.4
1400000 Cooling Water System Page 2 (9)
L27/38
35
29 49 C B DN100
34 A DN32
DN100
DN100
M 39 M
DN32
DN100
DN100
38 31
F12 F10 F5 33 F6 F4 F8 F1
F7 36 B
30
PSL
1102 A C
TE TE
1104A 1104B PT
1102A F13
PT
1102B 9
DN100
TE
1102
32
13
TE
1002
TE TE
18
E8 1103 16
1005
E2 37
Gearbox E7 E7 A C
17 B
PT PSL
1002 M
15 1002
14
E6 E6 12 4
M
DN100
E3 10 E1 3
DN100
4 2
M 3
DN100
11 1
DN32
Connections:
E1 LT cooling water - inlet
E2 LT cooling water - outlet
E3 LT cooling water stand-by pump - pressure
E6 LT cooling water to gear cooler (on gear/engine)
Item Description E7 LT cooling water from gear cooler (on gear/engine)
1 Seachest low E8 LT cooling water to expansion tank (venting)
2 Seachest high F1 HT cooling water - inlet
3 Sea water filter F4 HT cooling water stand-by pump - pressure
4 Sea water pump F5 HT cooling water to heat recovery system
9 Overboard discharge valve F6 HT cooling water from heat recovery system
10 LT pump F7 HT cooling water to expansion tank (venting)
11 LT stand-by pump F8 HT cooling water from expansion tank (venting)
12 Regulating valve (optional) F10 Engine preheating - inlet
13 Charging air cooler, LT section F12 Engine preheating - outlet
14 Orifice for cooling water to gearbox F13 HT cooling water - outlet (to cooler)
15 Gear oil cooler
16 Engine lubricating oil cooler
17 LT thermostatic valve Sea water filters (item 3):
18 Central cooler We recommend a filter with max 3 mm meshsize to
29 LT expansion tank prevent clogging of the central cooler.
30 HT pump
31 HT stand-by pump
32 Charging air cooler HT section Thermostatic valves (items 17, 34 and 36):
33 Adjustment valve for heat recovery
34 Thermostatic valve for heat recovery A, B and C refer to port position (diverting mode)
35 Heat recovery
36 HT thermostatic valve
2055131-1.2
12.31
MAN Diesel & Turbo
1694925-0.4
Page 3 (9)
Cooling Water System 1400000
L27/38
Cooling Water System Water Quality
The engine is designed for freshwater cooling only. The fresh water used as coolant, should be as clean
Therefore the cooling water system has to be ar- as possible.
ranged as a centralised or closed cooling water
system. All recommendable types are described in The pH value should be between 6.5 and 8 at 20°C.
the following.
The total hardness of the water must be max 10°dH
The engine design is almost pipeless, i.e. the water (German hardness degrees). If the hardness is higher,
flows through internal cavities inside the front-end box the water should be diluted with some soft water.
and the cylinder units. The front-end box contains all
large pipe connections. On the aft-end, the water to The contents of chlorine, chloride, silicate and
the gear oil cooler has to be connected by the yard. sulphate must be as low as possible and must not
exceed the following values:
The engine is equipped with built-on freshwater Chlorine: 10 PPM
pumps for both the high and low temperature cool-
Chloride: 50 PPM
ing water systems. To facilitate automatic start-up
of stand-by pumps, non-return valves are standard. Silicate: 150PPM
Sulphate: 100PPM
Thermostatic valve elements, which control the high
and low temperature cooling water system, are also The fresh water must be treated with additives in or-
integrated parts of the front-end box. der to reduce the risk of corrosion in the engine. Anti
corrosive agents are not included in our usual scope
In case the HT cooler as alternative is a part of the of supply. The freshwater cooling system should be
LT cooling water system the LT thermostatic valves treated prior to carrying out sea trials.
are to be replaced by “dummies” inside the front-end
box and an external thermostatic valve housing is There are two basic types of chemical additives:
required to be placed in the LT circuit just after the · Chromate base
HT freshwater cooler.
· Nitrite base or similar
The engine is equipped with a two stage charge air
Additives of chromate base are often considered to
cooler.The first stage is placed in the high temperature
be more effective, but we advise against using them
cooling water system. The charging air temperature
due to their extreme poisonousness and they are not
after the turbocharger is at its maximum, making a
permitted if a freshwater generator is incorporated
higher degree of heat recovery possible, when the
in the plant.
heat is dissipated to the high temperature cooling
water.
For information on additives recommended by us,
please refer to “Cooling water inhibitors”, which can
The second stage of the charge air cooler is placed
be forwarded on request.
in the low temperature system.
New engines, supplied by us are cleaned and ni-
It will cool the charging air further down before enter-
trated. Providing the freshwater inhibiting is correctly
ing the combustion chamber.
maintained then future cleaning of the system should
hardly be necessary. However if it should be required,
For special applications i.e. sailing in arctic waters
we would be pleased to assist with recommendations
with low air temperatures and direct air intake from
for degreasing, de-scaling with acid and inhibiting.
deck, a regulating system can be applied to control
the water flow to the second stage of the charge air
cooler in order to increase the charging air tempera-
ture, at low load.
12.31
MAN Diesel & Turbo
L27/38
Velocity recommendations for freshwater and sea The pumps in parallel, layout point 2 see fig 6.5, are
water pipes: as standard designed to fulfil:
Freshwater: Suction pipe: 2.0 - 2.5 m/s Capacity: Determined by the cooler manufacturer.
Delivery pipe: 2.0 - 2.5 m/s Approx 100 - 175% of fresh water flow
in the cooler, depending on the central
Sea water: Suction pipe: 1.0 - 1.5 m/s cooler.
Delivery pipe: 1.5 - 2.5 m/s Pressure: 1.8 - 2.0 bar
Sea water temperature: Max 32°C
Central Cooling Water System The volume of sea water required to circulate through
a known sized cooler to remove a known amount of
Sea Water Filter, Item 3 heat, is very sensitive and dependent on the sea
water temperature.
Design data:
Capacity: See sea water pump The relation between sea water temperature and
Pressure drop the necessary water flow in the central cooler is
across clean filter: Max 0.05 bar shown in fig 6.6.
Pressure drop
across dirty filter: Max 0.1 bar
Mesh size: ##-5 mm
Free filter hole area:
Min two times the normal pipe area.
Flow
%
Lay-out point 2
20
~325C SW pump
10
2032534-8.0
Layout point 1 0
~305C SW pump
15 20 25 30 32 5C
Two pumps Sea water temperature
2031309-2.0
75% 100% V
(m3/h) Fig 6.6 Necessary water flow
Fig 6.5 Pump characteristic Depending on the actual characteristic of the system
resistance curve and the pump characteristic curve,
the sea water flow with only one pump in service will
be approx 75%. This means that the cooling capacity
can be obtained with only one pump until reaching
a sea water temperature of approx 30°C.
12.31
MAN Diesel & Turbo
1694925-0.4
Page 5 (9) Cooling Water System 1400000
L27/38
The back pressure in single pump operation must LT Stand-by Pump, Item 11
be observed as a low back pressure may lead to
unfavourable operation and cavitation of impeller. The stand-by pumps should be of the centrifugal type.
We are pleased to advise on more specific ques-
tions concerning the layout of pumps and location Design data:
of orifices, etc. Capacity: See planning data, for the
built-on freshwater pump
Pressure: See planning data, for the
Central Cooler(s), Item 18 built-on freshwater pump
With such flexibility it is possible to carry out repair The HT freshwater cooler will be a plate cooler in
and maintenance during a voyage especially in tem- stainless steel.
perate climates where the sea water temperature is
below the design temperature. Design data:
Heat transfer: See planning data
Pressure drop HT: Max 0.5 bar
LT Freshwater Pump, Item 10 Pressure drop LT: Max 0.5 bar
12.31
MAN Diesel & Turbo
L27/38
The re-circulated water is led directly to the suction Circulating Pump for Preheater, Item 38
side of the built-on pumps.
For preheating the engine a pump should be installed
to circulate high temperature cooling water trough
Expansion Tanks, Items 29 and 49 the preheater.
The stand-by pumps should be of the centrifugal type. Engine type Heating power
6L27/38 9 kW
Design data: 7L27/38 10.5 kW
Capacity: See planning data, for the 8L27/38 12 kW
built-on freshwater pump 9L27/38 13.5 kW
Pressure: See planning data, for the
built-on freshwater pump
Temperature: Max 95°C
The figures are based on raising the engine tempera-
ture to 40°C (20-60°C) for a period of 10 hours includ-
ing the cooling water contained within the engine.
12.31
MAN Diesel & Turbo
1694925-0.4
Page 7 (9) Cooling Water System 1400000
L27/38
The preheater can be of the electrical type. If suf- For each plant, special consideration should be
ficient central heating capacity is available, a plate given to the following design criteria: Sea water
type heat exchanger can be installed. It is important temperatures, pressure loss in coolers, valves and
that the inhibited fresh water, used in the main en- pipes, pump capacities etc, for which reason these
gine cooling system, is not mixed with water from components have not been specified in this guide.
the central heating system.
By layout of the freshwater generator we recommend A disadvantage of most closed cooling water systems
that no more than 90% of the heat available at MCR is the poor heat transfer coefficient.
is utilised due to safety margins, part load operation
and deviations in ambient conditions. LT coolers with very small temperature differences
between the cooling water and the sea or raw water,
The expected obtainable freshwater production using require a relatively large heat exchanger to enable
a normal generator of the single vacuum evaporator sufficient heat transfer.
type can be estimated.
The 27/38 engine is a high efficient main engine
Design data: calling for high efficient coolers. Therefore some
Capacity: m= 0.03 x Q m3/24h designs cannot be recommended.
Q: Utilised heat in kW
Pressure: Max 2.5 bar We are available to offer advice for specific cooler
Pressure drop: Max 0.5 bar types, but the final responsibility for design, pressure
Temperature: 80°C losses, strength and system maintenance remains
with the yard and the ship owner. We reserve the
right not to accept proposed coolers, which seems
Different Arrangements of Central Cooling to be insufficient for its purpose.
Systems
Also when using other types of closed cooling water
There are many variations of centralised cooling systems the HT and LT cooling water systems have
systems and we are available to discuss various to be separated.
changes to suit an owner’s or builder’s specific wishes.
12.31
MAN Diesel & Turbo
1694925-0.4
1400000 Cooling Water System Page 8 (9)
L27/38
Box Cooler The temperature of the sea water has influence on
the heat exchanger efficiency as well. We recom-
The box cooling system has through many years mend that a temperature of 25°C or 32°C is used,
proven to be a reliable closed cooling water system. depending on the vessel’s operating area.
The box cooler is a pre-manufactured tube bundle
for mounting in a sea chest. The tube bundle is normally of corrosion resistant
material with a non-metallic coating. The coating
The movement of the sea water across the heat ex- protects the vessel from galvanic corrosion between
changer is initiated by the movement of the heated the sea chest and the box cooler. Uncoated coolers
sea water upwards because of the lower density may be used, but special consideration has to be
compared with that of the surrounding water. This given to the galvanic separation of the box cooler
means that the heat transfer is less dependant on the and the hull. In waters with mussels and shell fish
ship’s speed, compared to coolers mounted on the these might want to live on the tube bundle, which
shell of the vessel. However the speed of the vessel the different box cooler manufacturers have different
does have some influence on the cooling area. For solutions to avoid.
vessels sailing at below 3 knots at MCR, i.e. tugs,
dredgers etc, the speed has to be considered when
designing the cooler.
Y Y
tH3=805C
Heat- Pre-
Gear oil Main recovery heater
cooler engine option
tL1=385C
HT
cooler
12.31
MAN Diesel & Turbo
1694925-0.4
Page 9 (9) Cooling Water System 1400000
L27/38
Design data:
Heat transfer: See planning data
Pressure drop
through all coolers: Max 0.5 bar
Min vessel
speed at MCR: Normally more than 3 knots
12.31
MAN Diesel & Turbo 010.000.002-04
M010.000.002-04-0001
Summary
Remove contamination/residue from operating fluid systems, ensure/re-
establish operating reliability.
Cooling water systems containing deposits or contamination prevent effec-
tive cooling of parts. Contamination and deposits must be regularly elimina-
ted.
This comprises the following:
Cleaning the system and, if required,
removal of limescale deposits,
flushing the system.
Cleaning
The cooling water system must be checked for contamination at regular
intervals. Cleaning is required if the degree of contamination is high. This
work should ideally be carried out by a specialist who can provide the right
cleaning agents for the type of deposits and materials in the cooling circuit.
The cleaning should only be carried out by the engine operator if this cannot
be done by a specialist.
Oil sludge Oil sludge from lubricating oil that has entered the cooling system or a high
concentration of anticorrosive agents can be removed by flushing the system
with fresh water to which some cleaning agent has been added. Suitable
cleaning agents are listed alphabetically in the table entitled "Cleaning agents
for removing oil sludge". Products by other manufacturers can be used pro-
viding they have similar properties. The manufacturer's instructions for use
must be strictly observed.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew HDE - 777 4 - 5% 4 h at 50 – 60 °C
Nalfleet MaxiClean 2 2 - 5% 4 h at 60 °C
Unitor Aquabreak 0.05 – 0.5% 4 h at ambient temperature
Vecom Ultrasonic 4% 12 h at 50 – 60 °C
Multi Cleaner
Table 1: Cleaning agents for removing oil sludge
Lime and rust deposits Lime and rust deposits can form if the water is especially hard or if the con-
centration of the anticorrosive agent is too low. A thin lime scale layer can be
left on the surface as experience has shown that this protects against corro-
sion. However, limescale deposits with a thickness of more than 0.5 mm
obstruct the transfer of heat and cause thermal overloading of the compo-
Cooling water system
the elements that are responsible for water hardness, this forms what is
known as ferrous sludge which tends to gather in areas where the flow
velocity is low.
General
Products that remove limescale deposits are generally suitable for removing
rust. Suitable cleaning agents are listed alphabetically in the table entitled
"Cleaning agents for removing lime scale and rust deposits". Products by
M010.000.002-04-0001 EN 1 (3)
010.000.002-04 MAN Diesel & Turbo
other manufacturers can be used providing they have similar properties. The
manufacturer's instructions for use must be strictly observed. Prior to clean-
M010.000.002-04-0001
ing, check whether the cleaning agent is suitable for the materials to be
cleaned. The products listed in the table entitled "Cleaning agents for remov-
ing lime scale and rust deposits" are also suitable for stainless steel.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew SAF-Acid 5 - 10% 4 h at 60 - 70 °C
Descale-IT 5 - 10% 4 h at 60 - 70 °C
Ferroclean 10% 4 - 24 h at 60 - 70 °C
Nalfleet Nalfleet 9 - 068 5% 4 h at 60 – 75 ℃
Unitor Descalex 5 - 10% 4 - 6 h at approx. 60 °C
Vecom Descalant F 3 – 10% Approx. 4 h at 50 – 60°C
Table 2: Cleaning agents for removing limescale and rust deposits
In emergencies only Hydrochloric acid diluted in water or aminosulphonic acid may only be used
in exceptional cases if a special cleaning agent that removes limescale
deposits without causing problems is not available. Observe the following
during application:
▪ Stainless steel heat exchangers must never be treated using diluted
hydrochloric acid.
▪ Cooling systems containing non-ferrous metals (aluminium, red bronze,
brass, etc.) must be treated with deactivated aminosulphonic acid. This
acid should be added to water in a concentration of 3 - 5 %. The tem-
perature of the solution should be 40 - 50 °C.
▪ Diluted hydrochloric acid may only be used to clean steel pipes. If hydro-
chloric acid is used as the cleaning agent, there is always a danger that
acid will remain in the system, even when the system has been neutral-
ised and flushed. This residual acid promotes pitting. We therefore rec-
ommend you have the cleaning carried out by a specialist.
The carbon dioxide bubbles that form when limescale deposits are dissolved
can prevent the cleaning agent from reaching boiler scale. It is therefore
absolutely necessary to circulate the water with the cleaning agent to flush
away the gas bubbles and allow them to escape. The length of the cleaning
process depends on the thickness and composition of the deposits. Values
are provided for orientation in the table entitled "Detergents for removing lime
scale and rust deposits“.
Following cleaning The cooling system must be flushed several times once it has been cleaned
using cleaning agents. Replace the water during this process. If acids are
used to carry out the cleaning, neutralise the cooling system afterwards with
suitable chemicals then flush. The system can then be refilled with water that
has been prepared accordingly.
Cooling water system
Only carry out the cleaning operation once the engine has
cooled down
Start the cleaning operation only when the engine has cooled down.
2012-08-20 - de
Hot engine components must not come into contact with cold water.
Open the venting pipes before refilling the cooling water system.
Blocked venting pipes prevent air from escaping which can lead to
thermal overloading of the engine.
General
2 (3) M010.000.002-04-0001 EN
MAN Diesel & Turbo 010.000.002-04
M010.000.002-04-0001
The products to be used can endanger health and may be harmful to
the environment.
Follow the manufacturer's handling instructions without fail.
General
M010.000.002-04-0001 EN 3 (3)
010.000.002-03
Cooling water
M010.000.002-03-0001
inspecting
Summary
Acquire and check typical values of the operating media to prevent or limit
damage.
The fresh water used to fill the cooling water circuits must satisfy the specifi-
cations. The cooling water in the system must be checked regularly in
accordance with the maintenance schedule.
The following work/steps is/are necessary:
Acquisition of typical values for the operating fluid,
evaluation of the operating fluid and checking the concentration of the anti-
corrosive agent.
Tools/equipment required
Equipment for checking the The following equipment can be used:
fresh water quality ▪ The MAN Diesel & Turbo water testing kit, or similar testing kit, with all
necessary instruments and chemicals that determine the water hardness,
pH value and chloride content (obtainable from MAN Diesel & Turbo or
Mar-Tec Marine, Hamburg)
Equipment for testing the When using chemical additives:
concentration of additives ▪ Testing equipment in accordance with the supplier's recommendations.
Testing kits from the supplier also include equipment that can be used to
determine the fresh water quality.
Cooling water
General
M010.000.002-03-0001 EN 1 (2)
010.000.002-03
M010.000.002-03-0001
2013-04-11 - de
Cooling water
General
2 (2) M010.000.002-03-0001 EN
010.000.023-13
D010.000.023-13-0001
Preliminary remarks
As is also the case with the fuel and lubricating oil, the engine cooling water
must be carefully selected, handled and checked. If this is not the case, cor-
rosion, erosion and cavitation may occur at the walls of the cooling system in
contact with water and deposits may form. Deposits obstruct the transfer of
heat and can cause thermal overloading of the cooled parts. The system
must be treated with an anticorrosive agent before bringing it into operation
for the first time. The concentrations prescribed by the engine manufacturer
must always be observed during subsequent operation. The above especially
applies if a chemical additive is added.
Requirements
Limit values The properties of untreated cooling water must correspond to the following
limit values:
Properties/Characteristic Properties Unit
Water type Distillate or fresh water, free of foreign matter. -
Total hardness max. 10 °dH*
pH value 6.5 - 8 -
Chloride ion content max. 50 mg/l**
Table 1: Cooling water - properties to be observed
Testing equipment The MAN Diesel water testing equipment incorporates devices that deter-
mine the water properties directly related to the above. The manufacturers of
anticorrosive agents also supply user-friendly testing equipment. Notes for
cooling water check see in 010.005 Engine – Work Instructions
010.000.002-03.
Additional information
Engine cooling water specifications
Distillate If distilled water (from a fresh water generator, for example) or fully desalina-
ted water (from ion exchange or reverse osmosis) is available, this should
ideally be used as the engine cooling water. These waters are free of lime
and salts which means that deposits that could interfere with the transfer of
heat to the cooling water, and therefore also reduce the cooling effect, can-
not form. However, these waters are more corrosive than normal hard water
as the thin film of lime scale that would otherwise provide temporary corro-
sion protection does not form on the walls. This is why distilled water must
be handled particularly carefully and the concentration of the additive must
2013-06-20 - de
be regularly checked.
Hardness The total hardness of the water is the combined effect of the temporary and
permanent hardness. The proportion of calcium and magnesium salts is of
General
D010.000.023-13-0001 EN 1 (7)
010.000.023-13
Treatment prior to initial Treatment with an anticorrosive agent should be carried out before the
commissioning of engine engine is brought into operation for the first time to prevent irreparable initial
damage.
Only the additives approved by MAN Diesel & Turbo and listed in the tables
under the section entitled „Approved cooling water additives“ may be used.
2 (7) D010.000.023-13-0001 EN
010.000.023-13
Required approval A cooling water additive may only be permitted for use if tested and
approved as per the latest directives of the ICE Research Association (FVV)
D010.000.023-13-0001
"Suitability test of internal combustion engine cooling fluid additives.” The test
report must be obtainable on request. The relevant tests can be carried out
on request in Germany at the staatliche Materialprüfanstalt (Federal Institute
for Materials Research and Testing), Abteilung Oberflächentechnik (Surface
Technology Division), Grafenstraße 2 in D-64283 Darmstadt.
Once the cooling water additive has been tested by the FVV, the engine
must be tested in the second step before the final approval is granted.
In closed circuits only Additives may only be used in closed circuits where no significant consump-
tion occurs, apart from leaks or evaporation losses. Observe the applicable
environmental protection regulations when disposing of cooling water con-
taining additives. For more information, consult the additive supplier.
Chemical additives
Sodium nitrite and sodium borate based additives etc. have a proven track
record. Galvanised iron pipes or zinc sacrificial anodes must not be used in
cooling systems. This corrosion protection is not required due to the prescri-
bed cooling water treatment and electrochemical potential reversal that may
occur due to the cooling water temperatures which are usual in engines
nowadays. If necessary, the pipes must be deplated.
Slushing oil
This additive is an emulsifiable mineral oil with added slushing ingredients. A
thin film of oil forms on the walls of the cooling system. This prevents corro-
sion without interfering with heat transfer, and also prevents limescale depos-
its on the walls of the cooling system.
The significance of emulsifiable corrosion-slushing oils is fading. Oil-based
emulsions are rarely used nowadays for environmental protection reasons
and also because stability problems are known to occur in emulsions.
Anti-freeze agents
If temperatures below the freezing point of water in the engine cannot be
excluded, an anti-freeze solution that also prevents corrosion must be added
to the cooling system or corresponding parts. Otherwise, the entire system
must be heated.
Engine cooling water specifications
Sufficient corrosion protection can be provided by adding the products listed
in the table entitled „Anti-freeze solutions with slushing properties“ (Military
specification: Sy-7025) while observing the prescribed minimum concentra-
tion. This concentration prevents freezing at temperatures down to -22 °C
and provides sufficient corrosion protection. However, the quantity of anti-
freeze solution actually required always depends on the lowest temperatures
that are to be expected at the place of use.
Anti-freezes are generally based on ethylene glycol. A suitable chemical anti-
corrosive agent must be added if the concentration of the anti-freeze solution
2013-06-20 - de
prescribed by the user for a specific application does not provide an appro-
priate level of corrosion protection, or if the concentration of anti-freeze solu-
tion used is lower due to less stringent frost protection requirements and
does not provide an appropriate level of corrosion protection. Considering
General
that anti-freeze agents listed in the table „Anti-freeze solutions with slushing
D010.000.023-13-0001 EN 3 (7)
010.000.023-13
properties“ also contain corrosion inhibitors and their compatibility with other
anticorrosive agents is generally not given, only pure glycol may be used as
D010.000.023-13-0001
Biocides
If you cannot avoid using a biocide because the cooling water has been con-
taminated by bacteria, observe the following steps:
▪ You must ensure that the biocide to be used is suitable for the specific
application.
▪ The biocide must be compatible with the sealing materials used in the
cooling water system and must not react with these.
▪ The biocide and its decomposition products must not contain corrosion-
promoting components. Biocides whose decomposition products con-
tain chloride or sulphate ions are not permitted.
▪ Biocides that cause foaming of cooling water are not permitted.
this has been done, the engine cooling water must be immediately treated
with anticorrosive agent. Once the engine has been brought back into opera-
tion, the cleaned system must be checked for leaks.
General
4 (7) D010.000.023-13-0001 EN
010.000.023-13
D010.000.023-13-0001
system
Treated cooling water may become contaminated when the engine is in
operation, which causes the additive to loose some of its effectiveness. It is
therefore advisable to regularly check the cooling system and the cooling
water condition. To determine leakages in the lube oil system, it is advisable
to carry out regular checks of water in the compensating tank. Indications of
oil content in water are, e.g. discoloration or a visible oil film on the surface of
the water sample.
The additive concentration must be checked at least once a week using the
test kits specified by the manufacturer. The results must be documented.
D010.000.023-13-0001 EN 5 (7)
010.000.023-13
D010.000.023-13-0001
Protective measures
Anticorrosive agents contain chemical compounds that can pose a risk to
health or the environment if incorrectly used. Comply with the directions in
the manufacturer's material safety data sheets.
Avoid prolonged direct contact with the skin. Wash hands thoroughly after
use. If larger quantities spray and/or soak into clothing, remove and wash
clothing before wearing it again.
If chemicals come into contact with your eyes, rinse them immediately with
plenty of water and seek medical advice.
Anticorrosive agents are generally harmful to the water cycle. Observe the
relevant statutory requirements for disposal.
Auxiliary engines
If the same cooling water system used in a MAN Diesel & Turbo two-stroke
main engine is used in a marine engine of type 16/24, 21/ 31, 23/30H, 27/38
or 28/32H, the cooling water recommendations for the main engine must be
observed.
Analysis
We analyse cooling water for our customers in our chemical laboratory. A 0.5
l sample is required for the test.
6 (7) D010.000.023-13-0001 EN
010.000.023-13
D010.000.023-13-0001
1,000 litres
Product Nitrite Na-Nitrite
(NO2) (NaNO2)
General
D010.000.023-13-0001 EN 7 (7)
MAN Diesel & Turbo
1690751-3.0
Page 1 (1) Engine ventilation 1400000
L21/31
L27/38
The air intake to the engine room should be dimen- Approx 50% of the ventilating air should be blown in
sioned in such a way that a sufficient quantity of air at the level of the top of the main engine close to the
is available not only for the main engine, auxiliaries, air inlet of the turbocharger. Air should not be blown
boilers etc, but also to ensure adequate ventilation directly onto heat emitting components or directly
and fresh air when work and service are in progress. onto electric or other water sensitive apparature.
We recommend the ventilation capacity should be min A small airflow should be evenly distributed around
50% more than required air consumption (in tropical the engine and reduction gear in order to dissipate
conditions more than 100% should be considered) radiated heat.
for main engine, auxiliaries, boilers etc.
With closed engine room and all air consuming equip-
It is important that the air is free of oil and sea water ment operating, there should always be positive air
to prevent fouling of the ventilators and filters. pressure in the engine room.
The air consumption of the main engine appears Surplus air should be led up through the casing via
from the planning data. special exhaust openings. Alternatively extraction
fans should be installed.
03.43
MAN Diesel & Turbo
3700005-4.1
Page 1 (3) Power, Outputs, Speed 1402150
L27/38
Engine Ratings
Reference conditions:
ISO 3046-1: 2002; ISO 15550: 2002
Air temperature Tr K/°C 298/25
Air pressure pr kPa 100
Relative humidity Φr % 30
Cooling water temperature upstream charge air cooler Tcr K/°C 298/25
Table 2 Standard reference conditions.
12.44 - Tier II
MAN Diesel & Turbo
3700005-4.1
1402150 Power, Outputs, Speed Page 2 (3)
L27/38
Available Outputs
at maximum torque 1)
Remarks
PApplication
1)
Maximum torque given by available output and nominal speed.
2)
According to DIN ISO 3046-1 MAN Diesel & Turbo has specified a maximum continuous rating for marine engines listed in the
column PApplication
Engine Fuel: according to ISO 8217 DMA/DMB/DMC-grade fuel or RM-grade fuel, fulfilling the stated quality requirements
POperating: Available output under local conditions and 1. No de-rating due to ambient conditions is ne-
dependent on application. eded as long as following conditions are not
exceeded:
Dependend on local conditions or special applica-
tion demands a further load reduction of PApplication, ISO
might be needed.
12.44 - Tier II
MAN Diesel & Turbo
3700005-4.1
Page 3 (3) Power, Outputs, Speed 1402150
L27/38
2. De-rating due to ambient conditions and ne- TcxCooling water temperature inlet charge air
gative intake pressure before compressor or cooler (LT-stage) [K] being considered
exhaust gas back pressure after turbocharger (Tcx = 273 + tcx)
with O ≥ 0
12.44 - Tier II
MAN Diesel & Turbo
3700158-7.0
Page 1 (1) Main Particulars 1402150
L27/38
Cycle : 4-stroke
Configuration : In-line
Bore : 270 mm
Stroke : 380 mm
3700147-9.1
Page 1 (1) Operating Data and Set Points 1402150
L27/38
Normal Alarm set points Reduced
value at full Shutdown
load of
load at ISO of engine
Low High engine
conditions
Lubricating oil system
Temp. after cooler (inlet engine) 68 - 73° C 80° C 85° C
Pressure after filter (inlet engine) 4.0 - 4.8 bar
< 700 rpm 2.0 bar 1.9 bar 1.8 bar
> 700 rpm 2.8 bar 2.6 bar 2.5 bar
Pressure before filter 4.2 - 5.0 bar
Pressure drop across filter 0.1 - 0.3 bar 0.8 bar 1.3 bar
Pressure inlet turbocharger 1.4 - 1.8 bar 1.3 bar
Lub oil level low level
Temperature main bearing 80 - 95° C 103° C 105° C 108° C
Fuel oil system
Pressure after filter - MDO 3.0 - 3.5 bar 1 bar
Pressure after filter - HFO 4 - 10 bar 3 bar
high leakage
Leaking oil
level
Temperature inlet engine - MDO 20 - 40° C 45° C
Temperature inlet engine - HFO 80 - 140° C
Fuel oil viscosity - HFO 11 - 13 cSt 10 cSt 14 cSt
Cooling water system
Press. LT system, inlet engine 2.0 - 3.0 bar 1.3 bar
Press. HT system, inlet engine 2.0 - 3.0 bar
< 700 rpm 1.1 bar 1.0 bar 0.9 bar
> 700 rpm 2.7 bar 1.6 bar 1.5 bar
Temp. HT system, outlet engine 75 - 85° C 92° C 95° C 97° C
Temp. HT system, inlet engine 65 - 70° C
Temp. LT system, inlet engine 25 - 40° C
Temp. LT system, outlet engine 35 - 45° C
Exhaust gas and charge air
Exh. gas temp. inlet TC 480 - 530° C 570° C 590° C
510° C 530° C
Exh. gas temp. outlet cyl 370 - 450° C average average average
-50° C +50° C ±70° C
Exh. gas temp. outlet TC 300 - 350° C 450° C
3700305-0.0
Page 1 (1) Operating Data and Set Points 1402150
L27/38
Normal Alarm set points Reduced
value at full Shutdown
load of
load at ISO of engine
Low High engine
conditions
Lubricating oil system
Temp. after cooler (inlet engine) 68 - 73° C 80° C 85° C
Pressure after filter (inlet engine) 4.0 - 4.8 bar 3.0 bar 1.8 bar
Pressure before filter 4.2 - 5.0 bar
Pressure drop across filter 0.1 - 0.3 bar 0.8 bar 1.3 bar
Pressure inlet turbocharger 1.4 - 1.8 bar 1.1 bar
Lub oil level low level
Temperature main bearing 80 - 95° C 100° C 105° C
Fuel oil system
Pressure after filter - MDO 3.0 - 3.5 bar 1 bar
Pressure after filter - HFO 4 - 10 bar 3 bar
high leakage
Leaking oil
level
Temperature inlet engine - MDO 20 - 40° C
Temperature inlet engine - HFO 80 - 140° C
Fuel oil viscosity - HFO 11 - 13 cSt 10 cSt 14 cSt
Cooling water system
Press. LT system, inlet engine 2.0 - 3.0 bar 0.4 bar + SP
Press. HT system, inlet engine 2.0 - 3.0 bar 0.4 bar + SP 0.3 bar + SP 0.2 bar + SP
Temp. HT system, outlet engine 75 - 85° C 92° C 95° C 97° C
Temp. HT system, inlet engine 65 - 70° C
Temp. LT system, inlet engine 25 - 40° C
Temp. LT system, outlet engine 35 - 45° C
Exhaust gas and charge air
Exh. gas temp. inlet TC 480 - 530° C 590° C 590° C
510° C
Exh. gas temp. outlet cyl 370 - 450° C average average average
-50° C +50° C ±50° C
Exh. gas temp. outlet TC 300 - 350° C 450° C
SP = Static pressure
3700019-8.0
Page 1 (3) Spare Parts for Unrestricted Service 1487000
L27/38
Spare parts for unrestricted service, according to the classification societies requirements/recommendations.
For multi-engine installations spares are only necessary for one engine.
Cylinder Head
Cylinder head with valves 11616 1 1
Valve, inlet 11616 2 2
Valve rotation device 11616 3 6
Valve cone 11616 4 3
O-ring 11616 5 6
Valve spindle, exhaust 11616 7 4
Pressure spring 11616 11 6
O-ring 11616 A3 1
Gasket 11616 A5 1
O-ring 11616 A6 1
O-ring 11616 A7 1
Valve seat ring, exhaust 11616 F9 4
O-ring 11616 F10 4
Valve seat ring, inlet 11616 F11 2
Indicator valve 11618 1 1
Connecting socket 11618 2 1
Union nut 11618 3 1
Threaded socket 11618 4 1
Molykote 11618 5 1
Insulation glove 11618 6 1
Safety valve 11618 A1 1
Gasket 11618 A2 1
Pipe, safety valve 11618 A3 1
Piston and piston rings
Ring Package 11614 1-2 1
Piston 11614 13 1
Cylinder liner
Cylinder liner 11610 1 1
Flame ring 11610 5 1
Sealing ring 11610 7 1
O-ring 11610 9 1
Sealing ring 11610 10 1
Connecting rod
Connecting rod stem 11612 10 1
Cylinder head, top cover
O-ring 11620 4 1
10.40. Tier II
MAN Diesel & Turbo
3700019-8.0
1487000 Spare Parts for Unrestricted Service Page 2 (3)
L27/38
10.40, Tier II
MAN Diesel & Turbo
3700019-8.0
Page 3 (3) Spare Parts for Unrestricted Service 1487000
L27/38
Plate No. and Item No. refer to the spare parts plates in the instruction book.
10.40, Tier II
MAN Diesel & Turbo
3700020-8.0
Page 1 (1) Spare Parts for Restricted Service 1487000
L27/38
Spare parts for restricted service, according to the classification societies requirements/recommendations.
Plate No. and Item No. refer to the spare parts plates in the instruction book.
10.40, Tier II
MAN Diesel & Turbo 14 88 010
Description
3700125-2.1
Tier II 1 (11)
L27/38 EN
14 88 010 MAN Diesel & Turbo
Standard tools (unrestricted service)
2015-03-19 - en
Description
3700125-2.1
2 (11) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 010
Description
3700125-2.1
Tier II 3 (11)
L27/38 EN
14 88 010 MAN Diesel & Turbo
Standard tools (unrestricted service)
2015-03-19 - en
Description
3700125-2.1
4 (11) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 010
Description
3700125-2.1
Tier II 5 (11)
L27/38 EN
14 88 010 MAN Diesel & Turbo
Standard tools (unrestricted service)
Turbocharger system
Name Sketch Supply per ship Drawing Remarks
Working Spare Item no
Eye screw for lifting 1 036
2015-03-19 - en
Description
3700125-2.1
6 (11) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 010
Description
3700125-2.1
Tier II 7 (11)
L27/38 EN
14 88 010 MAN Diesel & Turbo
2015-03-19 - en
Description
3700125-2.1
8 (11) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 010
Description
3700125-2.1
Tier II 9 (11)
L27/38 EN
14 88 010 MAN Diesel & Turbo
10 (11) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 010
Description
3700125-2.1
Tier II 11 (11)
L27/38 EN
MAN Diesel & Turbo 14 88 010
Description
3700127-6.1
Tier II 1 (9)
L27/38 EN
14 88 010 MAN Diesel & Turbo
Standard tools (restricted service)
2015-03-19 - en
Description
3700127-6.1
2 (9) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 010
Description
3700127-6.1
Tier II 3 (9)
L27/38 EN
14 88 010 MAN Diesel & Turbo
Standard tools (restricted service)
Turbocharger system
Name Sketch Supply per ship Drawing Remarks
Working Spare Item no
Eye screw for lifting 1 036
2015-03-19 - en
Description
3700127-6.1
4 (9) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 010
Description
3700127-6.1
Tier II 5 (9)
L27/38 EN
14 88 010 MAN Diesel & Turbo
2015-03-19 - en
Description
3700127-6.1
6 (9) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 010
Description
3700127-6.1
Tier II 7 (9)
L27/38 EN
14 88 010 MAN Diesel & Turbo
8 (9) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 010
Description
3700127-6.1
Tier II 9 (9)
L27/38 EN
MAN Diesel & Turbo 14 88 050
Additional tools
Additional tools
Cylinder head
Name Sketch Supply per ship Drawing Remarks
Working Spare Item no
Grinding tool for cylinder
head/liner 1 126
Description
3700126-4.6
Tier II 1 (11)
L27/38 EN
14 88 050 MAN Diesel & Turbo
2 (11) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 050
Additional tools
Working Spare Item no
Grinding tool for valves 1 283
Plate
(used with item 329) 1 317
Extractor for
valve seat rings 1 329
Description
3700126-4.6
Tier II 3 (11)
L27/38 EN
14 88 050 MAN Diesel & Turbo
Additional tools
4 (11) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 050
Additional tools
Working Spare Item no
Piston ring opener 1 190
Description
3700126-4.6
Tier II 5 (11)
L27/38 EN
14 88 050 MAN Diesel & Turbo
Additional tools
6 (11) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 050
Additional tools
Turbocharger system
Name Sketch Supply per ship Drawing Remarks
Working Spare Item no
Eye screw for lifting 1 036
Description
3700126-4.6
Tier II 7 (11)
L27/38 EN
14 88 050 MAN Diesel & Turbo
Additional tools
8 (11) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 050
Additional tools
Working Spare Item no
Setting device for fuel injec- 1 366
tion pump
Description
3700126-4.6
Tier II 9 (11)
L27/38 EN
14 88 050 MAN Diesel & Turbo
Additional tools
2015-03-18 - en
Description
3700126-4.6
10 (11) Tier II
L27/38 EN
MAN Diesel & Turbo 14 88 050
Additional tools
Hydraulic tools
Name Sketch Supply per ship Drawing Remarks
Working Spare Item no
Resetting device for 1 092
hydraulic cylinder
Description
3700126-4.6
Tier II 11 (11)
L27/38 EN
MAN Diesel & Turbo
Plate
Page 1 (2) Hand tools 1488070
L21/31, L27/38
2014.07.07 - 3700064-6.1
MAN Diesel & Turbo
Plate
1488070 Hand tools Page 2 (2)
L21/31, L27/38
Item No. Qty Item Designation Item No. Qty Item Designation
2014.07.07 - 3700064-6.1
MAN Diesel & Turbo 14 02 000
Description
1699862-8.2
TCR 1 (1)
L27/38 EN
MAN Diesel & Turbo 14 02 000
Front end box for GenSet approx. 2420 Front end box for propulsion approx.
kg 2170 kg
Description
1689476-6.3
shaft [mm]
5 cyl. 2378 376
6 cyl. 2823 427
7 cyl. 3268 477
8 cyl. 3713 528
9 cyl. 4158 528
2014-11-24 - en
Description
1689476-6.3
Description
1689476-6.3
1690730-9.1
Page 1 (1) Fuel oil system 1435000
L21/31
L27/38
General The built-on equipment is designed for use of fuel oil
modules, normally referred to as booster modules.
The engine can be equipped with different equipment For multi engine installations a common fuel oil feed
depending on fuel oil quality. system should cover all engines.
The standard engine, for operation on MDO (Marine
Diesel Oil), is equipped with built-on:
Fuel oil quality
Fuel oil primary pump
o
Double filter with paper inserts We recommend to use heavy fuel up to 380 cSt/50 C,
Lubrication of fuel oil pumps even though the engine is designed for operation on
o
Fuel oil pumps with leak oil seal HFO up to 700 cSt/50 C, depending on the actual
Uncooled fuel injection valves fuel quality.
The MDO built-on equipment is designed for single For fuel oil quality, see Quality Requirements
engine installation. For multi engine installations it 1435000.
is recommended to have either two separate fuel
supplies or the built-on pumps have to be replaced The maximum injection viscosity is 12-14 cSt.
by electrical pumps.
Velocity recommendations for fuel oil pipes:
The standard engine, for operation on HFO (Heavy
Fuel Oil), is equipped with built-on: Marine Diesel Oil: Suction pipe: 0.5 - 1.0m/s
Delivery pipe: 1.5 - 2.0 m/s
Fuel oil duplex filter
Fuel oil back pressure valve Heavy Fuel Oil: Suction pipe: 0.3 - 0.8 m/s
Lubrication of fuel oil pumps Delivery pipe: 0.8 - 1.2 m/s
Fuel oil pumps without leak oil seal
Uncooled fuel injection valves
Equipment for cleaning of turbocharger
turbine side during operation
08.45
MAN Diesel & Turbo
General
bx
bx = br x ß br =
ß
tbar Engine type specific reference charge air temperature before cylinder
see »Reference conditions« in »Fuel oil consumption for emissions standard«.
Example
Reference values:
br = 200 g/kWh, tr = 25° C, tbar = 40° C, pr = 1.0 bar
At Site:
tx = 45° C, tbax = 50° C, px = 0.9 bar
ß = 1+ 0.0006 (45 – 25) + 0.0004 (50 – 40) + 0.07 (1.0 – 0.9) = 1.023
bx = ß x br = 1.023 x 200 = 204.6 g/kWh
All data provided in the attached document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depend-
ing on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each
project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions.
12.12
MAN Diesel & Turbo
3700004-2.3
Page 1 (3) Fuel Oil Consumption for Emissions Standard 1402090
L27/38
All data provided in the attached document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depend-
ing on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each
project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions.
12.37 - Tier II
MAN Diesel & Turbo
L27/38
Relative humidity Φr % 30
Engine type specific reference charge air temperature before cylinder tbar 1) °C 40
All data provided in the attached document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depend-
ing on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each
project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions.
12.37 - Tier II
MAN Diesel & Turbo
3700004-2.3
Page 3 (3) Fuel Oil Consumption for Emissions Standard 1402090
L27/38
For different net calorific value, the SFOC will be corrected in [%] by:
Net calorific value NCV rise 427 kJ/kg - 1.0 %
Increased negative intake pressure before compressor leads to increased fuel oil consumption, calculated
as increased air temperature before turbocharger:
Increased exhaust gas back pressure after turbine leads to increased fuel oil consumption, calculated as
increased air temperature before turbocharger:
Charge air blow-off for exhaust gas temperature control (plants with catalyst) leads to increased fuel oil
consumption:
For every increase of the exhaust gas temperature by 1° C, due to activation of charge air blow-off device,
an addition of 0.05 g/kWh to be considered.
All data provided in the attached document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depend-
ing on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each
project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions.
12.37 - Tier II
MAN Diesel & Turbo
3700304-9.1
Page 1 (3) Fuel oil system – MDO 1435000
L27/38
Fuel oil system for operation on gas/diesel oil
5 4
LAL
28 x 2
DN 32
20 x 2
28 x 2
To sludge
28 x 2
B1
3
8 7
PSL
1421
To sludge
M B3
2
PT PT
1424 1423
9
18 x 2
LSH
28 x 2
Return to bunker/settling tank
1425
20 x 2
20 x 2 B7A B7 20
B4 B7
Clean fuel oil return
1
to service tank
To sludge tank
From bunker/
settling tank
Item Description
Shut-off valve at B4 is to be placed as close to the
1 Prefilter for purifier connections as possible
2 Transfer pump
3 Purifier
4 MDO service tank
5 Sightglass for MDO overflow Service tank (item 4):
2169644-5
14.27 - Tier II
MAN Diesel & Turbo
3700304-9.1
1435000 Fuel oil system – MDO Page 2 (3)
L27/38
Fuel oil storage Purifier, item 3
The storage and handling system comprises of bunker For engines operating on MDO we recommend
tanks, pipe systems and transfer systems. cleaning of the oil by a purifier to remove water.
For the blended fuel oil (M3 in accordance to BS
MA100 fuel oil specification) which can be ex-
Cleaning systems pected in some bunker places, the purifier is also
an important cleaning device. We recommend the
The cleaning system normally comprises of a settling automatic self-cleaning type.
tank, pipe system and equipment for cleaning of the
MDO prior to use in the engine. As a guideline for the selection of purifier, the fol-
lowing formula can be used:
The settling tank should be designed to provide the
most efficient sludge and water separation. The tank Design data:
should be provided with baffles to reduce mixing of
sludge with the fuel. The bottom of the tank should Capacity: V = C × (24/T)
have a slope toward the sludge drain valve(s), and
the pump suction must not be in the vicinity of the V: The nominal capacity of the purifier in litres/
sludge space. hour
C: Consumption at MCR in litres/hour
We recommend that the capacity of a single set- T: Daily separating time, depending on purifier
tling tank is sufficient to ensure minimum 24 hours (20-22 hours)
operation.
Guidance given by the manufacturer of the purifier
must be observed.
Prefilter, item 1
If aux engines are fed from the same fuel oil system,
To protect the purifier pump (item 2), a prefilter should the fuel oil consumption has to include all engines.
be inserted before the pump.
Pre-heating is normally not necessary, but a purify-
Design data: ing temperature of approx 40°C is recommended
for better separation. Some Marine Diesel Oils have
Capacity: See oil pump, item 2 a high content of “paraffin” which clogs up filters and
Mesh size: 0.8 – 1.0 mm can cause unintended engine stopping. To avoid
this, preheating can be necessary.
Oil pump to purifier, item 2 A heat exchanger and a thermostatic valve using
the main engine HT cooling water as heating media
The pump can be driven directly by the purifier or by can be installed, if necessary.
an independent motor.
14.27 - Tier II
MAN Diesel & Turbo
3700304-9.1
Page 3 (3) Fuel oil system – MDO 1435000
L27/38
Attention must be paid that the fuel oil inlet pipe is Fuel oil consumption
connected to the side of the tank in a position to
avoid sludge and water contamination of the MDO. For calculating the necessary tank size, purifier,
stand-by pumps, etc, the consumption stated in the
A vent pipe from the tank should be led up to the deck planning data, based on engine MCR, should be used.
level minimum 500 mm above the tank. Precaution
should be taken that water does not enter the tank These values include an addition for engine driven
through the vent pipe. pumps plus 3% tolerance in accordance with ISO
requirements.
To ensure satisfactory suction when starting up the
main engine, the lowest oil level in the service tank
should be at least 500 mm above the suction to the Cooler requirements
primary pump (item 8 in fig 6.1) and the stand-by
primary pump. Fuel oil temperatures before engine / fuel oil injec-
tion pumps (MDO/MGO):
Duplex suction filter, item 6 If the fuel oil temperature before engine / fuel injec-
tion pumps exceeds 40° C or the viscosity is below
A duplex suction filter with magnetic inserts should 2.2 cSt a cooler must be built-in, in order to ensure
be installed in the suction line of the fuel oil primary the lubricating properties for the injection pumps.
pump to protect the pump. The filter should be de-
signed for the capacity of the built-on primary pump
with a mesh size of 0.5-0.8 mm. Notes
See 1400000 List of capacities. We should be pleased to review your piping diagrams
and give our comments and recommendations. The
shipyard is responsible for the choice of method,
design and execution.
14.27 - Tier II
MAN Diesel & Turbo
3700363-5.0
Page 1 (6) Fuel oil system – HFO 1435000
L27/38
Fuel oil system for operation on heavy fuel oil
20 x 2
35
30
20 x 2
20 x 2
Marine diesel
Heavy fuel oil
DN 32
28 x 2
oil
7 LAL LAL
34
33
DN 32
To sludge To sludge
DN 32
To sludge
20 x 2
22 x 2
14
13
PSL
PSL 32
M
16A VAL/H
M
DN 32 DPAH TAH
11 TI
FI 31
8A 10 12 15 17
9A
16
28 x 2
M
DN 32 18
TAL PI
To sludge
8
9
28 x 2
28 x 2
Return to bunker tank (HFO)
From bunker tank (HFO)
PT PT
6 5 1424 1423 TE
28 x 2
28 x 2
1424
1 12 x 1.5 DN 32
To sludge
To sludge
19 B1
LSH
4A 4 1425 20 DN 32
20 x 2 B7A B7 B4 B7
3A 3
M M
To sludge
2A 2
To sludge tank
to service tank
2164117-1
DN 32 DN 32
2014.07.04 - Tier II
MAN Diesel & Turbo
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1435000 Fuel oil system – HFO Page 2 (6)
L27/38
2014.07.04 - Tier II
MAN Diesel & Turbo
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Page 3 (6) Fuel oil system – HFO 1435000
L27/38
Design data: Guidance given by the manufacturer of the sepera-
tors must be observed.
Capacity: According to separator
Pressure: Max 2.5 bar If aux engines are supplied from the same fuel oil
Temperature: Max 70°C system, the fuel oil consumption has to include all
engines.
The preheater must be able to raise the temperature The service tank should be dimensioned to contain
of the oil from approx 60°C to approx 98°C, which is purified HFO for operating for at least 12 hours.
the temperature of the oil for purifying.
The tank must be insulated and the oil temperature in
Design data: the tank should be kept at minimum 60 °C. Depend-
ing on separating temperature and tank insulation
Capacity: P = v × t/1710 the temperature may rise to above 90°C.
P: Capacity of the preheater in kW Attention must be paid that the fuel oil inlet pipe is
v: Flow through preheater in litres/hour connected to the side of the tank in a position to
t: Temperature difference approx 40°C avoid sludge and water contamination of the HFO.
(engine operating)
The feed from the service tank to the mixing pipe
Max pressure: 4 bar is to be connected in a suitable distance above the
Max pressure loss: 0.5 bar bottom of the service tank to avoid sludge and water
contamination in the pipe.
The specific load on heating surface for an electric
preheater is recommended not to exceed 1.2 W/cm2. A vent pipe from the tank should be led up to the deck
level minimum 500 mm above the tank. Precaution
should be taken that water does not enter the tank
Purifier/clarifier, items 5 and 6 through the vent pipe.
Capacity: V = C × (24/T)
Pressure pumps, items 9 and 9A
V:The nominal capacity of the separators in litres/hour
C: Consumption at MCR in litres/hour The HFO system must be pressurised to avoid
T: Daily separating time, depending on purifier gas separation in the fuel oil piping. Pressurising is
(20-22 hours) maintained by the pumps installed between the HFO
service tank and the automatic filter.
2014.07.04 - Tier II
MAN Diesel & Turbo
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1435000 Fuel oil system – HFO Page 4 (6)
L27/38
Design data: Fuel oil consumption measuring, item 11
Type: Screw or gear pump with relief valve For engines with pressurised HFO system a fuel
Capacity: MCR consumption + flushing oil consumption meter can be fitted between the auto-
matic filter (item 10) and the mixing tank (item 12).
Pressure: Max 4 bar
A spring loaded valve has to be installed in parallel.
Temperature: Max 90°C In case of the measuring device, the valve will open
Viscosity at normal operation: and ensure fuel supply to the engine.
Max 140 cSt
(corresponding to 70°C)
Viscosity for dimensioning of el–motor: Mixing pipe, item 12
1000 cSt
The main purpose of the mixing pipe is to ensure
good ventilation of gas from the hot fuel oil.
Pressure regulating valve, item 14
Furthermore, the mixing pipe ensures a gradual
temperature balance by mixing the hot returned oil
The pressure regulating valve is to be adjusted to a
from the engine with the oil from the daily service
pressure of approx 4 bar and the relief valve setting
tank thereby reducing the heat requirements from
for supply pumps, items 9 and 9A, is adjusted to a
the final preheater.
higher pressure.
The mixing pipe should be dimensioned to contain
If the capacity of the pressure pumps (items 9 and
fuel oil for 10-15 minutes operation at MCR load,
9A) exceeds the fuel oil consumption too much, or
and in any case not less than 50 litres.
if the plant often operates at low load, the surplus
oil by-passed by the pressure regulating valve has
Minimum diameter of mixing pipe: 200 mm.
to be cooled down by a by-pass oil radiator, to avoid
unintended heating of the fuel supply.
Because the capacity of the fuel oil primary pump
is higher than the consumption of the engine, the
surplus oil from engine flange connection B4 must be
Automatic filter, item 10
returned to the mixing pipe and must be adequately
insulated.
An automatic filter should be installed between the
supply pumps and the mixing pipe.
The flange connection B2 must be connected to a
drain tank and not to the mixing pipe.
As the flow is limited to the consumption of the engine,
a filter with 10 µm mesh size should be used in order
to achieve optimal filtration. In case of malfunction of
Prefilter, item 15
the filter, a manually cleaned by-pass filter has to be
installed in parallel to the automatic filter.
To protect the fuel oil circulation pumps a duplex
prefilter is recommended between the mixing pipe
Design data:
(item 12) and the circulating pumps (items 16 and
16A).
Capacity : MCR consumption
Pressure : Normally 4 bar
Max 8 bar
Temperature : Max 90°C
Mesh size : 10 µm absolute (main supply)
35 µm absolute (by-pass supply)
2014.07.04 - Tier II
MAN Diesel & Turbo
3700363-5.0
Page 5 (6) Fuel oil system – HFO 1435000
L27/38
Design data (depending on fuel type): The above capacities include a safety margin of 15%
but the necessary capacity depends on the actual
Capacity: See the planning data fuel and condition. We will be pleased to carry out
Operating temperature: Max 150°C calculations for a specific condition on request.
Pressure: Max 10 bar
Pressure drop by clean filter: Max 0.05 bar
Pressure drop by dirty filter: Max 0.1 bar
Fuel type IF 80 IF 180 IF 380
Mesh size: 0.5 – 0.8 mm
final temp t= 110 °C t=131 °C t=147 °C
kW kW kW
HFO circulating pump, items 16 and 16A 6L27/38 18 25 30
7L27/38 21 29 35
The pressurised HFO system has a high degree of
recirculation. 8L27/38 25 33 40
9L27/38 28 38 45
Design data (depending on fuel type):
In order to heat the HFO to the proper viscosity The viscosity control equipment should be able to
before the injection valves (12±2 cSt), the oil is led switch over to thermostatic control in case of mal-
through a preheater. functioning.
2014.07.04 - Tier II
MAN Diesel & Turbo
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1435000 Fuel oil system – HFO Page 6 (6)
L27/38
The fuel oil pipe system must be made of seamless The MDO treatment and feed system
precision steel tubes which can be assembled by
means of either cutting ring or clamp ring fittings. The engine is designed for pier to pier operation on
HFO. However, change-over to MDO might become
necessary. For instance during:
Fuel oil consumption
Repair of engine and fuel oil system
For calculating the necessary size of tank, separa- Docking
tors, stand-by pumps, etc, the consumption stated More than 5 days stop
in the planning data, based on engine MCR, should Environmental legislation requiring use of
be used. low-sulphur fuels
The consumption includes an addition for engine The layout of MDO treatment and feed system
driven pumps plus 5% tolerance in accordance with should be in accordance with the recommendations
ISO requirements. for MDO.
The low calorific heat value of the heavy fuel oil cor-
responds to 40,225 kJ/kg.
2014.07.04 - Tier II
MAN Diesel & Turbo D010.000.023-05-0001
bustion properties and the stability of the fuel. This means that the operating
D010.000.023-05-0001
behaviour of the engine can depend on properties that are not defined in the
specification. This particularly applies to the oil property that causes forma-
tion of deposits in the combustion chamber, injection system, gas ducts and
2015-01-20 - de
1 (9)
D010.000.023-05-0001 MAN Diesel & Turbo
Blends The addition of engine oils (old lubricating oil, ULO –used lubricating oil) and
Specification of heavy fuel oil (HFO)
additives that are not manufactured from mineral oils, (coal-tar oil, for exam-
ple), and residual products of chemical or other processes such as solvents
(polymers or chemical waste) is not permitted. Some of the reasons for this
are as follows: abrasive and corrosive effects, unfavourable combustion
characteristics, poor compatibility with mineral oils and, last but not least,
adverse effects on the environment. The order for the fuel must expressly
state what is not permitted as the fuel specifications that generally apply do
not include this limitation.
If engine oils (old lubricating oil, ULO – used lubricating oil) are added to fuel,
this poses a particular danger as the additives in the lubricating oil act as
emulsifiers that cause dirt, water and catfines to be transported as fine sus-
pension. They therefore prevent the necessary cleaning of the fuel. In our
experience (and this has also been the experience of other manufacturers),
this can severely damage the engine and turbocharger components.
The addition of chemical waste products (solvents, for example) to the fuel is
prohibited for environmental protection reasons according to the resolution
of the IMO Marine Environment Protection Committee passed on 1st January
1992.
Leak oil collector Leak oil collectors that act as receptacles for leak oil, and also return and
overflow pipes in the lube oil system, must not be connected to the fuel tank.
Leak oil lines should be emptied into sludge tanks.
Viscosity (at 50 ℃) mm2/s (cSt) max. 700 Viscosity/injection viscosity
Viscosity (at 100 ℃) max. 55 Viscosity/injection viscosity
Density (at 15 °C) g/ml max. 1.010 Heavy fuel oil processing
Flash point °C min. 60 Flash point
(ASTM D 93)
Pour point (summer) max. 30 Low-temperature behaviour
(ASTM D 97)
Pour point (winter) max. 30 Low-temperature behaviour
(ASTM D 97)
Coke residue (Conrad- Weight % max. 20 Combustion properties
son)
Sulphur content 5 or Sulphuric acid corrosion
legal requirements
Ash content 0.15 Heavy fuel oil processing
Vanadium content mg/kg 450 Heavy fuel oil processing
Water content Vol. % 0.5 Heavy fuel oil processing
Sediment (potential) Weight % 0.1
Aluminium and silicium mg/kg max. 60 Heavy fuel oil processing
Operating Instruction
content (total)
D010.000.023-05-0001
2 (9)
MAN Diesel & Turbo D010.000.023-05-0001
Additional information
The purpose of the following information is to show the relationship between
the quality of heavy fuel oil, heavy fuel oil processing, the engine operation
and operating results more clearly.
Selection of heavy fuel oil Economical operation with heavy fuel oil within the limit values specified in
the table entitled The fuel specification and corresponding properties for
heavy fuel oil is possible under normal operating conditions, provided the
system is working properly and regular maintenance is carried out. If these
requirements are not satisfied, shorter maintenance intervals, higher wear
and a greater need for spare parts is to be expected. The required mainte-
nance intervals and operating results determine which quality of heavy fuel oil
should be used.
It is an established fact that the price advantage decreases as viscosity
increases. It is therefore not always economical to use the fuel with the high-
est viscosity as in many cases the quality of this fuel will not be the best.
Viscosity/injection viscosity Heavy fuel oils with a high viscosity may be of an inferior quality. The maxi-
mum permissible viscosity depends on the preheating system installed and
the capacity (flow rate) of the separator.
The prescribed injection viscosity of 12 – 14 mm2/s (for GenSets, 23/30H
and 28/32H: 12 - 18 cSt) and corresponding fuel temperature upstream of
the engine must be observed. This is the only way to ensure efficient atomi-
sation and mixture formation and therefore low-residue combustion. This
also prevents mechanical overloading of the injection system. For the prescri-
bed injection viscosity and/or the required fuel oil temperature upstream of
the engine, refer to the viscosity temperature diagram.
Operating Instruction
D010.000.023-05-0001
Heavy fuel oil processing Whether or not problems occur with the engine in operation depends on how
carefully the heavy fuel oil has been processed. Particular care should be
taken to ensure that highly-abrasive inorganic foreign matter (catalyst parti-
2015-01-20 - de
cles, rust, sand) are effectively removed. It has been shown in practice that
wear as a result of abrasion in the engine increases considerably if the alumi-
num and silicium content is higher than 15 mg/kg.
Viscosity and density influence the cleaning effect. This must be taken into
account when designing and making adjustments to the cleaning system.
3 (9)
D010.000.023-05-0001 MAN Diesel & Turbo
Settling tank Heavy fuel oil is precleaned in the settling tank. The longer the fuel remains in
Specification of heavy fuel oil (HFO)
the tank and the lower the viscosity of heavy fuel oil is, the more effective the
precleaning process will be (maximum preheating temperature of 75 °C to
prevent the formation of asphalt in heavy fuel oil). A settling tank is sufficient
for heavy fuel oils with a viscosity of less than 380 mm2/s at 50 °C. If the
heavy fuel oil has a high concentration of foreign matter, or if fuels in accord-
ance with ISO-F-RM, G/H/K380 or H/K700 are to be used, two settling tanks
will be required one of which must be sized for 24-hour operation. Before the
content is moved to the service tank, water and sludge must be drained from
the settling tank.
Separators A separator is particularly suitable for separating material with a higher spe-
cific density – such as water, foreign matter and sludge. The separators must
be self-cleaning (i.e. the cleaning intervals must be triggered automatically).
Only new generation separators should be used. They are extremely effective
throughout a wide density range with no changeover required, and can sep-
arate water from heavy fuel oils with a density of up to 1.01 g/ml at 15 °C.
Table Achievable proportion of foreign matter and water (following separa-
tion) shows the prerequisites that must be met by the separator. These limit
values are used by manufacturers as the basis for dimensioning the separa-
tor and ensure compliance.
The manufacturer's specifications must be complied with to maximize the
cleaning effect.
If the treatment is in accordance with the MAN Diesel specifications and the
correct separators are chosen, it may be assumed that the results stated in
2015-01-20 - de
the table entitled Achievable Contents of Foreign Matter and Water for inor-
ganic foreign matter and water in heavy fuel oil will be achieved at the engine
inlet.
4 (9)
MAN Diesel & Turbo D010.000.023-05-0001
Results obtained during operation in practice show that the wear occurs as a
be present in the heavy fuel oils. In most cases, these catalyst particles are
D010.000.023-05-0001
aluminium silicates causing a high degree of wear in the injection system and
the engine. The aluminium content determined, multiplied by a factor of
between 5 and 8 (depending on the catalytic bond), is roughly the same as
2015-01-20 - de
5 (9)
D010.000.023-05-0001 MAN Diesel & Turbo
Flash point (ASTM D 93) National and international transportation and storage regulations governing
Specification of heavy fuel oil (HFO)
the use of fuels must be complied with in relation to the flash point. In gen-
eral, a flash point of above 60 °C is prescribed for diesel engine fuels.
Low-temperature behaviour The pour point is the temperature at which the fuel is no longer flowable
(ASTM D 97) (pumpable). As the pour point of many low-viscosity heavy fuel oils is higher
than 0 °C, the bunker facility must be preheated, unless fuel in accordance
with RMA or RMB is used. The entire bunker facility must be designed in
such a way that the heavy fuel oil can be preheated to around 10 °C above
the pour point.
Pump characteristics If the viscosity of the fuel is higher than 1000 mm2/s (cSt), or the temperature
is not at least 10 °C above the pour point, pump problems will occur. For
more information, also refer to Low-temperature behaviour (ASTM D 97).
Combustion properties If the proportion of asphalt is more than two thirds of the coke residue (Con-
radson), combustion may be delayed which in turn may increase the forma-
tion of combustion residues, leading to such as deposits on and in the injec-
tion nozzles, large amounts of smoke, low output, increased fuel consump-
tion and a rapid rise in ignition pressure as well as combustion close to the
cylinder wall (thermal overloading of lubricating oil film). If the ratio of asphalt
to coke residues reaches the limit 0.66, and if the asphalt content exceeds
8%, the risk of deposits forming in the combustion chamber and injection
system is higher. These problems can also occur when using unstable heavy
fuel oils, or if incompatible heavy fuel oils are mixed. This would lead to an
increased deposition of asphalt (see Compatibility).
Ignition quality Nowadays, to achieve the prescribed reference viscosity, cracking-process
products are used as the low viscosity ingredients of heavy fuel oils although
the ignition characteristics of these oils may also be poor. The cetane num-
ber of these compounds should be > 35. If the proportion of aromatic hydro-
carbons is high (more than 35 %), this also adversely affects the ignition
quality.
The ignition delay in heavy fuel oils with poor ignition characteristics is longer;
the combustion is also delayed which can lead to thermal overloading of the
oil film at the cylinder liner and also high cylinder pressures. The ignition delay
and accompanying increase in pressure in the cylinder are also influenced by
the end temperature and compression pressure, i.e. by the compression
ratio, the charge-air pressure and charge-air temperature.
The disadvantages of using fuels with poor ignition characteristics can be
limited by preheating the charge air in partial load operation and reducing the
output for a limited period. However, a more effective solution is a high com-
pression ratio and operational adjustment of the injection system to the igni-
tion characteristics of the fuel used, as is the case with MAN Diesel & Turbo
piston engines.
The ignition quality is one of the most important properties of the fuel. This
value does not appear in the international specifications because a standar-
Operating Instruction
dised testing method has only recently become available and not enough
D010.000.023-05-0001
experience has been gathered at this point in order to determine limit values.
The parameters, such as the calculated carbon aromaticity index (CCAI), are
therefore aids that are derived from quantifiable fuel properties. We have
2015-01-20 - de
established that this method is suitable for determining the approximate igni-
tion quality of the heavy fuel oil used.
A testing instrument has been developed based on the constant volume
combustion method (fuel combustion analyser FCA) and is currently being
tested by a series of testing laboratories.
The instrument measures the ignition delay to determine the ignition quality
6 (9)
MAN Diesel & Turbo D010.000.023-05-0001
Figure 2: Nomogram for determining the CCAI – assigning the CCAI ranges to engine
types
The CCAI can be calculated using the following formula:
CCAI = D - 141 log log (V+0.85) - 81
7 (9)
D010.000.023-05-0001 MAN Diesel & Turbo
Sulphuric acid corrosion The engine should be operated at the coolant temperatures prescribed in the
Specification of heavy fuel oil (HFO)
operating handbook for the relevant load. If the temperature of the compo-
nents that are exposed to acidic combustion products is below the acid dew
point, acid corrosion can no longer be effectively prevented, even if alkaline
lube oil is used.
The BN values specified in 010.005 Engine - Operating instructions
010.000.023-11 are sufficient, providing the quality of lubricating oil and the
engine's cooling system satisfy the requirements.
Compatibility The supplier must guarantee that the heavy fuel oil is homogeneous and
remains stable, even after the standard storage period. If different bunker oils
are mixed, this can lead to separation and the associated sludge formation in
the fuel system during which large quantities of sludge accumulate in the
separator that block filters, prevent atomisation and a large amount of resi-
due as a result of combustion.
This is due to incompatibility or instability of the oils. Therefore heavy fuel oil
as much as possible should be removed in the storage tank before bunker-
ing again to prevent incompatibility.
Blending the heavy fuel oil If heavy fuel oil for the main engine is blended with gas oil (MGO) to obtain
the required quality or viscosity of heavy fuel oil, it is extremely important that
the components are compatible (see Compatibility).
Additives for heavy fuel oils MAN Diesel & Turbo SE engines can be operated economically without addi-
tives. It is up to the customer to decide whether or not the use of additives is
beneficial. The supplier of the additive must guarantee that the engine opera-
tion will not be impaired by using the product.
The use of heavy fuel oil additives during the warranty period must be avoi-
ded as a basic principle.
Additives that are currently used for diesel engines, as well as their probable
effects on the engine's operation, are summarised in the table below Addi-
tives for heavy fuel oils – classification/effects.
Precombustion additives ▪ Dispersing agents/stabil-
isers
▪ Emulsion breakers
▪ Biocides
Combustion additives ▪ Combustion catalysts
(fuel savings, emissions)
Post-combustion additives ▪ Ash modifiers (hot corro-
sion)
▪ Soot removers (exhaust-
gas system)
Table 3: Additives for heavy fuel oils – Classification/effects
Heavy fuel oils with low From the point of view of an engine manufacturer, a lower limit for the sul-
Operating Instruction
phur content of heavy fuel oils does not exist. We have not identified any
D010.000.023-05-0001
sulphur content
problems with the low-sulphur heavy fuel oils currently available on the mar-
ket that can be traced back to their sulphur content. This situation may
2015-01-20 - de
change in future if new methods are used for the production of low-sulphur
heavy fuel oil (desulphurisation, new blending components). MAN Diesel &
Turbo will monitor developments and inform its customers if required.
If the engine is not always operated with low-sulphur heavy fuel oil, corre-
sponding lubricating oil for the fuel with the highest sulphur content must be
selected.
8 (9)
MAN Diesel & Turbo D010.000.023-05-0001
Tests
Sampling To check whether the specification provided and/or the necessary delivery
conditions are complied with, we recommend you retain at least one sample
of every bunker oil (at least for the duration of the engine's warranty period).
To ensure that the samples taken are representative of the bunker oil, a sam-
ple should be taken from the transfer line when starting up, halfway through
the operating period and at the end of the bunker period. "Sample Tec" by
Mar-Tec in Hamburg is a suitable testing instrument which can be used to
take samples on a regular basis during bunkering.
Analysis of samples To ensure sufficient cleaning of the fuel via the separator, perform regular
functional check by sampling up- and downstream of the separator.
Analysis of HFO samples is very important for safe engine operation. We can
analyse fuel for customers at MAN Diesel & Turbo laboratory (PrimeServLab).
Operating Instruction
D010.000.023-05-0001
2015-01-20 - de
9 (9)
MAN Diesel & Turbo D010.000.023-04-0001
Specification
The suitability of a fuel depends on the engine design and the available
cleaning options as well as compliance with the properties in the following
table that refer to the as-delivered condition of the fuel.
The properties are essentially defined using the ISO 8217-2012 standard as
the basis. The properties have been specified using the stated test proce-
dures.
Properties Unit Testing method Designation
ISO-F specification DMB
Density at 15 °C kg/m3 ISO 3675 < 900
Kinematic viscosity at 40 °C mm2/s ≙ cSt ISO 3104 > 2.0
< 11 *
Pour point (winter quality) °C ISO 3016 <0
Pour point (summer quality) °C <6
Flash point (Pensky Martens) °C ISO 2719 > 60
Total sediment content weight % ISO CD 10307 0.10
Water content vol. % ISO 3733 < 0.3
Sulphur content weight % ISO 8754 < 2.0
Ash content weight % ISO 6245 < 0.01
Coke residue (MCR) weight % ISO CD 10370 < 0.30
Cetane index - ISO 4264 > 35
Hydrogen sulphide mg/kg IP 570 <2
Acid number mg KOH/g ASTM D664 < 0.5
Oxidation resistance g/m3 ISO 12205 < 25
Lubricity μm ISO 12156-1 < 520
(wear scar diameter)
Other specifications:
Operating Instruction
ASTM D 975 2D
2014-12-02 - de
1 (2)
D010.000.023-04-0001 MAN Diesel & Turbo
Specification of diesel oil (MDO)
Additional information
During transshipment and transfer, MDO is handled in the same manner as
residual oil. This means that it is possible for the oil to be mixed with high-
viscosity fuel or heavy fuel oil – with the remnants of these types of fuels in
the bunker ship, for example – that could significantly impair the properties of
the oil.
Lubricity Normally, the lubricating ability of diesel oil is sufficient to operate the fuel
injection pump. Desulphurisation of diesel fuels can reduce their lubricity. If
the sulphur content is extremely low (< 500 ppm or 0.05%), the lubricity may
no longer be sufficient. Before using diesel fuels with low sulphur content,
you should therefore ensure that their lubricity is sufficient. This is the case if
the lubricity as specified in ISO 12156-1 does not exceed 520 μm.
You can ensure that these conditions will be met by using motor vehicle die-
sel fuel in accordance with EN 590 as this characteristic value is an integral
part of the specification.
The fuel must be free of lubricating oil (ULO – used lubricating oil, old oil).
Fuel is considered as contaminated with lubricating oil when the following
concentrations occur:
Ca > 30 ppm and Zn > 15 ppm or Ca > 30 ppm and P > 15 ppm.
The pour point specifies the temperature at which the oil no longer flows. The
lowest temperature of the fuel in the system should be roughly 10 °C above
the pour point to ensure that the required pumping characteristics are main-
tained.
A minimum viscosity must be observed to ensure sufficient lubrication in the
fuel injection pumps. The temperature of the fuel must therefore not exceed
45 °C.
Seawater causes the fuel system to corrode and also leads to hot corrosion
of the exhaust valves and turbocharger. Seawater also causes insufficient
atomisation and therefore poor mixture formation accompanied by a high
proportion of combustion residues.
Solid foreign matters increase mechanical wear and formation of ash in the
cylinder space.
We recommend the installation of a separator upstream of the fuel filter. Sep-
aration temperature: 40 – 50°C. Most solid particles (sand, rust and catalyst
particles) and water can be removed, and the cleaning intervals of the filter
elements can be extended considerably.
Analyses
Analysis of fuel samples is very important for safe engine operation. We can
analyse fuel for customers at MAN Diesel & Turbo laboratory (PrimeServLab).
2 (2)
MAN Diesel & Turbo D010.000.023-01-0001
Military specification
Diesel oils that satisfy specification NATO F-75 or F-76 may be used.
Specification
The suitability of fuel depends on whether it has the properties defined in this
specification (based on its composition in the as-delivered state).
The DIN EN 590 and ISO 8217-2012 (Class DMA or Class DMZ) standards
have been extensively used as the basis when defining these properties. The
properties correspond to the test procedures stated.
Properties Unit Test procedure Typical value
Density at 15 °C ≥ 820.0
kg/m3 ISO 3675 ≤ 890.0
Kinematic viscosity 40 °C ≥2
mm2/s (cSt) ISO 3104 ≤ 6.0
Filterability*
in summer and °C DIN EN 116 ≤0
in winter °C DIN EN 116 ≤ -12
Flash point in closed cup °C ISO 2719 ≥ 60
Sediment content (extraction method) weight % ISO 3735 ≤ 0.01
Water content Vol. % ISO 3733 ≤ 0.05
Sulphur content ISO 8754 ≤ 1.5
Ash weight % ISO 6245 ≤ 0.01
Coke residue (MCR) ISO CD 10370 ≤ 0.10
Hydrogen sulphide mg/kg IP 570 <2
Acid number mg KOH/g ASTM D664 < 0.5
Oxidation stability g/m3 ISO 12205 < 25
Lubricity μm ISO 12156-1 < 520
(wear scar diameter)
Biodiesel content (FAME) % (v/v) EN 14078 not permissible
Operating Instruction
D010.000.023-01-0001
* The process for determining the filterability in accordance with DIN EN 116 is similar to the process for determining
the cloud point in accordance with ISO 3015
1 (2)
D010.000.023-01-0001 MAN Diesel & Turbo
Specification of gas oil/diesel oil (MGO)
Additional information
Use of diesel oil If distillate intended for use as heating oil is used with stationary engines
instead of diesel oil (EL heating oil according to DIN 51603 or Fuel No. 1 or
no. 2 according to ASTM D 396), the ignition behaviour, stability and behav-
iour at low temperatures must be ensured; in other words the requirements
for the filterability and cetane number must be satisfied.
Viscosity To ensure sufficient lubrication, a minimum viscosity must be ensured at the
fuel pump. The maximum temperature required to ensure that a viscosity of
more than 1.9 mm2/s is maintained upstream of the fuel pump, depends on
the fuel viscosity. In any case, the fuel temperature upstream of the injection
pump must not exceed 45 °C.
Lubricity Normally, the lubricating ability of diesel oil is sufficient to operate the fuel
injection pump. Desulphurisation of diesel fuels can reduce their lubricity. If
the sulphur content is extremely low (< 500 ppm or 0.05%), the lubricity may
no longer be sufficient. Before using diesel fuels with low sulphur content,
you should therefore ensure that their lubricity is sufficient. This is the case if
the lubricity as specified in ISO 12156-1 does not exceed 520 μm.
You can ensure that these conditions will be met by using motor vehicle die-
sel fuel in accordance with EN 590 as this characteristic value is an integral
part of the specification.
Analyses
Analysis of fuel samples is very important for safe engine operation. We can
analyse fuel for customers at MAN Diesel & Turbo laboratory (PrimeServLab).
Operating Instruction
D010.000.023-01-0001
2014-12-02 - de
2 (2)
MAN Diesel & Turbo 3.3.1
6680 3.3.1-02
Biofuel
Other designations Biodiesel, FAME, vegetable oil, rapeseed oil, palm oil, frying fat
Origin Biofuel is derived from oil plants or old cooking oil.
Provision
Transesterified and non-transesterified vegetable oils can be used.
Transesterified biofuels (biodiesel, FAME) must comply with the standard EN
14214.
Non-transesterified biofuels must comply with the specifications listed in
Table "Non-transesterified bio-fuel - Specifications".
These specifications are based on experience to date. As this experience is
limited, these must be regarded as recommended specifications that can be
adapted if necessary. If future experience shows that these specifications are
too strict, or not strict enough, they can be modified accordingly to ensure
safe and reliable operation.
When operating with bio-fuels, lubricating oil that would also be suitable for
operation with diesel oil (see "Specification of lubricating oil (SAE 40) for
operation with gas oil, diesel oil (MGO/MDO) and biofuels") must be used.
Properties/Characteristics Unit Test method
Density at 15 °C 900 - 930 kg/m 3
DIN EN ISO 3675,
EN ISO 12185
Flash point > 60 °C DIN EN 22719
lower calorific value > 35 MJ/kg DIN 51900-3
(typical: 37 MJ/kg)
Viscosity/50 °C < 40 cSt (corresponds to a viscos- DIN EN ISO 3104
ity/40 °C of < 60 cSt)
Cetane number > 40 FIA
Coke residue < 0.4% DIN EN ISO 10370
Sediment content < 200 ppm DIN EN 12662
Oxidation stability (110 °C) >5h ISO 6886
Phosphorous content < 15 ppm ASTM D3231
Na and K content < 15 ppm DIN 51797-3
Ash content < 0.01% DIN EN ISO 6245
Water content < 0.5% EN ISO 12537
Bio fuel specification
Analyses
Analysis of fuel samples is very important for safe engine operation. We can
analyse fuel for customers at our laboratory (PrimeServLab).
Bio fuel specification
2013-02-07 - de
General
3700063-9.0
Page 1 (2) Explanatory notes for biofuel 1435000
L21/31
L27/38
Operation with biofuel Caution:
Not transesterified biofuel with a pour point above
Please contact MAN Diesel & Turbo at an early 20° C carries a risk of flocculation and may clog up
stage of project. pipes and filters unless special precautions are taken.
For example: • Fuel cooler for circulation fuel oil feeding part
=> to be modified.
• Biodiesel (FAME) In this circuit a temperature above pour point of
the biofuel is needed without overheating of the
Esterified biofuel is comparable to MDO (ISO-F-DMB/ supply pumps.
ISO-F-DMC), therefore standard layout of fuel oil
system for MDO-operation to be used. • Sensor pipes to be isolated or heated and located
near to main pipes.
Categori 2 - not transesterified biofuel and pour
point below 20° C • To prevent injection nozzles from clogging indi-
cator filter size 0.010 mm has to be used instead
For example: of 0.034 mm.
• Palm oil
• Stearin
• Animal fat
• Frying fat
11.01
MAN Diesel & Turbo
3700063-9.0
1435000 Explanatory notes for biofuel Page 2 (2)
L21/31
L27/38
Requirements on engine Please be aware
• Injection pumps with special coating and with • Depending on the quality of the biofuel, it may
sealing oil system. be necessary to carry out one oil change per
year (this is not taken into account in the details
• Fuel pipes and leak fuel pipes must be equipped concerning lubricating oil consumption).
with heattracing (not to be applied for biofuel
category 1). Heattracing to be applied for biofuel • An addition to the fuel oil consumption is ne-
category 2 outside covers of injection pump area cessary:
and for biofuel category 3 also inside injection
pump area. 2 g/kWh addition to fuel oil consumption (see
chapter fuel oil consumption)
• Inlet valve lubrication (L32/40)
• Engine operation with fuels of low calorific value
• Nozzle cooling to be appied for biofuel category like biofuel, requires an output reduction:
2 and 3. (L32/40)
• LCV ≥ 38 MJ/kg Power reduction 0%
• Charge air temperature before cylinder 55° C to
minimize ignition delay. • LCV ≥ 36 MJ/kg Power reduction 5%
11.01
MAN Diesel & Turbo D010.000.023-06-0001
Example: Heavy fuel oil with Prescribed injection viscosity Required temperature of heavy fuel oil
180 mm²/s at 50 °C in mm²/s at engine inlet* in °C
≥ 12 126 (line c)
≤ 14 119 (line d)
Table 1: Determining the viscosity-temperature curve and the required preheating
temperature
1 (2)
D010.000.023-06-0001 MAN Diesel & Turbo
* With these figures, the temperature drop between the last preheating
Viscosity-temperature diagram (VT diagram)
device and the fuel injection pump is not taken into account.
A heavy fuel oil with a viscosity of 180 mm2/s at 50 °C can reach a viscosity
of 1,000 mm2/s at 24 °C (line e) – this is the maximum permissible viscosity
of fuel that the pump can deliver.
A heavy fuel oil discharge temperature of 152 °C is reached when using a
recent state-of-the-art preheating device with 8 bar saturated steam. At
higher temperatures there is a risk of residues forming in the preheating sys-
tem – this leads to a reduction in heating output and thermal overloading of
the heavy fuel oil. Asphalt is also formed in this case, i.e. quality deterioration.
The heavy fuel oil lines between the outlet of the last preheating system and
the injection valve must be suitably insulated to limit the maximum drop in
temperature to 4 °C. This is the only way to achieve the necessary injection
viscosity of 14 mm2/s for heavy fuel oils with a reference viscosity of 700
mm2/s at 50 °C (the maximum viscosity as defined in the international specifi-
cations such as ISO CIMAC or British Standard). If heavy fuel oil with a low
reference viscosity is used, the injection viscosity should ideally be 12 mm2/s
in order to achieve more effective atomisation to reduce the combustion resi-
due.
The delivery pump must be designed for heavy fuel oil with a viscosity of up
to 1,000 mm2/s. The pour point also determines whether the pump is capa-
ble of transporting the heavy fuel oil. The bunker facility must be designed so
as to allow the heavy fuel oil to be heated to roughly 10 °C above the pour
point.
Viscosity
The viscosity of gas oil or diesel oil (marine diesel oil) upstream of the
engine must be at least 1.9 mm2/s. If the viscosity is too low, this may
cause seizing of the pump plunger or nozzle needle valves as a result
of insufficient lubrication.
This can be avoided by monitoring the temperature of the fuel. Although the
maximum permissible temperature depends on the viscosity of the fuel, it
must never exceed the following values:
▪ 45 °C at the most with MGO (DMA) and MDO (DMB)
A fuel cooler must therefore be installed.
If the viscosity of the fuel is < 2 cSt at 40 °C, consult the technical service of
MAN Diesel & Turbo SE in Augsburg.
Operating Instruction
D010.000.023-06-0001
2014-11-06 - de
2 (2)
MAN Diesel & Turbo 14 40 000
Description
3700291-5.2
1 (5)
L27/38 EN
14 40 000 MAN Diesel & Turbo
Lubricating oil system
Connections
D4 Lub oil stand-by pump, suction D8 Lub oil from purifier
D5 Lub oil stand-by pump, pressure D12 Filling of lub oil
D7 Lub oil to purifier H Venting of crankcase
2 (5)
L27/38 EN
MAN Diesel & Turbo 14 40 000
open.
Description
3700291-5.2
3 (5)
L27/38 EN
14 40 000 MAN Diesel & Turbo
Lubricating oil system
Prefilter, item 20
To protect the purifier pump, item 21, a prefilter should be inserted before
the pump.
Design data:
▪ Capacity: See oil pump, item 21
▪ Mesh size: 0.8-1.0 mm
The preheater must be enlarged in size if necessary, so that it can heat the
Description
3700291-5.2
4 (5)
L27/38 EN
MAN Diesel & Turbo 14 40 000
Description
3700291-5.2
5 (5)
L27/38 EN
MAN Diesel & Turbo 010.000.023-11
Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)
Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)
General
The specific output achieved by modern diesel engines combined with the
use of fuels that satisfy the quality requirements more and more frequently
increase the demands on the performance of the lubricating oil which must
therefore be carefully selected.
Medium alkalinity lubricating oils have a proven track record as lubricants for
the moving parts and turbocharger cylinder and for cooling the pistons.
Lubricating oils of medium alkalinity contain additives that, in addition to
other properties, ensure a higher neutralisation reserve than with fully com-
pounded engine oils (HD oils).
International specifications do not exist for medium alkalinity lubricating oils.
A test operation is therefore necessary for a corresponding long period in
accordance with the manufacturer's instructions.
Only lubricating oils that have been approved by MAN Diesel & Turbo may be
used. These are listed in the table entitled "Lubricating oils approved for use
in heavy fuel oil-operated MAN Diesel & Turbo four-stroke engines".
Specifications
Base oil The base oil (doped lubricating oil = base oil + additives) must have a narrow
distillation range and be refined using modern methods. If it contains paraf-
fins, they must not impair the thermal stability or oxidation stability.
The base oil must comply with the limit values in the table below, particularly
in terms of its resistance to ageing:
Properties/Characteristics Unit Test method Limit value
Make-up - - Ideally paraffin based
Low-temperature behaviour, still flowable °C ASTM D 2500 -15
Flash point (Cleveland) °C ASTM D 92 > 200
operation (HFO)
Medium alkalinity lubricating The prepared oil (base oil with additives) must have the following properties:
oil
Additives The additives must be dissolved in the oil and their composition must ensure
General
that after combustion as little ash as possible is left over, even if the engine is
provisionally operated with distillate oil.
D010.000.023-11-0001 EN 1 (5)
010.000.023-11 MAN Diesel & Turbo
The ash must be soft. If this prerequisite is not met, it is likely the rate of dep-
osition in the combustion chamber will be higher, particularly at the outlet
Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)
valves and at the turbocharger inlet housing. Hard additive ash promotes pit-
ting of the valve seats, and causes valve burn-out, it also increases mechani-
cal wear of the cylinder liners.
Additives must not increase the rate, at which the filter elements in the active
or used condition are blocked.
Washing ability The washing ability must be high enough to prevent the accumulation of tar
and coke residue as a result of fuel combustion. The lubricating oil must not
absorb the deposits produced by the fuel.
Dispersion capability The selected dispersibility must be such that commercially-available lubricat-
ing oil cleaning systems can remove harmful contaminants from the oil used,
i.e. the oil must possess good filtering properties and separability.
Neutralisation capability The neutralisation capability (ASTM D2896) must be high enough to neutral-
ise the acidic products produced during combustion. The reaction time of
the additive must be harmonised with the process in the combustion cham-
ber.
For tips on selecting the base number, refer to the table entitled “Base num-
ber to be used for various operating conditions".
Evaporation tendency The evaporation tendency must be as low as possible as otherwise the oil
consumption will be adversely affected.
Additional requirements The lubricating oil must not contain viscosity index improver. Fresh oil must
not contain water or other contaminants.
Neutralisation properties Lubricating oils with medium alkalinity and a range of neutralization capabili-
(BN) ties (BN) are available on the market. According to current knowledge, a rela-
tionship can be established between the anticipated operating conditions
and the BN number as shown in the table entitled "Base number to be used
for various operating conditions". However, the operating results are still the
overriding factor in determining which BN number provides the most efficient
engine operation.
Approx. BN Engines/Operating conditions
of fresh oil
(mg KOH/g oil)
20 Marine diesel oil (MDO) of a lower quality and high sulphur content or heavy fuel oil with a sulphur
content of less than 0.5 %
30 generally 23/30H and 28/32H. 23/30A, 28/32A and 28/32S under normal operating conditions.
2013-05-23 - de
For engines 16/24, 21/31, 27/38, 32/40, 32/44CR, 32/44K, 40/54, 48/60 as well as 58/64 and
operation (HFO)
51/60DF for exclusively HFO operation only with a sulphur content < 1.5 %.
General
2 (5) D010.000.023-11-0001 EN
MAN Diesel & Turbo 010.000.023-11
Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)
of fresh oil
(mg KOH/g oil)
40 Under unfavourable operating conditions 23/30A, 28/32A and 28/32S, and where the corre-
sponding requirements for the oil service life and washing ability exist.
In general 16/24, 21/31, 27/38, 32/40, 32/44CR, 32/44K, 40/54, 48/60 as well as 58/64 and
51/60DF for exclusively HFO operation providing the sulphur content is over 1.5 %.
50 32/40, 32/44CR, 32/44K, 40/54, 48/60 and 58/64, if the oil service life or engine cleanliness is
insufficient with a BN number of 40 (high sulphur content of fuel, extremely low lubricating oil
consumption).
Table 3: Base number to be used for various operating conditions
Operation with low-sulphur To comply with the emissions regulations, the sulphur content of fuels used
fuel nowadays varies. Fuels with a low-sulphur content must be used in environ-
mentally-sensitive areas (SECA). Fuels with a higher sulphur content may be
used outside SECA zones. In this case, the BN number of the lubricating oil
selected must satisfy the requirements for operation using fuel with a high-
sulphur content. A lubricating oil with low BN number may only be selected if
fuel with a low-sulphur content is used exclusively during operation.
However, the results obtained in practiсe that demonstrate the most efficient
engine operation are the factor that ultimately determines, which additive
fraction is permitted.
Cylinder lubricating oil In engines with separate cylinder lubrication systems, the pistons and cylin-
der liners are supplied with lubricating oil via a separate lubricating oil pump.
The quantity of lubricating oil is set at the factory according to the quality of
the fuel to be used and the anticipated operating conditions.
Use a lubricating oil for the cylinder and lubricating circuit as specified above.
Speed governor Multigrade oil 5W40 should ideally be used in mechanical-hydraulic control-
lers with a separate oil sump, unless the technical documentation for the
speed governor specifies otherwise. If this oil is not available when filling,
15W40 oil may be used instead in exceptional cases. In this case, it makes
no difference whether synthetic or mineral-based oils are used.
The military specification for these oils is O-236.
operation (HFO)
their products. If you have any questions, we will be happy to provide you
with further information.
Oil during operation There are no prescribed oil change intervals for MAN Diesel & Turbo medium
General
speed engines. The oil properties must be regularly analysed. The oil can be
used for as long as the oil properties remain within the defined limit values
(see table entitled "Limit values for used lubricating oil“). An oil sample must
D010.000.023-11-0001 EN 3 (5)
010.000.023-11 MAN Diesel & Turbo
be analysed every 1-3 months (see maintenance schedule). The quality of the
oil can only be maintained if it is cleaned using suitable equipment (e.g. a
Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)
separator or filter).
Temporary operation with Due to current and future emission regulations, heavy fuel oil cannot be used
gas oil in designated regions. Low-sulphur diesel fuel must be used in these regions
instead.
If the engine is operated with low-sulphur diesel fuel for less than 1,000 h, a
lubricating oil which is suitable for HFO operation (BN 30 – 55 mg KOH/g)
can be used during this period.
If the engine is operated provisionally with low-sulphur diesel fuel for more
than 1,000 h and is subsequently operated once again with HFO, a lubricat-
ing oil with a BN of 20 must be used. If the BN 20 lubricating oil from the
same manufacturer as the lubricating oil is used for HFO operation with
higher BN (40 or 50), an oil change will not be required when effecting the
changeover. It will be sufficient to use BN 20 oil when replenishing the used
lubricating oil.
If you wish to operate the engine with HFO once again, it will be necessary to
change over in good time to lubricating oil with a higher BN (30 – 55). If the
lubricating oil with higher BN is by the same manufacturer as the BN 20 lubri-
cating oil, the changeover can also be effected without an oil change. In
doing so, the lubricating oil with higher BN (30 – 55) must be used to replen-
ish the used lubricating oil roughly 2 weeks prior to resuming HFO operation.
Limit value Procedure
Viscosity at 40 ℃ 110 - 220 mm²/s ISO 3104 or ASTM D 445
Base number (BN) at least 50 % of fresh oil ISO 3771
Flash point (PM) At least 185 ℃ ISO 2719
Water content max. 0.2 % (max. 0.5 % for brief peri- ISO 3733 or ASTM D 1744
ods)
n-heptane insoluble max. 1.5 % DIN 51592 or IP 316
Metal content depends on engine type and operat-
Lubricating oil (SAE 40) - Specification for heavy fuel
ing conditions
Guide value only .
Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
Table 4: Limit values for used lubricating oil
Tests
Regular analysis of lube oil samples is very important for safe engine opera-
2013-05-23 - de
4 (5) D010.000.023-11-0001 EN
MAN Diesel & Turbo 010.000.023-11
Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)
Manufacturer
20 30 40 50
BP Energol IC-HFX 204 Energol IC-HFX 304 Energol IC-HFX 404 Energol IC-HFX 504
CASTROL TLX Plus 204 TLX Plus 304 TLX Plus 404 TLX Plus 504
CEPSA —— Troncoil 3040 Plus Troncoil 4040 Plus Troncoil 5040 Plus
CHEVRON Taro 20DP40 Taro 30DP40 Taro 40XL40 Taro 50XL40
(Texaco, Caltex) Taro 20DP40X Taro 30DP40X Taro 40XL40X Taro 50XL40X
EXXON MOBIL —— Mobilgard M430 Mobilgard M440 Mobilgard M50
—— Exxmar 30 TP 40 Exxmar 40 TP 40
LUKOIL Navigo TPEO 20/40 Navigo TPEO 30/40 Navigo TPEO 40/40 Navigo TPEO 50/40
Navigo TPEO 55/40
PETROBRAS Marbrax CCD-420 Marbrax CCD-430 Marbrax CCD-440 ——
REPSOL Neptuno NT 2040 Neptuno NT 3040 Neptuno NT 4040 ——
SHELL Argina S 40 Argina T 40 Argina X 40 Argina XL 40
Argina XX 40
TOTAL LUBMAR- —— Aurelia TI 4030 Aurelia TI 4040 Aurelia TI 4055
INE
Table 5: Approved lubricating oils for heavy fuel oil-operated MAN Diesel & Turbo four-stroke engines.
operation (HFO)
General
D010.000.023-11-0001 EN 5 (5)
MAN Diesel & Turbo 010.000.023-07
Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil
Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil
(MGO/MDO) and biofuels
(MGO/MDO) and biofuels
General
The specific output achieved by modern diesel engines combined with the
use of fuels that satisfy the quality requirements more and more frequently
increase the demands on the performance of the lubricating oil which must
therefore be carefully selected.
Doped lubricating oils (HD oils) have a proven track record as lubricants for
the drive, cylinder, turbocharger and also for cooling the piston. Doped lubri-
cating oils contain additives that, amongst other things, ensure dirt absorp-
tion capability, cleaning of the engine and the neutralisation of acidic com-
bustion products.
Only lubricating oils that have been approved by MAN Diesel & Turbo may be
used. These are listed in the tables below.
Specifications
Base oil The base oil (doped lubricating oil = base oil + additives) must have a narrow
distillation range and be refined using modern methods. If it contains paraf-
fins, they must not impair the thermal stability or oxidation stability.
The base oil must comply with the following limit values, particularly in terms
of its resistance to ageing.
Properties/Characteristics Unit Test method Limit value
Make-up - - Ideally paraffin based
Low-temperature behaviour, still flowable °C ASTM D 2500 -15
Flash point (Cleveland) °C ASTM D 92 > 200
Ash content (oxidised ash) Weight % ASTM D 482 < 0.02
Compounded lubricating oils The base oil to which the additives have been added (doped lubricating oil)
(HD oils) must have the following properties:
2013-04-11 - de
Additives The additives must be dissolved in the oil, and their composition must ensure
that as little ash as possible remains after combustion.
General
D010.000.023-07-0001 EN 1 (5)
010.000.023-07 MAN Diesel & Turbo
The ash must be soft. If this prerequisite is not met, it is likely the rate of dep-
osition in the combustion chamber will be higher, particularly at the outlet
Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil
(MGO/MDO) and biofuels
valves and at the turbocharger inlet housing. Hard additive ash promotes pit-
ting of the valve seats, and causes valve burn-out, it also increases mechani-
cal wear of the cylinder liners.
Additives must not increase the rate, at which the filter elements in the active
or used condition are blocked.
Washing ability The washing ability must be high enough to prevent the accumulation of tar
and coke residue as a result of fuel combustion.
Dispersion capability The selected dispersibility must be such that commercially-available lubricat-
ing oil cleaning systems can remove harmful contaminants from the oil used,
i.e. the oil must possess good filtering properties and separability.
Neutralisation capability The neutralisation capability (ASTM D2896) must be high enough to neutral-
ise the acidic products produced during combustion. The reaction time of
the additive must be harmonised with the process in the combustion cham-
ber.
Evaporation tendency The evaporation tendency must be as low as possible as otherwise the oil
consumption will be adversely affected.
Additional requirements The lubricating oil must not contain viscosity index improver. Fresh oil must
not contain water or other contaminants.
The operating conditions of the engine and the quality of the fuel determine
the additive fractions the lubricating oil should contain. If marine diesel oil is
used, which has a high sulphur content of 1.5 up to 2.0 weight %, a base
number of appr. 20 should be selected. However, the operating results that
ensure the most efficient engine operation ultimately determine the additive
content.
gas oil, diesel oil (MGO/MDO) and biofuels
Cylinder lubricating oil In engines with separate cylinder lubrication systems, the pistons and cylin-
der liners are supplied with lubricating oil via a separate lubricating oil pump.
The quantity of lubricating oil is set at the factory according to the quality of
the fuel to be used and the anticipated operating conditions.
Use a lubricating oil for the cylinder and lubricating circuit as specified above.
Speed governor Multigrade oil 5W40 should ideally be used in mechanical-hydraulic control-
lers with a separate oil sump, unless the technical documentation for the
speed governor specifies otherwise. If this oil is not available when filling,
15W40 oil may be used instead in exceptional cases. In this case, it makes
2013-04-11 - de
2 (5) D010.000.023-07-0001 EN
MAN Diesel & Turbo 010.000.023-07
Experience with the drive engine L27/38 has shown that the operating tem-
perature of the Woodward controller UG10MAS and corresponding actuator
Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil
(MGO/MDO) and biofuels
for UG723+ can reach temperatures higher than 93 °C. In these cases, we
recommend using synthetic oil such as Castrol Alphasyn HG150. The
engines supplied after March 2005 are already filled with this oil.
Lubricating oil additives The use of other additives with the lubricating oil, or the mixing of different
brands (oils by different manufacturers), is not permitted as this may impair
the performance of the existing additives which have been carefully harmon-
ised with each another, and also specially tailored to the base oil.
Selection of lubricating oils/ Most of the mineral oil companies are in close regular contact with engine
warranty manufacturers, and can therefore provide information on which oil in their
specific product range has been approved by the engine manufacturer for
the particular application. Irrespective of the above, the lubricating oil manu-
facturers are in any case responsible for the quality and characteristics of
their products. If you have any questions, we will be happy to provide you
with further information.
Oil during operation There are no prescribed oil change intervals for MAN Diesel & Turbo medium
speed engines. The oil properties must be regularly analysed. The oil can be
used for as long as the oil properties remain within the defined limit values
(see table entitled "Limit values for used lubricating oil“). An oil sample must
be analysed every 1-3 months (see maintenance schedule). The quality of the
oil can only be maintained if it is cleaned using suitable equipment (e.g. a
separator or filter).
Temporary operation with Due to current and future emission regulations, heavy fuel oil cannot be used
gas oil in designated regions. Low-sulphur diesel fuel must be used in these regions
instead.
If the engine is operated with low-sulphur diesel fuel for less than 1,000 h, a
lubricating oil which is suitable for HFO operation (BN 30 – 55 mg KOH/g)
can be used during this period.
If the engine is operated provisionally with low-sulphur diesel fuel for more
than 1,000 h and is subsequently operated once again with HFO, a lubricat-
Tests
Regular analysis of lube oil samples is very important for safe engine opera-
2013-04-11 - de
D010.000.023-07-0001 EN 3 (5)
010.000.023-07 MAN Diesel & Turbo
SHELL Gadinia 40
Gadinia AL40
Sirius X40 2)
Rimula R3+40 2)
STATOIL MarWay 1540
gas oil, diesel oil (MGO/MDO) and biofuels
MarWay 1040 2)
TOTAL LUBMARINE Caprano M40
Disola M4015
Table 3: Lubricating oils approved for use in MAN Diesel & Turbo four-stroke Diesel engines that run on gas oil and
diesel fuel
If marine diesel oil is used, which has a very high sulphur content of 1.5 up
1)
4 (5) D010.000.023-07-0001 EN
MAN Diesel & Turbo 010.000.023-07
Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil
(MGO/MDO) and biofuels
Viscosity at 40 ℃ 110 - 220 mm²/s ISO 3104 or ASTM D445
Base number (BN) at least 50 % of fresh oil ISO 3771
Flash point (PM) At least 185 ℃ ISO 2719
Water content max. 0.2 % (max. 0.5 % for brief peri- ISO 3733 or ASTM D 1744
ods)
n-heptane insoluble max. 1.5 % DIN 51592 or IP 316
Metal content depends on engine type and operat-
ing conditions
Guide value only .
Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
When operating with biofuels: max. 12 % FT-IR
biofuel fraction
Table 4: Limit values for used lubricating oil
General
D010.000.023-07-0001 EN 5 (5)
MAN Diesel & Turbo 010.000.023-21
D010.000.023-21-0001
General
For compressed air quality observe the ISO 8573-1:2010. Compressed air
must be free of solid particles and oil (acc. to the specification).
Requirements
Compressed air quality of Starting air must conform to the following quality acc. to the ISO
starting air system 8573-1:2010 as minimum.
Purity with respect to solid particles Quality class 6
Particle size > 40µm max. concentration < 5 mg/m3
Purity with respect to humidity Quality class 7
Residual water content < 5 mg/m3
Purity with respect to oil Quality class 5
For catalysts For catalysts, unless otherwise stated by relevant sources, the following
specifications are applicable:
Specification for compressed air
Compressed air quality for Starting air for soot blowing must conform to the following quality acc. to the
soot blowing ISO 8573-1:2010 as minimum.
▪ Purity with respect to solid parti- Quality class 2
cles
▪ Purity with respect to humidity Quality class 3
▪ Purity with respect to oil Quality class 2
2013-07-04 - de
Compressed air quality for Starting air for atomisation of reducing agents must conform to the following
atomisation of reducing quality acc. to the ISO 8573-1:2010 as minimum.
agents
D010.000.023-21-0001 EN 1 (2)
010.000.023-21 MAN Diesel & Turbo
cles
▪ Purity with respect to humidity Quality class 3
▪ Purity with respect to oil Quality class 2
Clogging of catalyst
To prevent clogging of catalyst and catalyst lifetime shortening, the
compressed air specification must always be observed.
Specification for compressed air
2013-07-04 - de
2 (2) D010.000.023-21-0001 EN
MAN Diesel & Turbo
3700212-6.1
Page 1 (4) Starting air system 1450000
L21/31
L27/38
General through the safe start function which is connected to
the safety system mounted on the engine.
The compressed air system on the engine consists
of a starting system, starting control system and Further, the starting valve also acts as an emergency
safety system. Further, the system supplies air to starting valve which makes it possible to activate the
the jet system and the stop cylinders on each fuel air starter manually in case of power failure.
injection pump.
The compressed air is supplied from the starting air Safety System
receivers (30 bar) through a reduction station, where
from compressed air at max. 10 bar is supplied to As standard the engine is equipped with an emer-
the engine. The reduction station should be located gency stop. It consists of one on-off valve, see
as near the starting air receiver as possible. diagram, which activates one stop cylinder on each
To avoid dirt particles in the internal system, a strainer fuel injection pump.
equipped with a drain valve is mounted in the inlet
line to the engine. Air supply must not be interrupted when the engine
is running.
Starting System
Pneumatic Start Sequence
The engine is started by means of a built-on air
starter, which is a turbine motor with gear box, safety When the starting valve is opened, air will be supplied
clutch and drive shaft with pinion. Further, there is a to the drive shaft housing of the air starter.
main starting valve.
The air supply will - by activating a piston - bring the
drive pinion into engagement with the gear rim on
Control System the engine flywheel.
The air starter is activated electrically with a pneu When the pinion is fully engaged, the pilot air will
matic 3/2-way solenoid valve. The valve can be acti- flow to, and open the main starting valve, whereby
vated manually from the starting box on the engine, air will be led to the air starter, which will start to
and it can be arranged for remote control, manual turn the engine.
or automatic.
When the RPM exceeds approx. 158, at which firing
For remote activation the starting coil is connected has taken place, the starting valve is closed whereby
so that every starting signal to the starting coil goes the air starter is disengaged.
12.15
MAN Diesel & Turbo
3700212-6.1
1450000 Starting air system Page 2 (4)
L21/31
L27/38
10 x 1
12 x 1.5
7
C
PT
** DN32 G
1322 PI
C A F
** DN32 G PI B
A F
to consumers
B PSL
PT
1312 3A
3
A1 A2DN 6
10 bar 30 bar 4
*** DN 50
6 E
22 x 2
5
to drain
22 x 2
Drain mounted at E
lowest point to drain
2
1 1A
M M
Connections:
A1 Starting air - inlet Vertical installation of the starting air receiver is recom
A2 Starting air - before pressure reducing valve mended. For horizontal installation, the slope must be
min 5 degrees as shown.
**
The pipe length between receiver and main engine 3, 3A min 5°
starting air pipe is to be as short as possible
*** E
max 10 m from air receiver to engine To drain
12.15
MAN Diesel & Turbo
3700212-6.1
Page 3 (4) Starting air system 1450000
L21/31
L27/38
Compressor, items 1 and 1A Starting air receiver, items 3 and 3A
The pressure switch (PSL) for aut start/stop of the The starting air receiver should, preferably, be
compressors 1 and 1A is to be connected to the vertically installed and secured to a bulkhead, thus
charging air pipe as close as possible to the starting ensuring easy acess to the water drain valve. If
air receiver, to compensate for pressure peaks from space conditions do not permit vertical mounting,
the compressor. If the pipe is short, a buffer tank or the receiver may be minimum 5° off the horizontal,
damper is recommended. with the drain valve at the lowest position.
All of the starting air receivers, items 3 and 3A, should Two starting air receivers are standard equipment
be pressurized to 30 bar for approx 60 minutes. for each plant. Table on next page descripe minimum
values of starting air capacity.
Artic conditions 30 minutes.
Compressors are to be installed with total capacity Pressure reducing valve, item 5
sufficient for charging air receivers of capacities
specified from atmospheric to full pressure in the As standard the engines are fitted with a 10 bar air
course of one hour. starter. Therefore the air supply needs to be reduced
from 30 bar to 10 bar before inlet engine.
Two or more compressors of total capacity as speci-
fied are to be installed’. If the engine is fitted with a 30 bar air starter (option),
there will be a pressure reducing valve for stop air
Calculation (example): pressure installed.
12.15
MAN Diesel & Turbo
3700212-6.1
1450000 Starting air system Page 4 (4)
L21/31
L27/38
1 x 250 ltr
L21/31 / 6 - 7 cylinder 2 x 250 ltr
1 x 500 ltr
12.15
MAN Diesel & Turbo 010.000.023-17
Requirements
Fuel oil engines: As minimum, inlet air (combustion air) must be cleaned in a
filter of the G3 class as per EN779. For engine operation in the environment
with a risk of higher inlet air contamination (e.g. due to sand storms, due to
loading the grain crops cargo vessels or in the surroundings of cement
plants) additional measures must be taken.
Gas engines and dual-fuel engines: As minimum, inlet air (combustion air)
must be cleaned in a filter of the G3 class as per EN779. Gas engines or
dual-fuel engines must only be equipped with a dry filter. Oil bath filters are
not permitted because they enrich the inlet air with oil mist. This is not per-
missible for gas operated engines. For engine operation in the environment
with a risk of higher inlet air contamination (e.g. due to sand storms, due to
loading the grain crops cargo vessels or in the surroundings of cement
plants) additional measures must be taken.
In general, the following applies: The concentration downstream of the air fil-
ter and/or upstream of the turbocharger inlet must not exceed the following Specifications for intake air (combustion air)
limit values.
Properties Typical value Unit *
Dust (sand, cement, CaO, Al2O3 etc.) max. 5 mg/Nm3
Chlorine max. 1.5
Sulphur dioxide (SO2) max. 1.25
Hydrogen sulphide (H2S) max. 5
Salt (NaCl) max. 1
2013-02-04 - de
D010.000.023-17-0001 EN 1 (2)
010.000.023-17 MAN Diesel & Turbo
Intake air shall not contain any flammable gases. Make sure that the
combustion air is not explosive.
Specifications for intake air (combustion air)
2013-02-04 - de
General
2 (2) D010.000.023-17-0001 EN
MAN Diesel & Turbo
3700196-9.0
Page 1 (1) Turbocharger - make MAN 1459000
General
Description
The engines are as standard equipped with a turbo nozzle ring made of a special wear resistant material.
charger of the radial type MAN NR/R, NR/S and TCR.
Air intake silencer with filter, and compressor casing
The rotor, comprising compressor, turbine wheel and with one outlet.
shaft, is supported in floating plain bearing bushes.
Lubrication of the two plain bushes is an integrated
The turbine wheel is an integrated part of the shaft. part of the engine lub. oil system.
Gas admission casing with gas outlet diffusor mat The turbocharger has no water cooling.
ched to the exhaust pipe arrangement and a turbine
L21/31 L27/38
215 kW/cyl. 6 cyl. TCR16 340 kW/cyl. 6 cyl. TCR18
1000 rpm 800 rpm
7 cyl. TCR18 7 cyl. TCR20
8 cyl. NR24/R
11.42 - Tier II
MAN Diesel & Turbo
3700195-7.0
Page 1 (2) Exhaust Gas Velocity 1459000
L21/31
L27/38
11.42 - Tier II
MAN Diesel & Turbo
3700195-7.0
1459000 Exhaust Gas Velocity Page 2 (2)
L21/31
L27/38
The exhaust gas velocities are based on the pipe dimensions in the table below.
T D2
D1
Flow area
DN D1 D2 T
A
Norminel diameter mm mm mm
10-3 m2
11.42 - Tier II
MAN Diesel & Turbo
3700199-4.0
Page 1 (1) Exhaust gas system 1459000
L27/38
Position of gas outlet on turbocharger Fig 1 shows alternative positions for the exhaust gas
outlet and if requested the outlet can be turned to a
The turbocharger outlet is fitted with a round flange, desired position prior to dispatch.
adapted for direct installation of an expansion bellow.
G*
0o
Intermedian flange
From 0o to 45o
continuously adjustable F
From 270o to 359o
continuously
adjustable 45o
20
D
270o
C
CL - Crankshaft
B 445
Engine A B C D E F G*
type mm mm mm mm mm mm mm
6L27/38 (TCR 18) 703 1053 1798 427 315 762 550
7L27/38 (TCR 20) 754 1053 1844 514 315 822 600
8L27/38 (TCR 20) 754 1053 1844 514 315 822 650
9L27/38 (TCR 20) 805 1053 1844 514 315 822 650
* Exhaust pipe dimension
11.42 - Tier II
MAN Diesel & Turbo
3700200-6.0
Page 1 (1) Exhaust gas system 1459000
L27/38
A
Lateral
BC mm Movement diagram
30
DN
DN 500
DN 550
20 DN 600
LN
10
Axial
0 10 20 30 40 50 60 70 80 90 100 110 mm
6 S 02
N × øD
11.42 - Tier II
MAN Diesel & Turbo
3700248-6.0
Page 1 (1) Exhaust gas system 1459000
L21/31
L27/38
Standard silencer
Absorbtive type.
Noise attenuation 35 dB(A).
E
D
F
C G I
4 E06
B H
A
12.37
MAN Diesel & Turbo
3700071-1.0
Page 1 (11) System Description - SaCoSone 1475000
L21/31
L27/38
System overview
General information
SaCoSone PROPULSION is the safety, control and monitoring system for MAN small bore diesel engines,
types L21/31 and L27/38.
All engine mounted sensors and actuators are connected to the system and controlled by the engine attached
SaCoSone PROPULSION. Optional, the system also monitors and supervises the gearbox. Additionally, there
is the possibility of monitoring propeller sensors like shaft bearing temperatures. SaCoSone PROPULSION
controls and monitors all engine functions including clutch control and the visualisation of engine-related pre-
alarms, system-alarms, safety actions, operating values and operation status.
In this context, safety actions means shutdown of the engine, as well as request for load reductions and if
required, auto disengaging.
Schematics
Cabling diagram
3700071-1.0
1475000 System Description - SaCoSone Page 2 (11)
L21/31
L27/38
System bus diagram
Ethernet
RS 422
RS 422
Ethernet
Ethernet
Ethernet
control bus
Control Module Display Module/ Display Module/ Control Module Control Module Control Module Gateway
Small/Gearbox LOP2 LOP1 Small/Safety Small/Alarm Small /Splashoil Module
optional optional optional
CAN3
CAN3
Gearbox &
Safety
Propeller
Extension Unit
Extension Unit
optional optional
Components
Foreign gearbox
Control Unit •
Splash-Oil Unit «
Gateway Cabinet «
Control Unit
The Control Unit contains two Control Modules S (CMS), the CMS/alarm and the CMS/safety and is directly
attached to the engine.
3700071-1.0
Page 3 (11) System Description - SaCoSone 1475000
L21/31
L27/38
Control Module S/alarm (CMS/alarm)
The Control Module S/alarm contains all engine related control functions, pre-alarming and redundant shut-
downs. In addition system alarms like monitoring of all connected sensors and actuators are part of the CMS/
alarm functionality.
The CMS/alarm also offers a MODbus RS422 interface to the vessel alarm system.
Control functions:
The Control Module S/safety contains all engine, propeller and gearbox related shutdowns and load reduc-
tions. In addition system alarms like monitoring of all connected sensors and actuators are part of the CMS/
safety functionality.
The CMS/safety also offers a MODbus RS422 interface to the Propulsion Control System, in case an Alpha
Propeller is applied.
Slow downs, shut downs and pre alarms can be found in the engine serial no. related list of measuring and
control devices, or in the application specific list of alarms and safeties.
On the Local Operating Panel (abbr. LOP), all operating values available in the system, as well as alarms,
shutdowns and system alarms, and engine operation status indications are displayed. Furthermore, some
basic operator actions are handled from the LOP:
• Start of engine
• Stop of engine
• Acknowledge and reset of alarms, shutdowns, etc.
• Manual emergency stop
• Engine speed lower/raise
• Clutching/Declutching (optional)
• Pitch setting (optional)
The LOP consists, due to classification requirements for single propulsion plants, of two Display Modules
(DM), where one DM is the backup for the other DM. Even though, when both DM are working properly, it is
possible to have two different views on the DMs.
The Splash-oil Unit is optional in case that splash-oil monitoring is applied. The unit contains one Control
Module S/Splashoil which includes the whole splash-oil monitoring functionalities, such as pre-alarm, shut-
down, sensor monitoring, etc.
3700071-1.0
1475000 System Description - SaCoSone Page 4 (11)
L21/31
L27/38
Gateway Cabinet (opt.)
The Gateway Cabinet (GC) is optional and is required in case EDS will be applied. The Gateway Cabinet will
also be supplied if the ship alarm system must be connected via MODBUS TCP. In case of applied Gateway
Module (GM), there are only data handling functions realized within it, no control functions alarming a safety
function are implemented.
The optional Remote Operating Panel can be mounted within engine control room or wheelhouse. It consists
of one Display Module on which operating values and status are indicated. The ROP is only used for indica-
tion of operating values and status and provides no control authority.
The Gearbox & Propeller Unit (GPU) contains a Control Module S/Gearbox, which receives measuring data
from sensors located on gearbox or propeller or on the shaft. The collected data are transmitted to the differ-
ent modules in order to create alarms, realise control functions or submitting them to PCS or alarm system.
The GPU is only applied, in case of an AMG gearbox from Alpha Propeller.
In case there are more sensors on gearbox and propeller and shaft, the Gearbox & Propeller Extension Unit
(GPEU) provides several additional I/Os and a CANopen coupler for the connection to the GPU.
Technical data
Dimensions
3700071-1.0
Page 5 (11) System Description - SaCoSone 1475000
L21/31
L27/38
System description
Safety system
Safety functions
The safety system monitors all operating data of the engine and initiates the required actions, i.e. engine shut-
down, in case the limit values are exceeded. The safety system is integrated in the CMS/safety. The safety
system directly actuates the emergency shut-down device and the stop facility of the speed governor.
Emergency stop
Emergency stop is an engine shutdown initiated by an operator manual action like pressing an emergency
stop button. An emergency stop button is placed at the LOP on engine. For connection of an external emer-
gency stop button there is one input channel at the Control Unit.
Automatic shutdown
Auto shutdown is an engine shutdown initiated by any automatic supervision of engine internal parameters. If
an engine shutdown is triggered by the safety system, the emergency stop signal has an immediate effect on
the emergency shut-down device and the speed control. At the same time the emergency stop is triggered,
SaCoSone issues a signal resulting in disengaging the clutch. The following list of criteria leading to an auto-
matic shutdown and might be incomplete. For more details see the “List of measuring and control devices”.
• Engine overspeed
• HT cooling water pressure inlet too low
• HT cooling water temperature outlet too high
• Lube oil pressure at engine inlet low
• Gear lube oil pressure too low
• Gear pinion bearing fore temp. too high
• Gear pinion bearing after temp. too high
• Gear wheel bearing fore temp. too high
• Gear wheel bearing after temp. too high
• Gear clutch bearing temp. too high
• Gear clutch support bearing temp. too high
• Splash oil temperature rod bearing too high (optional)
• Main bearing temperature too high (optional)
• High oil mist concentration in crankcase (optional)
• Remote Shutdown (optional)
Load reductions
After the exceeding of certain parameters, a load reduction to 60% is necessary. The safety system super-
vises these parameters and requests a load reduction, if necessary. The load reduction has to be carried out
by an external system (PCS, PMS). For safety reasons, SaCoSone PROPULSION will not reduce the load
by itself. The following list of criteria leading to a load reduction request and might be incomplete. For more
details see the “List of measuring and control devices”.
3700071-1.0
1475000 System Description - SaCoSone Page 6 (11)
L21/31
L27/38
• Exhaust gas temperature at turbocharger inlet too high
• HTCW pressure too low
• HTCW temperature cylinder row outlet too high
• Lube oil temperature engine inlet too high
• Charge air temperature too high
• Lube oil filter differential pressure too high
• Gear lube oil temperature too high
• Gear thrust bearing temperature too high
Auto disengagements
If SaCoSone PROPULSION is used for clutch monitoring, it will carry out automatic disengagements of the
clutch to protect gearbox, propeller or engine against destruction. In this case, the clutch will be opened as
fast as possible.
The following list of criteria leading to an automatic disengagement and might be incomplete. For more details
see the “List of measuring and control devices”.
Clutch medium pressure low
Automatic shutdown of the engine
Manual emergency stop of the engine
Alarm/monitoring system
Alarming
The alarm function of SaCoSone PROPULSION supervises all necessary parameters and generates alarms
to indicate discrepancies when required. The alarms will be transferred to ship alarm system via Modbus data
communication.
Self-monitoring
SaCoSone PROPULSION carries out independent self-monitoring functions. Thus, for example the connect-
ed sensors are checked constantly for function and wire break. In case of a fault SaCoSone PROPULSION
reports the occurred malfunctions in single system components via system alarms.
Control
SaCoSone PROPULSION controls all engine-internal functions as well as external components, for example:
• Start/stop sequences:
• Local and remote start/stop sequence.
• Activation of start device. Control (auto start/stop signal) regarding prelubrication oil pump.
• Monitoring and control of the acceleration period.
• Jet system:
• For air fuel ratio control purposes, compressed air is lead to the turbocharger at start and at load
steps.
3700071-1.0
1475000 System Description - SaCoSone Page 7 (11)
L21/31
L27/38
• Control signals for external functions:
• HT cooling water preheating unit
• Prelubrication oil pump control
Governor
Speed adjustment
Remote speed setting is either possible via analogue 4-20 mA signal or by using binary lower/raise contacts.
Load sharing
For load sharing purposes (several engines on one shaft) or other applications droop will be required. The
speed droop is adjustable from 0-10% as the application requires.
Load sharing for two propellers on one shaft requires electronic speed governing and will be realized by
master/slave load sharing.
Engine stop
Engine stop can be initiated local at the LOP and remote via a hardware channel or the bus interface.
SaCoSone PROPULSION monitors the relevant temperatures and pressures of the gearbox and propeller.
The system also provides hardwired interfaces for the control of the clutch.
3700071-1.0
1475000 System Description - SaCoSone Page 8 (11)
L21/31
L27/38
Interface to PCS
Engine unloaded
Engage speed OK
R422 *
Override external
3700071-1.0
1475000 System Description - SaCoSone Page 9 (11)
L21/31
L27/38
Interface to ship alarm system
This interface serves for data exchange to ship alarm systems or integrated automation systems (IAS).
The status messages, alarms and safety actions, which are generated in the system, can be transferred. All
measuring values and alarms acquired by SaCoSone are available for transfer.
SaCoSone uses the MODbus RTU protocol.
Overview
R422
CAN 2
CAN1
3700071-1.0
1475000 System Description - SaCoSone Page 10 (11)
L21/31
L27/38
Interface to the plant
Plant
terminal block
Gear eng . disc clutch disengaged
Control Unit
Control Module /alarm Ext. load signal (geno load for load sharing ) PMS
terminal
block
3700071-1.0
1475000 System Description - SaCoSone Page 11 (11)
L21/31
L27/38
SaCoSone EXPERT
The Ethernet interface at the Display Module can be used for the connection of SaCoSone EXPERT.
Power supply
The plant has to provide electric power for the automation and monitoring system. In general a redundant,
uninterrupted 24V DC (+20% -30% and max ripple 10%) power supply is required for SaCoSone.
CoCoS-EDS (optional)
The Ethernet connection to CoCoS-EDS is realised by means of the Gateway Cabinet (GC), which is con-
nected to the Control Unit via the system bus.
If the Splash-oil Monitoring is applied, the engine will be equipped with a Splash-oil Unit, which is connected
to the Control Unit via the system bus.
Abbreviations
Abbreviation Meaning
CMS Control Module S
CU Control Unit
DM Display Module
GM Gateway Module
GPU Gearbox & Propeller Unit
GPEU Gearbox & Propeller Extension Unit
GC Gateway Cabinet
LOP Local Operating Panel
ROP Remote Operating Panel
SEU Safety Extension Unit
SU Splashoil Unit
3700072-3.0
Page 1 (2) Modbus interface - SaCoSone 1475000
L21/31
L27/38
Data Bus Interface (Machinery Alarm System)
This interface serves for data exchange to ship alarm systems or integrated automation systems (IAS).
The status messages, alarms and safety actions, which are generated in the system, can be transferred. All
measuring values and alarms acquired by SaCoSone PROPULSION are available for transfer.
The Modbus RTU protocol is the standard protocol used for the communication with ship alarm system.
The bus interface provides a serial connection. The protocol is implemented according to the following defini-
tions:
• Modbus application protocol specification, Modbus over serial line specification and implementation
guide,
Available interface:
• RS422 – Standard, 4 + 2 wire (cable length <= 100m), cable type as specified by the circuit diagram,
line termination: 150 Ohms
Settings
Function Codes
The following function codes are available to gather data from the SaCoSone controllers:
3700072-3.0
1475000 Modbus Interface - SaCoSone Page 2 (2)
L21/31
L27/38
Message Frame Separation
Provided Data
Provided data includes measured values and alarm or state information of the engine.
Measured values are digitized analogue values of sensors, which are stored in a fixed register of the Con-
trol Module Small. Measured values include media values (pressures, temperatures) where, according to
the rules of classification, monitoring has to be done by the machinery alarm system. The data type used is
signed integer of size 16 bit. Measured values are scaled by a constant factor in order to provide decimals of
the measured.
Pre-alarms, shutdowns and state information from the SaCoSone system are available as single bits in fixed
registers. The data type used is unsigned of size 16 bit. The corresponding bits of alarm or state information
are set to the binary value „1“, if the event is active.
��
Contents of List of Signals
For detailed information about the transferred data, please refer to the ”list of signals“ of the engine’s docu-
mentation set. This list contains the following information:
Field Description
Address The address (e.g.: MW15488) is the software address used in the Control Module Small.
The hexadecimal value (e.g.: 3C80) of the software address that has to be used by the
HEX
Modbus master when collecting the specific data.
Information of alarms, reduce load, shutdown, etc. are available as single bits.
Bit
Bits in each register are counted 0 to 15.
The dedicated denomination of the measuring point or limit value as listed in the
Meas. Point
„list of measuring and control devices“.
Description A short description of the measuring point or limit value.
Information about how the value of the data has to be evaluated by the Modbus master
Unit
(e.g. „°C/100“ means: reading a data value of „4156“ corresponds to 41,56 °C).
Origin Name of the system where the specific sensor is connected to, or the alarm is generated.
Life Bit
In order to enable the alarm system to check whether the communication with SaCoS is working, a life bit is
provided in the list of signals (MW15861; Bit2). This Bit is alternated every 10 seconds by SaCoS. Thus, if it
remains unchanged for more than 10 seconds, the communication is down.
1696426-4.3
Page 1 (2) PTO on engine front 1485000
L27/38
PTO on forward end of engine propulsion system, all necessary information con-
cerning the PTO is needed.
The engine can be supplied with a PTO on the forward
end, as an extension to the crankshaft, see fig 1. Generally, a flexible coupling between the PTO and
the generator and/or driven machinery will be neces-
The PTO can be dimensioned to transmit the full sary and this coupling must be selected to transmit
engine power. If a plant is to be supplied with PTO it the PTO requirements, accommodate and absorb any
must be planned in co–operation with us. For carrying vibrations which may be present. Usually a toothed
out the torsional vibration analysis of the complete coupling will not be allowed.
11.10
MAN Diesel & Turbo
1696426-4.3
1485000 PTO on engine front Page 2 (2)
L27/38
Max axial force Furthermore it should be observed that the crank-
shaft position is fixed by the guide bearing at the aft
In principle the PTO must not induce any extra axial end of the engine. Crankshaft extension measured
forces on the guide bearing of the crankshaft. How- at the forward end with a temperature rise of 65 °C
ever, a constant force of max 9000 N can be accepted. corresponds to the values in the shown table.
This includes a contribution from the crankshaft, if
the engine has an inclination in relation to horizontal. This extension may cause the flexible coupling be-
tween the PTO shaft and the driven part to create
For a 5° inclination to aft end the contribution will an additional axial force on the crankshaft guide
be as stated below. bearing and this must be taken into consideration.
11.10
MAN Diesel & Turbo
1694916-6.3
Page 1 (1) Weights of Main Components 1402000
L27/38
Description Approx. weight (kg)
10.04