project guide • generator set

M 25 CProject Guide • Generator Set

m

M 25 C Generator Set

Introduction

Caterpillar Motoren GmbH & Co. KGP. O. Box, D-24157 KielGermanyPhone +49 431 3995-01Telefax +49 431 3995-2193

Issue Juli 2008

Information for the user of this project guide

The project information contained in the following is not binding, since technical data of products mayespecially change due to product development and customer requests. Caterpillar Motoren reservesthe right to modify and amend data at any time. Any liability for accuracy of information providedherein is excluded.

Binding determination of data is made by means of the Technical Specification and such other agree-ments as may be entered into in connection with the order. We will supply further binding data, draw-ings, diagrams, electrical drawings, etc. in connection with a corresponding order.

This edition supersedes the previous edition of this project guide.

All rights reserved. Reproduction or copying only with our prior written consent.

m


Global Resource from One SourceWhen you select Cat Marine Power for yourvessel, look to Cat Financial for world-classfinancial support. With marine lending offices inEurope, Asia and the US supporting Caterpillar’sworldwide marine distribution network, CatFinancial is anchored in your homeport. We alsohave over 20 years of marine lending experience,so we understand your unique commercialmarine business needs. Whether you’re in theoffshore support, cargo, ship assist, towing, fish-ing or passenger vessel industry, you can counton Cat Financial for the same high standard youexpect from Caterpillar.

www.CAT.com/CatMarineFinanceVisit our web-site or see your local Cat dealerto learn how our marine financing plans and options can help your business succeed.

Marine Financing GuidelinesPower: Cat and MaK.Financial Products: Construction, term

and repower financing.Repayment: Loan terms up to

10 years, with longeramortizations available.

Financed Amount: Up to 80% of yourvessel cost.

Rates: Fixed or variable.Currency: US Dollars, Euros and

other widely tradedcurrencies.

Ocean-Going Vessels

Pleasure Craft

Commercial Vessels

m


GlobalDealer Network Maintenance

Training

Commissioning

RemanufacturedParts

GenuineSpare Parts

DICAREDiagnostic Software

RepairsEngineUpgrades

Overhauls

Customer SupportAgreements

(CSAs)

Providing integrated solutions for your power system meansmuch more than just supplying your engines. Beyond completeauxiliary and propulsion power systems, we offer a broad port-folio of customer support solutions and financing options. Ourglobal dealer network takes care of you wherever you are –worldwide. Localized dealers offer on-site technical expertisethrough marine specialists and an extensive inventory of all thespare parts you might need.

To find your nearest dealer, simply go to:www.cat-marine.com or www.mak-global.com

m


m


Contents

Page

1. Engine description 1 - 2 2. General data and outputs 3 - 4 3. Restrictions for low load operation 5 4. Load application and recovery behaviour 6 - 7 5. Technical data 8 - 9 6. Genset dimensions and weights 10 - 13 7. Maintenance platform 14 8. Required dimensions of generator 15 9. Space requirement for dismantling of charge air cooler and

turbocharger cartridge 1610. System connections 1711. Fuel oil system 18 - 3012. Lubricating oil system 31 - 3713. Cooling water system 38 - 4414. Flow velocities in pipes 4515. Starting air system 4616. Combustion air system 4717. Exhaust system 48 - 5318. Air borne sound power level 5419. Foundation 55 - 5620. Control and monitoring system 57 - 6621. Diagnostic system DICARE 67 - 6822. Diesel engine management system DIMOS 6923. Standard acceptance test run 7024. EIAPP certificate 7125. Painting/Preservation 72 - 7326. Lifting of gensets 7427. Engine parts 75

m

1M 25 C Generator Set

1. Engine description

The M 25 C is a four stroke diesel engine, turbocharged and intercooled with direct fuel injection.

In-line engine M 25 C

Cylinder configuration: 6, 8, 9 in-lineBore: 255 mmStroke: 400 mmStroke/Bore-Ratio: 1.57Swept volume: 20.4 l/Cyl.Output/cyl.: 317/330 kWBMEP: 25.8 barRevolutions: 720/750 rpmMean piston speed: 9.6/10.0 m/sTurbocharging: pulseDirection of rotation: counter-clockwise,

viewed from driving end

6 5 4 3 2 1 Cyl. number

Free end Driving end

Control side

Exhaust side

m

2 M 25 C Generator Set

1. Engine description

Engine design

- Designed for heavy fuel operation up to 700 cSt/50 °C, fuel grade acc. to CIMAC H55 K55, ISO 8217,1996 (E), ISO-F-RMH55 RMK55.

- 1-piece dry engine block made of nodular cast iron. It incorporates the crankshaft bearing, cam-shaft bearing, charge air receiver, vibration damper housing and gear drive housing.

- Underslung crankshaft with corrosion resistant main and big end bearing shells.

- Natural hardened liners, centrifugally casted, with calibration insert.

- Composite type pistons with steel crown and nodular cast iron skirt.

- Piston ring set consisting of 2 chromium plated compression rings, first ring with chrom-ceramiclayer and 1 chromium plated oil scraper ring. All ring grooves are hardened and located in the steelcrown.

- 2-piece connecting rod, fully machined, obliquely split with serrated joint.

- Cylinder head made of nodular cast iron with 2 inlet and 2 exhaust valves with valve rotators.Direct cooled exhaust valve seats.

- Camshaft made of sections per cylinder allowing a removal of the pieces sideways.

- Turbocharger supplied with inboard plain bearings lubricated by engine lubricating oil.

- 2-stage fresh water cooling system with 2-stage charge air cooler.

- Nozzle cooling for heavy fuel operation only with engine lubricating oil.

m


2. General data and outputs

Remark:The generator outputs are based on 95 % efficiency and a power factor of 0,8.

Output definition

The maximum continuous rating stated by Caterpillar Motoren refers to the following reference condi-tions according to "IACS" (International Association of Classification Societies) for main and auxiliaryengines:

Reference conditions according to IACS (tropical conditions):air pressure 100 kPa (1 bar)air temperature 318 K (45 °C)relative humidity 60 %seawater temperature 305 K (32 °C)

The permissible overload is 10 % for one hour every twelve hours. The maximum fuel rack position islimited to 110 % continuous rating.

Fuel consumption

The fuel consumption data refer to the following reference conditions:intake temperature 298 K (25 °C)charge air temperature 318 K (45 °C)charge air coolant inlet temperature 298 K (25 °C)net heating value of the Diesel oil 42700 kJ/kgtolerance 5 %

Specification of the fuel consumption data without fitted-on pumps; for each pump fitted on an additio-nal consumption of 1 % has to be calculated.

720 rpm / 60 Hz 750 rpm / 50 Hz

EnginekWm

GeneratorkWe

EnginekWm

GeneratorkWe

6 M 25 C 1900 1805 1980 1881

8 M 25 C 2534 2407 2640 2580

9 M 25 C 2850 2708 2970 2822

m


Lubricating oil consumption

Actual data can be taken from the technical data.

Nitrogen oxide emissions (NOx-values)

NOx-limit values according to MARPOL 73/78 Annex VI: 12.1 g/kWh (n = 720 rpm)12.0 g/kWh (n = 750 rpm)

Generator according to cycle D2: 11.0 g/kWh (n = 720 rpm)10.5 g/kWh (n = 750 rpm)

General installation aspect:

Inclination angles at which gensets and essential aux. machinery is to operate satisfactorily:

Heel to each side: 15°Rolling to each side: + 22.5°Trim by head and stern: 5°Pitching: + 7.5°

2. General data and outputs

m


3. Restrictions for low load operation

The engine can be started, stopped and run on heavy fuel oil under all operating conditions.

The HFO system of the engine remains in operation and keeps the HFO at injection viscosity. The tem-perature of the engine injection system is maintained by circulating hot HFO and heat losses are com-pensated.The lube oil treatment system (lube oil separator) remains in operation, the lube oil is separated con-tinuously.The operating temperature of the engine cooling water is maintained by the cooling water preheater.Below 25 % output heavy fuel operation is neither efficient nor economical.A change-over to diesel oil is recommended to avoid disadvantages as e.g. increased wear and tear,contamination of the air and exhaust gas systems and increased contamination of lube oil.

Cleaning run of engine

1 h 2 3 4 5 6 8 10 15 20 24 h

PE %

100

70

5040

30

20

15

10

8

6

HFO-operation

3 h 2 1 h 30 min 15 min 0

Cleaning run after partial load operation

Load increase periodapprox. 15 min.

Restricted HFO-operation

Emergency start in the event of black out

Emergency start with gravity feed fuel from the diesel oil day tank is possible.The bottom edge of the diesel oil day tank has to be arranged approx. 4 m above injection pump level.

m


4. Load application and recovery behaviour

Example: 9 M 25 C, 2850 kW, 720 rpm, bmep = 25.8 bar

1. max. load from 0 % to 30 % output2. max. load from 30 % to 52 % output3. max. load from 52 % to 71 % output4. max. load from 71 % to 100 % output

bmep at cont. rating of diesel engine

[bar]

Limiting curve for1st load step

Limiting curve for2nd load step

Limiting curve for3rd load step

[%]

Load

incr

ease

ref

erre

d to

con

tinuo

us r

atin

g

The permissible load increase according to ISO 8528-5 and IACS must be carried out in several steps,depending on the mean effective pressure. The ship‘s network must be designed so that this permissi-ble load increase is kept. The shipyard is to provide the approval of the responsible classificationsociety in time before classification acceptance of the engine.

Reference values for load steps, depending on bmep at continuous rating

m


4. Load application and recovery behaviour

Standard settings:

- Droop 4 %- Fuel rack 110 %- Speed setting range + 5 %

Standard speed governor, make RE, type 1102, equipped with:

- Speed setting motor (24 V DC/100 % continuous duty) for a setting speed of 4 - 8 sec/Hz- Start fuel limiter- Shut-down solenoid (24 V DC/100 % continuous duty) for remote stop (not for automatic engine

stop)- Infinitely adjustable from the outside at the governor, 0 - 10 % droop

DE-drive only with electronic governor, maker: RE, type Viking 25 (standard) or Woodward 723+(option)

Recovery behaviour after load increase based on reference values for load steps as well as unloading.

m


5. Technical data

Cylinder 6 8 9 Performance data Maximum continous rating acc. ISO 3046/1 kW 1900 2000 2534 2660 2850 3000

Speed rpm 720 750 720 750 720 750 Minimum speed rpm 240 250 240 250 240 250 Brake mean effektive pressure bar 25.8 26.1 25.8 26.1 25.8 26.1 Charge air pressure bar 3.1 3.2 3 3.2 3.2 Compression pressure bar 172 175 172 175 172 175 Firing pressure bar 204 208 204 208 200 204 Combustion air demand (ta = 20 °C) m3/h 11100 12850 14515 15665 16550 17020 Delivery/injection timing ° b. TDC 11/8 11/8 11/8 Exhaust gas temperature after cylinder/turbine

°C 360/305 360/290 370/325 370/320 380/320

Specific fuel oil consumption Const. speed 1) 100 % 85 % 75 % 50 %

g/kWh g/kWh g/kWh g/kWh

184183185193

184183185193

184183185193

Lubricating oil consumption 2) g/kWh 0.6 0.6 0.6 Turbocharger type HPR6000 HPR6000 HPR6000 Fuel Engine driven feed pump (for gas oil/MDO only) m3/h/bar 1.5/3 1.5/3 1.5/3

Mesh size MDO fine filter mm 0.025 0.025 0.025 Mesh size HFO selfcleaning filter mm 0.010 0.010 0.010 Mesh size HFO fine filter mm 0.034 0.034 0.034 Nozzle cooling by lubricating oil system for heavy fuel only

Lubricating Oil Engine driven pump m3/h/bar 89/10 93/10 89/10 93/10 89/10 93/10 Working pressure on engine inlet bar 4 - 5 4 - 5 4 - 5 Prelubrication pump m3/h/bar 6.6/5 10/5 10/5 Temperature at engine inlet °C 60-65 60-65 60-65 Temperature controller DN mm 80 100 100 Selfcleaning filter DN mm 80 80 80 Mesh size selfcleaning filter mm 0.03 0.03 0.03

m


5. Technical data

Cylinder 6 8 9 Fresh water cooling Engine content m3 0.4 0.5 0.6 Pressure at engine inlet min/max bar Header tank capacity m3

Temperature at engine outlet °C

2.5/6.0 0.2

80 - 90

2.5/6.0 0.25

80 - 90

2.5/6.0 0.3

80 - 90 Two circuit system Engine driven pump HT m3/h/bar 40/3.7 55/3.5 60/3.7 Independent pump HT m3/h/bar 40/3.0 55/3.0 60/3.0 HT-Controller DN mm 80 100 100 Water demand LT-charge air cooler m3/h 40 45 50 Temperature at LT-charge air cooler inlet

°C 38 38 38

Heat Dissipation Specific jacket water heat kJ/kWh 500 500 500 Specific lub. oil heat kJ/kWh 490 490 490 Lub. oil cooler MJ/h 931 970 1242 1294 1396 1455 Jacket water MJ/h 950 990 1267 1320 1425 1485 Charge air cooler (HT-Stage) 3) MJ/h 2160 2255 2808 2934 3096 3240 Charge air cooler (LT-Stage) 3) MJ/h 828 884 1116 1116 1260 1260 (HT-Stage after engine) Heat radiation engine MJ/h 306 408 460 Exhaust gas Silencer/spark arrester DN 25 dBA mm 500 600 600 DN 35 dBA mm 500 600 600 Pipe diameter DN after turbine mm 500 600 600 Maximum exhaust gas pressure drop

bar 0.03 0.03 0.03

Temperature 5) at 25 °C air intake °C 305 290 325 320 320 320 45 °C air intake °C 330 306 340 335 340 339 Mass 5) at 25 °C air intake kg/h 13570 16120 17940 20070 20442 22000 45 °C air intake kg/h 13027 14146 17222 18044 19624 19600 Starting air Starting air pressure max. bar 30 30 30 Minimum starting air pressure bar 10 10 10 Air consumption per Start 4) Nm3 0.8 0.8 0.8 1) Reference conditions: LCV = 42700 kJ/kg, ambient temperature 25 °C charge air temperature 45 °C,

tolerance 5 %, + 1 % for each engine driven pump 2) Standard value, tolerance + 0.3 g/kWh, related on full load 3) Charge air heat based on 45 °C ambient temperature 4) Preheated engine 5) Tolerance 10 %, relative air humidity 60 %

m


6. Genset dimensions and weights

Removal of:

Piston in transverse direction X1 = 3760 mmin longitudinal direction X2 = 4340 mmin transverse dir. reduced X1 red. = 3640 mm

Cylinder Liner in transverse direction Y1 = 3850 mmin longitudinal direction Y2 = 4075 mmin transverse dir. reduced Y1 red. = 3640 mm

Reduced removal height with special tools only.

Genset centre distance Minimum2700 mm (2 gensets side by side)

Dry weight Dimensions [mm]

Engine Genset 1)Type

A 1 ) B C D E F [t] [t]

6 M 25 C 8070 6735 2950 1340 2479 1700 21 44

8 M 25 C 9130 7795 3097 1340 2534 1700 28 49

9 M 25 C 9460 8125 3097 1340 2534 1700 30 54

1) Dependent on generator make/type

m


6. Genset dimensions 6 M 25 C

Scal

e 1

: 50

m



Scal

e 1

: 50

m


7. Maintenance platform (option)

The platform, located at the control side of the genset, is normally designed and manufactured by theshipyard. As an option Caterpillar Motoren can supply a platform including stairs and ladder.

m


8. Required dimensions of generator

Generators structural requirements for MaK diesel gensets M 25 C

- Mounting flap for anti-condensation heater above the mounts- With air cooling the air outlet above the mounts- The mounts are to be designed with 4 alignment screws- Plain bearings must be removable without coupling removal

Type Design A max. B C Ø D max.

Ø d F H Ø M S min.

6 M 25 C 2700

8 M 25 C 3000

9 M 25 C

B 20

2900

1700 1900 1500 200 250 405 45 220

Contact surfaces for each pedestal in one piece and free of paint

m


9. Space requirement for dismantling of charge air cooler andturbocharger cartridge

Charge air cooler cleaning

Cleaning is carried out with charge air cooler dismantled. A container to receive the cooler and clean-ing liquid is to be supplied by the yard. Intensive cleaning is achieved by using ultra sonic vibrators.

Turbocharger Removal/Maintenance

Caterpillar Motoren recommends to provide a lifting device above the bearing housing of the turbo-charger (see "S").

Weights of Turbocharger [kg] Dimensions [mm]

Turbo-charger, compl.

Silencer Compressor housing

Turbine inlet housing

Exhaust-gas elbow

Car-tridge

Rotor P R S

563 63 136 125 68 150 32 1454 729 437

m


10. System connections

C12 Generator Cooler, InletC13 Generator Cooler, OutletC14 Charge Air Cooler LT, Inlet DN 65C15 Charge Air Cooler LT, Outlet DN 65C17 Charge Air Cooler HT, Outlet DN 80C21 Freshwater Pump HT, Inlet DN 80C55c Connection Flushing Pipe DN 50

Selfcleaning Filter

C58 Luboil Force Pump, Outlet DN 80C59 Luboil Inlet, Selfcleaning Filter DN 80C60 Separator Connection, Suction Side DN 50C61 Separator Connection, Delivery Side DN 50C65 Luboil Filling DN 50C76 Fuel Inlet, Duplex Filter DN 32C78 Fuel, Outlet DN 32C86 Starting Air DN 40C91a Exhaust Gas Outlet 6 M 25 C DN 500

8/9 M 25 C DN 600

m


11. Fuel oil systemMarine gas oil / marine diesel oil operation

Two fuel product groups are permitted for MaK engines:

Pure distillates: Gas oil, marine gas oils, diesel fuel

Distillate/mixed fuels: Marine gas oil (MGO), marine diesel oil (MDO). The differ-ence between distillate/mixed fuels and pure distillates arehigher density, sulphur content and viscosity.

Max. injection viscosity 12 cSt (2 °E)

Day tank DT 1: To be layed out for heat dissipation from injection pumps,approx. 1.5 kW/cylinder

Strainer (separate) DF 2: Mesh size 0.32 mm, dimensions see HFO-system

Preheater (separate) DH 1: Heating capacity

Not required with:- MGO < 7 cSt/40 °C- Heated day tank

Q [kW] =Peng. [kW]

166

MGO MDO

Designation Max. viscosity[cSt/40 °C]

Designation Max. viscosity[cSt/40 °C]

ISO 8217: 1996 ISO-F-DMA 1.5 - 6.0 ISO-F-DMB ISO-F-DMC

1114

ASTM D 975-78 No. 1 D No. 2 D

2.44.1

No. 2 D No. 4 D

4.124.0

DIN DIN EN 590 8

m


Feed pump (fitted) DP 1: Capacity see technical data

Pressure regulating valve (fitted) DR 2

Fine filter (fitted) DF 1: Duplex filter, mesh size see technical data.

Separator DS 1: Recommended for MGORequired for MDO

Capacity

V [l/h] = 0.22 · Peng. [kW]


m



Accessories and fittings:DF1 Fine filter (duplex filter) KP1 Fuel injection pumpDF2 Primary filter (duplex filter) KT1 Drip fuel tankDF3 Coarse filter FQ1 Flow quantity indicatorDH1 Preheater LI Level indicatorDH2 Electrical preheater (separator) LSH Level switch highDP1 Diesel oil feed pump LSL Level switch lowDP3 Transfer pump (to day tank) PDI Diff. pressure indicatorDP5 Transfer pump (separator) PDSH Diff. pressure switch highDR2 Pressure regulating valve PI Pressure indicatorDS1 Separator PSL Pressure switch lowDT1 Day tank, min. 1 m above crankshaft level PT Pressure transmitterDT4 Storage tank TI Temperature indicator

TT Temperature transmitter (PT 100)Connecting points:C73 Fuel inlet C75 Connection, stand-by pumpC78 Fuel outlet C81 Drip fuelC81b Drip fuel (filter pan)

General notes:For location, dimensions and design(e. g. flexible connection) of the con-necting points see engine installa-tion drawing.DH1 not required with:- MGO < 7 cSt/40°- heated diesel oil day tank DT1

Notes:p Free outlet requireds Please refer to the measuring

point list regarding design of themonitoring devices

z For systems without stand-bypump connect C75 for filling-upof the engine system!

m


11. Fuel oil systemHeavy fuel operation

1)An

indi

catio

n of

the

appr

oxim

ate

equi

vale

nts

inki

nem

atic

vis

cosi

ty a

t 50

°C a

nd R

edw

. I s

ec.

100

°F is

giv

en b

elow

:

Kine

mat

ic v

isco

sity

at

100

°C m

m2 /s

(cSt

)Ki

nem

atic

vis

cosi

ty a

t 5

0 °C

mm

2 /s (c

St)

Kine

mat

ic v

isco

sity

at

100

°F R

edw

. I s

ec.

Fuel

sha

ll be

free

of u

sed

lubr

icat

ing

oil (

ulo)

2)IS

O: 9

753)

ISO:

981

4)IS

O: 9

855)

ISO:

not

lim

ited

6)IS

O: C

arbo

n Re

sidu

e 10

7)IS

O: 0

.20

7

10

15

2

5

35

4

5

55

30

40

80

180

380

500

700

200

300

600

1500

3000

5000

7000

Requ

irem

ents

for r

esid

ual f

uels

for d

iese

l eng

ines

(as

bunk

ered

)

De

sign

atio

n:

CIM

AC

A 10

CI

MAC

B

10

CIM

AC

C 10

CI

MAC

D

15

CIM

AC

E 25

CI

MAC

F

25

CIM

AC

G 35

CI

MAC

H

35

CIM

AC

K 35

CI

MAC

H

45

CIM

AC

K 45

CI

MAC

H

55

CIM

AC

K 55

Re

late

d to

ISO8

217

(200

5):F

- RM

A30

RMB3

0 RM

B30

RMD8

0 RM

E180

RM

F180

RM

G380

RM

H380

RM

K380

RM

H500

RM

K500

RM

H700

RM

K700

Char

acte

ristic

Di

m.

Lim

it

Dens

ity a

t 15

°C

kg/m

3m

ax95

02)

97

5 3)

98

0 4)

991

99

1 10

10

991

1010

99

1 10

10

m

ax

10

15

25

35

45

55

Kin.

vis

cosi

ty a

t 100

°C

cSt1

)m

in6

5)15

5)

Flas

h po

int

°C

min

60

60

60

60

60

60

Pour

poi

nt

(win

ter)

(sum

mer

) °C

max

0 624

30

30

30

30

30

Carb

on R

esid

ue

(Con

rads

on)

% (m

/m)

max

12

6)

14

14

15

20

18

22

22

22

Ash

% (m

/m)

max

0.

10

0.10

0.

10

0.15

0.

15

0.15

7)

0.15

7)

0.15

7)

Tota

l sed

im, a

fter a

gein

g %

(m/m

) m

ax

0.10

0.

10

0.10

0.

10

0.10

0.

10

Wat

er

% (V

/V

max

0.

5 0.

5 0.

5 0.

5 0.

5 0.

5

Sulp

hur

% (m

/m)

max

3.

5 4.

0 4.

5 4.

5 4.

5 4.

5

Vana

dium

m

g/kg

m

ax

150

30

0 35

0 20

0 50

0 30

0 60

0 60

0 60

0

Alum

iniu

m +

Sili

con

mg/

kg

max

80

80

80

80

80

80

Zinc

m

g/kg

m

ax

15

15

15

15

15

15

Phos

phor

m

g/kg

m

ax

15

15

15

15

15

15

Calc

ium

m

g/kg

m

ax

30

30

30

30

30

30

m



Visc

osity

/tem

pera

ture

dia

gram

m



Minimum requirements for storage, treatment and supply systems

Bunker tanks: In order to avoid severe operational problems due to incom-patibility, each bunkering must be made in a separate stor-age tank.

Settling tanks: In order to ensure a sufficient settling effect, the followingsettling tank designs are permissible:

- 2 settling tanks, each with a capacity sufficient for24 hours full load operation of all consumers

- 1 settling tank with a capacity sufficient for 36 hours fullload operation of all consumers and automatic filling

- Settling tank temperature 70 - 80 °C

Day tank: Two day tanks are required. The day tank capacity mustcover at least 4 hours/max. 24 hours full load operation of allconsumers. An overflow system into the settling tanks andsufficient insulation are required.

Guide values for temperatures

Fuel viscosity cSt/50 °C

Tank temperature [°C]

30 - 80 70 - 80

80 - 180 80 - 90

> 180 - 700 max. 98

Separators: Caterpillar Motoren recommends to install two self-clean-ing separators. Design parameters as per supplier recom-mendation. Separation temperature 98 °C! Maker and typeare to be advised to Caterpillar Motoren.

m


Pressure pumps HP 1/HP 2: Screw type pump with mechanical seal.Installation vertical or horizontal. Delivery head 5 bar.

Capacity

V [m3/h] = 0.4 .. Peng. [kW]

1000


Supply system (Separate components): A closed pressurized system between daytank and engineis required as well as the installation of an automatic back-flushing filter with a mesh size of 10 μm (absolute).

Strainer HF 2: Mesh size 0.32 mm

DN H1 H2 W D Output [kW] mm

< 5000 32 249 220 206 180

< 10000 40 330 300 250 210

< 20000 65 523 480 260 355

> 20000 80 690 700 370 430

m



Self cleaning filter HF 4: Mesh size 10 μm sphere passing mesh, make Boll & Kirch*,without by-pass filter.

* In case of Caterpillar Motoren supply.

= 8000 kW, Type 6.60, DN 50 > 8000 kW, Type 6.64, DN 100<

Dismantling of sieve300 mm

Dismantling of sieve600 mm

Pressure regulating valve HR 1: Controls the pressure at the engine inlet, approx. 4 bar.

Engine outputs

= 8000 kW > 8000 kW<

m


Final preheater HH 1/HH 2: Heating media:

- Electric current (max. surface power density 1.1 W/cm2)- Steam- Thermal oil

Temperature at engine inlet max 150 °C.

Viscosimeter HR 2: Controls the injection viscosity to 10 - 12 cSt.

Fine filter (fitted) HF 1: - Mesh size 34 μm- Without heating- Differential pressure indication and alarm contact fitted

V [m3/h] = 0.7 ...... Peng. [kW]

1000

Circulating pumps HP 3/HP 4: Design see pressure pumps.

Capacity


Mixing tank (without insulation) HT 2:

Vent

Inletfrompressurepump

Fromengine

Outletto engine

Engineoutput

Volume Dimensions [mm] Weight

[kW] [l] A D E [kg]

< 4000 50 950 323 750 70

< 10000 100 1700 323 1500 120

> 10000 200 1700 406 1500 175

m



Mixing receiver HT 4: Permits the individual change-over to gas oil/MDO. Re-duces the temperature variation during change over.Capacity: approx. 30 lDimensions: Ø approx. 320 mm

height approx. 665 mmwithout insulation

Diesel oil intermediate tank DT 2: Required for the individual change-over to gas oil/MDO.Capacity: approx. 49 lDimensions: see mixing receiver

Diesel oil feed pump DP 1: Capacity and delivery headsee heavy fuel oil circulating pump HP 3/HP 4

Fuel Cooler DH 3: Required for heat dissipation with MGO/MDO operation.

m



Notes:ff Flow verlocity in circuit system

< 0.5 m/sm Lead vent pipe beyond day tank

levelp Free outlet requireds Please refer to the measuring


tt Neither insulated nor heated pipeu From diesel oil separator or diesel

oil transfer pump

All heavy fuel pipes have to be insu-lated.---- heated pipe

Connecting points:C76 Inlet duplex filterC78 Fuel outletC81 Drip fuelC81b Drip fuel (filter pan)

Accessories and fittings:DH3 MGO/MDO coolerDP1 Diesel oil feed pumpDR2 Pressure regulating valveDT1 Diesel oil day tankDT2 Diesel oil intermediate tankHF1 Fine filter (duplex filter)HF2 Primary filterHF4 Self cleaning filterHH1 Heavy fuel final preheaterHH2 Stand-by final preheaterHH4 Heating coilHP1/HP2 Pressure pumpHP3/HP4 Circulating PumpHR1 Pressure regulating valveHR2 ViscometerHT1 Heavy fuel day tankHT2 Mixing tank

General notes:For location, dimensions and design (e. g. flexible connection) of the connectingpoints see engine installation drawing. Valve fittings with loose cone are not ac-cepted in the admission and return lines.

Tanks and separators integrated inthe main engine system

HT4 Mixing receiverKP1 Injection pumpFQI Flow quantity indicatorLI Level indicatorLSH Level switch highLSL Level switch lowPDI Diff. pressure indicatorPDSH Diff. pressure switch highPDSL Diff. pressure switch lowPI Pressure indicatorPSL Pressure switch lowPT Pressure transmitterTI Temperature indicatorVI Viscosity indicatorVSH Viscosity Control switch highVSL Viscosity Control switch low

- Peak pressuresmax. 16 bar

m



Heavy fuel oil supply- and booster standard module

(Pressurized System), up to IFO 700 for steam and thermaloil heating, up to IFO 180 for electr. heating

Technical specification of the main components:

1. Primary filter

1 pc. Duplex strainer 540 microns

2. Fuel pressure pumps, vertical installation

2 pcs. Screw pumps with mechanical seal

3. Pressure regulating system

1 pc. Pressure regulating valve

4. Self cleaning fine filter

1 pc. Automatic self cleaning fine filter 10 microns absolut (without by-pass filter)

5. Consumption measuring system

1 pc. Flowmeter with local totalizer

6. Mixing tank with accessories

1 pc. Pressure mixing tank approx. 49 lvolume up to 4,000 kWapprox. 99 lvolume from 4,001 - 20,000 kW

(with quick-closing valve)

7. Circulating pumps, vertical installation

2 pcs. Screw pumps with mechanical seal

8. Final preheater

2 pcs. Shell and tube heat exchangers each 100 % (saturated 7 bar or thermal oil 180 °C)each 100 % electrical

m


9. a) Heating medium control valve (steam/thermaloil)b) Control cabinet (electrical)

1 pc. control valve with built-on positioning drive 1 pc. control cabinet for electr. preheater

10. Viscosity control system

1 pc. automatic viscosity measure and control system VAF

Module controlled automatically with alarms and startersPressure pump starters with stand-by automaticCirculating pump starters with stand-by automaticPI-controller for viscosity controllingStarter for the viscosimeterAnalog output signal 4 - 20 mA for viscosity

AlarmsPressure pump stand-by startLow level in the mixing tankCirculating pump stand-by startSelf cleaning fine filter pollutionViscosity alarm high/lowThe alarms with potential free contacts

Alarm cabinet with alarms to engine control room and connection possibility for remote start/stop andindicating lamp of fuel pressure and circulating pumps

Performance and materials:The whole module is tubed and cabled up to the terminal strips in the electric switch boxes which areinstalled on the module. All necessary components like valves, pressure switches, thermometers,gauges etc. are included. The fuel oil pipes are equipped with trace heating (steam, thermaloil orelectrical) where necessary.The module will be tested hydrostatical and functional in the workshop without heating.


Steam Thermal oil

Electric Steam Thermal oil

Electric Steam Thermal oil

Steam Thermal oil

For power in kW up to (50/60 Hz) 4000/4800 4000/4800 8000/9600 8000/9600 12000/14400 20000/24000 Length in mm 2200 2700 3200 3500 3500 3500 Width in mm 1200 1200 1200 1200 1350 1500 Height in mm 2000 2000 2000 2000 2000 2000 Weight (approx.) in kg 2300 2400 2500 2700 3100 3600

m


12. Lubricating oil system

Lube oil quality

The viscosity class SAE 40 is required.

Wear and tear and thus the service life of the engine depend on the lube oil quality. Therefore highrequirements are made for lubricants:

Constant uniform distribution of the additives at all operating conditions. Perfect cleaning (detergenteffect) and dispersing power, prevention of deposits from the combustion process in the engine. Suffi-cient alkalinity in order to neutralize acid combustion residues. The TBN (total base number) must bebetween 30 and 40 KOH/g at HFO operation. For MDO operation the TBN is 12 - 20 depending on sulphurcontent.

I Approved in operationII Permitted for controlled use

When these lube oils are used, Caterpillar Motoren must be informed because at the moment there is insufficient experience availablefor MaK-engines. Otherwise the warranty is invalid.

1) Synthetic oil with a high viscosity index (SAE 15 W/40). Only permitted if the oil inlet temperatures can be decreased by 5 - 10 °C.

Manufacturer Diesel oil/Marine-diesel oil operation

I II HFO operation I II

AGIP DIESEL SIGMA S CLADIUM 120

X X

CLADIUM 300 S CLADIUM 400 S

XX

BP ENERGOL DS 3-154 VANELLUS C 3

XX

ENERGOL IC-HFX 304 ENERGOL IC-HFX 404

XX

CALTEX DELO 1000 MARINE DELO 2000 MARINE

XX

DELO 3000 MARINE DELO 3400 MARINE

XX

CASTROL MARINE MLC MXD 154 TLX PLUS 204

X

XX

TLX PLUS 304 TLX PLUS 404

XX

CEPSA KORAL 1540 X CHEVRON DELO 1000 MARINE OIL

DELO 2000 MARINE OIL XX

DELO 3000 MARINE OIL DELO 3400 MARINE OIL

XX

TOTAL LUBMARINE DISOLA M 4015 AURELIA 4030

XX

AURELIA XL 4030 AURELIA XT 4040

XX

ESSO EXXMAR 12 TP EXXMAR CM+ ESSOLUBE X 301

XXX

EXXMAR 30 TP EXXMAR 40 TP EXXMAR 30 TP PLUS EXXMAR 40 TP PLUS

X

XX

X

MOBIL MOBILGARD 412 MOBILGARD ADL MOBILGARD M 430 MOBILGARD 1-SHC 1)

XXX

X

MOBILGARD M 430 MOBILGARD M 440

XX

SHELL GADINIA GADINIA AL ARGINA S ARGINA T

XXXX

ARGINA T ARGINA X

XX

TEXACO TARO 16 XD TARO 12 XD TARO 20 DP

XXX

TARO 30 DP TARO 40 XL

XX

m



Lube oil quantities/- change intervals: Circulating quantity: approx. 0,9 l/kW output

The change intervals depend on:- the quantity- fuel quality- quality of lube oil treatment (filter, separator)- engine load

By continuous checks of lube oil samples (decisive arethe limit values as per "MaK Operating Media") an opti-mum condition can be reached.

Force pump (fitted) LP 1: Gear type pump

Suction strainer (fitted) LF 4

Selfcleaning filter (fitted) LF 2: Mesh size 30 μm passing mesh. Without by-pass filter.Without flushing oil treatment. Differential pressure in-dication and alarm contact fitted.

Cooler (separate) LH 1: Plate type (plates made of stainless steel)Option on request: fitted on genset

m



Dimensions [mm] Weight

DN D F G H [kg]

6 M 25 C 80 200 171 267 151 27

8/9 M 25 C 100 220 217 403 167 47

Temperature controller (separate) LR 1: P-controller with manual emergency adjustmentOption on request:fitted on genset (in combination with the cooler)

Prelubrication pump (fitted) LP 5: Delivery head 5 barContinuous lubrication is carried out with stopped genset.Starter to be supplied by the yard.

Circulating tank LT 1: Located in the base frame, equipped with low level switchand level control stick.

Hz Capacity [m3/h] Electr. motor [kW]

50 6.6 3.0 6 M 25 C

60 8.0 3.6

50 10.4 5.5 8/9 M 25 C

60 12.7 6.6

m



Crankcase ventilation: The location of the ventilation is on top of the engine blocknear to the turbocharger (see system connections C 91).

The vent pipe DN 80 must be equipped with a condensatetrap and drain. It has to be enlarged to DN 100 approx. 1 mafter the connection point and to be arranged separately foreach genset. Crankcase pressure max. 150 Pa (15 mm WC).

Treatment at MGO/MDO operation

The service life of the lube oil will be extended by by-passtreatment.

Centrifuge (Option) LS 2: For MGO/MDO operation onlyMinimum requirement

Separator LS 1: Design:- Separating temperature 85 - 95 °C- Quantity to be cleaned three times/day- Self cleaning type

Separation capacity

Veff [l/h] = 0.18 · Peng [kW]

For auxiliary gensets: Strongly recommended1 separator for max. 3 engines

For diesel-electric drive: Required1 separator for max. 3 engines with automatically switchover in intervalls of 1.5 hours. See treatment at heavy fueloperation.

m


12. Lubricating oil systemMGO/MDO operation

Accessories and fittings:LF2 Self cleaning filterLF4 Suction strainerLH1 CoolerLH2 PreheaterLP1 Force pumpLP5 Prelubrication pumpLP9 Transfer pump (separator)LR1 Temperature control valveLR2 Pressure regulating valveLS1 SeparatorLS2 CentrifugeLT1 Sump tank

General notes:For location, dimensions and de-sign (e. g. flexible connection) ofthe connecting points see engineinstallation drawing.

Notes:f Drain* Optionh Please refer to the measuring

point list regarding design ofthe monitoring devices

o See "crankcase ventilation in-stallation instructions"

p Free outlet required

Connecting points:C58 Force pump, delivery sideC59 Luboil inlet, luboil coolerC60 Separator connection, suction

side or drain or filling pipeC61 Separator connection, delivery

side or from by-pass filterC65 Luboil fillingC91 Crankcase ventilation to stackNC Normally closed

LI Level indicatorLSL Level switch lowPDI Diff. pressure indicatorPDSH Diff. pressure switch highPI Pressure indicatorPSL Pressure switch lowPSLL Pressure switch lowPT Pressure transmitterTI Temperature indicatorTSHH Temperature switch highTT Temperature transmitter (PT 100)

m


12. Lubricating oil systemTreatment at heavy fuel operation

Separator LS 1: Required with the following design:- Separating temperature 95 °C- Quantity to be cleaned five times/day- Self cleaning type

Separation capacity

Veff [l/h] = 0.29 . Peng. [Total kW]

For auxiliary gensets: 1 separator per genset recommended1 separator for maximum 3 gensets required

The following is to be observed: 1. The separator is switched over successively and auto-matically controlled in intervals of 1.5 hours to the re-spective sump tank of the diesel genset.

2. The change over valves are to be provided with mutualmechanical or electric interlocks in order to avoid faultsin switching over.

3. All diesel gensets (operation, stand-by, stopped) are tobe included in these change over intervals.

4. If a diesel genset is not available (servicing, maintenanceetc.), it must be taken out of the interval control. For this acontact of a higher ranking start/stop automatic (inte-grated in the power management system) must be pro-vided for the interval control.

5. The separator must always be running or restarted aftera failure/black-out.

Change over valves and the automatic switch over controlsystem have to be supplied by the yard.

For diesel-electric drive: 1 Separator per genset required

m


12. Lubricating oil systemHeavy fuel operation

Accessories and fittings:LF2 Self cleaning filterLF4 Suction strainerLH1 CoolerLH2 PreheaterLP1 Force pumpLP5 Prelubrication pumpLP9 Transfer pump (separator)LR1 Temperature control valveLR2 Pressure regulating valveLS1 SeparatorLT1 Sump tank

General notes:For location, dimensions and de-sign (e. g. flexible connection) ofthe connecting points see engineinstallation drawing.

Notes:f Drainh Please refer to the measuring

point list regarding design ofthe monitoring devices

o See "crankcase ventilation in-stallation instructions"

p Free outlet required

Connecting points:C58 Force pump, delivery sideC59 Luboil inlet, luboil coolerC60 Separator connection, suction

side or drain or filling pipeC61 Separator connection, delivery

side or from by-pass filterC65 Luboil fillingC91 Crankcase ventilation to stackNC Normally closed

LI Level indicatorLSL Level switch lowPDI Diff. pressure indicatorPDSH Diff. pressure switch highPI Pressure indicatorPSL Pressure switch lowPSLL Pressure switch lowPT Pressure transmitterTI Temperature indicatorTSHH Temperature switch highTT Temperature transmitter (PT 100)

m


13. Cooling water system

The heat generated by the engine (cylinder, turbocharger, charge air and lube oil) is to be eliminated bymeans of treated freshwater acc. to the MaK coolant regulations.

The inlet temperature in the LT-circuit is max. 38 °C.

Two-circuit cooling: with two-stage charge air cooler.

HT-cooling water pump (fitted) FP 1

HT-temperature controller (fitted) FR 1: P-controller with manual emergency adjustment.

LT-temperature controller (separate) FR 2: P-controller with manual emergency adjustment(basis). Option: PI-controller with electric drive.Not required with the combination of the main en-gine LT-system.

* Minimum, depending on total cooling water flow

Dimensions [mm] Weight

DN D F G H [kg]

6/8/9 M 25 C HT 80 200 171 267 151 27

3 x 6 M 25 C LT 125* 250 241 489 200 67

3 x 8/9 M 25 C LT 150* 285 254 489 200 80

m


ρ · H · VP = [kW]

367 · η

.

P - Power [kW]PM - Power of electr. motor [kW]V - Flow rate [m3/h]H - Delivery head [m]ρ - Density [kg/dm3]η - Pump efficiency

0.70 for centrifugal pumps

< 1.5 kW1.5 - 4 kW4 - 7.5 kW

> 7.5 - 40 kW> 40 kW

PM = 1.5 · PPM = 1.25 · PPM = 1.2 · PPM = 1.15 · PPM = 1.1 · P

.

Preheater with pump Consisting of circulating pump (5 m3/h), electric heater(fitted on base frame) FH 5/FP 7: FH 5/FP 7: FH 5/FP 7: FH 5/FP 7: FH 5/FP 7: (18 kW) and switch cabinet (separate: W x H x D = 450 x

300 x 150 mm). Voltage 380 - 460, frequency 50/60 Hz.

HT-cooler (separate) FH 1: Plate type (plates made of titanium), size depending on thetotal heat to be dissipated.

For auxiliary genset normally integrated in the main enginecooling system.

LT-cooler (separate) FH 2: Plate type (plates made of titanium), size depending on thetotal heat to be dissipated.

For auxiliary genset normally integrated in the main enginecooling system.

Header tank FT 1/FT 2: For auxiliary genset normally integrated in the main enginesystem.

- Arrangement: min. 4 m above crankshaft centre line.- Size acc. to technical engine data, in case of several en-

gines + 25 % volume per engine.- All continuous vents from engine are to be connected.

Drain tank with filling pump: Is recommended to collect the treated water when carryingout maintenance work (to be installed by the yard).

Electric motor driven pumps: Option for fresh and seawater , vertical design.Rough calculation of power demand for the electric bal-ance.


m



Heat balance 6 M 25 C

m




m


13. Cooling water systemIntegrated in the main engine LT-cooling water system

XH1 Generator coolerLI Level indicatorLSL Level switch lowPI Pressure indicatorPT Pressure transmitterTI Temperature indicatorTSHH Temperature switch highTT Temperature transmitter (PT 100)

General notes:For location, dimensions and design(e. g. flexible connection) of the con-necting points see engine installa-tion drawing.

Notes:h Please refer to the measuring


Connecting points:C12 Generator cooler, inletC13 Generator cooler, outletC14 Charge air cooler LT, inletC15 Charge air cooler LT, outletC17 Charge air cooler HT, outletC21 Freshwater pump HT, inletC37 Vent

Accessories and fittings:CH1 Charge air cooler HTCH2 Charge air cooler LTDH3 Fuel oil cooler from MDO operationFH5 Freshwater preheaterFP1 Freshwater pump (fitted on engine) HTFP7 Preheating pumpFR1 Temperature control valve HTLH1 Luboil cooler

to central coolingsystem LT

from central coolingsystem LT

m


13. Cooling water systemHT- and LT circuit

LH1 Luboil coolerSF1 Seawater filterSP1 Seawater pumpSP2 Seawater stand-by pumpST1 Sea chestXH1 Generator coolerLI Level indicatorLSL Level switch lowPI Pressure indicatorPSLL Pressure switch lowPT Pressure transmitterTI Temperature indicatorTSHH Temperature switch highTT Temperature transmitter (PT 100)

General notes:For location, dimensionsand design (e. g. flexibleconnection) of the connect-ing points see engine instal-lation drawing.With skin cooler not re-quired:- Seawater system (SP1,

SP2, SF1, ST1)Measurement 2103 only forDE-drive

Accessories and fittings:CH1 Charge air cooler HTCH2 Charge air cooler LTDH3 Fuel oil cooler from MDO operationFH1 Freshwater cooler HTFH2 Freshwater cooler LTFH5 Freshwater preheaterFP1 Freshwater pump (fitted on engine) HTFP4 Freshwater pump (separate) LTFP6 Freshwater stand-by pump LTFP7 Preheating pumpFR1 Temperature control valve HTFR2 Temperature control valve LTFR6 Sensor for temperatur control valveFT1 Compensation tank HTFT2 Compensation tank LT

Notes:h Please refer to the measuring


Connecting points:C12 Generator cooler, inletC13 Generator cooler, outletC14 Charge air cooler LT, inletC15 Charge air cooler LT, outletC17 Charge air cooler HT, outletC21 Freshwater pump HT, inletC37 Vent

m


14. Flow velocities in pipes

Example: di = 100 mm, V = 60 m3/hVelocity in the pipe 2.1 m/s

m


15. Starting air system

Required pressure 30 bar

Min. starting air pressure and air consumption see technical data.

General notes:For location, dimensions and design (e. g. flexible connection) ofthe connecting points see engine installation drawing.

Clean and dry starting air is required.

Notes:a Control aird Water drain (to be mounted at the lowest point)e To other gensetsh Please refer to the measuring point list regarding design of

the monitoring devices* Automatic drain required

Connecting points:C86 Connection, starting air

Accessories and fittings:AC1 CompressorAC2 Stand-by compressorAR1 Starting valveAR4 Pressure reducing valveAR5 Oil and water separatorAT1 Starting air receiverAT2 Starting air receiverPI Pressure indicatorPSL Pressure switch low, only for main enginePT Pressure transmitter

AT1/AT2 Option:- Typhon valve- Relief valve with pipe connection

m


16. Combustion air system

General: To obtain good working conditions in the engine room and toensure trouble free operation of all equipment attentionshall be paid to the engine room ventilation and the supply ofcombustion air.

The combustion air required and the heat radiation of allconsumers/heat producers must be taken into account.

Air intake from engine room (standard): - Fans are to be designed for a slight overpressure in theengine room.

- On system side the penetration of water, sand, dust, andexhaust gas must be avoided.

- When operating under tropical conditions the air flowmust be conveyed directly to the turbocharger.

- The temperature at turbocharger filter should not fall be-low + 10 °C.

- In cold areas warming up of the air in the engine roommust be ensured.

Air intake from outside: - The intake air duct is to be provided with a filter. Penetra-tion of water, sand, dust and exhaust gas must beavoided.

- Connection to the turbocharger is to be established via anexpansion joint (to be supplied by the yard). For this pur-pose the turbocharger will be equipped with a connectionsocket.

- At temperatures below + 10 °C the Caterpillar Motoren/Application Engineering must be consulted.

- The max pressure loss (incl. silencer and exhaust gasboiler) of 30 mbar is applicable as value for the total flowresistance of plants with separate intake air filter!

Radiated heat: see technical dataTo dissipate the radiated heat a slight and evenly distributedair current is to be led along the engine exhaust gas mani-fold starting from the turbocharger.

m


17. Exhaust system

Position of exhaust gas nozzle: A nozzle position of 0, 30, 45, 60 and 90° is possible.The exhaust outlet of the turbocharger has a fixed positionof 45°.Transition pieces for outlets of 0, 30, 60 and 90° areavailable.

Exhaust compensator:

Design of the pipe cross-section: The pressure loss is to be minimized in order to optimize fuelconsumption and thermal load of the engine.

Max. flow velocity: 40 m/s (guide value).

Max pressure loss (incl. silencer and exhaust gas boiler):30 mbar(lower values will reduce thermal load of the engine).

The aforesaid value is also applicable as value for the totalflow resistance of plants with separate intake air filter!

Notes regarding installation: - Arrangement of the first expansion joint directly on theexhaust gas nozzle

- Arrangement of the first fixed point in the conduit directlyafter the expansion joint

- Drain opening to be provided (protection of turbochargerand engine against water)

- Each engine requires an exhaust gas pipe (one commonpipe for several engines is not permissible).

If it should be impossible to use the standard transitionpiece supplied by Caterpillar Motoren, the weight of thetransition piece manufactured by the shipyard must not ex-ceed the weight of the standard transition piece. A drawingincluding the weight will then have to be submitted ap-proval.

Diameter DN Length [mm] Weight [kg]

6 M 25 C 500 360 42

8/9 M 25 C 600 450 76

m


17. Exhaust system

t = Exhaust gas temperature (°C)G = Exhaust gas massflow (kg/h)Δp = Resistance/m pipe length (mm WC/m)d = Inner pipe diameter (mm)w = Gas velocity (m/s)l = Straight pipe length (m)L' = Spare pipe length of 90° bent pipe (m)L = Effective substitute pipe length (m)ΔPg = Total resistance (mm WC)

Example (based on diagram data A to E):t = 335 °C, G = 25000 kg/hl = 15 m straight pipelength, d = 700 mm3 off 90° bend R/d = 1.51 off 45° bend R/d = 1.5ΔPg = ?

Δp = 0.83 mm WC/mL' = 3 · 11 m + 5.5 mL = l + L' = 15 m + 38.5 m = 53.5 mΔPg = Δp · L = 0.83 mm WC/m · 53.5 m = 44.4 mm WC

Resistance in exhaust gas piping

m


17. Exhaust system

0.031 0.063 0.125 0.25 0.5 1 2 4 8 f [kHz]

160

150

140

130

120

110

100

140 140 139135

133 132 131126

123

0.031 0.063 0.125 0.25 0.5 1 2 4 8 f [kHz]

160

150

140

130

120

110

100

140 139 139134

133 132 130125

122

Exhaust sound power level Lw not attenuated [1 x 1 m from open pipe]The noise measurements are made with a probe inside the exhaust pipe.

Tolerance + 2 dB

LwOct [dB](reference 10-12 W)



6 M 25 C (1900 kW/720 min-1, 1980 kW/750 rpm)

9 M 25 C (2850 kW/720 min-1, 2970 kW/750 rpm)

8 M 25 C (2540 kW/720 min-1, 2640 kW/750 rpm)

0.031 0.063 0.125 0.25 0.5 1 2 4 8 f [kHz]

160

150

140

130

120

110

100

139137 138

132 132 130 129

122 119

m


17. Exhaust system

Silencer: Design according to the absorbtion principle with wide-band attenuation over a great frequency range and lowpressure loss due to straight direction of flow. Sound ab-sorbing filling consisting of resistant mineral wool.

Sound level reduction 25 dB(A), alternatively 35 dB(A).Max. permissible flow velocity 40 m/s.

Silencer with spark arrester: Soot separation by means of a swirl device (particles arespun towards the outside and separated in the collectingchamber). Sound level reduction 25 dB(A) or 35 dB(A). Max.permissible flow velocity 40 m/s.

Silencers are to be insulated by the yard. Foundation brack-ets are provided as an option.

m


17. Exhaust system

Silencer/Spark arrestor and silencer: Installation: vertical/horizontalFlange according to DIN 86044Counterflanges, screws and gaskets are included, withoutsupports and insulation

Silencer

Spark arrestor and silencer

Attenuation 25 dB (A) 35 dB (A)

DN D B L kg L kg

6 M 25 C 500 950 588 3185 710 3940 750

8/9 M 25 C 600 1100 659 3760 1100 4760 1300

Exhaust gas boiler: Each engine should have a separate exhaust gas boiler. Al-ternatively, a common boiler with separate gas sections foreach engine is acceptable.

Particularly when exhaust gas boilers are installed attentionmust be paid not to exceed the maximum recommendedback pressure.

m


17. Exhaust system

Cleaning the turbocharger compressor: The components for cleaning (dosing vessel, pipes, shut-offvalve) are engine mounted.

Water is fed before compressor wheel via injection pipesduring full load operation every 24 to 48 hours.

Cleaning the turbine blade andnozzle ring: At heavy fuel operation only.

The cleaning is carried out with clean fresh water "wetcleaning" during low load operation at regular intervals, de-pending on the fuel quality, 250 to 500 hours.

Duration of the cleaning period is approx. 20 minutes. Freshwater of 1.5 bar is required.

During cleaning the water drain should be checked. There-fore the shipyard has to install a funnel after connectionpoint C36.

Water flow[l/min]

Injection time[min]

6 - 18 15 - 20

C36 Drain, DN 25

C42 Fresh water supply,DN 16,with quick coupling device

Dirty water tank

m


18. Air borne sound power level

The airborne noise of the engines is measured as a sound power level according to EN ISO 9614-2/Accuracy class 3.

Tolerance + 2 dB




6 M 25C (1900 kW/720 rpm, 1980 kW/750 rpm)

9 M 25 C (2850 kW/720 rpm, 2970 kW/750 rpm)

8 M 25 C (2540 kW/720 rpm, 2640 kW/750 rpm)

111

105108

111112

117

111

95

100

105

110

115

120

125

0.063 0.125 0.25 0.5 1 2 4 [kHz]

115 110112

113113

117

116

95

100

105

110

115

120

125

0.063 0.125 0.25 0.5 1 2 4 [kHz]

116 111113

114

113

118120

95

100

105

110

115

120

125

0.063 0.125 0.25 0.5 1 2 4 [kHz]

m


Gensets have to be resiliently mounted.

This provides an activ insulation against forces generated by the engine as well as protection againstvibration from rigidly mounted main engines.

The ship's foundation does not require machining. Unevenness is to be compensated by weldingplates and shims (to be provided by the shipyard).

Major components:- Bonded rubber rails for active insulation of dynamic engine forces- Flexible pipe connection for all media- Side stoppers, see foundation plan- Axial stoppers, see foundation plan- Shims and welding plates, see foundation plan

Details are shown on binding installation drawings. No. of major components:

19. FoundationResilient mounting

Bondedrubber rails*

Side stoppers

Axial stoppers

6 M 25 C 16 4 4

8 M 25 C 20 4 4

9 M 25 C 22 4 4

* Dimension [mm]L x W x H = 440 x 150 x 80Weight 16 kg

Structure borne sound level Lv, expected (measured in the test cell)

Lv Oct [dB](reference5*10-8 m/s)

46

707378

81858687

94

90

51

4647

51

60596664

20

30

40

50

60

70

80

90

100

110

0.031 0.063 0.125 0.25 0.5 1 2 4 8Frequency [kHz]

above

below

m


19. FoundationFoundation plan

1) To be supplied by the yard

The genset will sag approx. 3.5 mm once thejacks have been removed.Recommendations for erection/adjustment ac-cording to binding installation drawings.

m


20. Control and monitoring system

Engine control panel

m



Genset control

m



Engine monitoring

m



Monitoring: M 25 C aux. genset / DE-drive

SensorMeasur.-point

Monitoring point Abbrev. Action

Fitted Separate

Remarks

1105 Luboil pressure PAL OA A

1106 Luboil pressure PALL OAMS

B

1112 Luboil differential pressure selfcleaning filter

PDAH OA B

1142 Luboil pressure prelubrication PL B Starting interlock

1202 Luboil temperature engine inlet

TAH OA A

1251 Smoke concentration crankcase

QAH OA B above 2200 kW 1 device f. 1251+1253

1253 Smoke concentration crankcase

QAHOAMS

Babove 2200 kW 1 device f. 1251+1253

1311 Luboil level sump tank LAL OA B

2102 FW pressure high temp. circuit engine inlet

PAL OA A

2103 FW pressure high temp. circuit engine inlet

PALL OAMS

B For DE-drive only

2112 FW pressure low temp. circuit charge air cooler inlet

PAL OA A

2211 FW temp. high temp. circuit engine outlet

TAH OA A

2212 FW temp. high temp. circuit engine outlet

TAHH OAMS

B

2229 Fresh water temp. low temp. circuit

TI A

2321 Oil ingress in fresh water cooler outlet

QAH OA B1 Option For DE-drive only

5102 Fuel oil pressure engine inlet

PAL OA A

5105 Fuel oil pressure pressure pump

PAL OA B* Starting stand-by pump from pump control

5111 Fuel oil differential pressure before and after filter

PDAH OA B

5112 Fuel oil differential pressure before and after autom. filter

PDAH OA B*

5115 Fuel oil differential pressure circulating pump

PDAL OA B* Starting stand-by pump from pump control

* located in the fuel pressure system

m



SensorMeasur.-point


Fitted Separate

Remarks

5116 Fuel oil differential pressure before and after circulating pump

PDAL OA B*

5201 Fuel oil temperature engine inlet

TAL OA A 1 Sensor f. 5201+5202

5202 Fuel oil temperature engine inlet

TAH OA A 1 Sensor f. 5201+5202

5251 Fuel oil viscosity engine inlet

VAH OA A* 1 Sensor f. 5251, 5252 + (5253 DICARE if available)

5252 Fuel oil viscosity engine inlet

VAL OA A* 1 Sensor f. 5251, 5252 + (5253 DICARE if available)

5301 Level of leak fuel LAH OA B

5333 Fuel level mixing tank LAL OA B*

6101 Starting air pressure engine inlet

PAL OA A

6105 Shut down air pressure on engine

PAL OA B

7201 Charge air temperature engine inlet

TAH OA A

7301 Water in charge air manifold QAH OA B

8211 8221

Exhaust gas temp. per cyl./ and after turbocharger

T OA A Only thermocouples Option for aux. genset

8221 Exhaust temperature after turbocharger

TAH OA A

8231 Exhaust temperature before turbocharger

TAHTAHH

OAMS

A Option for aux. genset

9404 Engine overspeed S OAMS

B

9405 Engine speed stop starting air

S B

9409 Working hour meter/engine S B

9419 Engine speed NI A

9503 Stop lever in pos. operation S B Genset ready for operation

9561 Barring gear engaged S B Start interlock

9601 Electronic units/terminal point X1/voltage failure

S OA B

9611 RPM switch/voltage failure/ wire break

S OA B


* located in the fuel pressure system

m



Abbreviations

B = Binary sensor OA = Visual and audible alarmA = Analogue sensor AD = Autom. speed/load reduction

MS = Autom. engine stopLAH = Level alarm high QA = Measurement alarmLAL = Level alarm low QAH = Measurement alarm highNI = Speed indication S = SpeedP = Pressure TAH = Temperature alarm highPAL = Pressure alarm low TAHH = Temperature alarm high highPALL = Pressure alarm low low TAL = Temperature alarm lowPDAH = Pressure difference alarm high VAH = Viscosity alarm highPDAL = Pressure difference alarm low VAL = Viscosity alarm low

Sensors for DICARE see item 21

SensorMeasur.-point


Fitted Separate

Remarks

9615 Failure electronic governor S OA B With electronic governor only

9616 Failure electronic governor S OAMS

B With electronic governor only

9622 Exhaust gas temp. average equipment, voltage failure

S OA B Option for aux. Genset

9631 Crankcase oil mist detector voltage, lens/lamp

QA OA B If provided

9751 Temperature controller voltage failure

OA B Dependent from system

9761 Viscosity control, voltage failure


9771 Freshwater preheater, voltage failure


9775 Fuel oil preheater, voltage failure



Option for DE-drive only: Modbus RTU connection to alarm system

m



Local and remote indicatorsRemote indication interfacing

* no

t Cat

erpi

llar M

otor

en s

uppl

y

mA

VΩ

mV

mA

V

Sens

or S

igna

ls fr

om th

een

gine

RPM

sw

itch

unit

Anal

og-m

onito

ring

equi

pmen

t *

Disp

lay

(mA)

Rem

ote

indi

cato

rop

tion

Turb

ocha

rger

spee

dop

tion

Rem

ote

indi

cato

ren

gine

spe

edop

tion

Mon

itor

*

Sign

al ty

pe4-

20 m

A

0 - 10 V

0 - 10 V

Indi

cato

rs

At t

he e

ngin

e Re

mot

e 96

x 9

6Fu

el te

mpe

ratu

re a

t eng

ine

inle

t ⊗

Diffe

rent

ial p

ress

ure

fuel

filte

r

Mea

n in

ject

ion

pum

p ra

ck p

ositi

on

⊗

Lubo

il te

mpe

ratu

re a

t eng

ine

inle

t

Diffe

rent

ial p

ress

ure

lubo

il fil

ter

Fr

eshw

ater

tem

pera

ture

at e

ngin

e in

let H

T

Fres

hwat

er te

mpe

ratu

re a

t eng

ine

outle

t HT

⊗

Fres

hwat

er te

mpe

ratu

re L

T ⊗

Fr

eshw

ater

tem

pera

ture

bef

ore

inte

rcoo

ler

Fr

eshw

ater

tem

pera

ture

afte

r int

erco

oler

Char

ge a

ir te

mpe

ratu

re b

efor

e in

terc

oole

r 3)

Char

ge a

ir te

mpe

ratu

re b

efor

e en

gine

⊗

Ex

haus

t gas

tem

pera

ture

afte

r cyl

inde

r 3)

Exha

ust g

as te

mpe

ratu

re b

efor

e/af

ter t

urbo

char

ger 3)

G

auge

boa

rd (f

itted

on

engi

ne)

Fuel

pre

ssur

e ⊗

Lubo

il pr

essu

re

⊗

Fres

hwat

er p

ress

ure

HT

⊗

Fres

hwat

er p

ress

ure

LT

⊗

Star

t air

pres

sure

⊗

Ch

arge

air

pres

sure

afte

r int

erco

oler

⊗

Sh

ut d

own

air p

ress

ure

En

gine

spe

ed

⊗1)

Char

ge a

ir te

mpe

ratu

re b

efor

e in

terc

oole

r 4)

Exha

ust g

as te

mpe

ratu

re a

fter c

ylin

der 4)

Exha

ust g

as te

mpe

ratu

re b

efor

e/af

ter t

urbo

char

ger 4)

⊗2)

1) A

ltern

ativ

ely

144

x 14

4 2) O

nly

288

x 14

4, n

ot w

ith D

ICAR

E ON

-LIN

E av

aila

ble

3) O

nly

if ex

haus

t gas

tem

pera

ture

mon

itorin

g is

not

prov

ided

4) O

nly

if ex

haus

t gas

tem

pera

ture

mon

itorin

g is

pr

ovid

ed

⊗ O

ptio

n

m



Protection system Operating voltage: 24 V DCType of protection: IP 55

Protection against false polarity and transient protection provided.

Designed for: 3 starting interlock inputs6 automatic stop inputs1 manual stop input

The input and output devices are monitored for wire break.

Rpm switch unit system Designed for:3 rpm switching pointsAnalogue outputs for speed:1 x 0-10 V, 1 x 4-20 mA, 1 x frequency

only Genset only DE

m


20. Control and monitoring systemProtection system

Rpm switch unit

m



Start/stop logic

m


21. Diagnostic system DICARE

DICARE is an efficient expert system which collects permanently the actual operating data of the en-gine, scales them to ISO condition, compares them with the nominal values and evaluates all detecteddeviations from these nominal values. Out of this comparison a printable diagnosis results which easecondition based maintenace considerably.

The sensor equipment of the engine laid out for the "on-line operation" with analogue transmitters viaa data converter feeds the PC with measured data on-line for evaluation and storing. Due to the auto-matically established history files trends can be made visible.

Benefits of DICARE:

• Early detection of wear.• Optimum operating condition due to clearly laid out display of deviating engines parameters.• Reduction of maintenance cost due to recognition of trends.• Longer service life of components due to display of comparison of actual vs. desired values.• Information about the engine condition by means of remote access possibilities.• Allows personnel and material planning by early, condition-based recognition of contamination or

wear.

Option: Installed in junction box

m


21. Diagnostic system DICARE

Transmitter for DICARE ON-LINE M 25 C

= Transmitter from engine monitoring

LocationL = SeparateM = EngineDS = RPM switch system

Designation Transmitter Signal Meas. point no. CM

Location

Fuel viscosity 4 - 20 mA 5253 L

Fuel temperature after viscomat PT 100 5206 L

Fuel temperature at engine inlet PT 100 5201 M

Injection pump rack position 4 - 20 mA 9509 DS

Lube oil pressure 4 - 20 mA 1105 M

Lube oil temperature at engine inlet PT 100 1202 M

Freshwater pressure HT 4 - 20 mA 2102 M

Freshwater temperature at engine inlet HT PT 100 2201 M

Freshwater temperature at engine outlet HT PT 100 2211 M

Differential pressure charge air cooler 4 - 20 mA 7307 M

Intake air pressure 4 - 20 mA 6181 M

Intake air temperature before turbocharger PT 100 7206 M

Charge air pressure after intercooler 4 - 20 mA 7109 M

Charge air temperature before intercooler NiCrNi mV 7309 M

Charge air temperature at engine inlet PT 100 7201 M

Exhaust gas temperature for each cylinder and after turbocharger

NiCrNi mV 8211/8221 M

Exhaust gas temperature before turbocharger NiCrNi mV 8231 M

Engine speed 4 - 20 mA 9419 DS

Turbocharger speed 4 - 20 mA 9429 M

Service hour counter (manual input) Counter binary 9409 DS

m


22. Diesel engine management system DIMOS

DIMOS is a computer aided maintenance and spare part management system for Caterpillar Motorendiesel engines. The DIMOS-system will include a data base which is filled with information derivedfrom the operating instructions and the spares catalogue of your respective engine type. This systemenables to administration and check the following four major subjects:1. Maintenance2. Material management3. Statistics4. Budget control.

These four major subjects are provided with many internal connections, so that no double inputs arerequired. All you need for running the DIMOS-system is commercial PC hardware.

The advantages are evident:• Precise follow-up regarding the maintenance intervals as specified by Caterpillar Motoren. No

scheduled date will be forgotten and no history file will be missed.• Immediate access to maintenance and component information.• Quick and simple modification of data is possible at any time.• Extensive and permanently up-to-date decision documents for maintenance with precise updating

of terms.• A lot of paper work can be omitted, and this means a considerable saving of time.• This can be taken from the DIMOS databank as well as from the CD-Rom and the standard docu-

mentation.From various single information to an integrated system

DIMOS

Engine operatinginstructions

Engine spare partscatalogues

Maintenanceschedule

Maintenancejob cards

Maintenanceplanning

Work ordercreation

History andstatistics

Inventory andpurchase

O U T P U T

I N P U TDIMOS

Engine operatinginstructions

Engine spare partscatalogues

Maintenanceschedule

Maintenancejob cards

Maintenanceplanning

Work ordercreation

History andstatistics

Inventory andpurchase

O U T P U T

I N P U T

m


23. Standard acceptance test run

In addition to that the following functional tests will be carried out:

- governor test- overspeed test- emergency shut-down via minimum oil pressure- start/stop via central engine control- starting trials up to a minimum air pressure of 10 bar- measurement of crank web deflection (cold/warm condition)

After the acceptance main running gear, camshaft drive and timing gear train will be inspectedthrough the opened covers. Individual inspection of special engine components such as piston orbearings is not intended, because such inspections are carried out by the classification societies atintervals on series engines.

Engine movement due to vibration referred to the global vibration characteristics of the engine:

The basis for assessing vibration severity are the guidelines ISO 10816-6.

According to these guidline the MaK engine will be assigned to vibration severity grade 28, class 5. Onthe engine block the following values will not be exceeded:

Displacement Seff < 0.448 mm f > 2 Hz < 10 HzVibration velocity Veff < 28.2 mm/s f > 10 Hz < 250 HzVibration acceleration aeff < 44.2 m/s2 f > 250 Hz < 1000 Hz

The acceptance test run of the complete genset is carried out on the testbed with customary equip-ment and auxiliaries using exclusively MDO and under the respective ambient conditions of thetestbed. During this test run the fuel rack will be blocked at the contractual output value. In case ofdeviations from the contractual ambient conditions the fuel consumption will be converted to standardreference conditions.

The engine will be run at the following load stages acc. to the rules of the classification societies. Afterreaching steady state condition of pressures and temperatures these will be recorded and registeredacc. to the form sheet of the acceptance test certificate:

Load [%] Duration [min] 25 30 50 30 85 30 100 60 110 30

- with puric ohmic load (cos ϕ = 1)- load application acc. to ISO 3046- without parallel operation

m


24. Engine International Air Pollution Prevention Certificate

The MARPOL Diplomatic Conference has agreed about a limitation of NOx emissions, referred to asAnnex VI to Marpol 73/78.

When testing the engine for NOx emissions, the reference fuel is Marine Diesel Oil (Distillate) and thetest is performed according to ISO 8178 test cycles:

D2: Auxiliary genset at 100 % speedE2: Diesel electric propulsion at 100 % speed

Subsequently, the NOx value has to be calculated using different weighting factors for different loadsthat have been corrected to ISO 8178 conditions.

An EIAPP (Engine International Air Pollution Prevention) certificate will be issued for each engineshowing that the engine complies with the regulation. At the time of writing, only an interim certificatecan be issued due to the regulation not yet in force.

According to the IMO regulations, a Technical File shall be made for each engine. This Technical Filecontains information about the components affecting NOx emissions, and each critical component ismarked with a special IMO number. Such critical components are injection nozzle, injection pump,camshaft, cylinder head, piston, connecting rod, charge air cooler and turbocharger. The allowablesetting values and parameters for running the engine are also specified in the Technical File.

The marked components can later, on-board the ship, be easily identified by the surveyor and thus anIAPP (International Air Pollution Prevention) certificate for the ship can be issued on basis of theEIAPP and the on-board inspection.

Output [%] 100 75 50 25 10

D2 weighting factor 0,20 0,50 0,15 0,15 -

E2 weighting factor 0,05 0,25 0,30 0,30 0,10

m


25. Painting/Preservation

Inside preservation

N 576-3.3Up to 1 year, engine protected from moisture.- Main running gear and internal mechanics

Outside preservation

N 576-3.1 - Tectyl lightEuropeStorage in the open, protected from moisture, up to 1 year

Appearance of the engine:- Castings with red oxide antirust paint- Pipes and machined surfaces left as bare metal- Attached components with colours of the makers

N 576-3.2 - Tectyl heavy-dutyOverseasStorage in the open, protected from moisture, up to 1 year

Appearance of the engine:- Castings with red oxide antirust paint- Pipes and machined surfaces left as bare metal- Attached components with colours of the makers

N 576-4.1 - Clear VarnishClear varnish painting is applicable within Europe for land transportation with protection frommoisture. It is furthermore applicable for storage in a dry and tempered atmosphere.

Clear varnish painting is not permissible for:- Sea transportation of engines- Storage of engines in the open, even if they are covered with tarpaulin

VCI packaging as per N 576-5.2 is always required!Durability and effectiveness are dependent on proper packing, transportation, and storage, i.e. theengine must be protected from moisture, the VCI foil must not be torn or destroyed.Checks are to be carried out at regular intervals.If the above requirements are not met, all warranty claims in connection with corrosion damages shallbe excluded.

m


25. Painting/Preservation

Appearance of the engine:- Castings with red oxide antirust paint- Pipes and machined surfaces left as bare metal- Attached components with colours of the makers- Surfaces sealed with clear varnish- Bare metal surfaces with light preservation

N 576-4.3 - Painting- No VCI packaging:

Short-term storage in the open, protected from moisture, max. 4 weeks- With VCI packaging:

Storage in the open, protected from moisture, up to 1 year

Appearance of the engine:- Surfaces mostly painted with varnish- Bare metal surfaces provided with light or heavy-duty preservation

N 576-5.2 - VCI packagingStorage in the open, protected from moisture, up to 1 year.Applies for engines with painting as per application groups N 576-4.1 to -4.4Does not apply for engines with Tectyl outside preservation as per application groups N 576-3.1 and -3.2.

Description:- Engine completely wrapped in VCI air cushion foil, with inserted VCI-impregnated flexible

PU-foam mats.

N 576-5.2 Suppl. 1 - Information panel for VCI preservation and inspectionApplies for all engines with VCI packaging as per application group N 576-5.2

Description:- This panel provides information on the kind of initial preservation and instructions for inspection.- Arranged on the transport frame on each side so as to be easily visible.

N 576-6.1 - Corrosion Protection Period, Check, and RepreservationApplies to all engines with inside and outside storage

Description:- Definitions of corrosion protection period, check, and represervation

m


26. Lifting of gensets

For the purpose of transport the genset is equipped with a lifting device which shall remain the prop-erty of Caterpillar Motoren. It has to be returned in a useable condition free of charge.

m


27. Engine parts

Cylinder head, Weight 240 kg

Connecting rod, Weight 79 kg Piston, Weight 46 kg

Cylinder liner, Weight 162 kg

© 2008 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos,„Caterpillar Yellow“ and the POWER EDGE trade dress, as well as corporate identityused herein, are trademarks of Caterpillar and may not be used without permission

Europe, Africa, Middle East

Caterpillar MarinePower SystemsNeumühlen 922763 Hamburg/Germany

Phone: +49 40 2380-3000Telefax: +49 40 2380-3535

Caterpillar Marine Asia Pacific Pte Ltd14 Tractor RoadSingapore 627973/SingaporePhone: +65 68287-600Telefax: +65 68287-624

Caterpillar Marine Trading(Shanghai) Co., Ltd.25/F, Caterpillar Marine Center1319, Yan’an West Road200050 Shanghai/P. R.ChinaPhone: +86 21 6226 2200Telefax: +86 21 6226 4500

Asia PacificHeadquarters

Caterpillar MarinePower SystemsNeumühlen 922763 Hamburg/Germany

Phone: +49 40 2380-3000Telefax: +49 40 2380-3535

For more information please visit our website:www.cat-marine.com or www.mak-global.com

Caterpillar Marine Power SystemsAmericas

MaK Americas Inc.

3450 Executive WayMiramar Park of CommerceMiramar, FL. 33025/USAPhone: +1 954 447 71 00Telefax: +1 954 447 71 15

Subject to change without notice.Leaflet No. 225 · 07.08 · e · L+S · VM3

project guide • generator set

Documents