MARINE PROPULSION INSTALLATION AUDIT

Heru Hermawan
Online Guest Lecture FTK ITS – Ikatan Alumni Fakultas Teknologi Kelautan ITS
 AGENDA

1. Engine Performance Curve for Engine Propeller

Matching Design
2. Cooling System Design Consideration
3. Fuel System
4. Exhaust & Air System Design Consideration
5. Starting System Design Consideration
6. Monitoring System Design & Interfacing with CPP
7. Sea Trial Procedure
AGENDA
1. Engine Performance Curve for Engine Propeller
Matching Design
2. Cooling System Design Consideration
3. Fuel System
4. Exhaust & Air System Design Consideration
5. Starting System Design Consideration
6. Monitoring System Design & Interfacing with CPP
7. Sea Trial Procedure
Source : Engine-Propeller Matching, Surjo, 2005
C280-8/3084 BHP@900 RPM

Normal Load

Heavy Load

Lug Curve
POWER MANUFACTURE TOLERANCE
(%)

101.5
Power Tolerance
100
98.5
Governor Overrun Curve

Propeller/Water Jet Tolerance

98.5 100 101.5 RPM (%)

AGENDA
1. Engine Performance Curve for Engine Propeller
Matching Design
2. Cooling System Design Consideration
3. Fuel System
4. Exhaust & Air System Design Consideration
5. Starting System Design Consideration
6. Monitoring System Design & Interfacing with CPP
7. Sea Trial Procedure
COOLING SYSTEM
98 Deg C

C280

38 Deg C

32 Deg C
HX
COOLING SYSTEM Thermostat
Expansion
Tank
98 Deg C

Jacket Water Pump C280

38 Deg C
AC/OC Water Pump

Sea Water Pump

HX

32 Deg C
COMBINE COOLING SYSTEM
 STANDBY PUMP

FW Stand-by
Pump C280

SW Stand-by AC/OC Stand-by

Pump Pump
Sea Water Pump Fresh Water Pump AC/OC Water Pump
 Outlet
Connection

Expansion
Tank
 STBD
Expansion
Tank

Heat Exchanger

PORT
Expansion
Tank
DESIGN QUESTION
How to maintain
98 & 38 Deg C ?

1) Heat Exchanger Design Sizing

2) Pipe Restriction Design Sizing
OUTPUT DESIGN
DATA FROM MAKER Pipe Diameter & Lay-out
Heat Rejection/Heat Balance Heat Exchanger Model
Water Pump Performance
EXTERNAL RESISTANCE ( A – B/ 1 - 2 & 3 – 4)
A

C280
B

1 2
HX

4
APROACH……
HEAT BALANCE…… Example
AGENDA
1. Engine Performance Curve for Engine Propeller
Matching Design
2. Cooling System Design Consideration
3. Fuel System
4. Exhaust & Air System Design Consideration
5. Starting System Design Consideration
6. Monitoring System Design & Interfacing with CPP
7. Sea Trial Procedure
FUNDEMANTAL DESIGN PRINCIPLE

Main
Fuel
Day
Tank Tank

Primary Fuel Filter

Fuel Cooler
Transfer Pump Centrifugal Fuel Water
Separator
 DESIGN QUESTION

Main
Fuel
Day
Tank Tank

Max inlet restriction : 20 kPA/2.9 psi

Max temperature : 40 deg C
FUEL SYTEM – INTERNAL ENGINE
 FUEL SYTEM – FUEL PURIFIER

- Fuel Centrifuge and

Pump are in one
package
- Stand by unit
sometime required

Could be
eliminated
 A L P ROJECT
E O N ACTU
L
EXAMP
AGENDA
1. Engine Performance Curve for Engine Propeller
Matching Design
2. Cooling System Design Consideration
3. Fuel System
4. Exhaust & Air System Design Consideration
5. Starting System Design Consideration
6. Monitoring System Design & Interfacing with CPP
7. Sea Trial Procedure
Total Line Restriction
Should be designed less than
10 inch H2O
(we called this EXHAUST BACK
PRESSURE)
 CRANKCASE FUMES
DISPOSAL

Design Guideline :
Size vent pipe for 0.04
m3/hr.bkW with maximum
of 13 mm H2O pressure
drop in piping
 Crankcase Fumes
Disposal

Exhaust Gas Pipe

DESIGN SUMMARY
1. EXHAUST PIPE DIAMETER TO MEET EXHAUST BACK PRESSURE
2. VENTILATION AIR
Air Flow to E/R = Engine Combustion Air Flow + Air Flow for Heat Removal

IN E DATA
ENG
AGENDA
1. Engine Performance Curve for Engine Propeller
Matching Design
2. Cooling System Design Consideration
3. Fuel System
4. Exhaust & Air System Design Consideration
5. Starting System Design Consideration
6. Monitoring System Design & Interfacing with CPP
7. Sea Trial Procedure
Air Starting Motor

Air Supply
DESIGN QUESTION
Source : ABS Regulation for Steel Vessel under 90 meters
 A L P ROJECT
E O N ACTU
L
EXAMP
AGENDA
1. Engine Performance Curve for Engine Propeller
Matching Design
2. Cooling System Design Consideration
3. Fuel System
4. Exhaust & Air System Design Consideration
5. Starting System Design Consideration
6. Monitoring System Design & Interfacing with CPP
7. Sea Trial Procedure
WHEEL HOUSE

CONTROL ROOM

ENGINE SIDE
LOAD FEEDBACK
AGENDA
1. Engine Performance Curve for Engine Propeller
Matching Design
2. Cooling System Design Consideration
3. Fuel System
4. Exhaust & Air System Design Consideration
5. Starting System Design Consideration
6. Monitoring System Design & Interfacing with CPP
7. Sea Trial Procedure
Evaluation of Propulsion System Performance to ensure they
are properly matched for maximum performance and fuel
efficiency

Actual Engine-Propulsion Matching Points are CORRECT

(Fuel Rate vs RPM approach)

Installations are correctly sized according to Project Guide

(Various Pressure & Temperature Measurements)
Installations are correctly sized according to Project
Guide, main parameters measurement :

External Circuit Resistance – Cooling System

Water Cooling Temperature – Cooling System
Exhaust Back Pressure – Exhaust System
Engine Room Temperature – Ventilation System
Fuel Pipe Restriction – Fuel System
Fuel Pressure – Fuel System
Engine Crankcase Pressure – Crankcase Fumes Disposal System
 EXTERNAL RESISTANCE, kPa (psi)
C280-6 & C280-8

C280-12 & C280-16

 Water Pressure

Fuel Inlet Pressure

Crankcase Pressure
 Exhaust Back Pressure

AC/OC Water
Pump Inlet
Pressure
PERFORMANCE ANALYSIS
 Example on
Performance Troubleshooting

Engine RPM can not achieve 1000 RPM

Performance Band
Actual Load

Load Band
Not Ok
Not Ok

Ok
Ok
Terima Kasih
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[Heru Hermawan]
[Power Systems Sales]
[heru.Hermawan@trakindo.co.id