M43CProject Guide • Propulsion

E x c e l l e n c e o n B o a rdE x c e l l e n c e o n B o a rd

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Introduction

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

Issue September 2005

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.

Major revisions of issue September 2005 are

- Technical data revised- Resilient mounting

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

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Page

1. Engine description 1 - 2 2. General data and outputs 3 - 4 3. Restrictions for low load operation 5 4. CP-propeller operation 6 - 7 5. Technical data 8 - 11 6. Engine dimensions 12 - 22 7. Required dismantling space for charge air cooler,

torsional vibration damper and turbocharger cartridge 23 8. Maintenance platform 24 9. System connections 2510. Fuel oil system 26 - 3711. Lubricating oil system 38 - 4212. Cooling water system 43 - 5013. Flow velocities in pipes 5114. Starting air system 52 - 5315. Combustion air system 5416. Exhaust system 55 - 6817. Air borne sound power level 6918. Foundation 70 - 7519. Resilient mounting 76 - 7720. Power transmission 78 - 7921. Data for torsional vibration calculation 8022. Control and monitoring system 81 - 9723. Diagnostic system DICARE 98 - 9924. Diesel engine management system DIMOS 10025. Standard acceptance test run 10126. EIAPP certificate 10227. Painting/Preservation 103 - 10428. Lifting of engines 10529. Engine parts 106

Contents

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1. Engine description

The M 43 C is a four stroke diesel engine, non-reversible, turbocharged and intercooled with direct fuelinjection.

In-line engine M 43 C

Cylinder configuration: 6, 7, 8, 9 in-lineBore: 430 mmStroke: 610 mmStroke/Bore-Ratio: 1.42Swept volume: 88.6 l/Cyl.Output/cyl.: 900 / 1,000 kWBMEP: 24.4/23.7 / 27.1/26.4 barRevolutions: 500/514 rpmMean piston speed: 10.2/10.5 m/sTurbocharging: single logDirection of rotation: clockwise, option: counter-clockwise

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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 bearings, cam-shaft bearings, 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 chromium-ce-ramic plated running surfaces and 1 chromium plated oil scraper ring. All ring grooves are hard-ened and located in the steel crown.

- 3-piece connecting rod with the possibility to dismount the piston without opening the big end bear-ing.

- 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 with engine lubricating oil.

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2. General data and outputs

Output definition

The maximum continuous rating (locked output) stated by Caterpillar Motoren refers to the followingreference conditions according to "IACS" (International Association of Classification Societies) formain and auxiliary engines:

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)

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 42,700 kJ/kgtolerance 5 %Specification of the fuel consumption data without fitted-on pumps; for each pump fitted on an addi-tional consumption of 1 % has to be calculated.

Lubricating oil consumption

Actual data can be taken from the technical data.

Engine kW

6 M 43 C 5,400 / 6,000

7 M 43 C 6,300 / 7,000

8 M 43 C 7,200 / 8,000

9 M 43 C 8,100 / 9,000

The maximum fuel rack position is mechani-cally limited to 100 % output for CPP applica-tions. Limitation of 110 % for gensets and DE ap-plications.

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4

Soot and emissions (NOx-values)

NOx-limit values according IMO-regulations: 12.98 g/kWh (n = 500 rpm)

Main engine: CP propeller, according to cycle E2: 11.78 g/kWh

In combination with Flex Cam Technology (FCT) (optional) the soot emission will be lower than0.3 FSN in the operation range between 10 and 100 % load.

Emergency operation without turbocharger

Emergency operation is permissible only with MDO and up to approx. 15 % of the MCR.

Rotor dismantled:Constant speed 500 rpm, Combinator operation 360 rpmRotor blocked: Constant speed 500 rpm, Combinator operation 350 rpm

General installation aspect:

Inclication angles of ships at which engine running must be possible:

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

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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

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4. CP propeller operation

The design area for the combinator has to be on the right-hand side of the theoretical propeller curveand may coincide with the theoretical propeller curve in the upper speed range.

A load above the output limit curve is to be avoided by the use of the load control device or overloadprotection device.

Binding data (depending on the type of vessel, rated output, speed and the turbocharging system) willbe established upon order processing.

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

50% 60% 70% 80% 90% 100% 110%

Engine speed [%]

En

gin

e o

utp

ut

[%]

Power Limit Curve for overload protection

Recommended combinator curve

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4. CP propeller operation

Loading conditions at operating temperature

0 45 50 60 300Time [s]

Engi

ne o

utpu

t [%

]

100

7570

50

25

0

Emergency loading

Loading with constant speed

Loading with combinatormin. speed = 70 % nominal speed

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5. Technical data 900 kW

Cylinder 6 7 8 9 Performance data Maximum continous rating acc. ISO 3046/1 kW 5,400 6,300 7,200 8,100 Speed 1/min 500/514 500/514 500/514 500/514 Minimum speed 1/min 165 165 165 165 Brake mean effektive pressure bar 24.4 24.4 24.4 24.4 Charge air pressure bar 3.1 3.1 3.1 3.1 Compression pressure bar 170 170 170 170 Firing pressure bar 190 190 190 190 Combustion air demand (ta = 20 °C) m3/h 33,500 38,900 44,800 50,500 Delivery/injection timing ° v. OT 6.5/- 6.5/- 6.5/- 6.5/- Exhaust gas temperature after cylinder/turbine

°C 355/271 370/295 350/280 375/290

Specific fuel oil consumption n = const 1) 100 % 500/514 1/min 85 % 500/514 1/min 75 % 50 %

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

176175178185

176175178185

176175178185

176175178185

Lubricating oil consumption 2) g/kWh 0.6 0.6 0.6 0.6 Turbocharger type TPL71C TPL71C TPL76C TPL76C Fuel Engine driven booster pump m3/h/bar -/- -/- -/- -/- Stand-by booster pump m3/h/bar 4/5 4.7/5 5.4/5 6.0/5 Mesh size MDO fine filter mm 0.025 0.025 0.025 0.025 Mesh size HFO automatic filter mm 0.010 0.010 0.010 0.010 Mesh size HFO fine filter mm 0.034 0.034 0.034 0.034 Nozzle cooling by lubricating oil system Lubricating Oil Engine driven pump m3/h/bar 146/10 146/10 203/10 203/10 Independent pump m3/h/bar 100/10 120/10 160/10 180/10 Working pressure on engine inlet bar 4 - 5 4 - 5 4 - 5 4 - 5 Engine driven suction pump m3/h/bar -/- -/- -/- -/- Independent suction pump m3/h/bar 175/3 175/3 240/3 240/3 Priming pump pressure m3/h/bar 16/5 16/5 20/5 20/5 Sump tank content m3 8.4 9.8 11.2 12.6 Temperature at engine inlet °C 60-65 60-65 60-65 60-65 Temperature controller NB mm 125 125 150 150 Double filter NB mm 150 150 150 150 Mesh size double filter mm 0.08 0.08 0.08 0.08 Mesh size automatic filter mm 0.034 0.034 0.034 0.034

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5. Technical data 900 kW

Cylinder 6 7 8 9 Fresh water cooling Engine content m3 0.6 0.7 0.8 0.9 Pressure at engine inlet min/max bar 2.5/6.0 2.5/6.0 2.5/6.0 2.5/6.0 Header tank capacity m3 0.6 0.6 0.6 0.6 Temperature at engine outlet °C 80 - 90 80 - 90 80 - 90 80-90 Two circuit system Engine driven pump HT m3/h/bar -/- -/- -/- -/- Independent pump HT m3/h/bar 100/4.7 110/4.6 120/4.6 130/4.5 HT-Controller NB mm 125 125 125 125 Water demand LT-charge air cooler m3/h 80 80 100 100 Temperature at LT-charge air cooler inlet °C 38 38 38 38 Heat Dissipation Lub. oil cooler kW 736 858 980 1103 Jacket water kW 750 875 1,000 1,125 Charge air cooler (HT-Stage) 3) kW 1,880 2,150 2,520 2,770 Charge air cooler (LT-Stage) 3) kW 440 520 620 700 (HT-Stage after engine) Heat radiation engine kW 256 297 333 389 Exhaust gas Silencer/spark arrester NB 35 dBA mm 900 900 1,000 1,000 Pipe diameter NB after turbine mm 900 900 1,000 1,000 Maximum exhaust gas pressure drop bar 0.03 0.03 0.03 0.03 Starting air Starting air pressure max. bar 30 30 30 30 Minimum starting air pressure bar 14 14 14 14 Air consumption per start 4) Nm3 2.4 2.4 3 3 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

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5. Technical data 1,000 kW

Cylinder 6 7 8 9 Performance data Maximum continous rating acc. ISO 3046/1 kW 6,000 7,000 8,000 9,000 Speed 1/min 500/514 500/514 500/514 500/514 Minimum speed 1/min 165 165 165 165 Brake mean effektive pressure bar 27.1 27.1 27.1 27.1 Charge air pressure bar 3.5 3.5 3.5 3.5 Compression pressure bar 190 190 190 190 Firing pressure bar 207 207 207 207 Combustion air demand (ta = 20 °C) m3/h 35,000 40,850 47,350 53,250 Delivery/injection timing ° v. OT 6.5/- 6.5/- 6.5/- 6.5/- Exhaust gas temperature after cylinder/turbine

°C 395/283 400/300 400/281 405/295

Specific fuel oil consumption n = const 1) 100 % 500/514 1/min 85 % 500/514 1/min 75 % 50 %

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

177/178 176/177

178185

177/178 176/177

178185

177/178 176/177

178185

177/178 176/177

178185

Lubricating oil consumption 2) g/kWh 0.6 0.6 0.6 0.6 Turbocharger type TPL71C TPL71C TPL76C TPL76C Fuel Engine driven booster pump m3/h/bar -/- -/- -/- -/- Stand-by booster pump m3/h/bar 4.2/5 4.9/5 5.6/5 6.3/5 Mesh size MDO fine filter mm 0.025 0.025 0.025 0.025 Mesh size HFO automatic filter mm 0.010 0.010 0.010 0.010 Mesh size HFO fine filter mm 0.034 0.034 0.034 0.034 Nozzle cooling by lubricating oil system Lubricating Oil Engine driven pump m3/h/bar 146/10 146/10 203/10 203/10 Independent pump m3/h/bar 100/10 120/10 160/10 180/10 Working pressure on engine inlet bar 4 - 5 4 - 5 4 - 5 4 - 5 Engine driven suction pump m3/h/bar -/- -/- -/- -/- Independent suction pump m3/h/bar 175/3 175/3 240/3 240/3 Priming pump pressure m3/h/bar 16/5 16/5 20/5 20/5 Sump tank content m3 8.2 9.5 10.9 12.2 Temperature at engine inlet °C 60-65 60-65 60-65 60-65 Temperature controller NB mm 125 125 150 150 Double filter NB mm 150 150 150 150 Mesh size double filter mm 0.08 0.08 0.08 0.08 Mesh size automatic filter mm 0.03 0.03 0.03 0.03

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5. Technical data 1,000 kW

Cylinder 6 7 8 9 Fresh water cooling Engine content m3 0.6 0.7 0.8 0.9 Pressure at engine inlet min/max bar 2.5/6.0 2.5/6.0 2.5/6.0 2.5/6.0 Header tank capacity m3 0.6 0.6 0.6 0.6 Temperature at engine outlet °C 80 - 90 80 - 90 80 - 90 80-90 Two circuit system Engine driven pump HT m3/h/bar 100/4.7 110/4.6 120/4.6 130/4.5 Independent pump HT m3/h/bar 100/3.0 110/3.0 120/3.0 130/3.0 HT-Controller NB mm 125 125 150 150 Water demand LT-charge air cooler m3/h 80 100 100 100 Temperature at LT-charge air cooler inlet °C 38 38 38 38 Heat Dissipation Lub. oil cooler kW 820 960 1,090 1,225 Jacket water kW 835 975 1,195 1,250 Charge air cooler (HT-Stage) 3) kW 2,210 2,545 2,910 3,280 Charge air cooler (LT-Stage) 3) kW 500 580 685 790 (HT-Stage after engine) Heat radiation engine kW 260 300 330 390 Exhaust gas Silencer/spark arrester NB 35 dBA mm 900 900 1,000 1,000 Pipe diameter NB after turbine mm 900 900 1,000 1,000 Maximum exhaust gas pressure drop bar 0.03 0.03 0.03 0.03 Starting air Starting air pressure max. bar 30 30 30 30 Minimum starting air pressure bar 14 14 14 14 Air consumption per start 4) Nm3 2.4 2.4 3 3 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

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6. Engine dimensions

Removal of:

Piston in transverse direction X1 = 3,530 mmin longitudinal direction X2 = 3,975 mm

Cylinder Liner in transverse direction Y1 = 4,165 mmin longitudinal direction Y2 = 4,610 mmin transverse dir. reduced Y1 red = 3,705 mm

Engine centre distance 3,400 mm(2 engines side by side)

Turbocharger at driving end

A E

6 M 43 C 3,650 8,251

7 M 43 C 4,380 8,981

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6. Engine dimensions

Turbocharger at driving end

A E

8 M 43 C 5,110 9,798

9 M 43 C 5,840 10,528

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6. Engine dimensions

Turbocharger at free end

Engine centre distance 3,400 mm(2 engines side by side)

A E

6 M 43 C 3,650 7,905

7 M 43 C 4,380 8,635

A E

8 M 43 C 5,110 9,452

9 M 43 C 5,840 10,182

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6. Engine dimensions

6 M 43 C, Turbocharger at driving end

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6. Engine dimensions

7 M 43 C, Turbocharger at driving end

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17

6. Engine dimensions

8 M 43 C, Turbocharger at driving end

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18

6. Engine dimensions

9 M 43 C, Turbocharger at driving end

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19

6. Engine dimensions

6 M 43 C, Turbocharger at free end

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20

6. Engine dimensions

7 M 43 C, Turbocharger at free end

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21

6. Engine dimensions

8 M 43 C, Turbocharger at free end

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6. Engine dimensions

9 M 43 C, Turbocharger at free end

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7. Required dismantling space for charge air cooler, torsionalvibration damper and turbocharger cartridge

Charge air cooler

Cleaning is carried out with charge air coolerdismantled. A container to receive the coolerand cleaning liquid is to be supplied by the yard.Intensive cleaning is achieved by using ultrasonic vibrators.

Turbocharger dismantling

Removal of cartridge after removal of air silencefilter and compressor delivery casing.

* splitted charge air cooler

Engine type Charge air cooler Weight [kg]

Removal of turbocharger cartridge Weight [kg]

6/7 M 43 C 1,138 460

8/9 M 43 C 1,124 820

Engine type Damper Ø Weight

kW mm kg X mm

900 1,100 960 2,010 6 M 43 C

1,000 1,100 960 2,010

900 1,340 1,538 2,250 7 M 43 C

1,000 1,340 1,538 2,250

900 1,340 1,538 2,250 8 M 43 C

1,000 1,480 2,527 2,390

900 1,340 1,608 2,250 9 M 43 C

1,000 1,480 2,527 2,390

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8. Maintenance platform

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

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9. System connections

C25

C86

C59C58C51C53C76C78

C14 Charge Air Cooler Cooling Water LT, Inlet C58 Luboil Force Pump, Delivery SideC15 Charge Air Cooler Cooling Water LT, Outlet C59 Luboil Inlet, Duplex FilterC16 Charge Air Cooler HT, Inlet C76 Duplex Filter, Fuel InletC25 Cooling Water HT, Outlet C78 Fuel, OutletC51 Luboil Force Pump, Suction Side C86 Connection Starting AirC53 Luboil Discharge C91 Crankcase Ventilation

C91

C14 C15 C16

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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.

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

Max. injection viscosity 12 cSt (2 °E)

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

Intermediate tank (separate) DT 2: Capacity 100 l

Preheater (separate) DH 1: Heating capacity

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

Q [kW] =Peng. [kW]

166

10. Fuel oil systemMGO / MDO operation

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27

Feed pump (separate) DP 1/DP 2: Capacity see technical dataScrew type pump with mechanical seal.Installation vertical or horizontal.Delivery head 5 bar.

Pressure regulating valve (separate) DR 2: Dimensions see HFO-system/Pressure regulatingvalve.

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].

10. Fuel oil systemMGO / MDO operation

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10. Fuel oil systemMGO / MDO operation

General notes:For location, dimensions and design (e. g. flexible connection) of the disconnecting points see engine installation drawing.DH1 not required with: - Gas oil < 7 cSt/40°

- heated diesel oil day tank DT1

Accessories and fittings:DF1 Fuel fine filter (duplex filter) KD2 Pressure peak damperDF2 Fuel primary filter (duplex filter) KP1 Fuel injection pumpDF3 Fuel coarse filter KT1 Drip fuel tankDH1 Diesel oil preheater FQI Flow quantity indicatorDH2 Electrical preheater for diesel oil (separator) LI Level indicatorDP1 Diesel oil feed pump LSH Level switch highDP2 Diesel oil stand-by feed pump LSL Level switch lowDP3 Diesel oil transfer pump (to day tank) PDI Diff. pressure indicatorDP5 Diesel oil transfer pump (separator) PDSH Diff. pressure switch highDR2 Fuel pressure regulating valve PI Pressure indicatorDS1 Diesel oil separator PSL Pressure switch lowDT1 Diesel oil day tank PT Pressure transmitterDT4 Diesel oil storage tank TI Temperature indicator

TT Temperature transmitter (PT 100)Connecting points:C76 Inlet duplex filter C80b Drip fuel connection (cut off pump)C78 Fuel outlet C81 Drip fuel connectionC80 Drip fuel connection C81b Drip fuel connectionC80a Drip fuel connection (injection pump)

Notes:p Free outlet requireds Please refer to the measuring

point list regarding design of themonitoring devices

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Desi

gnat

ion:

CIM

ACCI

MAC

CIM

ACCI

MAC

CIM

ACCI

MAC

CIM

ACCI

MAC

CIM

ACCI

MAC

CIM

ACCI

MAC

CIM

ACA

10B

10C

10D

15E

25F

25G

35H

35K

35H

45K

45H

55K

55

Rela

ted

to IS

O821

7 (9

6):F

-RM

A10

RMB1

0RM

C10

RMD1

5RM

E25

RMF2

5RM

G35

RMH3

5RM

K35

RMH4

5RM

K45

RMH5

5RM

K55

Char

acte

ristic

Dim

.Li

mit

Dens

ity a

t 15

°Ckg

/m3

max

950

2)97

53)

98

0 4)

991

99

1

10

1099

110

1099

110

10

max

1015

25

3545

55

Kin.

vis

cosi

ty a

t 100

°CcS

t 1)m

in6

5)15

5)

Flas

h po

int

°Cm

in60

6060

6060

60

0Po

ur p

oint

(win

ter)

(s

umm

er)

°Cm

ax6

2430

30

30

30

30

Carb

on R

esid

ue(C

onra

dson

)%

(m/m

)m

ax12

6)

14

1415

2018

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

ax0.

100.

100.

10

0.

100.

10

0.

10

Wat

er%

(V/V

max

0.5

0.8

1.0

1.0

1.0

1.0

Sulp

hur

% (m

/m)

max

3.5

4.0

5.0

5.0

5.0

5.0

Vana

dium

mg/

kgm

ax15

0

30

035

020

050

030

060

0

60

0

60

0

Alum

iniu

m +

Sili

con

mg/

kgm

ax80

8080

8080

80

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.

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

)10. Fuel oil system

Heavy fuel operation

m

30

Visc

osity

/tem

pera

ture

dia

gram

10. Fuel oil systemHeavy fuel operation

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31

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. Separating temperature 98 °C! Maker and typeare to be advised to Caterpillar Motoren.

10. Fuel oil systemHeavy fuel operation

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32

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

Capacity

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

1,000

10. Fuel oil systemHeavy fuel operation

DN H1 H2 W D Output[kW] mm

< 10,000 40 330 300 250 210

< 20,000 65 523 480 260 355

> 20,000 80 690 700 370 430

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

m

33

Self cleaning filter HF 4: Mesh size 10 µm (absolute), make Boll & Kirch*, without by-pass filter.

* In case of Caterpillar Motoren supply.

= 8,000 kW, Type 6.60, DN 50 > 8,000 kW, Type 6.61, DN 100<

10. Fuel oil systemHeavy fuel operation

Dismantling of sieve300 mm

Dismantling of sieve300 mm

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

Engine outputs

= 8,000 kW > 8,000 kW<

m

34

Design head: 5 bar

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]

1,000

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

Capacity

10. Fuel oil systemHeavy fuel operation

Mixing tank (without insulation) HT 2:

Vent

Inletfrompressurepump

Fromengine

Outletto engine

Engine output Volume Dimensions [mm] Weight

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

< 10,000 100 1,700 323 1,500 120

> 10,000 200 1,700 406 1,500 175

m

35

10. Fuel oil systemHeavy fuel operation

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 320 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 l volume up to 4,000 kWapprox. 99 l volume 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

36

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 cloggedViscosity 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.

10. Fuel oil systemHeavy fuel operation

Steam Thermal oil

Electric Steam Thermal oil

Steam Thermal oil

Thermal oil

For power in kW up to (50/60 Hz) 8,000/9,600 8,000/9,600 12,000/14,400 20,000/24,000 30,000/36,000 Length in mm 3,200 3,500 3,500 3,500 6,000 Width in mm 1,200 1,200 1,350 1,500 1,700 Height in mm 2,000 2,000 2,000 2,000 2,000 Weight (approx.) in kg 2,500 2,700 3,100 3,600 4,600

m

37

10. Fuel oil systemHeavy fuel operation

Notes:ff Flow verlocity in circuit system

< 0.5 m/sp Free outlet requireds Please refer to the measuring point

list regarding design of the monitor-ing devices

u From diesel oil separator or dieseloil transfer pump

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

Connecting points:C76 Inlet duplex filterC78 Fuel outletC80 Drip fuel connectionC80b Drip fuel connection (cut off

pump)C81 Drip fuel connectionC81b Drip fuel connection (filter pan)

Accessories and fittings:DH3 Gas oil coolerDT1 Diesel oil day tankHF1 Fine filter (duplex filter)HF2 Primary filterHF3 Coarse filterHF4 Self cleaning fuel filterHH1 Heavy fuel final preheaterHH2 Stand-by final preheaterHH3 Heavy fuel preheater (separator)HH4 Heating coilHP1/HP2 Pressure pumpHP3/HP4 Circulating PumpHP5/HP6 Heavy fuel transfer pump (separator)HR1 Pressure regulating valveHR2 ViscometerHS1/HS2 Heavy fuel separatorHT1 Heavy fuel day tankHT2 Mixing tank

- Peak pressures max. 16 bar- Silicon dampers required

HT5/HT6 Settling tankKD2 Pressure peak damperKP1 Injection pumpKT2 Sludge tankFQI Flow quantity indicatorLI Level indicatorLSH Level switch highLSL Level switch lowPDI Diff. pressure indicatorPDSH Diff. pressure switch highPDSL Diff. pressure switch lowPI Pressure indicatorPT Pressure transmitterTI Temperature indicatorTT Temperature transmitter (PT 100)VI Viscosity indicatorVSH Viscosity Control switch highVSL Viscosity Control switch low

General notes:For location, dimensions and de-sign (e. g. flexible connection) ofthe disconnecting points see en-gine installation drawing. Novalve fittings with loose conemust be installed by the shipyardin the admission and return lines.

m

38

11. 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 Hydraulic governor

AGIP DIESEL SIGMA S CLADIUM 120

X X

CLADIUM 300 CLADIUM 400

X X

OSO 68 OTE 68

BP ENERGOL DS 3-154 VANELLUS C 3

XX

ENERGOL IC-HFX 304 ENERGOL IC-HFX 404

XX

ENERGOL HLP 68 ENERGOL THB 68

CALTEX DELO 1000 MARINE DELO 2000 MARINE

XX

DELO 3000 MARINE DELO 3400 MARINE

XX

RANDO HD 68 REGAL R & O 68

CASTROL MARINE MLC MHP 154 TLX PLUS 204

X

XX

TLX PLUS 304 TLX PLUS 404

XX

PERFECTO T 68 HYSPIN AWH-M 68

CEPSA KORAL 1540 X HD TURBINAS 68 CHEVRON DELO 1000 MARINE OIL

DELO 2000 MARINE OIL XX

DELO 3000 MARINE OIL DELO 3400 MARINE OIL

XX

EP HYDRAULIK OIL 68 OC TURBINE OIL 68

ELF DISOLA M 4015 AURELIA 4030

XX

AURELIA 4030 AURELIA XT 4040

XX

MISOLA H 68 TURBINE T 68

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

XTERESSO 68 TROMAR T

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

XXX

X

MOBILGARD M 430 MOBILGARD M 440MOBILGARD M 50

XX

D.T.E. OIL HEAVY

SHELL GADINIA SIRIUS FB ARGINA S ARGINA T

XXXX

ARGINA T ARGINA X

XX

TELLUS OIL T 68 TURBO OIL T 68

TEXACO TARO 16 XD TARO 12 XD TARO 20 DP

XXX

TARO 30 DP TARO 40 XL

XX

RANDO OIL 68 REGAL OIL 68 R & O

TOTAL HMA SUPER X 420 RUBIA FP

XX

HMA SUPER X 430 HMA SUPER X 440

XX

PRESLIA 68 AZOLLA ZS 68

m

39

11. Lubricating oil system

Lube oil quantities/- change intervals: Circulating quantity:approx. 1.3 l/kW output with separate tank

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: Screw type pump

Lub oil stand-by force pump (separate) LP 2: - principle per engine- in case of Caterpillar Motoren supply vertical design

only

Suction Strainer (separate) LF 4: Mesh size 2 - 3 mm - to be supplied by the yard.

Self cleaning filter (separate) LF 2: Mesh size 30 µm (absolute), type 6.46, make Boll &Kirch*. Without by-pass filter. Without flushing oil treat-ment.

* In case of Caterpillar Motoren supply.

DN A B C Weight [kg]

6/7 M 43 C 125 440 580 260 195

8/9 M 43 C 150 490 655 300 250

m

40

11. Lubricating oil system

Duplex filter (fitted) LF 1: Mesh size 80 µmDifferential pressure indication and alarm contact fitted.

Cooler (separate) LH 1: Plate type (plates made of stainless steel)

Temperature controller (separate) LR 1: P-controller with manual emergency adjustment

Dimensions [mm] Weight

DN D F G H [kg]

6/7 M 43 C 125 250 241 489 200 67

8/9 M 43 C 150 285 254 489 200 80

Discharge to circulating tank: DN 300 at driving end or free end. Compensator to be sup-plied by the yard.

Circulation tank: Volume

Oil filling approx. 80 % of tank volume.

V [m3] =1.7 · Peng. [kW]

1000

m

41

11. Lubricating oil system

Recommendation of pipe location in the circulating tank

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 150 must be equipped with a condensatetrap and drain. It has to be arranged separately for each en-gine. Crankcase pressure max. 150 Pa.

Treatment at MGO/MDO operation

Separator LS 1: Required with the following design:- Separating temperature 85 - 95 °C- Quantity to be cleaned three times/day- Self cleaning type

Veff [l/h] = 0.18 · Peng [kW]

Treatment 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

Veff [l/h] = 0.29 · Peng [kW]

Discharge from engine

Separator suction pipeFlushing oil from automatic filter

Separator return pipe

Suction pipe force pumpSuction pipe stand-by force pump

m

42

11. Lubricating oil system

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

Notes:h Please refer to the measuring

point list regarding design of themonitoring devices

o See "crankcase ventilation" instal-lation instructions

p Free outlet requiredy Provide an expansation joint

Connecting points:C51 Force pump, suction sideC53 Luboil dischargeC58 Force pump, delivery sideC59 Luboil inlet, duplex filterC62 Drip oil, duplex filterC91 Crankcase ventilation to stack

Accessories and fittings:LF1 Duplex luboil filter LI Level indicatorLF2 Luboil automatic filter LSL Level switch lowLF4 Suction strainer PDI Diff. pressure indicatorLH1 Luboil cooler PDSH Diff. pressure switch highLH2 Luboil preheater PI Pressure indicatorLP1 Luboil force pump PSL Pressure switch lowLP2 Luboil stand-by force pump PSLL Pressure switch lowLP9 Transfer pump (separator) PT Pressure transmitterLR1 Luboil thermostat valve TI Temperature indicatorLR2 Oil pressure regulating valve TSHH Temperature switch highLS1 Luboil separator TT Temperature transmitter (PT 100)LT1 Luboil sump tank

m

43

12. Cooling water system

D im ensions [m m ] W eight

D N D F G H [kg]

6/7 M 43 C H T 125 250 241 489 200 67

8/9 M 43 C H T 150 285 254 489 200 80

6/7/8/9 M 43 C LT 150* 285 254 489 200 80

The heat generated by the engine (cylinder, charge air and lube oil) is to be dissipated by means oftreated freshwater acc. to the MaK coolant regulations.

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

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

LT-cooling water pump (separate) FP 4/FP 6

HT-cooling water pump (separate) FP 3/FP 5: Option: fitted

HT-temperature controller (separate) FR 1: P-controller with manual emergency adjustment(basis). Option: PI-controller with electric drive.See charge air thermostat

* Minimum, depending on total cooling water flow

m

44

12. Cooling water system

LT-temperature controller (separate) FR 2: P-controller with manual emergency adjustment(basis). Option: PI-controller with electric drive.See charge air thermostat.

Preheater (separate) FH 5/FP 7: Consisting of circulating pump (8 m3/h), electricheater (45 kW) and switch cabinet. Voltage 400 - 480,frequency 50/60 Hz. Weight 145 kg.

Charge air heating: Control unit for charge air heating in part load con-dition with electric/pneumatic 2 position flap.

m

45

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

.

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

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

Header tank FT 1/FT 2: - Arrangement: according NPSH-value HT/LT pump max.16 m above crankshaft centre.

- Size acc. to technical engine data.- 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.

12. Cooling water system

m

46

12. Cooling water system

Heat balance 6 M 43 C - 1,000 kW/cyl.

Heat balance 6 M 43 C - 900 kW/cyl.

m

47

12. Cooling water system

Heat balance 7 M 43 C - 1,000 kW/cyl.

Heat balance 7 M 43 C - 900 kW/cyl.

m

48

12. Cooling water system

Heat balance 8 M 43 C - 1,000 kW/cyl.

Heat balance 8 M 43 C - 900 kW/cyl.

m

49

12. Cooling water system

Heat balance 9 M 43 C - 1,000 kW/cyl.

Heat balance 9 M 43 C - 900 kW/cyl.

m

50

12. Cooling water system

General notes:For location, dimensions and de-sign (e. g. flexible connection) ofthe disconnecting points see en-gine installation drawing.

With skin cooler not required:- Seawater system (SP1, SP2,SF1, ST1) Temp. - control valveFR3 required, if heat recovery in-stalled.

Notes:f Drainh Please refer to the measur-

ing point list regarding de-sign of the monitoring de-vices

Connecting points:C14 Charge air cooler LT, inletC15 Charge air cooler LT, outletC16 Charge air cooler HT, inletC25 Cooling water, engine outletC37 Vent

Accessories and fittings:CH1 Charge air cooler HT FT1 Compensation tank HTCH2 Charge air cooler LT FT2 Compensation tank LTCR3 Sensor for charge air temperature control valve LH1 Luboil coolerCR4 Flap for charge air heating LH3 Gear luboil coolerDH3 Gas oil cooler SF1 Seawater filterFH1 Freshwater cooler HT SP1 Seawater pumpFH2 Freshwater cooler LT SP2 Seawater stand-by pumpFH3 Heat Consumer ST1 Sea chestFH5 Freshwater preheater LI Level indicatorFP3 Freshwater pump (separate) HT LSL Level switch lowFP4 Freshwater pump (separate) LT PI Pressure indicatorFP5 Freshwater stand-by pump HT PSL Pressure switch lowFP6 Freshwater stand-by pump LT PSLL Pressure switch lowFP7 Preheating pump PT Pressure transmitterFR1 Temperature control valve HT TI Temperature indicatorFR2 Temperature control valve LT TSHH Temperature switch highFR3 Temperature control valve HT TT Temperature transmitter (PT 100)FR6 Sensor for temperature control valve

m

51

13. Flow velocities in pipes

Example: di = 100 mm, V = 60 m3/hVelocity in the pipe 2,1 m/s

m

52

14. Starting air system

Requirement of Classification Societies (regarding design)

- No. of starts: 6- No. of receivers: min. 2

Receiver capacity acc. to GL recommendation AT 1/AT 2

When CO2 fire extinguishing plants are arranged in the engine room, the blow-off connection of thesafety valve is to be piped to the outside.

1 Filling valve DN 182 Pressure gauge G 1/43* Relief valve DN 74 Drain valve DN 85 Drain valve DN 8 (for vertical position)6 Connection aux. air valve G1/27 To starting valve at engine8 Typhon valve DN 16

Option:* with pipe connection G 1/2

6/7 Cyl. 8/9 Cyl.

Single-engine plant 2 x 500 l 2 x 750 l

Twin-engine plant 2 x 1,000 l 2 x 1,500 l

Receiver capacity [l]

Lmm

D Ø mm Valve head

Weightapprox. kg

500 3,355 480 DN 50 320

750 2,810 650 DN 50 480

1,000 3,670 650 DN 50 620

1,500 3,650 800 DN 50 880

m

53

14. Starting air system

Compressor AC 1/AC 2: 2 compressors with a total output of 50 % each are required.

The filling time from 0 to 30 bar must not exceed 1 hour.

Capacity

V [m3/h] = Σ VRec. · 30.

VRec. - Total receiver volume [m³]

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

Clean and dry starting air is required. A starting air filter has tobe installed before engine, if required.

The air receivers are to be drained sufficiently at least once perday.

Notes:a Control aird Water drain (to be mounted at the lowest point)e To engine no. 2h Please refer to the measuring point list regarding design of

the monitoring devicesj 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 receiver (air bottle)AT2 Starting air receiver (air bottle)PI Pressure indicatorPSL Pressure switch low, only for main enginePT Pressure transmitter

m

54

15. Combustion air system

General:General:General:General: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.

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

55

16. Exhaust system

Position of exhaust gas nozzle: A nozzle position of 0, 30, 60 and 90° is possible.

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).

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 forapproval.

Diameter DN Length [mm]

6/7 M 43 C 900 500

8/9 M 43 C 1,000 620

m

56

16. Exhaust systemResistance in exhaust gas piping

From the basic formula:∆Pg = ε · (N/m²)

follows for the diagram, with 1 m pipe length,k = 7 and 1.013 barthe derived formula:

∆P = (mm WS/m pipelength)

l · P · w² d · 2

1.174 · m²1010 · d5.314 · p

d = Inner pipe diameter (m) t = Gas temperature (°C) m = Exhaust gas massflow (kg/h) w = Gas velocity (m/sec) P = Engine power (kW) p = density (kg/m³) q = specific massflow (kg/kW) ε = Resistance factor L = Effective substitute length (m) ∆Pg = Total flow resistance (mbar) R = Average bend radius (m)

Example:Pretext: P = 6,300 kW, q = 7.5 kg/kWh, t = 320 °C Solution: 1. m = P · q = 6,300 · 7.5 = 47,250 kg/h

l = 15 m straight exhaust pipe 900 NB 2. ∆p = 0.8 mm WS/m pipe3 off 90 °C-bend R/d = 2 3. l' = 14 m for the 90°-Kr. l' = 7 m für den 45°-bend1 off 45 °C-bend R/d = 2 4. L = i + Σ l' = 15 + (3 · 14) + 7 = 64 m

Required: ∆Pg in the exhaust pipe 5. ∆Pg = ∆p · L = 0.8 · 64 = 51.2 mm WS

m

57

16. Exhaust system

134

142

133

136

149

160

156

155

159

146

139

130

135

141

126

135

132

129

122

121

157

137

138

127

100

110

120

130

140

150

160

170

10

12,5

16

20

25

31,5

40

50

63

80

100

125

160

200

250

315

400

500

630

800

1000

1250

1600

2000

Freq

uenc

y [H

z]

LW [dB] (reference 10-12

W)

M 43 C - Inside exhaust gas pipe - Exhaust sound power level Lw

m

58

16. Exhaust system

Exh

au

st

Data

6M

43C

/ 5

400 k

W

269

270

276

283

307

300

293

286

285

290

22410

268

90

30

680

3455

5

38285

2151

5

25815

29455

33175

3675

5

110

135

160

185

210

235

260

285

310

335

360 2

70

02

97

03

24

03

51

03

78

04

050

43

20

45

90

48

60

51

30

En

gin

e P

ow

er

[kW

]

Exhaust Gas Temperature [°C]

50

55

60

65

70

75

80

85

90

95

En

gin

e P

ow

er

[%]

Exh

au

st G

as T

em

pe

ratu

re @

45

°C A

mb

ien

t T

em

p

Exh

au

st G

as T

em

pe

ratu

re @

25

°C A

mb

ien

t T

em

p

Exh

au

st G

as F

low

@ 2

5°C

Am

bie

nt T

em

pera

ture

Exh

au

st G

as F

low

@ 4

5°C

Am

bie

nt T

em

pera

ture

m

59

16. Exhaust system

Exh

au

st

Data

7M

43C

/ 6

300 k

W

297

305

320

330

315

323

339

350

355

335

443195

39805

35290

30770

25640

41470

38215

33880

29540

24145

110

135

160

185

210

235

260

285

310

335

360 3

150

34

65

378

040

95

441

047

25

50

40

535

556

70

598

5

En

gin

e P

ow

er

[kW

]

Exhaust Gas Temperature [°C]

50

55

60

65

70

75

80

85

90

95

En

gin

e P

ow

er

[%]

Exh

aust

Gas T

em

pera

ture

@ 4

5°C

Am

bie

nt

Tem

pe

Exh

aust

Gas T

em

pera

ture

@ 2

5°C

Am

bie

nt

Tem

pe

Exh

aust

Gas F

low

@ 2

5°C

Am

bie

nt

Tem

pera

ture

Exh

aust

Gas F

low

@ 4

5°C

Am

bie

nt

Tem

pera

ture

m

60

16. Exhaust system

Exh

au

st

Data

8M

43C

/ 7

200 k

W

278

280

285

295

295

298

302

313

323

305

56

51990

47135

40980

36440

30400

49910

45250

39340

34980

29185

11

0

13

5

16

0

18

5

21

0

23

5

26

0

28

5

31

0

33

5

36

0 36

00

39

60

43

20

468

05

04

054

00

57

60

61

20

64

80

68

40

En

gin

e P

ow

er

[kW

]

Exhaust Gas Temperature [°C]

50

55

60

65

70

75

80

85

90

95

En

gin

e P

ow

er

[%]

Exhaust

Gas T

em

pera

ture

@ 4

5°C

Am

bie

nt T

em

pera

t

Exhaust

Gas T

em

pera

ture

@ 2

5°C

Am

bie

nt T

em

pera

t

Exh

au

st G

as F

low

@ 2

5°C

Am

bie

nt T

em

pe

ratu

re

Exh

au

st G

as F

low

@ 4

5°C

Am

bie

nt T

em

pe

ratu

re

m

61

16. Exhaust system

Ex

ha

us

t D

ata

9M

43

C / 8

10

0 k

W

290

295

315

325

350

345

323

307

308

330

33400

39960

45830

51685

56090

6

32065

38360

44000

49618

53850

110

135

160

185

210

235

260

285

310

335

360 4

050

44

55

48

60

52

65

567

06

07

56

48

06

885

72

90

76

95

En

gin

e P

ow

er

[kW

]

Exhaust Gas Temperature [°C]

50

55

60

65

70

75

80

85

90

95

En

gin

e P

ow

er

[%]

Exhaust

Gas T

em

pera

ture

@ 4

5°C

Am

bie

nt

Tem

pera

Exhaust

Gas T

em

pera

ture

@ 2

5°C

Am

bie

nt

Tem

pera

Exhaust

Gas F

low

@ 2

5°C

Am

bie

nt

Tem

pera

ture

Exhaust

Gas F

low

@ 4

5°C

Am

bie

nt

Tem

pera

ture

m

62

16. Exhaust system

Exh

au

st

Data

6M

43C

/ 6

000 k

W

270

270

275

295

287

286

292

313

348

328

43330

39535

34630

30240

24000

41600

37950

33390

29030

23040

11

0

13

5

16

0

18

5

21

0

23

5

26

0

28

5

31

0

33

5

36

0 300

0330

036

00

39

00

4200

450

0480

051

00

54

00

570

0

En

gin

e P

ow

er

[kW

]

Exhaust Gas Temperature [°C]

50

55

60

65

70

75

80

85

90

95

En

gin

e P

ow

er

[%]

Exhaust G

as T

em

pera

ture

@ 4

5°C

Am

bie

nt

Tem

pe

Exhaust G

as T

em

pera

ture

@ 2

5°C

Am

bie

nt

Tem

pe

Exhaust G

as F

low

@ 2

5°C

Am

bie

nt T

em

pera

ture

Exhaust G

as F

low

@ 4

5°C

Am

bie

nt T

em

pera

ture

m

63

16. Exhaust system

Exh

au

st

Data

7M

43C

/ 7

000 k

W

295

300

310

330

313

318

329

350

352

330

47850

42660

38700

33610

28490

45935

40955

37150

32265

27350

110

135

160

185

210

235

260

285

310

335

360 3

500

385

042

00

45

50

4900

5250

560

059

50

63

00

665

0

En

gin

e P

ow

er

[kW

]

Exhaust Gas Temperature [°C]

50

55

60

65

70

75

80

85

90

95

En

gin

e P

ow

er

[%]

Exh

au

st G

as T

em

pe

ratu

re @

45

°C A

mb

ien

t T

em

pe

Exh

au

st G

as T

em

pe

ratu

re @

25

°C A

mb

ien

t T

em

pe

Exh

au

st G

as F

low

@ 2

5°C

Am

bie

nt

Te

mpe

ratu

re

Exh

au

st G

as F

low

@ 4

5°C

Am

bie

nt

Te

mpe

ratu

re

m

64

16. Exhaust systemE

xh

au

st

Data

8M

43C

/ 8

000 k

W

280

277

280

290

297

294

297

307

319

301

56405

51350

45825

39025

33740

54150

49295

43990

37465

32390

11

0

13

5

16

0

18

5

21

0

23

5

26

0

28

5

31

0

33

5

36

0 40

00

44

00

48

00

52

00

56

00

60

00

64

00

68

00

72

00

76

0

En

gin

e P

ow

er

[kW

]

Exhaust Gas Temperature [°C]

50

55

60

65

70

75

80

85

90

95

En

gin

e P

ow

er

[%]

Exh

aust G

as T

em

pera

ture

@ 4

5°C

Am

bie

nt T

em

per

Exh

aust G

as T

em

pera

ture

@ 2

5°C

Am

bie

nt T

em

per

Exh

aust G

as F

low

@ 2

5°C

Am

bie

nt T

em

pera

ture

Exh

aust G

as F

low

@ 4

5°C

Am

bie

nt T

em

pera

ture

m

65

16. Exhaust system

Exh

au

st

Data

9M

43C

/ 9

000 k

W

290

305

325

350

345

323

307

308

290

330

37000

43650

50250

55400

62145

35520

41900

48240

53200

59660

110

135

160

185

210

235

260

285

310

335

360 4

50

04

95

054

00

58

50

63

00

675

07

20

07

65

081

00

85

50

En

gin

e P

ow

er

[kW

]

Exhaust Gas Temperature [°C]

50

55

60

65

70

75

80

85

90

95

En

gin

e P

ow

er

[%]

Exh

aust G

as T

em

pe

ratu

re @

45

°C A

mbie

nt T

em

pera

Exh

aust G

as T

em

pe

ratu

re @

25

°C A

mbie

nt T

em

pera

Exh

au

st G

as F

low

@ 2

5°C

Am

bie

nt

Tem

pera

ture

Exh

au

st G

as F

low

@ 4

5°C

Am

bie

nt

Tem

pera

ture

m

66

16. 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 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 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

67

16. 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 35 dB (A)

DN D A B L kg

6/7 M 43 C 900 1,680 650 1,100 5,620 3,000

8/9 M 43 C 1,000 1,780 650 1,160 6,120 3,750

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 recommendedtotal exhaust gas back pressure.

m

68

16. 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 hours.

Cleaning the turbine blade andnozzle ring: The cleaning is carried out with clean fresh water "wet

cleaning" during low load operation at regular intervals, de-pending on the fuel quality, 150 hours.

Duration of the cleaning period is approx. 20 minutes. Freshwater of 2 - 2.5 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 M 43 C 23 - 27 10

7/8/9 M 43 C 32 - 38 10

C42 Fresh water supplyC36 Drain

Dirty water tank

Connection of C42 with quick coupling device

m

69

17. Air borne sound power level

The noise level is measured in a test cell with a turbocharger air filter. The measuring points are atcamshaft level respective above cylinder head cover.

Noise level for M 43 C engines

Tolerance + 2 dB

Lw Oct [dB](reference10-12 W)

126

111

105

110

93

113

115116

102

90

95

100

105

110

115

120

125

130

0.063 0.125 0.25 0.5 1 2 4 8 LwFrequency [kHz]

m

70

18. Foundation

Support distance a = 2,090 mmF = TN / a

2. Dynamic load: The dynamic forces and moments are superimposed on thestatic forces. They result on the one hand from the firingforces causing a pulsating torque and on the other handfrom the external mass forces and mass moments.

The tables indicate the dynamic forces and moments aswell as the related frequencies.

External foundation forces and frequencies:

The following information is relevant to the foundation design and the aftship structure.

The engine foundation is subjected to both static and dynamic loads.

1. Static load: The static load results from the engine weight which is dis-tributed approximately evenly over the engine’s foundationsupports and the mean working torque TN resting on thefoundation via the vertical reaction forces. TN increases theweight on one side and reduces it on the other side by thesame amount.

Output[kW]

Speed[1/min]

TN

[kNm]

6 M 43 C 5,400 / 6,000 500 103.1 / 114.6

7 M 43 C 6,300 / 7,000 500 120.3 / 133.7

8 M 43 C 7,200 / 8,000 500 137.5 / 152.8

9 M 43 C 8,100 / 9,000 500 154.7 / 171.9

m

71

All forces and moments not indicated are irrelevant or do not occur. The effect of these forces andmoments on the ship’s foundations depends on the type of engine mounting.

2.1 Rigid mounting:The vertical reaction forces resulting from the torque variation Mx are the most important distur-bances to which the engine foundation is subjected. As regards dynamic load, the indicated momentsMx only represent the exciting values and can only be compared among each other. The actual forcesto which the foundation is subjected depend on the mounting arrangement and the rigidity of the foun-dation itself.

Output[kW]

Speed[rpm] Order-No.

Frequency[Hz]

Mx

[kNm]

6 M 43 C 5,400 / 6,000 500 3.0 6.0

25.0 50.0

85.3 / 97.3 40.1 / 44.1

7 M 43 C 6,300 / 7,000 500 3.5 7.0

29.3 58.3

176.0 / 185.0 25.5 / 28.7

8 M 43 C 7,200 / 8,000 500 4.0 8.0

33.3 66.6

145.2 / 155.0 18.1 / 20.3

9 M 43 C 8,100 / 9,000 500 4.5 9.0

37.5 75.0

133.3 / 143.5 11.5 / 13.1

Output[kW]

Speed[rpm]

Order-No. Frequency[Hz]

My[kNm]

Mz[kNm]

6 M 43 C 5,400 / 6,000 500 — —

7 M 43 C 6,300 / 7,000 500 24

16.6 33.3

59.9 9.5

—

8 M 43 C 7,200 / 8,000 500 — —

9 M 43 C 8,100 / 9,000 500 12

8.3 16.6

30.8 107.6 —

18. Foundation

m

72

18. Foundation

In order to make sure that there are no local resonant vibra-tions in the ship’s structure, the natural frequencies of im-portant components and partial structures must be a suffi-cient gap from the indicated main exciting frequencies.

The dynamic foundation forces can be considerably re-duced by means of resilient engine mounting.

General note: The shipyard is solely responsible for the adequate designand quality of the foundation.

Information on foundation bolts (required pretightening tor-ques, elongation, yield point), steel chocks, side stoppersand alignment bolts is to be gathered from the foundationplans.

Examples "for information only" for the design of the screwconnections will be made available as required.

If pourable resin is used it is recommendable to employ au-thorized workshops of resin manufacturers approved by theclassification societies for design and execution.

It has to be taken into account that the permissible surfacepressure for resin is lower than for steel chocks and there-fore the tightening torques for the bolts are reduced corre-spondingly.

m

73

18. Foundation

6/7 M 43 C 8/9 M 43 C

1 Pair 2 Pairs *

Side stoppers

Side stopper to be with 1 wedge (see sketch). Wedge to be placed at operating temperature andsecured by welding.

Dimensioning according to classification society and cast resin suppliers requirements.

* 1 pair at end of cylinder housingand 1 pair between cyl. 4 and 5.

m

74

18. Foundation

Number of Bolts

Jacking Bolts - To be protected against contact/bond with resin- After setting of resin dismantle the jacking screws completely

Fitted bolts Foundation bolts

6 M 43 C 4 28

7 M 43 C 4 32

8 M 43 C 4 36

9 M 43 C 4 40

To be supplied by yard:

Foundation bolts, fittedbolts, nuts and tensionsleeves, side stoppers,steel chocks, cast resin

The shipyard is solely re-sponsible for adequatedesign and quality of thefoundation.

m

75

18. Foundation

Proposal for rigid mounting

Bolts and chocks are yard supply. Design responsibility is with the yard.

Tightening force M 39 Tightening torque (oil) M 39

Cast resin / Steel Cast resin / Steel

Through bolts [N]

Fitted bolts [N]

Through bolts M [Nm]

Fitted bolts M [Nm]

max. 340,000 max. 340,000 max. 2,050 max. 2,050

m

76

19. Resilient mounting

Major components:- Conical rubber elements for active insolation of dynamic engine forces and structure born noise

are combined horizontal, lateral and vertical stoppers to limit the engine movements.- Dynamically balanced highly flexible coupling.- Flexible connections for all media.- Special designed exhaust gas below.

Details are shown on binding installation drawings.

No. of elements:

Important note:- The resilient mounting alone does not provide garant for a quiet ship. Other sources of noise like

propeller, gearbox and aux. engines have to be considered as well.- Radial restoring forces of the flexible coupling (due to seaway) may be of importance for the layout

of the reduction gear.

Comical rubber elements

6 M 43 C 8

7 M 43 C 8

8 M 43 C 10

9 M 43 C 10

m

77

19. Resilient mounting

Structure borne sound level Lv, expected M 43 C

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

7468

89

104

80

878894

394645

52535054

65

20

30

40

50

60

70

80

90

100

110

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

above

below

m

78

20. Power transmission

Coupling between engine and gearbox

For all types of plants the engines will be equipped with flexible flange couplings.

The guards for the flexible couplings should be of perforated plate or gratings to ensure an optimumheat dissipation (yard supply).

Mass moments of inertia

Selection of flexible couplings

The calculation of the coupling torque for main couplings is carried out acc. to the following formula.

Po Engine outputno Engine speedTKN Nominal torque of the coupling in the catalog

For installations with a gearbox PTO it is recommended to oversize the PTO coupling by the factor 2in order to have sufficient safety margin in the event of misfiring.

Speed[rpm]

Engine[kgm2]

Flywheel [kgm2]

Total[kgm2]

6 M 43 C 1,870 3,300

7 M 43 C 2,370 3,800

8 M 43 C 2,750 4,180

9 M 43 C

500

3,330

1,430

4,760

TKN >Po

ωPo

2 · π · no

=

m

79

20. Power transmission

Fly wheel and flexible coupling

1) without torsional limit device2) with torsional limit device3) length of hub

Space for OD-Box to be considered!

Make Vulkan Power Speed Nominal torque

of coupling BR 2200 1) / BR 2201 2)

Type D L1 1) L1 2) L2 L4 3) Weight [kg]

[kW] [rpm] [kNm] Rato [mm] [mm] [mm] [mm] [mm] 1) 2)

6 M 43 C 6,000 500 125 G 392 Q 1,255 972 1,002 317 385 1,660 1,960

7 M 43 C 7,000 500 160 G 482 Z 1,480 1,162 1,248 402 480 2,727 3,284

8 M 43 C 8,000 500 180 G 482 W 1,480 1,162 1,248 402 480 2,727 3,284

9 M 43 C 9,000 500 200 G 482 Q 1,480 1,162 1,248 402 480 2,727 3,284

Power take-off from the free endThe connection requires a highly flexible coupling.The definite coupling type is subject to confirmation by the torsional vibration calculation.

6 M 43 C 7 M 43 C 8 M 43 C 9 M 43 C

6,000 kW 7,000 kW 3,500 kW —

m

80

21. Data for torsional vibration calculation

Details to be submitted for the torsional vibration calculation

A torsional vibration calculation is made for each installation. For this purpose exact data of all compo-nents are required. See table below:

1. Main propulsion

Clutch existing ? yes no

Moments of Inertia: Engaged ............. kgm² Disengaged: .............. kgm²

Flexible Coupling: Make .................. Type: ....... Size

Gearbox: Make ................... Type: ....... Gear ratio .........

Moments of Inertia and dyn. torsional rigidity (Mass elastic system)

Shaft drawings with all dimensions

CPP D = ............ mm Blade No. ........

Moments of Inertia: in air ............. kgm² / in water = ............. kgm²

Exciting moment in percent of nominal moment = ............. %

Operation mode CPP: const. speed Combinator:

Speed range from: ................. – rpm

Normal speed range: CPP = 0.6 Nominal speed

2. PTO from gearbox: yes no

If yes, we need the following information:

Clutch existing? yes no

Moments of Inertia: Engaged: ............ kgm2 Disengaged: .............. kgm²

Flexible coupling: Make: .............. type .................... Size ..............

Gearbox: .................. Make: .............. type .................... Gear ratio: .............

Moments of Inertia and dyn. torsional rigidity (Mass diagram)

Kind of PTO driven machine: ............................ Rated output .............. kW

Power characteristics, operation speed range .............. rpm

3. PTO from free shaft end: yes no

If yes, we need the following information:

Clutch existing? yes no

Moments of Inertia: Engaged: ............ kgm2 Disengaged: .............. kgm²

Flexible coupling: Make ............. type .................... Size ..............

Gearbox: .................. Make ............. type .................... Gear ratio .............

Moments of Inertia and dyn. torsional rigidity (Mass diagram)

Kind of PTO driven machine: ........................... Rated output .............. kW

Power characteristics, operating speed range .............. rpm

4. Explanation:

Moments of Inertia and dyn. torsional rigidity in absolut dimensions, i. e. not reduced.

m

81

22. Control and monitoring system

Cen Un

Engi

neCo

uplin

gG

earb

oxSh

aft G

ener

ator

Prop

elle

r/Sh

aft/

OD

Rem

ote

Cont

rol

Emer

genc

ySt

oprp

mEn

gine

Term

inal

Brid

ge

pSt

art

Brid

ge C

ontro

l Pa

nel

Sing

le e

ngin

e CP

P-pr

opul

sion

pla

nt

m

82

22. Control and monitoring system

Engine control panel

m

83

22. Control and monitoring system

Remote control for single engine plant with CP propeller

m

84

22. Control and monitoring systemRemote control for twin engine plant with one CP propeller

m

85

22. Control and monitoring system

Speed control

Single engine plant with CPP: The engine is equipped with a mech./hydr. speed governor UG40 DI (Digital Interface) make WOODWARD. It essentialy corre-sponds to the UG 40 D-governor additionally with the followingequipment:

- Steppermotor for remote speed setting inside the governorhead.

- 4 - 20 mA remote speed setting- Adjustable speed setting range with changing of parameters

at UG 40 DI.- Programmable up and down rates for raise-low speed set-

ting.- Speed setting knob at governor dial (emergency speed set-

ting).- Start fuel limiter- Shut-down solenoid (24 V DC/100 % duty cycle) only for re-

mote stop (not emergency stop)- Voltage supply 18 - 32 V DC- Alarm output

Relay output activated at:- Speed reference signal outside 2 - 22 mA- Fuel limit failure- feedback error- Other detectable internal errors

Additional equipment: - Fitted hydraulic booster- Serrated drive shaft (for easy service)- Steplessly adjustable droop on the governor from 0 - 10 %.- Device for optimization of the governor characteristic- The governor is driven via the standard governor drive

Option: - Electronic governors make WOODWARD with mechanicalback-up

m

86

Speed control

Twin engine plant with one CPP: The engines are equipped with an actuator (optional with mech.back-up). Electronic governors are installed in a separate con-trol box.

The governor comprises the following functions:

- Speed setting range to be entered via parameters- Adjustable acceleration and deceleration times- Starting fuel limiter- Input for stop (not emergency stop)- 18 - 32 V DC voltage supply- Alarm output- Droop operation (primary shaft generator)- Isochronous load distribution by master/slave princip for twin

engine propulsion plants via double-reduction gear

22. Control and monitoring system

Twin engine plant with one CPP Single engine plant with CPP

Control box electronic governorwith mounting frame and shock absorber

m

87

22. Control and monitoring system

Engine monitoring

m

88

22. Control and monitoring system

List of measuring point: Main engine M 43 C all classes

Sensoric

Separate parts

Measur.-point

Monitoring point Abbrev. Action

MDO/HFO MDO/HFO HFO

Remarks

1104 Luboil pressure PAL OA B Starting stand-by pump from pump control

1105 Luboil pressure PAL OA A

1106 Luboil pressure PALL OAMS

B

1111 Luboil differential pressure duplex filter

PDAH OA B

1112 Luboil differential pressure autom. filter

PDAH OA B

1202 Lubricating oil temperature engine inlet

TAH OA A

1203 Lubricating oil temperature engine inlet

TAHH OAAD

B

1251 Smoke concentration crankcase

QAH OA B# # 1 device f. 1251+1253

1253 Smoke concentration crankcase

QAH OAMS

B# # 1 device f. 1251+1253

2101 FW pressure high temp. circuit engine inlet

PAL OA B Starting stand-by pump from pump control

2102 FW pressure high temp. circuit engine inlet

PAL OA A

2103 FW pressure high temp. circuit engine inlet

PALL OAMS

B

2111 FW pressure low temp. circuit cooler inlet

PAL OA B Starting stand-by pump from pump control

2112 Fresh water pressure low temp. circuit cooler inlet

PAL OA A

2201 Fresh water temp. high temp. circuit engine inlet

TAL OA A

2211 Fresh water temp. high temp. circuit engine outlet

TAH OA A

2212 Fresh water temp. high temp. circuit engine outlet

TAHH OAAD

B

2229 Fresh water temp. low temp. circuit

TAL OA A

2321 Oil ingress in fresh water cooler outlet

QAH OA B Option

5101 Fuel oil pressure engine inlet

PAL OA B Not provided with HFO Starting stand-by pump from pump control

m

89

22. Control and monitoring system

List of measuring point: Main engine M 43 C all classes

* located in the fuel pressure system

Sensoric

Separate parts

Measur.-point

Monitoring point Abbrev. Action

MDO/HFO MDO/HFO HFO

Remarks

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 duplex filter

PDAH OA B

5112 Fuel oil differential pressure autom. filter

PDAH OA B *

5115 Fuel oil differential pressure circulating pump

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

5116 Fuel oil differential pressure 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

5206 Fuel oil temperature on viscosimeter

TI A

5251 Fuel oil viscosity engine inlet

VAH OA # # 1 Sensor f. 5251,

5252 + 5253

5252 Fuel oil viscosity engine inlet

VAL OA # # 1 Sensor f. 5251,

5252 + 5253

5253 Fuel oil viscosity engine inlet

V A# # 1 Sensor f. 5251,

5252 + 5253

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

6106 Starting air after main starting valve

P B Activating of alarm system

6181 Air intake pressure, absolute engine room

PI A

7109 Charge air pressure engine inlet

PI A

7201 Charge air temperature engine inlet

TAH OA A

m

90

22. Control and monitoring system

List of measuring point: Main engine M 43 C all classes

Sensoric

Separate parts

Measur.-point

Monitoring point Abbrev. Action

MDO/HFO MDO/HFO HFO

Remarks

7206 Air intake temperature before turbocharger

TI A Air intake temperature

7301 Water in charge air manifold QAH OA B

7307 Charge air differential pressure inlet/outlet charge air cooler

PDI A

7309 Charge air temperature inlet charge air cooler

TI A

8211 Exhaust gas temp. deviation from average each cylinder

TAHTAHH

OAAD

A

8221 Exhaust temperature after turbocharger

TAHTAHH

OAAD

A

8231 Exhaust temperature before turbocharger

TAH OA A

9401 Engine speed S B Alarm suppression

9402 Engine speed S B Start/stop luboil stand-by pump

9403 Engine speed n < 0,7 n nom

S B Alarm suppression

9404 Engine overspeed S OAMS

B

9409 Working hour meter/engine S B

9411 Engine speed S B Start/stop of luboil gear box stand-by pump from pump control

9419 Engine speed NI A

9429 Speed turbocharger NI A

9509 Injection pump/fuel rack GI A

9531 Load/>=Engine limit curve speed governor

GI B Overload indiction (CP-propeller)

9532 Load/>=Engine limit curve speed governor

GI A Load control (CP-propeller)

9561 Barring gear engaged B Start interlock

9601 Electronic units/terminal point X1/voltage failure

OA B

9611 RPM switch/voltage failure, wire break

OA B

m

91

22. Control and monitoring system

List of measuring point: Main engine M 43 C all classes

Sensoric

Separate parts

Measur.-point

Monitoring point Abbrev. Action

MDO/HFO MDO/HFO HFO

Remarks

9615 Failure electronic governor OA B only with electronic governor

9616 Failure electronic governor OA MS

B only with electronic governor

9622 Exhaust gas temp. average equipment, voltage failure

OA B

9631 Crankcase oil mist detector voltage, lens/lamp

OA B

9671 Safety system failure OA B

9677 Override active OA B

9717 Electrical start/stop equipment/voltage failure

OA B

9751 Temperature controller voltage failure

OA B Dependent from system

9761 Viscosity control, voltage failure

OA B Dependent from system

9771 Preheater freshwater, voltage failure

OA B Dependent from system

9775 Preheater fuel oil, voltage failure

OA B Dependent from system

AbbreviationsB = Binary sensor AD = Autom. speed/load reductionA = Analogue sensor MS = Autom. engine stopOA = Visual and audible alarm

GI = Position indication QA = Measurement alarmLAH = Level alarm high QAH = Measurement alarm highLAL = Level alarm low S = SpeedNI = Speed indication TAH = Temperature alarm highP = Pressure TAHH = Temperature alarm high highPAL = Pressure alarm low TAL = Temperature alarm lowPALL = Pressure alarm low low TI = Temperature indicationPDI = Pressure difference indication V = ViscosityPDAH = Pressure difference alarm high VAH = Viscosity alarm highPDAL = Pressure difference alarm low VAL = Viscosity alarm lowPI = Pressure indication

m

92

22. Control and monitoring system

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Local and remote indicators

m

93

22. Control and monitoring system

Remote indication interfacing

* not Caterpillar Motoren supply

Remote indicatoroption

Turbochargerspeedoption

Remote indicatorengine speed

option

m

94

22. Control and monitoring system

Protection system Version = unattended engine room seagoing vessel

Operating voltage: 24 V DCType of protection: IP 55 for wall-mounting type housing

IP 20 for 19" subrack type

Protection against false polarity and transient protection provided.

Designed for: 4 starting interlock inputs6 automatic stop inputs6 automatic reduction inputs4 manual stop inputs

The input and output devices are monitored for wire break.

m

95

22. Control and monitoring system

Protection system

m

96

22. Control and monitoring system

Rpm switch system Operating voltage: 24 V DCType of protection:IP 55 for wall-mounting type housingIP 20 for 19" subrack type

Designed for:8 rpm switching pointsAnalogue outputs for speed:2 x 0-10 V, 2 x 4-20 mA, 2 x frequencyAnalogue outputs for fuel rack position:0 - 10 V, 2 x 4-20 mA plus 2 binary outputs

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97

22. Control and monitoring system

Rpm switch system

m

98

23. 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.

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99

23. Diagnostic system DICARE

Transmitter for DICARE ON-LINE M 43 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

100

24. 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

101

25. 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 < 1,000 Hz

The acceptance test run is carried out on the testbed with customary equipment and auxiliaries usingexclusively MDO and under the respective ambient conditions of the testbed. During this test run thefuel rack will be blocked at the contractual output value. In case of deviations from the contractualambient conditions the fuel consumption will be converted to standard reference 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]

50 30

85 30

100 60

110 30

m

102

26. 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. The regulation is in force since May 19, 2005. Ships constructed after 1st ofJanuary 2000 (date of keel-laying) will be required to comply (also retroactively if the Annex VI entersinto force after this date).

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:

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.

E2: Diesel electric propulsion, controllable pitch propeller

Speed [%] 100 100 100 100

Power [%] 100 75 50 25

Weighting factor 0.2 0.5 0.15 0.15

m

103

27. Painting/Preservation

Outside Preservation, Light N 576-3.1up to 6 months, within Europe.For transportation and outdoor storage (protected from moisture)

Appearance of the engine:- Castings with red oxide antirust paint- Pipes and machined surfaces left as bare metal- Attached components painted in the colours of the makers- Corrosion protection with Tectyl 846K19

Outside Preservation, Heavy-Duty N 576-3.2up to 12 months outside of EuropeFor transportation and outdoor storage (protected from moisture)

Appearance of the engine:- Castings with red oxide antirust paint- Pipes and machined surfaces left as bare metal- Attached components painted in the colours of the makers- Corrosion protection with Tectyl 506EH

Inside Preservation N 576-3.3up to 1 year, protected from moisture.

- Main running gear and inner mechanics

Engine with Clear Varnish N 576-4.1without additional measures no outdoor storage.For shipment and outdoor storage (protected from moisture) an additional corrosion protection is re-quired!

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

m

104

Engine with Grey Primer N 576-4.2without additional measures no outdoor storage.For shipment and outdoor storage (protected from moisture) an additional corrosion protection is re-quired!

Appearance of the engine:- Surfaces mostly with grey primer

Engine with Coat of Varnish N 576-4.3without additional measures no outdoor storage.For shipment and outdoor storage (protected from moisture) an additional corrosion protection is re-quired!

Appearance of the engine:- Surfaces mostly painted with varnish.

27. Painting/Preservation

m

105

28. Lifting of engines

For the purpose of transport the engine 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

106

29. Engine parts

Cylinder head, Weight 1100 kg

Connecting rod, Weight 558 kg Piston, Weight 214 kg

Cylinder liner, Weight 709 kg

Subject to change without notice.Leaflet No. 235 · 09.05 · e · G+D · VM3

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

Caterpillar Marine Power SystemsEurope, Africa, Middle East

Caterpillar MarinePower SystemsNeumühlen 922763 Hamburg/Germany

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

Caterpillar Marine AsiaPacific Pte Ltd14 Tractor RoadSingapore627973/SingaporePhone: +65 68287-600Telefax: +65 68287-624

Americas

MaK Americas Inc.

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

Caterpillar Marine Trading(Shanghai) Co., Ltd.Rm 2309, Lippo Plaza222, Huai Hai Zhong Road200021 Shanghai/P. R.ChinaPhone: +86 21 5396 5577Telefax: +86 21 5396 7007

Asia PacificHeadquarters

Caterpillar MarinePower SystemsNeumühlen 922763 Hamburg/Germany

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