WARTSILA WAGE Engines | WARTSILA AUXPAC INSTRUCTION MANUAL 6. ALO 0210 470210116002L ) zt — = < = STRUCTION I IN Document ID DBAB257098 - Installation He NTS0108002 Engine type 645W A4L20 Engine number PAAE101845, PAAE101846, PAAE101847 Project : NTS0108002 This manual is intended for the personal use of engine operators and should always be at their disposal, The content of this manual shall neither be copied nor communicated to a third person, ‘Warsi Finland Oy ‘Vaasa Factory ‘Tothasjentie 2, FIN-85101 Vaasa, Finland ‘el +368 10 709 0000, The 74251 wva sf Fax (Service) +358 6 358 7355 Fax (Spare paris) +368 10 709 1380 ; WARTSILA| © Copyright by Wartsilé Finland Oy All rights reserved. No part of this booklet may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright ownerONTACT WARTSILA Wéartsila Finland Oy, Services Services Office Vaasa Tarhaajantie 2 F-65380 Vaasa P.O, Box 252 FI-65101 Finland Wartsila service numbers 24 hours: 24hrs Phone +358 10 709 080 Fax +358 10 709 1380 Switchboard +358 10 709 0000 (Office hours 7.30-16.30) E-mail [email protected] Homepage www.wartsila.com/services WARTSILATable of Cont Table of Contents 00. Contents, instructions, terminology. 00.1. About this manual. 00.2, General operation and maintenance instructions... 00.3. Terminology. 00.4. Designations and markings. ‘00.4.1. Designation of bearings.. 00.5. Risk Reduction, 00.5.1. General identified hazards. 00.5.2. Hazards due to moving parts... 00.5.3, Hazards due to incorrect operating condition 00.5.4. Hazards due to leakage, breakdown or improper component assembly... 00.5.5. Electrical hazards. 00.5.6, Other hazard 00.6. Welding precaution 00.6.1. Personal safety when welding, 00.6.2. Protecting equipment when welding. 00.6.3. Welding precautions for engine control system.. 00.7. Hazardous substances. 00.7.1. Fuel oils. 00.7.2, Lubricating oils. - 00.7.3. Cooling water additives, nitrite based. 00.7.4. Fly ashes and exhaust gas dust. 00.7.5. Lead in beatingS...n.n. 00.7.6. Fluoride rubber products... vrnmanranenentnnsO = 19 ia 00-24 01. Main Data, Operating Data and General Design...» 01.1, Main data for Wairtsila Auxpac 20. 01.1.1. Recommended operating data. 01.1.2. Reference conditions... 01.1.3. Exhaust emissions. 01.2. General engine design. 01.3. General generator design 01.3.1. Installation. 01-4 surnnensnnet 25: 7 01-7 01-9 02. Fuel, Lubricating Oil, Cooling Water............ 02.1. Fuel oil 02.1.1, Fuel treatment. 02.1.2. Maximum limits of fuel characteristics. 02.1.3. Comments on fuel characteristics. 02.1.4. Measures to avoid difficulties when running on heavy fvel... 02.1.5. General advice... 02.2. Lubricating cil 02.2.1., System oll characteristics. 02.2.2. Lubricating oil qualities... 02.2.3. Maintenance and control of the lubricating oi... 02.2.4. Handiing of olf samples... 02.2.5. Dispatch and transport. 02.3. Cooling water. 02.3.1. Additives... . Wartsila Auxpac (D2) Table of Contents -i02.3.2. Treatmer 028. Oil requirements & oil quality..... 028.1. Requirements and oil quali (028.2. Condemning limits for used lubricating (028.3. Change of lubricating oil brand. 028.4. Approved lubricating oil qualities for Wartsilé 20 engines... 026.2: Raw water quality requirements. 02C.3. Approved cooling water additves.. 026.4, Use of aye 03. Start, Stop and Operation. 03.1. First start-up preparations... 03.1.1. Visual inspection. 03.1.2. Cooling system.. 03.1.3. Fuel system... 03.1.4. Lubricating oil system. 03.1.5. Air inlet and exhaust gas system. 03.1.6. Starting air system. 03.1.7. Control system... 03.1.8. Generator. 03.2, Statt smn 08.2.1. Local stat. 03.2.2. Remote and automatic start. 7 03-1 03.2.3. Start afier a prolonged stop (more than 8 hy). 03-1 03.2.4. Start after overhaul... 7 03 - 11 | 03.3. Stop. 03.3.1. Local stop.. 03.3.2. Remote stop.. 03.3.3. Automatic shutdown: 03.3.4. Emergency stop.. 03.4, Operation. 03.4.1, Normal operating follow-up. 03.4.2. In connection with maintenance work. 03.4.3, Running-i. 03.4.4. Frequency setting. 03.4.5. Voltage setting. 03.4.6. Load application 04, Maintenance Schedule .. 04.1. How to define loading level a 04.2, Every second day. ‘ ae 04 = 2 04.3. Once a WEEK. nen ss Interval: 50 operating hours. Interval: 100 operating hours.. Interval: 250 operating hours.. Interval: 500 operating hours.... .8. Interval: 1000 operating hour (04.9, Interval: 2000 Operating Hours.. (04.10. Interval: 4000 operating hours.. 04.11, Interval: 8000 operating hours. (04.12. Interval: (8000-20000) operating hours. SRRERRE Table of Contents - i Wartsild Auxpac (D2)Table of Contents 04.13. Interval: 16000 operating hours.. 04.14. Interval: 24000 operating hours. 04.15, Interval: 24000 operating hours/after 5 year 04,16, Interval: 48000 operating hours. 05. Maintenance tools. 05.1. About Spare Parts Catalog 05.2. Ordering maintenance tools. 06, Adjustments, Clearances and Wear Limits...... 06.1. Adjustments... 06.2. Clearances and wear limits (at 20°C). 07. Tightening Torques and Instructions for Screw Connections. 07.1. Tightening torques for screws and nuts. 07.4.4. A: Crankshaft and fiywhee| 07.1.2. B: Camshaft and intermediate gear... 07.1.3. C: Valve mechanism and muttinousing. 07.4.4. D: Injection pump. 07.1.5. E: Fue! injection valv 07.1.6. F: Piston... 07.4.7. G: Engine driven pumps. 07.4.8. H: Free end of crankshaft. : 07.1.9. |: Side screws for main bearings, screws for oll sump and rubber mounts... 07.1.10. J: Intermediate gear for balancing shafts. 07.1.41. K: Balancing shafts. 07.1.12. L: Turbocharger fastening screws.. 07.1.13, M: Generator connection (AVK). 07.1.14. M: Generator connection (FENXI) 07.2. Use of locking fluid 07.3. Hydraulically tightened connections. 07.3.1. Pressures for hydraulically tightened connections. 07.3.2. Maintenance of hydraulic too! set. 07.3.3. Dismantling hydraulically tightened screw connections. 07.3.4. Reassembling hydraulically tightened screw connections... ee 07-13, 08, Operating Troubles, Emergency Operation..... 08.1. Troubleshooting. 08.2. Troubleshooting, generator. 08.3, Emergency operation. (08.3.1. Operation with defective air cooler. 08.3.2, Operation with defective turbocharger. 08.3.3. Operation with defective cams.. 08.3.4. Operation with removed piston and connecting rod. 09.2. Power plant installation: 10, Engine Block wth Oil Sump and Cylinder Liner... 10.1. Engine block and covers... 10.2; Oil sump.. 10.3. Main bearings. 10.3.1. Checking the tightening of main bearing screws... + Wartsilé Auxpac (D2) Table of Contents - iTable of Conte 10.3.2. Dismantling of a main bearing. 10.3.3. Inspection of main bearings and Journals. 10.3.4. Assembling of main bearing. 10.4. Fiywheel/thrust bearing 10.4.1. Dismantling of flywheelithrust bearing. 10.4.2. Inspection of flywheelithrust bearings, 10.4.3. Assembling of fywheelithrust bearin 10.4.4. Measurement of thrust bearing axial clearance... 10.5. Cylinder liner... 10.5.1. Maintenance of cylinder liner. 40.5.2, Removing of cylinder liner. 10.5.3. Inspection of oylinder line 10.5.4. Mounting of cylinder liner. 410-9 ieinnennnnne 4 = 9 10-14 10-11 oe = 1 10-13 10-14 40-14 11, Crank Mechanism: Crankshaft, Connecting Rod, Piston... 14.4, Crankhatt...nmmnnen 11.1.1. Balancing of orankshal 41.1.2. Crankshaft alignment... 14.2. Flywheel. 11.2.1. Chamfered gear rita 44.2.2. Replacing the gear rim... 11.3, Tuming deviee.. 11.4, Connecting rod and piston. 11.4.1. Connecting rod.. 11.4.2. Piston....... 11.4.3. Checking the tighten ing 41.4.4. Removing and eismanting of piston and connecting 10d... 11.4.5. Maintenance of piston, piston rings and connecting rod bearings... 11.4.8. Assembling and mounting of piston and connecting rod... 11-6 11E. Balancing shaft mechanism for 4-cylinder engines.. 116.1. Counterbalancing of 4-cylinder engines. 11.2. Removal of balancing shafis bearing bushes... 11.3. Installing balancing shafts bearing bushes... 11E.4. Adjusting backlash between intermediate gear 12. Cylinder Head with Valves............. 12.4. Functions of the cylinder head drilling... 12.2, Removal the cylinder head. 4. General maintenance of the cylinder hea 12.2.2. Mounting the cylinder head screws. 12.2.5. Adjusting valve : + 42.3. Exhaust and inlet valves and seat ring... 12.3.1. Dismantling valves... 12.3.2. Checking and reconditioning of valves and seats. 12.3.3. Lapping.. i 12.3.4, Machine grinding.. 12.3.5. Change of seat ring... 42.3.6. Use of Loctite products for locking the seats and centre sleeves, 12.3.7, Reassembling the engine valves... 12.4. Operation and maintenance of the indicator valve... 42.4.1. Cylinder firing pressure checking... ‘Fable of Contents - iv Wartsila Auxpac (D2)124A. Testing the cylinder tightness. 42A.1. Connecting the tool for Wartsilé Auxoat 124.2. Measurement. - 13. Camshaft Driving Gears. Intermediate gears and camshaft gear... Maintenance of carnshaft gearing.. Basic adjustment of valve timi Removing of camshaft driving gear.. Mounting of the camshaft gearing.. 43.2. Crankshaft ring gear 14, Valve Mechanism and Camshaft. 44.1. Valve mechanism. 14.1.1. Function of valve mechanism... 14.1.2. Maintenance of valve mechanism... 44.2. Camshaft a 44.2.1. Removing of camshatt piece. 14.2.2. Mounting of camshaft piece. 14.3. Camshaft bearings... 14.3.1. Changing of camshaft bearing bush. 44.3.2. Changing of camshaft bearing bush No.1 15.4. Turbocharget....m 18.1.1. KBB turbocharger speed measurement 16.1.2. Turbocharger maintenance. 18.1.3. Water cleaning of the turbine. 15.1.4. Turbine cleaning procedure... 15.1.5. Water cleaning of the compressor 15.1.6. Operation with damaged turbocharger... 15.2. Charge air cooler. : 18.21. Charge air cooler maintenance. 15.2.2. Cleaning of charge air cooler air side.. 1.2.3, Cleaning of air cooler inser... 16-1. 16-4 16-4 46. Injection System....... 16.1. Injection pump 16.1.1. Function of injection pump. 16.2. Maintenance of injection pump. 16-2 16.2.1. Removal of injection pump... snot =2 16.2.2. Mounting of injection pump. oo =3, 16-5 16-5 16-6 16.2.3. Removal of injection pump element. 16.2.4. Changing of plunger sealing rings...... 46.2.5. Mounting of injection pump element. 16.2.6. Control of fuel injection timing. 16.27. Injection pump overhaul. 16.3. Injection linen. 16.4, Injection valve, 16.4.1. Removing of injection valve... 16.4.2. Overhauling of injection valve. 16.4.3. Mounting of injection valve. 16.5. Pneumatic overspeed trip device, + Wartsilé Auxpac (D2) Table of Contents - v47. Fuel System........ 417.1. Fuel oll safety fiter.. 17.2. Maintenance... 17.3. Venting. 18. Lubricating Oil System. 48.1. Lubricating oil system maintenance.. 18.2. Lubricating oil pump. 48.2.1. Removing the lubricating cil pump. 18.2.2. Dismantting the lubricating oll pump.. 18.2.3, Inspection of lubricating oll pump.. 18.2.4. Assembling the lubricating oll PUMP. nn 18.2.5, Mounting of the lubricating oil pump.. 18.3, Lubricating oil pressure regulating valve and 18.3.1. Maintenance.. srnnnnnnnninnnn 18.3.2. Adjustment of the lubricating oil pressre........ nit 8-7 18.4, Lubricating oil cooler 18.4.1. Lubricating oil cooler maintenance. 18.4.2. Dismantiing of cooler. : 18.4.3, Assembling of cooler... 18.4.4. Cleaning of oil side... 18.4.5. Cleaning of water side. 18.5. Thermostatic VaNvE...enmnnn 18.5.1. Maintenance of thermostatic valve. 48.6. Centrifugal fte 18.6.1. Cleaning of centrifugal fier. 48.7. Prelubricating pump. 18.7.1. Maintenance of prelubricating oll pump... 18-12 18-14 18-16 18-17 18N. Lubricating oil automatic filter. 18N.1. Maintenance of automatic fille. ..i.cens 48N.1.1. Filter candies inspection and cleanin, 49. Cooling Water System. 19.1. HT circui 19.2. Venting and pressure control of HT-circut.. 19.3. LT circu. 19.4. Relief valve and venting of LT circuit. 19.5. Preheating. 19.6. Monitoring. 19,7. Cooling water system maintenance 7.1. Cleaning, 19.8. Water Pump. 19.8.1. Maintenance of water pum 19.9. Temperature control system. 19.9.1. LT and HT thermostatic valve. 19.9.2. Maintenance of the Temperature Control System. 19.9.3.LT throttle valves.. 19.9.4. HT throttle valves.. 20. Exhaust System... 20-1 20.1. Exhaust manifold. ve 20-1 20.1.1. Changing the expansion bellows. 20-2 20.1.2. Checking the tightening of multiduct screws... 20-3 Fable of Contents - vi Wartsilé Auxpac (D2)reece 21. Starting Air System. 21.1. Starting device. 21.1.1. Disassembly of starting device... 21.1.2. Cleaning and inspection. 21.1.3. Assembly of starting device. 24.2. Starting air vessel and pipin 24.3. Pheumatic system.. 21.4. Maintenance of Starting Air System. 22. Control Mechanism. 22.2.1. Stop lever in the stop position, 22.3, Speed control... 22.3.1. Actuator. 22.3.3. Mounting of actuator... 22.4, Electro-pneumatic overspeed trip device. 22.4.1. Check and adjustment of stop position. 22.4.2. Check of tripping speed. 22.4.3, Adjustment of tripping speed... 22.4.4, Maintenance... 23. Instrumentation and Automation. 23.1. AuxPac UNIC-C1 system. 23.1.1, Parts of the UNIC-C1 system. 23.1.2. LCP (Local Control Panel)... 23.1.3, Module MCM. 23.1.4, Actuator ProAct 23.1.5, Module ESM... 23.1.6. Power supply and module POM 23.1.7. Functionality of the MCM main controller 23.1.8, Sensors.. 23.2. Maintenance and Troubleshooting... 23.2.1. Controls and Indicators..rsssreser 23.2.2. Checking the sensors, 23.2.3. Generating set speed sensor... 23.2.4, Turbocharger speed sensor. 23.3. Maintenance of electrical contacts... sesensensin 2 44 23-47 23-48 23A. GeneratOf vs. 23A.1. Disassembly of the generator 238.11. Disassembly (example)... 23A.1.2. Assembly of the generator 23A.2. Insulation testing. 23A.3, Replacement of bali bearing... 230.4. Maintenance of sleeve bearing: 23A.4.1. Oil change. 23A.4.2. Dismanting and assembling of the bearing. 238.5, Fault finding of generator (electrical) 23A.5.1. Testing of the generator. » Waitsil& Auxpac (D2) Table of Contents - viiTable of Cont Fable of Contents - viil Wartsilé Auxpac (D2)Contents, Instructions, Terminology OO Instrumentation and Automation J Main data, Operating Data and General Design O1 ¢ Fuel, Lubricating Oil, Cooling Water O2 Start, Stop and Operation O3 _ Maintenance Schedule O4 a Maintenance Tools O5 ¢ Adjustments, Clearances and Wear Limits O06 Tightening Torques and Use of Hydraulic Tools O7 = Operating Troubles, Emergency Operation O8 Specific Installation Data O9 a Engine Block with Bearings, Cylinder Liners and Oil Sump 10 ro) Crank Mechanism: Crankshaft, Connecting Rod, Piston 11 =—_ Cylinder Head with Valves 12 _ Camshaft DrivingGear 13 Valve Mechanism and Camshaft 14 oO Turbocharging and Air Cooling 15 a | Injection System 16 oc Fuel System 17 Lubricating Oil System 18 Cooling Water System 19 —/ Exhaust System 20 a Starting Air System 21 : = Control Mechanisn 22 23enema Bemcuae 00. Contents, instructions, terminology 00.1. About this manual “ This manual is intended for engine operating and maintenance per- sonnel. The manual contains technical data, maintenance instruc- tions, and instructions for correct and economical operation of the engine. It also contains instructions for personal protection and first aid, as well as for handling fuel, lubricating oil, and cooling water ad- ditives during normal operation and maintenance work. The reader is assumed to have basic general knowledge of engine operation and maintenance. Such information is therefore not provi- ded in this manual. The Wartsila engines are equipped as agreed upon in the sales docu- ments. This manual may contain descriptions of components that are not included in every delivery. No claims can therefore be made on \Wartsilé on the basis of the contents of this manual. The system diagrams (fuel system, lube oil system, cooling water system, etc.) included in this manual are only indicative and do not cover every installation. For detailed system diagrams, see the in- stallation specific drawings. ‘The exact engine design in every detail is defined by the engine num- ber which is located on the engine name plate. Note! In all correspondence with Wartsila, and when ordering spare parts, the engine type and the engine number found on the engine name plate must be stated. This Manual is supplemented by the Spare Parts Catalogue including sectional drawings or exterior views of all components (partial as- semblies).. Wartsilé reserves for itself the right to minor alterations and improve- ments owing to engine development without being obliged to make the corresponding changes in this manual. Wartsila Auxpac (D2) 00-100.2. General operation and maintenance instructions va 00.3. ‘* Read this manual carefully before starting to operate or maintain the engine. Keep an engine log book for every engine. © Observe utmost cleanliness and order in all maintenance work. * Before dismantling, check that all concerned systems are drained and the pressure is released. After dismantling, immediately cover holes for lubricating oil, fuel oil, and air with tape, plugs, clean cloth or similar material. © When replacing a wom-out or damaged partwith anew one, check for markings on the old part, for instance, identification marking, cylinder or bearing number, and mark the new part with the same data at the same location. Enter every exchange in the engine log along with the reason for the exchange clearly stated. ‘* In marine applications, all changes which may influence the NOx emission of the engine, for instance, change of components and ‘engine settings, must be recorded in the "Record Book of Engine Parameters" according to “Annex VI to MARPOL 73/78". * After assembly, check that all screws and nuts are tightened and locked according to the instructions in this manual. Check that all shields and covers are fully functional, in their places and closed. Note! Preventive maintenance is important when it comes to fire protection. Inspect fuel lines, lubricating oil ines and connections regularly. Terminology ve The most important terms used in this manual are explained below. See also Fig 1. Driving end and free end The driving ends the end of the engine where the flywheel is located. The free end is the end opposite the driving end, 00-2 Wartsilé Auxpac (D2)Operating side and rear side The operating side (or manoeuvring side) is the longitudinal side of the engine where the instrument panel (Local Display Unit) or oper: ating devices (start and stop, local panel, speed governor) are loca- ted. The rear side is the longitudinal side of the engine opposite the op- erating side. Details located at the operating side may be marked with an "M" (ma- noeuvring side), and details located at the rear side with a "B" (back side, or B bank on V engines). Designation of cylinders According to ISO 1204 and DIN 6265, the designation of cylinders begins at the driving end. In a V-engine the cylinders in the left bank, seen from the driving end, are termed A1, A2 etc. and in the right bank B1, B2 etc. Terminology and cylinder designations (Inline (L) engine to the left and V engine to the right) Driving end Driving end Clockwise rotation Counter-clockwise rotation Fig 00-1 v2 Rotational direction Clockwise rotating engine: When looking at the engine from the driv- ing end, the crankshaft rotates clockwise. Counter-clockwise rotating engine: When looking at the engine from the driving end, the crankshaft rotates counter-clockwise. Top dead centre and bottom dead centre Bottom dead centre, abbreviated BDC, is the bottom turning point of the piston in the cylinder. Wartsité Auxpac (D2) 00-300.4. enema Top dead centre, abbreviated TDG, is the top turning point of the pis- ton in the cylinder. TDC for every cylinder is marked on the graduation of the flywheel. During a complete working cycle, which in a four-stroke engine com- prises two crankshatt rotations, the piston reaches TDC twice: © TDC at scavenging. This occurs when the exhaust stroke of a working cycle ends and the suction stroke of the next one begins. Both the exhaust and inlet valves are slightly open and scavenging takes place. If the crankshaft is turned to and fro near this TDC, both the exhaust and inlet valves will move. TDC at firing. This occurs after the compression stroke and before the working stroke, Slightly before this TDC, the fuel injection takes place (on an engine in operation). All valves are closed and will not move if the crankshaft is turned. When watching the camshaft and the injection pump, it is possible to notice that the pump tappet roller is on the lifting side of the fuel cam. . High pressure pumps and Accumulators (CR engines only) On anin-Line (L)-engine, the Common Rail pumps and accumulators are numbered 1, 2, 3, and so on, starting from the driving end, that is, not according to the cylinder numbers. OnaV-engine, the left side bank pumps and accumulators are termed A1, A2, and so on, and the right bank equipment B1, B2, and so on, starting from the driving end. Turbochargers: Turbocharger on A-bank side is defined as Turbocharger A (TC A) ‘Turbocharger on B-bank side is defined as Turbocharger B (TC B). Designations and markings 00.4.1. Designation of bearings va Main bearings The shield bearing (nearest the flywheel) is No. 0, the first standard main bearing is No. 1, the second No. 2 etc. 00-4 Wartsila Auxpac (D2)minology Note! During maintenance use a permanent marker pencil to mark any re- moved bearing caps on the rear with their designated position number according to designation procedure. Designation of bearings * lo Ss oH \g ls Fig 00-2 v2 Thrust bearings The thrust bearing rails are located at the shield bearing. The outer rails close to the flywheel are marked with 00 and the inner rails with 0. Camshaft bearings The camshaft bearings are designated as the main bearings, the thrust bearing bushes being designated 00 (outer) and 0 (inner). Wartsilé Auxpac (D2) 00-500.5. Camshaft gear bearings ‘The bearing bushes are designated 00 (outer) and 0 (inner). Upper and lower bearing shells In bearings where both the shells are identical, the upper one should be marked with "UP". Risk Reduction Mt Read the engine manual before installing, operating or servicing the engine and/or related equipment. Failure to follow the instructions can cause personal injury, loss of life and damage to property, Proper personal safety equipment, for example, gloves, hard hat, safety glasses and ear protection must be used in alll circumstances. Missing, unsuitable or defective safety equipment might cause seri- ‘ous personal injury or loss of life. 00.5.1. General identified hazards ui The table below lists general hazards, hazardous situations and events which are to be noticed during normal operation and mainte- nance work. The table lists also the chapters in this manual which are concemad by the respective hazard, ‘Identified hazard, hazardous situation or| Concemed Notes event chapters Dropping parts during maintenance work| 4, 10, 17, 12, 13, 14, 15, 16, 17, 18, f __|19, 20, 21, 22,23] Turning device engaged during mainte- |3, 4, 10, 11, 12, | Warning light is ‘nance work and operated unintentionally] 13, 14, 16 ‘on when the turn ing device is en- Crankcase safety explosion valves _|3, 10, 23, Jopening due to crankcase explosion Noise level 3,4, 10,11, 12, 43, 14,15, 16, 17, 18, 19,20, 21, 22, 23 Running engine without covers 3,4, 10, 11, 12, 18,44, 16,21, 22 Risk of ejected parts in case of major |, 4, 10, 14, 12, failure 43, 14, 22 00-6 Wartsilé Auxpac (D2)Identified hazard; hazardous situation or|Concemed —_| Notes ‘event chapters Contact with electricity during mainte-|4, 11, 17, 18, 21, nance work if power not disconnected |22, 23 Electrical hezerd ifincorrect grounding |3, 4,11, 18, 19 of electrical equipment Ejection of components or emission of |3, 4, 12, 13, 14, high pressure gas due to high firingpres-| 16, 21 sures | Risk of ejected paris due to break down) 3, 15 of turbocharger Overspeed or explosion due to airgas |3, 4, 15. /Suction air must mixture in the charge air be taken from [gas free space. Ejection of fuel injector if not fastened | 4, 12, 16 ‘while the crankshaft is turned. Engine rotating due to engaged gear box| 3, 4, 10, 11, 12, or closed generator breaker during over-| 13, 14, 16 haul Fire or explosion due to leakage in fuel /| 3, 4, 16, 17, 18, gas line or lube oil system ___|20 Inhalation of exhaust gases due to leak-|3, 15, 20 Proper ventila- age tion of engine roomiplant is re~ quired. Inhalation of exhaust gas dust 4, 8, 10, 11, 12, 15, 20 Explosion or fire ifflammable gas/vapour| 3, 20 Proper ventila- is leaking into the insulation box tion and/or gas detectors are re- quired in the en- gine room. Touching of moving parts. 3,4, 8, 10, 11, 12, 13, 14, 15, 16, 17, 18, 21, 22, 23 Risk of oil spray from high-pressure ho- |3, 4,8, 10, 11, 12, ses 13, 14, 15, 16, 18, 19, 21, 22 a | 00.5.2. Hazards due to moving parts wi Running the engine without covers and coming in contact with moving parts Touching pump parts during unintentional start of electrically driven pump motor Turbocharger starting to rotate due to draft if not looked during maintenance Wairtsilé Auxpac (D2)© Thrusting a hand into the compressor housing when the silencer is removed and the engine is running © Unexpected movement of valve or fuel rack(s) due to a broken wire or a software/hardware failure in the control system * Unexpected movement of components * Turing device engaged during maintenance work © Accidental rotation of the crankshaft if the turning device is not engaged during maintenance work, for instance, because it has been removed for overhaul * Mechanical breakage (for example of a speed sensor) due to incorrect assembly of the actuator to the engine or faulty electrical connections. 00.5.3. Hazards due to incorrect operating conditions v: © Overspeed or explosion due to air-gas mixture in the charge air © Overspeed due to air-oil mist mixture in the charge air Malfunction of crankcase ventilation '* Crankcase explosion due to oil mist mixing with air during inspection after an oil mist shut down * Crankcase safety explosion valves opening due to a crankcase explosion. 00.5.4. Hazards due to leakage, breakdown or improper component assembly wu * A fuel or gas pipe bursting and spraying fuel or gas. * control oil pipe bursting and spraying oil (Common Rail) * VIC housing bursting and spraying oil if variable inlet close valve used) * Leakage of: = fuel at joints on the low and/or high pressure side - lube oil - high pressure water on DWI engines - HT water - charge air 00-8 Wartsilé Auxpac (D2)- exhaust gas = pressurised air from air container, main manifold or pipes - high pressure gas and sealing oll on GD engines ‘¢ Fire or explosion due to leakage from a fuel or gas line ‘Fire or explosion due to flammable gas/vapour (crude oil) leaking into the insulation box * Inhalation of exhaust gases or fuel gases due to leakage ‘* Failure of pneumatic stop * Elected components due to: breakdown of hydraulic tool - breakdown of hydraulic bolt ~ breakdown of turbocharger - high firing pressures = major failure Ejection of: - pressurised liquids and gases from the engine block or piping - high pressure fluid due to breakdown of hydraulic tool ~ gas due to high firing pressures - pressurised gases from high pressure gas system ~ high pressure fluid due to breakdown of HP sealing oil pipe high pressure air from compressed air supply pipes during maintenance of pneumatically operated equipment = cooling water or fuel/lube oil if sensor is loosened while the circuit is pressurised ~ leaks during maintenance work ‘© Oil spray if running without covers © Ejection of fuel injector if not fastened and: = the turning device is engaged and turned = the engine turns due to closed generator breaker or coupling. 00.5.5. Electrical hazards vi Fire or sparks due to damage or short circuit in electrical equipment © Contact with electricity during maintenance work if power not disconnected © Hazards due to incorrect grounding of electrical equipment Wartsilé Auxpac (D2) 00-9* Electrical shocks because electrical cables or connectors are damaged * Electrical shocks because electrical equipment is dismantled with the power connected * Incorrectly wired or disconnected emergency stop switch ‘* Overload of a control system component due to incorrect electrical connections, damaged control circuitry or incorrect voltage ‘* Engine out of control due to a failure in the shutdown circuitry ‘* Unexpected start-up or failed stop © Crankcase explosion if: - engine not safeguarded at high oil mist levels, due to energy supply failure - engine not (fully) safeguarded at high oil mist levels, due to failure in oil mist detector circuitry - engine not (fully) safeguarded at high oil mist levels, due to an incorrect electrical connector or leakage in a pipe connection. 00.5.6. Other hazards vt Injury may be caused by: © Slipping, tripping or falling © Improper treatment of water additives and treatment products © Touching the insulation box, turbo-charger, pipes, exhaust manifold, or other unprotected parts without protection during engine operation © Dropping parts during maintenance work * Starting maintenance work too early, thus, causing bums when handling hot components © Neglecting use of cranes and/or lifting tools * Not using proper tools during maintenance work © Not using correct protecting outfits when handling hot parts, thus, causing burns * Contact with fuel, lubrication oll or olly parts during maintenance work * Exposure to high noise levels © Touching or removing turbocharger insulation too soon after stopping the engine © Ejection of preloaded springs when dismantling components. Wartsila Auxpac (D2)( ©) VV 00.6. Dono Welding precautions 00. Personal safety when welding vi Itis important that the welder is familiar with the welding safety in- structions and knows how to use the welding equipment safely. 0.6.1.1, Welding hazards and precautions vs General work area hazards and precautions * Keep cables, materials and tools neatly organised. © Connect the work cable as close as possible to the area where welding is being performed. Do not allow parallel circuits through scaffold cables, hoist chains, or ground leads. © Use only double insulated or properly grounded equipment. ‘© Always disconnect power from equipment before servicing. ‘* Never touch gas cylinders with the electrode. © Keep gas cylinders upright and chained to support. Precautions against electrical shock ‘Warning! Electrical shock can Kill ‘© Wear dry, hole-free gloves. (Change when necessary to keep dry.) © Do not touch electrically “hot” parts or electrode with bare skin or wet clothing. Insulate the welder from the work piece and ground using dry insulation, for example, rubber mat or dry wood. © Ifin awet area the welder cannot be insulated from the work piece with dry insulation, use a semi-automatic, constant-voltage welder or stick welder with a voltage reducing device. Keep electrode holder and cable insulation in good condition. Do not use if insulation is damaged or missing. Wartsila Auxpac (D2)Precautions against fumes and gases Warning! Fumes and gases can be dangerous. '* Use ventilation or exhaust fans to keep the air breathing zone clear and comfortable, * Weara helmet and position the head so as to minimize the amount of fumes in the breathing zone. * Read warnings on electrode container and material safety data sheet (MSDS) for the electrode * Provide additional ventilation or exhaust fans where special ventilation is required. * Use special care when welding in a confined area. © Do not weld with inadequate ventilation, Precautions against welding sparks Warning! Welding sparks can cause fire or explosion ‘* Do notweld on containers which have held combustible materials, Check the containers before welding. * Remove flammable material from welding area or shield them from sparks and heat. © Keep a fire watch in area during and after welding. * Keep a fire extinguisher in the welding area. * Wear fire retardant clothing and hat. Use earplugs when welding overhead. Precautions against arc rays Wamingt Arc rays can burn eyes and skin. * Select a filter lens which is comfortable for you while welding, © Always use helmet when welding, * Provide non-flammable shielding to protect others. Wear clothing which protects skin while welding. 00-12 Wartsilé Auxpac (D2)Oo Precautions when welding in confined spaces ‘© Ensure that the ventilation is adequate, especially if the electrode requires special ventilation or if welding causes the formation of gas that may displace oxygen. © If the welder cannot be insulated from the welded piece and the electrode, use semi-automatic constant-voltage equipment with a cold electrode or a stick welder with voltage reducing device. * Provide the welder with @ helper and plan a method for retrieving the welder from the enclosure in case of an emergency. 00.6.2. Protecting equipment when welding va The main principles for protecting equipment when welding are: ‘© Preventing uncontrolled current loops © Preventing radiation ‘* Preventing the spread of welding splatter © Switching off or disconnecting all nearby electrical equipment. when possible. Preventing uncontrolled current loops. va Always check the welding current path. There should be a direct route from the welding point back to the return connection of the welding apparatus. The main current always flows along the path of least resistance. In certain cases the return current can therefore go via grounding wires and electronics in the control system. To avoid this, the distance be- tween the welding point and the return connection clamp of the weld- ing apparatus should always be the shortest possible. It must not in- clude electronic components. Pay attention to the connectivity of the return connection clamp. A bad contact might cause sparks and radiation. 00.6.2.2. Prevention of radiation vs The welding current and the arc is emitting a wide spectrum of elec- tromagnetic radiation. This might damage sensitive electronic equip- ment. To avoid such damages all cabinets and terminal boxes must be kept closed during welding. Sensitive equipment can also be protected by means of shielding with a grounded (earthed) conduetive plate. Wartsila Auxpac (D2) 00-1300.7. Also, avoid having the cables of the welding apparatus running in parallel with wires and cables in the control system. The high welding current can easily induce secondary currents in other conductive ma- terials. 00.6.2.3. Prevention of damage due to welding splatter vs Welding splatter is commonly flying from the welding arc. Few mate- rials withstand the heat from this splatter. Therefore all cabinets and terminal boxes should be kept closed during the welding. Sensors, actuators, cables and other equipment on the engine must be prop- erly protected. Welding splatter can also be a problem after it has cooled down; e.g. short-circuits, leaks. 00.6.3. Welding precautions for engine control system vs Electronic control systems are sensitive and can be seriously dam- aged by external voltage or high-current shocks. To avoid damaging the engine control system certain precautions must be taken when welding. Hazardous substances vt Fuel oils, lubricating oils and cooling water additives are environmen- tally hazardous. Take great care when handling these products or systems containing these products. 00.7.1. Fuel oils v3 Fuel oils are mainly non-volatile burning fluids, but they may also contain volatile fractions and therefore present a risk of fire and ex- plosion The fuel oils may cause long-term harm and damage in water envi- ronments and present a risk of contaminating the soil and ground water. Prolonged or repetitive contact with the skin may cause irritation and inctease the risk of skin cancer (polyaromatic hydrocarbons, etc.) Fumes that are irritating for eyes and respiratory organs, such as hy- drogen sulphide or light hydrocarbons, may be released during load- ing/bunkering 00-14 ‘Wairtsilé Auxpac (D2)oO O Meneame au Ke Notet ‘Study the safety instructions provided by the fuel oil supplier. 00.7.1.1. Safety precautions for fuel oil handling ve © Isolate the fuel oils from ignition sources, such as sparks from static electricity © Avoid breathing evaporated fumes, for instance, during pumping and when opening storage tanks. The fumes may contain toxic gases, for instance, hydrogen sulphide, Use a gas mask if necessary. * Keep the handling and storage temperatures below the flash point, * Store the fuelin tanks or containers designed for flammable fluids. ‘Note the risk of methane gas formation in the tanks due to bacterial activities during long-term storage. Methane gas causes risk of explosion, for instance, when unloading fuel and when opening storage tanks, When entering tanks, there is a risk of suffocation. * Donotrelease fuel into the sewage system, water systems or onto the ground, * Cloth, paper or any other absorbent material used to soak up spills are a fire hazard. Do not allow them to accumulate. ‘© Dispose of any waste containing fuel oll according to directives issued by the local or national environmental authorities. The waste is hazardous. Collection, regeneration and burning should be handled by authorised disposal plants. 0.7.1.2, Personal protection equipment for fuel oils ve Protection of Against oll mist: Use respirator with respiratory organs: combined particle and gas filter. Against evaporated fumes (hydrogen sulphide, etc.): Use respirator with inorganic gas filter. Hand protection: Use strong, heat and hydrocarbon resistant gloves (nitrile rubber for example). Eye protection: Wear goggles if splash risk exists. Skin and body Wear facial screen and covering clothes as protection: required. Use safety footwear when handling barrels. Wear protective clothing if hot product is handled. Wartsilé Auxpac (D2) 00-15ee 00.7.1.3. First aid measures for fuel oil accidents v3 Inhalation of fumes: — Move the victim to fresh air. Keep the victim warm and lying stil. Give oxygen or mouth to mouth resuscitation if needed. Seek medical advice after significant exposure or inhalation of oil mist. Skin contact: If the oil was hot, cool the skin immediately with plenty of cold water. Wash immediately with plenty of water and soap. Do not use solvents as they will disperse the oil and might cause skin absorption. Remove contaminated clothing. ‘Seek medical advice if irritation develops. Eye contact: Rinse immediately with plenty of water, for at least 15 minutes. Seek medical advice. If possible, keep rinsing until eye specialist has been reached Ingestion: Rinse the mouth with water. Do not induce vomiting as this may cause aspiration into the respiratory organs. Seek medical advice. 00.7. Lubricating oils v3 Fresh lubricating oils normally present no particular toxic hazard, but all lubricants should always be handled with great care. Used lubricating olls may contain significant amounts of harmful metal and PAH (polyaromatic hydrocarbon) compounds. Avoid prolonged oF repetitive contact with the skin. Prevent any risk of splashing. Keep away from heat, ignition sources and oxidizing agents. There is a risk of long term contamination of the soil and the ground water. Take every appropriate measure to prevent water and soil contamination. Notet Study and follow the safety information provided by the supplier of the lubricating oi. Wartsilé Auxpac (D2)C) 0.7.2.1. Safety precautions for handling lubricating oil |v When handling lubrication oils: ‘* Ensure adequate ventilation if there is a risk of vapours, mists or aerosols releasing. Do not breathe vapours, fumes or mist. * Keep the oil away from flammable materials and oxidants. © Keep the oll away from food and drinks. Do not eat, drink or smoke while handling lubricating oils. ‘© Use only equipment (containers, piping, etc.) that are resistant to hydrocarbons. Open the containers in well ventilated surroundings. Immediately take off all contaminated clothing. Note also the following: ‘* Empty packaging may contain flammable or potentially explosive vapours. ‘© Cloth, paper or any other absorbent material used to recover spills are fire hazards. Do not allow these to accumulate, Keep waste products in closed containers. © Waste containing lubricating oil is hazardous and must be disposed of according to directives issued by the local or national environmental authorities. Collection, regeneration and burning should be handled by authorised disposal plants. 00.7.2.2. Personal protection equipment for lubricating oils v3 Hand protection: Use impermeable and hydrocarbon resistant gloves (nitrile rubber for example). Eye protection: Wear goggles if splash tisk exists. ‘Skin and body Wear facial screen and covering clothes as protection: required. Use safety footwear when handling barrels. Wear protective clothing when handling hot products. 00.7.2.3. First aid measures for lubricating oil accidents vs Inhalation of fumes: Move the victim to fresh air. Keep the victim warm and lying still. Skin contact: Wash immediately with plenty of water and soap or cleaning agent. Do not use solvents (the oil is dispearsed and may be absorbed into the skin). Remove contaminated clothing. Seek medical advice if irritation develops, Wartsilé Auxpac (D2) 00-17eee. Eye contact Rinse immediately with plenty of water, and continue for at least 15 minutes. Seek medical advice. Ingestion Do not induce vomiting, in order to avoid the risk of aspiration into respiratory organs. Seek medical advice immediately. Aspiration of liquid If aspiration into the lungs is suspected product (during vomiting for example) seek medical advice immediately. 00.7.3. Cooling water additives, nitrite based va The products are toxic if swallowed. Concentrated product may cause serious toxic symptoms, pain, giddiness and headache. Significant intake results in greyish/blue discoloration of the skin and mucus membranes and a decrease in blood pressure. Skin and eye contact with the undiluted product can produce intense irritation. Diluted sol- utions may be moderately irritating. Note! ‘Study the safety information provided by the supplier of the product. 00.7.3.1. Safety precautions for handling cooling water additives v4 Avoid contact with skin and eyes. © Keep the material away from food and drinks. Do not eat, drink or smoke while handling it. * Keep the material in a well ventilated place with access to safety shower and eye shower. Soak up liquid spills in absorbent material and collect solids in a container. Wash floor with water as spillage may be slippery. Contact appropriate authorities in case of bigger spills. * Bulk material can be land dumped at an appropriate site in accordance with local regulations, 00.7.3.2, Personal protection equipment for cooling water additives vs Respiratory protection: Normally no protection is required. Avoid exposure to product mists. Hand protection: Wear rubber gloves (PVC or natural rubber for example) 00-18 Wartsila Auxpac (D2)oon Eye protection: Wear eye goggles. Skin and body Use protective clothing and take care to protection: minimise splashing. Use safety footwear when handling barrels. 0.7.3.3. First aid measures for accidents with cooling water additives ve Inhalation: In the event of over exposure to spray mists, move the victim to fresh air. Keep the victim warm and lying stil. If the effects persist, seek medical advice. Skin contact: Wash immediately with plenty of water and soap. Remove contaminated clothing. If O invitation persists, seek medical advice. Eye contact: Rinse immediately with plenty of clean water | and seek medical advice. If possible, keep rinsing until eye specialist has been reached. Ingestion: Rinse the mouth with water. Make the victim drink milk, fruit juice or water. Do not induce vomiting without medical advice. Immediately seek medical advice. Never give anything to drink to an unconscious person. 00.7.4. Fly ashes and exhaust gas dust vt eS Note! | Study the safety instructions before starting to overhaul the exhaust | gas system, or engine components that have been in contact with exhaust gases. Wartsila Auxpac (D2) 00-19mcs 0.7.4.1. Precautions for handling fly ashes and exhaust gas dust ve ‘When handling fly ashes, exhaust gas dust or any contaminated components, observe the following requirements and precautions: * Avoid inhaling and swallowing fly ashes and dusts. Prevent eye and skin contacts. * Avoid spreading and spilling the fly ashes and dusts to the environment. ‘* Take measures to avoid spreading the dust in the surrounding area when opening the manholes of the exhaust gas system, especially the Selective Catalytic Reduction (SCR) system (if included). Avoid spreading dust when handling exhaust gas system components. ‘* Take care that the ventilation is suitable when collecting dust arisen during the machining and cleaning of the components. * Apply appropriate disposal instructions for flue gas dust spillage. The dust collected from the exhaust gas system must be considered as hazardous waste. It must be treated according to the local regulations and legislation. 00.7.4.2. Personal protection equipment for fly ashes and exhaust gas dust va Respiratory organ Use P3 filter respirator against toxic particles. protection: For work inside the SCR or other places in the exhaust gas system, where the dust concentration is high, a respiration mask with fresh filtered compressed air supply is. recommended. Hand protection: Use gloves. Eye protection: Wear goggles. Skin and body Wear covering clothes. protection: Use proper protection also when machining or cleaning engine com- ponents that have been in contact with exhaust gases. 00.7.4.3. First aid measures for fly ash and exhaust gas accidents i Inhalation of ashes: Move the victim to fresh air. Keep the victim warm and lying stil. Give oxygen or mouth to mouth resuscitation if needed. Seek medical advice after a significant exposure. 00-20 Wartsilé Auxpac (D2)een Skin contact: If the ash is hot, cool the skin immediately with plenty of cold water. Wash immediately with plenty of water and soap. Do not use solvents as it disperses the ash and may cause skin absorption. Remove contaminated clothing. Seek medical advice itation develops. Eye contact: Rinse immediately with plenty of water for at least 15 minutes and seek medical advice. if possible, keep rinsing until eye specialist has been reached. Ingestion: Rinse the mouth with water. Do not induce vomiting as it may cause aspiration into respiratory organs. Seek medical advice. 00.7.5. Lead in bearings vo Lead has valuable lubricating properties and is therefore incorporated into many bearing alloys. The bearings in Wartsild engines contain lead and are therefore toxic. Bearings that are to be scrapped and contain lead must be disposed ‘of according to the local authority regulations. 00.7.6. Fluoride rubber products 00.7.6.1. Precautions when handling fluoride rubber products vt Normal sealing applications: In normal sealing applications the use of fluoride rubber products does not cause any health hazards. The products can be handled without any risk provided that normal industrial hygiene is maintained. When changing © rings of valve seats Always wear protective rubber gloves when changing the O rings of the valve seats. When handiing the remains of bumt fiuoride rubber When handling the remains of bumt fluoride rubber, for instance, when changing O-rings after a valve blow-by, wear impenetrable acid- proof gloves to protect the skin from the highly corrosive remains. ‘Appropriate glove materials are neoprene or PVC. All liquid remains must be considered to be extremely corrosive. Wartsila Auxpac (D2) 00-21| on ees | ! The remains can be neutralized with large amounts of calcium hy- droxide solution (lime water). Used gloves must be disposed of. Grinding dust Dust and particles originating from grinding or abrasion (wear) of flu- oride rubber may when burned form toxic degradation products. Smoking must therefore be prohibited in areas where fluoride rubber dust and particles are present. In case of fire When burned fluoride rubber can cause the formation of toxic and corrosive degradation products, for example, hydrofluoric acid, car- bonyl fluoride, carbon monoxide, and carbon fluoride fragments of low molecular weight. Operators handling the remains of burnt fluoride rubber must wear impenetrable acid-proof gloves to protect the skin from the highly cor- rosive remains. Appropriate glove materials are neoprene or PVC. All liquid state remains must be considered extremely corrosive. Burning (incineration) of fluoride rubber is allowed only when ap- proved incinerators equipped with gas emission reduction systems are used. Use of fluoride rubber products at temperatures above 275°C (627°F) Fluoride rubber can be used in most applications (up to 275°C) with- ‘out any substantial degradation or health hazard, Use or test of fluo- ride rubber at temperatures above 275°C must be avoided. If the ma- terial is exposed to higher temperatures, the temperature may get out of control. 00.7.6.2. Personal protection equipment for fluoride rubber products v3 Hand protection: Use impenetrable acid-proof gloves (neoprene or PVC). Inhalation protection: Use breathing mask. 00.7.6.3. First aid measures for accidents with fluoride rubber products v3 Inhaling: Move the victim from the danger zone. Make the victim blow his nose. Seek medical advice. Eye contact: Rinse immediately with water. Seek medical advice. 00-22 Wartsilé Auxpac (D2)—, ‘Skin contact: Rinse immediately with water. Put a 2 % solution of calcium gluconate gel on the exposed skin. if calcium gluconate gel is not available, continue to rinse with water. Seek medical advice. Wartsilaé Auxpac (D2) 00-2300-24 Wartsila Auxpac (D2)m) 01. Main Data, Operating Data and General Design 01.1. Main data for Wartsila Auxpac 20 vs Cylinder bore... 200 mm Stroke 280 mm Piston displacement per cylinder ... . 8.801 Number of valves .. 2 inlet and 2 exhaust Alternative cylinder configurations . 4,6,8,9, in line Direction of rotation .. . Clockwise Firing order Engine type Clockwise rotation 4120/1342 6120 | 1-5-3-6-2-4 L200. (|1-3-7-4-8-6.2.5. - a 9120 |1-7-4-2.863.05 ke Note! kWe is the electrical output of the genset. ‘Auxpac rating table 900 RPMI60Hz 1000 RPM/S0Hz Type Output kWe] | Voltage [V1 Type Output ke] | Voltage [VI [szowal20 | 520 | ABO s20w4L20 | 520 400 645W4L20 645, 450 6TOWAL20 670 400 | 760W6L20 70 | 450 790W6L20 790 400 875W6L20 875 450 860W8L20 860 400 975WEL20 975 450 000W6L20 1000 400 050W6L20 4050 450 “140W6L20 1140 400 2008120 1200 450 13508120 1350 400 1400WaL20 1400 450 1550W9L20 1850 400-690 14009120 1400 450-690 | _1700W9L20 1700 400 1600W9L20 1600 450-600 | _1740WOL20 1740 400-690 Wartsilé Auxpac (D2) o1-4neko oo The permissible overload is 10/% for one hour every 12 hours. The maximum fuel rack position is mechanically limited to 110/% contin- uous output for all auxiliary engines. Cooling water volume in the engine inftres Engine type 4120 | 6120 | @20 | 9120 HT-cooling water, 80 105 130 140 abt. (litres) LT-cooiing water, 80 85 90 5 abt. (Hires) Oil volume between max. and min. marks on the dipstick Oil volume between max. and min. marks HH abi. litres/mm tui Engine type 420 | 6120 | 8120 9120 Fenxi 900 RPM/60Hz 127 2 3.58 - Fenxi 1000 RPMISOHz 1.98 2 267 - ‘VK 900 RPM/60Hz 115 | 189 | 358 2.98 ‘AVK 1000 RPM/S0Hz 176 | 1.60 | 267 2.98 Lubricating oil volume, wet sump 900 RPMI6OHz 1000 RPM/SOHz Type Fenxifiires]_ | AVK [itres} Type Fenxi tres) AVK Titres} S20WAL20 #0 370 ‘520W4L20 640 570 6454120 410 370 670W4L20 640 570 T60W6L20 760 680, 790W6L20 760 680 ‘B75W6L20 760 680 860W6L20 760 680 975W6L20 760 680 4000W6L20 760 680 1050W6L20_ 760 680 1140W6L20 760 680 200W8L20 1740 1740 1350W8L20 1310 1310 1400W8L20 1930 1740 1550W9L20 1580 1460 1400W9L20 1580 1460 7OOWSL20 1580 1460 1600W9120 1580 1460 1740W91.20 1580 1460 01-2 Wairtsila Auxpac (D2)O O 01.1.1. Recommended operating data v3 Apply to normal operation at nominal speed. ‘alarm for high pressure drop over lube oil fitter Temperatures (°C) Normal values °) ‘Alarm (stop) limits 9 Load 100% 0-100 % Lube oll before engine 63-67 80 _| |Lube oil after engine 10 - 16 higher than before: HT water after engine 86-95 405 (110) HT water before engine 6-40 lower than after LT water before charge air cooler 35-50 Charge airin air receiver 45-70 5 Exhaust gas after ovinder ‘Soe test records 450 Preheating of HT water = 60 Gauge pressures (bar) i Normal values 0) Alarm (stop) limits 0%) Load 100% ____0-100% Lubricating oil before engine at a 40-50 3.0 (2.0) speed 900/100 RPM HT/LT water before HT/LT pump O75 (static) ee L HT water before engine 2.2 + static press. (x)(000) 4.0 + static press. LT water before charge air cooler 2.2 * static press. (x) 1.0 + static press. Fuel before engine (MD) 4-7 (%); (HF) 5-10 4 ‘Compressed air max. 30 18 Air startor 80 Charge air See test records ian Other pressures (bar) “Normal values °) ‘Alarm (stop) limits © Load 100 % 0- 400% Firing pressure See test records Opening pressure of safety valve 6-8 [on lube oil pump 7 Visual indicator and electronic <12-18 12-18 (x) Depending on installation. (08) Under 30% load the lubricating oil and water temperatures fall a little. Wartsilé Auxpac (D2) 01-3(xxx) See test records. (00x) HT pressure is higher than the LT pressure if combined cooling water system. 01.1. Reference conditions va ‘The output is available up to a charge air coolant temperature of max. 38 °C and an air temperature of max. 45 °C. For higher temperatures, the output has to be reduced according to the formula stated in ISO 3046-12002 (E). The statement applies to engines operating the following conditions, according to ISO: Total baromettic pressure 400 kPa Air temperature .. 25°C Relative humidity 30% Charge air coolant temperature 25°C For other than ISO 3046-1 conditions the same standard gives cor- rection factors on the fuel oil consumption. 01.1.3. Exhaust emissions ve The exhaust gas of diesel engines mainly consists of nitrogen, carbon dioxide (CO,) and water vapour, with smaller quantities of carbon monoxide (CO), sulphur oxides (SO,) and nitrogen oxides (NO), par- tially reacted and non-combusted hydrocarbons and particulates. An increasing concer over air pollution has resulted in the introduc- tion of exhaust emission regulations to the marine industry. Annex VI of MARPOL 73/78 developed by the International Maritime Organi- sation (IMO) represents the first worldwide set of regulations on ma- rine exhaust emissions. MARPOL 73/78 Annex VI includes regula- tions on nitrogen oxides, sulphur oxides, volatile organic compounds and ozone depleting substances. An engine intemational air pollution prevention (EIAPP) Statement of Compliance is issued for each en- gine showing compliance with IMO NOx regulations. The Wartsilé Auxpac generating sets comply with IMO MARPOL An- nex VI regulations and are supplied with an EIAPP Statement of Compliance. o1-4 ‘Wartsilé Auxpac (D2)General engine design ve The engine is a turbocharged intercooled 4-stroke diesel engine with direct fuel injection. The engine is designed and specified for conti- nous operation on heavy fuel oil (HFO), but can run on light fuel oil (LFO) without alterations. The maximum limits of fuel characteristics for a certain engine are stated in the documentation delivered with the generating set. The engine block is cast in one piece. The main bearings are under- neath. The main bearing cap is supported by two hydraulically ten- sioned main bearing screws and two horizontal side screws. The charge air receiver is cast into the engine block as is the cooling water header. The crankcase covers, made of ight metal, seal against the engine block by means of rubber seals. The lubricating oil sump is welded. The cylinder liners are the wet type. Cooling is optimised so that the inner surface temperature is correct. To eliminate the risk of bore pol- ishing, the liner is provided with an anti-polishing ring. The main bearings are fully interchangeable, bimetal bearings which can be accessed by removing the main bearing cap. The crankshaft is forged in one piece and is balanced by counter- weights as required. The connecting rods are drop forged. The big end is split and the mating faces are serrated. The small end bearing is stepped to ach- ieve large bearing surfaces. The big end bearings are of bimetal and are fully interchangeable. Wartsilai Auxpac (D2) 01-51. Valve mechanism, 2. Cylinder head, 3. Injection pump, 4, Injection valve, 5. Cylinder liner and anti-polishing-ring, 8. Camshaft, 7. Piston, 8. Connecting rod, 9. Engine block, 10. Crankshaft, 11. Main bearing, 12. Multi duct, 13. Exhaust ‘manifold, 14. Charge air cooler, 15. Relief valve, 16. Oil sump Fig 01-4 vi The pistons are of a composite type with forged steel or casted skirt and a forged crown screwed together. They are fitted with a Wartsila patented skirt lubricating system. The top ring grooves are hardened. Cooling oil enters the cooling space through the connecting rod. The piston ring set consists of two chrome-plated compression rings and one chrome-plated, spring-loaded oil scraper ring. The cylinder head, made of special cast iron, is fixed by four hydraul- ically tensioned screws. The head is of the double-deck type and cooling water is forced from the periphery towards the centre, giving efficient cooling in important areas. 01-6 Wartsila Auxpac (D2)oO) 01.3. ‘The inlet valves are stellited and the stems are chromium-plated. The valve seat rings are made of a special cast iron alloy and are replace able. ‘The exhaust valves are either stellited or with nimonic seats and chromium-plated stems, and seal against the directly cooled valve seat rings. ‘The seat rings, made of a corrosion and pitting resistant material, are replaceable. ‘The camshafts are assembled from pieces with integrated cams, there is a separate piece for each cylinder. The bearing journals are separate pieces and thus its possible to remove a camshaft section sideways. ‘The injection pumps have integrated roller components and can be changed without any adjustment. The pumps and piping are located in a closed space which has thermal insulation for heavy fuel running. The element can be changed without removing the pump housing. The turbocharger is located at the free end of the engine. The charge air cooler consists of a removable insert. The lubricating oil system includes a gear pump, oil filter, cooler with thermostat valve, centrifugal by-pass filter and an electrically driven prelubricating pump. The oil sump is dimensioned for the entire oil volume needed, and all cylinder numbers can be delivered in wet sump configuration. ‘The starting system. The engine is provided with an air driven starting turbine. The air starter acts directly on the flywheel. General generator design va ‘The generator is alr- or water-cooled (optional), brushless, constant- voltage synchronous generator and is of the self-excited type with an electronic voltage regulator integrated in the excitation system. ‘The generator is provided with one deep-groove ball bearings, cylin- drical roller bearings or sleeve bearing, depending on installation The air-cooled generator is internally cooled with a shaft-mounted fan. The fan, fitted at the drive-end, draws cooling air axially through the machine. Brushless synchronous generator consist of the main machine and the exciter. The main machine field winding is powered from the ex- citer rotor winding via a rotating, three-phase bridge-connected rec- tifier set. Wartsila Auxpac (D2) 01-7A synchronous generator with brushless excitation consists of two machines, the main machine and the exciter machine. To produce output power a synchronous generator needs to rotate, and a DC current in the main machine rotor for excitation. In a brushless gen- erator a small exciter machine with rotor and stator winding is provi- ded on the shaft. The exciter stator winding is supplied with a DC current from the AVR ( Automatic Voltage Regulator). When the ma- chine is rotating an AC voltage is then induced in the exciter rotor which is rectified by the rotating diodes mounted on the shaftand then fed to the main machine rotor. For initial voltage build up, the system is relying on a remanence voltage, as the power supply to the AVR is connected to the main machine stator.. More detailed information can be found in the manufacturer's manual. Brushless synchronous generator (example) 1. Stator frame and stator windings assembly, 2. Rotor and windings assembly, 3. AC exciter assombly, 4. Rectifier assembly, 6. Excitation equipment, 6. Shaft, 7. Bearing, 8. Cooling fan, 9. End shield, 10. Connecting box, 11. Water cooling element (optional) Fig 01- vw Wartsilé Auxpac (02)