WinGD X92DF Operation Manual

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Winterthur Gas & Diesel Ltd.

Winterthur Gas & Diesel AG

Winterthur Gas & Diesel S.A.

Schützenstrasse 3

P.O. Box 414, 8401

Winterthur, Switzerland

Operation Manual

X92DF

Tel. +41 (0)52 264 8844

Fax +41 (0)52 264 8866

www.wingd.com

Issue 002 2020-08

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Page 1 Operation Manual X92DF Issue 002 2020-08 Winterthur Gas & Diesel Ltd. Schützenstrasse 3 Tel. +41 (0)52 264 8844 Winterthur Gas & Diesel AG P.O. Box 414, 8401 Fax +41 (0)52 264 8866 Winterthur Gas & Diesel S.A. Winterthur, Switzerland www.wingd.com...
Page 2 Information in this publication is subject to change without notice. NO LIABILITY, WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS INTENDED FOR INFORMATION PURPOSES ONLY. www.wingd.com...
Page 3: Table Of Contents
X92DF Operation Manual Table of contents Introduction Operation Manual - change record......... .
Page 4 X92DF Operation Manual 4.14 LP Selective catalytic reduction system........
Page 5 X92DF Operation Manual 5.5.6 Pressure control valve..........
Page 6 X92DF Operation Manual 6.8.15 LDU-20 page - FAILURE SIMULATION....... .
Page 7 X92DF Operation Manual 6.10.3 User parameters and maintenance settings for WECS-9520....6.10.4 Failures and defects of WECS-9520 components......
Page 8 X92DF Operation Manual 10.3 Examine the supply unit for servo oil leakage....... .
Page 9 X92DF Operation Manual List of tables Introduction Change record ..................... Data module codes (descriptive data) ............Data module codes (procedural data) ............List of abbreviations and acronyms ............. Design and function of systems LP SCR SYSTEM STATUS (MAIN PAGE) ..........
Page 10 X92DF Operation Manual 6-18 GAV MANUAL VALVE TEST ............... 6-19 GVU & VALVE TEST ................... 6-20 KNOCK CONTROL ..................6-21 LOG MESSAGES ..................6-22 MAIN FUEL INJECTION ................6-23 PAGE INDEX ....................6-24 PERFORMANCE DATA DIESEL ..............6-25 PERFORMANCE DATA GAS ..............
Page 11 X92DF Operation Manual 10-7 Lubricating oil supply pressure at the engine inlet is too low ...... 10-8 Lubricating oil supply pressure upstream of the injectors is too low ... 10-9 Lubricating oil supply temperature at the engine inlet is too high ....
Page 12 X92DF Operation Manual 10-49 Scavenge air temperature in the piston underside is too high ....10-50 Starting air supply pressure is too low ............10-51 Pressure of the air spring air supply is too high .......... 10-52 Pressure of the air spring air supply is too low ..........
Page 13 X92DF Operation Manual List of illustrations Introduction Side view (generic) ..................End view (generic, seen from the driving end) ..........Standard and LEFT engine (generic, seen from the driving end) ....Engine numbering (generic) ................ Design and function of the engine Pressure - volume diagram and schematic of the two-stroke diesel cycle ..
Page 14 X92DF Operation Manual 4-28 HP SCR system - change from Tier III to bypass ........4-29 HP SCR system - purging and venting ............4-30 HP SCR system - emergency bypass ............4-31 HP SCR system - preparation ..............4-32 HP SCR system - Tier III ................
Page 15 X92DF Operation Manual 5-29 Local maneuvering stand (generic) ............. 5-30 Local maneuvering stand ................5-31 Pick-up for speed measurement (generic) ..........5-32 Servo oil pump (example) ................5-33 Supply unit (example) .................. 5-34 Supply unit pilot fuel (generic) ..............5-35 Fuel pump (generic) ..................
Page 16 X92DF Operation Manual 6-17 CA SENSOR STATUS ................. 6-18 CYLINDER BALANCING DIESEL ............... 6-19 CYLINDER BALANCING GAS ..............6-20 CYLINDER LUBRICATION ................. 6-21 iCAT (integrated Cylinder lubricant Auto Transfer) ........6-22 DYNAMIC COMBUSTION CONTROL (DCC) ..........6-23 EXHAUST VENTILATION ................
Page 17 X92DF Operation Manual 6-65 Local control cabinet ................... 6-66 WECS-9520 manual control panel .............. 6-67 Failure ID and LED indications on FCM-20 ..........Operation Cooling water system with bypass cooling ..........Cooling water system without bypass cooling ..........Cooling water system with circulation ............
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Page 19: Introduction
X92DF Operation Manual 1 Introduction Operation Manual - change record......... .
Page 20: Change Record
AA00-0000-00AAA-003A-A X92DF Operation Manual Operation Manual - change record Operation Manual - change record Tab 1-1 Change record New issue 002, 2020-07 - New chapter added: LP Selective catalytic reduction system. - Updated the iGPR schematic in the chapter: “Integrated gas pressure regulation”.
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Page 22 The data, instructions, graphics and illustrations etc in this manual are related to drawings from WinGD. These data relate to the date of issue of the manual (the year of the issue is shown on the title page and on the footer). All instructions, graphics and illustrations etc can change because of continuous new development and modifications.
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Page 24: Technical Documentation Set
AA00-0000-00AAA-018B-A X92DF Operation Manual Technical documentation set Technical documentation set Because of the continuous development of the engine, the technical documentation for the engine changes and is regularly updated. The change record shows all changes. Important data and changes are given directly to the customer in the service bulletins.
Page 25 External supplier documentation The documentation from external suppliers gives data about the parts of the engine that are not supplied by WinGD, such as turbocharger, automatic filter or damper. Most of this documentation also contains data about spare parts. 1.3.5...
Page 26: Data Module Codes (Descriptive Data)
00 = applicable to all engines inde- acters [0-9] pendent of the number of cylinders; ## = applicable only to engines with that specific number of cylinders. #### WinGD design group number 4 numeric char- arbitrary 5551 acters [0-9] Used for sequential numbering of data...
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Page 28: Data Module Codes (Procedural Data)
00 = applicable to all engines inde- acters [0-9] pendent of the number of cylinders; ## = applicable only to engines with that specific number of cylinders. #### WinGD design group number 4 numeric char- arbitrary 5556 acters [0-9] Used for sequential numbering for the...
Page 29 AA00-0000-00AAA-018E-A X92DF Operation Manual Data module codes (procedural data) Code Description Length/type Property Example Shipdex item location code. A = infor- 1 alphabetic Shipdex specif- mation related to items installed on the character [A-D] product; B = information related to items installed on a major assembly re- moved from the product;...
Page 30: About This Book
X92DF Operation Manual About this book About this book In the sections that follow you find the definitions of WinGD for this book. 1.6.1 Definitions for general text For general text in this book the definitions that follow are applicable: •...
Page 31 AA00-0000-00AAA-018C-A X92DF Operation Manual About this book 1.6.2 Warnings Warnings in procedures give data about a hazard. Warnings have the basic structure that follows: • Signal word The signal words that follow are applicable: ○ WARNING ○ CAUTION • Hazard The hazard data gives the dangerous situation.
Page 32: About The Engine
Operation Manual About the engine About the engine In the sections that follow you find the definitions of WinGD for the engine. 1.7.1 Groups of components Each component of the engine has a four-digit material number. WinGD has divided these components related to the first digit of the number into 9 groups: •...
Page 33: Side View (Generic)
AA00-0000-00AAA-018L-A X92DF Operation Manual About the engine 1.7.2 Engine sides and ends - names The sides and ends of the engine have the names and abbreviations that follow (refer to Figure Figure 1-2): • DE - Driving End (end that has a flange to attach the propeller shaft) •...
Page 34: End View (Generic, Seen From The Driving End)
AA00-0000-00AAA-018L-A X92DF Operation Manual About the engine Fig 1-2 End view (generic, seen from the driving end) Legend Exhaust side Fuel side Turbocharger Supply unit Auxiliary blower Rail unit Flywheel - 34 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 35 AA00-0000-00AAA-018L-A X92DF Operation Manual About the engine 1.7.3 Standard and LEFT engine An engine is one of two types (refer to Figure 1-3): • A standard engine has the exhaust side (ES) on the right side of the engine (seen from the driving end).
Page 36: Engine Numbering (Generic)
AA00-0000-00AAA-018L-A X92DF Operation Manual About the engine 1.7.4 Numbering of items WinGD uses the definitions for the numbering of items as follows (refer to Figure 1-4): • In axial direction the numbering starts from the flywheel. • In radial direction the numbering starts from the center of the flywheel.
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Page 38: List Of Abbreviations
AA00-0000-00AAA-005A-A X92DF Operation Manual List of abbreviations List of abbreviations Tab 1-4 List of abbreviations and acronyms Short form Full form, meaning Angle Calculation Module crank Angle Determination Algorithm ahead alarm Alarm and Monitoring System as required astern ASTM American Society for Testing and Materials...
Page 39 AA00-0000-00AAA-005A-A X92DF Operation Manual List of abbreviations Short form Full form, meaning Emission Control Area Engine Control Room Engine Control System eg or e.g. for example (exempli gratia) Exhaust Gas Recirculation ELBA ELectrical BAlancer Exhaust Side Engine Safety System FAME...
Page 40 AA00-0000-00AAA-005A-A X92DF Operation Manual List of abbreviations Short form Full form, meaning Injection Control Unit ie or i.e. that is (id est) iELBA integrated ELectrical BAlancer iGPR integrated Gas Pressure Regulation International Maritime Organization Ind. Indenture Input Output Module International Standard Organization...
Page 41 Top Dead Center UNIC UNIfied Controls Universal Serial Bus exhaust Valve Control Unit Variable Exhaust valve Closing Variable Exhaust valve Opening Variable Injection Timing WECS-9520 WinGD Engine Control System 9520 - 41 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 42 AA00-0000-00AAA-005A-A X92DF Operation Manual List of abbreviations Short form Full form, meaning Waste Heat Recovery WiCE WinGD Integrated Control Electronics WinGD Winterthur Gas & Diesel Ltd. Work Load Limit - 42 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 43: Safety
X92DF Operation Manual 2 Safety Safety precautions and safety rules.........
Page 44: Safety Precautions And Safety Rules
AA00-0000-00AAA-012A-A X92DF Operation Manual Safety precautions and safety rules Safety precautions and safety rules 2.1.1 General safety precautions Use the data given below as a guide to the personnel. • Lighting Make sure that there is good permanent lighting in the engine room. Have a sufficient number of hand lamps available at different locations in the engine room.
Page 45 AA00-0000-00AAA-012A-A X92DF Operation Manual Safety precautions and safety rules 2.1.2 General safety rules If you do work at or near the engine, obey the rules that follow to prevent risks of harm or damage to personal, to equipment, or to environment.
Page 46 AA00-0000-00AAA-012A-A X92DF Operation Manual Safety precautions and safety rules • Rules for electric welding Do electric welding near the engine only if the engine is stopped. Set to OFF the electronic system and wait a minimum of one minute. Disconnect electronic modules or sensors in a radius of two meters from the welding place.
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Page 48: Safety Precautions And Safety Rules For Natural Gas
AA00-0000-00AAA-012H-A X92DF Operation Manual Safety precautions and safety rules for natural gas Safety precautions and safety rules for natural gas 2.2.1 General High concentrations of natural gas can cause dizziness and there is a risk of suffocation. Make sure that all related spaces have good airflow.
Page 49 AA00-0000-00AAA-012H-A X92DF Operation Manual Safety precautions and safety rules for natural gas 2.2.3 Precautions for work in gas hazardous zones If you do work in a gas hazardous zone, obey the rules that follow to prevent risks of harm or damage to personal, to equipment, or to environment: •...
Page 50: Contamination And Fire In The Scavenge Air Spaces
AA00-0000-00AAA-012B-A X92DF Operation Manual Contamination and fire in the scavenge air spaces Contamination and fire in the scavenge air spaces 2.3.1 Causes of contamination The primary cause of contamination is when combustion materials are blown between the piston and cylinder into the scavenge air spaces (blow-by). The contamination will be more if the fuel is not fully burned, which causes exhaust smoke.
Page 51 AA00-0000-00AAA-012B-A X92DF Operation Manual Contamination and fire in the scavenge air spaces 2.3.2 Causes of fire The causes of fires are as follows: • If sealing rings of the piston rod gland are defective, system oil and cylinder oil will collect in the piston underside.
Page 52: Fire-Fighting In The Scavenge Air Space
AA00-0000-00AAA-140B-A X92DF Operation Manual Fire-fighting in the scavenge air space Fire-fighting in the scavenge air space Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 53 AA00-0000-00AAA-140B-A X92DF Operation Manual Fire-fighting in the scavenge air space PROCEDURE If you think there is no fire, do the steps as follows: Decrease the engine power. Cut out the injection of the related cylinder. Increase the feed rate of the lubricating oil in the related cylinder to the maximum, although there is high temperature in the related cylinder.
Page 54: Explosions In The Crankcase
AA00-0000-00AAA-012C-A X92DF Operation Manual Explosions in the crankcase Explosions in the crankcase Examples of explosions in the crankcase of diesel engines have shown that they can only occur in special conditions, and thus do not occur frequently. The cause of crankcase explosions is oil mist. Oil mist comes from components that have become unusually hot.
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Page 56: Prevent Explosions In The Crankcase
AA00-0000-00AAA-012D-A X92DF Operation Manual Prevent explosions in the crankcase Prevent explosions in the crankcase Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 57 AA00-0000-00AAA-012D-A X92DF Operation Manual Prevent explosions in the crankcase PROCEDURE If an oil mist detector activates an alarm, do as follows: Decrease immediately the engine speed (power). Stop the engine if possible. Let the engine temperature decrease for a minimum of 20 minutes.
Page 58: Prevention Of Explosions In The Exhaust Gas System (Gas Mode)
• There is an electrical power failure to the engine control system (ECS). Related to the safety concept of WinGD the engine has the items and functions that follow: • The components of the exhaust gas system upstream of the turbochargers are resistant to explosions.
Page 59: Exhaust Ventilation
AA00-0000-00AAA-012G-A X92DF Operation Manual Prevention of explosions in the exhaust gas system (gas mode) 2.7.2 Ventilation sequence The ventilation sequence removes unburned gas from the exhaust gas system to the air. After an engine stop, if necessary the engine safety system (ESS) or the ECS sends a signal for a ventilation request.
Page 60: Access To Engine Spaces
AA00-0000-00AAA-012E-A X92DF Operation Manual Access to engine spaces Access to engine spaces Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel...
Page 61 AA00-0000-00AAA-012E-A X92DF Operation Manual Access to engine spaces PROCEDURE Make sure that there is always a safety person on the outer side of the engine. Wear the correct safety equipment. For a DF engine, obey the safety rules for natural gas, refer to section 2.2 Safety...
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Page 63: Design And Function Of The Engine
X92DF Operation Manual 3 Design and function of the engine Short description of the DF engine......... .
Page 64: Short Description Of The Df Engine
The engine control system (ECS) electronically controls all important engine functions (eg speed control, overspeed protection, and fuel injection). The engine control can have different remote controls, which are related to the WinGD specifications from recommended manufacturers. - 64 - Issue 002 2020-08 Winterthur Gas &...
Page 65: Pressure - Volume Diagram And Schematic Of The Two-Stroke Diesel Cycle
AA00-0000-00AAA-020B-A X92DF Operation Manual Short description of the DF engine 3.1.1 Cycle of a two-stroke DF engine in diesel mode The sequences of a two-stroke DF engine in diesel mode are as follows (refer to Figure 3-1): • Sequence 1 - 2 The piston moves up and thus compresses the scavenge air.
Page 66: Pressure - Volume Diagram And Schematic Of The Two-Stroke Otto Cycle
AA00-0000-00AAA-020B-A X92DF Operation Manual Short description of the DF engine 3.1.2 Cycle of a two-stroke DF engine in gas mode The sequences of a two-stroke DF engine in gas mode are as follows (refer to Figure 3-2): • Sequence 1 - 2 The piston moves up and thus compresses the scavenge air.
Page 67 AA00-0000-00AAA-020B-A X92DF Operation Manual Short description of the DF engine 3.1.3 Fuel sharing mode The optional fuel sharing mode enables an increased fuel flexibility. You can use liquid fuel (HFO, MDO, or MGO) and at the same time gas fuel. The fuel sharing mode has the limits that follow: •...
Page 68: Use Of The Engine
AA00-0000-00AAA-020C-A X92DF Operation Manual Use of the engine Use of the engine 3.2.1 Intended use The engine is intended to drive a propeller of a vessel. The engine changes the chemical energy of the fuel to mechanical energy. The engine must only be used in the operating range as given in the data sheets, refer to chapter 11.
Page 69 AA00-0000-00AAA-020C-A X92DF Operation Manual Use of the engine 3.2.2 Incorrect use Incorrect use of the engine can result in personal injury and in damage to physical properties. Personal injury or damage to physical properties caused by incorrect use will be the responsibility of the operating company.
Page 70: Tuning Options
AA00-0000-00AAA-020C-A X92DF Operation Manual Use of the engine 3.2.3 Tuning Related to the contract the engine has one of the tuning options that follow (refer to Figure 3-4): • Standard tuning The standard tuning gives a good fuel consumption over the full engine power range.
Page 71 In this configuration the installation must have been done related to the specified rules of the classification societies and of WinGD. You can operate the two engines in different modes, for example port engine (001) is in diesel mode and, if gas mode is applicable, starboard engine (002) is in gas mode.
Page 72: The Relation Between Engine And Propeller
AA00-0000-00AAA-042B-A X92DF Operation Manual The relation between engine and propeller The relation between engine and propeller 3.3.1 General There is a specified relation between the propeller speed and the absorbed power in ships that have fixed pitch propellers. The relation is between the propeller and the speed at which it turns.
Page 73: Schematic Diagram - Relation Speed/Power (Fpp)
AA00-0000-00AAA-042B-A X92DF Operation Manual The relation between engine and propeller 3.3.2 Fixed pitch propeller (FPP) 3.3.2.1 Continuous service rating Point A (Figure 3-7) shows the power and speed of a ship that operates at contractual speed in calm seas with a new clean hull and propeller. A power / speed combination at point D is necessary for the same ship at the same speed during service conditions with aged hull and average weather.
Page 74 AA00-0000-00AAA-042B-A X92DF Operation Manual The relation between engine and propeller • Line 2 is the overload limit. This is a constant MEP line from 100% power and 93.8% speed to 110% power and 103.2% speed. 103.2% speed is the intersection point between the nominal propeller property and 110% power.
Page 75: Schematic Diagram - Relation Speed/ Power (Cpp)
AA00-0000-00AAA-042B-A X92DF Operation Manual The relation between engine and propeller 3.3.3 Controllable pitch propeller (CPP) 3.3.3.1 Load ranges After engine start, the engine operates at an idle speed of up to 70% of the rated engine speed with zero pitch. From idle speed, the propeller pitch must be increased with constant engine...
Page 76 Operation Manual The relation between engine and propeller (eg shaft generator adjustment) when there are an authorized representatives of the engine builder on board. More requests must be agreed from WinGD. 3.3.3.2 Control System The CPP control functions are usually part of the engine control system and include the functions in the paragraphs that follow.
Page 77: Design And Function Of Systems
X92DF Operation Manual 4 Design and function of systems General for systems............
Page 78: General For Systems
AA00-0000-00AAA-043U-A X92DF Operation Manual General for systems General for systems In the chapters that follow you can find a short description of the systems of the engine. The descriptions and figures are generic and simplified. You can find an overview of the used line codes in Figure 4-1.
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Page 80: Cooling Water System
AA00-0000-00AAA-043A-A X92DF Operation Manual Cooling water system Cooling water system The cooling water system supplies the items that follow with cooling water: • Cylinder liner • Cylinder cover • Exhaust valve cages • Scavenge air cooler (SAC). For the schematic diagrams, refer to section 13.1 Schematic diagrams -...
Page 81: Cooling Water System (Generic And Simplified)
AA00-0000-00AAA-043A-A X92DF Operation Manual Cooling water system Fig 4-2 Cooling water system (generic and simplified) Cyl. 1 Cyl. n Legend Automatic venting unit Orifice Cyclone separator Shut-off valve cooling water inlet Temperature control valve Drain valve (usually closed) Check valve...
Page 82: Wash-Water System
AA00-0000-00AAA-043P-A X92DF Operation Manual Wash-water system Wash-water system The wash-water system supplies the scavenge air cooler (SAC) with wash-water. This lets you wash the SAC, refer to 9.5 Clean the scavenge air cooler during operation. To regularly wash the SAC increases the service life of the cooler and keeps the performance in the specified range.
Page 83: Wash-Water System (Generic And Simplified)
AA00-0000-00AAA-043P-A X92DF Operation Manual Wash-water system Fig 4-3 Wash-water system (generic and simplified) 11 12 Legend Wash-water tank Cyclone separator Scavenge air cooler (SAC) Turbocharger Auxiliary blower - 83 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 84: System Oil System
AA00-0000-00AAA-043B-A X92DF Operation Manual System oil system System oil system The system oil system supplies the items that follow with system oil: • Bearings • Gear wheels • Vibration dampers • Pistons • Crosshead assemblies • iELBA (optional) • Other running parts •...
Page 85: System Oil System (Generic And Simplified)
AA00-0000-00AAA-043B-A X92DF Operation Manual System oil system Fig 4-4 System oil system (generic and simplified) PLANT ENGINE ENGINE PLANT 23 22 22 23 Legend Turbocharger Crosshead iELBA (optional) Thrust bearing Torsional vibration damper (optional) Oil sample valve Axial vibration damper...
Page 86: Servo Oil System
AA00-0000-00AAA-043Q-A X92DF Operation Manual Servo oil system Servo oil system The servo oil system supplies the items that follow with servo oil: • Exhaust valve control units (VCU) • Cylinder lubricating pumps • Injection control units, if applicable. For the schematic diagrams, refer to section 13.1 Schematic diagrams -...
Page 87: Servo Oil System (Generic And Simplified)
AA00-0000-00AAA-043Q-A X92DF Operation Manual Servo oil system Fig 4-5 Servo oil system (generic and simplified) Cyl. 1 Cyl. 2 Cyl. n Legend Injection control unit (ICU) for X82 and X92 Oil pipe to exhaust valve Exhaust valve control unit (VCU)
Page 88: Cylinder Oil System
AA00-0000-00AAA-043R-A X92DF Operation Manual Cylinder oil system Cylinder oil system The cylinder oil system supplies cylinder oil onto the cylinder liners. The engine control system (ECS) controls the adjustable load-related supply rate of cylinder oil to each lubrication point. The engine has an automatic pre-lubrication sequence. At each engine start the ECS automatically starts this sequence.
Page 89 AA00-0000-00AAA-043R-A X92DF Operation Manual Cylinder oil system Fig 4-6 Cylinder oil system (generic and simplified, with and without iCAT) iCAT Cyl. 1 Cyl. n Legend Oil sample valve Square collector pipe Lubricating quill Rail unit Cylinder lubricating pump Change-over valve...
Page 90: Starting Air System
AA00-0000-00AAA-043C-A X92DF Operation Manual Starting air system Starting air system The starting air system turns the crankshaft before the usual combustion cycle of the engine is started. For the schematic diagrams, refer to section 13.1 Schematic diagrams - general. The starting air system has the engine connections as interface to the plant as follows (in...
Page 91: Starting Air System (Generic And Simplified)
AA00-0000-00AAA-043C-A X92DF Operation Manual Starting air system Fig 4-7 Starting air system (generic and simplified) Cyl. 1 Cyl. n Legend Solenoid valve Disengaging device turning gear Flame arrestor Starting air supply pipe Safety valve Valve unit for start E Drain valve...
Page 92: Scavenge Air System
AA00-0000-00AAA-043S-A X92DF Operation Manual Scavenge air system Scavenge air system The scavenge air system replaces the exhaust gas in the cylinder with fresh air. For the schematic diagrams, refer to section 13.1 Schematic diagrams - general. The scavenge air comes in from the outside through a duct or from the engine room. The scavenge air enters at the silencer of the turbocharger.
Page 93 AA00-0000-00AAA-043S-A X92DF Operation Manual Scavenge air system Fig 4-8 Scavenge air system 00148 Legend Exhaust gas manifold Drains Exhaust gas outlet Auxiliary blower Scavenge air inlet Piston underside Turbine Piston Compressor Scavenge air receiver Scavenge air cooler Cylinder liner Water separator...
Page 94: Control Air System
AA00-0000-00AAA-043T-A X92DF Operation Manual Control air system Control air system The control air system supplies the air spring of the exhaust valves and the starting air system with control air. For the schematic diagrams, refer to section 13.1 Schematic diagrams - general.
Page 95: Control Air System (Generic And Simplified)
AA00-0000-00AAA-043T-A X92DF Operation Manual Control air system Fig 4-9 Control air system (generic and simplified) Cyl. 1 Cyl. n Legend Air bottle Starting air shut-off valve Control air supply Valve unit for start Air tank Collector for leakage oil from the air spring...
Page 96: Exhaust Gas System
AA00-0000-00AAA-043D-A X92DF Operation Manual Exhaust gas system 4.10 Exhaust gas system The exhaust gas system collects the exhaust gas of the cylinders in a manifold. The remaining energy of the exhaust gas is used to operate the turbine of the turbocharger (002,...
Page 97: Exhaust Gas System (Generic And Simplified)
AA00-0000-00AAA-043D-A X92DF Operation Manual Exhaust gas system Fig 4-10 Exhaust gas system (generic and simplified) Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. n Legend Turbocharger bypass pipe Exhaust gas manifold Turbocharger Exhaust valve - 97 - Issue 002 2020-08...
Page 98: Fuel System
AA00-0000-00AAA-043E-A X92DF Operation Manual Fuel system 4.11 Fuel system The fuel system supplies the injection valves of the cylinders with the applicable quantity of fuel. For the schematic diagrams, refer to section 13.1 Schematic diagrams - general. The fuel system has the engine connections as interface to the plant as follows (in...
Page 99 AA00-0000-00AAA-043E-A X92DF Operation Manual Fuel system • Pressure control valve The pressure control valve (001) has different functions to control the flow and the pressure in the fuel rail. • Relief valve The relief valve (002) is a safety device. If the fuel pressure increases to more than the set value, the relief valve opens.
Page 100: Fuel System With Flv (Generic And Simplified)
AA00-0000-00AAA-043E-A X92DF Operation Manual Fuel system Fig 4-11 Fuel system with FLV (generic and simplified) Cyl. 1 Cyl. n Legend Pressure control valve Injection valve Relief valve Supply unit Flow limiting valve (FLV) Fuel pump Fuel rail Pressure retaining valve...
Page 101: Fuel System With Icu (Generic And Simplified)
AA00-0000-00AAA-043E-A X92DF Operation Manual Fuel system Fig 4-12 Fuel system with ICU (generic and simplified) Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. n 60 50 49 Legend Pressure control valve Injection valve Relief valve Supply unit Injection control unit (ICU)
Page 102: Gas System
AA00-0000-00AAA-043F-A X92DF Operation Manual Gas system 4.12 Gas system The gas system supplies the gas admission valves (GAV) of the cylinders with the applicable quantity of gas. For the schematic diagrams, refer to section 13.1 Schematic diagrams - general. The gas system has the engine connections as interface to the plant as follows (in...
Page 103: Gas System (Generic And Simplified)
AA00-0000-00AAA-043F-A X92DF Operation Manual Gas system Fig 4-13 Gas system (generic and simplified) Legend Gas detection Shut-off valve Exhaust valve control unit (VCU) Gas admission valve (GAV) Pilot fuel pump unit Vent valve Control air supply Pilot fuel valve - 103 - Issue 002 2020-08 Winterthur Gas &...
Page 104: Pilot Fuel System
AA00-0000-00AAA-043M-A X92DF Operation Manual Pilot fuel system 4.13 Pilot fuel system The pilot fuel system supplies the pilot injection valves of the cylinders with the applicable quantity of pilot fuel. For the schematic diagrams, refer to section 13.1 Schematic diagrams - general.
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Page 106: Lp Selective Catalytic Reduction System
The LP SCR system is installed after the turbocharger. The system design and the supply of components is divided between the LP SCR system supplier, the shipyard and WinGD/engine builder. The LP SCR system adds a urea water solution to the exhaust gas flow. Chemical reactions change nitrogen oxides to molecular nitrogen and water, which are not dangerous.
Page 107: Lp Scr Temperature Controlled (Example)
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system • Valves The valves in the LP SCR system are used for the different operation modes. The LP SCR system has the valves that follow: ○ V1 - reactor inlet valve ○...
Page 108: Lp Scr Bypass Rate Controlled (Example)
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system Fig 4-15 LP SCR bypass rate controlled (example) 002 003 Legend Engine Burner Urea dosing unit LP SCR reactor Decomposition unit Turbocharger 4.14.2 Operation modes The LP SCR system can be operated if the exhaust gas temperature is in the permitted limits.
Page 109 AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system 4.14.2.2 LP SCR system - preparation In this operation mode, exhaust gas causes the temperature of the LP SCR reactor to slowly increase. Urea solution is not injected. The valves have the conditions that follow: •...
Page 110: Lp Scr Control System Layout
LP Selective catalytic reduction system 4.14.3 LP SCR control system The main tasks of the WinGD control system for the LP SCR system are as follows: • Calculate the setpoint position for the turbine bypass valve (V4) to control the exhaust gas temperature.
Page 111: Lp Scr System - Principal Control Configuration
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system Fig 4-17 LP SCR system - principal control configuration Engine room Signals External main control panel (E73) 4.14.3.1 Messages of the LP SCR control system The LP SCR control system gives three messages to the alarm and monitoring system (AMS).
Page 112: Control Box E70 With Option Spc
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system 4.14.3.2 Control box E70 The control box E70 is installed on the engine and has switches and visual indicators. Fig 4-18 Control box E70 with option SPC Legend SCR bypass switch...
Page 113: Control Box E71 With Option Spc
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system 4.14.3.3 Control box E71 The control box E71 is installed on the engine or in the engine room and has switches below the LDU-20. Fig 4-19 Control box E71 with option SPC...
Page 114: Control Boxes E72 And E73
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system 4.14.3.4 Control box E72 or E73 The control box E72 (without SPC) or E73 (with SPC) is installed in the engine control room and has switches below the LDU-20. Fig 4-20...
Page 115: Lp Scr System Status (Main Page)
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system 4.14.4 LDU-20 pages The LDU-20 panel has the pages that follow (examples). Fig 4-21 LDU-20 page - LP SCR SYSTEM STATUS (MAIN PAGE) Tab 4-1 LP SCR SYSTEM STATUS (MAIN PAGE)
Page 116: Lp Scr System Overview
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system Fig 4-22 LDU-20 page - LP SCR SYSTEM OVERVIEW Tab 4-2 LP SCR SYSTEM OVERVIEW Item Function Effect INTERFACES button Opens the interfaces page INDEX button Opens the index page SCREENSHOT button...
Page 117: Lp Scr Interfaces
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system Fig 4-23 LDU-20 page - LP SCR INTERFACES Tab 4-3 LP SCR INTERFACES Item Function Effect OVERVIEW button Opens the SCR system overview page INDEX button Opens the index page SCREENSHOT button...
Page 118: Lp Scr Software Info
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system Fig 4-24 LDU-20 page - LP SCR SOFTWARE INFO Tab 4-4 LP SCR SOFTWARE INFO Item Function Effect INDEX button Opens the index page SCREENSHOT button Makes a screenshot of the current screen...
Page 119: Lp Scr Page Index
AA00-9270-00AAA-043B-A X92DF Operation Manual LP Selective catalytic reduction system Fig 4-25 LDU-20 page - LP SCR PAGE INDEX Tab 4-5 LP SCR PAGE INDEX Item Function Effect INDEX button Opens the index page SCREENSHOT button Makes a screenshot of the current screen...
Page 120: Hp Selective Catalytic Reduction System
The HP SCR system is installed between the exhaust gas manifold and the turbocharger. The system design and the supply of components is divided between the HP SCR system supplier, the shipyard and WinGD/engine builder. The HP SCR system adds an urea water solution as reducing agent to the exhaust gas flow.
Page 121: Hp Scr System - Layout
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system • Venting/sealing unit The venting/sealing unit supplies compressed air into the exhaust gas pipes for the functions that follow: ○ Blow out the exhaust gas from the reactor and the pipes after stop of the HP SCR system ○...
Page 122: Operation Limits Of Exhaust Gas Temperature After Exhaust Gas Manifold
The engine control system (ECS) calculates this value related to the engine load and to the exhaust gas pressure. NOTE: WinGD recommends to do a test of the valves regularly during engine stop, refer to Figure 4-40. 4.15.2 Operation modes The HP SCR system has the operation modes that follow.
Page 123: Hp Scr System - Emergency Bypass
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system 4.15.2.1 HP SCR system - emergency bypass In this operation mode, the HP SCR system is bypassed. The HP SCR control system opens the valve V3 quickly. The engine operates in Tier II mode.
Page 124: Hp Scr System - Change From Tier Iii To Bypass
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system 4.15.2.2 HP SCR system - bypass In this operation mode, the HP SCR system is bypassed. The engine operates in Tier II mode. Urea solution is not injected. If you change from Tier III mode to bypass mode, the HP SCR control system changes the valve conditions and starts the preservation sequence.
Page 125: Hp Scr System - Purging And Venting
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system Legend Mixing duct Venting/sealing unit Reactor Urea solution supply unit Turbine of turbocharger Soot blowing unit Engine Fig 4-29 HP SCR system - purging and venting Legend Mixing duct Venting/sealing unit...
Page 126 AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system Fig 4-30 HP SCR system - emergency bypass Legend Mixing duct Venting/sealing unit Reactor Urea solution supply unit Turbine of turbocharger Soot blowing unit Engine - 126 - Issue 002 2020-08...
Page 127: Hp Scr System - Preparation
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system 4.15.2.3 HP SCR system - preparation In this operation mode, exhaust gas causes the temperature of the HP SCR reactor to slowly increase. The engine operates in Tier II mode. Urea solution is not injected.
Page 128: Hp Scr System - Tier Iii
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system 4.15.2.4 HP SCR system - Tier III In this operation mode, the HP SCR system is set to ON. The engine operates in Tier III mode. Urea solution is injected. The valves have the conditions that follow: •...
Page 129: Hp Scr
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system 4.15.2.5 HP SCR system - at engine stop If you stop the engine in Tier III mode, the HP SCR system changes to bypass mode after some time. Related to the condition the venting/sealing unit starts for some minutes, refer to Para 4.15.2.2.
Page 130 AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system 4.15.3.1 Control box E48 The control box E48 is installed in the engine room and has switches and visual indicators. Fig 4-34 Control box E48 00561 Legend SCR bypass switch Option SPC - Indication - SPC running...
Page 131 AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system 4.15.3.2 Control box E49 The control box E49 is installed in the engine control room and has switches below the LDU-20. Fig 4-35 Control box E49 00562 Legend LDU-20 Option SPC - SPC bypass switch...
Page 132: Control Box E50
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system 4.15.3.3 Control box E50 The control box E50 is installed on the engine and has switches below the LDU-20. Fig 4-36 Control box E50 00563 Legend LDU-20 SCR bypass switch Option SPC - SPC bypass switch 4.15.3.4...
Page 133: Hp Scr System Status (Main Page)
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system Fig 4-37 LDU-20 page - HP SCR SYSTEM STATUS (MAIN PAGE) Tab 4-7 HP SCR SYSTEM STATUS (MAIN PAGE) Item Function Effect OVERVIEW button Opens the SCR system overview page INTERFACES button...
Page 134: Hp Scr System Overview
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system Fig 4-38 LDU-20 page - HP SCR SYSTEM OVERVIEW Tab 4-8 HP SCR SYSTEM OVERVIEW Item Function Effect INTERFACES button Opens the interfaces page MAN CTRL button Opens the manual control page...
Page 135: Hp Scr Interfaces
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system Fig 4-39 LDU-20 page - HP SCR INTERFACES Tab 4-9 HP SCR INTERFACES Item Function Effect OVERVIEW button Opens the SCR system overview page MAN CTRL button Opens the manual control page...
Page 136: Hp Scr Manual Valve Control
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system Fig 4-40 LDU-20 page - HP SCR MANUAL VALVE CONTROL Tab 4-10 HP SCR MANUAL VALVE CONTROL Item Function Effect OVERVIEW button Opens the SCR system overview page INTERFACES button Opens the interfaces page...
Page 137: Hp Scr Software Info
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system Item Function Effect Button and indication Gives manual control of the related valve and shows the sta- tus (serviceable only if the manual mode is permitted) Status indication Shows the engine status...
Page 138: Page - Hp Scr
AA00-9270-00AAA-043A-A X92DF Operation Manual HP Selective catalytic reduction system Item Function Effect DB number Shows identification number of the installation Fig 4-42 LDU-20 page - HP SCR PAGE INDEX Tab 4-12 HP SCR PAGE INDEX Item Function Effect INDEX button...
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Page 140: Example Of Spc
AA00-9270-00AAA-043C-A X92DF Operation Manual Steam production control system 4.16 Steam production control system The steam production control system (SPC) supplies the steam production of the ship with exhaust gas, which has a higher temperature. SPC is an optional system. NOTE: The engine obeys the IMO NOx limits, with and without steam production.
Page 141: Ldu-20 Page - Steam Production Control
AA00-9270-00AAA-043C-A X92DF Operation Manual Steam production control system Fig 4-44 LDU-20 page - STEAM PRODUCTION CONTROL Tab 4-13 STEAM PRODUCTION CONTROL (SPC) Item Function Effect ON/OFF button Starts or stops the SPC system INDEX button Opens the index page SCREENSHOT button...
Page 142 AA00-9270-00AAA-043C-A X92DF Operation Manual Steam production control system Item Function Effect PressCtrl mode 1 button Starts the PressCtrl mode 1 This mode is applicable only, if the steam pressure signal from the steam plant is correct. SPC compares the setpoint and the actual steam pressure. If there is a difference, it opens or closes the EWG to change the steam pressure.
Page 143: Ldu For The Steam Boost Mode
AA00-9270-00AAA-043C-A X92DF Operation Manual Steam production control system 4.16.4 LDU screen for steam boost mode Fig 4-45 LDU for the steam boost mode - 143 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 144 AA00-9270-00AAA-043C-A X92DF Operation Manual Steam production control system 4.16.5 Activate the steam boost mode Before activating the steam boost mode, make sure the LDU-Screen (Figure 4-45) shows the following: • Firing Pressure Gas Mode is (5) “OK” • Servo Oil (6) is “OK”...
Page 145: Design And Function Of Components
X92DF Operation Manual 5 Design and function of components Group 1 - Engine frame and bearings 5.1.1 Bedplate............
Page 146 X92DF Operation Manual 5.5.8 Exhaust valve control unit..........
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Page 148: Group 1 - Engine Frame And Bearings
AA00-1115-00AAA-043A-A X92DF Operation Manual Bedplate Group 1 - Engine frame and bearings 5.1.1 Bedplate The bedplate is the basic structure of the engine. The bearing girders (001, Figure 5-1) are attached in the bedplate and hold the crankshaft. The bottom part of the bedplate is the crankcase and collects lubricating oil. This oil flows back to the oil supply system through oil drains (002).
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Page 150: Main
AA00-1132-00AAA-043A-A X92DF Operation Manual Main bearing 5.1.2 Main bearing The main bearings hold the crankshaft (007, Figure 5-2) and transmit the forces through the bearing girders (008) into the bedplate. The bottom bearing shell (006) is installed in the bearing girder (008) of the bedplate and the top bearing shell (004) in the bearing cover (003).
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Page 152: Thrust Bearing
AA00-1203-00AAA-043A-A X92DF Operation Manual Thrust bearing 5.1.3 Thrust bearing The thrust bearing is installed on the crankshaft at the driving end of the engine. The thrust bearing flange (014, Figure 5-3) transmits the axial thrust from the propeller through the thrust pads into the bedplate: •...
Page 153: Thrust Bearing (Generic)
AA00-1203-00AAA-043A-A X92DF Operation Manual Thrust bearing Fig 5-3 Thrust bearing (generic) Legend Column Crankshaft Oil pipe 2-part oil baffle Nozzle Flywheel Arbor support Bedplate Bedplate Thrust pad (engine side) Thrust pad (driving end) Thrust bearing flange Bearing cover Column Crankshaft gear wheel...
Page 154: Monoblock Column
AA00-1406-00AAA-043A-A X92DF Operation Manual Monoblock column 5.1.4 Monoblock column The monoblock column is the middle part of the engine. The monoblock column is installed on the bedplate and holds the cylinders. On the exhaust side (ES) the monoblock column has one relief valve (001,...
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Page 156: Tie Rod
AA00-1903-00AAA-043A-A X92DF Operation Manual Tie rod 5.1.5 Tie rod The tie rods (004, Figure 5-5) keep the cylinder block (002), column (003) and bedplate (005) together at four locations around each cylinder. Fig 5-5 Tie rod (generic) Legend Protection cover...
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Page 158: Group 2 - Cylinder
AA00-2124-00AAA-043A-A X92DF Operation Manual Cylinder liner Group 2 - Cylinder 5.2.1 Cylinder liner The cylinder liner (004, Figure 5-6) is one of the primary parts of the engine. The cylinder liner (004) is on the cylinder jacket (006) and holds the cylinder cover and the water guide jackets.
Page 159: Cylinder - Cooling Water Outlet (Generic)
AA00-2124-00AAA-043A-A X92DF Operation Manual Cylinder liner Fig 5-7 Cylinder - cooling water outlet (generic) Legend Exhaust valve cage Cooling water outlet Cylinder cover Cooling water flows from the bottom water guide jacket to the top water guide jacket. Then the...
Page 160: Lubricating Quill (Generic)
AA00-2138-00AAA-043A-A X92DF Operation Manual Lubricating quill 5.2.2 Lubricating quill The lubricating quills spray oil onto the cylinder liner wall. The lubricating quills are installed on the circumference of the cylinder liner. The cylinder lubricating pump supplies a specified quantity of cylinder oil at high pressure...
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Page 162: Gas Admission Valve
AA00-2140-00AAA-043A-A X92DF Operation Manual Gas admission valve 5.2.3 Gas admission valve The two gas admission valves (GAV) per cylinder supply the gas to each combustion chamber. When the GAV opens, there is an injection of gas into the combustion chamber.
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Page 164: Piston Rod Gland
AA00-2303-00AAA-043A-A X92DF Operation Manual Piston rod gland 5.2.4 Piston rod gland The piston rod gland keeps the dirty cylinder oil in the scavenge space and thus prevents contamination of the bearing oil in the crankcase. Also, the piston rod gland seals the scavenge air from the crankcase.
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Page 166: Conventional Injection Valve
AA00-2722-00AAA-043B-A X92DF Operation Manual Conventional injection valve 5.2.5 Conventional injection valve The injection valves are installed in the cylinder cover of each cylinder. The injection valves spray the fuel into the combustion chamber. The injection control unit (ICU) controls the timing and the quantity of the injected fuel related to the power.
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Page 168: Starting Valve
AA00-2728-00AAA-043A-A X92DF Operation Manual Starting valve 5.2.6 Starting valve The starting valve in each cylinder cover supplies pressurized air into the combustion chamber in the two situations that follow: • To start the engine before combustion starts • To decrease the engine speed when combustion has stopped.
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Page 170: Relief Valve
AA00-2740-00AAA-043A-A X92DF Operation Manual Relief valve 5.2.7 Relief valve A relief valve is installed in each cylinder cover. The relief valve is used to relief the air from the cylinder for slow-turning. NOTE: Do not open the relief valve to release pressure during engine operation.
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Page 172: Exhaust Valve (Generic)
AA00-2751-00AAA-043A-A X92DF Operation Manual Exhaust valve 5.2.8 Exhaust valve The exhaust valve in each cylinder cover releases the exhaust gas of the combustion into the exhaust gas manifold. The hydraulic oil pressure from the exhaust valve control unit (VCU) opens the exhaust valve. The pneumatic pressure of the air spring closes the exhaust valve.
Page 173 AA00-2751-00AAA-043A-A X92DF Operation Manual Exhaust valve • Air spring When the exhaust valve is closed, compressed air flows through an air inlet connection into the air spring (011). When the exhaust valve opens, this air is compressed to a higher value.
Page 174: Pilot Injection Valve
AA00-2790-00AAA-043A-A X92DF Operation Manual Pilot injection valve 5.2.9 Pilot injection valve The two pilot injection valves per cylinder supply pilot fuel to each combustion chamber during gas mode to ignite the gas-air mixture. The ECS controls the pilot injection valves. The ECS calculates the injection timing and the pilot fuel quantity related to the engine load.
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Page 176: Group 3 - Crankshaft, Connecting Rod And Piston
AA00-3103-00AAA-043A-A X92DF Operation Manual Crankshaft Group 3 - Crankshaft, connecting rod and piston 5.3.1 Crankshaft The crankshaft turns as it gets the power from the pistons. The crankshaft transmits the power to the attached propeller shaft of the ship. Main bearings on the two sides of each crank (002, Figure 5-16) hold the crankshaft in position.
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Page 178: Torsional Vibration Damper
AA00-3130-00AAA-043A-A X92DF Operation Manual Torsional vibration damper 5.3.2 Torsional vibration damper The torsional vibration damper decreases the torsional vibrations in the shafting system and in other components of the engine. If a torsional vibration damper is necessary for the engine, one of the two damper types that follow can be used.
Page 179 AA00-3130-00AAA-043A-A X92DF Operation Manual Torsional vibration damper 5.3.2.1 Steel spring damper A steel spring damper (Figure 5-17) is a tuned torsional vibration damper. It consists of two main parts: • The inner part (inner star (005) and spring pack (004)) is attached to the crankshaft flange at the free end.
Page 180 AA00-3130-00AAA-043A-A X92DF Operation Manual Torsional vibration damper 5.3.2.2 Viscous damper A viscous damper (Figure 5-18) is a tuned torsional vibration damper. It consists of two main parts: • The housing (002) is fully sealed and is attached to the crankshaft flange at the free end.
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Page 182: Axial Vibration Damper (Generic)
AA00-3140-00AAA-043A-A X92DF Operation Manual Axial vibration damper 5.3.3 Axial vibration damper The axial vibration damper decreases the axial vibrations of the crankshaft. The axial vibration damper is attached with bolts to the last bearing girder at the free end of the engine.
Page 183 AA00-3140-00AAA-043A-A X92DF Operation Manual Axial vibration damper 5.3.3.1 Function Oil flows from the oil inlet (012) through the top cylinder half (002) into the two annular spaces (003). When the crankshaft (004) moves in an axial direction, the pressure of the oil in the compressed annular space (003) increases.
Page 184: Turning Gear
AA00-3206-00AAA-043A-A X92DF Operation Manual Turning gear 5.3.4 Turning gear The turning gear slowly turns the crankshaft and thus moves the pistons, if the pinion (002, Figure 5-21) is engaged on the flywheel (003). The electric motor (001) turns the pinion (002) and is attached on the driving end of the engine.
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Page 186: Connecting Rod And Connecting Rod Bearing (Generic)
AA00-3303-00AAA-043A-A X92DF Operation Manual Connecting rod and connecting rod bearing 5.3.5 Connecting rod and connecting rod bearing The connecting rod connects the crosshead with the crankshaft and converts the linear movement of the piston into a circular movement of the crankshaft.
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Page 188: Crosshead And Guide Shoe
AA00-3326-00AAA-043A-A X92DF Operation Manual Crosshead and guide shoe 5.3.6 Crosshead and guide shoe The crosshead guides the piston rod (009, Figure 5-23) and absorbs the lateral forces that come from the connecting rod (005). The piston rod (009) is attached to the compression shim (007) and the crosshead pin (006) with screws.
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Page 190: Piston
AA00-3403-00AAA-043A-A X92DF Operation Manual Piston 5.3.7 Piston The piston moves in each cylinder. The piston rings seal the combustion chamber. The piston transmits the force from the gas that expands in the cylinder to the crankshaft through the connecting rod.
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Page 192: Group 4 - Supply Unit Drive And Control Components
AA00-4104-00AAA-043A-A X92DF Operation Manual Supply unit drive Group 4 - Supply unit drive and control components 5.4.1 Supply unit drive The supply unit drive is installed at the driving end of the engine on the fuel side. The crankshaft gear wheel (003, Figure 5-25) moves the intermediate wheel (001).
Page 193 AA00-4104-00AAA-043A-A X92DF Operation Manual Supply unit drive Fig 5-25 Supply unit drive (generic) Legend Intermediate wheel Gear wheel (servo oil pumps) Flywheel Intermediate wheel Crankshaft gear wheel Crankshaft Gear wheel (servo oil pump) - 193 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 194: Starting Air Shut-Off Valve (Example)
AA00-4325-00AAA-043A-A X92DF Operation Manual Starting air shut-off valve 5.4.2 Starting air shut-off valve The starting air shut-off valve supplies the starting air pipe with starting air. The starting air shut- off valve has a hand-wheel with three positions: • CLOSED •...
Page 195 AA00-4325-00AAA-043A-A X92DF Operation Manual Starting air shut-off valve During the start sequence the MCM-20 / IOM-20 module operates the solenoid valves (014) and (016). The control air from the control air inlet (017) opens the control valve (001) through the solenoid valve CV7014C (014) and releases the pressure in the valve space (002).
Page 196: Control Air Supply (Generic)
AA00-4605-00AAA-043A-A X92DF Operation Manual Control air supply 5.4.3 Control air supply The control air supply supplies control air to the engine. The plant supply systems supply compressed air with the specified properties at the two engine connections that follow: •...
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Page 198: Local Maneuvering Stand
AA00-4618-00AAA-043A-A X92DF Operation Manual Local maneuvering stand - Option A 5.4.4 Local maneuvering stand - Option A The local maneuvering stand has the local control panel (001, Figure 5-28) and is attached to the engine at the free end. The local control panel has the components necessary for engine operation.
Page 199 AA00-4618-00AAA-043A-A X92DF Operation Manual Local maneuvering stand - Option A 5.4.4.1 Local control panel NOTE: If a fault occurs in the remote control, which prevents engine control from the control room, you can operate the engine from the local control panel.
Page 200: Local Maneuvering Stand - Option B
AA00-4618-00AAB-043A-A X92DF Operation Manual Local maneuvering stand - Option B 5.4.5 Local maneuvering stand - Option B The local maneuvering stand has the local control panel (001, Figure 5-29) and the instrument panel (002) and is attached to the engine at the free end. The local control panel has the components necessary for engine operation.
Page 201 AA00-4618-00AAB-043A-A X92DF Operation Manual Local maneuvering stand - Option B 5.4.5.1 Local control panel The local control panel (001) has the electronic components that follow: • ME tachometer The ME tachometer (003) shows the engine speed in the ahead or astern directions.
Page 202: Local Maneuvering Stand - Option C
AA00-4618-00AAC-043A-A X92DF Operation Manual Local maneuvering stand - Option C 5.4.6 Local maneuvering stand - Option C The local maneuvering stand has the local control cabinet E26 (001, Figure 5-30) and other terminal boxes. They are attached to the engine at the free end. The terminal boxes have the components necessary for engine operation.
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Page 204: Pick-Up For Speed Measurement
AA00-4628-00AAA-043A-A X92DF Operation Manual Pick-up for speed measurement 5.4.7 Pick-up for speed measurement To measure the engine speed (rpm), proximity sensors are installed in a speed pick-up unit, attached to the support near the flywheel. For safety, there are three electrically isolated proximity sensor groups as follows: •...
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Page 206: Group 5 - Supply Unit, Pumps And Control Valves
AA00-5551-00AAA-043A-A X92DF Operation Manual Servo oil pump Group 5 - Supply unit, pumps and control valves 5.5.1 Servo oil pump The servo oil pumps (004, Figure 5-32) supply the servo oil system with oil during usual operation. The number of servo oil pumps is related to the engine.
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Page 208: Supply Unit
AA00-5552-00AAA-043A-A X92DF Operation Manual Supply unit 5.5.2 Supply unit The supply unit includes the servo oil pumps and the fuel pumps. The supply unit is installed on the column at the driving end of the engine. The gear wheels and intermediate wheels in the supply unit operate the fuel pumps and servo oil pumps, refer to section 5.4.1 Supply unit...
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Page 210: Supply Unit Pilot Fuel
AA00-5555-00AAA-043A-A X92DF Operation Manual Supply unit pilot fuel 5.5.3 Supply unit pilot fuel The supply unit pilot fuel increases the pressure of the pilot fuel to the necessary value. The supply unit pilot fuel (Figure 5-34) has the items that follow: •...
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Page 212: Fuel Pump
AA00-5556-00AAA-043A-A X92DF Operation Manual Fuel pump 5.5.4 Fuel pump The fuel pumps (001, Figure 5-35) supply the fuel rail with fuel at high pressure. The number of fuel pumps is related to the engine. Fig 5-35 Fuel pump (generic) Legend...
Page 213: Fuel Pump - Cross Section (Example)
AA00-5556-00AAA-043A-A X92DF Operation Manual Fuel pump Fig 5-36 Fuel pump - cross section (example) Legend HP fuel to fuel rail Guide piston Fuel inlet Driver (of pump plunger) Pump plunger Regulating sleeve Compression spring Toothed rack Bottom spring carrier Fuel outlet...
Page 214: Injection Control Unit
AA00-5564-00AAA-043A-A X92DF Operation Manual Injection control unit 5.5.5 Injection control unit For each cylinder there is one injection control unit (ICU) installed on the fuel rail. The ICU changes the electrical signal from the ECS to the required fuel quantity for the injection.
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Page 216: Pressure Control Valve
AA00-5562-00AAA-043A-A X92DF Operation Manual Pressure control valve 5.5.6 Pressure control valve The pressure control valve (PCV) (002, Figure 5-38) is attached to the fuel rail (007) and has the functions that follow: • Usual operation During usual operation the engine software controls the fuel flow and thus the fuel pressure.
Page 217: Pressure Control Valve - Location (Example)
AA00-5562-00AAA-043A-A X92DF Operation Manual Pressure control valve Fig 5-38 Pressure control valve - location (example) Legend Solenoid valve (ZV7061S) Fuel return pipe Pressure control valve (10-5562_E0_5) Rail unit Relief valve Fuel rail Fuel return pipe Drain pipe - 217 - Issue 002 2020-08 Winterthur Gas &...
Page 218: Flow Limiting Valve
AA00-5565-00AAA-043A-A X92DF Operation Manual Flow limiting valve 5.5.7 Flow limiting valve For each cylinder there is one flow limiting valve installed on the fuel rail. The position of the piston (003, Figure 5-39) gives the quantity of fuel for the injection. When the injection valves open, the piston (003) moves to the right until the injection stops.
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Page 220: Exhaust Valve Control Unit
AA00-5612-00AAA-043A-A X92DF Operation Manual Exhaust valve control unit 5.5.8 Exhaust valve control unit The exhaust valve control units (VCU) control the servo oil to the exhaust valve of the related cylinders. The exhaust valve control units are attached to the servo oil rail.
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Page 222: Group 6 - Scavenge Air Components
AA00-6420-00AAA-043A-A X92DF Operation Manual Scavenge air receiver Group 6 - Scavenge air components 5.6.1 Scavenge air receiver The scavenge air receiver (005, Figure 5-41) supplies the cylinders with the applicable quantity of air. The scavenge air receiver is a welded assembly attached to the cylinder block on the exhaust side.
Page 223: Scavenge Air Receiver - Cross Section (Example)
AA00-6420-00AAA-043A-A X92DF Operation Manual Scavenge air receiver Fig 5-42 Scavenge air receiver - cross section (example) Legend Air space Outlet to piston underside Longitudinal wall Flap Receiver space - 223 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 224: Turbocharger
8.3 Start the engine - general. WinGD recommends to regularly clean the turbochargers and the silencers, refer to section Clean the turbocharger during operation. This prevents or decreases contamination of the turbochargers and thus increases the time between overhauls.
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Page 226: Auxiliary Blower
AA00-6545-00AAA-043A-A X92DF Operation Manual Auxiliary blower 5.6.3 Auxiliary blower The two auxiliary blowers supply air from the air space into the receiver space during the engine start and during operation at low load. Flaps prevent airflow back from the receiver space to the air space during usual operation of the turbochargers and during engine stop.
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Page 228: Switch Box (Generic)
AA00-6547-00AAA-043A-A X92DF Operation Manual Auxiliary blower switch box 5.6.4 Auxiliary blower switch box The auxiliary blower switch box controls and gives data about the condition of the auxiliary blowers. Fig 5-45 Switch box (generic) Legend Indicator (auxiliary blower No. 2 running) Restart push button Indicator (auxiliary blower No.
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Page 230: Scavenge Air Cooler
Air flow Cooling water inlet Cooling water outlet Cover WinGD recommends to regularly clean the scavenge air coolers, refer to section 9.5 Clean the scavenge air cooler during operation. This prevents or decreases contamination of the scavenge air coolers and thus increases the time between overhauls.
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Page 232: Water Separator
AA00-6708-00AAA-043A-A X92DF Operation Manual Water separator 5.6.6 Water separator The water separator removes water from the scavenge air. This prevents damage and gives better combustion in the cylinders. Water occurs when the scavenge air cooler (SAC) decreases the temperature of wet air. Water also occurs during the wash procedure of the SAC.
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Page 234: Cylinder Lubrication
AA00-7218-00AAB-043A-A X92DF Operation Manual Cylinder lubrication Group 7 - Cylinder lubrication 5.7.1 Cylinder lubrication For more data about the cylinder oil system, refer to section 4.6 Cylinder oil system. 5.7.1.1 Cylinder lubricating pump Each cylinder has a cylinder lubricating pump. The cylinder lubricating pumps are connected to the distributor pipe (mini-rail) in the rail unit.
Page 235: Usual Vertical Oil Supply
AA00-7218-00AAB-043A-A X92DF Operation Manual Cylinder lubrication 5.7.1.2 Supply of cylinder oil Cylinder oil is injected on to the cylinder liner wall through the lubricating quills installed on the circumference of the support ring. The nozzle tip in the lubricating quill has holes in specified positions. The cylinder oil flows out of these holes at high pressure.
Page 236: Effect Of Second Order Moments (M2V) Of The Engine
AA00-7752-00AAA-043A-A X92DF Operation Manual Integrated electrical balancer (iELBA) 5.7.2 Integrated electrical balancer (iELBA) The optional integrated ELectrical BAlancer (iELBA) decreases second order vertical mass moments (M2v) of the engine, refer to Figure 5-50. NOTE: For the engine itself it is not necessary to install a balancer. But a balancer decreases the exitation forces of the engine.
Page 237: Ielba - Function
AA00-7752-00AAA-043A-A X92DF Operation Manual Integrated electrical balancer (iELBA) Fig 5-51 iELBA - function Legend Gear wheel Housing Counterweight Column Bearing - 237 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 238 AA00-7752-00AAA-043A-A X92DF Operation Manual Integrated electrical balancer (iELBA) 5.7.2.2 Control system Each iELBA has two control cabinets (E38 and E39). The control system monitors the speed of the electric motor and the rotating speeds and phases of the counterweights (002) and of the flywheel of the engine.
Page 239: Ielba - Control Cabinet
AA00-7752-00AAA-043A-A X92DF Operation Manual Integrated electrical balancer (iELBA) 5.7.2.4 Control cabinet Figure 5-52 shows the buttons and indications on the control cabinet of the iELBA. Fig 5-52 iELBA - control cabinet - 239 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 240 AA00-7752-00AAA-043A-A X92DF Operation Manual Integrated electrical balancer (iELBA) Tab 5-1 iELBA - control cabinet Item Function Effect Drive Power Consumption indica- Shows the electric motor current (in Ampere) tion Manual Start button Starts the iELBA (in manual mode) Manual Stop button...
Page 241: Ielba - Error Indication
AA00-7752-00AAA-043A-A X92DF Operation Manual Integrated electrical balancer (iELBA) Table 5-2 - iELBA - error indication shows the possible iELBA error indications related to the number of flashes of the indicator light. NOTE: The error indications are active in automatic mode and in manual mode.
Page 242: Group 8 - Pipes
AA00-8135-00AAA-043A-A X92DF Operation Manual Exhaust waste gate Group 8 - Pipes 5.8.1 Exhaust waste gate The optional exhaust waste gate is a by-pass pipe to the turbine (006, Figure 5-53) of the turbochargers. The valve (007) in this pipe controls the flow of exhaust gas through the turbines (006).
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Page 244: Crank Angle Sensor Unit On Intermediate Wheel (Example)
AA00-9223-00AAA-043A-A X92DF Operation Manual Crank angle sensor unit Group 9 - Monitoring instruments 5.9.1 Crank angle sensor unit The crank angle sensor unit is installed on the supply unit drive at the driving end. There are two crank angle systems that monitor the teeth on the intermediate wheel. The two...
Page 245: Crank Angle Sensor Unit On Flywheel (Example)
AA00-9223-00AAA-043A-A X92DF Operation Manual Crank angle sensor unit Two more proximity sensors (002, Figure 5-55) are used to find the crank angle marks (004) for TDC and BDC on the flywheel (003). All proximity sensors are connected as follows: •...
Page 246: Water In Oil Monitor
AA00-9313-00AAA-043A-A X92DF Operation Manual Water in oil monitor 5.9.2 Water in oil monitor The optional water in oil monitor continuously monitors the concentration of water in the oil supply pipe. The water in oil monitor continuously sends a signal to the alarm and monitoring system (AMS).
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Page 248: Oil Mist Detector
AA00-9314-00AAA-043A-A X92DF Operation Manual Oil mist detector 5.9.3 Oil mist detector The oil mist detection system continuously monitors the concentration of oil mist in the crankcase, in the supply unit drive and in the supply unit. If there is a high oil mist concentration, the oil mist detector activates an alarm.
Page 249: Oil Mist Detector - Schematic Diagram (Example)
AA00-9314-00AAA-043A-A X92DF Operation Manual Oil mist detector Fig 5-58 Oil mist detector - schematic diagram (example) Legend Control panel Control unit E15.1 Power supply Supply unit Data cable Crankcase and gear box To alarm system Sensor To safety system Data communication is between the control unit (006, Figure 5-58) and the control panel (001).
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Page 251: Control System
X92DF Operation Manual 6 Control system Engine control system UNIC..........
Page 252 X92DF Operation Manual 6.8.33 LDU-20 page - IMO CRC INFO........
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Page 254: Engine Control System Unic
The engine control system (ECS) is an embedded system that has a modular design. Some parts and functions in the ECS system configuration are optional and are related to the application. The name of the WinGD engine control system is UNIfied Controls Flex (UNIC-flex). It has the items that follow: •...
Page 255: Ecs Modules
AA00-0000-00AAA-043K-A X92DF Operation Manual Engine control system UNIC Fig 6-1 ECS modules 00214 Legend Input output module (IOM-10) Cylinder control module (CCM-20) Main control module (MCM-11) Local display unit (LDU-20) 6.1.2 Functions of the engine control system The main functions of the engine control system are as follows: •...
Page 256 AA00-0000-00AAA-043K-A X92DF Operation Manual Engine control system UNIC 6.1.3 External control systems The Diesel Engine CoNtrol and OptImizing Specification (DENIS) and the engine control system (ECS) are designed so that different remote controls can be used. All nodes are fully specified.
Page 257 AA00-0000-00AAA-043K-A X92DF Operation Manual Engine control system UNIC 6.1.3.2 Alarm and monitoring system The alarm and monitoring system (AMS) is an external system and monitors the engine. The AMS gives the operator alarms and status data of the engine to make sure of safe and satisfactory engine operation.
Page 258: Signal Flow Diagram
AA00-0000-00AAA-043K-A X92DF Operation Manual Engine control system UNIC Fig 6-2 Signal flow diagram Signals for Alarm / Indication Signals for Alarm Signals for Alarm and Slowdown Indications UNIC Alarm Signals Feedback Signals from UNIC Command Orders from RCS Ethernet to ECR Manual Control...
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Page 260: Engine Control System Wecs-9520
(PCS) and the Alarm and Monitoring System (AMS) (Para 6.2.5). These data buses are the interface between the operator and engine control. Software updates must be done only with the supervision of a WinGD service engineer and in accordance with regulations that WinGD has set. 6.2.2 Components The primary components of the WECS-9520 are as follows: •...
Page 261 AA00-0000-00AAB-043K-A X92DF Operation Manual Engine control system WECS-9520 For safety, all important input and output signals of the modules have redundancy. If an FCM-20 becomes defective, the engine will continue to operate. The power supply also has redundancy. A defective FCM-20 must only be replaced with the online spare.
Page 262 AA00-0000-00AAB-043K-A X92DF Operation Manual Engine control system WECS-9520 The other actuators will continue to control the fuel pressure. At less than the medium load, the pressure relief valve releases unwanted fuel. 6.2.3.1.5 Monitored items The fuel pressure is monitored. If the pressure is out of the tolerance, a failure indication shows.
Page 263 AA00-0000-00AAB-043K-A X92DF Operation Manual Engine control system WECS-9520 The timing can be set to the applicable crank angles. A controlled quantity of lubricating oil flows above, into and below the piston ring pack. If an FCM-20 or bus becomes defective, the other FCM-20 module or bus makes sure that control of the cylinder oil system continues.
Page 264 AA00-0000-00AAB-043K-A X92DF Operation Manual Engine control system WECS-9520 6.2.4.1.4 Injection control The fuel injection control is as follows: • Data from the crank angle and VIT are used to calculate the injection start. • The rail valves are activated to release the injection.
Page 265 AA00-0000-00AAB-043K-A X92DF Operation Manual Engine control system WECS-9520 • After the crankshaft has completed one full turn, the timing for the subsequent cycle is compared to the deadtime of the cycle before and corrected. 6.2.4.2.4 Emergency mode If a valve stroke sensor becomes defective, the system uses the average time settings from the serviceable cylinders for the open and close dead-times.
Page 266 AA00-0000-00AAB-043K-A X92DF Operation Manual Engine control system WECS-9520 The WECS-9520 selects a cylinder at random and starting air flows into this cylinder. The position of the crankshaft means that the engine will start to turn slowly ahead, astern or stay in position.
Page 267 AA00-0000-00AAB-043K-A X92DF Operation Manual Engine control system WECS-9520 6.2.5.1 Propulsion control system The propulsion control system (PCS) has the subsystems that follow: • The remote control system (RCS) • The electronic speed control system (SCS) • The safety system •...
Page 268 AA00-0000-00AAB-043K-A X92DF Operation Manual Engine control system WECS-9520 • Transfers the fuel command to the WECS-9520. The fuel quantity limit is related to the scavenge air pressure and engine protection. The WECS-9520 receives a fuel command signal from the governor. This signal is transmitted to all the FCM-20.
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Page 270: Engine Control System Wice
The optional angle calculation modules (ACM #1 and #2) are installed in the terminal boxes E96.1 and E96.2. Redundant system buses connect all these modules. Software updates must be done only with the supervision of a WinGD service engineer and in accordance with regulations that WinGD has set. - 270 - Issue 002 2020-08 Winterthur Gas &...
Page 271 AA00-0000-00AAC-043K-A X92DF Operation Manual Engine control system WiCE 6.3.2 Functions of the engine control system The main functions of the engine control system are as follows: • Starting valve control • Servo oil pressure control • Exhaust valve control •...
Page 272 AA00-0000-00AAC-043K-A X92DF Operation Manual Engine control system WiCE 6.3.3 External control systems The Diesel Engine CoNtrol and OptImizing Specification (DENIS) and the engine control system (ECS) are designed so that different remote controls can be used. All nodes are fully specified.
Page 273 AA00-0000-00AAC-043K-A X92DF Operation Manual Engine control system WiCE 6.3.3.2 Alarm and monitoring system The alarm and monitoring system (AMS) is an external system and monitors the engine. The AMS gives the operator alarms and status data of the engine to make sure of safe and satisfactory engine operation.
Page 274: Intelligent Combustion Control
AA00-9308-00AAA-043A-A X92DF Operation Manual Intelligent combustion control Intelligent combustion control The intelligent combustion control (ICC) permanently monitors and automatically controls the combustion process. The ICC is part of the engine control system (ECS). All ICC modifications of the engine control parameters obey the IMO regulations and are related to the IMO certificate of the vessel.
Page 275: Icc - Pressure Diagram
AA00-9308-00AAA-043A-A X92DF Operation Manual Intelligent combustion control 6.4.1 Pressure calculation In the ICC system, the compression pressure of each cycle is calculated with the polynomial formula and the data of the piston position. The peak firing pressure (002, Figure 6-3) is the highest measured pressure value in the crank angle range between the start of the injection and approximately 20°CA after TDC.
Page 276: Icc - Control Schematic
AA00-9308-00AAA-043A-A X92DF Operation Manual Intelligent combustion control 6.4.2 ICC control A pressure transmitter is installed on each cylinder cover. The cylinder pressure data of each cylinder is taken as an analogue input signal from the pressure transmitter into the ECS.
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Page 278: Gas Valve Unit And External Gas Supply System
AA00-8014-00AAA-042A-A X92DF Operation Manual Gas valve unit and external gas supply system Gas valve unit and external gas supply system 6.5.1 External gas supply The external gas supply system upstream of the gas valve unit (GVU) contains the gas supply pipes and the pressurized gas supply.
Page 279: Gvu-Ed
AA00-8014-00AAA-042A-A X92DF Operation Manual Gas valve unit and external gas supply system 6.5.4.1 GVU-ED This closed design Figure 6-5 has pipes with double walls installed in a gas-tight area. This gas- tight area has continuous and sufficient airflow. This design can be safely installed in engine rooms.
Page 280: Gvu-Od
AA00-8014-00AAA-042A-A X92DF Operation Manual Gas valve unit and external gas supply system Fig 6-6 GVU-OD The isolated room Figure 6-7 is gas-tight and follows these standards: All electrical equipment follows the standards in the ATEX Directives (Equipment for potentially explosive atmospheres) An ATEX approved airlock of sufficient dimensions for one person is installed at the entrance of the GVU room.
Page 281: Gvu-Od: Schematic Diagram For Installation
AA00-8014-00AAA-042A-A X92DF Operation Manual Gas valve unit and external gas supply system Fig 6-7 GVU-OD: Schematic Diagram for Installation 6.5.5 GVU control panel The control system controls all functions of the GVU. The control system sends a signal to the solenoids that control pneumatically activated valves.
Page 282 AA00-8014-00AAA-042A-A X92DF Operation Manual Gas valve unit and external gas supply system Fig 6-8 GVU Control Panel 6.5.6 Purging the fuel gas pipes (Inerting) Use inert gas like nitrogen to replace the fuel gas in the fuel gas pipes. This process makes sure that there is no gas leakage into the engine room and removes possible dangers.
Page 283: Fuel Gas Removal From The Fuel Gas Pipes: Schematic Diagram
AA00-8014-00AAA-042A-A X92DF Operation Manual Gas valve unit and external gas supply system Fig 6-9 Fuel gas removal from the fuel gas pipes: Schematic Diagram - 283 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 284: Igpr - Schematic Diagram
AA00-8904-00AAA-043A-A X92DF Operation Manual Integrated gas pressure regulation Integrated gas pressure regulation The integrated gas pressure regulation (iGPR) controls the gas pressure of the gas that is supplied to the engine inlet. The iGPR control system has also other functions as follows: •...
Page 285 AA00-8904-00AAA-043A-A X92DF Operation Manual Integrated gas pressure regulation • Starts step 2 (automatic leakage test): ○ Activates the leakage test active signal from iGPR to PCS and ECS. • Pressurizes the iGPR piping. • Monitors the pressure drop in the iGPR piping.
Page 286 AA00-8904-00AAA-043A-A X92DF Operation Manual Integrated gas pressure regulation If there is a usual gas trip and the ECS parameter “vent valve active mode” is OFF, or if there is a gas trip with automatic inerting request, or if there is an engine shutdown, the iGPR control system automatically starts the steps that follow: •...
Page 287 AA00-8904-00AAA-043A-A X92DF Operation Manual Integrated gas pressure regulation • If the inerting sequence was not successful, the iGPR control system activates the inerting failed signal from iGPR to PCS. 6.6.6 Engine maintenance If you have to do maintenance on the engine or on the iGPR or on the supply line, you have to start the related maintenance mode, refer to section 8.22 Prepare the engine for standstill...
Page 288: Ldu-20 - Overview
AA00-0000-00AAA-043H-A X92DF Operation Manual Local display unit (LDU-20) - general Local display unit (LDU-20) - general 6.7.1 Local display unit (LDU-20) The LDU-20 (Figure 6-11) is a multi-purpose module that has an LCD color display (009), ten multi-function buttons (004 to 008) and a rotary button (003).
Page 289: Ldu-20 Color Display - General Items
AA00-0000-00AAA-043H-A X92DF Operation Manual Local display unit (LDU-20) - general 6.7.2 Color display The color display (009) of the LDU-20 shows different pages for each application. After boot-up, or when you push the HOME button, the MAIN page is shown.
Page 290: Local Display Unit (Ldu-20) - Option For Unic - Pages
AA00-0000-00AAA-131I-A X92DF Operation Manual Operate the local display unit (LDU-20) Local display unit (LDU-20) - Option for UNIC - pages 6.8.1 Operate the local display unit (LDU-20) Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
Page 291: Ldu-20 - Navigation Menu
AA00-0000-00AAA-131I-A X92DF Operation Manual Operate the local display unit (LDU-20) PROCEDURE Fig 6-13 LDU-20 - navigation menu 00210 To change between LDU-20 pages, do the steps that follow: Push and hold the rotary button for three seconds to show the page navigation...
Page 292 AA00-0000-00AAA-131I-A X92DF Operation Manual Operate the local display unit (LDU-20) To operate the engine from the MAIN page, do the steps that follow: NOTE: The changes have an immediate effect on the engine. Make sure that the LDU-20 is the active control location. If necessary, select the CTRL.TR button to transfer control.
Page 293 Push the rotary button to take a screenshot of the page. NOTE: The screenshot will be automatically saved to the USB drive. If necessary, send the saved xx.png file to WinGD. To download backup files from the SYSTEM STATUS page, do the steps that follow: NOTE: The dialog box that is shown gives an option to download, or not to download the backup files to the selected modules.
Page 294 NOTE: You use the partial upgrade wizard to adjust software parameters, which the user does not usually have access. A file from WinGD stored on a USB drive is necessary. NOTE: Connect the USB drive to the USB port on the back of the LDU-20.
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Page 296: Ldu-20 Pages - General For Df Engine
AA00-9606-01AAA-043B-A X92DF Operation Manual LDU-20 pages - general for DF engine 6.8.2 LDU-20 pages - general for DF engine In the chapters that follow you can find a description of the LDU-20 pages that follow: • 6.8.3 LDU-20 page - MAIN •...
Page 297 AA00-9606-01AAA-043B-A X92DF Operation Manual LDU-20 pages - general for DF engine • 6.8.37 LDU-20 page - TEMPERATURES • 6.8.38 LDU-20 page - USER PARAMETERS • 6.8.40 LDU-20 page - LOG ENTRY DATA • 6.8.41 LDU-20 page - DATE • 6.8.42 LDU-20 page - ETHERNET •...
Page 298: Ldu-20 Page - Main
AA00-9606-02AAA-043B-A X92DF Operation Manual LDU-20 page - MAIN 6.8.3 LDU-20 page - MAIN Fig 6-14 MAIN - 298 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 299 AA00-9606-02AAA-043B-A X92DF Operation Manual LDU-20 page - MAIN Tab 6-1 MAIN Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 300 AA00-9606-02AAA-043B-A X92DF Operation Manual LDU-20 page - MAIN Item Function Effect Control location Shows the active control location Shows: Local, ECR manual, ECR remote or Bridge External fuel command setpoint Shows the fuel command setpoint that the ECS calculates re-...
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Page 302: Control Locations
AA00-9606-03AAA-043B-A X92DF Operation Manual LDU-20 page - CONTROL LOCATIONS 6.8.4 LDU-20 page - CONTROL LOCATIONS Fig 6-15 CONTROL LOCATIONS 00153 - 302 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 303: Control Locations
AA00-9606-03AAA-043B-A X92DF Operation Manual LDU-20 page - CONTROL LOCATIONS Tab 6-2 CONTROL LOCATIONS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 304: Fuel Mode Control
AA00-9606-04AAA-043B-A X92DF Operation Manual LDU-20 page - FUEL MODE CONTROL 6.8.5 LDU-20 page - FUEL MODE CONTROL Fig 6-16 FUEL MODE CONTROL - 304 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 305 AA00-9606-04AAA-043B-A X92DF Operation Manual LDU-20 page - FUEL MODE CONTROL Tab 6-3 FUEL MODE CONTROL Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 306: Ca Sensor Status
AA00-9606-05AAA-043B-A X92DF Operation Manual LDU-20 page - CA SENSOR STATUS 6.8.6 LDU-20 page - CA SENSOR STATUS Fig 6-17 CA SENSOR STATUS - 306 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 307 AA00-9606-05AAA-043B-A X92DF Operation Manual LDU-20 page - CA SENSOR STATUS Tab 6-4 CA SENSOR STATUS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 308: Cylinder Balancing Diesel
AA00-9606-06AAA-043B-A X92DF Operation Manual LDU-20 page - CYLINDER BALANCING DIESEL 6.8.7 LDU-20 page - CYLINDER BALANCING DIESEL Fig 6-18 CYLINDER BALANCING DIESEL - 308 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 309: Cylinder Balancing Diesel
AA00-9606-06AAA-043B-A X92DF Operation Manual LDU-20 page - CYLINDER BALANCING DIESEL Tab 6-5 CYLINDER BALANCING DIESEL Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 310: Cylinder Balancing Gas
AA00-9606-07AAA-043B-A X92DF Operation Manual LDU-20 page - CYLINDER BALANCING GAS 6.8.8 LDU-20 page - CYLINDER BALANCING GAS Fig 6-19 CYLINDER BALANCING GAS - 310 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 311: Cylinder Balancing Gas
AA00-9606-07AAA-043B-A X92DF Operation Manual LDU-20 page - CYLINDER BALANCING GAS Tab 6-6 CYLINDER BALANCING GAS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 312: Page - Cylinder Lubrication
AA00-9606-08AAA-043B-A X92DF Operation Manual LDU-20 page - CYLINDER LUBRICATION 6.8.9 LDU-20 page - CYLINDER LUBRICATION Fig 6-20 CYLINDER LUBRICATION NOTE: Some indications on this LDU-20 page are only applicable for a DF engine. - 312 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 313 AA00-9606-08AAA-043B-A X92DF Operation Manual LDU-20 page - CYLINDER LUBRICATION Tab 6-7 CYLINDER LUBRICATION Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 314: Ldu-20 Page - Icat
AA00-9606-09AAA-043B-A X92DF Operation Manual LDU-20 page - iCAT 6.8.10 LDU-20 page - iCAT Fig 6-21 iCAT (integrated Cylinder lubricant Auto Transfer) - 314 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 315 AA00-9606-09AAA-043B-A X92DF Operation Manual LDU-20 page - iCAT Tab 6-8 iCAT (integrated Cylinder lubricant Auto Transfer) Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 316 AA00-9606-09AAA-043B-A X92DF Operation Manual LDU-20 page - iCAT Item Function Effect Index button Opens the INDEX page Print button Makes a screenshot of the current screen, refer to section 6.8.31 LDU-20 page - SCREENSHOT Transfer Mode status Shows the transfer mode status: •...
Page 317 AA00-9606-09AAA-043B-A X92DF Operation Manual LDU-20 page - iCAT Page left intentionally blank - 317 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 318: Page - Dynamic Combustion Control (Dcc)
AA00-9606-10AAA-043B-A X92DF Operation Manual LDU-20 page - DYNAMIC COMBUSTION CONTROL (DCC) 6.8.11 LDU-20 page - DYNAMIC COMBUSTION CONTROL (DCC) Fig 6-22 DYNAMIC COMBUSTION CONTROL (DCC) - 318 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 319 AA00-9606-10AAA-043B-A X92DF Operation Manual LDU-20 page - DYNAMIC COMBUSTION CONTROL (DCC) Tab 6-9 DYNAMIC COMBUSTION CONTROL (DCC) Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 320: Exhaust Ventilation
AA00-9606-11AAA-043B-A X92DF Operation Manual LDU-20 page - EXHAUST VENTILATION 6.8.12 LDU-20 page - EXHAUST VENTILATION Fig 6-23 EXHAUST VENTILATION - 320 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 321 AA00-9606-11AAA-043B-A X92DF Operation Manual LDU-20 page - EXHAUST VENTILATION NOTE: For a description of the exhaust ventilation refer to section 2.7 Prevention of explosions in the exhaust gas system (gas mode). Tab 6-10 EXHAUST VENTILATION Item Function Effect START AST button...
Page 322: Exhaust Valves
AA00-9606-12AAA-043B-A X92DF Operation Manual LDU-20 page - EXHAUST VALVES 6.8.13 LDU-20 page - EXHAUST VALVES Fig 6-24 EXHAUST VALVES - 322 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 323 AA00-9606-12AAA-043B-A X92DF Operation Manual LDU-20 page - EXHAUST VALVES Tab 6-11 EXHAUST VALVES Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 324: Failure List
AA00-9606-13AAA-043B-A X92DF Operation Manual LDU-20 page - FAILURE LIST 6.8.14 LDU-20 page - FAILURE LIST Fig 6-25 FAILURE LIST - 324 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 325 AA00-9606-13AAA-043B-A X92DF Operation Manual LDU-20 page - FAILURE LIST Tab 6-12 FAILURE LIST Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 326: Failure Simulation
AA00-9606-14AAA-043B-A X92DF Operation Manual LDU-20 page - FAILURE SIMULATION 6.8.15 LDU-20 page - FAILURE SIMULATION Fig 6-26 FAILURE SIMULATION - 326 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 327: Failure Simulation
AA00-9606-14AAA-043B-A X92DF Operation Manual LDU-20 page - FAILURE SIMULATION Tab 6-13 FAILURE SIMULATION Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 328: Page - Fuel Sharing (If Applicable)
AA00-9606-15AAA-043B-A X92DF Operation Manual LDU-20 page - FUEL SHARING (if applicable) 6.8.16 LDU-20 page - FUEL SHARING (if applicable) Fig 6-27 FUEL SHARING (if applicable) - 328 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 329 AA00-9606-15AAA-043B-A X92DF Operation Manual LDU-20 page - FUEL SHARING (if applicable) Tab 6-14 FUEL SHARING (if applicable) Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 330: Fuel System
AA00-9606-16AAA-043B-A X92DF Operation Manual LDU-20 page - FUEL SYSTEM 6.8.17 LDU-20 page - FUEL SYSTEM Fig 6-28 FUEL SYSTEM NOTE: Some indications on this LDU-20 page are only applicable for a DF engine. - 330 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 331 AA00-9606-16AAA-043B-A X92DF Operation Manual LDU-20 page - FUEL SYSTEM Tab 6-15 FUEL SYSTEM Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 332: Gas Pressure
AA00-9606-17AAA-043B-A X92DF Operation Manual LDU-20 page - GAS PRESSURE 6.8.18 LDU-20 page - GAS PRESSURE Fig 6-29 GAS PRESSURE - 332 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 333 AA00-9606-17AAA-043B-A X92DF Operation Manual LDU-20 page - GAS PRESSURE Tab 6-16 GAS PRESSURE Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 334: Gas Admission Valves
AA00-9606-18AAA-043B-A X92DF Operation Manual LDU-20 page - GAS ADMISSION VALVES 6.8.19 LDU-20 page - GAS ADMISSION VALVES Fig 6-30 GAS ADMISSION VALVES - 334 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 335 AA00-9606-18AAA-043B-A X92DF Operation Manual LDU-20 page - GAS ADMISSION VALVES Tab 6-17 GAS ADMISSION VALVES Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 336: Gav Manual Valve Test
AA00-9606-19AAA-043B-A X92DF Operation Manual LDU-20 page - GAV MANUAL VALVE TEST 6.8.20 LDU-20 page - GAV MANUAL VALVE TEST Fig 6-31 GAV MANUAL VALVE TEST - 336 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 337 AA00-9606-19AAA-043B-A X92DF Operation Manual LDU-20 page - GAV MANUAL VALVE TEST Tab 6-18 GAV MANUAL VALVE TEST Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 338: Gvu & Valve Test
AA00-9606-20AAA-043B-A X92DF Operation Manual LDU-20 page - GVU & VALVE TEST 6.8.21 LDU-20 page - GVU & VALVE TEST Fig 6-32 GVU & VALVE TEST - 338 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 339 AA00-9606-20AAA-043B-A X92DF Operation Manual LDU-20 page - GVU & VALVE TEST Tab 6-19 GVU & VALVE TEST Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 340: Knock Control
AA00-9606-21AAA-043B-A X92DF Operation Manual LDU-20 page - KNOCK CONTROL 6.8.22 LDU-20 page - KNOCK CONTROL Fig 6-33 KNOCK CONTROL - 340 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 341: Knock Control
AA00-9606-21AAA-043B-A X92DF Operation Manual LDU-20 page - KNOCK CONTROL Tab 6-20 KNOCK CONTROL Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 342: Log Messages
AA00-9606-22AAA-043B-A X92DF Operation Manual LDU-20 page - LOG MESSAGES 6.8.23 LDU-20 page - LOG MESSAGES Fig 6-34 LOG MESSAGES 00164 - 342 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 343 AA00-9606-22AAA-043B-A X92DF Operation Manual LDU-20 page - LOG MESSAGES Tab 6-21 LOG MESSAGES Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 344: Main Fuel Injection
AA00-9606-23AAA-043B-A X92DF Operation Manual LDU-20 page - MAIN FUEL INJECTION 6.8.24 LDU-20 page - MAIN FUEL INJECTION Fig 6-35 MAIN FUEL INJECTION - 344 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 345 AA00-9606-23AAA-043B-A X92DF Operation Manual LDU-20 page - MAIN FUEL INJECTION Tab 6-22 MAIN FUEL INJECTION Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 346: Page Index
AA00-9606-24AAA-043B-A X92DF Operation Manual LDU-20 page - PAGE INDEX 6.8.25 LDU-20 page - PAGE INDEX Fig 6-36 PAGE INDEX - 346 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 347 AA00-9606-24AAA-043B-A X92DF Operation Manual LDU-20 page - PAGE INDEX Tab 6-23 PAGE INDEX Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 348: Performance Data Diesel
AA00-9606-25AAA-043B-A X92DF Operation Manual LDU-20 page - PERFORMANCE DATA DIESEL 6.8.26 LDU-20 page - PERFORMANCE DATA DIESEL Fig 6-37 PERFORMANCE DATA DIESEL - 348 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 349 AA00-9606-25AAA-043B-A X92DF Operation Manual LDU-20 page - PERFORMANCE DATA DIESEL Tab 6-24 PERFORMANCE DATA DIESEL Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 350: Performance Data Gas
AA00-9606-26AAA-043B-A X92DF Operation Manual LDU-20 page - PERFORMANCE DATA GAS 6.8.27 LDU-20 page - PERFORMANCE DATA GAS Fig 6-38 PERFORMANCE DATA GAS - 350 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 351 AA00-9606-26AAA-043B-A X92DF Operation Manual LDU-20 page - PERFORMANCE DATA GAS Tab 6-25 PERFORMANCE DATA GAS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 352: Pilot Fuel Injection
AA00-9606-27AAA-043B-A X92DF Operation Manual LDU-20 page - PILOT FUEL INJECTION 6.8.28 LDU-20 page - PILOT FUEL INJECTION Fig 6-39 PILOT FUEL INJECTION - 352 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 353 AA00-9606-27AAA-043B-A X92DF Operation Manual LDU-20 page - PILOT FUEL INJECTION Tab 6-26 PILOT FUEL INJECTION Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 354: Pilot Fuel Pressure
AA00-9606-28AAA-043B-A X92DF Operation Manual LDU-20 page - PILOT FUEL PRESSURE 6.8.29 LDU-20 page - PILOT FUEL PRESSURE Fig 6-40 PILOT FUEL PRESSURE - 354 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 355 AA00-9606-28AAA-043B-A X92DF Operation Manual LDU-20 page - PILOT FUEL PRESSURE Tab 6-27 PILOT FUEL PRESSURE Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 356: Scavenge Air - Ewg (Optional)
AA00-9606-29AAA-043B-A X92DF Operation Manual LDU-20 page - SCAVENGE AIR - EWG (optional) 6.8.30 LDU-20 page - SCAVENGE AIR - EWG (optional) Fig 6-41 SCAVENGE AIR - EWG (optional) - 356 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 357 AA00-9606-29AAA-043B-A X92DF Operation Manual LDU-20 page - SCAVENGE AIR - EWG (optional) This LDU-20 page is only applicable, if the engine has a controllable exhaust waste gate. Tab 6-28 SCAVENGE AIR - EWG (optional) Item Function Effect START AST button...
Page 358: Ldu-20 Page - Screenshot
AA00-9606-30AAA-043B-A X92DF Operation Manual LDU-20 page - SCREENSHOT 6.8.31 LDU-20 page - SCREENSHOT This function saves a screenshot of the page to a USB drive (if connected). The saved screenshot is a 640 x 480 pixel image in the xx.png format.
Page 359 AA00-9606-30AAA-043B-A X92DF Operation Manual LDU-20 page - SCREENSHOT Page left intentionally blank - 359 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 360: Software Info
AA00-9606-31AAA-043B-A X92DF Operation Manual LDU-20 page - SOFTWARE INFO 6.8.32 LDU-20 page - SOFTWARE INFO Fig 6-42 SOFTWARE INFO - 360 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 361 AA00-9606-31AAA-043B-A X92DF Operation Manual LDU-20 page - SOFTWARE INFO Tab 6-29 SOFTWARE INFO Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 362: Imo Crc Info
AA00-9606-32AAA-043B-A X92DF Operation Manual LDU-20 page - IMO CRC INFO 6.8.33 LDU-20 page - IMO CRC INFO Fig 6-43 IMO CRC INFO - 362 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 363 AA00-9606-32AAA-043B-A X92DF Operation Manual LDU-20 page - IMO CRC INFO Tab 6-30 IMO CRC INFO Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 364: Software Tools
AA00-9606-33AAA-043B-A X92DF Operation Manual LDU-20 page - SOFTWARE TOOLS 6.8.34 LDU-20 page - SOFTWARE TOOLS Fig 6-44 SOFTWARE TOOLS 00167 - 364 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 365 AA00-9606-33AAA-043B-A X92DF Operation Manual LDU-20 page - SOFTWARE TOOLS Tab 6-31 SOFTWARE TOOLS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 366: System Status
AA00-9606-34AAA-043B-A X92DF Operation Manual LDU-20 page - SYSTEM STATUS 6.8.35 LDU-20 page - SYSTEM STATUS Fig 6-45 SYSTEM STATUS 00166 - 366 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 367 AA00-9606-34AAA-043B-A X92DF Operation Manual LDU-20 page - SYSTEM STATUS Tab 6-32 SYSTEM STATUS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 368: System Settings
AA00-9606-35AAA-043B-A X92DF Operation Manual LDU-20 page - SYSTEM SETTINGS 6.8.36 LDU-20 page - SYSTEM SETTINGS Fig 6-46 SYSTEM SETTINGS 00169 - 368 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 369 AA00-9606-35AAA-043B-A X92DF Operation Manual LDU-20 page - SYSTEM SETTINGS Tab 6-33 SYSTEM SETTINGS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 370: Ldu-20 Page - Temperatures
AA00-9606-36AAA-043B-A X92DF Operation Manual LDU-20 page - TEMPERATURES 6.8.37 LDU-20 page - TEMPERATURES Fig 6-47 TEMPERATURES - 370 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 371 AA00-9606-36AAA-043B-A X92DF Operation Manual LDU-20 page - TEMPERATURES Tab 6-34 TEMPERATURES Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 372: User Parameters
AA00-9606-37AAA-043B-A X92DF Operation Manual LDU-20 page - USER PARAMETERS 6.8.38 LDU-20 page - USER PARAMETERS Fig 6-48 USER PARAMETERS 00159 - 372 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 373 AA00-9606-37AAA-043B-A X92DF Operation Manual LDU-20 page - USER PARAMETERS Tab 6-35 USER PARAMETERS Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 374: Gas Leak Test
AA00-9606-38AAA-043B-A X92DF Operation Manual LDU-20 page - GAS LEAK TEST 6.8.39 LDU-20 page - GAS LEAK TEST Fig 6-49 GAS LEAK TEST - 374 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 375 AA00-9606-38AAA-043B-A X92DF Operation Manual LDU-20 page - GAS LEAK TEST Tab 6-36 GAS LEAK TEST Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 376: Log Entry Data
AA00-9606-39AAA-043B-A X92DF Operation Manual LDU-20 page - LOG ENTRY DATA 6.8.40 LDU-20 page - LOG ENTRY DATA Fig 6-50 LOG ENTRY DATA 00165 - 376 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 377 AA00-9606-39AAA-043B-A X92DF Operation Manual LDU-20 page - LOG ENTRY DATA NOTE: Some data on this screen are only applicable to WinGD SW developers, eg the ID and status flag numbers. Tab 6-37 LOG ENTRY DATA Item Function Effect START AST button...
Page 378: Page - Date
AA00-9606-40AAA-043B-A X92DF Operation Manual LDU-20 page - DATE 6.8.41 LDU-20 page - DATE Fig 6-51 DATE - 378 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 379 AA00-9606-40AAA-043B-A X92DF Operation Manual LDU-20 page - DATE Tab 6-38 DATE Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 380: Ldu-20 Page - Ethernet
AA00-9606-41AAA-043B-A X92DF Operation Manual LDU-20 page - ETHERNET 6.8.42 LDU-20 page - ETHERNET Fig 6-52 ETHERNET - 380 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 381 AA00-9606-41AAA-043B-A X92DF Operation Manual LDU-20 page - ETHERNET Tab 6-39 ETHERNET Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 382: Ielba Control
AA00-9606-42AAA-043B-A X92DF Operation Manual LDU-20 page - iELBA Control (optional) 6.8.43 LDU-20 page - iELBA Control (optional) Fig 6-53 iELBA Control - 382 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 383: Ielba Control
AA00-9606-42AAA-043B-A X92DF Operation Manual LDU-20 page - iELBA Control (optional) Tab 6-40 iELBA Control Item Function Effect START AST button Starts the engine in astern direction (for reversible engine) STOP button Stops the engine START AHD button Starts the engine in ahead direction CTRL.
Page 384: Manual Control Panel (Mcp) - Option For Wice - Pages
AA00-4618-00AAC-131A-A X92DF Operation Manual Operate the manual control panel (MCP) Manual control panel (MCP) - Option for WiCE - pages 6.9.1 Operate the manual control panel (MCP) Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours...
Page 385: Mcp Page - Main Locked
AA00-4618-00AAC-131A-A X92DF Operation Manual Operate the manual control panel (MCP) PROCEDURE Fig 6-54 MCP page - MAIN locked Legend UNLOCK button Navigation field To unlock the function buttons, do the steps that follow: Touch the UNLOCK button (001, Figure 6-54) with your finger.
Page 386 AA00-4618-00AAC-131A-A X92DF Operation Manual Operate the manual control panel (MCP) To change the speed command setting, do the steps that follow: To increase the speed command setting, turn the fuel dial knob clockwise. To decrease the speed command setting, turn the fuel dial knob counterclockwise.
Page 387 AA00-4618-00AAC-131A-A X92DF Operation Manual Operate the manual control panel (MCP) Page left intentionally blank - 387 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 388: System Info
AA00-4618-03AAA-043B-A X92DF Operation Manual MCP page - SYSTEM INFO - Option for WiCE 6.9.2 MCP page - SYSTEM INFO - Option for WiCE Fig 6-55 MCP page - SYSTEM INFO Tab 6-41 SYSTEM INFO Item Function Effect Engine Shows data for the engine...
Page 389 AA00-4618-03AAA-043B-A X92DF Operation Manual MCP page - SYSTEM INFO - Option for WiCE Page left intentionally blank - 389 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 390: Mcp Page - Trend
AA00-4618-04AAA-043B-A X92DF Operation Manual MCP page - TREND - Option for WiCE 6.9.3 MCP page - TREND - Option for WiCE Fig 6-56 MCP page - TREND Tab 6-42 TREND Item Function Effect Selection field Highlights the selected parameters Diagram field...
Page 391 AA00-4618-04AAA-043B-A X92DF Operation Manual MCP page - TREND - Option for WiCE Page left intentionally blank - 391 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 392: Mcp Page - Fuel Mode Control
AA00-4618-06AAA-043B-A X92DF Operation Manual MCP page - FUEL MODE CONTROL - Option for WiCE 6.9.4 MCP page - FUEL MODE CONTROL - Option for WiCE Fig 6-57 MCP page - FUEL MODE CONTROL - 392 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 393 AA00-4618-06AAA-043B-A X92DF Operation Manual MCP page - FUEL MODE CONTROL - Option for WiCE Tab 6-43 FUEL MODE CONTROL Item Function Effect DIESEL button Switches to diesel mode, green LED comes on Indication field Shows data for diesel mode Shows: Diesel mode not available, Press again to confirm...
Page 394: Mcp Page - Gas System
AA00-4618-07AAA-043B-A X92DF Operation Manual MCP page - GAS SYSTEM 6.9.5 MCP page - GAS SYSTEM Fig 6-58 MCP page - GAS SYSTEM Tab 6-44 GAS SYSTEM Item Function Effect FAIL RESET button Resets a failure that occurred during gas preparation...
Page 395 AA00-4618-07AAA-043B-A X92DF Operation Manual MCP page - GAS SYSTEM Page left intentionally blank - 395 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 396: Mcp Page - Main
AA00-4618-01AAA-043B-A X92DF Operation Manual MCP page - MAIN 6.9.6 MCP page - MAIN Fig 6-59 MCP page - MAIN - 396 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 397 AA00-4618-01AAA-043B-A X92DF Operation Manual MCP page - MAIN Tab 6-45 MAIN Item Function Effect Indication field Shows data for start interlocks and for limiters Start interlock Info: Turning Gear Engaged, Main Start Air Valve Closed, Exhaust Venting Request, Shaft Locking Device...
Page 398: Mcp Page - Instruments
AA00-4618-02AAA-043B-A X92DF Operation Manual MCP page - INSTRUMENTS 6.9.7 MCP page - INSTRUMENTS Fig 6-60 MCP page - INSTRUMENTS Tab 6-46 INSTRUMENTS Item Function Effect Indication field Shows the values of the displayed instruments NOTE: The number of the displayed instruments is related to the engine.
Page 399 AA00-4618-02AAA-043B-A X92DF Operation Manual MCP page - INSTRUMENTS Page left intentionally blank - 399 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 400: Mcp Page - Open User Parameters
AA00-4618-05AAA-043B-A X92DF Operation Manual MCP page - Adjust user parameters 6.9.8 MCP page - Adjust user parameters Fig 6-61 MCP page - Open user parameters Item Name Effect when touched Navigation field: MENU Opens the sub-navigation fields: • INFO •...
Page 401: Mcp Page - Select User Parameter
AA00-4618-05AAA-043B-A X92DF Operation Manual MCP page - Adjust user parameters Fig 6-62 MCP page - Select user parameter Item Name Effect when touched User parameter Makes the related user parameter ad- justable. - 401 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 402 AA00-4618-05AAA-043B-A X92DF Operation Manual MCP page - Adjust user parameters Fig 6-63 MCP page - Adjust user parameter Item Name Effect when touched Adjustable user parameter. Makes the related adjustable user pa- rameter option non-adjustable. User parameter regulators Two possible effects: •...
Page 403 AA00-4618-05AAA-043B-A X92DF Operation Manual MCP page - Adjust user parameters Page left intentionally blank - 403 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 404: Mcp Page - Fuel / Lubrication System
AA00-4618-08AAA-043B-A X92DF Operation Manual MCP page - FUEL / LUBRICATION SYSTEM 6.9.9 MCP page - FUEL / LUBRICATION SYSTEM Fig 6-64 MCP page - FUEL / LUBRICATION SYSTEM - 404 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 405: Fuel / Lubrication System
AA00-4618-08AAA-043B-A X92DF Operation Manual MCP page - FUEL / LUBRICATION SYSTEM Tab 6-47 FUEL / LUBRICATION SYSTEM Item Function Effect LFO button Changes to LFO (Light Fuel Oil) HFO button Changes to HFO (Heavy Fuel Oil) LOW BN button Changes to low BN cylinder oil...
Page 406: Local Control Cabinet
AA00-4618-00AAC-043B-A X92DF Operation Manual Local control cabinet - general 6.9.10 Local control cabinet - general The local control cabinet has the items that follow, refer to Figure 6-65: • Touch screen (001) of the manual control panel (MCP) • Fuel dial knob (002) The manual control panel (MCP) is a multi-purpose module.
Page 407: Navigation Menu Of The Manual Control Panel (Mcp)
AA00-4618-00AAC-043B-A X92DF Operation Manual Local control cabinet - general Tab 6-48 Navigation menu of the manual control panel (MCP) Button Effect HOME Opens the main page INSTRUMENTS Opens the instrument page FUEL MODE Opens a sub menu for the pages that follow: •...
Page 408 AA00-4618-00AAC-043B-A X92DF Operation Manual Local control cabinet - general Button Effect LOCAL MANUAL CONTROL Green Changes from current control to local manual control, during control transfer the related two green LEDs flash, then the green LED shows the current control position...
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Page 410: Manual Control Panel (Mcp) - Option For Wecs-9520 - Pages
AA00-0000-00AAB-131A-A X92DF Operation Manual Do regular checks for WECS-9520 6.10 Manual control panel (MCP) - Option for WECS-9520 - pages 6.10.1 Do regular checks for WECS-9520 Periodicity Description Unscheduled Support equipment Description Part No. None Supplies Description None Spare Parts Description Part No.
Page 411 AA00-0000-00AAB-131A-A X92DF Operation Manual Do regular checks for WECS-9520 PROCEDURE Do each month an engine start in the LOCAL MANUAL CONTROL mode. Do each three months the checks that follow. Do a check of the level switches as follows: 2.1.1 Do a check of the electrical cable junctions.
Page 412: Wecs-9520 Manual Control Panel
AA00-4618-00AAB-043B-A X92DF Operation Manual WECS-9520 manual control panel 6.10.2 WECS-9520 manual control panel The WECS-9520 manual control panel is a multi-purpose module that has an LCD display (001, Figure 6-66) and 15 function buttons (003). Some of the function buttons have a LED indication (002).
Page 413 AA00-4618-00AAB-043B-A X92DF Operation Manual WECS-9520 manual control panel Tab 6-50 WECS-9520 manual control panel Button Effect START AHEAD None Starts the engine in ahead direction STOP Stops the engine, red LED comes on START ASTERN None Starts the engine in astern direction...
Page 414 AA00-4618-00AAB-043B-A X92DF Operation Manual WECS-9520 manual control panel Button Effect SOUND OFF-ALM. ACKN. None Sets to OFF the acoustic alarms (bell or buzzer) and changes alarm indications that flash to alarm indications that come on constantly Shows data about the version and does a check of the soft-...
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Page 416: User Parameters
AA00-0000-00AAB-043L-A X92DF Operation Manual User parameters and maintenance settings for WECS-9520 6.10.3 User parameters and maintenance settings for WECS-9520 The operator can get access to the user parameter settings without a password. The operator can get access to the maintenance settings only with a password or a key.
Page 417 AA00-0000-00AAB-043L-A X92DF Operation Manual User parameters and maintenance settings for WECS-9520 Item Parameter Function Inj. venting (Injection bleed) This function lets you bleed the injector pipes and ICUs. You can select one cylinder, or more than one cylinder. If the fuel rail pressure is more than 250 bar, the function will not operate.
Page 418: Maintenance Settings
AA00-0000-00AAB-043L-A X92DF Operation Manual User parameters and maintenance settings for WECS-9520 6.10.3.2 Maintenance settings For the available maintenance settings in ADJUST refer to Table 6-52 - Maintenance settings. Tab 6-52 Maintenance settings Item Parameter Function Crank Angle (Crank angle For crank angle settings and checks after mainte-...
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Page 420: Failure Id And Led Indications On Fcm-20
AA00-0000-00AAB-410C-A X92DF Operation Manual Failures and defects of WECS-9520 components 6.10.4 Failures and defects of WECS-9520 components Failures and defects of WECS-9520 components cause failure messages, which are transmitted to the operator flexView and alarm and monitoring system (AMS). The tables that follow will help you understand all failure indications. A two-digit LED display for the failure ID is given on the FCM-20.
Page 421: Wecs-9520 Failure Groups
AA00-0000-00AAB-410C-A X92DF Operation Manual Failures and defects of WECS-9520 components Tab 6-53 WECS-9520 failure groups Failure group Failure effect Procedure WECS-9520 pas- Failures of redundant systems (fail- Find the cause and repair as soon sive failures ure of a redundant component, sys- as possible.
Page 422: Led Color Codes
AA00-0000-00AAB-410C-A X92DF Operation Manual Failures and defects of WECS-9520 components 6.10.4.4 LED codes 6.10.4.4.1 LED color codes The color codes of the LEDs are as follows: Tab 6-55 LED color codes Color Green, stays on Indicates a correct function Green, flashes...
Page 423: Examples Of Failure Ids
AA00-0000-00AAB-410C-A X92DF Operation Manual Failures and defects of WECS-9520 components 6.10.4.6 LED indications on FCM-20 at start After the power is set to ON, on the right side of the FCM-20 the LED indications are as follows: • The SSI CA1 and CA2, and the CAN S1, S2 and M LEDs show red for approximately four seconds.
Page 424 • If necessary, replace damaged items. NOTE: For more data refer to the flexView screen. If you cannot repair a fault, speak to or send a message to WinGD. - 424 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 425 X92DF Operation Manual 7 Installation Installation............. .
Page 426 • Engine stays • Extinguishing system • Auxiliary systems. NOTE: The latest version of the Marine Installation Manual and the installation drawings are available on the WinGD website. https://www.wingd.com/ - 426 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 427: Operation
X92DF Operation Manual 8 Operation Prepare the engine before start - general........
Page 428: Prepare The Engine Before Start - General
AA00-0000-00AAA-120A-A X92DF Operation Manual Prepare the engine before start - general Prepare the engine before start - general If you have done maintenance work on the engine, make sure that you have done the related function tests and the engine is ready for operation.
Page 429 AA00-0000-00AAA-120A-A X92DF Operation Manual Prepare the engine before start - general • Control air system Make sure that the quality of the control air obeys the related specifications in section 12.2 Compressed air. Make sure that control air is available at the engine connection 49 (control air supply inlet).
Page 430: Prepare The Engine Before Start
AA00-0000-00AAA-121A-A X92DF Operation Manual Prepare the engine before start Prepare the engine before start Periodicity Description Engine start Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 431 AA00-0000-00AAA-121A-A X92DF Operation Manual Prepare the engine before start PROCEDURE Make sure that all values for operation are in the correct range, refer to section 11.2 List of usual values and safeguard settings - general. Prepare the control system for operation.
Page 432: Cooling Water System With Bypass Cooling
AA00-0000-00AAA-121A-A X92DF Operation Manual Prepare the engine before start Prepare the cooling water system for operation. For an engine with a bypass cooling water system (refer to Figure 8-1), and when the liner wall temperature is between 60°C and 90°C (for example when...
Page 433: Cooling Water System Without Bypass Cooling
AA00-0000-00AAA-121A-A X92DF Operation Manual Prepare the engine before start For an engine without a bypass cooling water system (refer to Figure 8-2), and when the liner wall temperature is between 60°C and 90°C (for example when the engine is pre-heated or after engine full stop for a sufficient period), release...
Page 434: Cooling Water System With Circulation
AA00-0000-00AAA-121A-A X92DF Operation Manual Prepare the engine before start For an engine with an internal circulation cooling water system (with circulation pump and temperature control valve, refer to Figure 8-3), and when the liner wall temperature is between 60°C and 90°C (for example when the engine is pre-...
Page 435 AA00-0000-00AAA-121A-A X92DF Operation Manual Prepare the engine before start Prepare the air systems for operation. Set all valves to their correct positions for operation. Drain the air system at the related drain valves. 4.2.1 Open the first drain valve. 4.2.2 After no more water flows out from the valve, close the drain valve.
Page 436 AA00-0000-00AAA-121A-A X92DF Operation Manual Prepare the engine before start For a DF engine, prepare the gas system for operation. Do a visual check of the gas pipes for damage. If damage is found, replace the defective gas pipes immediately. Do the gas related checks. If alarms or failure messages occur, repair the related item.
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Page 438: Start The Engine - General
AA00-0000-00AAA-130A-A X92DF Operation Manual Start the engine - general Start the engine - general 8.3.1 Usual start conditions The engine must be prepared for operation. All the auxiliary systems must be in correct operation related to section 8.2 Prepare the engine before start.
Page 439 AA00-0000-00AAA-130A-A X92DF Operation Manual Start the engine - general • For an engine with three turbochargers and one or two turbochargers are defective: Make sure that the exhaust gas temperature at the serviceable turbochargers inlet is less than the maximum permitted temperature.
Page 440: Start The Engine
AA00-0000-00AAA-131A-A X92DF Operation Manual Start the engine Start the engine Periodicity Description Engine start Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
Page 441 AA00-0000-00AAA-131A-A X92DF Operation Manual Start the engine PROCEDURE If there is a clutch coupling between engine and propeller, do the steps that follow: Engage the clutch coupling. Keep the clutch coupling engaged during operation to prevent damage to the engine.
Page 442: Do Checks During Operation - General
AA00-0000-00AAA-130B-A X92DF Operation Manual Do checks during operation - general Do checks during operation - general During operation, do regular checks of the operating values, refer to section 8.6 Do checks during operation. This prevents damage to the engine if malfunctions occur.
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Page 444: Do Checks During Operation
AA00-0000-00AAA-131B-A X92DF Operation Manual Do checks during operation Do checks during operation Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel...
Page 445 AA00-0000-00AAA-131B-A X92DF Operation Manual Do checks during operation PROCEDURE Refer to section 11.2 List of usual values and safeguard settings - general for the usual values for operation. In the control system, do a check of the data that follow: •...
Page 446 AA00-0000-00AAA-131B-A X92DF Operation Manual Do checks during operation For a DF engine, do also the checks that follow: 14.1 Do regular checks (leak checks) of the gas piping system, refer to the related data or documentation. 14.2 Do daily a check of the cylinder compression pressures on the related control panel.
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Page 448: Do Regular Safety Checks
AA00-0000-00AAA-340A-A X92DF Operation Manual Do regular safety checks Do regular safety checks Periodicity Description Months Unscheduled After maintenance work Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 4.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 449 AA00-0000-00AAA-340A-A X92DF Operation Manual Do regular safety checks PROCEDURE Make sure that the remote control system (RCS), the engine safety system (ESS), and the alarm and monitoring system (AMS) are set to ON. Do a check of the EMERGENCY STOP buttons: On the control panel in the engine control room (ECR), push the EMERGENCY STOP button.
Page 450 AA00-0000-00AAA-340A-A X92DF Operation Manual Do regular safety checks Do a check of the auxiliary blowers: Make sure that main bearing oil is available. If applicable, set to ON the turbocharger oil supply. Do a check of the applicable lubricating oil pressure, refer to section 11.2 List of...
Page 451 AA00-0000-00AAA-340A-A X92DF Operation Manual Do regular safety checks Do a check of the turning gear interlocks: Make sure that the turning gear is engaged. Make sure that the pressure transmitter PT5017C and the switch ZS5016C do not operate. NOTE: The pressure transmitter PT5017C operates at 2.0 bar.
Page 452: Maneuver The Ship - General
AA00-0000-00AAA-130C-A X92DF Operation Manual Maneuver the ship - general Maneuver the ship - general Maneuvering is the operation between leaving a port and approaching to port. Maneuvering also includes all changes during usual operation, for example changing of direction. The conditions as follows affect the speed of the ship: •...
Page 453 AA00-0000-00AAA-130C-A X92DF Operation Manual Maneuver the ship - general 8.8.2 Maneuvering at overload The engine should only be operated at overload (110% of CMCR power) during sea trials and when there is an authorized representative of the engine builder on board the ship. The limit for operation of the engine at overload is a maximum of one hour each day (refer also to section 3.3 The relation between engine and...
Page 454: Maneuver The Ship
AA00-0000-00AAA-131C-A X92DF Operation Manual Maneuver the ship Maneuver the ship Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description Specialization...
Page 455 AA00-0000-00AAA-131C-A X92DF Operation Manual Maneuver the ship PROCEDURE Select the applicable control console. To change the speed, do the steps that follow: Use the rotary button to select the fuel command button. Turn the rotary button to set the related fuel injection quantity.
Page 456: Change-Over The Diesel Fuel - General
In this situation a change-over is not possible. 8.10.1 Automatic fuel change-over WinGD recommends the installation and use of an automatic fuel change-over system to prevent problems during the change-over procedure. •...
Page 457 BN. For more data refer to the related procedures. 8.10.4.1 Engine with iCAT If the engine has an iCAT system (integrated Cylinder lubricant Auto Transfer system), WinGD recommends as follows, when you change-over the fuel: • If the iCAT system is in auto mode, the iCAT system automatically changes-over the cylinder oil at the correct time.
Page 458: Cylinder Lubricant Quantity
AA00-0000-00AAA-130D-A X92DF Operation Manual Change-over the diesel fuel - general Fig 8-4 Cylinder lubricant quantity Cylinder lubricant quantity in piping and measuring tank: ∗ ∗ [ ] = [ ] = [ ] = Volume piping: ∑ = ∑ ∗...
Page 459 AA00-0000-00AAA-130D-A X92DF Operation Manual Change-over the diesel fuel - general Page left intentionally blank - 459 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 460: Change-Over To And From Gas - General
When you operate the engine continuously in gas mode for more than one week, WinGD recommends to change back to diesel mode one time each week. In diesel mode operate the engine for approximately 5 to 10 minutes at a high load of a minimum of 60%.
Page 461 AA00-0000-00AAA-130H-A X92DF Operation Manual Change-over to and from gas - general 8.11.3 Change-over related to fuel sharing mode If the engine has the optional fuel sharing mode, the liquid fuel in use can be HFO or MDO. NOTE: You have to set the value for the ratio of liquid fuel to gas in the RCS.
Page 462: Change-Over The Diesel Fuel Automatically
• None PRELIMINARY OPERATIONS • WinGD recommends to always do this automatic change-over procedure when possible. There is no load limit of the engine to do an automatic fuel change-over. - 462 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 463 AA00-0000-00AAA-131E-A X92DF Operation Manual Change-over the diesel fuel automatically PROCEDURE Start the automatic change-over procedure, refer to the instructions of the manufacturer. CLOSE UP • None - 463 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 464: Change-Over From Hfo To Mdo Manually
• None PRELIMINARY OPERATIONS • WinGD recommends to do a manual change-over only, if an automatic change-over system is not installed or if the automatic change-over system is unserviceable. - 464 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 465 AA00-0000-00AAA-131D-A X92DF Operation Manual Change-over from HFO to MDO manually PROCEDURE Make a full time schedule for the change-over to obey the ECA rules. If you operate the engine with MDO for a long period, you must change the cylinder oil to the applicable BN at the related time, refer to section 8.10 Change-over the diesel...
Page 466: Change-Over From Mdo To Hfo Manually
• None PRELIMINARY OPERATIONS • WinGD recommends to do a manual change-over only, if an automatic change-over system is not installed or if the automatic change-over system is unserviceable. - 466 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 467 AA00-0000-00AAA-131H-A X92DF Operation Manual Change-over from MDO to HFO manually PROCEDURE Make a full time schedule for the change-over to obey the ECA rules. Make sure that you have changed the cylinder oil to the applicable BN, refer to section 8.10 Change-over the diesel fuel -...
Page 468: Change-Over To And From Gas
AA00-0000-00AAA-131J-A X92DF Operation Manual Change-over to and from gas 8.15 Change-over to and from gas Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.1 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 469 AA00-0000-00AAA-131J-A X92DF Operation Manual Change-over to and from gas PROCEDURE To change-over from liquid fuel to gas, do as follows: Make sure that the engine operates with MDO. On the related control panel start the gas mode request. NOTE: The ECS makes a test, if gas mode is available. Then the ECS sends a signal to the gas pressure control system.
Page 470: Stop The Engine - General
At the local control panel of the engine. Related to the situation and to the planned tasks after engine shutdown, WinGD recommends to operate the engine with marine diesel oil (MDO) for some time before you stop the engine, refer to section 8.13 Change-over from HFO to MDO...
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Page 472: Stop The Engine
AA00-0000-00AAA-131G-A X92DF Operation Manual Stop the engine 8.17 Stop the engine Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel Description...
Page 473 AA00-0000-00AAA-131G-A X92DF Operation Manual Stop the engine PROCEDURE Select the applicable control panel. Decrease the engine load to the minimum. On the control panel push the STOP button. NOTE: The ECS shuts down the engine in a controlled manner. For a DF engine, start the exhaust ventilation sequence, if there is a ventilation request.
Page 474: Emergency Stop The Engine - General
AA00-0000-00AAA-140A-A X92DF Operation Manual Emergency stop the engine - general 8.18 Emergency stop the engine - general To stop the engine in an emergency, do the procedure given in section 8.19 Emergency stop the engine. - 474 - Issue 002 2020-08...
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Page 476: Emergency Stop The Engine
AA00-0000-00AAA-141A-A X92DF Operation Manual Emergency stop the engine 8.19 Emergency stop the engine Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.1 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 477 AA00-0000-00AAA-141A-A X92DF Operation Manual Emergency stop the engine PROCEDURE In the control room (control console), or on the local control panel, push the EMERGENCY STOP button. NOTE: The ECS stops the engine immediately. For a DF engine, start the exhaust ventilation sequence, if there is a ventilation request.
Page 478: Prepare The Engine After Stop - General
AA00-0000-00AAA-150A-A X92DF Operation Manual Prepare the engine after stop - general 8.20 Prepare the engine after stop - general After a decrease of the engine speed to less than 8% the ECS automatically starts the post- lubrication of the cylinders.
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Page 480: Prepare The Engine For A Short Service Break
AA00-0000-00AAA-151A-A X92DF Operation Manual Prepare the engine for a short service break 8.21 Prepare the engine for a short service break Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 481 AA00-0000-00AAA-151A-A X92DF Operation Manual Prepare the engine for a short service break PROCEDURE Make sure that the auxiliary systems continue to operate. If possible, keep the cooling water warm to prevent too much temperature decrease of the engine. Open the indicator valves in the cylinder covers.
Page 482: Prepare The Engine For Standstill Maintenance
AA00-0000-00AAA-151B-A X92DF Operation Manual Prepare the engine for standstill maintenance 8.22 Prepare the engine for standstill maintenance Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 483 AA00-0000-00AAA-151B-A X92DF Operation Manual Prepare the engine for standstill maintenance PROCEDURE Open the indicator valves in the cylinder covers. Engage the turning gear. Stop the fuel supply to the engine as follows: Stop the fuel supply system from the plant.
Page 484 AA00-0000-00AAA-151B-A X92DF Operation Manual Prepare the engine for standstill maintenance For a DF engine, stop the gas system. If you have to do maintenance downstream of the block valve (CV7285), do as follows: 8.1.1 Make sure that the valve positions are in degassing state.
Page 485 12.2.2 Find the cause and repair the fault. 12.3 If necessary, apply anti-corrosion oil to give protection. If the engine must have preservation for a long period, speak to or send a message to WinGD for the applicable preservation procedures. CLOSE UP • None...
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Page 487: Service During Operation
X92DF Operation Manual 9 Service during operation Do an analysis of the system oil......... . .
Page 488: Do An Analysis Of The System Oil
AA00-0000-00AAA-371B-A X92DF Operation Manual Do an analysis of the system oil Do an analysis of the system oil Periodicity Description Working hours 3000 Working hours 6000 Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 489 Send the sample bottles in an applicable package to a laboratory for analysis. Do the procedures related to the results, refer to section [section not applicable for this engine] or to the document “Lubricants” on the WinGD website (https:// www.wingd.com/). CLOSE UP •...
Page 490: Do An Analysis Of The Cylinder Oil
AA00-0000-00AAA-371A-A X92DF Operation Manual Do an analysis of the cylinder oil Do an analysis of the cylinder oil Periodicity Description Weeks Unscheduled After a fuel change Unscheduled After a cylinder oil change Unscheduled After a feed rate change Duration for performing preliminary requirements 2.0 man-hours...
Page 491: Location Of Ball Valves - Dirty Oil Samples
AA00-0000-00AAA-371A-A X92DF Operation Manual Do an analysis of the cylinder oil PROCEDURE Fig 9-1 Location of ball valves - dirty oil samples Closed Open Open Closed 00010 Do this procedure at a minimum of one time each week, and do it also in the conditions that follow: •...
Page 492 If the oil analyses are different, do the applicable recommended procedures related to the oil analysis from the laboratory, refer to section [section not applicable for this engine] or to the document “Lubricants” on the WinGD website (https:// www.wingd.com/). CLOSE UP •...
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Page 494: Replace The Filter Element Of The Duplex Filter
AA00-7200-00AAA-200A-A X92DF Operation Manual Replace the filter element of the duplex filter Replace the filter element of the duplex filter Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 495 AA00-7200-00AAA-200A-A X92DF Operation Manual Replace the filter element of the duplex filter PROCEDURE Change over to the clean filter chamber. Drain the clogged filter chamber. Remove the cover of the clogged filter chamber. Remove the filter element from the filter chamber.
Page 496: Clean The Turbocharger During Operation
AA00-6500-00AAA-200A-A X92DF Operation Manual Clean the turbocharger during operation Clean the turbocharger during operation Periodicity Description Weeks Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 497 AA00-6500-00AAA-200A-A X92DF Operation Manual Clean the turbocharger during operation PROCEDURE Decrease the engine power to approximately 25 to 85%. Clean the compressor of the turbocharger, refer to the documentation of the manufacturer. Clean the turbine of the turbocharger, refer to the documentation of the manufacturer.
Page 498: Clean The Scavenge Air Cooler During Operation
AA00-6600-00AAA-200A-A X92DF Operation Manual Clean the scavenge air cooler during operation Clean the scavenge air cooler during operation Periodicity Description Weeks Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 499: Sac - Clean During Operation (Example)
AA00-6600-00AAA-200A-A X92DF Operation Manual Clean the scavenge air cooler during operation PROCEDURE Fig 9-2 SAC - clean during operation (example) PLANT ENGINE 1381A 1371A Turbocharger 1361A 1361L Washing Plant SAC 1381L 1371L Scavenge Air Cooler Blower Blower 4075A 4071A 00520...
Page 500 AA00-6600-00AAA-200A-A X92DF Operation Manual Clean the scavenge air cooler during operation Decrease the engine power to approximately 45%. Make sure that compressed air is available at the shut-off valve (001, Figure 9-2) and fresh water is available at the shut-off valve (009).
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Page 502: Do A Test Of The Exhaust Waste Valve
AA00-8135-00AAA-320A-A X92DF Operation Manual Do a test of the exhaust waste valve Do a test of the exhaust waste valve Periodicity Description Weeks Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.2 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 503 AA00-8135-00AAA-320A-A X92DF Operation Manual Do a test of the exhaust waste valve PROCEDURE On the related control panel manually open the exhaust waste valve. Make sure that the exhaust waste gate is open. Close the exhaust waste valve. If the check is incorrect, find the cause and repair the fault.
Page 504: Feed Rate Adjustments - Running-In
Running-in of new components - general Running-in of new components - general After an overhaul or an installation of new components of the piston running system, WinGD recommends a running-in procedure. This makes sure a correct film of cylinder oil on the piston running system is built.
Page 505 AA00-0000-00AAA-950B-A X92DF Operation Manual Running-in of new components - general Page left intentionally blank - 505 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 506: Running-In Of New Components
AA00-0000-00AAA-950A-A X92DF Operation Manual Running-in of new components Running-in of new components Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 72.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours Personnel...
Page 507 Set the feed rate to 0.9 g/kWh. CLOSE UP • After 72 hours set the feed rate to the usual settings. Refer to the document “Lubricants” on the WinGD website (https://www.wingd.com/) or to section [section not applicable for this engine] - 507 - Issue 002 2020-08 Winterthur Gas &...
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Page 509: 10 Troubleshooting
X92DF Operation Manual 10 Troubleshooting 10.1 Troubleshooting - general data..........
Page 510: Troubleshooting - General Data
This list gives data about the related malfunction. Refer to the specified sequence during troubleshooting. For repair work refer to the related section of the Maintenance Manual. If you cannot repair the malfunction, speak to or send a message to WinGD. - 510 - Issue 002 2020-08 Winterthur Gas &...
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Page 512: Servo Oil Pressure In The Distributor Pipe (Mini Rail) Is Not In The Permitted Range
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components 10.2 Malfunctions of systems and components 10.2.1 Table of malfunctions Malfunctions of the water systems (XX10NN to XX19NN) • Table 10-1 - Supply pressure of the cylinder cooling water is too low •...
Page 513: Temperature Difference Of The Fuel Outlet Of The Two Fuel Pumps Is Too High (For X35/-B Or X40/-B Engine)
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components • Table 10-28 - Temperature difference of the fuel outlet of the two fuel pumps is too high (for X35/-B or X40/-B engine) • Table 10-29 - Leakage flow from the rail unit is too high •...
Page 514 AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components • Table 10-59 - A fuel pump actuator has a failure • Table 10-60 - Power supply to the power supply box E85 has a failure • Table 10-61 - Unwanted engine speed decrease •...
Page 515: Supply Pressure Of The Cylinder Cooling Water Is Too Low
There are leaks in the cooling wa- • Find the cause and repair the fault. ter system (for example cracks in a cylinder liner) For X92DF, the booster pump is • Repair the booster pump. defective Tab 10-2 Supply temperature of the cylinder cooling water is too low...
Page 516: Supply Temperature Of The Cooling Water To The Sac Is Too Low
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components Tab 10-5 Supply temperature of the cooling water to the SAC is too low Indication Possible cause Procedure TE1371A The cooling water supply system • Find the cause and repair the fault.
Page 517: Lubricating Oil Supply Pressure At The Engine Inlet Is Too Low
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components 10.2.3 Malfunction of the oil systems (XX20NN to XX31NN) Tab 10-7 Lubricating oil supply pressure at the engine inlet is too low Indication Possible cause Procedure PT2001A The oil supply system is defective •...
Page 518: Servo Oil Leakage Flow From The Servo Oil Supply Unit Is Too High
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components Tab 10-12 Servo oil leakage flow from the servo oil supply unit is too high Indication Possible cause Procedure LS2055A The servo oil unit or a servo oil • Find the cause and repair the fault, refer to...
Page 519: Piston Cooling Oil Temperature Downstream Of A Piston Is Too High
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components Tab 10-16 Piston cooling oil temperature downstream of a piston is too high Indication Possible cause Procedure TE2501-nnA This is a result of the malfunction • Do the repair shown there.
Page 520: Damper Oil Supply Pressure Upstream Of The Torsional Vibration Damper Is Too Low
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components Tab 10-21 Damper oil supply pressure upstream of the torsional vibration damper is too low Indication Possible cause Procedure PT2711A There is an incorrect setting of the • Set the throttle valve to the correct value.
Page 521: Fuel Supply Temperature Is Not In The Permitted Range
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components 10.2.4 Malfunction of the fuel system (XX34NN) Tab 10-25 Fuel supply temperature is not in the permitted range Indication Possible cause Procedure TE3411A The fuel supply system is defec- • Find the cause and repair the fault.
Page 522: Fuel Leakage Flow From Fuel Rail Items Is Too High (Engine With Icu)
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components NOTE: The leakage flow from the FLV is related to the viscosity of the used fuel. Tab 10-31 Fuel leakage flow from fuel rail items is too high (engine with ICU)
Page 523: Gas Concentration In Piston Underside Is Too High
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components 10.2.5 Malfunctions of systems for DF engine (XX33NN to XX39NN) Tab 10-34 Gas concentration in piston underside is too high Indication Possible cause Procedure AE3315C There is a leakage in the gas sys- •...
Page 524: Exhaust Gas Temperature Downstream Of A Cylinder Is Too High
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components 10.2.6 Malfunctions of the exhaust gas system (XX37NN) Tab 10-37 Exhaust gas temperature downstream of a cylinder is too high Indication Possible cause Procedure TE3701-nnA The scavenge air flow is too low •...
Page 525: Exhaust Gas Temperature Downstream Of A Turbocharger Is Too High
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components Tab 10-40 Exhaust gas temperature downstream of a turbocharger is too high Indication Possible cause Procedure TE3731-nnA A turbocharger surges • As a temporary procedure, decrease the engine load. • If applicable, open the exhaust waste gate valve.
Page 526: Scavenge Air Temperature In The Receiver Is Too High
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components 10.2.7 Malfunction of the air systems (XX40NN to XX44NN) Tab 10-43 Scavenge air temperature in the receiver is too high Indication Possible cause Procedure TE4031-nnA This is a result of the malfunction •...
Page 527: Condensation Flow At A Water Separator Is Too High
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components Tab 10-47 Condensation flow at a water separator is too high Indication Possible cause Procedure LS4071-nnA The filter in the return pipe is clog- • Clean the filter. The opening in the return pipe is •...
Page 528: Pressure Of The Air Spring Air Supply Is Too Low
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components Tab 10-52 Pressure of the air spring air supply is too low Indication Possible cause Procedure PT4341A There is an incorrect setting of the • Set the control air supply to the correct val-...
Page 529: Temperature Of A Thrust Bearing Pad Is Too High
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components 10.2.8 Miscellaneous malfunctions (XX45NN to XX52NN) Tab 10-57 Temperature of a thrust bearing pad is too high Indication Possible cause Procedure TE4521A This is a result of the malfunction • Do the repair shown there.
Page 530: Power Supply To The Power Supply Box E85 Has A Failure
AA00-0000-00AAA-410C-A X92DF Operation Manual Malfunctions of systems and components Tab 10-60 Power supply to the power supply box E85 has a failure Indication Possible cause Procedure XS5056A The power supply is set to OFF • Set to ON the power supply.
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Page 532: Examine The Supply Unit For Servo Oil Leakage
AA00-0000-00AAA-311A-A X92DF Operation Manual Examine the supply unit for servo oil leakage 10.3 Examine the supply unit for servo oil leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 533: Example Of Inspection Point
AA00-0000-00AAA-311A-A X92DF Operation Manual Examine the supply unit for servo oil leakage PROCEDURE Do a check of the level switch LS2055A for free flow. If necessary, clean the bore of the pipe of the level switch. Carefully do a check of the temperature of the oil leakage pipe of each servo oil pipe to find the leakage pipe that has an oil flow.
Page 534 AA00-0000-00AAA-311A-A X92DF Operation Manual Examine the supply unit for servo oil leakage If there is no oil flow from none of the leakage pipes, find (if applicable) the connecting pipe that has a leakage as follows: Carefully loosen the screw plug of the inspection point of the first connecting pipe a maximum of two turns.
Page 535 AA00-0000-00AAA-311A-A X92DF Operation Manual Examine the supply unit for servo oil leakage Page left intentionally blank - 535 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 536: Examine The Supply Unit For Fuel Leakage
AA00-0000-00AAA-311B-A X92DF Operation Manual Examine the supply unit for fuel leakage 10.4 Examine the supply unit for fuel leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 537: Supply Unit (Example) And Example Of Inspection Point
AA00-0000-00AAA-311B-A X92DF Operation Manual Examine the supply unit for fuel leakage PROCEDURE Do a check of the level switch LS3426A (if applicable also LS3427A) for free flow. If necessary, clean the bore of the pipe of the level switch. Carefully do a check of the temperature of the fuel leakage pipe (002,...
Page 538 AA00-0000-00AAA-311B-A X92DF Operation Manual Examine the supply unit for fuel leakage Step 4 again for the other inspection points. If the related HP fuel pipes are tight, a fuel pump is defective. Thus do an overhaul of the fuel pump, refer to the Maintenance Manual 5556-1.
Page 539 AA00-0000-00AAA-311B-A X92DF Operation Manual Examine the supply unit for fuel leakage Page left intentionally blank - 539 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 540: Examine The Rail Unit For Leakage
AA00-0000-00AAA-311E-A X92DF Operation Manual Examine the rail unit for leakage 10.5 Examine the rail unit for leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 541 AA00-0000-00AAA-311E-A X92DF Operation Manual Examine the rail unit for leakage PROCEDURE Do a check of the level switch LS3444A (if applicable also LS3445A) for free flow. If necessary, clean the bore of the pipe of the level switch. Carefully look into the rail unit to find the cause of the leakage.
Page 542: Examine The Icu Or Fuel Pipes For Fuel Leakage
AA00-0000-00AAA-311D-A X92DF Operation Manual Examine the ICU or fuel pipes for fuel leakage 10.6 Examine the ICU or fuel pipes for fuel leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 543: Leakage On Icu And Pipes (Generic)
AA00-0000-00AAA-311D-A X92DF Operation Manual Examine the ICU or fuel pipes for fuel leakage PROCEDURE Fig 10-3 Leakage on ICU and pipes (generic) Legend HP fuel pipe to injection valve Fuel rail Screw Fuel leakage pipe Screw-in union Screw-in union Fuel leakage pipe...
Page 544 AA00-0000-00AAA-311D-A X92DF Operation Manual Examine the ICU or fuel pipes for fuel leakage If fuel continues to flow from the screw-in union (003), do as follows (an HP fuel pipe (001) is defective): 3.4.1 Stop the engine. 3.4.2 Remove each of the three HP fuel pipes (001) until you find the defective HP fuel pipe (refer to the Maintenance Manual 8733-1).
Page 545: Leakage On Connecting Pipes (Generic)
AA00-0000-00AAA-311D-A X92DF Operation Manual Examine the ICU or fuel pipes for fuel leakage Fig 10-4 Leakage on connecting pipes (generic) 011 012 Legend Valve Connecting pipe Screw-in union Valve Leakage pipe Valve Fuel rail Leakage pipe Screw-in union Screw-in union...
Page 546: Temporary Cut Out A Defective Injection Valve
AA00-0000-00AAA-662A-A X92DF Operation Manual Temporary cut out a defective injection valve 10.7 Temporary cut out a defective injection valve Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 547 AA00-0000-00AAA-662A-A X92DF Operation Manual Temporary cut out a defective injection valve PROCEDURE Cut out the injection of the related cylinder. NOTE: If possible, the exhaust valve must always operate. For an engine with direct controlled injection valves, disconnect the electrical connection from the injection valve.
Page 548: Temporary Cut Out A Defective Exhaust Valve Drive
AA00-0000-00AAA-662D-A X92DF Operation Manual Temporary cut out a defective exhaust valve drive 10.8 Temporary cut out a defective exhaust valve drive Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 549 AA00-0000-00AAA-662D-A X92DF Operation Manual Temporary cut out a defective exhaust valve drive PROCEDURE Cut out the defective cylinder from the injection, refer to section 10.7 Temporary cut out a defective injection valve. Disconnect the electrical connection to the related exhaust valve control unit (VCU).
Page 550: Temporary Isolate A Cylinder With Cooling Water Leakage
AA00-0000-00AAA-662B-A X92DF Operation Manual Temporary isolate a cylinder with cooling water leakage 10.9 Temporary isolate a cylinder with cooling water leakage Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 551: Exhaust Valve With Pressure Element
AA00-0000-00AAA-662B-A X92DF Operation Manual Temporary isolate a cylinder with cooling water leakage PROCEDURE Isolate the defective cylinder from the cooling water system. Make sure that there is no air spring air pressure. Lock the exhaust valve in the open position as follows:...
Page 552 AA00-0000-00AAA-662B-A X92DF Operation Manual Temporary isolate a cylinder with cooling water leakage CLOSE UP • The engine can be started and operated at decreased load, refer to section 8.3 Start the engine - general - 552 - Issue 002 2020-08...
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Page 554: Disconnect The Fuel Pump
AA00-5556-00AAA-510B-A X92DF Operation Manual Disconnect the fuel pump 10.10 Disconnect the fuel pump Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 555: Fuel Pump (Example) - Isolate
AA00-5556-00AAA-510B-A X92DF Operation Manual Disconnect the fuel pump PROCEDURE Fig 10-6 Fuel pump (example) - isolate Release the pressure and drain the related HP fuel pipe (001, Figure 10-6). Remove the related HP fuel pipe (001) from the fuel pump (002). For the applicable procedure, refer to the Maintenance Manual.
Page 556 AA00-5556-00AAA-510B-A X92DF Operation Manual Disconnect the fuel pump WARNING Injury Hazard: Make sure that no personnel are near the flywheel or the engine, before you operate the turning gear. Operate the turning gear until the cam (006, Figure 10-7) is at the highest position.
Page 557 AA00-5556-00AAA-510B-A X92DF Operation Manual Disconnect the fuel pump Page left intentionally blank - 557 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 558: Connect The Fuel Pump
AA00-5556-00AAA-730B-A X92DF Operation Manual Connect the fuel pump 10.11 Connect the fuel pump Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 559: Fuel Pump (Example) - Connect
AA00-5556-00AAA-730B-A X92DF Operation Manual Connect the fuel pump PROCEDURE Fig 10-8 Fuel pump (example) - connect Release the pressure and drain the related HP fuel pipe (007, Figure 10-8). Remove the flange (005) from the fuel pump (002). Remove the flange (006) from the HP fuel pipe (007).
Page 560 AA00-5556-00AAA-730B-A X92DF Operation Manual Connect the fuel pump WARNING Injury Hazard: Make sure that no personnel are near the flywheel or the engine, before you operate the turning gear. Operate the turning gear until the cam (006, Figure 10-9) is at the highest position.
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Page 562: Temporary Isolate A Defective Turbocharger
AA00-6500-00AAA-662A-A X92DF Operation Manual Temporary isolate a defective turbocharger 10.12 Temporary isolate a defective turbocharger Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 4.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 563: Not All Turbochargers Are Defective (Example)
AA00-6500-00AAA-662A-A X92DF Operation Manual Temporary isolate a defective turbocharger PROCEDURE Stop the engine. If not all turbochargers are defective, isolate the defective turbocharger from the exhaust gas system and from the scavenge air system. NOTE: This step is only applicable for an engine with more than one turbocharger, and if one ore two turbochargers are serviceable.
Page 564: All Turbochargers Are Defective (Example)
AA00-6500-00AAA-662A-A X92DF Operation Manual Temporary isolate a defective turbocharger If all turbochargers are defective, isolate the defective turbochargers from the scavenge air system. NOTE: This step is applicable for an engine with one, two, or three turbochargers, and none of the turbochargers are serviceable.
Page 565 AA00-6500-00AAA-662A-A X92DF Operation Manual Temporary isolate a defective turbocharger Page left intentionally blank - 565 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 566: Temporary Isolate The Exhaust Waste Gate
AA00-8135-00AAA-662A-A X92DF Operation Manual Temporary isolate the exhaust waste gate 10.13 Temporary isolate the exhaust waste gate Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 0.5 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 567: Exhaust Waste Gate (Example)
AA00-8135-00AAA-662A-A X92DF Operation Manual Temporary isolate the exhaust waste gate PROCEDURE Fig 10-12 Exhaust waste gate (example) Legend Exhaust gas manifold Indicator Cardan rod Ball valve 50-8135_E0_3 (air spring air) Positioner and feedback with EMC module Flange Actuator Valve Plate...
Page 568 AA00-8135-00AAA-662A-A X92DF Operation Manual Temporary isolate the exhaust waste gate Stop the engine. Loosen the screws of the flange (008, Figure 10-12), but do not loosen one of the two middle screws. Turn the flange (008) to close the exhaust waste gate.
Page 569 AA00-8135-00AAA-662A-A X92DF Operation Manual Temporary isolate the exhaust waste gate Page left intentionally blank - 569 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 570: Isolate A Defective Engine At Twin Engine Installation
AA00-0000-00AAA-662C-A X92DF Operation Manual Isolate a defective engine at twin engine installation 10.14 Isolate a defective engine at twin engine installation Periodicity Description Unscheduled Duration for performing preliminary requirements 0.0 man-hours Duration for performing the procedure 1.0 man-hours Duration for performing the requirements after job completion 0.0 man-hours...
Page 571 AA00-0000-00AAA-662C-A X92DF Operation Manual Isolate a defective engine at twin engine installation PROCEDURE Engage the shaft locking device of the defective engine. Refer to the related documentation of the manufacturer. NOTE: This prevents the windmilling effect on the propeller of the defective engine (shaft movement), when you operate the other engine.
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Page 573: 11 Technical Data
X92DF Operation Manual 11 Technical data 11.1 Engine data.............
Page 574: General Data
AA00-0000-00AAA-030A-A X92DF Operation Manual Engine data 11.1 Engine data The standard data of the X92DF engine is given in Table 11-1 - General data. Tab 11-1 General data Item Value Unit Cylinder bore 920 mm Piston stroke 3468 mm Speed range...
Page 575: Rated Power
AA00-0000-00AAA-030A-A X92DF Operation Manual Engine data Tab 11-2 Rated power Rating Speed Power BSFC in diesel BSGC in gas BSPC in gas Mean pis- point mode mode mode ton speed [rpm] [kW/cyl.] [g/kWh] [g/kWh] [g/kWh] [m/s] [bar] 5320 180.9 141.2 17.3...
Page 576: List Of Usual Values And Safeguard Settings - General
AA00-0000-00AAA-030K-A X92DF Operation Manual List of usual values and safeguard settings - general 11.2 List of usual values and safeguard settings - general For each system of the engine the tables in the chapter that follows give the values for usual operation and the trigger values for safeguard settings.
Page 577 AA00-0000-00AAA-030K-A X92DF Operation Manual List of usual values and safeguard settings - general • Trigger value This list gives the value at which the related safeguard function starts. For the analysis elements (AE) of concentration: ○ max - maximum concentration For the level switches (LS) and flow switches (FS): ○...
Page 578: Function Code
AA00-0000-00AAA-030K-A X92DF Operation Manual List of usual values and safeguard settings - general 11.2.2 Signal codes - identification An example of a signal code is shown in Figure 11-2. Fig 11-2 Signal codes PT 1012 C 00207 Legend Function code...
Page 579: Function Group
AA00-0000-00AAA-030K-A X92DF Operation Manual List of usual values and safeguard settings - general Tab 11-4 Function group Code Signal type System 10 to 19 Signals from the engine Cooling water 20 to 29 Signals from the engine System oil, cooling oil...
Page 580: Fuel System
AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings 11.3 List of usual values and safeguard settings On the pages that follow you find the values for usual operation and the trigger values for safeguard settings as follows: •...
Page 581 SAC This value is applicable for stable operation condition. This value is applicable for transient operation condition. WinGD recommends a setpoint value of 25°C. 36°C is only permitted if the seawater temperature is 32°C. - 581 - Issue 002 2020-08...
Page 582 AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings Tab 11-7 Oil systems (XX2NNN, part 1) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Lubricating oil supply - system side Main lubricating oil / pressure [bar] / engine 4.2 to 5...
Page 583: Oil Systems (Xx2Nnn, Part 2)
AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings Tab 11-8 Oil systems (XX2NNN, part 2) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Servo oil...
Page 584: Oil Systems (Xx2Nnn, Part 3 (Turbocharger Bearing Oil))
AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings Tab 11-9 Oil systems (XX2NNN, part 3 (turbocharger bearing oil)) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion...
Page 585: Oil Systems (Xx2Nnn, Part 4)
AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings Tab 11-10 Oil systems (XX2NNN, part 4) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Damper oil Damper oil / pressure [bar] / inlet torsional 2.8 to 5.0...
Page 586: Gas System (Xx33Nn And Xx39Nn)
AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings Tab 11-11 Gas system (XX33NN and XX39NN) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Gas leakage detection...
Page 587: Fuel System (Xx34Nn)
AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings Tab 11-12 Fuel system (XX34NN) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Fuel supply - system side...
Page 588 AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings Tab 11-13 Exhaust gas system (XX37NN) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Exhaust pipe / manifold Exhaust gas / temperature [°C] / outlet each...
Page 589: Air Systems (Xx40Nn To Xx44Nn)
AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings Tab 11-14 Air systems (XX40NN to XX44NN) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Scavenge air receiver Scavenge air / temperature [°C] / outlet...
Page 590 AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings Tab 11-15 Miscellaneous items (XX45NN to XX52NN) Description Usual op- Safeguard setting eration Medium / physical value / location Signal number Func- Trigger (value or tion value range) Thrust bearing Pad / temperature [°C] / thrust bearing...
Page 591: Failure Messages
AA00-0000-00AAA-033B-A X92DF Operation Manual List of usual values and safeguard settings Some items are continuously monitored for correct function. If an item becomes defective, the AMS sends a message to the ship alarm system, refer to Table 11-16 - Failure messages.
Page 592: Section Views (Generic Engine)
AA00-0000-00AAA-034A-A X92DF Operation Manual Section views (Generic engine) 11.4 Section views (Generic engine) - 592 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 593: Cross Section
AA00-0000-00AAA-034A-A X92DF Operation Manual Section views (Generic engine) 11.4.1 Engine - cross section Fig 11-3 Cross section - 593 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 594: Longitudinal Section
AA00-0000-00AAA-034A-A X92DF Operation Manual Section views (Generic engine) 11.4.2 Engine - longitudinal section Fig 11-4 Longitudinal section NOTE: The numbers shown in the figures relate to the four numbers shown in the data module code eg, WINGDX92-AA00-HA1-51-1132-00AAA-520A-A . - 594 - Issue 002 2020-08 Winterthur Gas &...
Page 595: 12 Operating Media
X92DF Operation Manual 12 Operating media 12.1 General for operating media..........
Page 596 Lubricants • Water NOTE: On the WinGD website go to your engine type, then to “OPERATION & MAINTENANCE”, then to “FUEL LUBRICANTS WATER”. On the pages that follow the specifications are available for the operating media that follow: • Compressed air •...
Page 597 AA00-0000-00AAA-018M-A X92DF Operation Manual General for operating media Page left intentionally blank - 597 - Issue 002 2020-08 Winterthur Gas & Diesel Ltd.
Page 598 • Purity class 2-4-2 (ISO 8573-1). 12.2.2 Recommended procedures for compressed air WinGD recommends to regularly do the procedures that follow to prevent explosions: • Regularly drain the starting air bottles to remove condensation. • Regularly clean the starting air pipes to remove oil that can come from the air compressors.
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Page 600 AA00-0000-00AAA-030D-A X92DF Operation Manual Scavenge air 12.3 Scavenge air The turbocharger compresses the air from the engine room or from outside for the scavenge air. The air must be as clean as possible to keep the wear of cylinder liner, piston rings, turbocharger compressor etc to a minimum.
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Page 602: Specifications For Gas Fuel
LNG storage. The gas supply system supplies natural gas at the correct temperature and pressure to the engine. For more data, refer to the documentation of the related manufacturer. The gas fuel has to obey the WinGD specifications, refer to Table 12-1 - Specifications for gas fuel.
Page 603: 13 Schematic Diagrams
X92DF Operation Manual 13 Schematic diagrams 13.1 Schematic diagrams - general..........
Page 604: Schematic Diagrams
AA00-0000-00AAA-043I-A X92DF Operation Manual Schematic diagrams - general 13.1 Schematic diagrams - general NOTE: The diagrams below are part of the Engine-Builder Drawing-Set and are not included in this operation manual. The diagrams below can be referenced directly in the specific Engine-Builder Drawing-Set.
Page 605: Process Codes
AA00-0000-00AAA-043I-A X92DF Operation Manual Schematic diagrams - general 13.1.1.3 System codes in the engine control diagram The system codes in the engine control diagram are as follows: • Code 10 - Fuel system • Code 20 - Oil system •...
Page 606 AA00-0000-00AAA-043I-A X92DF Operation Manual Schematic diagrams - general Fig 13-3 Signal codes PT 1012 C 00207 Legend Function code Running number Function group Applied system Tab 13-1 Function code Code First position Second position Analysis Control Control Element Flow Gauge...
Page 607: Function Group
AA00-0000-00AAA-043I-A X92DF Operation Manual Schematic diagrams - general Tab 13-2 Function group Code Signal type System 10 to 19 Signals from the engine Cooling water 20 to 29 Signals from the engine System oil, cooling oil Signals from the engine...
Page 608: Color Codes And Symbols - Electric Connection Diagram
AA00-0000-00AAA-043I-A X92DF Operation Manual Schematic diagrams - general 13.1.2 Electric connection diagram The electric connection diagram shows data about the bus routing connections (without cylinder related signals). You can find an overview of the used color codes and symbols in Figure 13-4.

WinGD X92DF Operation Manual

Table of Contents

List of Tables

2 Safety

4 Design and Function of Systems

5 Design and Function of Components

Group 1 - Engine Frame and Bearings

Group 2 - Cylinder

Group 3 - Crankshaft, Connecting Rod and Piston

Group 4 - Supply Unit Drive and Control Components

Group 5 - Supply Unit, Pumps and Control Valves

Group 6 - Scavenge Air Components

Group 7 - Cylinder Lubrication

Group 8 - Pipes

Group 9 - Monitoring Instruments

6 Control System

Local Display Unit (LDU-20) - Option for UNIC - Pages

Manual Control Panel (MCP) - Option for Wice - Pages

Manual Control Panel (MCP) - Option for WECS-9520 - Pages

Quick Links

Chapters

Troubleshooting

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Questions and answers

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Summary of Contents for WinGD X92DF