Dispatch Pattern, Testing, Spares and Tools Painting of Main Engine The painting specification (Fig. 9.01) indicates the minimum requirements regarding the quality and the dry film thickness of the coats of, as well as the standard colours applied on MAN B&W engines built in accordance with the “Copenhagen” standard. Paints according to builder’s standard may be used provided they at least fulfil the requirements stated in Fig. 9.01. Dispatch Pattern The dispatch patterns are divided into two classes, see Figs. 9.02 and 9.03: A: Short distance transportation and short term storage B: Overseas or long distance transportation or long term storage. Short distance transportation (A) is limited by a du- ration of a few days from delivery ex works until in- stallation, or a distance of approximately 1,000 km and short term storage. The duration from engine delivery until installation must not exceed 8 weeks. Dismantling of the engine is limited as much as possible. Overseas or long distance transportation or long term storage require a class B dispatch pattern. The duration from engine delivery until installation is assumed to be between 8 weeks and maximum 6 months. Dismantling is effected to a certain degree with the aim of reducing the transportation volume of the in- dividual units to a suitable extent. Note: Long term preservation and seaworthy packing are always to be used. Furthermore, the dispatch patterns are divided into several degrees of dismantling in which ‘1’ com- prises the complete or almost complete engine. Other degrees of dismantling can be agreed upon in each case. When determining the degree of dismantling, con- sideration should be given to the lifting capacities and number of crane hooks available at the engine maker and, in particular, at the yard (purchaser). The approximate masses of the sections appear from Fig. 9.03. The masses can vary up to 10% de- pending on the design and options chosen. Lifting tools and lifting instructions are required for all levels of dispatch pattern. The lifting tools (4 12 110 or 4 12 111), are to be specified when ordering and it should be agreed whether the tools are to be returned to the engine maker (4 12 120) or not (4 12 121). Furthermore, it must be considered whether a dry- ing machine, option 4 12 601, is to be installed dur- ing the transportation and/or storage period. Shop trials/Delivery Test Before leaving the engine maker’s works, the engine is to be carefully tested on diesel oil in the presence of representatives of the yard, the shipowner and the classification society. The shop trial test is to be carried out in accordance with the requirements of the relevant classification society, however a minimum as stated in Fig. 9.04. MAN B&W Diesel’s recommendations for trials are available on request. An additional test may be required for measuring the NO x emmissions, if required, option: 4 14 003. MAN B&W Diesel A/S S26MC Project Guide 480 100 100 178 54 99 9.01
Transcript
Dispatch Pattern, Testing, Spares and Tools
Painting of Main Engine
The painting specification (Fig. 9.01) indicates theminimum requirements regarding the quality andthe dry film thickness of the coats of, as well as thestandard colours applied on MAN B&W engines builtin accordance with the “Copenhagen” standard.
Paints according to builder’s standard may be usedprovided they at least fulfil the requirements statedin Fig. 9.01.
Dispatch Pattern
The dispatch patterns are divided into two classes,see Figs. 9.02 and 9.03:
A: Short distance transportation and short termstorage
B: Overseas or long distance transportation orlong term storage.
Short distance transportation (A) is limited by a du-ration of a few days from delivery ex works until in-stallation, or a distance of approximately 1,000 kmand short term storage.
The duration from engine delivery until installationmust not exceed 8 weeks.
Dismantlingof theengine is limitedasmuchaspossible.
Overseas or long distance transportation or longterm storage require a class B dispatch pattern.
The duration from engine delivery until installation isassumed to be between 8 weeks and maximum 6months.
Dismantling is effected to a certain degree with theaim of reducing the transportation volume of the in-dividual units to a suitable extent.
Note:Long term preservation and seaworthy packing arealways to be used.
Furthermore, the dispatch patterns are divided intoseveral degrees of dismantling in which ‘1’ com-prises the complete or almost complete engine.Other degrees of dismantling can be agreed upon ineach case.
When determining the degree of dismantling, con-sideration should be given to the lifting capacitiesand number of crane hooks available at the enginemaker and, in particular, at the yard (purchaser).
The approximate masses of the sections appearfrom Fig. 9.03. The masses can vary up to 10% de-pending on the design and options chosen.
Lifting tools and lifting instructions are required for alllevels of dispatch pattern. The lifting tools (4 12 110 or4 12 111), are to be specified when ordering and itshould be agreed whether the tools are to be returnedto the engine maker (4 12 120) or not (4 12 121).
Furthermore, it must be considered whether a dry-ing machine, option 4 12 601, is to be installed dur-ing the transportation and/or storage period.
Shop trials/Delivery Test
Before leaving the engine maker’s works, the engineis to be carefully tested on diesel oil in the presenceof representatives of the yard, the shipowner andthe classification society.
The shop trial test is to be carried out in accordancewith the requirements of the relevant classificationsociety, however a minimum as stated in Fig. 9.04.
MAN B&W Diesel’s recommendations for trials areavailable on request.
An additional test may be required for measuring theNOx emmissions, if required, option: 4 14 003.
MAN B&W Diesel A/S S26MC Project Guide
480 100 100 178 54 99
9.01
Spare Parts
List of spares, unrestricted service
The tendency today is for the classification societiesto change their rules such that required spare partsare changed into recommended spare parts.
MAN B&W Diesel, however, has decided to keep aset of spare parts included in the basic extent of de-livery (4 87 601) covering the requirements and rec-ommendations of the major classification societies,see Fig. 9.05.
This amount is to be considered as minimum safetystock for emergency situations.
Additional spare parts recommended byMAN B&W Diesel
The above-mentioned set of spare parts can be ex-tended with the ‘Additional Spare Parts Recom-mended by MAN B&W’ (option: 4 87 603), which fa-cilitates maintenance because, in that case, all thecomponents such as gaskets, sealings, etc.re-quired for an overhaul will be readily available,see Fig. 9.06.
Wearing parts
The consumable spare parts for a certain period arenot included in the above mentioned sets, but canbe ordered for the first 1, 2, up to 10 years’ service ofa new engine (option 4 87 629), a service year beingassumed to be 6,000 running hours.
The wearing parts supposed to be required, based onour service experience, are divided into 14 groups,see Table A in Fig. 9.07, each group including thecompo-nents stated in Tables B.
Large spare parts, dimensions and masses
The approximate dimensions and masses of thelarger spare parts are indicated in Fig. 9.08. A com-plete list will be delivered by the engine maker.
Tools
List of standard tools
The engine is delivered with the necessary specialtools for overhauling purposes. The extent of themain tools is stated in Fig. 9.09. A complete list willbe delivered by the engine maker.
The dimensions and masses of the main tools ap-pear from Figs. 9.10.
Most of the tools can be arranged on steel platepanels, which can be delivered as an option: 4 88660, see Fig. 9.11 ‘Tool Panels’.
If such panels are delivered, it is recommended toplace them close to the location where the overhaulis to be carried out.
MAN B&W Diesel A/S S26MC Project Guide
480 100 100 178 54 99
9.02
MAN B&W Diesel A/S S26MC Project Guide
480 100 100 178 55 00
9.03
Fig. 9.01: Specification for painting of main engine: 4 81 101
Components to be paintedbefore shipment from workshop
Type of paintNo. ofcoats/
Total dryfilm
thicknessµm
Colour:RAL 840HRDIN 6164MUNSELL
Component/surfaces, inside engine, ex-posed to oil and air1. Unmachined surfaces all over. However casttype crankthrows, main bearing cap, crossheadbearing cap, crankpin bearing cap, pipes insidecrankcase and chainwheel need not to bepainted but the cast surface must be cleaned ofsand and scales and kept free of rust
Engine alkyd primer, weatherresistant
Oil and acid resistant alkyd paint.Temperature resistant to mini-mum 80 °C
2/80
1/30
Free
White:RAL 9010DIN N:0:0.5MUNSELL N-9.5
Components, outside engine2. Engine body, pipes, gallery, brackets etc. Engine alkyd primer, weather re-
sistant
Final alkyd paint resistant to saltwater and oil, option: 4 81 103
2/80
1/30
Free
Light green:RAL 6019DIN 23:2:2MUNSELL10GY8/4
Heat affected components:3. Supports for exhaust receiverScavenge air-pipe inside
Paint, heat resistant to minimum200 °C
2/60 Alu:RAL 9006DIN N:0:2MUNSELL N-7.5
Components affected by water and cleaningagents4. Scavenge air cooler box inside Complete coating for long term
protection of exposed to moder-ately to severely corsive environ-ment and abrasion
2/75 Free
5. Gallery plates topside Engine alkyd primer, weather re-sistant
2/80 Free
6. Purchased equipment and instrumentspainted in makers colour are acceptableunless otherwise stated in the contract
ToolsUnmachined surfaces all over on handtools andlifting tools
Purchased equipment painted in makers colouris acceptable, unless otherwise stated in thecontract
Note:All paints are to be of good quality. Paints according to builder‘s standard may be used provided they at least fulfil theabove demands.Delivery standard for point 2, is a primed and finally painted condition, unless otherwise stated in the contract.
178 3U0 20-7.1
Class A + B: Comprises thefollowing basic variants:
Dismounting must be limited as much as possible.
The classes comprise the following basic variants:
A1 Option: 4 12 021, or B1, option: 4 12 031
• Engine
• Spare parts and tools
A2 Option: 4 12 022, or B2 option: 4 12 032
• Top section inclusive cylinder liner, cylindercovers complete, camshaft, piston rods com-plete, connecting rods complete, cooler boxwith cooler insert, exhaust receiver,turbocharger(s) and platforms with pipes
• Bedplate/cranshaft section inclusive turninggear and pipes
• Remaining parts, stay bolts, chains and etc.
Note:The engine supplier is responsible for the necessarylifting tools and lifting instruction for transportationpurpose to the yard. The delivery extent of the liftingtools, ownership and lend/lease conditions is to bestated in the contract.
Furthermore, it must be stated whether a drying ma-chine is to be installed during the transportationand/or storage period.
MAN B&W Diesel A/S S26MC Project Guide
412 000 002 178 55 01
Fig. 9.02: Dispatch pattern, engine with turbocharger on the aft end
The weights are for standard engines with solidforged crankshaft, integrated crosshead guides in frame boxand MAN B&W turbocharger.
All masses and dimensions are approximate and without packing and lifting tools. The masses of turningwheel, turbocharger specified in dispatch pattern outline can vary, and should be checked.
Moment compensators and tuning wheel are not included in dispatch pattern outline. Turning wheel isincluded.
Note:
* 10-12S26MC engines are with turbochargers on exhaust side
The masses can vary up to 10% depending on the design and the options chosen.
Fig. 9.03: Dispatch pattern, list of masses and dimension for engines with turbocharger aft
178 40 86-0.0
9.05
Before leaving the factory, the engine is to be care-fully tested on diesel oil in the presence of represen-tatives of Yard, Shipowner, Classification Society,and MAN B&W Diesel.
Minimum delivery test:
• Starting and manoeuvring test at no load
• Load testEngine to be started and run up to 50%of Specified MCR (M) in 1 hour.
Followed by:
• 0.50 hour running at 50% of specified MCR
• 0.50 hour running at 75% of specified MCR
• 1.00 hour running at 100% of specified MCR
• 0.50 hour running at 110% of specified MCR.
Only for Germanischer Lloyd:
• 0.75 hour running at 110% of specified MCR.
At each load change, all temperature and pressurelevels etc. should stabilise before taking new engineload readings.
Governor tests, etc:
• Governor test
• Minimum speed test
• Overspeed test
• Shut down test
• Starting and reversing test
• Turning gear blocking device test
• Start, stop and reversing from engine sidemanoeuvring console.
Fuel oil analysis to be presented. All tests must becarried out on diesel or gas oil.
An additional test may be required for measuring theNOx emissions, option: 4 14 003.
Exhaust valve, section 9082 Exhaust valves complete (Only 1 for GL)1 Pressure pipe for exhaust valve pipe
Fuel pump, section 9091 Fuel pump barrel, complete with plunger1 High-pressure pipe, each type1 Suction and puncture valve, complete
Fuel valve, section 9091 set Fuel valves for half the number of cylinders
on the engine for ABS1 set Fuel valves for all cylinders on one engine
for BV, CCS, DNVC, GL, KR, NKK, RINa, RSand IACS
Turbocharger, section 9101 Set of maker’s standard spare parts1 a) Spare rotor for one turbocharger, including:
compressor wheel, rotor shaft with turbineblades and partition wall, if any
Scavenge air blower, section 9101 set Rotor, rotor shaft, gear wheel or equivalent
working parts1 set Bearings for electric motor1 set Bearings for blower wheel1 Belt, if applied1 set Packing for blower wheel
Safety valve, section 9111 Safety valve, complete
Bedplate, section 9121 Main bearing shell in 2/2 of each size1 set Studs and nuts for 1 main bearing
MAN B&W Diesel A/S S26MC Project Guide
487 601 005 178 55 03
Delivery extent of spares
Class requirements Class recommendations
CCS:GL:
China Classification SocietyGermanischer Lloyd
ABS:BV:
American Bureau of ShippingBureau Veritas
KR: Korean Register of Shipping DNVC: Det Norske Veritas ClassificationNKK: Nippon Kaiji Kyokai LR: Lloyd’s Register of ShippingRINa: Registro Italiano NavaleRS Russian Maritime Register of Shipping
9.07
Fig. 9.05: List of spares, unrestricted service: 4 87 601
a) Only required for DNVC and RS.To be ordered separately as option: 4 87 660 for
other classiftication societies
The section figures refer to the instruction books.Subject to change without notice.
178 39 43-4.2
For easier maintenance and increased security in operation
Beyond class requirements
Cylinder cover, plate 9010144
501
504
100
pcspcs%pcs%pcs%
Studs for exhaust valveNuts for exhaust valveO-rings for cooling jacketColing jacketSealing betw. cyl.cover and linerSpring housings for fuel valveColling water pipes between liner andcover for one cylinder
Hydraulic tool for cylinder cover, plate 90161188
setpcspcs
Hydraulic hoses compl. with couplingsO-rings with backup rings, upperO-rings with backup rings, lower
Piston and piston rod, plate 902011522
boxpcspcspcs
Locking wire, 1=63 mPiston rings of each kindD-rings for piston skirtD-rings for piston rod
Piston rod stuffing box, plate 902051555
1510
1203030
pcspcspcspcspcspcspcspcs
Self locking nutsO-ringsTop scraper ringsPack sealing ringsCover sealing ringsLamellas for scraper ringsSprings for top scaper and sealing ringsSprings for scraper rings
Cylinder frame, plate 90301501
50
%pcs%
Studs for cylinder cover (1cyl.)BushingNuts for cyl.cover studs (1cyl.)
Cylinder liner and cooling jacket, plate 9030214
1005050
pcspcs%%%
Cooling jacket of each kindNon return valvesO-rings for one cylinder linerGaskets for cooling water connectionO-rings for cooling water pipes
∗ % Refer to one cylinder
Lubricator drive, plate 9030523
CouplingDiscs
Connecting rod and crosshead, plate 9040112
Telescopic pipeThrust piece
Chain drive and guide bars, plate 9060141 set
Guide barLocking plates and lock washers
Chain tightener, plate 906032 Locking plates for tightener
Camshaft, plate 9061111
Exhaust camFuel cam
Camshaft bearing and roller guide housing,plate 90613
Exhaust valve spindleExhaust valve seatO-ring exhaust valve/cylinder coverPiston ringsGuide ringsSealing ringsSafety valvesGaskets and O-rings for safety valvePiston completeDamper pistonO-rings and sealings between air pistonand exhaust valve housing/spindleLiner for spindle guideGaskets and O-ings for cool.w.conn.Conical ring in 2/2O-rings for spindle/air pistonNon-return valve
Valve gear, plate 9080235
pcspcs
Filter, completeO-rings of each kind
Valve gear, plate 9080512242442
pcspcspcspcspcspcspcspcs
Roller guide completeShaft pin for rollerBushing for rollerDiscsNon return valvePiston ringsDiscs for springSprings
Valve gear, details, plate 908061
1004
pcs%pcs
High pressure pipe, completeO-rings for high pressure pipesSealing discs
Cooling water outlet, plate 908102111
pcspcspcsset
Ball valveButterfly valveCompensatorGaskets for butterfly valve and comp.
Fuel pump, plate 909011133
5011
1004
pcspcspcspcs%pcspcs%pcs
Top coverPlunger/barrel, completeSuctions valvesPuncture valvesSealings, O-rings, gaskets and lock washersInternal springExternal springSealing and wearing ringsFelt rings
∗ % Refer to one engine
Fuel pump gear, plate 9090212222
1002
pcspcspcspcspcs%pcs
Fuel pump roller guide, completeShaft pin for rollerBushings for rollerInternal springsExternal springsSealingsRoller
High pressure pipe, complete of each kindO-rings for high pressure pipes
Overflow valve, plate 9091511
pcspcs
Overflow valve, completeO-rings of each kind
MAN B&W Diesel A/S S26MC Project Guide
487 603 020 178 55 04
Fig. 9.06b: Additional spare parts recommended by MAN B&W, option: 4 87 603
9.09
178 39 44-6.1
Turbocharger, plate 9100011
pcspcs
Spare rotor, complete with bearingsSpare part set for turbocharger
Scavenge air receiver, plate 9100121
pcspcs
Non-return valves completeCompensator
Exhaust pipes and receiver, plate 9100312
1
pcspcs
set
Compensator between TC and receiverCompensator between exhaust valve andreceiverGaskets for each compensator
Air cooler, plate 9100516 pcs Iron blocks (Corrosion blocks)
Safety valve, plate 91101100
2%pcs
Gasket for safety valveSafety valve, complete
Arrangement of safety cap, plate 91104100 % Bursting disc
MAN B&W Diesel A/S S26MC Project Guide
487 603 020 178 55 04
The plate figures refer to the instruction bookLiable to change without notice
Where nothing else is stated, the percentagewill refer to one engine
9.10
Fig. 9.06c: Additional spares part recommended by MAN B&W, option: 4 87 603
178 39 44-6.1
MAN B&W Diesel A/S S26MC Project Guide
487 611 010 178 55 06
Table AGroup No. Plate Qty. Descriptions
1 90201 1 set Piston rings for 1 cylinder
1 set O-rings for 1 cylinder
2 90205 1 set Lamella rings 3/3 for 1 cylinder
1 set O-rings for 1 cylinder
3 90205 1 set Top scraper rings 4/4 for 1 cylinder
1 set Sealing rings 4/4 for 1 cylinder
4 90302 1 Cylinder liner
1 set Outer O-rings for 1 cylinder
1 set O-rings for cooling water connections for 1 cylinder
1 set Gaskets for cooling water connection’s for 1 cylinder
1 set Sealing rings for 1 cylinder
5 90801 1 Exhaust valve spindle
1 set Piston rings for exhaust valve air piston and oil piston for 1 cylinder
6 90801 1 set O-rings for water connections for 1 cylinder
1 set Gasket for cooling for water connections for 1 cylinder
1 set O-rings for oil connections for 1 cylinder
7 90801 1 Spindle guide
2 Air sealing ring
1 set Guide sealing rings for 1 cylinder
8 90801 1 Exhaust valve bottom piece
1 set O-rings for bottom piece for 1 cylinder
9 90805 1 set Bushing for roller guides for 1 cylinder
1 set Washer for 1 cylinder
10 90901 1 Plunger and barrel for fuel pump
1 Suction valve complete
1 set O-rings for 1 cylinder
11 90910 1 Fuel valve nozzle
1 Spindle guide complete
1 set O-rings for 1 cylinder
12 1 Slide bearing for turbocharger for 1 engine
1 Guide bearing for turbocharger for 1 engine
13 1 set Guide bars for 1 engine
14 2 Set bearings for auxiliary blowers for 1 engine
The wearing parts are divided into 14 groups, each including the components stated in table A.
The average expected consumption of wearing parts is stated in tables B for 1,2,3... 10 years’ service of a new engine, aservice year being assumed to be of 6000 hours.
In order to find the expected consumption for a 6 cylinder engine during the first 18000 hours’ service, the extent stated foreach group in table A is to be multiplied by the figures stated in the table B (see the arrow), for the cylinder No. and servicehours in question.
Fig. 9.08 Large spare parts, dimensions and masses
Rotor for turbochargerType VTR304
80 kg
Rotor for turbochargerType NA34
40 kg
Cylinder cover 177 kgCylinder cover inclusive
starting and fuelvalves 190 kg
Piston completewith piston rod
153 kg
Cylinder liner 218 kgCylinder liner inclusive
cooling jacket387 kg
All dimensions are given in mm178 43 60-3.0
The engine is delivered with the following standardtools for dismantling and mounting of spare parts.Mass: Approximately 350 kg
Cylinder cover, section 9011 set Millingandgrinding tools forexhaustvalveseats1 set Cylinder cover studs, hydraulic jack1 Fuel valve extractor1 Cylinder cover lifting gear (part of cylinder
liner lifting gear)
Piston with rod and stuffing box, section 9021 set Lifting gears for piston1 Guide ring for piston1 Support for piston1 set Piston overhaul tools1 set Stuffing box overhaul tools1 set Tilting gears for piston1 Piston pressure testing tool
Cylinder liner and cylinder frame, section 9031 set Cylinder liner lifting gears1 set Piston lifting and tilting gears (only low lift)
Crosshead and connecting rod, section 9041 Lifting attachment for connecting rod1 Lifting tool for crosshead1 set Crosshead and crankpin bearing bolt
hydraulic jacks
Crankshaft and main bearing, section 9051 set Dismantling tools for lower main bearing shell1 Pin gauge for top dead centre1 Thrust bearing turning tool1 Crankcase relief valve testing tool
Camshaft, chain drive and reversingmechanism, section 9061 set Pin gauges for gear1 set Chain assembling tools1 set Chain disassembling tools1 set Main bearing studs, hydraulic jack1 set Cam adjusting tools
Starting air system, section 9071 set Starting valve overhaul tools
Exhaust valve and valve gear, section 9081 set Overhaul tools for high pressure connections1 Lifting device for roller guide1 Exhaust valve spindle and seat, pneumatic
grinding machine1 set Exhaust valve spindle and seat, checking
templates
Fuel valve and fuel pump, section 9091 Fuel valve test rig, VPU-6031 set Fuel pump barrel and plunger, lifting tools1 set Fuel oil high pressure pipe and connection,
overhaul tools1 set Fuel valve overhaul tools1 Fuel pump overhaul tool1 set Roller guide and fuel pump housing, lifting
tools
Turbocharger and air cooler system, section 9101 set Turbocharger overhaul and rotor cleaning
