WinGD X72 User manual

Operation Manual
X72
Issue 001 2021-01
Winterthur Gas & Diesel Ltd. Schützenstrasse 3 Tel. [phone]
Winterthur Gas & Diesel AG P.O. Box 414, 8401 Fax [phone]
Winterthur Gas & Diesel S.A. Winterthur, Switzerland www.wingd.com

© 2021 Winterthur Gas & Diesel Ltd. – All rights reserved
No part of this publication may be reproduced or copied in any form or by any means (electronic,
mechanical, graphic, photocopying, recording, taping or other information retrieval systems)
without the prior written permission of the copyright holder. Winterthur Gas & Diesel Ltd. makes
no representation, warranty (express or implied) in this publication and assumes no responsibility
for the correctness, errors or omissions of information contained herein. Information in this
publication is subject to change without notice.
NO LIABILITY, WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS
ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS
INTENDED FOR INFORMATION PURPOSES ONLY.
www.wingd.com

Table of contents
1 Introduction
1.1 Operation Manual - change record.......................................... 18
1.2 Preface..................................................................20
1.3 Technical documentation set................................................22
1.4 Data module codes (descriptive data)........................................24
1.5 Data module codes (procedural data)........................................26
1.6 About this book...........................................................28
1.7 About the engine..........................................................30
1.8 List of abbreviations.......................................................34
2 Design and function of the engine
2.1 Short description of the engine..............................................40
2.2 Use of the engine.........................................................42
2.3 The relation between engine and propeller................................... 46
2.4 Safety
2.4.1 Safety precautions and safety guidelines................................ 50
2.4.2 Contamination and fire in the scavenge air spaces........................54
2.4.3 Fire-fighting in the scavenge air space...................................56
2.4.4 Explosions in the crankcase............................................58
2.4.5 Prevent explosions in the crankcase.................................... 60
2.4.6 Access to engine spaces.............................................. 62
3 Design and function of the systems
3.1 General for systems.......................................................66
3.2 Cooling water system......................................................68
3.3 Wash-water system....................................................... 70
3.4 System oil system.........................................................72
3.5 Servo oil system..........................................................74
3.6 Cylinder oil system........................................................76
3.7 Starting air system........................................................ 78
3.8 Scavenge air system......................................................80
3.9 Control air system.........................................................82
3.10 Exhaust gas system.......................................................84
3.11 Fuel system..............................................................86
3.12 HP Selective catalytic reduction system......................................90
3.13 LP Selective catalytic reduction system..................................... 110
3.14 Steam production control system...........................................124
3.15 Synchro phasing system..................................................130
X72
Operation Manual
Winterthur Gas & Diesel Ltd. - 3 - Issue 001 2021-01

4 Design and function of the components
4.1 Group 1 - Framework and bearings
4.1.1 Bedplate........................................................... 140
4.1.2 Main bearing........................................................142
4.1.3 Thrust bearing...................................................... 144
4.1.4 Monoblock column...................................................146
4.1.5 Tie rod.............................................................148
4.2 Group 2 - Cylinder
4.2.1 Cylinder liner........................................................150
4.2.2 Lubricating quill..................................................... 152
4.2.3 Piston rod gland.....................................................154
4.2.4 Direct controlled injection valve........................................156
4.2.5 Starting valve.......................................................158
4.2.6 Exhaust valve.......................................................160
4.3 Group 3 - Crankshaft, connecting rod and piston
4.3.1 Crankshaft..........................................................162
4.3.2 Torsional vibration damper............................................164
4.3.3 Axial vibration damper............................................... 168
4.3.4 Turning gear........................................................170
4.3.5 Connecting rod and connecting rod bearing.............................172
4.3.6 Crosshead and guide shoe........................................... 174
4.3.7 Piston..............................................................176
4.4 Group 4 - Drive supply unit and control elements
4.4.1 Supply unit drive.................................................... 178
4.4.2 Starting air shut-off valve.............................................180
4.4.3 Control air supply....................................................182
4.4.4 Local maneuvering stand for UNIC.....................................184
4.4.5 Pick-up for speed measurement.......................................186
4.5 Group 5 - Supply unit, pumps and control valves
4.5.1 Servo oil pump......................................................188
4.5.2 Supply unit......................................................... 190
4.5.3 Fuel pump..........................................................192
4.5.4 Pressure control valve............................................... 194
4.5.5 Flow limiting valve...................................................196
4.5.6 Exhaust valve control unit............................................ 198
4.5.7 Fuel pump actuator..................................................200
4.6 Group 6 - Scavenge air system
4.6.1 Scavenge air receiver................................................202
4.6.2 Turbocharger....................................................... 204
4.6.3 Auxiliary blower..................................................... 206
4.6.4 Auxiliary blower switch box........................................... 208
4.6.5 Scavenge air cooler..................................................210
X72
Operation Manual
Winterthur Gas & Diesel Ltd. - 4 - Issue 001 2021-01

4.6.6 Water separator.....................................................212
4.7 Group 7 - Cylinder lubrication and balancer
4.7.1 Cylinder lubrication.................................................. 214
4.7.2 Integrated electrical balancer (iELBA)..................................216
4.8 Group 8 - Piping
4.8.1 Exhaust waste gate..................................................222
4.9 Group 9 - Monitoring system
4.9.1 Crank angle sensor unit..............................................224
4.9.2 Water in oil monitor..................................................226
4.9.3 Oil mist detector.....................................................228
4.9.4 Integrated sensor and pressure relief valve............................. 230
5 Control system of the engine
5.1 Engine control system UNIC...............................................232
5.2 Intelligent combustion control..............................................238
5.3 Local display unit (LDU-20) pages for UNIC
5.3.1 LDU-20 pages - general..............................................242
5.3.2 LDU-20 page - MAIN.................................................244
5.3.3 LDU-20 page - CONTROL LOCATIONS................................248
5.3.4 LDU-20 page - CA SENSOR STATUS..................................250
5.3.5 LDU-20 page - CYLINDER BALANCING DIESEL........................252
5.3.6 LDU-20 page - CYLINDER LUBRICATION..............................254
5.3.7 LDU-20 page - iCAT................................................. 256
5.3.8 LDU-20 page - DYNAMIC COMBUSTION CONTROL (DCC)..............260
5.3.9 LDU-20 page - EXHAUST VENTILATION...............................262
5.3.10 LDU-20 page - EXHAUST VALVES....................................264
5.3.11 LDU-20 page - FAILURE LIST........................................ 266
5.3.12 LDU-20 page - FAILURE SIMULATION.................................268
5.3.13 LDU-20 page - FUEL SYSTEM........................................270
5.3.14 LDU-20 page - KNOCK CONTROL....................................272
5.3.15 LDU-20 page - LOG MESSAGES......................................274
5.3.16 LDU-20 page - MAIN FUEL INJECTION................................276
5.3.17 LDU-20 page - PERFORMANCE DATA DIESEL.........................278
5.3.18 LDU-20 page - PILOT FUEL INJECTION...............................280
5.3.19 LDU-20 page - PILOT FUEL PRESSURE...............................282
5.3.20 LDU-20 page - SCAVENGE AIR - EWG (optional)....................... 284
5.3.21 LDU-20 page - SCREENSHOT........................................286
5.3.22 LDU-20 page - SOFTWARE INFO.....................................288
5.3.23 LDU-20 page - IMO CRC INFO........................................290
5.3.24 LDU-20 page - SOFTWARE TOOLS...................................292
5.3.25 LDU-20 page - SYSTEM STATUS..................................... 294
5.3.26 LDU-20 page - SYSTEM SETTINGS...................................296
5.3.27 LDU-20 page - TEMPERATURES..................................... 298
X72
Operation Manual
Winterthur Gas & Diesel Ltd. - 5 - Issue 001 2021-01

5.3.28 LDU-20 page - USER PARAMETERS..................................300
5.3.29 LDU-20 page - LOG ENTRY DATA.................................... 302
5.3.30 LDU-20 page - DATE................................................ 304
5.3.31 LDU-20 page - ETHERNET...........................................306
5.4 Control pages for other systems
5.4.1 Local display unit (LDU-20) - general...................................308
5.4.2 Operate the local display unit (LDU-20).................................310
6 Installation of the engine
6.1 Installation..............................................................318
7 Operation of the engine
7.1 Prepare the engine before start - general....................................320
7.2 Prepare the engine before start............................................322
7.3 Start the engine - general.................................................330
7.4 Start the engine..........................................................332
7.5 Do checks during operation - general.......................................334
7.6 Do checks during operation............................................... 336
7.7 Do regular safety checks..................................................340
7.8 Maneuver the ship - general...............................................344
7.9 Maneuver the ship.......................................................346
7.10 Change-over the diesel fuel - general.......................................348
7.11 Change-over the diesel fuel automatically...................................352
7.12 Change-over from HFO to MDO manually...................................354
7.13 Change-over from MDO to HFO manually...................................356
7.14 Stop the engine - general.................................................358
7.15 Stop the engine..........................................................360
7.16 Emergency stop the engine - general.......................................362
7.17 Emergency stop the engine............................................... 364
7.18 Prepare the engine after stop - general..................................... 366
7.19 Prepare the engine for a short service break.................................368
7.20 Prepare the engine for standstill or for maintenance..........................370
7.21 LP-SCR system: Change Tier mode........................................374
7.22 Special running condition: Cylinder cut out.................................. 378
7.23 Special running condition: Turbocharger cut out..............................384
8 Service during operation
8.1 Do an analysis of the system oil............................................394
8.2 Do an analysis of the cylinder oil...........................................396
8.3 Running-in of new components - general....................................400
8.4 Running-in of new components............................................402
8.5 Clean the turbocharger during operation....................................404
8.6 Clean the scavenge air cooler during operation..............................406
X72
Operation Manual
Winterthur Gas & Diesel Ltd. - 6 - Issue 001 2021-01

8.7 Replace the filter element of the duplex filter.................................410
8.8 Do a test of the exhaust waste valve........................................412
9 Troubleshooting
9.1 Troubleshooting - general data............................................ 416
9.2 Malfunctions of systems and components...................................418
9.3 Failures and defects of UNIC-flex components...............................438
9.4 Examine the supply unit for servo oil leakage................................440
9.5 Examine the supply unit for fuel leakage....................................444
9.6 Examine the ICU or fuel pipes for fuel leakage...............................448
9.7 Examine the FLV or fuel pipes for fuel leakage...............................452
9.8 Examine the rail unit for leakage...........................................456
9.9 Temporary isolate a cylinder with cooling water leakage.......................458
9.10 Temporary isolate a defective turbocharger..................................460
9.11 Temporary isolate the exhaust waste gate...................................464
9.12 Temporary cut out a defective injection valve................................ 468
9.13 Temporary cut out a defective exhaust valve drive............................470
9.14 Temporary isolate the HP SCR system......................................472
9.15 Connect the HP SCR system after isolation................................. 476
9.16 Disconnect the fuel pump.................................................480
9.17 Connect the fuel pump....................................................482
9.18 Isolate a defective engine at twin engine installation..........................484
10 Technical data
10.1 Engine data.............................................................488
10.2 List of usual values and safeguard settings - general......................... 490
10.3 List of usual values and safeguard settings..................................494
11 Operating media
11.1 General for operating media...............................................506
11.2 Compressed air..........................................................508
11.3 Scavenge air............................................................510
12 Schematic diagrams
12.1 Schematic diagrams - general.............................................512
X72
Operation Manual
Winterthur Gas & Diesel Ltd. - 7 - Issue 001 2021-01

X72
Operation Manual
Page left intentionally blank
Winterthur Gas & Diesel Ltd. - 8 - Issue 001 2021-01

List of tables
1 Introduction
1-1 Change record ............................................................................................. 18
1-2 Data module codes (descriptive data) ......................................................... 24
1-3 Data module codes (procedural data) ......................................................... 26
1-4 List of abbreviations and acronyms ............................................................. 34
3 Design and function of the systems
3-1 Operation limits of exhaust gas temperature after exhaust gas manifold ... 92
3-2 HP SCR SYSTEM STATUS (MAIN PAGE) ................................................. 103
3-3 HP SCR SYSTEM OVERVIEW ................................................................... 104
3-4 HP SCR INTERFACES ............................................................................... 105
3-5 HP SCR MANUAL VALVE CONTROL ........................................................ 106
3-6 HP SCR SOFTWARE INFO ........................................................................ 107
3-7 HP SCR PAGE INDEX ................................................................................ 108
3-8 LP SCR SYSTEM STATUS (MAIN PAGE) .................................................. 119
3-9 LP SCR SYSTEM OVERVIEW ................................................................... 120
3-10 LP SCR INTERFACES ................................................................................ 121
3-11 LP SCR SOFTWARE INFO ......................................................................... 122
3-12 LP SCR PAGE INDEX ................................................................................. 123
3-13 STEAM PRODUCTION CONTROL (SPC) ................................................. 125
4 Design and function of the components
4-1 iELBA - control cabinet ................................................................................ 220
4-2 iELBA - error indication ............................................................................... 221
5 Control system of the engine
5-1 MAIN ........................................................................................................... 245
5-2 CONTROL LOCATIONS ............................................................................. 249
5-3 CA SENSOR STATUS ................................................................................. 251
5-4 CYLINDER BALANCING DIESEL ............................................................... 253
5-5 CYLINDER LUBRICATION ......................................................................... 255
5-6 iCAT (integrated Cylinder lubricant Auto Transfer) ...................................... 257
5-7 DYNAMIC COMBUSTION CONTROL (DCC) ............................................. 261
5-8 EXHAUST VENTILATION ........................................................................... 263
5-9 EXHAUST VALVES ..................................................................................... 265
5-10 FAILURE LIST ............................................................................................. 267
5-11 FAILURE SIMULATION ............................................................................... 269
5-12 FUEL SYSTEM ........................................................................................... 271
5-13 KNOCK CONTROL ..................................................................................... 273
5-14 LOG MESSAGES ........................................................................................ 275
5-15 MAIN FUEL INJECTION ............................................................................. 277
5-16 PERFORMANCE DATA DIESEL ................................................................. 279
5-17 PILOT FUEL INJECTION ............................................................................ 281
X72
Operation Manual
Winterthur Gas & Diesel Ltd. - 9 - Issue 001 2021-01

5-18 PILOT FUEL PRESSURE ........................................................................... 283
5-19 SCAVENGE AIR - EWG (optional) .............................................................. 285
5-20 SOFTWARE INFO ....................................................................................... 289
5-21 IMO CRC INFO ........................................................................................... 291
5-22 SOFTWARE TOOLS ................................................................................... 293
5-23 SYSTEM STATUS ....................................................................................... 295
5-24 SYSTEM SETTINGS ................................................................................... 297
5-25 TEMPERATURES ....................................................................................... 299
5-26 USER PARAMETERS ................................................................................. 301
5-27 LOG ENTRY DATA ...................................................................................... 303
5-28 DATE ........................................................................................................... 305
5-29 ETHERNET ................................................................................................. 307
9 Troubleshooting
9-1 Supply pressure of the cylinder cooling water is too low ............................. 421
9-2 Supply temperature of the cylinder cooling water is too low ....................... 421
9-3 Cylinder cooling water temperature downstream of a cylinder is too high .. 421
9-4 Supply pressure of the cooling water to the SAC is too low ........................ 421
9-5 Supply temperature of the cooling water to the SAC is too low .................. 422
9-6 Temperature of the cooling water downstream of the SAC is too high ........ 422
9-7 Lubricating oil supply pressure at the engine inlet is too low ...................... 423
9-8 Lubricating oil supply pressure upstream of the injectors is too low ........... 423
9-9 Lubricating oil supply temperature at the engine inlet is too high ................ 423
9-10 Lubricating oil supply pressure upstream of the crossheads is too low ...... 423
9-11 Servo oil pressure in the distributor pipe (mini rail) is not in the permitted
range ........................................................................................................... 423
9-12 Servo oil leakage flow from the servo oil supply unit is too high ................. 424
9-13 Servo oil flow at a servo oil pump inlet is too low ........................................ 424
9-14 Bearing oil temperature at a bearing outlet is too high ................................ 424
9-15 Oil mist concentration is too high ................................................................ 424
9-16 Piston cooling oil temperature downstream of a piston is too high ............. 425
9-17 Piston cooling oil flow to a piston is not in the permitted range ................... 425
9-18 TC bearing oil temperature at a turbocharger outlet is too high .................. 425
9-19 TC bearing oil supply pressure upstream of a turbocharger is too low ....... 425
9-20 TC bearing oil temperature at a turbocharger inlet is too high (external oil
supply) ......................................................................................................... 425
9-21 Damper oil supply pressure upstream of the torsional vibration damper is
too low ......................................................................................................... 426
9-22 Damper oil supply pressure upstream of the axial vibration damper is too
low ............................................................................................................... 426
9-23 Cylinder oil supply pressure is too low ........................................................ 426
9-24 Cylinder oil flow is too low ........................................................................... 426
9-25 Fuel supply temperature is not in the permitted range ................................ 427
9-26 Fuel supply pressure at the engine inlet is too low ...................................... 427
9-27 Fuel leakage flow from the fuel supply unit is too high ................................ 427
9-28 Temperature difference of the fuel outlet of the two fuel pumps is too high
(for X35/-B or X40/-B engine) ...................................................................... 427
9-29 Leakage flow from the rail unit is too high ................................................... 427
X72
Operation Manual
Winterthur Gas & Diesel Ltd. - 10 - Issue 001 2021-01