Winterthur Gas & Diesel Ltd. X52 User manual

Operation Manual
X52
Issue 002 2018-11
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

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INTENDED FOR INFORMATION PURPOSES ONLY.
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Table Of Contents
1Introduction
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 Conventions...................................................................................................................................28
1.7 List of abbreviations.......................................................................................................................34
2Safety
2.1 Safety precautions and safety rules...............................................................................................40
2.2 Contamination and fire in the scavenge air spaces.......................................................................42
2.3 Fire-fighting in the scavenge air space..........................................................................................44
2.4 Explosions in the crankcase..........................................................................................................48
2.5 Prevent explosions in the crankcase.............................................................................................50
2.6 Access to engine spaces...............................................................................................................52
3 Design and function of the engine
3.1 Short description of the engine......................................................................................................56
3.2 Use of the engine...........................................................................................................................58
3.3 The relation between engine and propeller....................................................................................62
4 Design and function of systems
4.1 General for systems.......................................................................................................................68
4.2 Cooling water system.....................................................................................................................70
4.3 Wash-water system.......................................................................................................................72
4.4 System oil system..........................................................................................................................74
4.5 Servo oil system.............................................................................................................................76
4.6 Cylinder oil system.........................................................................................................................78
4.7 Starting air system.........................................................................................................................80
4.8 Scavenge air system......................................................................................................................82
4.9 Control air system..........................................................................................................................84
4.10 Exhaust gas system.......................................................................................................................86
4.11 Fuel system....................................................................................................................................88
4.12 HP Selective catalytic reduction system........................................................................................92
5 Design and function of components
5.1 Group 1 - Framework and bearings
5.1.1 Bedplate...............................................................................................................................114
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5.1.2 Main bearing........................................................................................................................116
5.1.3 Thrust bearing......................................................................................................................118
5.1.4 Monoblock column...............................................................................................................120
5.1.5 Tie rod..................................................................................................................................122
5.2 Group 2 - Cylinder
5.2.1 Cylinder liner........................................................................................................................124
5.2.2 Lubricating quill....................................................................................................................126
5.2.3 Piston rod gland...................................................................................................................128
5.2.4 Direct controlled injection valve...........................................................................................130
5.2.5 Starting valve.......................................................................................................................132
5.2.6 Exhaust valve.......................................................................................................................134
5.3 Group 3 - Crankshaft, connecting rod, and piston
5.3.1 Crankshaft............................................................................................................................136
5.3.2 Torsional vibration damper..................................................................................................138
5.3.3 Axial vibration damper.........................................................................................................142
5.3.4 Turning gear.........................................................................................................................144
5.3.5 Connecting rod and connecting rod bearing........................................................................146
5.3.6 Crosshead and guide shoe..................................................................................................148
5.3.7 Piston...................................................................................................................................150
5.4 Group 4 - Drive supply unit and control elements
5.4.1 Supply unit drive..................................................................................................................152
5.4.2 Starting air shut-off valve.....................................................................................................154
5.4.3 Control air supply.................................................................................................................156
5.4.4 Local maneuvering stand.....................................................................................................158
5.4.5 Pick-up for speed measurement..........................................................................................160
5.5 Group 5 - Supply unit, pumps, and control valves
5.5.1 Servo oil pump.....................................................................................................................162
5.5.2 Supply unit...........................................................................................................................164
5.5.3 Fuel pump............................................................................................................................166
5.5.4 Pressure control valve.........................................................................................................168
5.5.5 Flow limiting valve................................................................................................................170
5.5.6 Exhaust valve control unit....................................................................................................172
5.5.7 Fuel pump actuator..............................................................................................................174
5.6 Group 6 - Scavenge air system
5.6.1 Scavenge air receiver..........................................................................................................176
5.6.2 Turbocharger.......................................................................................................................178
5.6.3 Auxiliary blower....................................................................................................................180
5.6.4 Auxiliary blower switch box..................................................................................................182
5.6.5 Scavenge air cooler.............................................................................................................184
5.6.6 Water separator...................................................................................................................186
5.7 Group 7 - Cylinder lubrication
5.7.1 Cylinder lubrication..............................................................................................................188
5.7.2 Integrated electrical balancer (iELBA).................................................................................190
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5.8 Group 8 - Piping
5.8.1 Exhaust waste gate..............................................................................................................196
5.9 Group 9 - Monitoring system
5.9.1 Crank angle sensor unit.......................................................................................................198
5.9.2 Water in oil monitor..............................................................................................................200
5.9.3 Oil mist detector...................................................................................................................202
6 Control system
6.1 Engine control system..................................................................................................................206
6.2 Intelligent combustion control......................................................................................................212
6.3 Local display unit (LDU-20) - general..........................................................................................216
6.4 Local display unit (LDU-20) - pages
6.4.1 LDU-20 pages - general.......................................................................................................218
6.4.2 LDU-20 page - MAIN...........................................................................................................220
6.4.3 LDU-20 page - CONTROL LOCATIONS.............................................................................224
6.4.4 LDU-20 page - CA SENSOR STATUS................................................................................226
6.4.5 LDU-20 page - FUEL SYSTEM...........................................................................................228
6.4.6 LDU-20 page - CYLINDER BALANCING DIESEL...............................................................230
6.4.7 LDU-20 page - MAIN FUEL INJECTION.............................................................................232
6.4.8 LDU-20 page - PAGE INDEX..............................................................................................234
6.4.9 LDU-20 page - EXHAUST VALVES....................................................................................236
6.4.10 LDU-20 page - FAILURE LIST.............................................................................................238
6.4.11 LDU-20 page - CYLINDER LUBRICATION.........................................................................240
6.4.12 LDU-20 page - USER PARAMETERS.................................................................................242
6.4.13 LDU-20 page - PERFORMANCE DATA DIESEL................................................................244
6.4.14 LDU-20 page - TEMPERATURES.......................................................................................246
6.4.15 LDU-20 page - SOFTWARE INFO......................................................................................248
6.4.16 LDU-20 page - LOG MESSAGES........................................................................................250
6.4.17 LDU-20 page - LOG ENTRY DATA.....................................................................................252
6.4.18 LDU-20 page - SYSTEM STATUS......................................................................................254
6.4.19 LDU-20 page - SOFTWARE TOOLS...................................................................................256
6.4.20 LDU-20 page - SYSTEM SETTINGS...................................................................................258
6.4.21 LDU-20 page - ETHERNET.................................................................................................260
6.4.22 LDU-20 page - DATE...........................................................................................................262
6.4.23 LDU-20 page - SCAVENGE AIR - EWG (optional)..............................................................264
6.4.24 LDU-20 page - SCREENSHOT...........................................................................................266
6.4.25 LDU-20 page - iELBA Control (optional)..............................................................................268
6.5 Operate the local display unit (LDU-20).......................................................................................270
7 Installation
7.1 Installation....................................................................................................................................276
8 Operation
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8.1 Prepare the engine before start - general....................................................................................278
8.2 Prepare the engine before start...................................................................................................280
8.3 Start the engine - general............................................................................................................286
8.4 Start the engine............................................................................................................................288
8.5 Do checks during operation - general..........................................................................................290
8.6 Do checks during operation.........................................................................................................292
8.7 Do regular safety checks.............................................................................................................296
8.8 Maneuver the ship - general........................................................................................................300
8.9 Maneuver the ship.......................................................................................................................302
8.10 Change-over the diesel fuel - general..........................................................................................304
8.11 Change-over the diesel fuel automatically...................................................................................308
8.12 Change-over from HFO to MDO manually...................................................................................310
8.13 Change-over from MDO to HFO manually...................................................................................312
8.14 Stop the engine - general.............................................................................................................314
8.15 Stop the engine............................................................................................................................316
8.16 Emergency stop the engine - general..........................................................................................318
8.17 Emergency stop the engine.........................................................................................................320
8.18 Prepare the engine after stop - general.......................................................................................322
8.19 Prepare the engine for a short service break...............................................................................324
8.20 Prepare the engine for a long shutdown period...........................................................................326
9 Service during operation
9.1 Do an analysis of the system oil..................................................................................................330
9.2 Do an analysis of the cylinder oil.................................................................................................332
9.3 Replace the filter element of the duplex filter...............................................................................336
9.4 Clean the scavenge air cooler during operation..........................................................................338
9.5 Do a test of the exhaust waste valve...........................................................................................342
9.6 Running-in of new components - general....................................................................................344
9.7 Running-in of new components...................................................................................................346
10 Troubleshooting
10.1 Troubleshooting - general data....................................................................................................350
10.2 Malfunctions of systems and components...................................................................................352
10.3 Failures and defects of UNIC components..................................................................................370
10.4 Examine the supply unit for servo oil leakage..............................................................................372
10.5 Examine the supply unit for fuel leakage.....................................................................................376
10.6 Examine the rail unit for leakage..................................................................................................380
10.7 Examine the FLV or fuel pipes for fuel leakage...........................................................................382
10.8 Temporary cut out a defective injection valve..............................................................................386
10.9 Temporary cut out a defective exhaust valve drive......................................................................388
10.10 Temporary isolate a cylinder with cooling water leakage.............................................................390
10.11 Disconnent the fuel pump............................................................................................................394
10.12 Connect the fuel pump.................................................................................................................398
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10.13 Temporary isolate a defective turbocharger................................................................................402
10.14 Temporary isolate the exhaust waste gate..................................................................................406
10.15 Isolate a defective engine at twin engine installation...................................................................410
10.16 Temporary isolate the HP SCR system.......................................................................................412
10.17 Connect the HP SCR system after isolation................................................................................414
11 Technical data
11.1 Engine data..................................................................................................................................418
11.2 List of usual values and safeguard settings - general..................................................................420
11.3 List of usual values and safeguard settings.................................................................................424
11.4 Section views...............................................................................................................................436
12 Operating media
12.1 Cooling water...............................................................................................................................440
12.2 Cooling water additives................................................................................................................442
12.3 System oils...................................................................................................................................446
12.4 Cylinder oils.................................................................................................................................454
12.5 Different oils and lubricants..........................................................................................................460
12.6 List of system oils.........................................................................................................................462
12.7 List of cylinder oils........................................................................................................................464
12.8 List of lubricants for flywheel and pinion gear teeth.....................................................................468
12.9 Compressed air............................................................................................................................470
12.10 Scavenge air................................................................................................................................472
12.11 Diesel engine fuels.......................................................................................................................474
13 Schematic diagrams
13.1 Schematic diagrams - general.....................................................................................................488
13.2 List of diagrams............................................................................................................................494
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LIST OF TABLES
Table Page
CHAPTER 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
CHAPTER 4 - DESIGN AND FUNCTION OF SYSTEMS
4-1 Operation limits of exhaust gas temperature after exhaust gas manifold ........................ 94
4-2 SCR SYSTEM STATUS .................................................................................................. 105
4-3 SCR SYSTEM OVERVIEW ............................................................................................. 106
4-4 SCR INTERFACES ......................................................................................................... 107
4-5 SCR MANUAL VALVE CONTROL .................................................................................. 108
4-6 SCR SOFTWARE INFO .................................................................................................. 109
CHAPTER 5 - DESIGN AND FUNCTION OF COMPONENTS
5-1 iELBA - control cabinet .................................................................................................... 194
5-2 iELBA - error indication .................................................................................................... 195
CHAPTER 6 - CONTROL SYSTEM
6-1 MAIN ................................................................................................................................ 221
6-2 CONTROL LOCATIONS ................................................................................................. 225
6-3 CA SENSOR STATUS .................................................................................................... 227
6-4 FUEL SYSTEM ................................................................................................................ 229
6-5 CYLINDER BALANCING DIESEL ................................................................................... 231
6-6 MAIN FUEL INJECTION .................................................................................................. 233
6-7 PAGE INDEX ................................................................................................................... 235
6-8 EXHAUST VALVES ......................................................................................................... 237
6-9 FAILURE LIST ................................................................................................................. 239
6-10 CYLINDER LUBRICATION ............................................................................................. 241
6-11 USER PARAMETERS ..................................................................................................... 243
6-12 PERFORMANCE DATA DIESEL .................................................................................... 245
6-13 TEMPERATURES ........................................................................................................... 247
6-14 SOFTWARE INFO ........................................................................................................... 249
6-15 LOG MESSAGES ............................................................................................................ 251
6-16 LOG ENTRY DATA ......................................................................................................... 253
6-17 SYSTEM STATUS ........................................................................................................... 255
6-18 SOFTWARE TOOLS ....................................................................................................... 257
6-19 SYSTEM SETTINGS ....................................................................................................... 259
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Table Page
6-20 ETHERNET ..................................................................................................................... 261
6-21 DATE ............................................................................................................................... 263
6-22 SCAVENGE AIR - EWG (optional) .................................................................................. 265
6-23 iELBA Control .................................................................................................................. 269
CHAPTER 8 - OPERATION
8-1 Resistor values ................................................................................................................ 297
CHAPTER 10 - TROUBLESHOOTING
10-1 Supply pressure of the cylinder cooling water is too low ................................................. 354
10-2 Supply temperature of the cylinder cooling water is too low ............................................ 354
10-3 Cylinder cooling water temperature downstream of a cylinder is too high ....................... 354
10-4 Supply pressure of the cooling water to the SAC is too low ............................................ 354
10-5 Supply temperature of the cooling water to the SAC is too low ....................................... 354
10-6 Temperature of the cooling water downstream of the SAC is too high ............................ 355
10-7 Lubricating oil supply pressure at the engine inlet is too low ........................................... 356
10-8 Lubricating oil supply pressure upstream of the injectors is too low ................................ 356
10-9 Lubricating oil supply temperature at the engine inlet is too high .................................... 356
10-10 Lubricating oil supply pressure upstream of the crossheads is too low ........................... 356
10-11 Servo oil pressure in the distributor pipe (mini rail) is not in the permitted range ........... 356
10-12 Servo oil leakage flow from the servo oil supply unit is too high ...................................... 357
10-13 Servo oil flow at a servo oil pump inlet is too low ............................................................ 357
10-14 Bearing oil temperature at a bearing outlet is too high .................................................... 357
10-15 Oil mist concentration is too high ..................................................................................... 357
10-16 Piston cooling oil temperature downstream of a piston is too high .................................. 358
10-17 Piston cooling oil flow to a piston is not in the permitted range ....................................... 358
10-18 TC bearing oil temperature at a turbocharger outlet is too high ...................................... 358
10-19 TC bearing oil supply pressure upstream of a turbocharger is too low ............................ 358
10-20 TC bearing oil temperature at a turbocharger inlet is too high (external oil supply) ....... 358
10-21 Damper oil supply pressure upstream of the torsional vibration damper is too low ......... 359
10-22 Damper oil supply pressure upstream of the axial vibration damper is too low ............... 359
10-23 Cylinder oil supply pressure is too low ............................................................................. 359
10-24 Cylinder oil flow is too low ................................................................................................ 359
10-25 Fuel supply temperature is not in the permitted range .................................................... 360
10-26 Fuel supply pressure at the engine inlet is too low .......................................................... 360
10-27 Fuel leakage flow from the fuel supply unit is too high .................................................... 360
10-28 Leakage flow from the rail unit is too high ....................................................................... 360
10-29 Fuel leakage flow from fuel rail items is too high (engine with FLV) ................................ 360
10-30 Fuel leakage flow from fuel rail items is too high (engine with ICU) ................................ 360
10-31 Gas concentration in piston underside is too high ........................................................... 361
10-32 Difference pressure of pilot fuel filter is too high .............................................................. 361
10-33 Exhaust gas temperature downstream of a cylinder is too high ...................................... 362
10-34 Exhaust gas temperature difference downstream of all cylinders is too high .................. 362
10-35 Exhaust gas temperature upstream of a turbocharger is too high ................................... 362
10-36 Exhaust gas temperature downstream of a turbocharger is too high .............................. 363
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