wartsila o e rt flex82c mim

Marine Installation ManualIssue April 2011

Wrtsil Switzerland Ltd PO Box 414 CH-8401 Winterthur Switzerland 2011 Wrtsil Switzerland Ltd, Printed in Switzerland

Tel. +41 52 262 49 22 Fax +41 52 212 49 17 http://www.wartsila.com

This issue of this Marine Installation Manual (MIM) is the third edition covering the Wrtsil 612RT-flex82C two-stroke marine diesel engines. This manual covers the Wrtsil RT-flex82C engines with the following MCR: Power per cylinder, at R1 and R1+ at R1 Speed Mean effective pressure 97 rpm 20 bar 4520 kW / 6150 bhp at R1+ 102 rpm 19 bar

All data are related to engines compliant with IMO-2000 regulations Tier II and refer to cost-optimised and/or efficiency-optimised versions. Cost-optimised engines (CO) are fitted either with ABB TPL-B or MHI MET MA turbochargers; efficiency-optimised engines (EO) are fitted either with ABB A100-L or MHI MET MB turbochargers. Compared to the cost-optimised version, the efficiency-optimised version has no additional or particular requirements for the engine installation. The engine performance data (rating R1+) refer to winGTD version 3.1.2. The engine performance data (BSFC, BSEF and tEaT) and other data can be obtained from the winGTD-program, which can be downloaded from our Licensee Portal. This Marine Installation Manual is complete within itself, no additional documentation is necessary.

26.21.07.40 Issue IV.11 Rev. 0

Wrtsil Switzerland Ltd

Marine Installation Manual

List of contents

AA1 A2 A2.1 A2.2 A2.3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1Primary engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuning options for efficiency-optimised RT-flex82C engines . . . . . . . . . . . . . . . . . . . Delta Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low-Load Tuning (LLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Further aspects of engine tuning options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2 A3 A3 A3 A4

BB1 B2

Engine description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1Engine description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine numbering and designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1 B4

CC1 C1.1 C1.1.1 C1.1.2 C1.2 C1.2.1 C1.2.2 C1.2.3 C1.2.4 C1.2.5 C1.2.5.1 C1.2.5.2 C1.2.6 C1.2.7 C2 C2.1 C2.2 C2.3 C2.4 C3 C3.1 C4 C5

General engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1Engine rating field and load range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rating field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rating points R1, R2, R3 and R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Influence of propeller revolutions on the power requirement . . . . . . . . . . . . . . . . . . . Load range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sea trial power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sea margin (SM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light running margin (LR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine margin (EM) or operational margin (OM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous service rating (CSR=NOR=NCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contract maximum continuous rating (CMCR = Rx) . . . . . . . . . . . . . . . . . . . . . . . . . . Load range limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load range with main-engine driven generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ancillary system design parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1 C1 C2 C2 C2 C3 C3 C3 C4 C5 C5 C5 C5 C7 C8 C8 C8 C8 C8

Turbocharger and scavenge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C9 Turbocharger and scavenge air cooler selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C10 Auxiliary blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C18 Electrical power requirement of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C18


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C6 C7 C7.1 C7.1.1 C7.2 C7.2.1 C7.2.2 C7.2.3 C7.2.4 C7.2.5

Pressure and temperature ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C18 General Technical Data winGTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Availability of winGTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Download from Licensee Portal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using winGTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saving a project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C20 C20 C20 C20 C20 C21 C21 C22 C22

DD1 D1.1 D1.1.1 D1.1.2 D1.1.3 D1.2 D1.2.1 D1.2.1.1 D1.2.1.2 D1.3 D1.4 D1.4.1 D1.5 D1.5.1 D1.6 D1.7 D1.8 D2 D3 D3.1 D3.2 D3.3 D3.4 D3.5

Engine dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1Vibration aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1 External forces and moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1 Balancing free first order moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2 Balancing free second order moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2 Power related unbalance (PRU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3 Lateral engine vibration (rocking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4 Reduction of lateral vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5 Engine stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5 Electrically driven compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5 Longitudinal engine vibration (pitching) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6 Torsional vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6 Reduction of torsional vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7 Axial vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8 Reduction of axial vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8 Hull vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9 External forces and moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10 Summary of countermeasures for dynamic effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11 System dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12 Order forms for vibration calculations and simulation . . . . . . . . . . . . . . . . . . . . . . . . . Marine installation Torsional Vibration Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testbed installation Torsional Vibration Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . Marine installation Coupled Axial Vibration Calculation . . . . . . . . . . . . . . . . . . . . . . . . Marine installation Bending Vibration Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required information of OD-shafts for TVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D12 D13 D14 D15 D16 D17

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List of contents

EE1 E1.1 E2 E3 E3.1 E3.2

Auxiliary power generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System description and layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Waste heat recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power take off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangements of PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO power and speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1 E2 E2 E2 E2 E2

FF1 F1.1 F1.2 F1.2.1 F1.2.2 F1.2.3 F2 F2.1 F2.1.1 F2.1.1.1 F2.1.2 F2.1.3 F2.1.4 F2.1.5 F2.2 F2.2.1 F2.2.2 F2.2.3 F2.2.4 F2.2.5 F2.2.5.1 F2.2.6 F2.2.7 F2.2.8 F2.2.9 F2.2.9.1 F2.2.9.2 F2.2.9.3 F2.2.9.4 F2.2.9.5 F2.2.9.6

Ancillary systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part-load data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R1+ data for central fresh water cooling system (single-stage, integrated HT) . . . . R1+ data for central fresh water cooling system (single-stage, separate HT) . . . . . Questionnaire for engine data (winGTD, see section C7) . . . . . . . . . . . . . . . . . . . . . . Piping systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling water and pre-heating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central fresh water cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central fresh water cooling system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General recommendations for design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fresh water generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil systems for turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main lubricating oil system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil maintenance and treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil drain tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flushing the external lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation before flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flushing external lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flushing within the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning of lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder oil supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1 F1 F1 F2 F4 F6 F7 F7 F7 F12 F17 F17 F18 F20 F21 F21 F21 F26 F27 F27 F27 F27 F30 F32 F41 F42 F42 F43 F43 F43 F44


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F2.3 F2.3.1 F2.3.2 F2.3.2.1 F2.3.2.2 F2.3.2.3 F2.3.3 F2.3.4 F2.3.4.1 F2.3.5 F2.3.5.1 F2.3.5.2 F2.4 F2.4.1 F2.4.2 F2.4.3 F2.4.3.1 F2.4.4 F2.5 F2.6 F2.7 F2.8 F3 F3.1 F3.1.1 F3.2 F4 F4.1 F4.2 F5

Fuel oil systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel oil requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel oil treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settling tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized fuel oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy fuel oil system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flushing the external fuel oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation before flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flushing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and control air systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacities of air compressor and receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and control air system specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control air system supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General service and working air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leakage collection system and washing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine-room ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient temperature consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine air inlet Operating temperatures from 45C to 5C . . . . . . . . . . . . . . . . . . . Scavenge air system arctic conditions at operating temperatures below 5C . . . Air filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F45 F45 F52 F53 F53 F53 F54 F56 F59 F61 F62 F62 F63 F63 F63 F65 F65 F65 F66 F70 F72 F73 F74 F74 F74 F76

Pipe size and flow details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F78 Pipe velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F78 Piping symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F79 Engine pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F82

GG1 G1.1 G1.2 G1.3 G2 G2.1 G2.2 G2.2.1

Automation and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DENIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAPEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DENIS-9520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propulsion control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approved propulsion control systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G1 G3 G3 G3 G3 G3 G4 G5

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G2.2.2 G2.2.3 G2.3 G2.3.1 G2.3.2 G3 G3.1 G3.2 G3.3 G3.4 G3.5 G4 G4.1

Functions of the propulsion control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G7 Recommended manoeuvring characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G8 Interface to alarm and monitoring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G9 General layout Operator interface OPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G9 Alarm sensors and safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G11 WECS-9520 RT-flex engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WECS-9520 System layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WECS-9520 External 230 VAC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Online spare module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication to external systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabling notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G15 G15 G15 G15 G15 G17

MAPEX Engine Fitness Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G18 Mapex-PR (Piston-running Reliability) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G19

HH1 H2 H2.1 H2.2 H2.3 H2.4 H2.5 H2.5.1 H2.5.2 H2.5.3 H3 H4 H5 H5.1 H5.2 H5.3 H5.4 H5.4.1 H5.4.2 H5.4.3

General installation aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and masses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and masses of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermal expansion at the turbocharger expansion joint . . . . . . . . . . . . . . . . . . . . . . . Contents of fluid in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Space requirements and dismantling heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crane requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston dismantling heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling of scavenge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outlines of Wrtsil RT-flex82C engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1 H2 H2 H3 H4 H5 H5 H5 H5 H7 H8

Platform arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H30 Engine seating with epoxy resin chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drilling of the holes in the tank top plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chock thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pouring of the epoxy resin chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conditions before pouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening the holding-down studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H35 H35 H35 H35 H36 H36 H36 H36


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H5.5 H5.6 H5.7 H5.8 H5.9 H5.9.1 H6 H6.1 H7 H7.1 H7.2 H8 H8.1 H8.1.1 H8.1.2 H9 H9.1

Engine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine holding-down studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine seating side stoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chocking and drilling plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine alignment tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position of engine alignment tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H37 H39 H42 H47 H52 H53

Engine coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H56 Fitting coupling bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H56 Engine earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H59 Preventive action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H59 Main shaft earthing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H60 Engine stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stays arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of lateral stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Longitudinal stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H62 H62 H62 H62

Fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H70 Extinguishing agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H70

II1 I1.1 I1.1.1 I1.1.2 I1.2 I1.2.1 I1.2.2 I2 I2.1 I2.2 I2.3

Engine emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1Exhaust gas emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMO-2000 regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Establishment of emission limits for ships . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulation regarding NOx emissions of diesel engines . . . . . . . . . . . . . . . . . . . . . . . Measures for compliance with the IMO regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low NOx Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extended measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine surface sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine exhaust sound pressure level at funnel top . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine structure borne noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I1 I1 I1 I1 I2 I2 I2 I3 I3 I4 I5

JJ1 J2 J3

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J1 J2

Recommended special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J42

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J4 J5 J5.1

Special tools, obtainable on loan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J47 Storage proposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J50 Tool panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J51

KK1 K2 K3 K4 K4.1 K4.2 K4.2.1 K4.2.2

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illustrations, masses and weights of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage on board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection against corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage and security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secured spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K1 K1 K8 K20 K20 K20 K20 K21

LL1 L1.1 L1.2 L1.3 L2 L2.1 L2.2 L2.3 L2.4 L2.5 L3

Engine dispatch and installation . . . . . . . . . . . . . . . . . . . . . . . . . L1Dismantling pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Treatment against corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine dispatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine installation on board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing rust preventing oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation and assembly of sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing a complete engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing an engine from assembled sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . Engine installation with ship on slipway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shafting alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L1 L1 L2 L3 L4 L4 L4 L5 L5 L5 L6

MM1 M2 M3

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M1SI dimensions for internal combustion engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximate conversion factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference to other Wrtsil Ltd publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M1 M2 M3


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List of figures

Fig. A1 Fig. A2 Fig. A3 Fig. A4 Fig. B1 Fig. B2 Fig. B3 Fig. B4 Fig. C1 Fig. C2 Fig. C3 Fig. C4 Fig. C5 Fig. C6 Fig. C7 Fig. C8 Fig. C9 Fig. C10 Fig. C11 Fig. C12 Fig. C13 Fig. C14 Fig. C15 Fig. C16 Fig. C17 Fig. C18 Fig. C19 Fig. D1 Fig. D2 Fig. D3 Fig. D4 Fig. D5

Power/speed range of all IMO-2000 regulation compatible RTA and RT-flex engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic functional principle of Low-Load Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . Rating fields for Delta Tuning and Low-Load Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . Typical BSFC curves to illustrate Standard Tuning, Delta Tuning and Low-Load Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comparison of Wrtsil RT-flex and RTA engines and engines . . . . . . . . . . . . . . . . . Cross section of a typical Wrtsil RT-flex engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wrtsil RT-flex key parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine numbering and designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rating field of the Wrtsil RT-flex82C engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load range limits of an engine corresponding to a specific rating point Rx . . . . . . . Load diagram for a specific engine showing the corresponding power and speed margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load range limits, with the load diagram of an engine corresponding to a specific rating point Rx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load range diagram for an engine equipped with a main-engine driven generator, whether it is a shaft generator or a PTO-driven generator . . . . . . . . . . . . . . . . . . . . . Scavenge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger and scavenge air cooler selection 69RT-flex82C (ABB TPL turbochargers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger and scavenge air cooler selection 1012RT-flex82C (ABB TPL turbochargers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger and scavenge air cooler selection 69RT-flex82C (MHI MET MA turbochargers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger and scavenge air cooler selection 1012RT-flex82C (MHI MET MA turbochargers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger and scavenge air cooler selection 69RT-flex82C (ABB A100-L turbochargers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger and scavenge air cooler selection 1012RT-flex82C (ABB A100-L turbochargers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger and scavenge air cooler selection 69RT-flex82C (MHI MET MB turbochargers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger and scavenge air cooler selection 1012RT-flex82C (MHI MET MB turbochargers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . winGTD: Selection of engine window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . winGTD: Main window (cost-optimised) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . winGTD: Main window (efficieny-optimised) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . winGTD: General technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . winGTD: Two-stroke engine propulsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External forces and moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locating electrically driven compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Free external mass moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External forces and moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General arrangement of hydraulic stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A1 A4 A5 A5 B1 B2 B3 B4 C1 C3 C4 C6 C7 C9 C10 C11 C12 C13 C14 C15 C16 C17 C20 C21 C21 C21 C22 D1 D2 D3 D4 D5

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List of figures

Fig. D6 Fig. D7 Fig. D8 Fig. D9 Fig. D10 Fig. E1 Fig. E2 Fig. F3 Fig. F4 Fig. F5 Fig. F6 Fig. F7 Fig. F8 Fig. F9 Fig. F10 Fig. F11 Fig. F12 Fig. F13 Fig. F14 Fig. F15 Fig. F16 Fig. F17 Fig. F18 Fig. F19 Fig. F20 Fig. F21 Fig. F22 Fig. F23 Fig. F24 Fig. F25 Fig. F26 Fig. F27 Fig. F28 Fig. F29 Fig. F30 Fig. F31 Fig. F32 Fig. F33 Fig. F34 Fig. F35 Fig. F36 Fig. F37 Fig. F38

General arrangement of friction stays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration damper (Viscous type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration damper (Geislinger type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axial damper (detuner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OD-shafts for TVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat recovery, typical system layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tunnel PTO gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central fresh water cooling system with single-stage scavenge air cooler and integrated HT circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central fresh water cooling system with single-stage scavenge air cooler and separate HT cicuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central cooling water system expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central cooling water system expansion tank (HT circuit) . . . . . . . . . . . . . . . . . . . . . . Central cooling water system expansion tank (LT circuit) . . . . . . . . . . . . . . . . . . . . . . Fresh water generator installation alternative A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fresh water generator installation alternative B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-heating power requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connections and specifications for the engine lubrication system . . . . . . . . . . . . . . . Lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Separate lubricating oil system for 2 x ABB-TPL turbochargers . . . . . . . . . . . . . . . . Lubricating oil treatment and transfer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil treatment details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of vertical lubricating oil drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical drain connection details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Layout of vertical oil drains for 6RT-flex82C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Layout of vertical oil drains for 7RT-flex82C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Layout of vertical oil drains for 8RT-flex82C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Layout of vertical oil drains for 10RT-flex82C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Layout of vertical oil drains and back flushing pipe for 6,7,8&10RT-flex82C . . . . . . Dimensioning guide-lines and filling process of the lubricating oil drain tank . . . . . . Flushing the lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical viscosity / temperature diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connections and specifications for the engine lubrication system . . . . . . . . . . . . . . . Fuel oil system main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy fuel oil treatment and tank system layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized fuel oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel oil system mixing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel oil system flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and control air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leakage collection and washing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sludge oil trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of automatic water drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determination of exhaust pipe diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Estimation of exhaust gas density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D5 D7 D7 D8 D17 E1 E2 F8 F10 F14 F15 F16 F18 F19 F21 F22 F23 F25 F28 F29 F32 F34 F35 F36 F37 F38 F39 F40 F41 F48 F49 F50 F52 F55 F58 F59 F61 F64 F67 F68 F69 F70 F71


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Fig. F39 Fig. F40 Fig. F41 Fig. F42 Fig. F43 Fig. F44 Fig. F45 Fig. F46 Fig. F47 Fig. F48 Fig. F49 Fig. F50 Fig. F51 Fig. F52 Fig. F53 Fig. F54 Fig. F55 Fig. F56 Fig. F57 Fig. F58 Fig. G1 Fig. G2 Fig. G3 Fig. G4 Fig. G5 Fig. G6 Fig. G7 Fig. H1 Fig. H2 Fig. H3 Fig. H4 Fig. H5 Fig. H6 Fig. H7 Fig. H8 Fig. H9 Fig. H10 Fig. H11 Fig. H12 Fig. H13

Estimation of exhaust pipe diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct suction of combustion air main and auxiliary engine . . . . . . . . . . . . . . . . . . . Scavenge air system for arctic conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blow-off effect under arctic conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air filter size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piping symbols 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piping symbols 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piping symbols 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pipe connection plan for 6RT-flex82C engines fitted with 2x MHI MET 66MB . . . . Pipe connection plan for 6RT-flex82C engines fitted with 2x MHI MET 66MB . . . . Pipe connection plan for 6RT-flex82C engines fitted with 2x MHI MET 66MB . . . . Pipe connection plan for 6RT-flex82C engines fitted with 2x MHI MET 66MB . . . . Pipe connection plan for 6RT-flex82C engines fitted with 2x MHI MET 66MB . . . . Pipe connection plan for 6RT-flex82C engines fitted with 2x MHI MET 66MB . . . . Pipe connection plan for 8RT-flex82C engines fitted with 2x ABB TPL85-B . . . . . . Pipe connection plan for 8RT-flex82C engines fitted with 2x ABB TPL85-B . . . . . . Pipe connection plan for 8RT-flex82C engines fitted with 2x ABB TPL85-B . . . . . . Pipe connection plan for 8RT-flex82C engines fitted with 2x ABB TPL85-B . . . . . . Pipe connection plan for 8RT-flex82C engines fitted with 2x ABB TPL85-B . . . . . . Pipe connection plan for 8RT-flex82C engines fitted with 2x ABB TPL85-B . . . . . . EMA concept comprising DENIS, WECS and MAPEX modules . . . . . . . . . . . . . . . . RT-flex signal fow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DENIS-9520 remote control system layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended manoeuvring characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated/split solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAPEX-PR System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAPEX-MD Visualization software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermal expansion, dimensions X, Y, Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Space requirements and dismantling heights for vertical piston lifting . . . . . . . . . . . Dismantling of SAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 6RT-flex82C with 2 x ABB TPL80-B . . . . . . . . . . . . . . . . . . Side elevation and top view of Wrtsil 6RT-flex82C engines with 2 x ABB TPL80-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 7RT-flex82C with 2 x ABB TPL80-B . . . . . . . . . . . . . . . . . . Side elevation and top view of Wrtsil 7RT-flex82C engines with 2 x ABB TPL80-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 8RT-flex82C with 2 x ABB TPL85-B . . . . . . . . . . . . . . . . . . Side elevation and top view of Wrtsil 8RT-flex82C engines with 2 x ABB TPL85-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 9RT-flex82C with 2 x ABB TPL85-B . . . . . . . . . . . . . . . . . . Side elevation and top view of Wrtsil 9RT-flex82C engines with 2 x ABB TPL85-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 8RT-flex82C with 2 x ABB A185-L . . . . . . . . . . . . . . . . . . .

F71 F73 F74 F75 F77 F79 F80 F81 F82 F83 F84 F85 F86 F87 F88 F89 F90 F91 F92 F93 G1 G2 G6 G8 G10 G20 G20 H2 H4 H6 H7 H8 H9 H10 H11 H12 H13 H14 H15 H16

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Fig. H14 Fig. H15 Fig. H16 Fig. H17 Fig. H18 Fig. H19 Fig. H20 Fig. H21 Fig. H22 Fig. H23 Fig. H24 Fig. H25 Fig. H26 Fig. H27 Fig. H28 Fig. H29 Fig. H30 Fig. H31 Fig. H32 Fig. H33 Fig. H34 Fig. H35 Fig. H36 Fig. H37 Fig. H38 Fig. H39 Fig. H40 Fig. H41 Fig. H42 Fig. H43 Fig. H44 Fig. H45 Fig. H46

Side elevation and top view of Wrtsil 8RT-flex82C engines with 2 x ABB A185-L turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 8RT-flex82C with 2 x MHI MET66MA turbochargers . . . Side elevation and top view of Wrtsil 8RT-flex82C engines with 2 x MHI MET66MA turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 8RT-flex82C with 2 x MHI MET66MA turbochargers . . . Side elevation and top view of Wrtsil 8RT-flex82C engines with 2 x MHI MET66MA turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 7RT-flex82C with 2 x MHI MET71MA turbochargers . . . Side elevation and top view of Wrtsil 7RT-flex82C engines with 2 x MHI MET71MA turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 7RT-flex82C with 2 x MHI MET71MA turbochargers . . . Side elevation and top view of Wrtsil 7RT-flex82C engines with 2 x MHI MET71MA turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 8RT-flex82C with 2 x MHI MET83MA turbochargers . . . Side elevation and top view of Wrtsil 8RT-flex82C engines with 2 x MHI MET83MA turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End elevation of Wrtsil 10RT-flex82C with 2 x MHI MET83MA turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side elevation and top view of Wrtsil 10RT-flex82C engines with 2 x MHI MET83MA turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic platform outline view for 6RT-flex82C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic platform outline view for 7RT-flex82C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic platform outline view for 8RT-flex82C engines . . . . . . . . . . . . . . . . . . . . . . . . . . Basic platform outline view for 9&10RT-flex82C engines . . . . . . . . . . . . . . . . . . . . . . Engine seating and foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine seating (foundation) with epoxy resin chocks . . . . . . . . . . . . . . . . . . . . . . . . . Cross section of holding-down studs and epoxy resin chocks . . . . . . . . . . . . . . . . . . Sleeves and nuts for engine holding-down studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleeves and nuts for engine holding-down studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine seating side stoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6&7RT-flex82C engine side stopper arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8&9RT-flex82C engine side stopper arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10&11RT-flex82C engine side stopper arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . 12RT-flex82C engine side stopper arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6&7RT-flex82C chocking and drilling plan for engine seating with epoxy resin chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8&9RT-flex82C chocking and drilling plan for engine seating with epoxy resin chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10&11RT-flex82C chocking and drilling plan for engine seating with epoxy resin chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12RT-flex82C chocking and drilling plan for engine seating with epoxy resin chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drilling plan details: holes for thrust sleeves and normal holding-down studs . . . . . Alignment with hydraulic jack and wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H17 H18 H19 H20 H21 H22 H23 H24 H25 H26 H27 H28 H29 H31 H32 H33 H34 H37 H38 H39 H40 H41 H42 H43 H44 H45 H46 H47 H48 H49 H50 H51 H52


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List of figures

Fig. H47 Fig. H48 Fig. H49 Fig. H50 Fig. H51 Fig. H52 Fig. H53 Fig. H54 Fig. H55 Fig. H56 Fig. H57 Fig. H58 Fig. H59 Fig. H60 Fig. H61 Fig. I1 Fig. I2 Fig. I3 Fig. I4 Fig. I5 Fig. J1 Fig. J2 Fig. J3 Fig. J4 Fig. J5 Fig. J6 Fig. J7 Fig. J8 Fig. J9 Fig. J10 Fig. K1 Fig. K2 Fig. K3 Fig. K4 Fig. K5 Fig. K6 Fig. K7 Fig. K8 Fig. K9 Fig. K10 Fig. K11 Fig. K12 Fig. K13 Fig. K14 Fig. K15

Position of engine alignment tools for 67RT-flex82C . . . . . . . . . . . . . . . . . . . . . . . . . Position of engine alignment tools for 89RT-flex82C . . . . . . . . . . . . . . . . . . . . . . . . . Position of engine alignment tools for 10RT-flex82C . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coupling fitted bolt arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Details of coupling bolt and nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft earthing arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft earthing slip-ring arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft earthing with condition monitoring facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachment points for lateral stays hydraulic type . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachment points for lateral stays hydraulic type . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachment points for lateral stays hydraulic type . . . . . . . . . . . . . . . . . . . . . . . . . . . Details of lateral stays hydraulic type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachment points for lateral stays friction type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachment points for lateral stays friction type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Friction stays details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed dependent maximum average NOx emissions by engines . . . . . . . . . . . . . . . Wrtsil RT-flex82C: compliance with IMO regulations . . . . . . . . . . . . . . . . . . . . . . . . Engine sound pressure level at 1 m distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sound pressure level at funnel top of engine exhaust gas system . . . . . . . . . . . . . . Structure borne noise level at engine feet vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool panel storage arrangement (proposal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool panel location (proposal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool panel 1: General tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool panel 2: for valve seat grinding / control tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool panel 3: for nozzle dismantling / overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool panel 4: for cylinder liner / head dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool panel 5: for piston dismantling / overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool panel 6: for piston / various tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool panel 7: Crankcase tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool panel 8: for gear drive dismantling / control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thrust bearing pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting air valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston rod gland box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston complete with piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scavenging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Securing spare piston and rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Securing spare exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Securing spare exhaust valve cages without . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H53 H54 H55 H57 H58 H60 H60 H61 H63 H64 H65 H66 H67 H68 H69 I1 I2 I3 I4 I5 J50 J51 J52 J53 J54 J55 J56 J57 J58 J59 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K21 K21 K22

26.21.07.40 Issue IV.11 Rev. 0

l



List of figures

Fig. K16 Fig. L1

Securing spare cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K22 Lifting a complete engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3


m

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List of tables

Table A1 Table C1 Table C2 Table C3 Table C4 Table C5 Table D1 Table D2 Table D3 Table D4 Table D5 Table D6 Table D7 Table D8 Table E1 Table F1 Table F2 Table F3 Table F4 Table F5 Table F6 Table F7 Table F8 Table F9 Table F10 Table F11 Table F12 Table F13 Table F14 Table F15 Table F16 Table F17 Table F18 Table F19 Table F20 Table F21 Table F22 Table F23 Table G1

Primary engine data of Wrtsil RT-flex82C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scavenge air cooler parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of auxiliary blowers per engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical power consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure and temperature ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External forces and moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Countermeasures for external mass moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Countermeasures for lateral and longitudinal rocking . . . . . . . . . . . . . . . . . . . . . . . . . Countermeasures for torsional & axial vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marine installation Torsional Vibration Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testbed installation Torsional Vibration Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . Marine installation Coupled Axial Vibration Calculation . . . . . . . . . . . . . . . . . . . . . . . . Marine installation Bending Vibration Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO power and speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R1+ data for central fresh water cooling system with single-stage SAC and integrated HT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R1+ data for central fresh water cooling system with single-stage SAC and integrated HT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R1+ data for central fresh water cooling system with single-stage SAC and separate HT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R1+ data for central fresh water cooling system with single-stage SAC and separate HT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central fresh water cooling system with single-stage scavenge air cooler and integrated HT circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central fresh water cooling system with single-stage scavenge air cooler and separate HT circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil system: referring legend, remarks and data . . . . . . . . . . . . . . . . . . . . . Lubricating oil treatment and transfer system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . Global brands of lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local brands of lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of vertical lubricating oil drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum inclination angles at which the engine is to remain fully operational . . . . NAS 1638 cleanliness classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel oil requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy fuel oil treatment and tank system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel oil system mixing unit: nominal pipe diameters for connections A, B, C . . . . . Air receiver and air compressor capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control air capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leakage collection and washing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guidance for air filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended fluid velocities and flow rates for pipework . . . . . . . . . . . . . . . . . . . . . ISO flange dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JIS flange dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suppliers of remote control systems and electronic speed control systrems . . . . . .

A2 C9 C9 C18 C18 C19 D10 D11 D11 D11 D13 D14 D15 D16 E2 F2 F3 F4 F5 F9 F11 F24 F29 F30 F31 F32 F33 F44 F45 F51 F58 F63 F65 F66 F76 F78 F94 F95 G5

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List of tables

Table G2 Table G3 Table G4 Table H1 Table H2 Table H3 Table H4 Table H5 Table H6 Table H7 Table H8 Table H9 Table H10 Table H11 Table K1

Alarm and safety functions of Wrtsil RT-flex82C marine diesel engines . . . . . . . Alarm and safety functions of Wrtsil RT-flex82C marine diesel engines . . . . . . . Alarm and safety functions of Wrtsil RT-flex82C marine diesel engines . . . . . . . Engine dimensions and masses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and masses of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expected thermal expansion figures at turbocharger gas outlet . . . . . . . . . . . . . . . . Fluid quantities in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required properties of epoxy resin material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts list for engine seating with epoxy resin chocks . . . . . . . . . . . . . . . . . . . . . . . . . . Details and dimensions of epoxy resin chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number and diameter of holes drilled into top plate . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts list for wedge and hydraulic jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended quantities of fire extinguishing medium . . . . . . . . . . . . . . . . . . . . . . . List of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G12 G13 G14 H2 H3 H4 H5 H36 H36 H40 H51 H51 H52 H70 K7


o

26.21.07.40 Issue IV.11 Rev. 0


Index

AAddress Wrtsil Switzerland, A1 Air filtration, F76 Air flow requirements, F73 Air vents, F72 Alarm sensors and safety functions, G11 Aluminium, F46 Ambient temperature consideration, F74 Approved propulsion control systems, G5 Arctic conditions, F74 Ash, F46 Automatic back-flushing lubricating oil filter, F26 Automatic back-flushing fuel oil filter, F59 Automatic temperature control valve, F13 Auxiliary blower, C18 Availability of winGTD, C20 Axial vibration, D8

Dismantling of scavenge air cooler, H7 Duplex filter in the feed system, F60 Dynamic behaviour, D12

EEarthing slip-rings, H60 ECR manual control panel, G7 Electrical power consumers, C18 Electrically driven auxiliary blowers, C18 Electrically driven compensator, D5 Electronic speed control system, G7 EMA concept, G1 Engine air inlet, F74 Engine alignment tools, H52 Engine coupling, H56 Engine data, C8 Engine description, B1 Engine dismantling, L2 Engine dispatch, L3 Engine earthing, H59 Engine emissions, I1 Engine holding-down studs, H39 Engine installation and alignment, L4 Engine installation with ship on slipway, L5 Engine layoutfield and load range, C1 Engine margin (EM), C5 Engine noise, I3 Engine numbering and description, B4 Engine performance data, C8 Engine pre-heating, F20 Engine seating, H35, H38 Engine stays, D5, H62 Engine system data, F1 Engine-room ventilation, F73 Epoxy resin chocks, H35 Exhaust gas system, F70 External forces and moments, D1 Extinguishing agents, H70

BBack-flushing filter after the feed pumps, F60 Barred-speed range, D6

CCarbon residue, F46 Central cooler, F12 Central fresh water cooling system components, F12 Centrifugal separators, F53 Change-over duplex filter, F26 Chocking and drilling plan, H47 CMCR, C1, C5 Compensator, D2 Contents of fluid in the engine, H5 Continuous service rating, C5 Control air system supply, F65 Conversion factors, M2 Cross section, B2 Cylinder cooling water pump delivery head, F13 Cylinder cooling water system expansion tank, F13 Cylinder lubricating oil system, F27, F30

F DDelta Tuning, A3 DENIS-9520, G3 Design conditions, C8 Dimensions and masses, H2 Filling process of lub. oil tank, F40 Fire protection, H70 Fitting coupling bolts, H56 Flash point, F47 Flushing the fuel oil system, F61

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p



Index

Free first order moments, D2 Free second order moments, D2 Fresh water generator, F17, F18 Fresh water pump, F12 Fuel oil endheater, F57 Fuel oil feed pump, F56 Fuel oil filter, F59 Fuel oil requirements, F45 Fuel oil system, F45 Fuel oil system mixing unit, F57 Fuel oil treatment, F50, F52

Lubricating oil drain tank, F32 Lubricating oil full flow filters, F26 Lubricating oil low-pressure pump, F26 Lubricating oil maintenance and treatment, F27 Lubricating oil requirements, F27 Lubricating oil separator, F27 Lubricating oil system, F21 Lubricating oil system for turbocharger, F21

MMain bearing oil, F21 Main lubricating oil system, F21 Main lubricating oil system components, F26 Main shaft earthing system, H60 MAPEX Engine Fitness Family, G18

GGeneral service and working air, F65

HHeavy fuel oil system components, F56 High-temperature circuit, F12 High-pressure booster pump, F57 HT cooling water pump, F12 Hull vibration, D6, D9

NNoise, I3

OOperational margin (OM), C5 Order forms for vibration calculations and simulation, D12 Outline drawings, H8 Overload limit, C5 Overspeed limit, C6

IIgnition quality, F47 Illustrations of spare parts, K8 Installation and assembly of sub-assemblies, L4 Installing a complete engine, L5 Installing an engine from assembled sub-units, L5 Interface to alarm and monitoring system, G9 Introduction of the engine, A1 ISO Standard 15550, C8 ISO Standard 3046-1, C8

PPart-load data diagram, F1 Pipe connections, F7, F82 Pipe size and flow details, F78 Pipe velocities, F78 Piping symbols, F79 Piping systems, F7 Piston dismantling heights, H5 Pitching (longitudinal engine vibration), D6 Platform arrangements, H30 Pour point, F47 Power demand of an engine, C1 Power related unbalance (PRU), D3 Power take off (PTO), D6 Power/speed combination, C1 Pressure and temperature ranges, C18 Pressure regulating valve, F56 Pressurized fuel oil system, F54 Primary engine data, A2

LLateral engine vibration (rocking), D4 Leakage collection system, F66 Light running margin (LR), C4 List of spare parts, K1 Load range, C2 Load range with main-engine driven generator, C7 Load range limits, C5 Longitudinal engine vibration, D6 Low-Load Tuning, A3 Low-temperature circuit, F12 Lubricating oil cooler, F26


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Index

Propeller characteristics, C1 Propeller curve, C3 Propeller efficiency, C1 Protection against corrosion (spare parts), K20 PTO arrangements, E2

Space requirements and dismantling heights, H5 Special tools, available on loan, J1 Spraycoating with rust preventing oil, L1 Standard tools, J1 Starting air compressors, F65 Starting air receivers, F65 Starting and control air system specification, F65 Starting and control air systems, F63 Storage of spare parts on board, K20 Storage proposal, J1 Sulphur, F46 System dynamics, D12

QQuestionnaire for engine data, F6

RRating, C1 Rating field, C1 Rating points, C2 Recommended special tools, J1 Reduction of axial vibration, D8 Reduction of lateral vibration, D5 Reduction of torsional vibration, D7 Redundancy of WECS power supply, G15 Reference conditions, C8 Reference to other documentation, M3 Remote control system, G7 Removing rust preventing oils, L4 Rocking (lateral engine vibration), D4 RT-flex key parts, B3 RT-flex system, B1

TTC and SAC selection, C10 Temperature control, F12 Thermal expansion at TC expansion joint, H4 Tools, J1 Torsional vibration, D6 Trace metals, F46 Treatment against corrosion, L1 Tuning options of RT-flex engines, A3 Turbocharger and scavenge air coolers, C9 Turbocharger spare parts, K20, K21 Turbocharger weights, C9

SSafety system, G7 Scavenge air cooler parameters, C9 Scavenge air system, F74 Sea margin (SM), C3 Sea trial power, C3 Sea-water pump, F12 Sea-water strainer, F12 Sediment, F46 Separation efficiency, F54 Separator arrangement, F53 Service tanks (for fuel oil), F53 Settling tanks, F53 Shafting alignment, L6 Shafting system, D8 SI dimensions, M1 Side stoppers, H42 Signal flow diagram, G2 Silicon, F46

UUsing winGTD, C20

VVibration aspects, D1 Viscosity, F46

WWaste heat recovery, E2 Water in fuel oil, F47 WECS-9520, G15 WECS-9520 external power supply, G15 winGTD, C20 Working air, F65

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r



Abbreviations

ALM AMS BFO BN BSEF BSFC CCAI CCR CCW CMCR CO CPP CSR cSt DAH DENIS EM EO FCM FPP FQS FW GEA HFO HT IMO IND ISO kW kWe kWh LAH LAL LCV LI LR LSL LT LLT M MAPEX M1H

Alarm Attended machinery space Bunker fuel oil Base Number Brake specific exhaust gas flow Brake specific fuel consumption Calculated Carbon Aromaticity Index Conradson carbon Cylinder cooling water Contract maximum continuous rating (Rx) Cost-optimised Controllable pitch propeller Continuous service rating (also designated NOR and NCR) centi-Stoke (kinematic viscosity) Differential pressure alarm, high Diesel engine control and optimizing specification Engine margin Efficiency-optimised Flex control module Fixed pitch propeller Fuel quality setting Fresh water Scavenge air cooler (GEA manufacture) Heavy fuel oil High temperature International Maritime Organisation Indication International Standard Organisation Kilowatt Kilowatt electrical Kilowatt hour Level alarm, high Level alarm, low Lower calorific value Level indicator Light running margin Level switch, low Low temperature Low-Load Tuning Torque Monitoring and maintenance performance enhancement with expert knowledge External moment 1st order horizontal


s

26.21.07.40 Issue IV.11 Rev. 0


Abbreviations

M M1V M2V MCR MDO mep MET MHI MIM MMI N, n NAS NCR NOR OM OPI P PAL PI PLS ppm PRU PTO RCS RW1 SAC SAE S/G SHD SIB SLD SM SSU SU SW TBO TC TI tEaT UMS VI WCH WECS winGTD External moment 1st order vertical External moment 2nd order vertical Maximum continuous rating (R1) Marine diesel oil Mean effective pressure Turbocharger (Mitsubishi manufacture) Mitsubishi Heavy Industries Marine installation manual Manmachine interface Speed of rotation National Aerospace Standard Nominal continuous rating Nominal operation rating Operational margin Operator interface Power Pressure alarm, low Pressure indicator Pulse Lubricating System (cylinder liner) Parts per million Power related unbalance Power take off Remote control system Redwood seconds No. 1 (kinematic viscosity) Scavenge air cooler Society of Automotive Engineers Shaft generator Shut down Shipyard interface box Slow down Sea margin Saybolt second universal Supply unit Sea-water Time between overhauls Turbocharger Temperature indicator Temperature of exhaust gas after turbine Unattended machinery space Viscosity index Wrtsil Switzerland Wrtsil Engine Control System General Technical Data program

Torque variation

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t



A.

Introduction

The Wrtsil RT-flex system represents a major step forward in the technology of large diesel engines: Common-rail injection fully suitable for heavy fuel oil operation.

Engine power [kW] 100 000 80 000 RT-flex82C 60 000 50 000

Engine power [bhp] 120 000 100 000 80 000 60 000 all other RTA and RT-flex engines

The Marine Installation Manual (MIM) is for use by project and design personnel. Each chapter contains detailed information required by design en gineers and naval architects enabling them to op timize plant items and machinery space, and to carry out installation design work. This book is only distributed to persons dealing with this engine.

40 000 30 000 20 000

40 000

20 000

10 000 8000 6000 4000 10 000 8000 6000

50F20.0087

60

70

80 90 100

120 140 160 180 200 Engine speed [rpm]

Fig. A1

Power/speed range of all IMO-2000 regulation compatible RTA and RT-flex engines

This manual provides the information required for the layout of marine propulsion plants. It is not to be considered as a specification. The build specification is subject to the laws of the legislative body of the country of registration and the rules of the classification society selected by the owners. Its content is subject to the understanding that any data and information herein have been prepared with care and to the best of our knowledge. We do not, however, assume any liability with regard to unforeseen variations in accuracy thereof or for any consequences arising therefrom.

Wrtsil Switzerland Ltd PO Box 414 CH-8401 Winterthur, Switzerland Telephone: +41 52 2624922 Telefax: +41 52 2124917 http://www.wartsila.com


A1

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Marine Installation Manual A.

Introduction

A1

Primary engine dataBore x stroke [mm] Speed [rpm] 97 102 Engine power (MCR) 97 820 x 2646 102 87 87

Number of cylinders6 7 8 9 10 11 12

Power[kW] [bhp] [kW] [bhp] [kW] [bhp] [kW] [bhp] [kW] [bhp] [kW] [bhp] [kW] [bhp]

R127 120 36 900 31 640 43 050 36 160 49 200 40 680 55 350 45 200 61 500 49 720 67 650 54 240 73 800

R1+27 120 36 900 31 640 43 050 36 160 49 200 40 680 55 350 45 200 61 500 49 720 67 650 54 240 73 800

R221 720 29 520 25 340 34 440 28 960 39 360 32 580 44 280 36 200 49 200 39 820 54 120 43 440 59 040

R2+21 720 29 520 25 340 34 440 28 960 39 360 32 580 44 280 36 200 49 200 39 820 54 120 43 440 59 040

R324 300 33 060 28 350 38 570 32 400 44 080 36 450 49 590 40 500 55 100 44 550 60 610 48 600 66 120

R421 720 29 520 25 340 34 440 28 960 39 360 32 580 44 280 36 200 49 200 39 820 54 120 43 440 59 040

Brake specific fuel consumption (BSFC)Efficiency-optimised engines (Turbochargers: ABB 100-L or MHI MET MB) 100 % mep [g/kWh] [bar] 173 20.0 171 19.0 167 16.0 167 15.2 173 20.0 170 17.9

Cost-optimised (Turbochargers: ABB TPL or MHI MET MA) 100 % mep [g/kWh] [bar] 175 20.0 173 19.0 169 16.0 169 15.2 175 20.0 172 17.9

Lubricating oil consumption (for fully run-in engines under normal operating conditions)System oil Cylinder oil (Pulse lubricating system) Remark: approximately 8 kg/cyl per day guide feed rate 0.7 g/kWh *1)

*1) This data is for guidance only, it may have to be increased as the actual cylinder lubricating oil consumption in service is dependent on operational factors.

Table A1 Primary engine data of Wrtsil RT-flex82C

All brake specific fuel consumptions (BSFC) are quoted for fuel of lower calorific value 42.7 MJ/kg (10200 kcal/kg). All other reference conditions refer to ISO standard (ISO 3046-1). The figures for BSFC are given with a tolerance of +5 %. The values of power in kilowatt (kW) and fuel con sumption in g/kWh are the standard figures, and discrepancies occur between these and the corre sponding brake horsepower (bhp) values owing to the rounding of numbers.

To determine the power and BSFC figures accu rately in bhp and g/bhph respectively, the standard kW-based figures have to be converted by factor 1.36.

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A.

Introduction

A2

Tuning options for efficiency-optimised RT-flex82C engines A2.2 Low-Load Tuning (LLT)

With the introduction of the Wrtsil RT-flex en gines, a major step in the development of marine 2-stroke engine was taken. After the successful in troduction of Delta Tuning, Wrtsil Switzerland Ltd is taking this development even further by intro ducing Low-Load Tuning.

A2.1

Delta Tuning

The complete flexibility in engine setting that is an integral feature of the RT-flex common-rail system, enables fuel injection pressures and timing to be freely set at all loads. It is employed in special tun ing regimes to optimize brake specific fuel con sumption (BSFC) at individual engine loads. This concept was first applied in Delta Tuning, which reduced BSFC for Wrtsil RT-flex engines in the operating range below 90 % engine load. The concept has now been extended to Low-Load Tuning, which provides the lowest possible BSFC in the operating range of 40 to 70 % engine load. With Low-Load Tuning, RT-flex engines can be op erated continuously and reliably at any load in the range of 30 to 100 %. The Low-Load Tuning concept is based on the combination of a specifically designed turbocharg ing system setup and appropriately adjusted en gine parameters related to fuel injection and ex haust valve control. The reduced part-load BSFC in Low-Load Tuning is achieved by optimizing the turbocharger match for part-load operation. This is done by increasing the combustion pressure at less than 75 % load through an increased scavenge air pressure and a higher air flow (waste gate closed), and by blowing off part of the exhaust gas flow (waste gate open) at engine loads above 85 %. The higher scavenge air pressure at part-load automatically results in lower thermal load and better combustion over the entire part-load range. Low-Load Tuning requires the fitting of an exhaust gas waste gate (a pneumatically-operated valve, see figure A2) on the exhaust gas receiver before the turbocharger turbine. Exhaust gas blown off through the waste gate is by-passed to the main exhaust uptake. The waste gate is opened at en gine loads above 85 % to protect the turbocharger and the engine from overload.

Delta Tuning makes it possible to further reduce the specific fuel oil consumption while still comply ing with all existing emission legislation. Moreover, this is achieved only by changing software para meters and without having to modify a single en gine part. Delta Tuning option needs to be speci fied at a very early stage in the project. In realising Delta Tuning, the flexibility of the RTflex system in terms of free selection of injection and exhaust valve control parameters, specifically variable injection timing (VIT) and variable exhaust closing (VEC) is utilised for reducing the brake spe cific fuel consumption (BSFC) in the part load range below 90 % load. Due to the trade-off between BSFC and NOx emissions, the associated increase in NOx emissions at part load must then be compensated by a corresponding decrease in the full load NOx emissions. Hence, there is also a slight increase in full load BSFC, in order to maintain compliance of the engine with the IMO NOx regulations. The concept is based on tailoring the firing pres sure and firing ratio for maximum efficiency in the range up to 90 % load and then reducing them again towards full load. In this process, the same design-related limitations with respect to these two quantities are applied as in the specification of the Standard Tuning. The reliability of the engine is by no means im paired by the application of Delta Tuning since all existing limitations to mechanical stresses and thermal load are observed.


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Introduction

A Wrtsil RT-flex engine with Low-Load Tuning complies with the IMO Tier II regulations for NOx emissions. The engine parameters controlling the fuel injec tion and exhaust valve operational characteristic have to be selected appropriately in order to allow realizing the full potential of the concept while en suring compliance with the applicable NOx limit value. On the one hand, these parameters have toWaste gate

be specified in such a way that the transition be tween the bypass-closed and bypass-opened op erating ranges can be realized as smooth as pos sible. On the other hand, higher scavenge air pressure trendwise increases NOx emissions hence, for achieving the same weightened aver age value over the test cycle, the parameters also need to be adjusted appropriately for compensat ing this increase.

Exhaust gas receiver

EngineScavenge air receiver

Fig. A2

Schematic functional principle of Low-Load Tuning

A2.3

Further aspects of engine tuning optionsProject specification for RT-flex engines: Although Delta Tuning is realised in such a way that it could almost be considered a pushbutton op tion, its selection as well as the selection of LLT have an effect on other aspects of engine and sys tem design as well. Therefore the tuning option to be applied to RT-flex engines needs to be specified at a very early stage in the project: The calculations of the torsional and axial vibrations of the installation have to be per formed using the correct data. The layout of the ancillary systems has to be based on the correct specifications. In order to prepare the software for the RT-flex system control, the parameters also have to be known in due time before commissioning of the engine.

Tuning for de-rated engines: For various reasons, the margin against the IMO NOx limit decreases for de-rated engines. Delta Tuning and Low-load Tuning thus holds the highest benefits for engines rated close to R1 and R1+. With the de-rating, the effect diminishes and, in fact, Delta Tuning and Low-load Tuning are not applicable in the entire field (see figure A3). Effect on engine dynamics: The application of Delta Tuning or Low-Load Tun ing have an influence on the harmonic gas excita tions and, as a consequence, the torsional and axial vibrations of the installation. Hence, the corresponding calculations have to be carried out with the correct data in order to be able to apply ap propriate countermeasures, if necessary.

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A.

Introduction

Engine power [% R1+]100

Engine power [% R1+] R1 R1+100

R1

R1+

95

RT-flex82CDelta Tuning area

95

RT-flex82C R3Low-Load Tuning area

90

R3

90

85

Delta Tuning not applicable

85 Low-Load Tuning not applicable

80

R4

R2+ Engine speed [% R1+]85 90 95 100

80

R4

R2+ Engine speed [% R1+]

85 90 95 100

75 80F20.0004

75 80

Fig. A3

Rating fields for Delta Tuning and Low-Load Tuning

efficiency-optimised Standard Tuning Delta Tuning

Deviation of BSFC [g/kWh]

Low-Load Tuning

ISO conditions, tolerance +5 %

LoadFig. A4

75 %

90 %

100 %

Typical BSFC curves to illustrate Standard Tuning, Delta Tuning and Low-Load Tuning

Data for brake specific fuel consumption (BSFC) in table A1 and data in tables F1 to F4 refer to Stan dard Tuning. Data for Delta Tuning and Low-Load Tuning can be obtained from the winGTD (see figure C17).


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B.

Engine description

B1

Engine descriptionOverall sizes of engines Length [mm] Height [mm] Dry weight [t] 6 cyl. 11045 12530 745 12 cyl. 21015 1

wartsila o e rt flex82c mim

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