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M 46 DFProject Guide • Propulsion

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IM 46 DF Propulsion - 04.2012

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

Edition April 2012

Information for the user of this pro ject guide

The project information contained in the following is preliminary, since technical data of products may especially change due to product development and customer requests. Caterpillar Motoren reserves the right to modify and amend data at any time. Any liability for accuracy of information provided herein is excluded.

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

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

All information contained in this project guide is preliminary.

Introduction

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II M 46 DF Propulsion - 04.2012

Global Resource from One Source When you select Cat Marine Power for your vessel, look to Cat Financial for world-class financial support. With marine lending offices in Europe, Asia and the US supporting Caterpillar’ s worldwide marine distribution network, Cat Financial is anchored in your homeport. We also have over 20 years of marine lending experience, so we understand your unique commercial marine business needs. Whether you’re in the offshore support, cargo, ship assist, towing, fish- ing or passenger vessel industry , you can count on Cat Financial for the same high standard you expect from Caterpillar .

www . CA T .com / CatMarineFinance V isit our web-site or see your local Cat dealer to learn how our marine financing plans and options can help your business succeed.

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

and repower financing. Repayment : Loan terms up to

10 years, with longer amortizations available.

Financed Amount : Up to 80 % of your vessel cost.

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

other widely traded currencies.

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IIIM 46 DF Propulsion - 04.2012

Global Dealer Network Maintenance

T raining

Commissioning

Remanufactured Parts

Genuine Spare Parts

DICARE Diagnostic Software

Repairs Engine Upgrades

Overhauls

Customer Support Agreements

( CSAs )

Providing integrated solutions for your power system means much more than just supplying your engines. Beyond complete auxiliary and propulsion power systems, we offer a broad port- folio of customer support solutions and financing options. Our global dealer network takes care of you wherever you are – worldwide. Localized dealers offer on-site technical expertise through marine specialists and an extensive inventory of all the spare parts you might need.

To find your nearest dealer , simply go to: MARINE.CAT.COM

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IV M 46 DF Propulsion - 04.2012

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VM 46 DF Propulsion - 04.2012

Contents

Page1. Engine description

1.1 Engine description ............................................................................................................... 1

1.2 Engine design features ........................................................................................................ 2

2. General data and operation of the engine

2.1 General data and outputs .................................................................................................... 3 2.1.1 Output defi nition .................................................................................................................... 32.1.2 Fuel consumption .................................................................................................................. 42.1.3 Lube oil consumption ........................................................................................................... 42.1.4 Nitrogen oxide emissions (NOx values) ............................................................................. 42.1.5 Technical data ....................................................................................................................... 5

2.2 Engine dimensions ............................................................................................................... 72.2.1 Turbocharger at driving end ................................................................................................ 72.2.2 Turbocharger at free end ..................................................................................................... 8

2.3 Restrictions for low load operation .................................................................................. 9

2.4 Derating .................................................................................................................................. 10

2.5 Propulsion mode ................................................................................................................... 112.5.1 Controllable pitch propeller operation .............................................................................. 112.5.2 Diesel electric ........................................................................................................................ 14

2.6 Load application and recovery behaviour ....................................................................... 152.6.1 Fuel changeover procedure in gas mode ......................................................................... 16 a) Changeover from gas to diesel operation .................................................................... 16 b) Changeover from diesel to gas operation .................................................................... 16

3. Systems

3.1 Combustion air system ........................................................................................................ 173.1.1 General.................................................................................................................................... 173.1.2 Air intake from engine room (standard) ............................................................................ 173.1.3 Air intake from outside ......................................................................................................... 173.1.4 Radiated heat ......................................................................................................................... 17

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VI M 46 DF Propulsion - 04.2012

3.2 Starting air system ............................................................................................................... 183.2.1 Starting air quality requirements ........................................................................................ 183.2.2 System diagram ..................................................................................................................... 193.2.3 Starting air system components ......................................................................................... 20 a) Receiver capacity acc. to GL recommendation AT1/AT2 .......................................... 20 b) Compressor AC1/AC2 ...................................................................................................... 213.2.4 Starting air consumption (Slow turn) ................................................................................. 21

3.3 Exhaust system ..................................................................................................................... 223.3.1 General.................................................................................................................................... 223.3.2 Exhaust data .......................................................................................................................... 233.3.3 Exhaust expansion joint ....................................................................................................... 23 3.3.4 Silencer ................................................................................................................................... 233.3.5 Ventilation system ................................................................................................................. 253.3.6 Exhaust gas boiler ................................................................................................................. 253.3.7 Resistance in exhaust gas piping ....................................................................................... 263.3.8 Exhaust gas sound power level .......................................................................................... 273.3.8 Turbocharger cleaning device ............................................................................................ 28

3.4 Cooling water system .......................................................................................................... 293.4.1 Cooling water quality requirements ................................................................................... 293.4.2 System diagram heat balance ............................................................................................ 303.4.3 System diagram cooling water ........................................................................................... 323.4.4 Cooling water system components .................................................................................... 34 a) LT cooling water pump FP2 ............................................................................................ 34 b) LT cooling water stand-by pump FP6 ........................................................................... 34 c) HT cooling water pump (fi tted) FP1 .............................................................................. 34 d) HT cooling water stand-by pump FP5 .......................................................................... 34 e) HT temperature controller (separate) FR1 ................................................................... 34 f) LT-temperature controller (separate) FR2 ................................................................... 35 g) Pre-heater FH5/FP7 ......................................................................................................... 35 h) Charge air temperature controller CR1 ........................................................................ 35 i) HT cooler (separate) FH1 ................................................................................................ 35 j) LT cooler (separate) FH2 ................................................................................................. 35 k) Cooling water expansion tank FT1/FT2 ........................................................................ 363.4.5 Recommendation for cooling water system ..................................................................... 363.4.6 Flow velocities ....................................................................................................................... 37

3.5 Main fuel oil system, MGO/MDO operation .................................................................... 383.5.1 Quality requirements for MGO/MDO fuel/permitted fuels ............................................. 383.5.2 System diagram ..................................................................................................................... 39

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VIIM 46 DF Propulsion - 04.2012

3.5.3 MGO/MDO fuel system components ................................................................................. 40 a) Fine fi lter (fi tted) DF1 ....................................................................................................... 40 b) Strainer (separate) DF2 ................................................................................................... 40 c) Pre-heater (separate) DH1 ............................................................................................. 40 d) MGO/MDO cooler DH3 .................................................................................................... 40 e) Feed pump (separate) DP1/DP2 .................................................................................... 40 f) MGO/MDO service tank DT1 .......................................................................................... 41 g) Intermediate tank (separate) DT2 ................................................................................. 41 h) Separator DS1 .................................................................................................................. 41 3.5.4 Pilot fuel ignition system ...................................................................................................... 42 a) Quality requirements ....................................................................................................... 42 b) System diagram ............................................................................................................... 42 c) Pilot fuel ignition system components ......................................................................... 43

3.6 Main fuel oil system, HFO operation ................................................................................. 433.6.1 Quality requirements for HFO/permitted fuels ................................................................. 433.6.2 System diagram - Heavy fuel oil operation ....................................................................... 453.6.3 HFO system components ..................................................................................................... 46 a) Fine fi lter (fi tted) HF1 ....................................................................................................... 46 b) Strainer HF2 ...................................................................................................................... 46 c) Self-cleaning fi lter HF4 ................................................................................................... 47 d) Viscosimeter HR2 ............................................................................................................. 47 e) Pressurizing pumps HP1/HP2 ........................................................................................ 47 f) Circulating pumps HP3/HP4 ........................................................................................... 47 g) Pressure regulating valve HR1 ...................................................................................... 48 h) Final preheater HH1/HH2 ................................................................................................ 48 i) Mixing tank HT2 ............................................................................................................... 48 j) Settling tanks HT5/HT6 .................................................................................................... 49 k) Day tank DT1/HT1 ............................................................................................................ 49 l) Separators HS1/HS2 ........................................................................................................ 493.6.4 Viscosity / temperature diagram ........................................................................................ 50

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VIII M 46 DF Propulsion - 04.2012

3.6.5 Standard heavy fuel oil supply and booster module ....................................................... 51 a) Primary fi lter ..................................................................................................................... 51 b) Fuel pressure pumps ....................................................................................................... 51 c) Pressure regulating system ........................................................................................... 51 d) Self cleaning fi ne fi lter .................................................................................................... 51 e) Consumption measuring system ................................................................................... 51 f) Mixing tank with accessories ........................................................................................ 51 g) Circulating pumps ............................................................................................................ 51 h) Final preheater ................................................................................................................. 51 i) Viscosity control system ................................................................................................. 51 j) Cooler ................................................................................................................................. 51

3.7 Gas fuel system, gas operation .......................................................................................... 533.7.1 Quality requirements for gas fuel ....................................................................................... 533.7.2 System diagram ..................................................................................................................... 543.7.3 Gas fuel system components .............................................................................................. 54 a) Gas admission valve ........................................................................................................ 54 b) Gas valve unit (GVU) ........................................................................................................ 55

3.8 Lube oil system ..................................................................................................................... 563.8.1 Lube oil system quality requirements ................................................................................ 563.8.2 System diagram ..................................................................................................................... 583.8.3 Lube oil system components ............................................................................................... 59 a) Force pump (fi tted) LP1 ................................................................................................... 59 b) Stand-by force pump (separate) LP2 ............................................................................ 59 c) Strainer (separate) LF4 ................................................................................................... 59 d) Self-cleaning fi lter LF2 .................................................................................................... 59 e) Cooler (separate) LH1 ..................................................................................................... 60 f) Temperature controller (separate) LR1 ........................................................................ 61 g) Circulation tank LT1 ......................................................................................................... 61 h) Separator; treatment at MGO/MDO operation LS1 .................................................... 62 i) Separator; treatment at HFO operation LS1 ................................................................ 62 3.8.4 Recommendation for lube oil system ................................................................................ 63

4. Connecting parts engine

4.1 Power transmission ............................................................................................................. 654.1.1 Coupling between engine and gearbox ............................................................................ 654.1.2 Coupling between engine and generator ......................................................................... 674.1.3 Power take-off from the free end ....................................................................................... 67

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IXM 46 DF Propulsion - 04.2012

4.2 Data for torsional vibration calculation ........................................................................... 68

4.3 Resilient mounting ............................................................................................................... 69

4.4 Structure-borne noise level ................................................................................................ 70

4.5 Air-borne sound power level .............................................................................................. 71

5. Installation and arrangement

5.1 General installation aspect ................................................................................................ 72

5.2 System connections on the engine ................................................................................... 72

5.3 Space requirement for dismantling of charge air cooler and turbocharger cartridge 74

5.4 Foundation ............................................................................................................................. 755.4.1 External foundation forces and frequencies .................................................................... 755.4.2 Rigid mounting ....................................................................................................................... 77

5.5 Installation of fl exible pipe connections ......................................................................... 80

5.6 Notes regarding installation exhaust system ................................................................. 80

5.7 Installation of crankcase ventilation on the engine ...................................................... 81

5.8 Earthing of the engine .......................................................................................................... 82

5.9 Lifting of the engine ............................................................................................................. 83

6. Control and monitoring system

6.1 Engine control panel ............................................................................................................ 846.1.1 Remote control for twin-engine plant ................................................................................ 85

6.2 Speed control ........................................................................................................................ 86

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X M 46 DF Propulsion - 04.2012

6.3 Engine monitoring ................................................................................................................ 86

6.4 Engine monitoring and protection system ....................................................................... 87

6.5 Gas management system .................................................................................................... 89

6.6 Measuring points .................................................................................................................. 91

6.7 Local and remote indicators ............................................................................................... 95

7. Safety

7.1 Safety concept ...................................................................................................................... 96

8. Engine acceptance test .................................................................................. 98

9. Engine International Air Pollution Prevention Certifi cate ....................... 100

10. Painting/Preservation ..................................................................................... 101

11. Engine parts ...................................................................................................... 104

12. Flexible Camshaft Technology - FCT ............................................................ 105

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M 46 DF Propulsion - 04.2012 1

1

65432

1. Engine description

1.1 Engine description

The MaK M 46 DF is a turbocharged, intercooled, non-reversible four-stroke dual fuel engine which can be operated in two different modes.

In-line engine M 46 DF

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2 M 46 DF Propulsion - 04.2012

1. Engine description

1.2 Engine design features

bearings, charge air duct, vibration damper housing and gear drive housing.

located in the steel crown.

bearing.

routing.

operation mode.

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Engine output

Engine rating

Mean eff.pressure

Mean piston speed

bar m/s

6 M 46 DF

2.1 General data and outputs

2.1.1 Output definition

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2.1.2 Fuel consumption

Methane number

2.1.3 Lube oil consumption

2.1.4 Nitrogen oxide emissions (NOx values)

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2.1.5 Technical data

Performance data

6

SpeedMinimum speedBrake mean effective pressure

emission emission

1/min1/minbarbarbarm³/h

3.55 3.55 3.55 3.55

Fuel

Engine driven booster pump m³/hm³/hmmmmmm

Engine driven pump

Engine driven suction pump

Priming pump pressure/suction pump

Temperature at engine inlet

m³/h/barm³/h/bar

barm³/h/barm³/h/barm³/h/bar

m³

mmmmmmmm

4 - 5

16/5

125

4 - 5

16/5

125

4 - 5

11.2

4 - 5

12.6

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Fresh water cooling 6

Engine content

Temperature at engine outlet

m³barm³

m³/h/barm³/h/bar

mmm³/h

125 125

5122,364

1,125

mmmm

kg/h

kg/hbar

345 343 335 335

Starting air

Minimum starting air pressure

ventilation pipe

barbar 14

2.65.2

14

5.4

143.26.4

143.36.6


Preheated engine

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M 46 DF Propulsion - 04.2012


2.2 Engine dimensions

2.2.1 Turbocharger at driving end

Removal of:

Piston

Cylinder liner

Engine centre distance

Dimensions [mm][t]

6 M 46 DF 1,255 2151,255 2321,255 2321,255 232

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2.2.2 Turbocharger at free end

Engine centre distance

Dimensions [mm][t]

6 M 46 DF 1,255 2151,255 2321,255 2321,255 232

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2.3 Restrictions for low load operation

Liquid fuel

compensated.

15

6

Cleaning run of engine

Gas fuel

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2.4 Derating

operation.

Output per cylinder as a function of methane number

500

600

700

800

900

1000

40 50 60 70 80 90 100

Methane number [-]

Out

put p

ercy

linde

r [kW

]

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2. General data and operation of engine

The design area for the combinator has to be on the right-hand side of the theoretical propeller curve

protection device.

be established upon order processing.

2.5 Propulsion mode

Power limit curvefor controlable pitch propeller operation

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

50% 60% 70% 80% 90% 100% 110%Engine speed [%]

engi

ne p

ower

[%]

Powe limi rv fooverload rote ion

I

II

I orma tionII hor im tion llowed

To

90%

100%

80%

70%

60%

50%

40%

30%

20%

Power limit curvefor controlable pitch propeller operation

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

50% 60% 70% 80% 90% 100% 110%Engine speed [%]

Engi

ne p

ower

[%]

Powe limi rv fooverload rote ion

I

II

I orma tionII hor im tion llowed

To

90%

100%

80%

70%

60%

50%

40%

30%

20%

Power limit curve for overload protection

Power limit curvefor controllable pitch propeller operation

2.5.1 Controllable pitch propeller operation

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Time in seconds

Standard operation25 15

2.5.1 Controllable pitch propeller operation - diesel mode

Remarks:

Standard ramp up time will provide longest component lifetimes.

Ramp up time M 46 DF in diesel mode

0%10%20%30%40%50%60%70%80%90%100%110%

0 100 200 300 400 500 600

Time s]

Power

]

Diesel ode mergen

Diesel ode tion

0 20

m


Remarks:

Standard ramp up time will provide longest component lifetimes.

During fuel changeover to gas mode the power management should control a constant loading of


Time in seconds

Standard operation

2.5.1 Controllable pitch propeller operation - gas mode

Ramp up time M 46 DF in gas mode - Preliminary information

0%10%20%30%40%50%60%70%80%90%100%110%

0 100 200 300 400 500 600Time

Powe%]

Ga ode emergen

Ga ode andard ion

30 60

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2.5.2 Diesel electric


Standard loading up procedure in diesel mode

Steps 1. 2. 3.Diesel mode

5-10s5-10s 5-10s

100%

33%

66%

Time5-10s

Load

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2.6 Load application and recovery behaviour

Steps 1. 2. 3. 4. 5.

Diesel mode

0,0%

5,0%

10,0%

15,0%

20,0%

25,0%

30,0%

35,0%

1. 2. 3. 4. 5.Step

Power

0,0%

5,0%

10,0%

15,0%

20,0%

25,0%

30,0%

35,0%

0,0% 10,0% 20,0% 30,0% 40,0% 50,0% 60,0% 70,0% 80,0% 90,0% 100,0%

Current load [%]

Max

. Loa

d st

ep [%

]

Load steps M 46 DF

Maximum permissible load steps

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2.6.1 Fuel changeover procedure in gas mode

a) Changeover from gas to diesel operation:

b) Changeover from diesel to gas operation:

should compensate the increase or decrease in power demand.

self check procedures.

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3. Systems

3.1.1 General

3.1 Combustion air system

To obtain good working conditions in the engine room and to ensure trouble-free operation of all

into account.

3.1.2 Air intake from engine room (standard)

turbocharger.

3.1.3 Air intake from outside

must be prevented.

3.1.4 Radiated heat

See technical data

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3. Systems3. Systems

3.2 Starting air system

water.

3.2.1 Starting air quality requirements

pressure dewmg/m³

Residual oilcontent in mg/m³

1 32 1 13 5 5 14 15 3 55 256

Oil content

compressed air.

Particle size and density

Pressure dew point

of the contained vapor. The pressure dew point changes with the air pressure.

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3. Systems

3.2.2 System diagram

General notes:

installation drawing.

Notes:

h Please refer to the measuring point list regarding design of the monitoring devices

Connecting points:

Accessories and fittings:

enginePT Pressure transmitter

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3. Systems

3.2.3 Starting air system components

a) Receiver capacity acc. to GL recommendation AT1/AT2

[l] mmD ømm

625

5 Drain position vertical

2

valve is to be piped to the outside.

Requirement of classification societies (regarding design)

Single-engine plantTwin-engine plant

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3. Systems

b) Compressor AC1/AC2:

Rec.

Rec. - Total receiver volume [m³]

3.2.4 Starting air consumption (Slow turn)

6 M 46 DF

5.2 5.4 6.4 6.6

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3.3 Exhaust system

3.3.1 General

Position of exhaust gas nozzle:

Design of the pipe cross-section:

Ventilation:

Rupture disc:

possible.

consumption and thermal load of the engine.

3. Systems

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3.3.3 Exhaust expansion joint6 M 46 DF 423

3.3.2 Exhaust data

Engine[kg/h]

6 M 46 DF345 335 355

343 34533,425

335 325 345

335 335 335

Intake air temperature: 25°C

3. Systems

3.3.4 Silencer

mineral wool.

Silencer with spark arrestor:

Silencers are to be insulated by the yard. Foundation brackets are to be provided as an option.

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3. Systems

Dimension of silencer/spark arrestor and silencer:

included, without supports and insulation

Silencer

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3. Systems

Spark arrestor and silencer

D B kg6 M 46 DF

3.3.6 Exhaust gas boiler

back pressure.

3.3.5 Ventilation system

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3. Systems

3.3.7 Resistance in exhaust gas piping

Example (based on diagram data A to E):

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3. Systems

3.3.8 Exhaust gas sound power level

Exhaust gas sound power level MaK M 46 DF

(to be expected directly after turbo charger at open pipe (A0=1m²))

111

121126

130135 136

132128

123

60

70

80

90

100

110

120

130

140

31,5 63 125 250 500 1000 2000 4000 80001/1 octave band frequency [Hz]

soun

d po

wer

leve

l [dB

(A)]

ref:

10-1

2 W

Tole e: dB

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3. Systems

3.3.9 Turbocharger cleaning device

Cleaning the turbocharger compressor:

Cleaning the turbine blade and nozzle ring: The cleaning is carried out with clean fresh water “wet

cleaning“ during low load operation at regular intervals

During cleaning the water drain should be checked.

Dirt water tank

[l/min] [min]6 M 46 DF

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3. Systems

3.4 Cooling water system

3.4.1 Cooling water quality requirements

plant.

Requirements

Supplementary information

cooling water.

softened.

Treatment before operating the engine for the first time

prevent irreparable initial damage.

It is not allowed to run the engine without cooling water treatment!

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3. Systems

7 M 46 DF

3.4.2 System diagram heat balance

6 M 46 DF

6 M 46 DF

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3. Systems

8 M 46 DF

9 M 46 DF

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3. Systems

3.4.3 System diagram cooling water

Driving end

Notes:

f Drainh Please refer to the measuring

point list regarding design of the monitoring devices

General notes:For location, dimensions and

the connecting points see engine installation drawing.

Connecting points:


FR6 Sensor for temperature control valve

SP1 Seawater pump

ST1 Sea chest

PT Pressure transmitter

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3. Systems

3.4.3 System diagram cooling water

Notes:f Drainh Please refer to the measuring point list regarding design of the monitoring devices


FR6 Sensor for temperature control valve

SP1 Seawater pump

ST1 Sea chest


General notes:

points see engine installation drawing.

Connecting points:

Free end

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3. Systems

3.4.4 Cooling water system components

Two-circuit cooling:

a) LT cooling water pump FP2:

b) LT cooling water stand-by pump FP6:

c) HT cooling water pump (fitted) FP1:

d) HT cooling water stand-by pump FP5:

e) HT temperature controller (separate) FR1:

with two-stage charge air cooler.

Option: separate pump

Dimensions [mm][kg]D F

125 241254254

* Minimum, depending on

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3. Systems

f) LT temperature controller (separate) FR2:

g) Pre-heater (separate) FH5/FP7:

h) Charge air temperature controller CR1:

i) HT cooler (separate) FH1:

j) LT cooler (separate) FH2:

charge air thermostat.

part load conditions.

on the total heat to be dissipated.

on the total heat to be dissipated.

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k) Cooling water expansion tank FT1/FT2:

Drain tank with filling pump:

Electric motor driven pumps:

connected.

from the tank if it is detected.

Rough calculation of power demand for the electric balance.

3. Systems

3.4.5 Recommendation for cooling water system

PM

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3.4.6 Flow velocities

3. Systems

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3. Systems

3.5 Main fuel oil system, MGO/MDO operation

3.5.1 Quality requirements for MGO/MDO fuel/permitted fuels

Pure distillates:

Distillate/mixed fuels:

Designation Designation

116

2.44.1

4.1

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3. Systems


Disconnecting points:

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3. Systems

3.5.3 MGO/MDO fuel system components

a) Fine filter (fitted) DF1:

b) Strainer (separate) DF2:

c) Pre-heater (separate) DH1:

d) MGO/MDO cooler DH3:

e) Feed pump (separate) DP1/DP2:

Peng.

166

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f) MGO/MDO service tank DT1:

g) Intermediate tank (separate) DT2:

h) Separator DS1:

at least two service tanks. The minimum volume

consumption of the generating sets, enable an eight hours full load operation of the main engine.

The tank should be provided with a sludge compartment including a sludge drain valve and an

The utilisation must be in accordance with the

eff eng.

3. Systems

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3.5.4 Pilot fuel ignition system

b) System diagram

a) Quality requirements

Disconnecting points:

3. Systems

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3.6 Main fuel oil system, HFO operation

3.6.1 Quality requirements for HFO/permitted fuels

Bunker tanks:

a separate storage tank.

Minimum requirements for storage, treatment and supply systems

3. Systems

c) Pilot fuel ignition system components

Ignition fuel injector:

High-pressure pump:

desired pressure in closed loop control. The pump itself is based on a proven design. The inlet metering control of the pump ensures a

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3. Systems

Requirements for residual fuels for diesel engines (as bunkered)

Desi

gnat

ion

D15

E25

F25

K35

K45

K55

Rela

ted

to

Dim

.

kg/m

³

1525

3545

55

cSt

min

6 15

Flas

h po

int

min

624

12

1414

1522

2222

Tota

l sed

im, a

fter

agei

ng

Sulp

hur

3.5

3.5

3.5

3.5

3.5

3.5

mg/

kg

mg/

kg25

mg/

kg15

1515

1515

15

Phos

phor

mg/

kg15

1515

1515

15

mg/

kg

m


3. Systems

3.6.2 System diagram - Heavy fuel oil operation


KT2 Sludge tank


Notes:

s Please refer to the measuring point list regarding design of the monitoring devices

tt Pipe not insulated nor heatedu From diesel oil separator or diesel oil

transfer pump

---- heated pipe

Connecting points:

General notes:


and return lines.

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3. Systems

3.6.3 HFO system components

Supply system:

a) Fine filter (fitted) HF1:

b) Strainer HF2:

pressurized system

Without heating

and as close as possible to the engine.

D[mm]

65 523 355

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3. Systems

Dismantling of sieve Dismantling of sieve

c) Self-cleaning filter HF4: without

d) Viscosimeter HR2:

e) Pressure pumps HP1/HP2:

f) Circulating pumps HP3/HP4:

the bunkered fuel oil, so that the fuel will reach the

Peng.

Peng.

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Engine outputs

3. Systems

h) Final preheater HH1/HH2:

i) Mixing tank HT2:

for both heaters shall be arranged for separate and series operation. Parallel operation with half the

deposition.

g) Pressure regulating valve HR1:4 bar.

Engine output Dimensions [mm]

[l] D E [kg]

323

from pressure

pump

engine

this purpose there has to be an air cushion in the tank.

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3. Systems

j) Settling tanks HT5/HT6:

k) Day tank DT1/HT1:

for 24 hours full load operation of all consumers

hours full load operation of all consumers and

sludge drain valves at the lowest point, and is to be

Guide values for temperatures

Tank temperature

l) Separators HS1/HS2:separators. Design parameters as per supplier

m


3.6.4 Viscosity/temperature diagram

3. Systems

m


3. Systems

3.6.5 Standard heavy fuel oil supply and booster module

Technical specification of the main components:

a) Primary filter

b) Fuel pressure pumps, vertical installation 2 pcs. screw pumps with mechanical seal

c) Pressure regulating system 1 pc. pressure regulating valve

d) Self-cleaning fine filter

e) Consumption measuring system

f) Mixing tank with accessories

g) Circulating pumps, vertical installation 2 pcs. screw pumps with mechanical seal

h) Final preheater

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

i) Viscosity control system

j) Cooler

m


3. Systems

Module controlled automatically with alarms and starters

Starter for the viscosimeter

Alarms

indicating lamp of fuel pressure and circulating pumps

Performance and materials

Steam / ThermalElectric

Steam / ThermalSteam / ThermalSteam / ThermalSteam / Thermal

m


3. Systems

3.7 Gas fuel system, gas operation

3.7.1 Quality requirements for gas fuel

engine.

is available as an option.

kPa3

mg/ m 3

3 mg/ m 3 25mg/ m 3

mg/ m 3

mg/ m 3

mg/ m 3

5mg/ m 3

mg/m 3

Saturated fuel or water and condensates at

gas valve unit are not allowed

m



3.7.3 Gas fuel system components

3. Systems

a) Gas admission valve:

inlet stroke. The master electronic control module

m


3. Systems

b) Gas valve unit (GVU):

to switch valves.

~433

115

B

D1

m


3. Systems

3.8 Lube oil system

3.8.1 Lube oil system quality requirements

on sulphur content.

m


3. Systems

Manufacturer Diesel oil/marine-diesel oil operation

BP

m


3. Systems


General notes:


Notes:h Please refer to the measuring

point list regarding design of the monitoring devices

o See “crankcase ventilation“

Connecting points:



m


3. Systems

3.8.3 Lube oil system components

a) Force pump (fitted) LP1:

b) Stand-by force pump (separate) LP2:

c) Strainer (separate) LF4:

d) Self-cleaning filter LF2:

speed range

to be supplied by the yard.

tank.

WithoutWithout

m


3. Systems

Self-cleaning filter separate LF2 (option)

e) Cooler (separate) LH1:

Engine B E F S X Y [kg]

245

655 245

m


3. Systems

f) Temperature controller (separate) LR1:

Dimensions [mm]D F [kg]

125 241254

g) Circulation tank LT1:

eng.

crankshaft.

with a gas detection sensor. The vent outlet needs

m


3. Systems

Discharge to circulating tank:

h) Separator; treatment at MGO/MDO operation LS1:

i) Separator; treatment at HFO operation LS1:

yard.

Required

eff eng

Required

eff eng

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3.8.4 Recommendation for lube oil system

Lube oil quantities/change intervals:

The change intervals depend on:

are the limit values as per an optimum condition can be reached.

Suction pipes

installed close to the lube oil tank.

External lube oil piping system information

3. Systems

m


Prevention of seawater entering the engine

Expansion joints

Lube oil drain

inclined engine installation another drain pipe connection is available at the free end of the engine.

The slanted drain pipe needs to be immersed in the oil to ensure a medium based sealing and must be kept short.

Separator suction pipe

Discharge from engine

Separator return pipe

Suction pipe force pump

Recommendation of pipe location in the circulating tank (top view)

3. Systems

m


4.1 Power transmission


4.1.1 Coupling between engine and gearbox

The guardsyard supply

Mass moments of inertia

Speed[rpm]

Engine Total

6 M 46 DF

Selection of flexible couplings

P P T 2

P Engine outputn Engine speedT

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

m



Flywheel and flexible coupling

Power Speed

coupling[rpm] D

[mm] [mm] [mm] [mm]6 M 46 DF 125

1,1361,1361,136

without torsional limit devicewith torsional limit devicelength of hub

D

m


6 M 46 DF-

4.1.2 Coupling between engine and generator


1,255

15

ø D

Power Speed

coupling[rpm] D

[mm] [mm] [mm]6 M 46 DF 125

length of hub

4.1.3 Power take-off from the free end

m



4.2 Data for torsional vibration calculation

1. Main propulsion

Shaft drawings with all dimensions

2. PTO from gearbox:

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

3. PTO from free shaft end:

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

4. Explanation:

m


4.3 Resilient mounting

Major components:


elements6 M 46 DF

Important note:

of the reduction gear.

m


4.4 Structure-borne noise level


structure-borne noise level M 46 DFabove/below resilient mounting

(values below resilient mounting depend on foundation mobility)

93

106

95 97 9994

86

73 7478

67

108

64

76

67

7681 78

58

44 45 44

32

84

0

10

20

30

40

50

60

70

80

90

100

110

120

16

31,5 63 125

250

500

1000

2000

4000

8000

16000

frequency 1/1 octave band [Hz]

soun

d ve

loci

ty [d

B] r

ef: v

0 =

5 x

10-8

m/s

above esilient ntingbelo resilien ting

m


4.5 Air-borne sound power level

Noise level for M 46 DF engines

Air-borne sound power level Ma

96

111115

120 122124

122

129

70

80

90

100

110

120

130

140

63 125 250 500 1000 2000 4001/1 Octave [Hz]

soun

d po

wer

leve

l [dB

(A) r

e: 1

0-12 W

]

tole e: B


m


5.2 System connections on the engine

5.1 General installation aspect


C 14C 15C 16C 25C 51 Force pump, suction sideC 53C 58C 59C 62C 76aC 81e Drip fuel connection, pilot fuelC 91aC 96C 97 Flushing connection gas pipe

y

x

m



C 86C 91C 98

C 36 Drain, turbocharger washingC 42 Turbine cleaning connection C 76C 78 Fuel outletC 81b Drip fuel connection,

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5.3 Space requirement for dismantling of charge air cooler and turbocharger cartridge


cooler Removal of

turbocharger cartridge

6 M 46 DF1,124

Charge air cooler cleaning

yard.

Turbocharger dismantling

Removal of cartridge after removal of

housing.

Damper ø[mm] [kg]

[X mm]

6 M 46 DF

* splitted charge air cooler

m


5.4 Foundation


5.4.1 External foundation forces and frequencies

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

Static load

resting on the foundation via the vertical reaction forces. T

Output Speed[1/min]

T

6 M 46 DF

/a

Dynamic load

and mass moments.

m



Output Speed[rpm]

Order No. Frequency Mx

6 M 46 DF

3.525.5

33.366.6

154.2

4.5 133.311.5

Output Speed[rpm]

Order No. Frequency My Mz

6 M 46 DF — —24

16.633.3

—

— —12 16.6

—

m


5.4.2 Rigid mounting

are the most important disturbances

itself.

General note:

The shipyard is solely responsible for the adequate design and quality of the foundation.

side stoppers and alignment bolts is to be gathered from the foundation plans.


m


Side stoppers


1 pair 2 pairs*

Number of bolts Fitted bolts Foundation bolts6 M 46 DF 4

4 324 364

Jacking bolts

* 1 pair at end of engine block

steel chocks, cast resinTo be supplied by the yard

m



Proposal for rigid mounting

Through bolts Fitted bolts Through bolts Fitted bolts

m


5.5 Installation of flexible pipe connections


after engine alignment is completed.

Installation of steel expansion joints

5.6 Notes regarding installation exhaust system

not permissible).

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5.7 Installation of crankcase ventilation on the engine


The pipes should run upwards and must be laid to a safe outlet.Provide a gas detection sensor in the main vent pipe.

Main vent pipe

mounting engine

Drain

Piping sizes for crankcase ventilation

Engine connecting Main vent pipelubricating oil circulation

m


5.8 Earthing of the engine


Information about the execution of the earthing

Earthing connection on the engine

m


5.9 Lifting of the engine


X[m

m]

cran

es a

re b

eing

use

d.

Do n

ot p

ush

parts

of

the

engi

ne li

ke

c engi

ne

M 4

6 DF

Turb

ocha

rger

Turb

ocha

r-ge

r opp

osite

fre

e en

d

eigh

t

[t]S

Y[m

m]

[mm

]B

[mm

][m

m]

Mas

s di

men

sion

Mas

s di

men

sion

1

valid

bot

h fo

r eng

ine

with

con

vent

iona

l

132

132

365

365

365

Devi

ce to

be

used

for t

rans

port

of

Desi

gn, m

arki

ng, t

ests

etc

. acc

. to

rule

s

Belo

ngin

g to

this

are

test

she

ets

or te

st

t

m



6.1 Engine control panel

Engine control panel

m



6.1.1 Remote control for twin-engine plant with one CP propellerBridge

BridgeProtection

panel control stand

shutdown

of gas suppl to engine

Push button

shutdown of gas suppl

to engine room

Push button

Start air Engine speed

control standProtection

panel Bridge

shutdown


Push button


to engine room

Push button

Start airEngine speed

shutdown


Push button


to engine room

Push button

- Pilot fuel conditioning

- Fuel gas storage tank

- Engine- Pilot fuel conditioning


Push button

stopengine

shutdown


Push button


to engine room

Push button

- Pilot fuel conditioning


- Engine- Pilot fuel conditioning


Push button

stopengine

Engine room

unit unit

Engine

- Electronic speed governor

Engine

- Electronic speed governor

Propeller

scope ofsuppl

roptional scope ofsuppl

scope ofsuppl

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6.2 Speed control

tasks.

will be available for all MaK dual fuel engines.

6.3 Engine monitoring6.3 Engine monitoring

-

m


6.4 Engine monitoring and protection system

Engine control boxes include

System data

2 separate override inputsremote reset inputs

overload contact at rated speed


Local control panel Remote panel

m



6.4 Engine monitoring and protection system

m

89M 46 DF Propulsion - 04.2012

6.5 Gas management system


Power management

system

VesselGas management system

- Pilot fuel conditioning- Gas handling plant- Fuel gas storage tank- Inert gas supply- Room monitoring (optional)

Control system

- Engine- Pilot fuel conditioning- Gas handling plant - Fuel gas storage tank- Inert gas supply- Room monitoring (optional)

Alarm and monitoring system

Main switchboard

Alarm andmonitoring

system

Engine control room

Adjoining roomsGas handling roomFuel gas storage room

Ventilation

Control &monitoring(optional)

Gas detection(optional)

Fuel gas storagetank


Bilge monitoring(optional)

- Level- Temperature

Ventilation

control & monitoring(optional)

Inert gas supply



Gas supplyControl &

monitoring(optional)

- LNG vaporizer- Compressor

Ventilation



Door monitoring(optional)

Engine

- Electronic speed governor(ADEM)- LESS

Gas valve unit

Gas supplypiping

- Leakage- Pressure

- Temperature

Load sharingunit

Pilot fuelConditioning

Control &monitoring

Machinery space

Legend

Caterpillar scope ofsupply

Caterpillaroptional scope ofsupply

Notscope ofsupply

m


Gas management system (GMS)

The GMS controls and monitors the gas relevant plant components as there are:

- Fuel gas storage room - Gas handling room - Engine room - Adjoining room

The GMS provides an alarm system for the engine and the gas relevant plant components. It provides the communication to the vessel systems and manages the changeover from diesel to gas mode and vice versa.In case of a major failure it will initiate the gas shutdown to the engine or the engine room. An HMI-device will display all plant and engine data as well as all alarm conditions related to the connected systems.


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6.6 Measuring points

Meas. Point MODbus-Address

DescriptionSensor range

Remarks

1104 Lube oil pressure low - Start standby pump binary

110530009

Lube oil pressure low - Pre-alarm shutdown 4 - 20 mA

1106 Lube oil pressure low - Shutdown binary

111110033

Lube oil filter differential pressure high - Alarm binary

1111.1 Lube oil filter differential pressure - Indication 4 - 20 mA

1142 Pre lube oil pressure low - Starting interlock binary

120230010

Lube oil temp. at engine inlet high - Alarm / DICARE PT 100

1203 Lube oil temp at engine inlet high - Alarm / Load reduction PT 100

1211.x High temperature main bearing per bearing - Alarm / Load reduction PT 100 Option

1231.x High temperature conrod big end per cylinder - Alarm/Load reduction

SAW0 - 160°C

Option: Serial interface RS485

125110046

Oil mist concentration in crankcase high - Alarm binary 1 evaluation unit for 1251,1253,9631

1251.110001

Oil mist concentration in crankcase high - Pre-alarm binary1 evaluation unit for 1251,1253,96311251.1 (70 % from 1251)

1251.2 Opacity - Indication 4 - 20 mA 1 evaluation unit for 1251,1253,9631

1253 Oil mist concentration in crankcase high - Shutdown/SHO gas machinery sp. binary 1 evaluation unit for

1251,1253,9631

963110047

Oil mist detector failure - Alarm binary 1 evaluation unit for 1251,1253,9631

210230011

Cooling water pressure HT at engine inlet low - Alarm / DICARE 4 - 20 mA 40 kPa below operating

pressure

2103 Cooling water pressure HT at engine inlet low - Shutdown binary 60 kPa below operating pressure; stop delay: 20s

211230012

Cooling water pressure LT at engine inlet low - Alarm 4 - 20 mA 40 kPa below operating pressure

220130013

Cooling water temp. HT at engine inlet - Alarm / DICARE PT 100

221130014

Cooling water temp. HT at engine outlet high - Alarm / DICARE PT 100

2212 Cooling water temp. HT at engine outlet high- Load reduction PT 100

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Remarks

222930015

Cooling water temp. LT at engine inlet - Indication / Alarm PT 100

510230021

Fuel oil pressure at engine inlet low - Alarm 4 - 20 mA

511110036

Differential pressure fuel oil filter high - Alarm binary

520130022

Fuel oil temp. at engine inlet low - Alarm / DICARE PT 100 1 sensor for 5201 + 5202** not in use with HFO

520230022

Fuel oil temp. at engine inlet high - Alarm PT 100 1 sensor for 5201 + 5202** not in use with HFO

520630090

Fuel oil viscosity at viscomat - DICARE 4 - 20 mA

525330089

Fuel oil temp. after viscomat - DICARE PT 100

530110003

Leakage oil level at engine high - Alarm binary

610130032

Starting air at engine inlet low - Alarm 4 - 20 mA

610510048

Stopping air pressure at engine low - Alarm binary Alarm delay: 2s

618130019

Intake air pressure in engine room - DICARE 4 - 20 mA

710930248

Charge air pressure at engine inlet - Alarm / DICARE 4 - 20 mA

720130016

Charge air temp. at engine inlet high - Alarm PT 100

720630020

Intake air temperature at turbocharger inlet - DICARE PT 100

7301 Condense water in charge air canal binary

7307 Charge air diff. pressure at charge air cooler - DICARE 4 - 20 mA

7309 Charge air temp. at charge air cooler inlet - DICARE NiCr-Ni (mV)

8211.x Exhaust gas temp. after cylinder per cylinder - Load reduction NiCr-Ni (mV)

822130082

Exhaust gas temp. at turbocharger outlet - Load reduction NiCr-Ni (mV)

823130083

Exhaust gas temp. at turbocharger inlet - Indication DICARE NiCr-Ni (mV)

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Remarks

R130086

Temperature compensation thermocouples PT 100

R2 Temperature compensation thermocouples PT 100

R16 Electr. charge air temperature control PT 100

9419.1 RPM switching equipment - Shutdown 0 - 15 kHz

9419.2 RPM switching equipment - Shutdown 0 - 15 kHz

9419.3 Tertiary speed timing sensor (Camshaft 2) 5 Hz - 10 kHz

9419.4 Secondary speed timing sensor (Camshaft 1) 5 Hz - 10 kHz

9419.5 Primary speed timing sensor (Crankshaft) 5 Hz - 10 kHz

942930024

Turbine speed - Alarm*/DICARETurbine speed - FCTTurbine speed - Indication

4 - 20 mA4 - 20 mA0 - 10 V

* DNV

9503 Control lever at fuel rack - Stop position binary

9513 ECM not ready - Alarm / Starting interlock binary

9514 ECM Major alarm - Shutdown binary

9561 Turning gear engaged - Starting interlock binary

960210005

CANbus failure - Alarm binary

9603 ECM Minor alarm - Alarm binary

9717 Voltage failure at terminal X55 - Alarm binary

9836.110107

Sensor / isolation fault A01 - Alarm binary

9836.210007

Sensor / isolation fault A03 - Alarm binary

9962.130108

Common alarm A01 - Alarm binary

9962.230008

Common alarm A03 - Alarm binary

S1 Turning gear engaged - Contactor reverser ON binary

S2 Starting air pressure after main starting valve binary Stop cancellation

B1 Axle lever end position early binary

B2 Axle lever end position normal binary

B3 Air supply - FCT binary

B4 Axle lever end position normal binary

49101.x Pressure in each cylinder

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Remarks

45401 Fuel gas concentration crankcase air outlet - Pre-alarm 4 - 20 mA

49102/103 Crankcase pressure high - Indication / alarm 4 - 20 mA

49104/105 Pressure in leakage detection system - Pre-alarm/switch-over to diesel 4 - 20 mA

45101 Fuel gas pressure at GVU inlet 4 - 20 mA

45103/104 Fuel gas pressure at GVU outlet 4 - 20 mA

45201 Fuel gas temperature at GVU inlet PT 100

45301/302 Position of block valve 1 at GVU - Open/close binary

45303/304 Position of block valve 2 at GVU - Open/close binary

45305/306 Position of bleed valve 1 at GVU - Open/close binary



45102 Pressure between block valves 1 and 2 binary

45103/104 Fuel gas pressure at GVU outlet - Indication/alarm 4 - 20 mA/0-5 V

45105 Differential pressure ignition fuel oil duplex filter high (on engine) - Indication / Alarm binary

45106 Ignition fuel oil low pressure system press. low or high - Alarm 4 - 20 mA

45202 Ignition fuel oil low pressure system temp. low or high - Alarm PT 100

45107.1 Ignition fuel oil high pressure system - Indication 0 - 5 V

45107.2 Ignition fuel oil high pressure system - Indication 0 - 5 V

45311 Ignition fuel oil high pressure system leakage detection binary

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6.7 Local and remote indicators

Local control panelEngine start-stop and

monitoring system

digital lower / raise

misc. measurement values

exhaust gas temperature

engine speed / turbine speed

gas shut-off

gas mode request / operation

diesel mode request / operation

switchover gas failed

false start indication

gas mode interlock

starting interlock indication

remote control /repair indication

repair / engine / remote

start / stop indication

start / stop

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7. Safety

7.1 Safety concept

Additional safety requirements need to be fulfilled to operate a dual fuel engine on a marine application.The safety concept for the MaK dual fuel engine is designed according the upcoming IFG code to provide a gas safe machinery space.Single main engine applications are currently not included.

The main intention of the safety concept for the new dual fuel engine is to prevent the formation of a hazardous explosive atmosphere. Therefore a detection system is used in combination with automatic safety actions that will finally result in a changeover to diesel and flushing the gas supply line. Additionally a ventilation system for the exhaust pipe will inhibit an accumulation of fuel gas.

Already during the design phase ignition sources have been considered and were excluded where possible. The aim was to create a robust engine design.

This safety concept for the dual fuel engine is based on a gas-safe machinery space. This means that in case of a malfunction the dual fuel engine won‘t shut down, instead the fuel supply will switch over to fuel oil as there are MDO and HFO. The switchover from fuel oil to fuel gas or vice versa will be bumpless and without any losses in power performance of the engine.

To create a gas-safe machinery space the fuel gas pipes in the machinery space are double walled from the gas valve unit (which is not placed inside the machinery space) throughout the cylinders. A leakage monitoring system is installed. To ensure the gas safe machinery space at all times the following requirements need to be fulfilled in addition:

walled.

systems).

on fuel gas, the fuel gas supply lines need to be purged with inert gas.

m


needs to be ventilated.

Additionally to the machinery space special attention needs to be paid to the gas handling room and all rooms adjacent to possibly hazardous areas.

The engine control, monitoring and protection system consists of different functional components. It will include the start-stop system, the gas management, the monitoring system and the engine protection system. Caterpillar is developing a state-of-the-art system consisting of modular components based on communication via bus structure. A screen is fitted in the local control panel and will show measurement data as well as diagnostics and engine status.

7. Safety

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8. Engine acceptance test

The acceptance test run is carried out on the testbed with customary equipment and auxiliaries using exclusively MDO, natural gas and under the respective ambient conditions of the testbed. During this test run the engine power will be blocked at the contractual output value. In case of deviations from the contractual ambient conditions the fuel consumption will be converted to standard reference conditions.

The engine will be run at the following load stages in diesel and gas operation acc. to the rules of the classification societies. After reaching steady state condition of pressures and temperatures these will be recorded and registered acc. to the form sheet of the acceptance test certificate:

Diesel operation Gas operation

Additional functional tests

In addition to the acceptance test run the following functional tests will be carried out:

100 % power)

Standard acceptance test run

Load [%] Duration [min]50 3085 30

100 60110 30

Load [%] Duration [min]25 3050 3075 30

100 60

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8. Engine acceptance test

Standard acceptance test run

After the acceptance test run camshaft drive, running gear and timing gear train will be inspected through the opened covers. Individual inspection of special engine components such as pistons or bearings is not intended, because such inspections are carried out by the classification societies in regular intervals on production engines.

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

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

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

Displacement Seff < 0.448 mm f > 2 Hz < 10 HzVibration velocity Veff < 28.2 mm/s f > 10 Hz < 250 HzVibration acceleration aeff < 44.2m/s² f > 250 Hz < 1,000 Hz

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9. Engine International Air Pollution Prevention Certificate

The MARPOL diplomatic conference has agreed about a limitation of NOx emissions, referred to as Annex VI to Marpol 73/78.

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

Cycle E2 and D2: The engine type M 46 DF remains below the NOx limit value of 10.54 g/kWh.

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

An NOx emission evidence will be issued for each engine showing that the engine complies with the regulation. The evidence will come with EAPP (Engine Air Pollution Prevention) Statement of Compliance, EAPP (Engine Air Pollution Prevention) Document of Compliance or EIAPP (Engine International Air Pollution Prevention) Certificate according to the authorization by the flag state and related technical file. On basis of an EAPP Statement of Compliance or an EAPP Document of Compliance an EIAPP certificate can be applied for.

According to the IMO regulations, a technical file shall be prepared for each engine. This technical file contains information about the components affecting NOx emissions, and each critical component is marked with a special IMO number. Such critical components are piston, cylinder head, injection nozzle (element), camshaft section, fuel injection pump, turbocharger and charge air cooler. (For common rail engines the controller and the software are defined as NOx relevant components instead of the injection pump.) The allowable setting values and parameters for running the engine are also specified in the technical file.

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

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10. Painting / preservation

Inside preservation

N 576-3.3The preservation is sufficient for max. 2 years. It needs to be removed when the engine is commissioned!

Outside preservation

VCI 368 N 576-3.2Engine outside preservation with Cortec VCI 368 is applicable for Europe and overseas.It applies for sea and land transportation and storage of the engines in the open, protected from moisture. The duration of protection with additional VCI packaging is max. 2 years.

It must be removed before commissioning of the engines! Environmentally compatible disposal is to be ensured.

Durability and effect are determined by proper packaging, transportation, and storage, i.e. protected from moisture, stored at a dry place and sufficiently ventilated. Inspections are to be carried out at regular intervals.

Appearance of the engine:

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

Clear varnish painting is not permissible for:

The duration of protection with additional VCI packaging is max. 1 year!

VCI packaging as per N 576-5.2 is generally required!Durability and effect are determined by proper packaging, transportation, and storage, i.e. the engine is to be protected from moisture, VCI film not ripped or destroyed. Inspections are to be carried out at regular intervals.

m


If the above requirements are not met, all warranty claims in connection with corrosion damage shall be excluded.


N 576-4.3 - PaintingThe painting is applicable for Europe and overseas.It applies for sea and land transportation and short-term storage in the open (protected from moisture) up to max. 4 weeks.

In case of Europe and overseas shipment and storage in the open longer than 4 weeks VCI packaging as per N 576-5.2 is required.

The duration of protection with additional VCI packaging is max. 2 years!

Durability and effect are determined by proper packaging, transportation, and storage, i.e. protected from moisture, VCI film not ripped or destroyed. Inspections are to be carried out at regular intervals.


N 576-5.2 - VCI packagingCorrosion protection with VCI packaging applies for:

These engines are always to be delivered with VCI packaging! Nevertheless, they are not suitable for storage in the open!

to Europe and overseas or storage in the open (protected from moisture).


m


Durability and effect are determined by proper packaging, transportation, and storage, i.e. protected from moisture, VCI film not ripped or destroyed. Inspections are to be carried out at regular intervals.

Kind of scope depending on engine type. The mats are to be hung up in free position and should not come into contact with the painted surface.

the inside! The air cushion film is fastened to the transportation skid (wooden frame) by means of PVC scotch tape. In case of engines delivered without oil pan the overhanging VCI film between engine and transport frame is to be folded back upwards towards the engine before fastening the air cushion film.

Attention! The corrosion protection is only effective if the engine is completely wrapped with VCI film. The protective space thus formed around the component can be opened for a short time by slitting the film, but afterwards it must be closed again by means of adhesive tape.

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

Description:

N 576-6.1 - Corrosion protection period, check, and represervationThere will only be an effective corrosion protection of the engine if the definitions and required work according to factory standard N 576-6.1 are duly complied with.In general, the applied corrosion protection is effective for a period of max. 2 years if the engines or engine generator sets are protected from moisture. However, depending on the execution of the preservation shorter periods may be applicable.

After two years represervation must be carried out.

Every 3 months specific inspections are to be carried out at the engine or engine generator set at defined inspection points. Any corrosion that is found and existing condensation water are to be removed immediately.


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11. Engine parts

ø550

ø613

1271

.5

335

Cylinder liner, weight 651 kg

Connecting rod, weight 560 kg

1887

.7

Cylinder head, weight 1,160 kg

Piston, weight 214 kg

ø460

531

459

494

1,11

172

8

618

1,170

357

ø 56

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12. Flexible Camshaft Technology

The dual fuel engine has a modified FCT system, to ensure an optimal engine operation in all operating modes over the whole load range. The FCT system is basically known from the M 43 C diesel engine, where this technology is already validated.

Flexible Camshaft Technology (FCT):

FCT-positionsIntake & Exhaust

Crank angle [deg]

Valv

e lif

t [m

m]

Crank angle [deg]

Valv

e lif

t [m

m]

Crank angle [deg]

Valv

e lif

t [m

m]

Full Load Part Load

Gasmode

Dieselmode

Crank angle [deg]

Valv

e lif

t [m

m]

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Caterpillar Marine Power Systems

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2Subject to change without notice.Leaflet No. 255 · 04.12 · e · L+S · VM3

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