Year: 2006 Language: english Author: MAN B&W Diesel A/S Genre: Manual Publisher: MAN B&W Diesel A/S Series: Edition 0003 Format: PDF Quality: OCR without errors Number of pages: 623 Description: 50-108ME/ME-C Edition 0003 – 2006 VOLUME I OPERATION S900-0003 When referring to this page, please quote S-instruction S900, Edition 0003 It is important that all MAN Diesel A/S Engines are operated within the given specifi cations and performance tolerances specifi ed in the engines‘ Technical Files and are maintained according to the MAN Diesel A/S maintenance instructions, in order to comply with given emission regulations. In accordance with Chapter I of the code of Federal Regulations, Part 94, Subpart C, §94.211, NOTICE is hereby given, that Chapter I of the Code of Federal Regulations, Part 94, Subpart K, §94.1004 requires that the emissions related maintenance of the diesel engine, shall be performed as specifi ed in MAN Diesel A/S instructions, including, but not limited to, the instructions to that effect included in the Technical File. MAN Diesel
More...
In view of the continued development of our diesel engines, the present instruction book has been made to apply generally to our engines of the types: 50 – 108 ME/ME-C The different systems are explained on the basis of standard systems, whereas each particular engine is built to the specification in the contract for the plant in question, i.e. the information in this book is for guidance purposes only. All references to this instruction book should include title, edition No., and possibly page Example: Instruction book OPERATION, Edition 0001, Section 701-02, Page 3(12). For a specific engine, also the name of the vessel, the engine number and the engine builder should be specified. Further details may be found in: ❖ Plant installation drawings ❖ Instruction book Vol. I Operation ❖ Instruction book Vol. II Maintenance ❖ Instruction book Vol. III Components, Descriptions ❖ Shop trial/report ❖ Sea trial/report for the engine concerned. This book is subject to copyright protection. The book should therefore not, in whole or in part, be copied, reproduced, made public, or in any other way made available to any third party, without the written consent to this effect from MAN B&W Diesel A/S. This instruction book is divided into nine Chapters and an Index – as listed below: Chapter Title 701 Safety Precautions and Engine Data 702 Checks during Standstill Periods 703 Starting, Manoeuvring and Running 704 Special Running Conditions 705 Fuel and Fuel Treatment 706 Performance Evaluation & General Operation 707 Cylinder Condition 708 Bearings and Circulating Oil 709 Water Cooling Systems 710 Index Each Chapter is subdivided into separate sections and sub-sections. For convenience, the main titles and topics are summarized on the first page(s) of each chapter. The Index gives a comprehensive list of the subjects covered. Service Letters In order to ensure the most efficient, economic, and up-to-date operation of the MAN B&W engines, we, and our licensees, regularly send out ‘Service Letters’, containing first-hand information regarding accumulated service experience. The Service Letters can either deal with specific engine types, or contain general instructions and recommendations for all engine types, and are used as a reference when we prepare up-dated instruction book editions. Therefore, since new Service Letters could be of great importance to the operation of the plant, we recommend that the engine staff file them to supplement the relevant chapters of this instruction book. When referring to this page, please quote Operation Chapter 701 Edition 0001 Page 1 (2) MAN B&W Diesel A/S Safety Precautions and Engine Data Chapter 701
Index
Text Index Drawing No. Content 700 Frontpage 700-00 V70000-0003 Warning S900 S900-0003 Introduction 700-01 V70001-0001 Safety Precautions and Engine Data 701 Table of Contents 701TOC V701-0001TOC Safety precautions 701-01 V70101-0003 Guidance value automation 701-02 V70102-0010 Instrumentation 701-03 V70103-0003 Testbed adjustments 701-04 V70104-0001 IMO NOx components and technical file 701-05 V70105-0001 Checks during Standstill Periods 702 Table of Contents 702TOC V702-0003TOC Checks during Standstill Periods 702-01 V70201-0003 Starting, Manoeuvring and Running 703 Table of Contents 703TOC V703-0007TOC Preparations for Starting 703-01 V70301-0004 Starting-up 703-02 V70302-0001 Loading 703-03 V70303-0001 Running 703-04 V70304-0003 Preparations PRIOR to arrival in Port 703-05 V70305-0001 Stopping 703-06 V70306-0001 Operations AFTER arrival in Port 703-07 V70307-0001 Engine Control System 703-08 V70308-0005 MOP description 703-09 V70309-0005 Alarm Handling on the MOP 703-14 V70314-0007 Engine Operation 703-15 V70315-0005 Auxiliaries 703-16 V70316-0005 Maintenance 703-17 V70317-0003 Admin 703-18 V70318-0003 Troubleshooting Guide 703-20 V70320-0005 Starting Air System Plate 70304 VP70304-0002 Sequence Diagram, FPP Plant Plate 70305 VP70305-0002 Sequence Diagram, CPP Plant Plate 70309 VP70309-0001 Engine Control System Diagram Plate 70317 VP70317-0003 Diagram of Manoeuvring System Plate 70318 VP70318-0002 MOP Overview Plate 70319 VP70319-0003 MOP Alarm List Plate 70320 VP70320-0003 MOP Event Log Plate 70321 VP70321-0003 MOP Manual Cut-Out List Plate 70322 VP70322-0003 MOP Channel List Plate 70323 VP70323-0003 MOP Operation Plate 70324 VP70324-0005 MOP Status Plate 70325 VP70325-0004 MOP Process Information Plate 70326 VP70326-0004 MOP Cylinder Load Plate 70327 VP70327-0003 MOP Cylinder Pressure Plate 70328 VP70328-0003 Index Vol. 1 - Operation Manual Text Index Drawing No. MOP Hydraulic System Plate 70329 VP70329-0004 MOP Scavenge Air Plate 70330 VP70330-0005 MOP Cylinder Lubricators Plate 70331 VP70331-0004 MOP System View I/O Test Plate 70332 VP70332-0004 MOP Invalidated Inputs Plate 70333 VP70333-0003 MOP Network Status Plate 70334 VP70334-0003 MOP Set Time Plate 70335 VP70335-0002 MOP Version Plate 70336 VP70336-0002 Special Running Conditions 704 Table of Contents 704TOC V704-0001TOC Fire in Scavenge Air Box 704-01 V70401-0001 Ignition in Crankcase 704-02 V70402-0001 Turbocharger Surging (Stalling) 704-03 V70403-0001 Running with Cylinders or Turbochargers Out of Operation 704-04 V70404-0004 Running with cracked Cylinder cover studs and Staybolts 704-05 V70405-0001 Cutting cylinders out of action Plate 70401 VP70401-0001 Scavenge air drain pipes Plate 70402 VP70402-0002 Cutting turbochargers out of action Plate 70403 VP70403-0001 Turbocharger surging Plate 70404 VP70404-0001 Scavenge air spaces, fire exting. systems Plate 70405 VP70405-0001 Comp. for hydr. systems. Hydr. cyl. unit Plate 70406 VP70406-0001 Comp. for hydr. sys. (accumulator block) Plate 70407 VP70407-0001 Fuel and Fuel Treatment 705 Table of Contents 705TOC V705-0001TOC Fuel oil 705-01 V70501-0003 Pressurised Fuel Oil System 705-02 V70502-0002 Fuel Treatment 705-03 V70503-0001 Residual Fuel Standards Plate 70501 VP70501-0003 Fuel Oil System Plate 70502 VP70502-0002 Fuel oil pipes on engine Plate 70503 VP70503-0001 Fuel oil centrifuges. Modes of operation Plate 70504 VP70504-0001 Centrifuge flow rate and separation temp. (preheating) Plate 70505 VP70505-0001 Preheating of heavy fuel oil (prior to injection) Plate 70506 VP70506-0001 Performance Evaluation and General Operation 706 Table of Contents 706TOC V706-0003TOC Observations during Operation 706-01 V70601-0003 Evaluation of Records 706-02 V70602-0001 Cleaning of Turbochargers and Air Coolers 706-03 V70603-0003 Measuring Instruments 706-04 V70604-0001 Pressure Measurements and Engine Power Calculations 706-05 V70605-0001 Correction of Performance Parameters 706-06 V70606-0002 Turbocharger Efficiency 706-07 V70607-0004 Estimation of the Effective Engine Power without Indicator Diagrams 706-08 V70608-0002 Load Diagram for Propulsion alone Plate 70601 VP70601-0002 Load Diagram for Propulsion and Main Engine Driven Generator Plate 70602 VP70602-0002 Performance Observations (2 pages) Plate 70603 VP70603-0001 Readings relating to Thermodynamic Conditions Plate 70604 VP70604-0001 Vol. 1 - Operation Manual Index Text Index Drawing No. Synopsis Diagrams - for engine (Pi) (2 pages) Plate 70605 VP70605-0001 Synopsis Diagrams - for engine (Pmax) (2 - pages) Plate 70606 VP70606-0001 Synopsis Diagrams - for engine (Pe) (2-pages) Plate 70607 VP70607-0001 Synopsis Diagrams - for turbocharger (Pscav-Pe) (2-pages) Plate 70608 VP70608-0001 Synopsis Diagrams - for turbocharger (Pscav-Compressor) (2-pages) Plate 70609 VP70609-0001 Synopsis Diagrams - for air cooler (Pscav-Tair) (2-pages) Plate 70610 VP70610-0001 Specific Fuel Oil Consumption (Corrections) Plate 70611 VP70611-0001 Dry Cleaning of Turbocharger (Turbine side) Plate 70612 VP70612-0001 Water Cleaning Turbocharger (Turbine side) Plate 70613 VP70613-0001 Air Cooler Cleaning System (Option) Plate 70614 VP70614-0001 Normal Indicator Diagram Plate 70615 VP70615-0001 Correction to ISO Reference Ambient Conditions. (Pmax) Plate 70620 VP70620-0002 Correction to ISO Reference Ambient Conditions. (Texh.) Plate 70621 VP70621-0002 Correction to ISO Reference Ambient Conditions (Pcomp.) Plate 70622 VP70622-0002 Correction to ISO Reference Ambient Conditions. (Pscav.) Plate 70623 VP70623-0003 Correction to ISO Reference Ambient Conditions. (Example) Plate 70624 VP70624-0004 Calculation of Compressor Efficiency Plate 70625 VP70625-0002 Calculation of Total Turbocharger Efficiency Plate 70626 VP70626-0002 Power Estimation Plate 70627 VP70627-0002 Turbocharger Compressor Wheel Diameter and Slip Factor Plate 70628 VP70628-0003 Cylinder Condition 707 Table of Contents 707TOC V707-0003TOC Cylinder Condition 707-01 V70701-0005 Cylinder Lubrication 707-02 V70702-0003 Inspection of Nimonic Exhaust Valve Spindles 707-03 V70703-0002 Inspection through Scavenge Ports Plate 70701 VP70701-0001 Inspection through Scavenge Ports (Record) Plate 70702 VP70702-0001 Inspection through Scavenge Ports, Symbols Plate 70703 VP70703-0001 Inspection through Scavenge Ports (Pictures) Plate 70704 VP70704-0001 Inspection through Scavenge Ports, Evaluation Plate 70705 VP70705-0001 Factors influencing Cylinder Wear Plate 70706 VP70706-0002 Abrasive Particles Plate 70707 VP70707-0001 Abrasive Particles Plate 70708 VP70708-0001 Abrasive Particles Plate 70709 VP70709-0001 Cylinder oil Feed Rate during Running-in S/K/L-ME/ME-C engines (2-pages) Plate 70710 VP70710-0001 Cylinder Condition Report Plate 70711 VP70711-0002 Calculation of Condensate Amount Plate 70712 VP70712-0002 Cylinder Lubricating Oil Pipes Plate 70713 VP70713-0003 Running-in Load Plate 70714 VP70714-0001 Bearings and Circulating Oil 708 Table of Contents 708TOC V708-0003TOC Bearings 708-01 V70801-0001 Alignment of Main Bearings 708-02 V70802-0002 Circulating Oil and Oil System 708-03 V70803-0001 Maintenance of the Circulating Oil 708-04 V70804-0005 Turbocharger Lubrication 708-05 V70805-0001 Hydraulic System for ME Engines 708-08 V70808-0003 Index Vol. 1 - Operation Manual Text Index Drawing No. Main Bearing, Thick Shell Design Plate 70801 VP70801-0002 Main Bearing, Thin Shell Design Plate 70802 VP70802-0002 Crosshead Bearing Plate 70803 VP70803-0002 Crankpin Bearing Plate 70804 VP70804-0001 Main Bearing Assemblies Plate 70805 VP70805-0001 Guide Shoes and Strips Plate 70806 VP70806-0001 Thrust Bearing Assembly Plate 70807 VP70807-0001 Inspection of Bearings. Recording of Observations. Plate 70809 VP70809-0002 Inspection of Bearings. Location and Size of Damage in Bearing Shells Plate 70810 VP70810-0002 Acceptance Criteria for Tin-Aluminium Bearings with Overlayer (Crosshead Bearing Lower Shells) Plate 70811 VP70811-0002 Inspection of bearings. Location of Damage on Pin/Journal Plate 70812 VP70812-0002 Inspection of Bearings. Observations Plate 70813 VP70813-0002 Inspection of Bearings. Inspection Records, Example Plate 70814 VP70814-0002 Inspection of Bearings. Inspection Records, Blank Plate 70815 VP70815-0002 Report: Crankshaft Deflections (Autolog) Plate 70816 VP70816-0002 Crankshaft Deflection, Limits Plate 70817 VP70817-0003 Circulating Oil System (Outside Engine) (Engines with Uni-Lube System) Plate 70818 VP70818-0003 Circulating Oil System (Inside Engine) Plate 70820 VP70820-0002 Flushing of Main Lubricating Oil System. Location of Checkbag and Blank Flanges Plate 70821 VP70821-0002 Flushing of Main Lubricating Oil System. Dimension of Checkbag and Blank Flanges Plate 70822 VP70822-0002 Flushing of Main Lubricating Oil System. Flushing Log Plate 70823 VP70823-0002 Cleaning System, Stuffing Box Drain Oil (Option) Plate 70824 VP70824-0002 Turbocharger Lubricating Oil Pipes Plate 70828 VP70828-0001 Check Measurements Plate 70829 VP70829-0001 Gear Driven HPS, ELFI and ELVA Plate 70830 VP70830-0002 Gear Driven HPS and FIVA Plate 70831 VP70831-0002 Gear Driven HPS, ELFI and ELVA, Separate LPS Plate 70832 VP70832-0002 Gear Driven HPS and FIVA, Separate LPS Plate 70833 VP70833-0002 Elec. Driven HPS and FIVA, Separate LPS Plate 70834 VP70834-0002 Elec. Driven HPS and FIVA Plate 70835 VP70835-0002 6L42MC/ME KMU Plate 70836 VP70836-0001 Combined HPS, Common LPS and FIVA Plate 70837 VP70837-0002 Combined HPS, Separate LPS and FIVA Plate 70838 VP70838-0001 Gear Driven HPS and FIVA, Common LPS Plate 70839 VP70839-0001 ME/ME-C Engines. Detection of Malfunction and Leaks in Hydraulic System Plate 70840 VP70840-0001 Throttle Valve on Fuel Oil Pressure Booster Plate 70841 VP70841-0001 Drainholes in HCU Block Plate 70842 VP70842-0001 Level Switch on ME Cylinder Lubricator Plate 70843 VP70843-0001 Hydraulic Control Oil System (Separate LPS) Plate 70844 VP70844-0001 Double Wall Piping Plate 70845 VP70845-0001 Water Cooling Systems 709 Table of Contents 709TOC V709-0001TOC Water Cooling Systems 709-01 V70901-0001 Cooling Water Treatment 709-02 V70902-0003 Seawater Cooling System. Main and Auxiliary Engines Plate 70901 VP70901-0001 Vol. 1 - Operation Manual Index Text Index Drawing No. Jacket Cooling Water System Plate 70902 VP70902-0001 Central Cooling System Plate 70903 VP70903-0001 Preheating of Jacket Cooling Water Plate 70904 VP70904-0001
General: Correct operation and maintenance, which is the aim of this book, are crucial points for obtaining optimum safety in the engine room. The general measures mentioned here should therefore be routine practice for the entire engine room staff. WARNING ! Keep clear of space below crane with load. The opening of cocks may cause discharge of hot liquids or gases. Carefully consider which way liquids, gases or flames will move, and keep clear. The dismantling of parts may cause the release of springs. The removal of fuel valves (or other valves in the cylinder cover) may cause oil to run down onto the piston crown. If the piston is hot, an explosion might blow out the valve. When testing fuel valves, do not touch the spray holes as the jets may pierce the skin. Do not stand near crankcase doors or relief valves – nor in corridors near doors to the engine room casing – when alarms for oil mist, high lube oil temperature, no piston cooling oil flow, or scavenge box fire is registered. See also Chapter 704. WARNING ! In design and layout of the engines, MAN B&W Diesel A/S has the basic philosophy that the failure of one part should not result in the engine becoming inoperative. As some mechanical and electronical parts are essential for the safe functioning of the engine, such parts are duplicated to achieve redundant capability. Should such a redundant part become wholly or partly inoperative, the failing part must be changed or repaired immediately to re-establish redundancy of the part or – if an emergency situation requires operation of the engine – as soon as the vessel calls at the nearest port. Page 2 (5) When referring to this page, please quote Operation 701-01, Edition 0003 MAN B&W Diesel A/S Safety Precautions Chapter 701 701-01 Hydraulic System Cleanliness The engine room should be kept clean both above and below the floor plates. If there is a risk of grit or sand blowing into the engine room when the ship is in port, the ventilation should be stopped and ventilating ducts, skylights and engine room doors closed. Welding, or other work which causes spreading of grit and/or swarf, must not be carried out near the engine unless it is closed or protected, and the turbocharger air intake filters covered. The exterior of the engine should be kept clean, and the paintwork maintained, so that leakages can be easily detected. Fire Do not weld or use naked lights in the engine room, until it has been ascertained that no explosive gases, vapour or liquids are present. WARNING ! Before repair or maintenance work is started, the plant must be stopped and the current be switched off at the main switch. Open the drain valve to decrease the pressure to zero. During repairs, the drain valve must be open. Always measure the pressure and check that the system is depressurized before disassembling the part concerned from the system. Never service the hydraulic system when the pumps are running, unless absolutely necessary (bleeding the system). Leak detection must always be carried out using a long piece of wood to secure proper distance to eventually outflowing oil. Leaking seals cannot be repaired by tightening. Sealing is only possible by replacing the sealing elements with new parts. Never carry out welding or soldering on any part of the hydraulic system. Only use nitrogen as pre-charge gas on accumulators. WARNING ! Keep the areas around the relief valves free of oil, grease, etc. to prevent the risk of fire caused by the emitted hot air/gas in the event that the relief valves open. When referring to this page, please quote Operation 701-01, Edition 0003 Page 3 (5) MAN B&W Diesel A/S Safety Precautions Chapter 701 701-01 If the crankcase is opened before the engine is cold, welding and the use of naked flames will involve the risk of explosions and fire. The same applies to inspection of oil tanks and of the spaces below the floor. Attention is furthermore drawn to the danger of fire when using paint and solvents having a low flash point. Porous insulating material, soaked with oil from leakages, is easily inflammable and should be renewed. See also Sections 704-01, 02 and ‘Sealing Materials’ in this Section. Order/Tidiness Hand tools should be placed on easily accessible tool panels. Special tools should be fastened in the engine room, close to the area of application. No major objects must be left unfastened, and the floor and passages should be kept clear. Spares Large spare parts should, as far as possible, be placed near the area of application, well secured, and accessible by crane. All spares should be protected against corrosion and mechanical damage. The stock should be checked at intervals and replenished in good time. Lighting Ample working light should be permanently installed at appropriate places in the engine room, and portable working light should be obtainable everywhere. Special lamps should be available for insertion through the scavenge ports. Low Temperatures – freezing If there is a risk of freezing, then all engines, pumps, coolers, and pipe systems should be emptied of cooling water, or the cooling water treated to avoid freezing. Check and Maintain Measuring equipment, filter elements, and lubricating oil condition. Page 4 (5) When referring to this page, please quote Operation 701-01, Edition 0003 MAN B&W Diesel A/S Safety Precautions Chapter 701 701-01 Entering the Crankcase or Cylinder Check beforehand that the starting air supply to the engine and the starting air distributor, is shut off. In case of oil mist alarm, precautions must be taken before opening to crankcase (see Section 704-02). Turning Gear Before engaging the turning gear, check that the starting air supply is shut off, and that the indicator cocks are open. When the turning gear is engaged, check that the indicator lamp “Turning gear in” has switched on. Check turning gear starting blocking once every year. Slow-turning If the engine has been stopped for more than 30 minutes, slow-turning should always be effected, just before starting in order to safeguard free rotation of the engine, see Chapter 703. Feeling over Whenever repairs or alterations have been made to moving parts, bearings, etc., apply the “Feel-over sequence” (see Section 703-03) until satisfied that there is no undue heating (friction, oil-mist formation, blow-by, failure of cooling water or lubricating oil systems, etc.). Feel over after 10-15 minutes’ running, again after 1 hour’s running, and finally shortly after the engine has reached full load. See Section 703-03. Sealing Materials Use gloves when removing O-rings and other rubber/plastic-based sealing materials which have been subjected to abnormally high temperatures. These materials may have a caustic effect when being touched directly. The gloves should be made of neoprene or PVC. Used gloves must be discarded. WARNING ! Always ensure that the turning gear is engaged; even at the quay, the wake from other ships may turn the propeller and thus the engine. Page 5 (5) When referring to this page, please quote Operation 701-01, Edition 0003 MAN B&W Diesel A/S Safety Precautions Chapter 701 701-01 Safety Cap in Starting Air Line If the bursting disc of the safety cap is damaged due to excessive pressure in the starting air line, overhaul or replace the starting valve which caused the burst, and mount a new disc. If a new disc is not available immediately, turn the cover in relation to the cylinder, in order to reduce the leakage of starting air. Alarms It is important that all alarms lead to prompt investigation and remedy of the error. No alarm is insignificant. The most serious alarms are equipped with slow-down and/or shut-down functions. It is therefore important that all engine crew members are familiar with and well trained in the use and importance of the alarm system. Mount a new bursting disc and return the cover to the open position at the first opportunity. When referring to this page, please quote Operation 701-02, Edition 0010 Page 1 (19) MAN B&W Diesel A/S Guidance Value Automation Chapter 701 701-02 701-02 Guidance Value Automation General Basis for Guidance Values The values stated in the list on the following pages refer to layout point L1. (Nominal max. continuous rating). The values must only be used as a guidance in connection with the ‘List of Capacities of Auxiliary Machinery’ for dimensioning of auxiliary systems, and must not be used for determining the extent of the alarms or actions. The item numbers refer to the drawings showing the extent and placement of sensors for standard alarms and indicators on the engine, if the signal equipment is fitted. See Section 701-03, furtheron. For sensors placed in the systems outside the engine, see the actual pipe arrangements in the appropriate chapters. If the engine is provided with special equipment, some values may differ from this list. The correct values shall in such a case be obtained from the Plant Installation Drawings. The engine slow-down level corresponds to 40% of nominal MCR r/min. Engines specified and optimised at derated power may have other normal service values depending on layout power/revolutions and application. For derated engines, the testbed/trial values should be used. When setting the limits, maximum limits must be set at rising parameter and minimum limits at falling parameter.
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MAN B&W 50-108ME/ME-C Part I - Operation Manual
Language: english
Author: MAN B&W Diesel A/S
Genre: Manual
Publisher: MAN B&W Diesel A/S
Series: Edition 0003
Format: PDF
Quality: OCR without errors
Number of pages: 623
Description: 50-108ME/ME-C Edition 0003 – 2006 VOLUME I OPERATION S900-0003
When referring to this page, please quote S-instruction S900, Edition 0003
It is important that all MAN Diesel A/S Engines are operated within the given specifi cations
and performance tolerances specifi ed in the engines‘ Technical Files and are maintained
according to the MAN Diesel A/S maintenance instructions, in order to comply with given
emission regulations.
In accordance with Chapter I of the code of Federal Regulations, Part 94, Subpart C,
§94.211, NOTICE is hereby given, that Chapter I of the Code of Federal Regulations, Part
94, Subpart K, §94.1004 requires that the emissions related maintenance of the diesel
engine, shall be performed as specifi ed in MAN Diesel A/S instructions, including, but not
limited to, the instructions to that effect included in the Technical File.
MAN Diesel
More...
In view of the continued development of our diesel engines, the present instructionbook has been made to apply generally to our engines of the types:
50 – 108 ME/ME-C
The different systems are explained on the basis of standard systems, whereas each particular
engine is built to the specification in the contract for the plant in question, i.e. the
information in this book is for guidance purposes only.
All references to this instruction book should include title, edition No., and possibly page
Example: Instruction book OPERATION, Edition 0001, Section 701-02, Page 3(12).
For a specific engine, also the name of the vessel, the engine number and the engine builder
should be specified.
Further details may be found in:
❖ Plant installation drawings
❖ Instruction book Vol. I Operation
❖ Instruction book Vol. II Maintenance
❖ Instruction book Vol. III Components, Descriptions
❖ Shop trial/report
❖ Sea trial/report
for the engine concerned.
This book is subject to copyright protection. The book should therefore not, in whole or in
part, be copied, reproduced, made public, or in any other way made available to any third
party, without the written consent to this effect from MAN B&W Diesel A/S.
This instruction book is divided into nine Chapters and an Index – as listed below:
Chapter Title
701 Safety Precautions and Engine Data
702 Checks during Standstill Periods
703 Starting, Manoeuvring and Running
704 Special Running Conditions
705 Fuel and Fuel Treatment
706 Performance Evaluation & General Operation
707 Cylinder Condition
708 Bearings and Circulating Oil
709 Water Cooling Systems
710 Index
Each Chapter is subdivided into separate sections and sub-sections. For convenience, the
main titles and topics are summarized on the first page(s) of each chapter.
The Index gives a comprehensive list of the subjects covered.
Service Letters
In order to ensure the most efficient, economic, and up-to-date operation of the MAN B&W
engines, we, and our licensees, regularly send out ‘Service Letters’, containing first-hand
information regarding accumulated service experience.
The Service Letters can either deal with specific engine types, or contain general instructions
and recommendations for all engine types, and are used as a reference when we prepare
up-dated instruction book editions.
Therefore, since new Service Letters could be of great importance to the operation of the
plant, we recommend that the engine staff file them to supplement the relevant chapters of
this instruction book.
When referring to this page, please quote Operation Chapter 701 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Safety Precautions and Engine Data Chapter 701
Index
Text Index Drawing No.Content 700
Frontpage 700-00 V70000-0003
Warning S900 S900-0003
Introduction 700-01 V70001-0001
Safety Precautions and Engine Data 701
Table of Contents 701TOC V701-0001TOC
Safety precautions 701-01 V70101-0003
Guidance value automation 701-02 V70102-0010
Instrumentation 701-03 V70103-0003
Testbed adjustments 701-04 V70104-0001
IMO NOx components and technical file 701-05 V70105-0001
Checks during Standstill Periods 702
Table of Contents 702TOC V702-0003TOC
Checks during Standstill Periods 702-01 V70201-0003
Starting, Manoeuvring and Running 703
Table of Contents 703TOC V703-0007TOC
Preparations for Starting 703-01 V70301-0004
Starting-up 703-02 V70302-0001
Loading 703-03 V70303-0001
Running 703-04 V70304-0003
Preparations PRIOR to arrival in Port 703-05 V70305-0001
Stopping 703-06 V70306-0001
Operations AFTER arrival in Port 703-07 V70307-0001
Engine Control System 703-08 V70308-0005
MOP description 703-09 V70309-0005
Alarm Handling on the MOP 703-14 V70314-0007
Engine Operation 703-15 V70315-0005
Auxiliaries 703-16 V70316-0005
Maintenance 703-17 V70317-0003
Admin 703-18 V70318-0003
Troubleshooting Guide 703-20 V70320-0005
Starting Air System Plate 70304 VP70304-0002
Sequence Diagram, FPP Plant Plate 70305 VP70305-0002
Sequence Diagram, CPP Plant Plate 70309 VP70309-0001
Engine Control System Diagram Plate 70317 VP70317-0003
Diagram of Manoeuvring System Plate 70318 VP70318-0002
MOP Overview Plate 70319 VP70319-0003
MOP Alarm List Plate 70320 VP70320-0003
MOP Event Log Plate 70321 VP70321-0003
MOP Manual Cut-Out List Plate 70322 VP70322-0003
MOP Channel List Plate 70323 VP70323-0003
MOP Operation Plate 70324 VP70324-0005
MOP Status Plate 70325 VP70325-0004
MOP Process Information Plate 70326 VP70326-0004
MOP Cylinder Load Plate 70327 VP70327-0003
MOP Cylinder Pressure Plate 70328 VP70328-0003
Index Vol. 1 - Operation Manual
Text Index Drawing No.
MOP Hydraulic System Plate 70329 VP70329-0004
MOP Scavenge Air Plate 70330 VP70330-0005
MOP Cylinder Lubricators Plate 70331 VP70331-0004
MOP System View I/O Test Plate 70332 VP70332-0004
MOP Invalidated Inputs Plate 70333 VP70333-0003
MOP Network Status Plate 70334 VP70334-0003
MOP Set Time Plate 70335 VP70335-0002
MOP Version Plate 70336 VP70336-0002
Special Running Conditions 704
Table of Contents 704TOC V704-0001TOC
Fire in Scavenge Air Box 704-01 V70401-0001
Ignition in Crankcase 704-02 V70402-0001
Turbocharger Surging (Stalling) 704-03 V70403-0001
Running with Cylinders or Turbochargers Out of Operation 704-04 V70404-0004
Running with cracked Cylinder cover studs and Staybolts 704-05 V70405-0001
Cutting cylinders out of action Plate 70401 VP70401-0001
Scavenge air drain pipes Plate 70402 VP70402-0002
Cutting turbochargers out of action Plate 70403 VP70403-0001
Turbocharger surging Plate 70404 VP70404-0001
Scavenge air spaces, fire exting. systems Plate 70405 VP70405-0001
Comp. for hydr. systems. Hydr. cyl. unit Plate 70406 VP70406-0001
Comp. for hydr. sys. (accumulator block) Plate 70407 VP70407-0001
Fuel and Fuel Treatment 705
Table of Contents 705TOC V705-0001TOC
Fuel oil 705-01 V70501-0003
Pressurised Fuel Oil System 705-02 V70502-0002
Fuel Treatment 705-03 V70503-0001
Residual Fuel Standards Plate 70501 VP70501-0003
Fuel Oil System Plate 70502 VP70502-0002
Fuel oil pipes on engine Plate 70503 VP70503-0001
Fuel oil centrifuges. Modes of operation Plate 70504 VP70504-0001
Centrifuge flow rate and separation temp. (preheating) Plate 70505 VP70505-0001
Preheating of heavy fuel oil (prior to injection) Plate 70506 VP70506-0001
Performance Evaluation and General Operation 706
Table of Contents 706TOC V706-0003TOC
Observations during Operation 706-01 V70601-0003
Evaluation of Records 706-02 V70602-0001
Cleaning of Turbochargers and Air Coolers 706-03 V70603-0003
Measuring Instruments 706-04 V70604-0001
Pressure Measurements and Engine Power Calculations 706-05 V70605-0001
Correction of Performance Parameters 706-06 V70606-0002
Turbocharger Efficiency 706-07 V70607-0004
Estimation of the Effective Engine Power without Indicator Diagrams 706-08 V70608-0002
Load Diagram for Propulsion alone Plate 70601 VP70601-0002
Load Diagram for Propulsion and Main Engine Driven Generator Plate 70602 VP70602-0002
Performance Observations (2 pages) Plate 70603 VP70603-0001
Readings relating to Thermodynamic Conditions Plate 70604 VP70604-0001
Vol. 1 - Operation Manual Index
Text Index Drawing No.
Synopsis Diagrams - for engine (Pi) (2 pages) Plate 70605 VP70605-0001
Synopsis Diagrams - for engine (Pmax) (2 - pages) Plate 70606 VP70606-0001
Synopsis Diagrams - for engine (Pe) (2-pages) Plate 70607 VP70607-0001
Synopsis Diagrams - for turbocharger (Pscav-Pe) (2-pages) Plate 70608 VP70608-0001
Synopsis Diagrams - for turbocharger (Pscav-Compressor)
(2-pages)
Plate 70609 VP70609-0001
Synopsis Diagrams - for air cooler (Pscav-Tair) (2-pages) Plate 70610 VP70610-0001
Specific Fuel Oil Consumption (Corrections) Plate 70611 VP70611-0001
Dry Cleaning of Turbocharger (Turbine side) Plate 70612 VP70612-0001
Water Cleaning Turbocharger (Turbine side) Plate 70613 VP70613-0001
Air Cooler Cleaning System (Option) Plate 70614 VP70614-0001
Normal Indicator Diagram Plate 70615 VP70615-0001
Correction to ISO Reference Ambient Conditions. (Pmax) Plate 70620 VP70620-0002
Correction to ISO Reference Ambient Conditions. (Texh.) Plate 70621 VP70621-0002
Correction to ISO Reference Ambient Conditions (Pcomp.) Plate 70622 VP70622-0002
Correction to ISO Reference Ambient Conditions. (Pscav.) Plate 70623 VP70623-0003
Correction to ISO Reference Ambient Conditions. (Example) Plate 70624 VP70624-0004
Calculation of Compressor Efficiency Plate 70625 VP70625-0002
Calculation of Total Turbocharger Efficiency Plate 70626 VP70626-0002
Power Estimation Plate 70627 VP70627-0002
Turbocharger Compressor Wheel Diameter and Slip Factor Plate 70628 VP70628-0003
Cylinder Condition 707
Table of Contents 707TOC V707-0003TOC
Cylinder Condition 707-01 V70701-0005
Cylinder Lubrication 707-02 V70702-0003
Inspection of Nimonic Exhaust Valve Spindles 707-03 V70703-0002
Inspection through Scavenge Ports Plate 70701 VP70701-0001
Inspection through Scavenge Ports (Record) Plate 70702 VP70702-0001
Inspection through Scavenge Ports, Symbols Plate 70703 VP70703-0001
Inspection through Scavenge Ports (Pictures) Plate 70704 VP70704-0001
Inspection through Scavenge Ports, Evaluation Plate 70705 VP70705-0001
Factors influencing Cylinder Wear Plate 70706 VP70706-0002
Abrasive Particles Plate 70707 VP70707-0001
Abrasive Particles Plate 70708 VP70708-0001
Abrasive Particles Plate 70709 VP70709-0001
Cylinder oil Feed Rate during Running-in S/K/L-ME/ME-C
engines (2-pages)
Plate 70710 VP70710-0001
Cylinder Condition Report Plate 70711 VP70711-0002
Calculation of Condensate Amount Plate 70712 VP70712-0002
Cylinder Lubricating Oil Pipes Plate 70713 VP70713-0003
Running-in Load Plate 70714 VP70714-0001
Bearings and Circulating Oil 708
Table of Contents 708TOC V708-0003TOC
Bearings 708-01 V70801-0001
Alignment of Main Bearings 708-02 V70802-0002
Circulating Oil and Oil System 708-03 V70803-0001
Maintenance of the Circulating Oil 708-04 V70804-0005
Turbocharger Lubrication 708-05 V70805-0001
Hydraulic System for ME Engines 708-08 V70808-0003
Index Vol. 1 - Operation Manual
Text Index Drawing No.
Main Bearing, Thick Shell Design Plate 70801 VP70801-0002
Main Bearing, Thin Shell Design Plate 70802 VP70802-0002
Crosshead Bearing Plate 70803 VP70803-0002
Crankpin Bearing Plate 70804 VP70804-0001
Main Bearing Assemblies Plate 70805 VP70805-0001
Guide Shoes and Strips Plate 70806 VP70806-0001
Thrust Bearing Assembly Plate 70807 VP70807-0001
Inspection of Bearings. Recording of Observations. Plate 70809 VP70809-0002
Inspection of Bearings. Location and Size of Damage in Bearing
Shells
Plate 70810 VP70810-0002
Acceptance Criteria for Tin-Aluminium Bearings with Overlayer
(Crosshead Bearing Lower Shells)
Plate 70811 VP70811-0002
Inspection of bearings. Location of Damage on Pin/Journal Plate 70812 VP70812-0002
Inspection of Bearings. Observations Plate 70813 VP70813-0002
Inspection of Bearings. Inspection Records, Example Plate 70814 VP70814-0002
Inspection of Bearings. Inspection Records, Blank Plate 70815 VP70815-0002
Report: Crankshaft Deflections (Autolog) Plate 70816 VP70816-0002
Crankshaft Deflection, Limits Plate 70817 VP70817-0003
Circulating Oil System (Outside Engine) (Engines with Uni-Lube
System)
Plate 70818 VP70818-0003
Circulating Oil System (Inside Engine) Plate 70820 VP70820-0002
Flushing of Main Lubricating Oil System. Location of Checkbag and
Blank Flanges
Plate 70821 VP70821-0002
Flushing of Main Lubricating Oil System. Dimension of Checkbag and
Blank Flanges
Plate 70822 VP70822-0002
Flushing of Main Lubricating Oil System. Flushing Log Plate 70823 VP70823-0002
Cleaning System, Stuffing Box Drain Oil (Option) Plate 70824 VP70824-0002
Turbocharger Lubricating Oil Pipes Plate 70828 VP70828-0001
Check Measurements Plate 70829 VP70829-0001
Gear Driven HPS, ELFI and ELVA Plate 70830 VP70830-0002
Gear Driven HPS and FIVA Plate 70831 VP70831-0002
Gear Driven HPS, ELFI and ELVA, Separate LPS Plate 70832 VP70832-0002
Gear Driven HPS and FIVA, Separate LPS Plate 70833 VP70833-0002
Elec. Driven HPS and FIVA, Separate LPS Plate 70834 VP70834-0002
Elec. Driven HPS and FIVA Plate 70835 VP70835-0002
6L42MC/ME KMU Plate 70836 VP70836-0001
Combined HPS, Common LPS and FIVA Plate 70837 VP70837-0002
Combined HPS, Separate LPS and FIVA Plate 70838 VP70838-0001
Gear Driven HPS and FIVA, Common LPS Plate 70839 VP70839-0001
ME/ME-C Engines. Detection of Malfunction and Leaks in Hydraulic
System
Plate 70840 VP70840-0001
Throttle Valve on Fuel Oil Pressure Booster Plate 70841 VP70841-0001
Drainholes in HCU Block Plate 70842 VP70842-0001
Level Switch on ME Cylinder Lubricator Plate 70843 VP70843-0001
Hydraulic Control Oil System (Separate LPS) Plate 70844 VP70844-0001
Double Wall Piping Plate 70845 VP70845-0001
Water Cooling Systems 709
Table of Contents 709TOC V709-0001TOC
Water Cooling Systems 709-01 V70901-0001
Cooling Water Treatment 709-02 V70902-0003
Seawater Cooling System. Main and Auxiliary Engines Plate 70901 VP70901-0001
Vol. 1 - Operation Manual Index
Text Index Drawing No.
Jacket Cooling Water System Plate 70902 VP70902-0001
Central Cooling System Plate 70903 VP70903-0001
Preheating of Jacket Cooling Water Plate 70904 VP70904-0001
Table of Contents
701-01 Safety PrecautionsSpecial Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Order/Tidiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Low Temperatures – freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check and Maintain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Entering the Crankcase or Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turning Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Slow-turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Feeling over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sealing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Cap in Starting Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
701-02 Guidance Value Automation
General Basis for Guidance Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
701-03 Instrumentation
Figure 1: Measuring Instruments, Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 2: Location of Basic Measuring Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 3: Location of Basic Measuring Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 4: Location of Basic Measuring Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 5: Location of Basic Measuring Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 6: Location of Basic Measuring Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
701-04 TestbedAdjustments
Page 2 (2) When referring to this page, please quote Operation Chapter 701 Edition 0001
MAN B&W Diesel A/S
Chapter 701 Safety Precautions and Engine Data
Table of Contents
701-05 IMO NOx Components and Technical File
1. Check of IMO-ID, Markings on Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Fuel Valve Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Pressure Booster Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Hydraulic Piston Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Piston Crown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Checking Setting Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Checking the Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 ELFI Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Air Cooler Specifications (Nameplate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Auxiliary Blower Specifications (Nameplate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Survey methods including on-board verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 IMO surveys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Definitions and Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.2 ‘Standard MAN B&W performance check’. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2.3 Tolerances for ‘load points’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.4 Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.5 Back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Survey cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.1 Load-point ‘corrections’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.2 Test-bed survey – All engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.3 On board – Engine without VIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.4 On board – Engine with VIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.5 Scavenging-air temperature corrections on board. . . . . . . . . . . . . . . . . . . . . . . 8
4.3.6 Sea-water cooling system (SW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.7 Central cooling system – Optimal cooling (CC-O) . . . . . . . . . . . . . . . . . . . . . . 8
4.3.8 Central cooling system – Fixed cooler out temperature (CC-F) . . . . . . . . . . . . 9
4.3.9 Test-bed cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Correction to ISO ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4.1 Performance parameters correction to ISO ambient conditions . . . . . . . . . . . . 9
4.4.2 NOx emission correction to ISO ambient conditions . . . . . . . . . . . . . . . . . . . . . 9
4.5 Correction to reference performance conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. MAN B&W survey procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 On-board survey code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Manual procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Comments on component checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4 Survey example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
When referring to this page, please quote Operation 701-01, Edition 0003 Page 1 (5)
Safety Precautions Chapter 701 Special Dangers
General:Correct operation and maintenance, which is the aim of this book,
are crucial points for obtaining optimum safety in the engine room.
The general measures mentioned here should therefore be routine
practice for the entire engine room staff.
WARNING !
Keep clear of space below crane with load.
The opening of cocks may cause discharge of hot liquids or gases.
Carefully consider which way liquids, gases or flames will move, and
keep clear.
The dismantling of parts may cause the release of springs.
The removal of fuel valves (or other valves in the cylinder cover) may
cause oil to run down onto the piston crown. If the piston is hot, an
explosion might blow out the valve.
When testing fuel valves, do not touch the spray holes as the jets may
pierce the skin.
Do not stand near crankcase doors or relief valves – nor in corridors
near doors to the engine room casing – when alarms for oil mist, high
lube oil temperature, no piston cooling oil flow, or scavenge box fire is
registered. See also Chapter 704.
WARNING !
In design and layout of the engines, MAN B&W Diesel A/S has the basic
philosophy that the failure of one part should not result in the engine
becoming inoperative.
As some mechanical and electronical parts are essential for the safe
functioning of the engine, such parts are duplicated to achieve redundant
capability.
Should such a redundant part become wholly or partly inoperative, the
failing part must be changed or repaired immediately to re-establish
redundancy of the part or – if an emergency situation requires operation
of the engine – as soon as the vessel calls at the nearest port.
Page 2 (5) When referring to this page, please quote Operation 701-01, Edition 0003
MAN B&W Diesel A/S
Safety Precautions Chapter 701
701-01
Hydraulic System
Cleanliness
The engine room should be kept clean both above and below the floor plates.
If there is a risk of grit or sand blowing into the engine room when the ship is in
port, the ventilation should be stopped and ventilating ducts, skylights and engine
room doors closed.
Welding, or other work which causes spreading of grit and/or swarf, must not be
carried out near the engine unless it is closed or protected, and the turbocharger
air intake filters covered.
The exterior of the engine should be kept clean, and the paintwork maintained, so
that leakages can be easily detected.
Fire
Do not weld or use naked lights in the engine room, until it has been ascertained
that no explosive gases, vapour or liquids are present.
WARNING !
Before repair or maintenance work is started, the plant must be stopped
and the current be switched off at the main switch. Open the drain valve
to decrease the pressure to zero. During repairs, the drain valve must
be open.
Always measure the pressure and check that the system is depressurized
before disassembling the part concerned from the system.
Never service the hydraulic system when the pumps are running,
unless absolutely necessary (bleeding the system).
Leak detection must always be carried out using a long piece of wood to
secure proper distance to eventually outflowing oil.
Leaking seals cannot be repaired by tightening. Sealing is only possible
by replacing the sealing elements with new parts.
Never carry out welding or soldering on any part of the hydraulic system.
Only use nitrogen as pre-charge gas on accumulators.
WARNING !
Keep the areas around the relief valves free of oil, grease, etc. to prevent
the risk of fire caused by the emitted hot air/gas in the event that
the relief valves open.
When referring to this page, please quote Operation 701-01, Edition 0003 Page 3 (5)
MAN B&W Diesel A/S
Safety Precautions Chapter 701
701-01
If the crankcase is opened before the engine is cold, welding and the use of naked
flames will involve the risk of explosions and fire. The same applies to inspection
of oil tanks and of the spaces below the floor.
Attention is furthermore drawn to the danger of fire when using paint and solvents
having a low flash point.
Porous insulating material, soaked with oil from leakages, is easily inflammable
and should be renewed. See also Sections 704-01, 02 and ‘Sealing Materials’ in
this Section.
Order/Tidiness
Hand tools should be placed on easily accessible tool panels. Special tools should
be fastened in the engine room, close to the area of application.
No major objects must be left unfastened, and the floor and passages should be
kept clear.
Spares
Large spare parts should, as far as possible, be placed near the area of application,
well secured, and accessible by crane.
All spares should be protected against corrosion and mechanical damage. The
stock should be checked at intervals and replenished in good time.
Lighting
Ample working light should be permanently installed at appropriate places in the
engine room, and portable working light should be obtainable everywhere. Special
lamps should be available for insertion through the scavenge ports.
Low Temperatures – freezing
If there is a risk of freezing, then all engines, pumps, coolers, and pipe systems
should be emptied of cooling water, or the cooling water treated to avoid freezing.
Check and Maintain
Measuring equipment, filter elements, and lubricating oil condition.
Page 4 (5) When referring to this page, please quote Operation 701-01, Edition 0003
MAN B&W Diesel A/S
Safety Precautions Chapter 701
701-01
Entering the Crankcase or Cylinder
Check beforehand that the starting air supply to the engine and the starting air distributor,
is shut off.
In case of oil mist alarm, precautions must be taken before opening to crankcase
(see Section 704-02).
Turning Gear
Before engaging the turning gear, check that the starting air supply is shut off, and
that the indicator cocks are open.
When the turning gear is engaged, check that the indicator lamp “Turning gear in”
has switched on. Check turning gear starting blocking once every year.
Slow-turning
If the engine has been stopped for more than 30 minutes, slow-turning should always
be effected, just before starting in order to safeguard free rotation of the engine,
see Chapter 703.
Feeling over
Whenever repairs or alterations have been made to moving parts, bearings, etc.,
apply the “Feel-over sequence” (see Section 703-03) until satisfied that there is no
undue heating (friction, oil-mist formation, blow-by, failure of cooling water or lubricating
oil systems, etc.).
Feel over after 10-15 minutes’ running, again after 1 hour’s running, and finally
shortly after the engine has reached full load. See Section 703-03.
Sealing Materials
Use gloves when removing O-rings and other rubber/plastic-based sealing materials
which have been subjected to abnormally high temperatures.
These materials may have a caustic effect when being touched directly.
The gloves should be made of neoprene or PVC.
Used gloves must be discarded.
WARNING !
Always ensure that the turning gear is engaged; even at the quay, the
wake from other ships may turn the propeller and thus the engine.
Page 5 (5) When referring to this page, please quote Operation 701-01, Edition 0003
MAN B&W Diesel A/S
Safety Precautions Chapter 701
701-01
Safety Cap in Starting Air Line
If the bursting disc of the safety cap is damaged due to excessive pressure in the
starting air line, overhaul or replace the starting valve which caused the burst, and
mount a new disc.
If a new disc is not available immediately, turn the cover in relation to the cylinder,
in order to reduce the leakage of starting air.
Alarms
It is important that all alarms lead to prompt investigation and remedy of the error.
No alarm is insignificant. The most serious alarms are equipped with slow-down
and/or shut-down functions. It is therefore important that all engine crew members
are familiar with and well trained in the use and importance of the alarm system.
Mount a new bursting disc and return the cover to the open position at
the first opportunity.
When referring to this page, please quote Operation 701-02, Edition 0010 Page 1 (19)
MAN B&W Diesel A/S
Guidance Value Automation Chapter 701
701-02
701-02 Guidance Value Automation
General Basis for Guidance Values
The values stated in the list on the following pages refer to layout point L1.
(Nominal max. continuous rating).
The values must only be used as a guidance in connection with the ‘List of Capacities
of Auxiliary Machinery’ for dimensioning of auxiliary systems, and must not be
used for determining the extent of the alarms or actions.
The item numbers refer to the drawings showing the extent and placement of sensors
for standard alarms and indicators on the engine, if the signal equipment is
fitted. See Section 701-03, furtheron.
For sensors placed in the systems outside the engine, see the actual pipe arrangements
in the appropriate chapters.
If the engine is provided with special equipment, some values may differ from this
list. The correct values shall in such a case be obtained from the Plant Installation
Drawings.
The engine slow-down level corresponds to 40% of nominal MCR r/min.
Engines specified and optimised at derated power may have other normal service
values depending on layout power/revolutions and application.
For derated engines, the testbed/trial values should be used.
When setting the limits, maximum limits must be set at rising parameter and minimum
limits at falling parameter.
Vol 1 50-108 ME.pdf
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