WinGD X92DF User manual

Operation Manual
X92DF
Issue 002 2020-08
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

© 2020 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,
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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.
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Table of contents
1 Introduction
1.1 Operation Manual - change record.......................................... 20
1.2 Preface..................................................................22
1.3 Technical documentation set................................................24
1.4 Data module codes (descriptive data)........................................26
1.5 Data module codes (procedural data)........................................28
1.6 About this book...........................................................30
1.7 About the engine..........................................................32
1.8 List of abbreviations.......................................................38
2 Safety
2.1 Safety precautions and safety rules..........................................44
2.2 Safety precautions and safety rules for natural gas............................48
2.3 Contamination and fire in the scavenge air spaces............................ 50
2.4 Fire-fighting in the scavenge air space.......................................52
2.5 Explosions in the crankcase................................................54
2.6 Prevent explosions in the crankcase.........................................56
2.7 Prevention of explosions in the exhaust gas system (gas mode).................58
2.8 Access to engine spaces...................................................60
3 Design and function of the engine
3.1 Short description of the DF engine.......................................... 64
3.2 Use of the engine.........................................................68
3.3 The relation between engine and propeller................................... 72
4 Design and function of systems
4.1 General for systems.......................................................78
4.2 Cooling water system......................................................80
4.3 Wash-water system....................................................... 82
4.4 System oil system.........................................................84
4.5 Servo oil system..........................................................86
4.6 Cylinder oil system........................................................88
4.7 Starting air system........................................................ 90
4.8 Scavenge air system......................................................92
4.9 Control air system.........................................................94
4.10 Exhaust gas system.......................................................96
4.11 Fuel system..............................................................98
4.12 Gas system.............................................................102
4.13 Pilot fuel system.........................................................104
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4.14 LP Selective catalytic reduction system.....................................106
4.15 HP Selective catalytic reduction system.....................................120
4.16 Steam production control system...........................................140
5 Design and function of components
5.1 Group 1 - Engine frame and bearings
5.1.1 Bedplate........................................................... 148
5.1.2 Main bearing........................................................150
5.1.3 Thrust bearing...................................................... 152
5.1.4 Monoblock column...................................................154
5.1.5 Tie rod.............................................................156
5.2 Group 2 - Cylinder
5.2.1 Cylinder liner........................................................158
5.2.2 Lubricating quill..................................................... 160
5.2.3 Gas admission valve.................................................162
5.2.4 Piston rod gland.....................................................164
5.2.5 Conventional injection valve.......................................... 166
5.2.6 Starting valve.......................................................168
5.2.7 Relief valve.........................................................170
5.2.8 Exhaust valve.......................................................172
5.2.9 Pilot injection valve.................................................. 174
5.3 Group 3 - Crankshaft, connecting rod and piston
5.3.1 Crankshaft..........................................................176
5.3.2 Torsional vibration damper............................................178
5.3.3 Axial vibration damper............................................... 182
5.3.4 Turning gear........................................................184
5.3.5 Connecting rod and connecting rod bearing.............................186
5.3.6 Crosshead and guide shoe........................................... 188
5.3.7 Piston..............................................................190
5.4 Group 4 - Supply unit drive and control components
5.4.1 Supply unit drive.................................................... 192
5.4.2 Starting air shut-off valve.............................................194
5.4.3 Control air supply....................................................196
5.4.4 Local maneuvering stand - Option A................................... 198
5.4.5 Local maneuvering stand - Option B................................... 200
5.4.6 Local maneuvering stand - Option C................................... 202
5.4.7 Pick-up for speed measurement.......................................204
5.5 Group 5 - Supply unit, pumps and control valves
5.5.1 Servo oil pump......................................................206
5.5.2 Supply unit......................................................... 208
5.5.3 Supply unit pilot fuel................................................. 210
5.5.4 Fuel pump..........................................................212
5.5.5 Injection control unit................................................. 214
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5.5.6 Pressure control valve............................................... 216
5.5.7 Flow limiting valve...................................................218
5.5.8 Exhaust valve control unit............................................ 220
5.6 Group 6 - Scavenge air components
5.6.1 Scavenge air receiver................................................222
5.6.2 Turbocharger....................................................... 224
5.6.3 Auxiliary blower..................................................... 226
5.6.4 Auxiliary blower switch box........................................... 228
5.6.5 Scavenge air cooler..................................................230
5.6.6 Water separator.....................................................232
5.7 Group 7 - Cylinder lubrication
5.7.1 Cylinder lubrication.................................................. 234
5.7.2 Integrated electrical balancer (iELBA)..................................236
5.8 Group 8 - Pipes
5.8.1 Exhaust waste gate..................................................242
5.9 Group 9 - Monitoring instruments
5.9.1 Crank angle sensor unit..............................................244
5.9.2 Water in oil monitor..................................................246
5.9.3 Oil mist detector.....................................................248
6 Control system
6.1 Engine control system UNIC...............................................254
6.2 Engine control system WECS-9520........................................ 260
6.3 Engine control system WiCE.............................................. 270
6.4 Intelligent combustion control..............................................274
6.5 Gas valve unit and external gas supply system.............................. 278
6.6 Integrated gas pressure regulation.........................................284
6.7 Local display unit (LDU-20) - general.......................................288
6.8 Local display unit (LDU-20) - Option for UNIC - pages
6.8.1 Operate the local display unit (LDU-20).................................290
6.8.2 LDU-20 pages - general for DF engine................................. 296
6.8.3 LDU-20 page - MAIN.................................................298
6.8.4 LDU-20 page - CONTROL LOCATIONS................................302
6.8.5 LDU-20 page - FUEL MODE CONTROL................................304
6.8.6 LDU-20 page - CA SENSOR STATUS..................................306
6.8.7 LDU-20 page - CYLINDER BALANCING DIESEL........................308
6.8.8 LDU-20 page - CYLINDER BALANCING GAS...........................310
6.8.9 LDU-20 page - CYLINDER LUBRICATION..............................312
6.8.10 LDU-20 page - iCAT................................................. 314
6.8.11 LDU-20 page - DYNAMIC COMBUSTION CONTROL (DCC)..............318
6.8.12 LDU-20 page - EXHAUST VENTILATION...............................320
6.8.13 LDU-20 page - EXHAUST VALVES....................................322
6.8.14 LDU-20 page - FAILURE LIST........................................ 324
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6.8.15 LDU-20 page - FAILURE SIMULATION.................................326
6.8.16 LDU-20 page - FUEL SHARING (if applicable).......................... 328
6.8.17 LDU-20 page - FUEL SYSTEM........................................330
6.8.18 LDU-20 page - GAS PRESSURE......................................332
6.8.19 LDU-20 page - GAS ADMISSION VALVES..............................334
6.8.20 LDU-20 page - GAV MANUAL VALVE TEST............................ 336
6.8.21 LDU-20 page - GVU & VALVE TEST...................................338
6.8.22 LDU-20 page - KNOCK CONTROL....................................340
6.8.23 LDU-20 page - LOG MESSAGES......................................342
6.8.24 LDU-20 page - MAIN FUEL INJECTION................................344
6.8.25 LDU-20 page - PAGE INDEX......................................... 346
6.8.26 LDU-20 page - PERFORMANCE DATA DIESEL.........................348
6.8.27 LDU-20 page - PERFORMANCE DATA GAS............................350
6.8.28 LDU-20 page - PILOT FUEL INJECTION...............................352
6.8.29 LDU-20 page - PILOT FUEL PRESSURE...............................354
6.8.30 LDU-20 page - SCAVENGE AIR - EWG (optional)....................... 356
6.8.31 LDU-20 page - SCREENSHOT........................................358
6.8.32 LDU-20 page - SOFTWARE INFO.....................................360
6.8.33 LDU-20 page - IMO CRC INFO........................................362
6.8.34 LDU-20 page - SOFTWARE TOOLS...................................364
6.8.35 LDU-20 page - SYSTEM STATUS..................................... 366
6.8.36 LDU-20 page - SYSTEM SETTINGS...................................368
6.8.37 LDU-20 page - TEMPERATURES..................................... 370
6.8.38 LDU-20 page - USER PARAMETERS..................................372
6.8.39 LDU-20 page - GAS LEAK TEST......................................374
6.8.40 LDU-20 page - LOG ENTRY DATA.................................... 376
6.8.41 LDU-20 page - DATE................................................ 378
6.8.42 LDU-20 page - ETHERNET...........................................380
6.8.43 LDU-20 page - iELBA Control (optional)................................382
6.9 Manual control panel (MCP) - Option for WiCE - pages
6.9.1 Operate the manual control panel (MCP)............................... 384
6.9.2 MCP page - SYSTEM INFO - Option for WiCE.......................... 388
6.9.3 MCP page - TREND - Option for WiCE.................................390
6.9.4 MCP page - FUEL MODE CONTROL - Option for WiCE..................392
6.9.5 MCP page - GAS SYSTEM...........................................394
6.9.6 MCP page - MAIN...................................................396
6.9.7 MCP page - INSTRUMENTS..........................................398
6.9.8 MCP page - Adjust user parameters................................... 400
6.9.9 MCP page - FUEL / LUBRICATION SYSTEM...........................404
6.9.10 Local control cabinet - general........................................ 406
6.10 Manual control panel (MCP) - Option for WECS-9520 - pages
6.10.1 Do regular checks for WECS-9520.....................................410
6.10.2 WECS-9520 manual control panel.....................................412
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6.10.3 User parameters and maintenance settings for WECS-9520.............. 416
6.10.4 Failures and defects of WECS-9520 components........................420
7 Installation
7.1 Installation..............................................................426
8 Operation
8.1 Prepare the engine before start - general....................................428
8.2 Prepare the engine before start............................................430
8.3 Start the engine - general.................................................438
8.4 Start the engine..........................................................440
8.5 Do checks during operation - general.......................................442
8.6 Do checks during operation............................................... 444
8.7 Do regular safety checks..................................................448
8.8 Maneuver the ship - general...............................................452
8.9 Maneuver the ship.......................................................454
8.10 Change-over the diesel fuel - general.......................................456
8.11 Change-over to and from gas - general.....................................460
8.12 Change-over the diesel fuel automatically...................................462
8.13 Change-over from HFO to MDO manually...................................464
8.14 Change-over from MDO to HFO manually...................................466
8.15 Change-over to and from gas..............................................468
8.16 Stop the engine - general.................................................470
8.17 Stop the engine..........................................................472
8.18 Emergency stop the engine - general.......................................474
8.19 Emergency stop the engine............................................... 476
8.20 Prepare the engine after stop - general..................................... 478
8.21 Prepare the engine for a short service break.................................480
8.22 Prepare the engine for standstill maintenance............................... 482
9 Service during operation
9.1 Do an analysis of the system oil............................................488
9.2 Do an analysis of the cylinder oil...........................................490
9.3 Replace the filter element of the duplex filter.................................494
9.4 Clean the turbocharger during operation....................................496
9.5 Clean the scavenge air cooler during operation..............................498
9.6 Do a test of the exhaust waste valve........................................502
9.7 Running-in of new components - general....................................504
9.8 Running-in of new components............................................506
10 Troubleshooting
10.1 Troubleshooting - general data............................................ 510
10.2 Malfunctions of systems and components...................................512
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10.3 Examine the supply unit for servo oil leakage................................532
10.4 Examine the supply unit for fuel leakage....................................536
10.5 Examine the rail unit for leakage...........................................540
10.6 Examine the ICU or fuel pipes for fuel leakage...............................542
10.7 Temporary cut out a defective injection valve................................ 546
10.8 Temporary cut out a defective exhaust valve drive............................548
10.9 Temporary isolate a cylinder with cooling water leakage.......................550
10.10 Disconnect the fuel pump.................................................554
10.11 Connect the fuel pump....................................................558
10.12 Temporary isolate a defective turbocharger..................................562
10.13 Temporary isolate the exhaust waste gate...................................566
10.14 Isolate a defective engine at twin engine installation..........................570
11 Technical data
11.1 Engine data.............................................................574
11.2 List of usual values and safeguard settings - general......................... 576
11.3 List of usual values and safeguard settings..................................580
11.4 Section views (Generic engine) ........................................... 592
12 Operating media
12.1 General for operating media...............................................596
12.2 Compressed air..........................................................598
12.3 Scavenge air............................................................600
12.4 Gas fuels...............................................................602
13 Schematic diagrams
13.1 Schematic diagrams - general.............................................604
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List of tables
1 Introduction
1-1 Change record ............................................................................................. 20
1-2 Data module codes (descriptive data) ......................................................... 26
1-3 Data module codes (procedural data) ......................................................... 28
1-4 List of abbreviations and acronyms ............................................................. 38
4 Design and function of systems
4-1 LP SCR SYSTEM STATUS (MAIN PAGE) .................................................. 115
4-2 LP SCR SYSTEM OVERVIEW ................................................................... 116
4-3 LP SCR INTERFACES ................................................................................ 117
4-4 LP SCR SOFTWARE INFO ......................................................................... 118
4-5 LP SCR PAGE INDEX ................................................................................. 119
4-6 Operation limits of exhaust gas temperature after exhaust gas manifold ... 122
4-7 HP SCR SYSTEM STATUS (MAIN PAGE) ................................................. 133
4-8 HP SCR SYSTEM OVERVIEW ................................................................... 134
4-9 HP SCR INTERFACES ............................................................................... 135
4-10 HP SCR MANUAL VALVE CONTROL ........................................................ 136
4-11 HP SCR SOFTWARE INFO ........................................................................ 137
4-12 HP SCR PAGE INDEX ................................................................................ 138
4-13 STEAM PRODUCTION CONTROL (SPC) ................................................. 141
5 Design and function of components
5-1 iELBA - control cabinet ................................................................................ 240
5-2 iELBA - error indication ............................................................................... 241
6 Control system
6-1 MAIN ........................................................................................................... 299
6-2 CONTROL LOCATIONS ............................................................................. 303
6-3 FUEL MODE CONTROL ............................................................................. 305
6-4 CA SENSOR STATUS ................................................................................. 307
6-5 CYLINDER BALANCING DIESEL ............................................................... 309
6-6 CYLINDER BALANCING GAS .................................................................... 311
6-7 CYLINDER LUBRICATION ......................................................................... 313
6-8 iCAT (integrated Cylinder lubricant Auto Transfer) ...................................... 315
6-9 DYNAMIC COMBUSTION CONTROL (DCC) ............................................. 319
6-10 EXHAUST VENTILATION ........................................................................... 321
6-11 EXHAUST VALVES ..................................................................................... 323
6-12 FAILURE LIST ............................................................................................. 325
6-13 FAILURE SIMULATION ............................................................................... 327
6-14 FUEL SHARING (if applicable) ................................................................... 329
6-15 FUEL SYSTEM ........................................................................................... 331
6-16 GAS PRESSURE ........................................................................................ 333
6-17 GAS ADMISSION VALVES ......................................................................... 335
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6-18 GAV MANUAL VALVE TEST ....................................................................... 337
6-19 GVU & VALVE TEST ................................................................................... 339
6-20 KNOCK CONTROL ..................................................................................... 341
6-21 LOG MESSAGES ........................................................................................ 343
6-22 MAIN FUEL INJECTION ............................................................................. 345
6-23 PAGE INDEX ............................................................................................... 347
6-24 PERFORMANCE DATA DIESEL ................................................................. 349
6-25 PERFORMANCE DATA GAS ...................................................................... 351
6-26 PILOT FUEL INJECTION ............................................................................ 353
6-27 PILOT FUEL PRESSURE ........................................................................... 355
6-28 SCAVENGE AIR - EWG (optional) .............................................................. 357
6-29 SOFTWARE INFO ....................................................................................... 361
6-30 IMO CRC INFO ........................................................................................... 363
6-31 SOFTWARE TOOLS ................................................................................... 365
6-32 SYSTEM STATUS ....................................................................................... 367
6-33 SYSTEM SETTINGS ................................................................................... 369
6-34 TEMPERATURES ....................................................................................... 371
6-35 USER PARAMETERS ................................................................................. 373
6-36 GAS LEAK TEST ........................................................................................ 375
6-37 LOG ENTRY DATA ...................................................................................... 377
6-38 DATE ........................................................................................................... 379
6-39 ETHERNET ................................................................................................. 381
6-40 iELBA Control .............................................................................................. 383
6-41 SYSTEM INFO ............................................................................................ 388
6-42 TREND ........................................................................................................ 390
6-43 FUEL MODE CONTROL ............................................................................. 393
6-44 GAS SYSTEM ............................................................................................. 394
6-45 MAIN ........................................................................................................... 397
6-46 INSTRUMENTS .......................................................................................... 398
6-47 FUEL / LUBRICATION SYSTEM ................................................................. 405
6-48 Navigation menu of the manual control panel (MCP) .................................. 407
6-49 Function buttons of the manual control panel (MCP) .................................. 407
6-50 WECS-9520 manual control panel .............................................................. 413
6-51 User parameters .......................................................................................... 416
6-52 Maintenance settings .................................................................................. 418
6-53 WECS-9520 failure groups .......................................................................... 421
6-54 Failures of pulse lubrication ......................................................................... 421
6-55 LED color codes .......................................................................................... 422
6-56 Red fail LED and two-digit LED display ....................................................... 422
6-57 Examples of Failure IDs .............................................................................. 423
10 Troubleshooting
10-1 Supply pressure of the cylinder cooling water is too low ............................. 515
10-2 Supply temperature of the cylinder cooling water is too low ....................... 515
10-3 Cylinder cooling water temperature downstream of a cylinder is too high .. 515
10-4 Supply pressure of the cooling water to the SAC is too low ........................ 515
10-5 Supply temperature of the cooling water to the SAC is too low .................. 516
10-6 Temperature of the cooling water downstream of the SAC is too high ........ 516
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10-7 Lubricating oil supply pressure at the engine inlet is too low ...................... 517
10-8 Lubricating oil supply pressure upstream of the injectors is too low ........... 517
10-9 Lubricating oil supply temperature at the engine inlet is too high ................ 517
10-10 Lubricating oil supply pressure upstream of the crossheads is too low ...... 517
10-11 Servo oil pressure in the distributor pipe (mini rail) is not in the permitted
range ........................................................................................................... 517
10-12 Servo oil leakage flow from the servo oil supply unit is too high ................. 518
10-13 Servo oil flow at a servo oil pump inlet is too low ........................................ 518
10-14 Bearing oil temperature at a bearing outlet is too high ................................ 518
10-15 Oil mist concentration is too high ................................................................ 518
10-16 Piston cooling oil temperature downstream of a piston is too high ............. 519
10-17 Piston cooling oil flow to a piston is not in the permitted range ................... 519
10-18 TC bearing oil temperature at a turbocharger outlet is too high .................. 519
10-19 TC bearing oil supply pressure upstream of a turbocharger is too low ....... 519
10-20 TC bearing oil temperature at a turbocharger inlet is too high (external oil
supply) ......................................................................................................... 519
10-21 Damper oil supply pressure upstream of the torsional vibration damper is
too low ......................................................................................................... 520
10-22 Damper oil supply pressure upstream of the axial vibration damper is too
low ............................................................................................................... 520
10-23 Cylinder oil supply pressure is too low ........................................................ 520
10-24 Cylinder oil flow is too low ........................................................................... 520
10-25 Fuel supply temperature is not in the permitted range ................................ 521
10-26 Fuel supply pressure at the engine inlet is too low ...................................... 521
10-27 Fuel leakage flow from the fuel supply unit is too high ................................ 521
10-28 Temperature difference of the fuel outlet of the two fuel pumps is too high
(for X35/-B or X40/-B engine) ...................................................................... 521
10-29 Leakage flow from the rail unit is too high ................................................... 521
10-30 Fuel leakage flow from fuel rail items is too high (engine with FLV) ............ 521
10-31 Fuel leakage flow from fuel rail items is too high (engine with ICU) ............ 522
10-32 Fuel pressure in the fuel rail is too high (for X35/-B or X40/-B engine) ....... 522
10-33 Fuel pressure in the fuel rail is too low (for X35/-B or X40/-B engine) ........ 522
10-34 Gas concentration in piston underside is too high ....................................... 523
10-35 Difference pressure of pilot fuel filter is too high ......................................... 523
10-36 Gas supply pressure is too low ................................................................... 523
10-37 Exhaust gas temperature downstream of a cylinder is too high .................. 524
10-38 Exhaust gas temperature difference downstream of all cylinders is too
high .............................................................................................................. 524
10-39 Exhaust gas temperature upstream of a turbocharger is too high .............. 524
10-40 Exhaust gas temperature downstream of a turbocharger is too high .......... 525
10-41 Exhaust valve does not operate, unwanted noise ....................................... 525
10-42 Smoke is too dark ........................................................................................ 525
10-43 Scavenge air temperature in the receiver is too high .................................. 526
10-44 Scavenge air temperature in the receiver is too low ................................... 526
10-45 Scavenge air pressure is too high ............................................................... 526
10-46 Scavenge air pressure is too low ................................................................ 526
10-47 Condensation flow at a water separator is too high .................................... 527
10-48 Condensation flow upstream of a water separator is too high .................... 527
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10-49 Scavenge air temperature in the piston underside is too high .................... 527
10-50 Starting air supply pressure is too low ......................................................... 527
10-51 Pressure of the air spring air supply is too high .......................................... 527
10-52 Pressure of the air spring air supply is too low ............................................ 528
10-53 Oil leakage flow in the collector for leakage oil from the air spring is too
high .............................................................................................................. 528
10-54 Control air supply pressure is too low (usual supply) .................................. 528
10-55 Control air supply pressure is too low (stand-by supply) ............................. 528
10-56 Control air supply pressure is too low (safety supply) ................................. 528
10-57 Temperature of a thrust bearing pad is too high .......................................... 529
10-58 Cylinder liner wall temperature is too high .................................................. 529
10-59 A fuel pump actuator has a failure ............................................................... 529
10-60 Power supply to the power supply box E85 has a failure ............................ 530
10-61 Unwanted engine speed decrease .............................................................. 530
10-62 Unwanted engine stop ................................................................................. 530
11 Technical data
11-1 General data ................................................................................................ 574
11-2 Rated power ................................................................................................ 575
11-3 Function code .............................................................................................. 578
11-4 Function group ............................................................................................ 579
11-5 Applied system ............................................................................................ 579
11-6 Cooling water systems (XX10NN to XX19NN) ............................................ 581
11-7 Oil systems (XX2NNN, part 1) ..................................................................... 582
11-8 Oil systems (XX2NNN, part 2) ..................................................................... 583
11-9 Oil systems (XX2NNN, part 3 (turbocharger bearing oil)) ........................... 584
11-10 Oil systems (XX2NNN, part 4) ..................................................................... 585
11-11 Gas system (XX33NN and XX39NN) .......................................................... 586
11-12 Fuel system (XX34NN) ................................................................................ 587
11-13 Exhaust gas system (XX37NN) ................................................................... 588
11-14 Air systems (XX40NN to XX44NN) ............................................................. 589
11-15 Miscellaneous items (XX45NN to XX52NN) ................................................ 590
11-16 Failure messages ........................................................................................ 591
12 Operating media
12-1 Specifications for gas fuel ........................................................................... 602
13 Schematic diagrams
13-1 Function code .............................................................................................. 606
13-2 Function group ............................................................................................ 607
13-3 Applied system ............................................................................................ 607
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List of illustrations
1 Introduction
1-1 Side view (generic) ...................................................................................... 33
1-2 End view (generic, seen from the driving end) ............................................ 34
1-3 Standard and LEFT engine (generic, seen from the driving end) ............... 35
1-4 Engine numbering (generic) ........................................................................ 36
3 Design and function of the engine
3-1 Pressure - volume diagram and schematic of the two-stroke diesel cycle .. 65
3-2 Pressure - volume diagram and schematic of the two-stroke otto cycle ..... 66
3-3 Operating range .......................................................................................... 68
3-4 Tuning options ............................................................................................. 70
3-5 Twin engine propulsion (generic example) .................................................. 71
3-6 Schematic diagram - Relation Speed/Power (FPP) .................................... 73
3-7 Schematic diagram - Relation Speed/ Power (CPP) ................................... 75
4 Design and function of systems
4-1 Line codes for systems ................................................................................ 78
4-2 Cooling water system (generic and simplified) ............................................ 81
4-3 Wash-water system (generic and simplified) ............................................... 83
4-4 System oil system (generic and simplified) ................................................. 85
4-5 Servo oil system (generic and simplified) .................................................... 87
4-6 Cylinder oil system (generic and simplified, with and without iCAT) ........... 89
4-7 Starting air system (generic and simplified) ................................................ 91
4-8 Scavenge air system ................................................................................... 93
4-9 Control air system (generic and simplified) ................................................. 95
4-10 Exhaust gas system (generic and simplified) .............................................. 97
4-11 Fuel system with FLV (generic and simplified) ............................................ 100
4-12 Fuel system with ICU (generic and simplified) ............................................ 101
4-13 Gas system (generic and simplified) ........................................................... 103
4-14 LP SCR temperature controlled (example) ................................................. 107
4-15 LP SCR bypass rate controlled (example) .................................................. 108
4-16 LP SCR control system layout ..................................................................... 110
4-17 LP SCR system - principal control configuration ......................................... 111
4-18 Control box E70 with option SPC ................................................................ 112
4-19 Control box E71 with option SPC ................................................................ 113
4-20 Control boxes E72 and E73 ........................................................................ 114
4-21 LDU-20 page - LP SCR SYSTEM STATUS (MAIN PAGE) ......................... 115
4-22 LDU-20 page - LP SCR SYSTEM OVERVIEW ........................................... 116
4-23 LDU-20 page - LP SCR INTERFACES ....................................................... 117
4-24 LDU-20 page - LP SCR SOFTWARE INFO ................................................ 118
4-25 LDU-20 page - LP SCR PAGE INDEX ........................................................ 119
4-26 HP SCR system - layout .............................................................................. 121
4-27 HP SCR system - emergency bypass ......................................................... 123
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4-28 HP SCR system - change from Tier III to bypass ........................................ 124
4-29 HP SCR system - purging and venting ........................................................ 125
4-30 HP SCR system - emergency bypass ......................................................... 126
4-31 HP SCR system - preparation ..................................................................... 127
4-32 HP SCR system - Tier III ............................................................................. 128
4-33 HP SCR system - principal control configuration ........................................ 129
4-34 Control box E48 ........................................................................................... 130
4-35 Control box E49 ........................................................................................... 131
4-36 Control box E50 ........................................................................................... 132
4-37 LDU-20 page - HP SCR SYSTEM STATUS (MAIN PAGE) ......................... 133
4-38 LDU-20 page - HP SCR SYSTEM OVERVIEW .......................................... 134
4-39 LDU-20 page - HP SCR INTERFACES ....................................................... 135
4-40 LDU-20 page - HP SCR MANUAL VALVE CONTROL ................................ 136
4-41 LDU-20 page - HP SCR SOFTWARE INFO ............................................... 137
4-42 LDU-20 page - HP SCR PAGE INDEX ....................................................... 138
4-43 Example of SPC .......................................................................................... 140
4-44 LDU-20 page - STEAM PRODUCTION CONTROL .................................... 141
4-45 LDU for the steam boost mode ................................................................... 143
5 Design and function of components
5-1 Bedplate (generic) ....................................................................................... 148
5-2 Main bearing (generic) ................................................................................ 150
5-3 Thrust bearing (generic) .............................................................................. 153
5-4 Monoblock column (generic) ....................................................................... 154
5-5 Tie rod (generic) .......................................................................................... 156
5-6 Cylinder liner (generic) ................................................................................ 158
5-7 Cylinder - cooling water outlet (generic) ...................................................... 159
5-8 Lubricating quill (generic) ............................................................................ 160
5-9 Gas admission valve (generic) .................................................................... 162
5-10 Piston rod gland (generic) ........................................................................... 164
5-11 Injection valve (example) ............................................................................. 166
5-12 Starting valve (example) .............................................................................. 168
5-13 Relief valve (generic) ................................................................................... 170
5-14 Exhaust valve (generic) ............................................................................... 172
5-15 Pilot injection valve (generic) ....................................................................... 174
5-16 Crankshaft (generic) .................................................................................... 176
5-17 Steel spring damper (generic) ..................................................................... 179
5-18 Viscous damper (generic) ........................................................................... 180
5-19 Axial vibration damper (generic) .................................................................. 182
5-20 Axial vibration damper monitor (generic) ..................................................... 183
5-21 Turning gear (generic) ................................................................................. 184
5-22 Connecting rod and connecting rod bearing (generic) ................................ 186
5-23 Crosshead and guide shoe (example) ........................................................ 188
5-24 Piston (example) ......................................................................................... 190
5-25 Supply unit drive (generic) ........................................................................... 193
5-26 Starting air shut-off valve (example) ............................................................ 194
5-27 Control air supply (generic) ......................................................................... 196
5-28 Local maneuvering stand (generic) ............................................................. 198
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5-29 Local maneuvering stand (generic) ............................................................. 200
5-30 Local maneuvering stand ............................................................................ 202
5-31 Pick-up for speed measurement (generic) .................................................. 204
5-32 Servo oil pump (example) ........................................................................... 206
5-33 Supply unit (example) .................................................................................. 208
5-34 Supply unit pilot fuel (generic) ..................................................................... 210
5-35 Fuel pump (generic) .................................................................................... 212
5-36 Fuel pump - cross section (example) .......................................................... 213
5-37 Injection control unit (ICU) ........................................................................... 214
5-38 Pressure control valve - location (example) ................................................ 217
5-39 Flow limiting valve (generic) ........................................................................ 218
5-40 Exhaust valve control unit (VCU) (example) ............................................... 220
5-41 Scavenge air receiver (example) ................................................................. 222
5-42 Scavenge air receiver - cross section (example) ........................................ 223
5-43 Turbocharger (example) .............................................................................. 224
5-44 Auxiliary blower (generic) ............................................................................ 226
5-45 Switch box (generic) .................................................................................... 228
5-46 Scavenge air cooler (generic) ..................................................................... 230
5-47 Water separator (generic) ............................................................................ 232
5-48 Cylinder lubricating pump ............................................................................ 234
5-49 Usual vertical oil supply ............................................................................... 235
5-50 Effect of second order moments (M2v) of the engine ................................. 236
5-51 iELBA - function ........................................................................................... 237
5-52 iELBA - control cabinet ................................................................................ 239
5-53 Exhaust waste gate (generic) ...................................................................... 242
5-54 Crank angle sensor unit on intermediate wheel (example) ......................... 244
5-55 Crank angle sensor unit on flywheel (example) .......................................... 245
5-56 Water in oil monitor (generic) ...................................................................... 246
5-57 Oil mist detector (example) ......................................................................... 248
5-58 Oil mist detector - schematic diagram (example) ........................................ 249
6 Control system
6-1 ECS modules .............................................................................................. 255
6-2 Signal flow diagram ..................................................................................... 258
6-3 ICC - pressure diagram ............................................................................... 275
6-4 ICC - control schematic ............................................................................... 276
6-5 GVU-ED ...................................................................................................... 279
6-6 GVU-OD ...................................................................................................... 280
6-7 GVU-OD: Schematic Diagram for Installation ............................................. 281
6-8 GVU Control Panel ...................................................................................... 282
6-9 Fuel gas removal from the fuel gas pipes: Schematic Diagram .................. 283
6-10 iGPR - schematic diagram .......................................................................... 284
6-11 LDU-20 - overview ....................................................................................... 288
6-12 LDU-20 color display - general items .......................................................... 289
6-13 LDU-20 - navigation menu .......................................................................... 291
6-14 MAIN ........................................................................................................... 298
6-15 CONTROL LOCATIONS ............................................................................. 302
6-16 FUEL MODE CONTROL ............................................................................. 304
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6-17 CA SENSOR STATUS ................................................................................. 306
6-18 CYLINDER BALANCING DIESEL ............................................................... 308
6-19 CYLINDER BALANCING GAS .................................................................... 310
6-20 CYLINDER LUBRICATION ......................................................................... 312
6-21 iCAT (integrated Cylinder lubricant Auto Transfer) ...................................... 314
6-22 DYNAMIC COMBUSTION CONTROL (DCC) ............................................. 318
6-23 EXHAUST VENTILATION ........................................................................... 320
6-24 EXHAUST VALVES ..................................................................................... 322
6-25 FAILURE LIST ............................................................................................. 324
6-26 FAILURE SIMULATION ............................................................................... 326
6-27 FUEL SHARING (if applicable) ................................................................... 328
6-28 FUEL SYSTEM ........................................................................................... 330
6-29 GAS PRESSURE ........................................................................................ 332
6-30 GAS ADMISSION VALVES ......................................................................... 334
6-31 GAV MANUAL VALVE TEST ....................................................................... 336
6-32 GVU & VALVE TEST ................................................................................... 338
6-33 KNOCK CONTROL ..................................................................................... 340
6-34 LOG MESSAGES ........................................................................................ 342
6-35 MAIN FUEL INJECTION ............................................................................. 344
6-36 PAGE INDEX ............................................................................................... 346
6-37 PERFORMANCE DATA DIESEL ................................................................. 348
6-38 PERFORMANCE DATA GAS ...................................................................... 350
6-39 PILOT FUEL INJECTION ............................................................................ 352
6-40 PILOT FUEL PRESSURE ........................................................................... 354
6-41 SCAVENGE AIR - EWG (optional) .............................................................. 356
6-42 SOFTWARE INFO ....................................................................................... 360
6-43 IMO CRC INFO ........................................................................................... 362
6-44 SOFTWARE TOOLS ................................................................................... 364
6-45 SYSTEM STATUS ....................................................................................... 366
6-46 SYSTEM SETTINGS ................................................................................... 368
6-47 TEMPERATURES ....................................................................................... 370
6-48 USER PARAMETERS ................................................................................. 372
6-49 GAS LEAK TEST ........................................................................................ 374
6-50 LOG ENTRY DATA ...................................................................................... 376
6-51 DATE ........................................................................................................... 378
6-52 ETHERNET ................................................................................................. 380
6-53 iELBA Control .............................................................................................. 382
6-54 MCP page - MAIN locked ............................................................................ 385
6-55 MCP page - SYSTEM INFO ........................................................................ 388
6-56 MCP page - TREND .................................................................................... 390
6-57 MCP page - FUEL MODE CONTROL ......................................................... 392
6-58 MCP page - GAS SYSTEM ......................................................................... 394
6-59 MCP page - MAIN ....................................................................................... 396
6-60 MCP page - INSTRUMENTS ...................................................................... 398
6-61 MCP page - Open user parameters ............................................................ 400
6-62 MCP page - Select user parameter ............................................................. 401
6-63 MCP page - Adjust user parameter ............................................................. 402
6-64 MCP page - FUEL / LUBRICATION SYSTEM ............................................ 404
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6-65 Local control cabinet ................................................................................... 406
6-66 WECS-9520 manual control panel .............................................................. 412
6-67 Failure ID and LED indications on FCM-20 ................................................. 420
8 Operation
8-1 Cooling water system with bypass cooling .................................................. 432
8-2 Cooling water system without bypass cooling ............................................. 433
8-3 Cooling water system with circulation ......................................................... 434
8-4 Cylinder lubricant quantity ........................................................................... 458
9 Service during operation
9-1 Location of ball valves - dirty oil samples .................................................... 491
9-2 SAC - clean during operation (example) ..................................................... 499
9-3 Feed rate adjustments - running-in ............................................................. 504
10 Troubleshooting
10-1 Example of inspection point ........................................................................ 533
10-2 Supply unit (example) and example of inspection point .............................. 537
10-3 Leakage on ICU and pipes (generic) ........................................................... 543
10-4 Leakage on connecting pipes (generic) ...................................................... 545
10-5 Exhaust valve with pressure element .......................................................... 551
10-6 Fuel pump (example) - isolate ..................................................................... 555
10-7 Fuel pump (example) - cut out .................................................................... 555
10-8 Fuel pump (example) - connect ................................................................... 559
10-9 Fuel pump (example) - cut in ....................................................................... 559
10-10 Not all turbochargers are defective (example) ............................................ 563
10-11 All turbochargers are defective (example) ................................................... 564
10-12 Exhaust waste gate (example) .................................................................... 567
11 Technical data
11-1 Operating range .......................................................................................... 575
11-2 Signal codes ................................................................................................ 578
11-3 Cross section ............................................................................................... 593
11-4 Longitudinal section ..................................................................................... 594
13 Schematic diagrams
13-1 Line codes ................................................................................................... 604
13-2 Process codes ............................................................................................. 605
13-3 Signal codes ................................................................................................ 606
13-4 Color codes and symbols - electric connection diagram ............................. 608
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1 Introduction
1.1 Operation Manual - change record.......................................... 20
1.2 Preface..................................................................22
1.3 Technical documentation set................................................24
1.4 Data module codes (descriptive data)........................................26
1.5 Data module codes (procedural data)........................................28
1.6 About this book...........................................................30
1.7 About the engine..........................................................32
1.8 List of abbreviations.......................................................38
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1.1 Operation Manual - change record
Tab 1-1 Change record
New issue 002, 2020-07
- New chapter added: LP Selective catalytic reduction system.
- Updated the iGPR schematic in the chapter: “Integrated gas pressure regulation”.
- Improved the text and the formatting in the chapter: Stop the engine - general.
- Adjusted some values in the chapter: List of usual values and safeguard settings.
- Added instructions about the steam boost mode functionality in the chapter: Steam produc-
tion control system.
- Changed the overspeed limit in the chapter: The relation between engine and propeller.
New issue 001, 2019-06
Initial issue of the Operation Manual.
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