WÄRTSILÄ Vasa R22 User manual

This manual is intended for the personal use of engine operators and
should always be at their disposal. The content of this manual shall
neither be copied nor communicated to a third person.
Wärtsilä Finland Oy
Document ID
Installation
Engine type
Engine number
Project
Vasa R22

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AVAILABLE AT THE TIME OF PRINTING. HOWEVER, THE PUBLICATION DEALS
WITH COMPLICATED TECHNICAL MATTERS SUITED ONLY FOR SPECIALISTS IN
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TION CONTAINED HEREIN.

00.Contents, Instructions, Terminology
00.1 Contents of the Instruction Book
This Manual contains data and instructions for operation and
maintenanceoftheengine.Basicgeneralknowledgehasnotbeen
entered. Consequently, it is assumed that the engine operation
and maintenance staff is well informed of the care of diesel
engines.
Wärtsilä Diesel reserves for itself the right to minor alterations
and improvements owing to engine development without being
obliged to enter the corresponding changes in this Manual.
The diesel engines will be equipped as agreed upon in the sales
documents. No claim can be made on the basis of this Manual as
herearedescribedalsocomponentsnotincludedineverydelivery.
Exact engine build-up in all details is defined by the specifica-
tion number on the name plate located on the engine. In all
correspondence or when ordering spare parts, be careful
to state engine type, specification number and engine
number.
This Manual is supplemented by the Spare Parts Catalogue
including sectional drawings or exterior views of all components
(partial assemblies).
00.2 General rules
1 Read the corresponding item carefully in this Manual
before any steps are taken.
2 Keep an engine log book for every engine.
3 Observe the utmost cleanliness and order at all main-
tenance work.
4 Before dismantling, check that all systems concerned are
drained or the pressure released. After dismantling, immedi-
ately cover holes for lubricating oil, fuel oil and air with tape,
plugs, clean cloth or the like.
5 When replacing a worn-out or damaged part provided
with an identification mark stating cylinder or bearing num-
ber, mark the new part with the same number on the same
spot. Every exchange should be entered in the engine log and
the reason should be clearly stated.
6 After reassembling, check that all screws and nuts are
tightened and locked, if necessary.
22-9601 Contents, Instructions, Terminology 00
VASA 22 00 - 1

00.3 Terminology
The most important terms used in this manual are defined as
follows:
Operating side. The longitudinal side of the engine where the
operating devices are located (start and stop, instrument panel,
speed governor).
Rear side. The longitudinal side of the engine opposite the oper-
ating side.
Driving end. The end of the engine where the flywheel is located.
Free end. The end opposite the driving end.
Designation of cylinders. According to ISO 1204 and DIN 6265
the designation of cylinders begins at the driving end. In a
V-enginethecylindersintheleftbank,seenfromthedrivingend,
aretermedA1,A2etc.andintherightbankB1,B2etc.,seebelow:
Terminology
Designation of bearings. The designation of bearings begins
from the driving end. The thrust main bearing is No 1. If the
engine is provided with an extra main bearing, a so-called
shield bearing, this is termed 0. For the camshaft bearing the
thrust bearing is No 0.
Clockwise rotating engine. Whenlookingattheenginefromthe
driving end the shaft rotates clockwise.
Counter-clockwiserotatingengine.Whenlookingattheengine
from the driving end the shaft rotates counter-clockwise.
Bottom dead center, abbreviated BDC, is the bottom turning
point of the piston in the cylinder.
Top dead centre,abbreviated TDC, is the topturning pointof the
piston in the cylinder. TDC for every cylinder is marked on the
Driving end
Free end
1
2
4
5
63
Operating side
A6 A5 A4 A3 A2
A1
B6 B5 B4 B3 B2 B1
Fig 00-1 2200519426
00 Contents, Instructions, Terminology 22-9601
00 - 2 VASA 22

graduation of the flywheel. During a complete working cycle,
comprising in a four-stroke engine two crankshaft rotations, the
piston reaches TDC twice:
a) For the first time when the exhaust stroke of the previous
working cycle ends and the suction stroke of the following one
begins. Exhaust valvesas wellas inlet valves are then somewhat
open and scavenging takes place. If the crankshaft is turned to
and fro near this TDC, both exhaust and inlet valves will move,
afactthatindicatesthatthecrankshaftisnearthepositionwhich
can be named TDC at scavenging.
b) The second time is after the compression stroke and before the
working stroke. Slightly before this TDC the fuel injection takes
place (on an engine in operation) and this TDC can therefore be
definedTDCat firing. Characteristicisthatallvalvesareclosed
and do not move if the crankshaft is turned. When watching the
camshaft and the injection pump it is possible to note that the
pump tappet roller is on the lifting side of the fuel cam.
Flywheel graduation. The flywheel is divided in 360°, starting
fromTDCatfiringforcylinder1.TDCatfiringforeverycylinder
is indicated on the flywheel. There is a common mark for a pair
of cylinders in engines with even cylinder numbers, one cylinder
is at TDC at firing and the other is at TDC at scavenging. There
are separate scales for A- and B-bank in a V-engine. See also the
firing order in chapter 01. Firinginterval, in crank angles, can be
determined by dividing 720°with the number of cylinder.
Example of reading the flywheel
Example: OnaVASA12V22engine,thefueltimingisreadto17°
for cylinder A2 when the flywheel is in the position shown in the
above figure.
50 100
55443 3221 10
60 110
Clockwise rotating engine
130
80 120 CYL A2, 5 TDC
70
17¡
Cyl A2
TDC
Fig 00-2 2200539426
22-9601 Contents, Instructions, Terminology 00
VASA 22 00 - 3

Hightemperaturecoolingwatercircuit(HT-circuit).Thecooling
water for the engine block, cylinder head and turbocharger.
Low temperature cooling water circuit (LT-circuit). The cooling
water for the charge air cooler and the lubricating oil cooler.
00 Contents, Instructions, Terminology 22-9601
00 - 4 VASA 22

00A. Risk Reduction
00A.1 General
Read the engine manual including this appendix before installing,
operating or servicing the engine and/or related equipment.
Failure to follow the instructions can cause personal injury, loss of life
and/or property damage.
Proper personal safety equipment, e.g. gloves, hard hat, safety glasses
and ear protection must be used in all circumstances. Missing, imper-
fect or defective safety equipment might cause serious personal injury
or loss of life.
This appendix contains listed general identified hazards, hazardous
situations or events, which are to be noticed during normal operation
and maintenance work.
Identified hazard,hazardous situation or
event
Chapter of engine manual
3 4 8 1011121314151617181920212223
Dropping parts during maintenance work x x x x x x x x x x x x x x x
Turning device engaged during maintenance
work 1)
xx xxxxx x
Crankcase safety expl. valves will open if crank-
case explosion
xx x
Noiselevel xx xxxxxxxxxxxxxx
Running engine without covers x x x x x x x x x x
In case of major failure, risk of ejected parts x x x x x x x x
Contact with electricity during maintenance
work if power not disconnected
x x xx xxx
Electrical hazard if grounding of electrical equip-
ment is incorrect
xx x xx
Ejection of components / high pressure gas due
to high firing pressures
xx xxx x x
Risk of ejected parts due to break down of turbo-
charger
xx
Overspeed or explosion due to air-gas mixture in
the charge air 2)
xx x
Ejection of fuel injector if not fastened and turning
device engaged
xxx
Fire or explosion due to leakage on fuel / gas line
or lube oil system
xx xxx x
Inhalation of exhaust gases due to leakage 3) xxx
Inhalation of exhaust gas dust
Continues
xxxxx x x
200145 Risk Reduction Appendix A
00A - 1

Identified hazard,hazardous situation or
event
Chapter of engine manual
3 4 8 1011121314151617181920212223
Explosion or fire if flammable gas/vapour is leak-
ing into the insulation box. 4) xx
Touchingofmovingparts xxxxxxxxxxxx xxx
1) Warning light when turning device engaged.
2) Suction air to be taken from gas free space.
3) Require proper ventilation of engine room/plant.
4) Require proper ventilation and/or gas detector in the engine.
00A.1.1 General identified hazards, hazardous situ-
ations or events
00A.1.1.1 Hazards that may be due to moving parts
•
••
•Running engine without covers, coming in contact with moving
parts,
•
••
•Touching pump parts during unintentional start of el. driven
pump motor,
•
••
•Charger starts to rotate due to draft if not locked during mainte-
nance,
•
••
•Somebody sticks his hand into the compressor housing when the
silencer is removed and engine running,
•
••
•Unexpected movement of valve or fuel rack(s) due to broken wire
or soft / hardware failure in the control system,
•
••
•Unexpected movement of components,
•
••
•Turning device engaged during maintenance work,
•
••
•Turning device not engaged e.g. Turning device removed for
overhaul, during maintenance work could cause rotating crank-
shaft,
•
••
•Mechanical breakage (of e.g. speed sensor) due to erratic actuator
assembly to engine or electrical connections.
00A.1.1.2 Hazards that may be due to incorrect operating con-
ditions
•
••
•Overspeed or explosion due to air-gas mixture in the charge air,
•
••
•Overspeeding due to air-oil mist mixture in the charge air,
•
••
•Malfunction of crankcase ventilation,
•
••
•Oil mist detector will trip if water is present in lubricating oil,
•
••
•Crankcase explosion if oil mist is mixed with “fresh” air during
inspection after an oil mist shut down,
•
••
•Crankcase safety explosion valves will open if there is a crankcase
explosion.
Appendix A Risk Reduction 200145
00A - 2

00A.1.1.3 Hazards that may be due to different leakages, break-
down or improper assembly of component
•
••
•Fuel or gas pipe will burst and spray fuel / gas,
•
••
•Leakage of:
— fuel in joints on low and/or high pressure side,
— lube oil,
— high pressure water on DWI engines,
—HTwater,
— charge air,
— exhaust gas,
— pressurised air from air container, main manifold or pipes,
— high pressure gas and sealing oil on GD engines,
•
••
•Fire or explosion due to leakage on fuel line,
•
••
•Fire due to oil or fuel / gas leakage,
•
••
•Explosion or fire if flammable gas/vapour is leaking into the
insulation box,
•
••
•Inhalation of exhaust gases or fuel gases due to leakage,
•
••
•Failure of pneumatic stop,
•
••
•Ejected components due to:
— breakdown of hydraulic tool,
— breakdown of hydraulic bolt,
— breakdown of turbocharger,
— high firing pressures,
— major failure,
•
••
•Ejection of:
— pressurised liquids and gases from the block and pipings,
— high pressure fluid due to breakdown of hydraulic tool,
— gas due to high firing pressures,
— pressurised gases from high pressure gas system,
— high pressure fluid due to breakdown of HP sealing oil pipe,
— high pressure air during maintenance of oil mist detector main air
supply piping,
— cooling water or fuel/lube oil if sensor is loosened while the circuit
is pressurised,
— springs during maintenance work,
•
••
•Oil spray if running without covers,
•
••
•Ejection of fuel injector if not fastened and turning device en-
gaged.
200145 Risk Reduction Appendix A
00A - 3

00A.1.1.4 Hazards that may be due to electricity or incorrect
connections of electricity
•
••
•Fire or sparks due to damage or short circuit in electrical equip-
ment,
•
••
•Contact with electricity during maintenance work if power not
disconnected,
•
••
•Electrical hazard if grounding of electrical equipment is incorrect,
•
••
•Electrical shock if electrical equipment has a lead isolation break
or connector damage or is dismantled with power connected,
•
••
•Overheating of control system component due to erratic electrical
connections,
•
••
•Incorrectly wired or disconnected emergency stop switch,
•
••
•Overload of control system components due to damaged control
circuitry or incorrect voltage,
•
••
•Engine not controllable if failure in the shutdown circuitry,
•
••
•Unexpected start up or overrun,
•
••
•Crankcase explosion if:
— engine not safeguarded at high oil mist levels, due to energy supply
failure,
— engine not (fully) safeguarded at high oil mist levels, due to failure
in oil mist detector circuitry,
— engine not (fully) safeguarded at high oil mist levels, due to erratic
electrical connector or leakage in pipe connection.
00A.1.1.5 Other hazards and hazardous situations where it’s es-
pecially important to use personal safety equipment
•
••
•Slip, trip and fall,
•
••
•Water additives and treatment products (see appendix 02A, sec-
tion 02A.4),
•
••
•Touching the insulation box, turbo-charger, pipes exhaust mani-
fold or (other) unprotected parts without protection during engine
operation,
•
••
•Dropping parts during maintenance work,
•
••
•Starting maintenance work too early i.e. causing risk when han-
dling hot components,
•
••
•Neglecting use of cranes and/or lifting tools,
•
••
•Not using proper tools during e.g. maintenance work,
•
••
•Contact with fuel oil or oily parts during maintenance work (see
appendix 02A),
•
••
•Noise level,
•
••
•Touching or removing Turbocharger insulation,
•
••
•Preloaded fixation springs during check / replacement of sensor.
Appendix A Risk Reduction 200145
00A - 4