Man l32 40 Genset Imo Tier II Marine PDF

MAN Energy Solutions SE
Four-stroke diesel engine compliant with IMO Tier II

MAN L32/40 GenSet Project Guide – Marine
86224 Augsburg
P + 49 821 322- 0
F + 49 821 322-3382
www.man-es.com
MAN
L32/40
GenSet
All data provided in this document is non-binding.
This data serves informational purposes only
and is not guaranteed in any way. Depending on
the subsequent specific individual projects, the
relevant data may be subject to changes and
will be assessed and determined individually for
each project. This will depend on the particular
characteristics of each individual project,
especially specific site and operational conditions. Project Guide – Marine
Copyright © MAN Energy Solutions. Four-stroke diesel engine compliant with
D2366583EN-N1
Printed in Germany GGKMD-AUG-08180.5 IMO Tier II
MAN Energy Solutions
MAN L32/40 GenSet

Project Guide – Marine
Revision ............................................ 05.2017/1.4
MAN L32/40 GenSet IMO Tier II Project

Guide – Marine
2019-09-19 - 1.4
All data provided in this document is non-binding. This data serves informa-
tional purposes only and is especially not guaranteed in any way. Depending
on the subsequent specific individual projects, the relevant data may be sub-
ject to changes and will be assessed and determined individually for each
project. This will depend on the particular characteristics of each individual
project, especially specific site and operational conditions.
EN
MAN L32/40 GenSet IMO Tier II Project
Guide – Marine

2019-09-19 - 1.4
86224 Augsburg
Phone +49 821 322-0
Fax +49 821 322-3382
www.man-es.com
Copyright © 2019 MAN Energy Solutions

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
EN
Table of contents
Table of contents
1 Introduction ............................................................................................................................................ 9
1.1 Medium-speed marine GenSets ................................................................................................. 9
1.2 Engine description MAN L32/40 GenSet IMO Tier II ................................................................... 9
2 Engine and operation ........................................................................................................................... 13

2.1 Approved applications and destination/suitability of the engine ........................................... 13
2.2 Engine design ............................................................................................................................ 15
2.2.1 Engine cross section .............................................................................................. 15
2.2.2 Engine designations – Design parameters .............................................................. 16
2.2.3 Turbocharger assignments ..................................................................................... 16
2.2.4 Engine main dimensions, weights and views .......................................................... 17
2.2.5 Engine inclination ................................................................................................... 18
2.2.6 Engine equipment for various applications ............................................................. 19
2.3 Ratings (output) and speeds .................................................................................................... 21
2.3.1 General remark ...................................................................................................... 21
2.3.2 Standard engine ratings ......................................................................................... 21
2.3.3 Engine ratings (output) for different applications ..................................................... 23
2.3.4 Derating, definition of P Operating .......................................................................... 24
2.3.5 Engine speeds and related main data .................................................................... 24
2.3.6 Speed adjusting range ........................................................................................... 25
2.4 Increased exhaust gas pressure due to exhaust gas after treatment installations ............... 25
2.5 Starting ...................................................................................................................................... 27
2.5.1 General remarks .................................................................................................... 27
2.5.2 Type of engine start ............................................................................................... 27
2.5.3 Requirements on engine and plant installation ........................................................ 28
2.5.4 Starting conditions ................................................................................................. 29
2.6 Low-load operation ................................................................................................................... 30
2.7 Start-up and load application ................................................................................................... 33
2.7.1 General remarks .................................................................................................... 33
2.7.2 Start-up time .......................................................................................................... 33
2.7.3 Load application – Cold engine (emergency case) .................................................. 36
2.7.4 Load application for electric propulsion/auxiliary GenSet ........................................ 37
2.7.5 Load application – Load steps (for electric propulsion/auxiliary GenSet) ................. 38
2.8 Engine load reduction ............................................................................................................... 40
2.9 Engine load reduction as a protective safety measure ........................................................... 41
2.10 Engine operation under arctic conditions ................................................................................ 42
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2.11 GenSet operation ....................................................................................................................... 46

2.11.1 Operating range for GenSet/electric propulsion ...................................................... 46
2.11.2 Available outputs and permissible frequency deviations ......................................... 47
2.11.3 Generator operation/electric propulsion – Power management .............................. 48
2.11.4 Alternator – Reverse power protection ................................................................... 49
3 (284)
2.11.5 Earthing measures of diesel engines and bearing insulation on alternators ............. 50
Table of contents
2.12 Fuel oil, lube oil, starting air and control air consumption ..................................................... 53
2.12.1 Fuel oil consumption for emission standard: IMO Tier II .......................................... 53
2.12.2 Lube oil consumption ............................................................................................. 54
2.12.3 Starting air and control air consumption ................................................................. 55
2.12.4 Recalculation of fuel consumption dependent on ambient conditions ..................... 55
2.12.5 Influence of engine aging on fuel consumption ....................................................... 56
2.13 Planning data for emission standard IMO Tier II – Auxiliary GenSet ...................................... 57
2.13.1 Nominal values for cooler specification – MAN L32/40 IMO Tier II – Auxiliary GenSet
................................................................................................................................ 57
2.13.2 Temperature basis, nominal air and exhaust gas data – MAN L32/40 IMO Tier II –
Auxiliary GenSet ..................................................................................................... 58
2.13.3 Load specific values at ISO conditions – MAN L32/40 IMO Tier II – Auxiliary GenSet
................................................................................................................................ 59
2.13.4 Load specific values at tropical conditions – MAN L32/40 IMO Tier II – Auxiliary
GenSet .................................................................................................................. 60
2.14 Operating/service temperatures and pressures ...................................................................... 62
2.15 Leakage rate ............................................................................................................................. 66
2.16 Filling volumes .......................................................................................................................... 66
2.17 Internal media systems – Exemplary ....................................................................................... 68
2.18 Venting amount of crankcase and turbocharger ..................................................................... 72
2.19 Exhaust gas emission ............................................................................................................... 73
2.19.1 Maximum permissible NOx emission limit value IMO Tier II ..................................... 73
2.19.2 Smoke emission index (FSN) .................................................................................. 73
2.19.3 Exhaust gas components of medium-speed four-stroke diesel engines ................. 73
2.20 Noise .......................................................................................................................................... 75
2.20.1 Airborne noise ........................................................................................................ 75
2.20.2 Intake noise ........................................................................................................... 76
2.20.3 Exhaust gas noise .................................................................................................. 77
2.20.4 Blow-off noise example .......................................................................................... 78
2.20.5 Noise and vibration – Impact on foundation ........................................................... 79
2.21 Moments of inertia – Engine, damper, flywheel ...................................................................... 82
2.22 Arrangement of attached pumps ............................................................................................. 82
2.23 Foundation ................................................................................................................................ 83
2.23.1 Resilient mounting of GenSets ............................................................................... 83
2.23.2 General requirements for engine foundation ........................................................... 85
3 Engine automation ............................................................................................................................... 87

3.1 SaCoSone GENSET system overview ........................................................................................ 87
3.2 Power supply and distribution ................................................................................................. 90
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3.3 Operation ................................................................................................................................... 91

3.4 Functionality .............................................................................................................................. 91
3.5 Interfaces .................................................................................................................................. 93
3.6 Technical data ........................................................................................................................... 99
3.7 Installation requirements ......................................................................................................... 99
4 (284)
Table of contents
4 Specification for engine supplies ...................................................................................................... 101
4.1 Explanatory notes for operating supplies – Diesel engines .................................................. 101
4.1.1 Lube oil ................................................................................................................ 101
4.1.2 Fuel ...................................................................................................................... 101
4.1.3 Nozzle cooling ..................................................................................................... 103
4.1.4 Intake air .............................................................................................................. 103
4.2 Specification of lubricating oil (SAE 40) for operation with MGO/MDO and biofuels ........... 103
4.3 Specification of lubricating oil (SAE 40) for heavy fuel operation (HFO) .............................. 107
4.4 Specification of gas oil/diesel oil (MGO) ................................................................................ 112
4.5 Specification of diesel oil (MDO) ............................................................................................ 114
4.6 Specification of heavy fuel oil (HFO) ...................................................................................... 116
4.6.1 ISO 8217:2017 Specification of HFO ................................................................... 127
4.7 Viscosity-temperature diagram (VT diagram) ....................................................................... 129
4.8 Specification of engine cooling water .................................................................................... 131
4.9 Cooling water inspecting ........................................................................................................ 137
4.10 Cooling water system cleaning .............................................................................................. 138
4.11 Specification of intake air (combustion air) .......................................................................... 141
4.12 Specification of compressed air ............................................................................................. 142
5 Engine supply systems ...................................................................................................................... 145

5.1 Basic principles for pipe selection ......................................................................................... 145
5.1.1 Engine pipe connections and dimensions ............................................................ 145
5.1.2 Specification of materials for piping ...................................................................... 145
5.1.3 Installation of flexible pipe connections ................................................................. 146
5.1.4 Condensate amount in charge air pipes and air vessels ....................................... 151
5.2 Lube oil system ....................................................................................................................... 153
5.2.1 Lube oil system description .................................................................................. 153
5.2.2 Prelubrication/postlubrication ............................................................................... 164
5.2.3 Crankcase vent and tank vent .............................................................................. 165
5.3 Water systems ......................................................................................................................... 166
5.3.1 General ................................................................................................................ 166
5.3.2 GenSet design and components – Water systems ............................................... 167
5.3.3 Cooling water system diagrams ........................................................................... 170
5.3.4 Cooling water system description ........................................................................ 176
5.3.5 Cooling water collecting and supply system ......................................................... 183
5.3.6 Turbine washing ................................................................................................... 183
5.3.7 Cleaning of charge air cooler (ultrasonic) .............................................................. 185
5.3.8 Nozzle cooling system ......................................................................................... 186
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5.3.9 Nozzle cooling water module ............................................................................... 188

5.4 Fuel oil system ........................................................................................................................ 190
5.4.1 General ................................................................................................................ 190
5.4.2 Marine diesel oil (MDO) treatment system ............................................................. 191
5.4.3 Heavy fuel oil (HFO) treatment system .................................................................. 195
5.4.4 GenSet design and components – Fuel oil system ............................................... 201
5 (284)
5.4.5 Fuel oil supply system .......................................................................................... 203

Table of contents
5.4.6 Fuel oil supply at blackout conditions ................................................................... 214

5.4.7 Emergency MDO supply system .......................................................................... 215
5.4.8 Fuel oil leakage system ........................................................................................ 216
5.4.9 Fuel changeover .................................................................................................. 219
5.5 Compressed air system .......................................................................................................... 220
5.5.1 General ................................................................................................................ 220
5.5.2 Starting air system ............................................................................................... 222
5.5.3 Starting air receivers, compressors ...................................................................... 223
5.5.4 Jet assist ............................................................................................................. 225
5.5.5 Slow turn ............................................................................................................. 225
5.6 Engine room ventilation and combustion air ......................................................................... 225
5.6.1 General information .............................................................................................. 225
5.6.2 External intake air supply system .......................................................................... 227
5.7 Exhaust gas system ................................................................................................................ 230
5.7.1 General ................................................................................................................ 230
5.7.2 Components and assemblies of the exhaust gas system ..................................... 231
6 Engine room planning ........................................................................................................................ 233

6.1 Installation and arrangement ................................................................................................. 233
6.1.1 General details ..................................................................................................... 233
6.1.2 Installation drawings ............................................................................................. 234
6.1.3 Removal dimensions of piston and cylinder liner ................................................... 237
6.1.4 Removal dimensions of intercooler, lube oil cooler, main filter and turbocharger ... 240
6.1.5 3D Engine Viewer – A support programme to configure the engine room ............. 240
6.1.6 Lifting device ........................................................................................................ 241
6.1.7 Space requirement for maintenance ..................................................................... 245
6.1.8 Space requirement for removal of components .................................................... 246
6.1.9 Major spare parts ................................................................................................. 248
6.2 Exhaust gas ducting ............................................................................................................... 252
6.2.1 Example: Ducting arrangement ............................................................................ 252
6.2.2 Position of the outlet casing of the turbocharger .................................................. 253
7 Annex .................................................................................................................................................. 257

7.1 Safety instructions and necessary safety measures ............................................................. 257
7.1.1 General ................................................................................................................ 257
7.1.2 Safety equipment and measures provided by plant-side ...................................... 257
7.2 Programme for Factory Acceptance Test (FAT) ..................................................................... 261
7.3 Engine running-in ................................................................................................................... 264
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7.4 Definitions ............................................................................................................................... 266

7.5 Abbreviations .......................................................................................................................... 271
7.6 Symbols ................................................................................................................................... 272
7.7 Preservation, packaging, storage .......................................................................................... 276
7.7.1 General ................................................................................................................ 276
7.7.2 Storage location and duration .............................................................................. 277
6 (284)
7.7.3 Follow-up preservation when preservation period is exceeded ............................. 278
Table of contents
7.7.4 Removal of corrosion protection .......................................................................... 278
7.8 Engine colour .......................................................................................................................... 278
Index ................................................................................................................................................... 279

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7 (284)
MAN Energy Solutions 1
1 Introduction
1.2 Engine description MAN L32/40 GenSet IMO Tier II

1.1 Medium-speed marine GenSets
Figure 1: MAN Energy Solutions engine programme
GenSets
Applications for GenSets vary from auxiliary GenSets, GenSets for diesel-
electric propulsion up to offshore applications.
Project specific demands to be clarified at early project stage.
General
1 Introduction
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The “Work Horse” MAN L32/40 is in service 24 hours a day. As a pure auxili-
ary GenSet engine it is available with an output range between 3,000 kW mech
and 4,500 kW mech. The interacting of all important parts results to low wear
rates and long maintenance intervals.
MAN L32/40 GenSet IMO Tier II, Project Guide – Marine, EN 9 (284)
1 MAN Energy Solutions
Auxiliary GenSet concept

The diesel engine and the alternator are placed on a common rigid base
frame mounted on the ship's/erection hall's foundation by means of resilient
supports, type conical. Each engine is equipped with an engine driven HT
cooling water pump, an engine driven lube oil pump and an prelubrication
pump (electrical). The installed, individual HT thermostatic valve (wax type)
regulates the HT cooling water temperature leaving the engine. Lube oil
cooler and oi filter are part of the GenSet front end.
Figure 2: Auxiliary GenSet – Principle schema
Fuels
The MAN L32/40 GenSet engine was designed for operation with MGO
(DMA, DMZ), MDO (DMB) and with HFO up to a viscosity of 700 mm2/s (cSt)
at 50 °C. It is designed for fuels up to and including the specification CIMAC
2003 H/K700/DIN ISO 8217 and fuel temperatures up to 150 °C.
Stepped piston
Forged dimensionally stable steel crown (with shaker cooling) made from
high grade materials and skirt in spheroidal graphite cast iron (skirt also avail-
able in steel upon request). The stepped piston and the fire ring together pre-
1 Introduction
vent “bore polishing” of the cylinder liner, thereby reducing operating costs
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by keeping lubricating oil consumption consistently low. Chromium ceramic

coating of the first piston ring with wear resistant ceramic particles in the ring
surface results in minimal wear and tear, ensuring extremely long periods
between maintenance.
10 (284) MAN L32/40 GenSet IMO Tier II, Project Guide – Marine, EN
MAN Energy Solutions turbocharging system

Industry leading designed constant pressure turbocharging system using
state-of-the-art MAN Energy Solutions turbochargers with long bearing over-
haul intervals. High efficiency at full and part loads results in substantial air
surplus and complete combustion without residues and with low thermal
stresses on the combustion chamber components.
Cylinder head
The cylinder head has optimised combustion chamber geometry for
improved injection spray atomisation. This ensures balanced air-fuel mixture,
reducing combustion residue, soot formation and improving fuel economy.
Valves
Exhaust valves are designed with armoured, water cooled seats that keep
valve temperatures down. Propellers on the exhaust valve shaft provide rota-
tion by exhaust gas, resulting in the cleaning effect of the valve seat area dur-
ing valve closing.
Service friendly design

▪ Hydraulic tooling for tightening and loosening cylinder head nuts
▪ Clamps with quick release fasteners and/or clamp and plug connectors
▪ Generously sized access covers
Cylinder liner
The precision machined cylinder liner and separate cooling water collar rest
on top of the engine frame and is there isolated from any external deforma-
tion, ensuring optimum piston performance and long service life.
Electronics – SaCoSone
The MAN L32/40 GenSet is equipped with the Classification Society compli-
ant safety and control system SaCoSone. SaCoSone combines all functions
of modern engine management into one complete system. Thoroughly inte-
grated with the engine, it forms one unit with the drive assembly.
SaCoSone offers:
▪ Integrated self-diagnosis functions
▪ Maximum reliability and availability
▪ Simple use and diagnosis
▪ Quick exchange of modules (plug in)
▪ Trouble-free and time-saving commissioning
▪ Crankcase Monitoring System plus Oil Mist Detection
As a standard for all our four-stroke medium-speed engines manufac-
tured in Augsburg, these engines will be equipped with a Crankcase
1 Introduction
Monitoring System (CCM = Splash oil & Main bearing temperature) plus
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OMD (Oil Mist Detection). OMD and CCM are integral part of the MAN
Energy Solutions´ safety philosophy and the combination of both will
increase the possibility to early detect a possible engine failure and pre-
vent subsequent component damage.
Device for variable injection timing (VIT)

The VIT is designed to influence injection timing and thus ignition pressure
and combustion temperature. That enables engine operation in different load
ranges well balanced between low NOx emissions and low fuel consumption.
Sealed Plunger injection pumps (SP injection pumps)

The MAN L32/40 GenSet conventional injection system is equipped with
Sealed Plunger injection pumps. SP injection pumps have been designed for
an operation with all specified fuels.
Benefit:
+ The fuel and the lube oil within the injection pumps are completely separa-
ted and cannot get in contact with each other, so that the leakage fuel of the
SP injection pumps can be completely reused again.
+ For the same reason, there is no need for sealing oil anymore in the case of
continuous MGO operation.
Note:
For reusing the operation leakage the fuel oil system must be changed. To
specify the needed adaptions please contact MAN Energy Solutions for
assistance.
Core technologies in-house

As well as its expertise in engine design, development and manufacture,
MAN Energy Solutions is also a leader in the engineering and manufacturing
of the key technologies which determine the economic and ecological per-
formance of a diesel engine and constitute the best offer for our customers:
▪ High-efficiency turbochargers
▪ Advanced-electronic fuel injection equipment
▪ Electronic hardware and software for engine control, monitoring and
diagnosis
▪ High-performance exhaust gas after treatment systems
Our impressive array of computer aided design tools and one of the engine
industry’s largest, best-equipped foundries allow us to decisively shorten
product development and application engineering processes. Our mastery of
these engine technologies is the firm foundation for:
▪ Low emissions
▪ Low-operating costs
▪ Low-life cycle costs
▪ Long-service life
Committed to the future

Technologies which promise compliance with the IMO Tier III emission limits
valid from 2016 combined with further optimised fuel consumption and new
1 Introduction
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levels of power and flexibility are already under development at MAN Energy
Solutions. With this level of commitment MAN Energy Solutions` customers
can plan with confidence.
2 Engine and operation
2.1 Approved applications and destination/suitability of

the engine
2.1 Approved applications and destination/suitability of the engine
Approved applications
The MAN L32/40 GenSet has been approved by type approval as an auxili-
ary engine by all main classification societies (ABS, BV, CCS, ClassNK, CR,
CRS, DNV, GL, KR, LR, RINA, RS).
As marine auxiliary engine it may be applied for electric power generation1) for
auxiliary duties for applications as:
▪ Auxiliary GenSet2)
Note:
The engine is not designed for operation in hazardous areas. It has to be
ensured by the ship's own systems, that the atmosphere of the engine room
is monitored and in case of detecting a gas-containing atmosphere the
engine will be stopped immediately.
1)
See section Engine ratings (output) for different applications, Page 23.
2)
Not used for emergency case or fire fighting purposes.
Offshore
For offshore applications it may be applied as auxiliary engine.
Due to the wide range of possible requirements such as flag state regula-
tions, fire fighting items, redundancy, inclinations and dynamic positioning
modes all project requirements need to be clarified at an early stage.
Note:
The engine is not designed for operation in hazardous areas. It has to be
ensured by the ship's own systems, that the atmosphere of the engine room
is monitored and in case of detecting a gas-containing atmosphere the
engine will be stopped immediately.
Destination/suitability of the engine

Note:
Regardless of their technical capabilities, engines of our design and the
respective vessels in which they are installed must at all times be operated in
line with the legal requirements, as applicable, including such requirements
that may apply in the respective geographical areas in which such engines
are actually being operated.
Operation of the engine outside the specified operated range, not in line with
the media specifications or under specific emergency situations (e.g. sup-
pressed load reduction or engine stop by active "Override", triggered fire-
fighting system, crash of the vessel, fire or water ingress inside engine room)
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is declared as not intended use of the engine (for details see engine specific
operating manuals). If an operation of the engine occurs outside of the scope
of supply of the intended use a thorough check of the engine and its compo-
nents needs to be performed by supervision of the MAN Energy Solutions
service department. These events, the checks and measures need to be
documented.
Electric and electronic components attached to the engine –

2.1 Approved applications and destination/suitability of
the engine
Required engine room temperature

In general our engine components meet the high requirements of the Marine
Classification Societies.
The electronic components are suitable for proper operation within an air
temperature range from 0 °C to 55 °C. The electrical equipment is designed
for operation at least up to 45 °C.
Relevant design criteria for the engine room air temperature:
Minimum air temperature in the area of the engine and its components
≥ 5 °C.
Maximum air temperature in the area of the engine and its components
≤ 45 °C.
Note:
Condensation of the air at engine components must be prevented.
Note:
It can be assumed that the air temperature in the area of the engine and
attached components will be 5 – 10 K above the ambient air temperature
outside the engine room. If the temperature range is not observed, this can
affect or reduce the lifetime of electrical/electronic components at the engine
or the functional capability of engine components. Air temperatures at the
engine > 55 °C are not permissible.
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2.2 Engine design

2.2 Engine design
2.2.1 Engine cross section

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Figure 3: Cross section – Engine MAN L32/40 GenSet; view on counter coupling side
2.2 Engine design
2.2.2 Engine designations – Design parameters
Figure 4: Example to declare engine designations
Parameter Value Unit

Number of cylinders 6, 7, 8, 9 -
Cylinder bore 320 mm
Piston stroke 400
Displacement per cylinder 32.17 litre
Distance between cylinder centres 530 mm
Crankshaft diameter at journal, 290

in-line engine
Crankshaft diameter at crank pin 290

Table 1: Design parameters
2.2.3 Turbocharger assignments
No. of cylinders, config. GenSet

500 kW/cyl.,
720/750 rpm
6L NR29/S
7L NR29/S
8L NR34/S
9L NR34/S
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Table 2: Turbocharger assignments
Turbocharger assignments mentioned above are for guidance only and may
vary due to project-specific reasons. Consider the relevant turbocharger
Project Guides for additional information.
2.2 Engine design

2.2.4 Engine main dimensions, weights and views
Engine MAN L32/40 GenSet
Figure 5: Main dimensions – L engine
No. of cylinders, Lenght C1) Lenght A Lenght B1) Height H Weight1)

config.
mm t
6L 9,660 5,937 3,723 4,623 75.0
7L 10,190 6,467 79.0
8L 11,398 6,997 4,401 4,840 87.0
9L 12,165 7,527 91.0

1)
Depending on alternator applied.
Dimensions and weight specifications apply to GenSet and are for guidance only (weight given without media filling of
engine).
Minimum centreline distance for multi-engine installation, see section Installa-

tion drawings, Page 234.
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2.2 Engine design
2.2.5 Engine inclination
Figure 6: Angle of inclination
α Athwartships β Fore and aft
Max. permissible angle of inclination [°]1)

Application Athwartships α Fore and aft β
Heel to each side Rolling to each side Trim (static)2) Pitching
(static) (dynamic) (dynamic)
L < 100 m L > 100 m
Main engines 15 22.5 5 500/L 7.5
1)
Athwartships and fore and aft inclinations may occur simultaneously.
2)
Depending on length L of the ship.
Table 3: Inclinations
Note:
For higher requirements contact MAN Energy Solutions. Arrange engines
always lengthwise of the ship.
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2.2 Engine design

2.2.6 Engine equipment for various applications
Device/measure, (figure pos.) Ship, auxiliary engines

Charge air blow-off for cylinder pressure limitation (flap 2) Order related, required if intake
air ≤ 5 °C
Shut-off flap (flap 8) O
Turbocharger – Compressor cleaning device (wet) X1)
Turbocharger – Turbine cleaning device (dry) X
Turbocharger – Turbine cleaning device (wet) X
Two-stage charge air cooler X
Jet assist X
VIT X
Oil mist detector X
Splash oil monitoring X
Main bearing temperature monitoring X
Valve seat lubrication O
Cylinder lubrication X
Attached HT cooling water pump X
Attached lube oil pump X
X = required, O = optional
1)
Not required, if compressor is equipped with insertion casing and pipe and air is led through oilbath air cleaner
(instead of silencer).
Table 4: Engine equipment
Engine equipment for various applications – General description

Charge air blow-off for If engines are operated at full load at low air intake temperature, the high air
cylinder pressure limitation density leads to the danger of excessive charge air pressure and, conse-
(see flap 2 in figure quently, to excessive cylinder pressure. In order to avoid such conditions,
Overview flaps, Page part of the charge air is withdrawn downstream (flap 2, cold blow-off) of the
20) charge air cooler and blown off.
Shut-off flap (see flap 8 in The shut-off flap needs to be applied for engines where there is a risk of
figure Overview flaps, inflammable intake air. If the intake air contains combustible gases the engine
Page 20) cannot be stopped in normal way. In this exceptional situation the shut-off
flap will be closed to shut off the intake air and to stop the engine reliably. A
relief valve upstream of this flap may be applied for release of the com-
pressed air.
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2.2 Engine design
Figure 7: Overview flaps
Turbocharger – Compressor Depending on the quality of the intake air, deposits may be formed on the
cleaning device (wet) blades of the compressor wheel and diffuser. This contamination reduces the
efficiency of the compressor. Cleaning of the compressor is carried out with
water during operation at full load with a special compressor cleaning device.
Turbocharger – Turbine The turbochargers of engines operated with heavy fuel oil (HFO), marine die-
cleaning device (dry) sel oil (MDO) or marine gas oil (MGO) must be cleaned prior to initial opera-
tion and at regular intervals to remove combustion residue from the blades of
the turbine rotor and nozzle ring. Dry cleaning of the turbine should also be
applied, in case of operation with inferior gas quality. Dry cleaning of the tur-
bine is particularly suitable for cleaning the turbine rotor (turbine blades).
Herefore a special cleaning device to be used.
Turbocharger – Turbine The turbochargers of engines operated with heavy fuel oil (HFO), marine die-
cleaning device (wet) sel oil (MDO) or marine gas oil (MGO) must be cleaned prior to initial opera-
tion and at regular intervals to remove combustion residue from the blades of
the turbine rotor and nozzle ring. Wet cleaning of the turbine is particularly
suitable for cleaning the nozzle ring. Wet cleaning is carried out during opera-
tion at greatly reduced engine load in order to avoid overstressing the turbine
materials (thermal shock). Herefore a special cleaning device to be used.
Two-stage charge air cooler The two-stage charge air cooler consists of two stages which differ in the
temperature level of the connected water circuits. The charge air is first
cooled by the HT circuit (high temperature stage of the charge air cooler,
engine) and then further cooled down by the LT circuit (low temperature
stage of the charge air cooler, lube oil cooler).
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Jet assist Jet assist is used where special demands exist regarding fast acceleration
and/or load application.
In such cases, compressed air within a specified pressure range is passed
into the compressor casing of the turbocharger to be admitted to the com-
pressor wheel via inclined bored passages.
In this way, the compressor wheel and thereby also the turbine wheel is
2.3 Ratings (output) and speeds

additionally accelerated to adapt after a load application even faster to the
new operating point with accordingly positive effect on the engine perform-
ance.
Operation of the jet assist function is initiated by a control, and limited to a
fixed load range.
VIT For some engine types with conventional injection a VIT (Variable Injection
Timing) is available allowing a shifting of injection start. A shifting in the direc-
tion of “advanced injection” is supposed to increase the ignition pressure and
thus reduces fuel consumption. Shifting in the direction of “retarded injection”
helps to reduce NOx emissions.
Oil mist detector Bearing damage, piston seizure and blow-by in combustion chamber leads
to increased oil mist formation. As a part of the safety system the oil mist
detector monitors the oil mist concentration in crankcase to indicate these
failures at an early stage.
Splash oil monitoring The splash oil monitoring system is a constituent part of the safety system.
Sensors are used to monitor the temperature of each individual drive unit (or
pair of drive at V engines) indirectly via splash oil.
Main bearing temperature As an important part of the safety system the temperatures of the crankshaft
monitoring main bearings are measured just underneath the bearing shells in the bearing
caps. This is carried out using oil-tight resistance temperature sensors.
Valve seat lubrication For long-term engine operation (more than 72 hours within a two-week
period [cumulative with distribution as required]) with DM-grade fuel a valve
seat lubrication equipment needs to be attached to the engine. By this
equipment, oil is fed dropwise into the inlet channels and thereby lubricates
the inlet valve seats. This generates a damping effect between the sealing
surfaces of the inlet valves (HFO-operation leads to layers on the sealing sur-
faces of the inlet valves with a sufficient damping effect).
Cylinder lubrication Additionally to the lubrication by splash oil and oil mist the running surfaces
of cylinder liner, piston and piston rings are supplied with oil by a cylinder
lube oil pump.
2.3.1 General remark

The engine power which is stated on the type plate derives from the follow-
ing sections and corresponds to POperating as described in section Derating,
definition of P Operating, Page 24.
2.3.2 Standard engine ratings

500 kW/cyl., 720/750 rpm
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No. of cylinders, config. Engine rating PISO, standard1) 2)

720 rpm 750 rpm
kWmech. kWmech.
6L 3,000 3,000
7L 3,500 3,500
No. of cylinders, config. Engine rating PISO, standard1) 2)

720 rpm 750 rpm

kWmech. kWmech.
8L 4,000 4,000
9L 4,500 4,500
Note:
Power take-off on engine free end up to 100 % of rated output.
1)
PISO, standard as specified in DIN ISO 3046-1, see paragraph Reference conditions for engine rating, Page 22.
2)
Engine fuel: Distillate according to ISO 8217 DMA/DMB/DMZ-grade fuel or RM-grade fuel, fulfilling the stated qual-
ity requirements.
Table 5: Engine ratings
Reference conditions for engine rating

According to ISO 15550: 2002; ISO 3046-1: 2002
Air temperature before turbocharger tr K/°C 298/25
Total atmospheric pressure pr kPa 100
Relative humidity Φr % 30
Cooling water temperature inlet charge air cooler (LT stage) K/°C 298/25
Table 6: Reference conditions for engine rating
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2.3.3 Engine ratings (output) for different applications
PApplication, ISO: Available output under ISO conditions dependent on application

PApplication PApplication Max. fuel Max. permis- Tropic condi- Notes Optional
Available Available admission sible speed tions power take-
output in output (blocking) reduction at (tr/tcr/ off in per-
percentage maximum pr=100 centage of
from ISO torque1) kPa)2) ISO standard
standard output
output
Kind of application % kW/cyl. % % °C %
Electricity generation
Auxiliary engines in 100 500 110 - 45/38 3)

-
ships
1)
Maximum torque given by available output and nominal speed.
2)
tr = Air temperature at compressor inlet of turbocharger.
tcr = Cooling water temperature before charge air cooler.
pr = Atmospheric pressure.
3)
In accordance with DIN ISO 3046-1 and for further clarification of relevant sections within DIN ISO 8528-1, the
following is specified:
- The maximum output (MCR) has to be observed by the power management system of the plant.
- The range of 100 % up to 110 % fuel admission may only be used for a short time for governing purposes (e.g.
transient load conditions and suddenly applied load).
Table 7: Available outputs/related reference conditions MAN L32/40 GenSet
Note:
Power fluctuations in the electrical grid.
It is an intrinsic property of the powertrain of a generating set that it acts as a
torsional vibration system. This complex system consists of the engine, cou-
pling and generator (within or outside MAN Energy Solutions scope of sup-
ply) and the electric plant. Such electric power plant can be consisting of fur-
ther power sources as well as consumers (such as electric motors), trans-
formers, frequency converters, energy storage systems, bus bars or circuit
breakers and the entire distribution system (within or outside MAN Energy
Solutions scope of supply). The reciprocating engine, as well as the electric
power distribution or the other consumers and power sources excite the sys-
tem. As a consequence, the active power at the generator terminals is not
completely constant over time and some additional power oscillations so-
called power fluctuations occur. These power fluctuations do not affect the
operational safety of the generating set, as long as the stability requirements
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of the electric system in regards to frequency and voltage meet the class
requirements. In addition, this behavior is in accordance with ISO 8528-5 1)
and does as per MAN Energy Solutions experience not affect power system
stability in an unacceptable range. Gas operated engines tend to show
greater power fluctuations than engines operated with liquid fuels. This
belongs to the typical cyclical fluctuations of the Otto combustion process
that uses a premixed combustion. Please note that MAN Energy Solutions
quotations do not consider any specific limitations regarding power fluctua-

tions. On request by the purchaser, MAN Energy Solutions provides support

or further analysis of the overall system behavior, where the GenSets as well
as the electric distribution and consumers should be included in the analysis.
1)
Reciprocating internal combustion engine driven alternating current gener-
ating sets - Part 5: Generating sets.
2.3.4 Derating, definition of P Operating
POperating: Available rating (output) under local conditions and dependent on

application
Dependent on local conditions or special application demands a further load

reduction of PApplication, ISO might be required.
1. No derating
No derating necessary, provided that the conditions listed are met:
No derating up to stated reference

conditions (tropic), see 1.
Air temperature before turbocharger Tx ≤ 318 K (45 °C)
Ambient pressure ≥ 100 kPa (1 bar)
Cooling water temperature inlet charge air cooler (LT stage) ≤ 311 K (38 °C)
Intake air pressure before compressor ≥ –2 kPa1)
Exhaust gas back pressure after turbocharger ≤ 5 kPa1)
Relative humidity Φr ≤ 60 %
1)
Below/above atmospheric pressure.
Table 8: Derating – Limits of ambient conditions
2. Derating
Contact MAN Energy Solutions:
▪ If limits of ambient conditions mentioned in the upper table Derating –
Limits of ambient conditions, Page 24 are exceeded. A special calcula-
tion is necessary.
▪ If higher requirements for the emission level exist. For the permissible
requirements see section Exhaust gas emission, Page 73.

▪ If special requirements of the plant for heat recovery exist.
▪ If special requirements on media temperatures of the engine exist.
▪ If any requirements of MAN Energy Solutions mentioned in the Project
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Guide cannot be met.
2.3.5 Engine speeds and related main data
Rated speed rpm 720 750
Permissible range of speed 1)
Alarm overspeed (110 % of nominal speed) 792 825
2.4 Increased exhaust gas pressure due to exhaust gas

after treatment installations
Auto shutdown overspeed (115 % of nominal speed) 828 863
Speed adjusting range See section Speed adjusting range, Page 25
Alternator frequency Hz 60 50
Number of pole pairs - 5 4
According to section Operating range for GenSet/electric propulsion, Page 46 and figure Permissible frequency
1)
deviations and corresponding max. output, Page 48.

Table 9: Engine speeds and related main data
2.3.6 Speed adjusting range

The following specification represents the standard settings. For special
applications, deviating settings may be necessary.
Drive Speed droop Maximum speed at Maximum speed at Minimum speed
full load idle running
Electronic speed GenSets/electric propulsion plants
control
With load sharing 5% 100 % (+0.5 %) 105 % (+0.5 %) 60 %
via speed droop
or
Isochronous 0% 100 % (+0.5 %) 100 % (+0.5 %) 60 %

operation
Table 10: Electronic speed control
2.4 Increased exhaust gas pressure due to exhaust gas after treatment
installations
Resulting installation demands
If the recommended exhaust gas back pressure as stated in section Operat-

ing/service temperatures and pressures, Page 62 cannot be met due to
exhaust gas after treatment installations following limit values need to be
considered.
Exhaust gas back pressure after turbocharger
Operating pressure Δpexh, maximum specified 0 – 50 mbar
Operating pressure Δpexh, range with increase of fuel consumption or possible derating 50 – 80 mbar
Operating pressure Δpexh, where a customised engine matching is required > > 80 mbar
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Table 11: Exhaust gas back pressure after turbocharger
Intake air pressure before turbocharger

2.4 Increased exhaust gas pressure due to exhaust gas
after treatment installations
Operating pressure Δpintake, standard 0 – –20 mbar
Operating pressure Δpintake, range with increase of fuel consumption or possible derating –20 – –40 mbar
Operating pressure Δpintake, where a customised engine matching is required < –40 mbar
Table 12: Intake air pressure before turbocharger
Sum of the exhaust gas back pressure after turbocharger and the absolute value of the intake air pressure before
turbocharger
Operating pressure Δpexh + Abs(Δpintake), standard 0 – 70 mbar
Operating pressure Δpexh + Abs(Δpintake), range with increase of fuel consumption or possible 70 – 120 mbar
derating
Operating pressure Δpexh + Abs(Δpintake), where a customised engine matching is required > > 120 mbar
Table 13: Sum of the exhaust gas back pressure after turbocharger and the absolute value of the intake air
pressure before turbocharger
Maximum exhaust gas pressure drop – Layout

▪ Supplier of equipment in exhaust gas line have to ensure that pressure
drop Δpexh over entire exhaust gas piping incl. pipe work, scrubber,
boiler, silencer, etc. must stay below stated standard operating pressure
at all operating conditions.
▪ It is recommended to consider an additional 10 mbar for consideration of
aging and possible fouling/staining of the components over lifetime.
▪ A proper dimensioning of the entire flow path including all installed com-
ponents is advised or even the installation of an exhaust gas blower if
necessary.
▪ At the same time the pressure drop Δpintake in the intake air path must be
kept below stated standard operating pressure at all operating conditions
and including aging over lifetime.
▪ For significant overruns in pressure losses even a reduction in the rated
power output may become necessary.
▪ On plant side it must be prepared, that pressure sensors directly after
turbine outlet and directly before compressor inlet may be installed to
verify above stated figures.
By-pass for emergency operation
▪ Evaluate if the chosen exhaust gas after treatment installation demands a
by-pass for emergency operation.
▪ For scrubber application, a by-pass is recommended to ensure emer-
gency operation in case that the exhaust gas cannot flow through the
scrubber freely.
▪ The by-pass needs to be dimensioned for the same pressure drop as the
main installation that is by-passed – otherwise the engine would oper-
ated on a differing operating point with negative influence on the per-
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formance, e.g. a lower value of the pressure drop may result in too high
turbocharger speeds.
Single streaming per engine recommended/multi-streaming to be evaluated
project-specific
▪ In general each engine must be equipped with a separate exhaust gas
line as single streaming installation. This will prevent reciprocal influencing
of the engine as e.g. exhaust gas backflow into an engine out of opera-
tion or within an engine running at very low load (negative pressure drop
over the cylinder can cause exhaust gas back flow into intake manifold
2.5 Starting
during valve overlap).
▪ In case a multi-streaming solution is realised (i.e. only one combined
scrubber for multiple engines) this needs to be stated on early project
stage. Hereby air/exhaust gas tight flaps need to be provided to safe-
guard engines out of operation. A specific layout of e.g. sealing air mass
flow will be necessary and also a power management may become nec-
essary in order to prevent operation of several engines at very high loads
while others are running on extremely low load. A detailed analysis as
HAZOP study and risk analysis by the yard becomes mandatory.
Engine to be protected from backflow of media out of exhaust gas after
treatment installation
▪ A backflow of e.g. urea, scrubbing water, condensate or even rain from
the exhaust gas after treatment installation towards the engine must be
prevented under all operating conditions and circumstances, including
engine or equipment shutdown and maintenance/repair work.
Turbine cleaning
▪ Both wet and dry turbine cleaning must be possible without causing mal-
functions or performance deterioration of the exhaust system incl. any
installed components such as boiler, scrubber, silencer, etc.
White exhaust plume by water condensation
▪ When a wet scrubber is in operation, a visible exhaust plume has to be
expected under certain conditions. This is not harmful for the environ-
ment. However, countermeasures like reheating and/or a demister
should be considered to prevent condensed water droplets from leaving
the funnel, which would increase visibility of the plume.
▪ The design of the exhaust system including exhaust gas after treatment
installation has to make sure that the exhaust flow has sufficient velocity
in order not to sink down directly onboard the vessel or near to the plant.
At the same time the exhaust pressure drop must not exceed the limit
value.
Vibrations
▪ There must be a sufficient decoupling of vibrations between engine and
exhaust gas system incl. exhaust gas after treatment installation, e.g. by
compensators.
2.5 Starting
2.5.1 General remarks

Engine and plant installation need to be in accordance to the below stated

requirements and the required starting procedure.
Note:
Statements are relevant for non arctic conditions.
For arctic conditions consider relevant sections and clarify undefined details
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with MAN Energy Solutions.
2.5.2 Type of engine start
Normal start
The standard procedure of a monitored engine start in accordance to MAN
Energy Solutions guidelines.
Stand-by start
2.5 Starting
Shortened starting up procedure of a monitored engine start: Several pre-

conditions and additional plant installations required.
This kind of engine start has to be triggered by an external signal: "Stand-by
start required”.
Exceptional start (e.g. blackout start)

A monitored engine start (without monitoring of lube oil pressure) within one
hour after stop of an engine that has been faultless in operation or of an
engine in stand-by mode.
This kind of engine start has to be triggered by an external signal “Black
Start” and may only be used in exceptional cases.
Emergency start
Manual start of the engine at emergency start valve at the engine (if applied),
without supervision by the SaCoS engine control. These engine starts will be
applied only in emergency cases, in which the customer accepts, that the
engine might be harmed.
2.5.3 Requirements on engine and plant installation
General requirements on engine and plant installation

As a standard and for the start-up in normal starting mode (preheated
engine) following installations are required:
Engine ▪ Lube oil service pump (attached).
Plant ▪ Prelubrication pump (free-standing).
▪ Preheating HT cooling water system (60 – 90 °C).
▪ Preheating lube oil system (> 40 °C). For maximum admissible value see
table Lube oil, Page 63.
Requirements on engine and plant installation for "Stand-by Operation"

capability
To enable in addition to the normal starting mode also an engine start from
PMS (power management system) from stand-by mode with thereby short-
ened start-up time following installations are required:
Engine ▪ Lube oil service pump (attached).
Plant ▪ Prelubrication pump (free-standing) with low pressure before engine
(0.3 bar < pOil before engine < 0.6 bar).
▪ Preheating HT cooling water system (60 – 90 °C).

▪ Preheating lube oil system (> 40 °C). For maximum admissible value see
table Lube oil, Page 63.
▪ Power management system with supervision of stand-by times engines.
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Additional requirements on engine and plant installation for "Blackout

start" capability
Following additional installations to the above stated ones are required to
enable in addition a "Blackout start":
Engine ▪ HT CW service pump (attached) recommended.
▪ LT CW service pump (attached) recommended.
2.5 Starting
▪ Attached fuel oil supply pump recommended (if applicable).
Plant ▪ Equipment to ensure fuel oil pressure of > 0.6 bar for engines with con-
ventional injection system and > 3.0 bar for engines with common rail
system.
If fuel oil supply pump is not attached to the engine:
▪ Air driven fuel oil supply pump or fuel oil service tanks at sufficient height
or pressurised fuel oil tank.
2.5.4 Starting conditions
Type of engine start: Blackout start Stand-by start Normal start

Explanation: After blackout From stand-by mode After stand-still
Start-up time until load < 1 minute < 1 minute > 2 minutes
application:
General notes
- Engine start-up only within 1 h Maximum stand-by time 7 days1) Standard

after stop of engine that has Supervised by power
been faultless in operation or management system plant.
within 1 h after end of stand-by
mode. Stand-by mode is only possible
after engine has been faultless in
operation and has been faultless
stopped.
Additional external Blackout start Stand-by request -

signal:
If an engine has been in total for 7 days in stand-by mode, no extension of stand-by mode is allowed. The engine
1)
needs to be started and operated faultless before the next stand-by mode can be applied.
Table 14: Starting conditions – General notes

General engine status No start-blocking active Engine in proper condition Engine in proper
No start-blocking active condition
Note: No start-blocking active
Start-blocking of engine leads to
withdraw of "stand-by mode".
Engine to be turned No No Yes1)

before start?
Engine to be prehea- No2) Yes Yes

ted and prelubricated?
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1)
It is recommended to install Slow Turn. Otherwise the engine has to be turned by turning gear.
2)
Valid only, if mentioned above conditions (see table Starting conditions – General notes, Page 29) have been con-
sidered. Non-observance endangers the engine or its components.
Table 15: Starting conditions – Required engine conditions

2.6 Low-load operation
Lube oil system
Prelubrication period No1) Permanent Yes, previous to engine

start
Prelubrication pres- - See section Operating/service See section Operating/

sure before engine temperatures and pressures, service temperatures
Page 62 limits according figure and pressures, Page
"Prelubrication/postlubrication 62 limits according
lube oil pressure figure "Prelubrication/
(duration > 10 min)" postlubrication lube oil
pressure
(duration ≤ 10 min)"
Lube oil to be No1) Yes Yes

preheated?
HT cooling water
HT cooling water to be No1) Yes Yes

preheated?
Fuel system
For MGO/MDO opera- Sufficient fuel oil pressure at Supply pumps in operation or with starting command to
tion engine inlet needed. engine.
For HFO operation Sufficient fuel oil pressure at Supply and booster pumps in operation, fuel preheated to
engine inlet needed (MGO/ operating viscosity.
MDO-operation recommended). In case of permanent stand-by of liquid fuel engines or
Emergency fuel supply pumps during operation of an DF engine in gas mode a periodical
in MGO/MDO mode always. exchange of the circulating HFO has to be ensured to
avoid cracking of the fuel. This can be done by releasing a
certain amount of circulating HFO into the day tank and
substituting it with "fresh" fuel from the tank.
Valid only, if mentioned above conditions (see table Starting conditions – General notes, Page 29) have been
1)
considered. Non-observance endangers the engine or its components.

Table 16: Starting conditions – Required system conditions
Additional remark regarding "Blackout start"

If additional requirements on engine and plant installation for "Blackout start"
capability are fullfilled, it is possible to start up the engine in shorter time. But
untill all media systems are back in normal operation the engine can only be
operated according to the settings of alarm and safety system.
Definition
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Basically, the following load conditions are distinguished:
Overload: > 100 % (MCR) of the engine output (not admitted, see section
Engine ratings (output) for different applications, Page 23)
Full load (MCR): 100 % (MCR) of the engine output
Part load: < 100 % (MCR) of the engine output

Low load: < 25 % of the engine output
Correlations The best operating conditions for the engine prevail under even loading in the
range of 60 % to 90 % of full load.
During idling or engine operation at a low load, combustion in the combus-
tion chamber is incomplete.
This may result in the forming of deposits in the combustion chamber, which
will lead to increased soot emission and to increasing cylinder contamination.
This process is more acute in low-load operation and during manoeuvring
when the cooling water temperatures are not kept at the required level, and
are decreasing too rapidly. This may result in too low charge air and com-
bustion chamber temperatures, deteriorating the combustion at low loads
especially in heavy fuel operation.
Operation with heavy fuel oil Based on the above, the low-load operation in the range of < 25 % of the full
(fuel of RM quality) or with load is subjected to specific limitations. According to figure Time limitation for
MGO (DMA, DMZ) or low-load operation (left), duration of "relieving operation" (right), Page 31
MDO(DMB) immediately after a phase of low-load operation the engine must be operated
at > 70 % of the full load for some time in order to reduce the deposits in the
cylinders and the exhaust gas turbocharger again.
▪ Provided that the specified engine operating values are observed, there
are no restrictions at loads > 25 % of the full load.
▪ Continuous operation at < 25 % of the full load should be avoided when-
ever possible.
▪ No-load operation, particularly at nominal speed (alternator operation) is
only permissible for one hour maximum.
After 500 hours of continuous operation with liquid fuel, at a low load in the
range of 20 % to 25 % of the full load, the engine must be run-in again.
See section Engine running in, Page 264.

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* Generally, the time limits in heavy fuel oil operation apply to all HFO grades according to the des-
ignated fuel specification. In certain rare cases, when HFO grades with a high ignition delay
together with a high coke residues content are used, it may be necessary to raise the total level
of the limiting curve for HFO from 20 % up to 30 %.
P % of the full load t Operating time in hours (h)
Figure 8: Time limitation for low-load operation (left), duration of "relieving operation" (right)
Example for heavy fuel oil (HFO)

Line a Time limits for low-load operation with heavy fuel oil:
At 10 % of the full load, operation on heavy fuel oil is allowable for 19 hours
maximum.
Line b Duration of "relieving operation":
Let the engine run at a load > 70 % of the full load appr. within 1.2 hours to
burn the deposits formed.
Note:
The acceleration time from the actual load up to 70 % of the full load must
be at least 15 minutes.
Example for MGO/MDO

Line A Time limits for low-load operation with MGO/MDO:
At 17 % of the full load, operation on MGO/MDO is allowable appr. for 200
hours maximum.
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Line B Duration of "relieving operation":

Let the engine run at a load > 70 % of the full load appr. within 18 minutes to
burn the deposits formed.
Note:
The acceleration time from the actual load up to 70 % of the full load must
be at least 15 minutes.
2.7 Start-up and load application

2.7.1 General remarks

In the case of highly-supercharged engines, load application is limited. This is
due to the fact that the charge air pressure build-up is delayed by the turbo-
charger run-up. Besides, a low-load application promotes uniform heating of
the engine.
In general, requirements of the International Association of Classification
Societies (IACS) and of ISO 8528-5 are valid.
According to performance grade G2 concerning:
▪ Dynamic speed drop in % of the nominal speed ≤ 10 %.
▪ Remaining speed variation in % of the nominal speed ≤ 5 %.
▪ Recovery time until reaching the tolerance band ±1 % of nominal speed
≤ 5 seconds.
Clarify any higher project-specific requirements at an early project stage with
MAN Energy Solutions. They must be part of the contract.
In a load drop of 100 % nominal engine power, the dynamic speed variation
must not exceed:
▪ 12 % of the nominal speed.
▪ The remaining speed variation must not surpass 5 % of the nominal
speed.
To limit the effort regarding regulating the media circuits, also to ensure an
uniform heat input it always should be aimed for longer load application times
by taking into account the realistic requirements of the specific plant.
All questions regarding the dynamic behaviour should be clarified in close
cooperation between the customer and MAN Energy Solutions at an early
project stage.
Requirements for plant design:
▪ The load application behaviour must be considered in the electrical sys-
tem design of the plant.
▪ The system operation must be safe in case of graduated load applica-
tion.
▪ The load application conditions (E-balance) must be approved during the
planning and examination phase.
▪
The possible failure of one engine must be considered, see section Gen-
erator operation/electric propulsion – Power management, Page 48.
2.7.2 Start-up time

General remark Prior to the start-up of the engine it must be ensured that the emergency
2019-09-19 - 1.4
stop of the engine is working properly. Additionally all required supply sys-
tems must be in operation or in stand-by operation.
Start-up – Preheated engine For the start-up of the engine it needs to be preheated:
▪ Lube oil temperature ≥ 40 °C
▪ Cooling water temperature ≥ 60 °C
The required start-up time in normal starting mode (preheated engine), with
the required time for starting up the lube oil system and prelubrication of the
engine is shown in figure below.
Start-up – Cold engine In case of emergency, it is possible to start the cold engine provided the
required media temperatures are present:
▪ Lube oil > 20 °C, cooling water > 20 °C.
▪ Distillate fuel must be used until warming up phase is completed.
▪ The engine is prelubricated. Due to the higher viscosity of the lube oil of a
cold engine the prelubrication phase needs to be increased.
▪ The engine is started and accelerated up to 100 % engine speed within
1 – 3 minutes.
Before further use of the engine a warming up phase is required to reach at
least the level of the regular preheating temperatures (lube oil temperature
> 40 °C, cooling water temperature > 60 °C), see figure below.
Figure 9: Start-up time: Normal start for preheated engine (standard) and cold engine (emergency case)
Start-up – Engine in stand- For engines in stand-by mode the required start-up time is shortened
by mode accordingly to figure below.
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Figure 10: Start-up time: Stand-by start
Exceptional start-up with jet In exceptional case, the run-up time of the engine may be shortened accord-
assist ing to following figure. Be aware that this is near to the maximum capability
of the engine, so exhaust gas will be visible (opacity > 60 %). The shortest
possible run-up time can only be achieved with jet assist.
Note:
Exceptional start-up with jet assist can only be applied if following is provi-
ded:
▪ Engine to be equipped with jet assist.
▪ Sufficient air pressure for jet assist activation must be available.
▪ External signal from plant to be provided for request to SaCoSone for
start-up in exceptional case.
Explanation: Required to distinguish from normal start-up.
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Figure 11: Exceptional start-up with jet assist
General remark Relevance of the specific starting phases depends on the application and on
layout of the specific plant.
2.7.3 Load application – Cold engine (emergency case)

Cold engine – Warming up If the cold engine has been started and runs at nominal speed as prescribed
following procedure is relevant:
▪ Distillate fuel must be used until warming up phase is completed.
▪ Loading the engine gradually up to 30 % engine load within 6 to 8
minutes.
▪ Keep the load at 30 % during the warming up phase until oil temperature
> 40 °C and cooling water temperature > 60 °C are reached.
The necessary time span for this process depends on the actual media tem-
peratures and the specific design of the plant. After these prescribed media
temperatures are reached the engine can be loaded up according the dia-
gram for a preheated engine.
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Figure 12: Load application, emergency case; cold engines
2.7.4 Load application for electric propulsion/auxiliary GenSet

Load application – Preheated In general it is recommended to apply the load according to curve "Normal
engine loading" – see figure below. This ensures uniform heat input to the engine
and exhaust gas below the limit of visibility (opacity below 10 %). Jet assist is
not required in this case.
Load application – Engine at Even after the engine has reached normal engine operating temperatures it is
normal operating recommended to apply the load according to curve "Normal loading". Jet
temperatures assist is not required in this case. Even for "Short loading" no jet assist is
required. Load application according the "Short loading" curve may be affec-
ted by visible exhaust gas (opacity up to 30 %).
Emergency loading – "Emergency loading" is the shortest possible load application time for contin-
Preheated engine uously loading, applicable only in emergency case.
Note:
Stated load application times within figure(s) Load application, Page 38 is
valid after nominal speed is reached and synchronisation is done.
For this purpose, the power management system should have an own emer-
gency operation programme for quickest possible load application. Be aware
that this is near to the maximum capability of the engine, so exhaust gas will
be visible. The shortest possible load application time can only be achieved
with jet assist.
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Figure 13: Load application
2.7.5 Load application – Load steps (for electric propulsion/auxiliary GenSet)
Minimum requirements of The specification of the IACS (Unified Requirement M3) contains first of all
classification societies and guidelines for suddenly applied load steps. Originally two load steps, each
ISO rule 50 %, were described. In view of the technical progress regarding increasing
mean effective pressures, the requirements were adapted. According to
IACS and ISO 8528-5 a diagram is used to define – based on the mean
effective pressure of the respective engine – the number of load steps for a
load application from 0 % load to 100 % load. This diagram serves as a
guideline for four stroke engines in general and is reflected in the rules of the
classification societies.
Be aware, that for marine engines load application requirements must be

clarified with the respective classification society as well as with the shipyard
and the owner.
Accordingly MAN Energy Solutions has specified the following table.
Declared power mean effective pressure of the engine (pme) Number of load steps
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> 18 bar up to 22.5 bar 4
> 22.5 bar up to 27 bar 5
Declared power mean effective pressure of the engine (pme) Number of load steps

> 27 bar 6
The size of each load step to be calculated as:

100 % load divided by "Number of load steps".
For example:
100 % load / "4" = 25 % load increase per load step.
Table 17: Number of load steps dependent on the pme of the engine
Exemplary requirements
Minimum requirements concerning dynamic speed drop, remaining speed
variation and recovery time during load application are listed below.
Classification society Dynamic speed drop in % of the Remaining speed variation in % Recovery time until reaching
nominal speed of the nominal speed the tolerance band ±1 % of
nominal speed
Germanischer Lloyd ≤ 10 % ≤ 5% ≤ 5 sec
RINA
Lloyd´s Register ≤ 5 sec, max. 8 sec
American Bureau of ≤ 5 sec

Shipping
Bureau Veritas
Det Norske Veritas
ISO 8528-5
Table 18: Minimum requirements of some classification societies plus ISO rule
In case of a load drop of 100 % nominal engine power, the dynamic speed
variation must not exceed 10 % of the nominal speed and the remaining
speed variation must not surpass 5 % of the nominal speed.
Engine specific load steps – If the engine has reached normal operating temperature, load steps can be
Normal operating applied according to the diagram below. The load step has to be chosen
temperature depending on the desired recovery time. These curves are for engine plus
standard generator – plant specific details and additional moments of inertia
need to be considered. If low opacity values (below 30 % opacity) are
required, load steps should be maximum 20 % (without jet assist), maximum
25 % (with jet assist).
Before an additional load step will be applied, at least 20 seconds waiting
time after initiation of the previous load step needs to be considered.

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2.8 Engine load reduction
Figure 14: Load application by load steps – Speed drop and recovery time
Time between load steps of ≥ 20 sec. has to be ensured.
2.8 Engine load reduction
Sudden load shedding

For the sudden load shedding from 100 % to 0 % engine load, several
requirements of the classification societies regarding the dynamic and per-
manent change of engine speed have to be fulfilled.
In case of a sudden load shedding and related compressor surging, check
the proper function of the turbocharger silencer filter mat.
Recommended load reduction/stopping the engine

Figure Engine ramping down, generally, Page 41 shows the shortest possi-
ble times for continuously ramping down the engine.
Even with the stated shortest possible times for continuously ramping down
(Phase 1 and Phase 2) the requirements of ISO 8528-5 G2 will be fulfilled.

To limit the effort regarding regulating the media circuits and also to ensure
an uniform heat dissipation it always should be aimed for longer ramping
down times by taking into account the realistic requirements of the specific
plant.
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Before final engine stop, the engine has to be operated for a minimum of
1 minute at idling speed.
Run-down cooling
In order to dissipate the residual engine heat, the system circuits should be
kept in operation after final engine stop for a minimum of 15 minutes.
If for any reason the HT cooling water stand-by pump is not in function, the
2.9 Engine load reduction as a protective safety measure

engine has to be operated for 15 minutes at 0 % – 10 % load before final
stop, so that with the engine driven HT cooling water pump the heat will be
dissipated.
Figure 15: Engine ramping down, generally
Duration "Full load to stop finished"

Phase 1 2 3 4 5 -
Designation Load ramp- Load ramp- Idling Speed ramp- Stop Total duration
down down down finalisation, ≥
run-down
cooling
Speed [%] 100 100 100 100 – 0 0 -
Load [%] 100 – 80 80 – 0 0 0 0 -
Time [sec] 4 6 60 60 900 1,030

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2.9 Engine load reduction as a protective safety measure
Requirements for the power management system/propeller control

In case of a load reduction request due to predefined abnormal engine
parameter (e.g. high exhaust gas temperature, high turbine speed, high lube
oil temperature) the power output (load) must be ramped down as fast as
possible to ≤ 60 % load.
Therefore the power management system/propeller control has to meet the

2.10 Engine operation under arctic conditions
following requirements:
▪ After a maximum of 5 seconds after occurrence of the load reduction
signal, the engine load must be reduced by at least 5 %.
▪ Then, within the next time period of maximum 30 sec. an additional
reduction of engine load by at least 35 % needs to be applied.
▪ The “prohibited range” shown in figure Engine load reduction as a pro-
tective safety measure, Page 42 has to be avoided.
Figure 16: Engine load reduction as a protective safety measure
Arctic condition is defined as:

Air intake temperatures of the engine below +5 °C.
If engines operate under arctic conditions (intermittently or permanently), the
engine equipment and plant installation have to hold certain design features
and meet special requirements. They depend on the possible minimum air
intake temperature of the engine and the specification of the fuel used.
Minimum air intake temperature of the engine, tx:
▪ Category A
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+5 °C > tx > −15 °C

▪ Category B
–15 °C ≥ tx > −35 °C
▪ Category C
tx ≤ −35 °C
Special engine design requirements

Charge air blow-off according to categories A, B or C.
If arctic fuel (with very low lubricating properties) is used, the following actions
are required:
▪ The maximum permissible fuel temperatures and the minimum permissi-
ble viscosity before engine have to be kept.
▪ Fuel injection pump with sealing oil
The low viscosity of the arctic fuel can cause an increased leakage inside
conventional injection pumps, that may contaminate the lube oil. There-
fore sealing oil needs to be installed at the engine and must be activated
(dependent on engine type).
▪ Fuel injection valve
Switch off nozzle cooling to avoid corrosion caused by temperatures
below the dew point.
▪ Valve seat lubrication
Has to be equipped to the engine and to be activated to avoid increased
wear of the inlet valves (dependent on engine type).
Engine equipment
SaCoSone ▪ SaCoSone equipment is suitable to be stored at minimum ambient tem-
peratures of –15 °C.
▪ In case these conditions cannot be met, protective measures against cli-
matic influences have to be taken for the following electronic compo-
nents:
– EDS Databox APC620
– TFT-touchscreen
– Emergency switch module BD5937
These components have to be stored at places, where the temperature
is above –15 °C.
▪ A minimum operating temperature of ≥ 0 °C has to be ensured. The use
of an optional electric heating is recommended.
Alternators
Alternator operation is possible according to suppliers specification.
Plant installation
Intake air conditioning ▪ Air intake of the engine and power house/engine room ventilation have to
be two different systems to ensure that the power house/engine room
temperature is not too low caused by the ambient air temperature.
▪ It is necessary to ensure that the charge air cooler cannot freeze when
the engine is out of operation (and the cold air is at the air inlet side).
▪ Category A, B
No additional actions are necessary. The charge air before the cylinder is
preheated by the HT circuit of the charge air cooler (LT circuit closed).
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▪ Category C
An air intake temperature ≥ –35 °C has to be ensured by preheating.
Additionally the charge air before the cylinder is preheated by the HT cir-
cuit of the charge air cooler (LT circuit closed).
Instruction for minimum ▪ In general the minimum viscosity before engine of 1.9 cSt must not be
admissible fuel temperature undershoot.
▪ The fuel specific characteristic values “pour point” and “cold filter plug-
ging point” have to be observed to ensure pumpability respectively filter-
ability of the fuel oil.

▪ Fuel temperatures of ≤ –10 °C are to be avoided, due to temporarily
embrittlement of seals used in the engines fuel oil system. As a result
they may suffer a loss of function.
Minimum engine room ▪ Ventilation of engine room.
temperature The air of the engine room ventilation must not be too cold (preheating is
necessary) to avoid the freezing of the liquids in the engine room sys-
tems.
▪ Minimum power house/engine room temperature for design ≥ +5 °C.
Coolant and lube oil systems ▪ Coolant and lube oil system have to be preheated for each individual
engine, see section Starting conditions, Page 29.
▪ Design requirements for the preheater of HT systems:
– Category A
Standard preheater.
– Category B
50 % increased capacity of the preheater.
– Category C
100 % increased capacity of the preheater.
▪ Maximum permissible antifreeze concentration (ethylene glycol) in the
engine cooling water.
An increasing proportion of antifreeze decreases the specific heat
capacity of the engine cooling water, which worsens the heat dissipation
from the engine and will lead to higher component temperatures.
The antifreeze concentration of the engine cooling water systems (HT
and LT) within the engine room respectively power house is therefore
limited to a maximum concentration of 40 % glycol. For systems that
require more than 40 % glycol in the cooling water an intermediate heat
exchanger with a low terminal temperature difference should be provi-
ded, which separates the external cooling water system from the internal
system (engine cooling water).
▪ If a concentration of anti-freezing agents of > 50 % in the cooling water
systems is required, contact MAN Energy Solutions for approval.
▪ For information regarding engine cooling water see section Specification
for engine supplies, Page 101.
Insulation The design of the insulation of the piping systems and other plant parts
(tanks, heat exchanger, external intake air duct etc.) has to be modified and
designed for the special requirements of arctic conditions.
Heat tracing To support the restart procedures in cold condition (e.g. after unmanned sur-
vival mode during winter), it is recommended to install a heat tracing system

in the pipelines to the engine.
Note:
A preheating of the lube oil has to be ensured. For plants taken out of opera-
tion and cooled down below temperatures of +5 °C additional special meas-
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ures are required – in this case contact MAN Energy Solutions.
Heat extraction HT system and preheater sizes

After engine start, it is necessary to ramp up the engine to the below speci-
fied Range II to prevent too high heat loss and resulting risk of engine dam-
age.
Thereby Range I must be passed as quick as possible to reach Range II. Be

aware that within Range II low-load operation restrictions may apply.
If operation within Range I is required, the preheater size within the plant
must be capable to preheat the intake air to the level, where heat extraction
from the HT system is not longer possible.
Example 1:
▪ Operation at 20 % engine load and –45 °C intake air temperature wan-
ted.
▪ Preheating of intake air from –45 °C up to minimum –16.5 °C required.
=> According diagram preheater size of 9 kW/cyl. required.
▪ Ensure that this preheater size is installed, otherwise this operation point
is not permissible.
All preheaters need to be operated in parallel to engine operation until mini-
mum engine load is reached.
Figure 17: Required preheater size to avoid heat extraction from HT system
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2.11 GenSet operation
2.11.1 Operating range for GenSet/electric propulsion
Figure 18: Operating range for GenSet/electric propulsion

▪ MCR1
Maximum continuous rating.

▪ Range I
Operating range for continuous service.
▪ Range II
No continuous operation permissible.
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Maximum operating time less than 2 minutes.

1
In accordance with DIN ISO 3046-1 and for further clarification of relevant
sections within DIN ISO 8528-1, the following is specified:
▪ The maximum output (MCR) has to be observed by the power manage-
ment system of the plant.
▪ The range of 100 % up to 110 % fuel admission may only be used for a
short time for governing purposes (e.g. transient load conditions and

suddenly applied load).
IMO certification for engines with operating range for auxiliary GenSet
Test cycle type D2 will be applied for the engine´s certification for compliance
with the NOx limits according to NOx technical code.
2.11.2 Available outputs and permissible frequency deviations
General
Generating sets, which are integrated in an electricity supply system, are
subjected to the frequency fluctuations of the mains. Depending on the
severity of the frequency fluctuations, output and operation respectively have
to be restricted.
Frequency adjustment range

According to DIN ISO 8528-5: 1997-11, operating limits of > 2.5 % are
specified for the lower and upper frequency adjustment range.
Operating range
Depending on the prevailing local ambient conditions, a certain maximum
continuous rating will be available.
In the output/speed and frequency diagrams, a range has specifically been
marked with “No continuous operation permissible in this area”. Operation in
this range is only permissible for a short period of time, i.e. for less than 2
minutes. In special cases, a continuous rating is permissible if the standard
frequency is exceeded by more than 4 %.
Limiting parameters
Max. torque In case the frequency decreases, the available output is limited by the maxi-
mum permissible torque of the generating set.
Max. speed for continuous An increase in frequency, resulting in a speed that is higher than the maxi-
rating mum speed admissible for continuous operation, is only permissible for a
short period of time, i.e. for less than 2 minutes.
For engine-specific information see section Ratings (output) and speeds,
Page 21 of the specific engine.
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Figure 19: Permissible frequency deviations and corresponding max. output
2.11.3 Generator operation/electric propulsion – Power management
Operation of vessels with electric propulsion is defined as parallel operation

of main engines with generators forming a closed system.
The power supply of the plant as a standard is done by auxilliary GenSets
also forming a closed system.
In the design/layout of the plant a possible failure of one engine has to be
considered in order to avoid overloading and under-frequency of the remain-
ing engines with the risk of an electrical blackout.
Therefore we recommend to install a power management system. This
ensures uninterrupted operation in the maximum output range and in case
one engine fails the power management system reduces the propulsive out-
put or switches off less important energy consumers in order to avoid under-
frequency.
According to the operating conditions it is the responsibility of the ship's
operator to set priorities and to decide which energy consumer has to be
switched off.
The base load should be chosen as high as possible to achieve an optimum
engine operation and lowest soot emissions.
The optimum operating range and the permissible part loads are to be
observed (see section Low-load operation, Page 30).
Load application in case one engine fails

In case one engine fails, its output has to be made up for by the remaining
engines in the system and/or the load has to be decreased by reducing the
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propulsive output and/or by switching off electrical consumers.

The immediate load transfer to one engine does not always correspond with
the load reserve that the particular engine has available at the respective
moment. That depends on the engine's base load.
Be aware that the following section only serves as an example and is defi-

nitely not valid for this engine type. For the engine specific capability please
see figure(s) Load application by load steps – Speed drop and recovery time,
Page 39.
Figure 20: Maximum load step depending on base load (example may not be valid for this engine type)
Based on the above stated exemplary figure and on the total number of
engines in operation the recommended maxium load of these engines can
be derived. Observing this limiting maximum load ensures that the load from
one failed engine can be transferred to the remaining engines in operation
without power reduction.
Number of engines in parallel operation 3 4 5 6 7 8 9 10
Recommended maximum load in (%) of Pmax 50 75 80 83 86 87.5 89 90
Table 19: Exemplary – Recommended maximum load in (%) of Pmax dependend on number of engines in
parallel operation
2.11.4 Alternator – Reverse power protection
Definition of reverse power

If an alternator, coupled to a combustion engine, is no longer driven by this
engine, but is supplied with propulsive power by the connected electric grid
and operates as an electric motor instead of working as an alternator, this is
called reverse power. The speed of a reverse power driven engine is accord-
ingly to the grid frequency and the rated engine speed.
Demand for reverse power protection

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For each alternator (arranged for parallel operation) a reverse power protec-
tion device has to be provided because if a stopped combustion engine (fuel
admission at zero) is being turned it can cause, due to poor lubrication,
excessive wear on the engine´s bearings. This is also a classifications`
requirement.
Examples for possible reverse power occurences

▪ Due to lack of fuel the combustion engine no longer drives the alternator,
which is still connected to the mains.
▪ Stopping of the combustion engine while the driven alternator is still con-
nected to the electric grid.
▪ On ships with electric drive the propeller can also drive the electric trac-
tion motor and this in turn drives the alternator and the alternator drives
the connected combustion engine.
▪ Sudden frequency increase, e.g. because of a load decrease in an isola-
ted electrical system -> if the combustion engine is operated at low load
(e.g. just after synchronising).
Adjusting the reverse power protection relay

The necessary power to drive an unfired diesel or gas engine at nominal
speed cannot exceed the power which is necessary to overcome the internal
friction of the engine. This power is called motoring power. The setting of the
reverse-power relay should be, as stated in the classification rules, 50 % of
the motoring power. To avoid false tripping of the alternator circuit breaker a
time delay has to be implemented. A reverse power >> 6 % mostly indicates
serious disturbances in the generator operation.
Table Adjusting the reverse power relay, Page 50 below provides a sum-
mary.
Admissible reverse power Pel [%] Time delay for tripping the alternator circuit
breaker [sec]
Pel < 3 30
3 ≤ Pel < 8 3 to 10
Pel ≥ 8 No delay
Table 20: Adjusting the reverse power relay
2.11.5 Earthing measures of diesel engines and bearing insulation on alternators
General
The use of electrical equipment on diesel engines requires precautions to be
taken for protection against shock current and for equipotential bonding.
These measures not only serve as shock protection but also for functional
protection of electric and electronic devices (EMC protection, device protec-
tion in case of welding, etc.).
Earthing connections on the engine

Threaded bores M12, 20 mm deep, marked with the earthing symbol are
provided in the engine foot on both ends of the engine.
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It has to be ensured that earthing is carried out immediately after engine set-
up. If this cannot be accomplished any other way, at least provisional earth-
ing is to be effected right after engine set-up.

Figure 21: Earthing connection on engine (are arranged diagonally opposite each
1, 2 Connecting grounding terminal coupling side and engine free end (stamped
symbol) M12
Measures to be taken on the alternator

Shaft voltages, i.e. voltages between the two shaft ends, are generated in
electrical machines because of slight magnetic unbalances and ring excita-
tions. In the case of considerable shaft voltages (e.g. > 0.3 V), there is the
risk that bearing damage occurs due to current transfers. For this reason, at
least the bearing that is not located on the drive end is insulated (valid for
alternators > 1 MW output). For verification, the voltage available at the shaft
(shaft voltage) is measured while the alternator is running and excited. With
proper insulation, a voltage can be measured. In order to protect the prime
mover and to divert electrostatic charging, an earthing brush is often fitted on
the coupling side.
Observation of the required measures is the alternator manufacturer’s
responsibility.
Consequences of inadequate bearing insulation on the alternator and

insulation check
In case the bearing insulation is inadequate, e.g., if the bearing insulation was
short-circuited by a measuring lead (PT100, vibration sensor), leakage cur-
rents may occur, which result in the destruction of the bearings. One possi-
bility to check the insulation with the alternator at standstill (prior to coupling
the alternator to the engine; this, however, is only possible in the case of sin-
gle-bearing alternators) would be:
▪ Raise the alternator rotor (insulated, in the crane) on the coupling side.
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▪ Measure the insulation by means of the megger test against earth.

Note:
Hereby the max. voltage permitted by the alternator manufacturer is to be
observed.
If the shaft voltage of the alternator at rated speed and rated voltage is
known (e.g. from the test record of the alternator acceptance test), it is also
possible to carry out a comparative measurement.
If the measured shaft voltage is lower than the result of the “earlier measure-
ment” (test record), the alternator manufacturer should be consulted.
Earthing conductor
The nominal cross section of the earthing conductor (equipotential bonding
conductor) has to be selected in accordance with DIN VDE 0100, part 540
(up to 1 kV) or DIN VDE 0141 (in excess of 1 kV).
Generally, the following applies:
The protective conductor to be assigned to the largest main conductor is to
be taken as a basis for sizing the cross sections of the equipotential bonding
conductors.
Flexible conductors have to be used for the connection of resiliently mounted
engines.
Execution of earthing
The earthing must be executed by the shipyard, since generally it is not
scope of supply of MAN Energy Solutions.
Earthing strips are also not included in the MAN Energy Solutions scope of
supply.
Additional information regarding the use of welding equipment

In order to prevent damage on electrical components, it is imperative to earth
welding equipment close to the welding area, i.e., the distance between the
welding electrode and the earthing connection should not exceed 10 m.
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2.12 Fuel oil, lube oil, starting air and control air con-
sumption
2.12 Fuel oil, lube oil, starting air and control air consumption
2.12.1 Fuel oil consumption for emission standard: IMO Tier II
Engine MAN L32/40 auxiliary GenSet

500 kW/cyl., 720 rpm or 500 kW/cyl., 750 rpm
Engine speed 720 rpm 750 rpm
% Load 100 85 1)
75 50 25 100 85 1)
75 50 25
Specific fuel consumption 186.0 183.0 190.0 197.0 210.0 186.0 183.0 190.0 197.0 210.0
(g/kWh) with HFO or MDO
(DMB) without attached
pumps2) 3) 4)
Specific fuel consumption 187.0 183.8 190.7 197.1 210.0 187.0 183.8 190.7 197.1 210.0
(g/kWh) with MGO (DMA,
DMB) without attached
pumps2) 3) 4)
1)
Warranted fuel consumption at 85 % MCR.
2)
Tolerance for warranty +5 %.
Note:
The additions to fuel gas consumption must be considered before the tolerance for warranty is taken into account.
For consideration of fuel leakage amount please consider table Leakage rate, Page 66.
3)
Based on reference conditions, see table Reference conditions for fuel consumption, Page 54.
4)
Relevant for engine´s certification for compliance with the NOx limits according D2 Test cycle.
Table 21: Fuel oil consumption MAN L32/40 auxiliary GenSet
Additions to fuel consumption

1. Engine driven pumps increase the fuel consumption by:
(A percentage addition to the load specific fuel consumption for the specific
load [%] has to be considered).
For HT CW service pump (attached)
For all lube oil service pumps (attached)

GenSet, electric propulsion:
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load %: Actual load in [%] referred to the nominal output "100 %".
2. For exhaust gas back pressure after turbine > 50 mbar
Every additional 1 mbar (0.1 kPa) back pressure addition of 0.025 g/kWh to
sumption
be calculated.
Reference conditions for fuel consumption

According to ISO 15550: 2002; ISO 3046-1: 2002
Air temperature before turbocharger tr K/°C 298/25
Total atmospheric pressure pr kPa 100
Relative humidity Φr % 30
Exhaust gas back pressure after turbocharger1) kPa 5
Engine type specific reference charge air temperature before cylinder tbar2) K/°C 316/43
Net calorific value NCV kJ/kg 42,700

1)
Measured at 100 % load, accordingly lower for loads < 100 %.
2)
Specified reference charge air temperature corresponds to a mean value for all cylinder numbers that will be ach-
ieved with 25 °C LT cooling water temperature before charge air cooler (according to ISO).
Table 22: Reference conditions for fuel consumption MAN L32/40 GenSet
IMO Tier II requirements:

For detailed information see section Cooling water system description, Page
176.
IMO: International Maritime Organization
MARPOL 73/78; Revised Annex VI-2008, Regulation 13.
Tier II: NOx technical code on control of emission of nitrogen oxides from die-
sel engines.
2.12.2 Lube oil consumption

500 kW/cyl.; 720 rpm or 500 kW/cyl.; 750 rpm
Specific lube oil consumption 0.5 g/kWh1)
Total lube oil consumption [kg/h]1)

No. of cylinders, config. 6L 7L 8L 9L
Speed 720/750 rpm 1.5 1.8 2.0 2.3
1)
The value/values stated above is/are without any losses due to cleaning of filter and centrifuge or lube oil charge
replacement.
Tolerance for warranty +20 %.
Table 23: Total lube oil consumption
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Note:
As a matter of principle, the lube oil consumption is to be stated as total lube
oil consumption related to the tabulated ISO full load output (see section Rat-
ings (output) and speeds, Page 21).
sumption
2.12.3 Starting air and control air consumption
No. of cylinders, configuration 6L 7L 8L 9L

Control air consumption Nm /h
3 1)
1–5
Air consumption per start2) Nm3 1) 2.2 1.8 2.0 2.3
Air consumption per jet assist Nm 3 1)

1.85 1.85 2.95 2.95
activation (5 sec duration)3)
Air consumption jet assist in case of Nm3 4) To be considered:

emergency loading 20 jet assist activations during loading from 0 % to 100 % load
1)
Nm3 corresponds to one cubic metre of gas at 20 °C and 100.0 kPa abs.
2)
The air consumption per starting manoeuvre/slow turn activation depends on the inertia moment of the unit. The
stated air consumption refers only to the engine. For the electric propulsion a higher air consumption needs to be
considered due to the additional inertia moment of the generator (approximately increased by 50 %).
3)
The mentioned above air consumption per jet assist activation is valid for a jet duration of 5 seconds. The jet dura-
tion may vary between 3 sec and 10 sec, depending on the loading (average jet duration 5 sec).
4)
See accordingly section Load application – Load steps (for electric propulsion/auxiliary GenSet), Page 38.
Table 24: Starting air and control air consumption
2.12.4 Recalculation of fuel consumption dependent on ambient conditions
In accordance to ISO standard ISO 3046-1:2002 "Reciprocating internal

combustion engines – Performance, Part 1: Declarations of power, fuel and
lube oil consumptions, and test methods – Additional requirements for
engines for general use" MAN Energy Solutions has specified the method for
recalculation of fuel consumption for liquid fuel dependent on ambient condi-
tions for single-stage turbocharged engines as follows:
β = 1 + 0.0006 x (tx – tr) + 0.0004 x (tbax – tbar) + 0.07 x (pr – px)
The formula is valid within the following limits:

Ambient air temperature 5 °C – 55 °C
Charge air temperature before cylinder 25 °C – 75 °C

Ambient air pressure 0.885 bar – 1.030 bar

Table 25: Limit values for recalculation of liquid fuel consumption
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β Fuel consumption factor
tbar Engine type specific reference charge air temperature before cylinder
see table Reference conditions for fuel consumption, Page 54.
Unit Reference At test run or

sumption
at site
Specific fuel consumption [g/kWh] br bx
Ambient air temperature [°C] tr tx
Charge air temperature before cylinder [°C] tbar tbax
Ambient air pressure [bar] pr px
Table 26: Recalculation of liquid fuel consumption – Units and references
Example
Reference values:
br = 200 g/kWh, tr = 25 °C, tbar = 40 °C, pr = 1.0 bar
At site:
tx = 45 °C, tbax = 50 °C, px = 0.9 bar
ß = 1+ 0.0006 (45 – 25) + 0.0004 (50 – 40) + 0.07 (1.0 – 0.9) = 1.023
bx = ß x br = 1.023 x 200 = 204.6 g/kWh
2.12.5 Influence of engine aging on fuel consumption

The fuel oil consumption will increase over the running time of the engine.
Timely service can reduce or eliminate this increase. For dependencies see
figure Influence of total engine running time and service intervals on fuel oil
consumption, Page 56.
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Figure 22: Influence of total engine running time and service intervals on fuel oil consumption
2.13 Planning data for emission standard IMO Tier II –

Auxiliary GenSet
2.13 Planning data for emission standard IMO Tier II – Auxiliary GenSet
Note:
Stated figures are valid for a layout of the engine supply system as defined
within this documentation. Any modifications that affect the media flow from
attached pumps to the engine, required media flows, temperatures or pres-
sures need to be agreed on by MAN Energy Solutions.
2.13.1 Nominal values for cooler specification – MAN L32/40 IMO Tier II – Auxiliary GenSet
Reference conditions: Tropics
Air temperature °C 45
Cooling water temp. before charge air cooler (LT stage) 38
Total atmospheric pressure mbar 1,000
Relative humidity % 60
Table 27: Reference conditions: Tropics

Engine output kW 3,000 3,500 4,000 4,500
Speed rpm 720/750
Heat to be dissipated1)
Charge air: kW
Charge air cooler (HT stage) 849 956 1,110 1,214
Jacket cooling 463 544 618 699
Charge air cooler (LT stage) 420 487 572 639
Lube oil cooler2) 389 456 520 587
Nozzle cooling 12 14 16 18
Heat radiation (engine) 79 92 105 118
Flow rates3)
HT circuit (Jacket cooling + charge air cooler HT) m3/h 36 42 48 54
LT circuit (lube oil cooler + charge air cooler LT) 57 70 74 85
Lube oil 97 108 118 129
Nozzle cooling water 1.0 1.2 1.4 1.6

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Pumps
a) Attached
HT CW service pump m3/h 36 42 48 54
LT CW service pump not available

Auxiliary GenSet
Lube oil service pump for application with constant speed 102 113 124 136
Prelubrication pump 24 26 29 31
b) Free-standing 4)
LT CW stand-by pump m3/h 57 70 74 85
Nozzle CW pump 1.0 1.2 1.4 1.6
MGO/MDO supply pump 2.0 2.3 2.7 3.0
HFO supply pump 1.0 1.2 1.3 1.5
HFO circulating pump 2.0 2.3 2.7 3.0

1)
Tolerance: +10 % for rating coolers; –15 % for heat recovery.
2)
Without separator heat (30 kJ/kWh can be considered in general).
3)
Basic values for layout design of the coolers.
4)
Tolerances of the pumps delivery capacities must be considered by the pump manufacturer.
Table 28: Nominal values for cooler specification – MAN L32/40 IMO Tier II – Auxiliary GenSet
Note:
You will find further planning data for the listed subjects in the corresponding
sections.
▪ Minimal heating power required for preheating HT cooling water see
paragraph HE-027/Preheater, Page 181.
▪ Minimal heating power required for preheating lube oil see paragraph
H-002/Lube oil preheater, Page 154.
▪ Capacities of preheating pumps see paragraph P-047/HT preheating
pump, Page 181.
2.13.2 Temperature basis, nominal air and exhaust gas data – MAN L32/40 IMO Tier II –
Auxiliary GenSet


Engine output kW 3,000 3,500 4,000 4,500
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Speed rpm 720/750
Temperature basis
HT cooling water engine outlet1) °C 90 2)
LT cooling water air cooler inlet 38 °C (Setpoint 32 °C)3)

Auxiliary GenSet
Lube oil engine inlet 65
Nozzle cooling water engine inlet 60
Air data
Temperature of charge air at charge air cooler outlet °C 58.9 60 59.2 60.1
Air flow rate 4)

m /h
3
19,451 22,692 25,934 29,176
t/h 21.3 24.8 28.4 31.9
Charge air pressure (absolute) bar abs 4.12 4.13 4.12 4.13
Air required to dissipate heat radiation (engine) (t2 – t1 m3/h 25,307 29,524 33,742 37,960
= 10 °C)
Exhaust gas data5)
Volume flow (temperature turbocharger outlet)6) m3/h 39,868 46,585 53,179 59,901
Mass flow t/h 21.9 25.5 29.2 32.8
Temperature at turbine outlet °C 361 362 361 362
Heat content (190 °C) kW 1,121 1,315 1,497 1,691
Permissible exhaust gas back pressure after turbo- mbar 30

charger (maximum)
1)
HT cooling water flow first through water jacket and cylinder head, then through HT stage charge air cooler.
2)
Regulated by engine individual, installed HT thermostatic valve (wax type).
3)
For design see figures Cooling water system diagrams, Page 172.
4)
Under mentioned above reference conditions.
5)
All exhaust gas data values relevant for HFO operation. Tolerances: Quantity ±5 %; temperature ±20 °C.
Calculated based on stated temperature at turbine outlet and total atmospheric pressure according mentioned
6)
above reference conditions.

Table 30: Temperature basis, nominal air and exhaust gas data – MAN L32/40 IMO Tier II – Auxiliary
GenSet
2.13.3 Load specific values at ISO conditions – MAN L32/40 IMO Tier II – Auxiliary GenSet
Reference conditions: ISO

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Table 31: Reference conditions: ISO
Engine output % 100 85 75 50

Auxiliary GenSet
kW 3,000 2,550 2,250 1,500

Speed rpm 720/750
Heat to be dissipated 1)
Charge air: kJ/kWh

Charge air cooler (HT stage) 2)
876 761 764 401
Charge air cooler (LT stage)2) 465 448 473 437
Lube oil cooler3) 415 485 543 773
Air data
Temperature of charge air: °C

After compressor outlet 216 189 181 125
At charge air cooler outlet 40.6 37.3 36.2 30.8
Air flow rate kg/kWh 7.43 7.68 8.25 8.45
Exhaust gas data 4)
Mass flow kg/kWh 7.63 7.87 8.45 8.66
Heat content (190 °C) kJ/kWh 1,050 955 1,070 1,535
Permissible exhaust gas back pressure after turbo- mbar 30 -

charger (max.)
1)
2)
The values of the particular cylinder numbers can differ depending on the charge air cooler specification.
3)
4)
Tolerances: Quantity ±5 %; temperature ±20 °C.
Table 32: Load specific values at ISO conditions – MAN L32/40 IMO Tier II – Auxiliary GenSet
2.13.4 Load specific values at tropical conditions – MAN L32/40 IMO Tier II – Auxiliary
GenSet
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Engine output % 100 85 75 50

Auxiliary GenSet
kW 3,000 2,550 2,250 1,500
Speed rpm 720/750
Heat to be dissipated 1)
Charge air: kJ/kWh

Charge air cooler (HT stage) 2)
1,019 907 921 556
Charge air cooler (LT stage)2) 504 496 523 459
Lube oil cooler3) 467 547 612 866
Air data
Temperature of charge air: °C

After compressor outlet 244 216 207 147
At charge air cooler outlet 58.9 55.7 54.4 47.2
Air flow rate kg/kWh 7.10 7.33 7.88 8.07
Exhaust gas data 4)
Mass flow kg/kWh 7.30 7.53 8.09 8.29
Heat content (190 °C) kJ/kWh 1,345 1,255 1,392 1,868
Permissible exhaust gas back pressure after turbo- mbar 30 -

charger (max.)
1)
2)
The values of the particular cylinder numbers can differ depending on the charge air cooler specification.
3)
4)
Tolerances: Quantity ±5 %; temperature ±20 °C.
Table 34: Load specific values at tropical conditions – MAN L32/40 IMO Tier II – Auxiliary GenSet
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2.14 Operating/service temperatures and pressures
Intake air (conditions before compressor of turbocharger)

Min. Max.
Intake air temperature compressor inlet 5 °C1) 45 °C2)
Intake air pressure compressor inlet –20 mbar -
Conditions below this temperature are defined as "arctic conditions" – see section Engine operation under arctic
1)
conditions, Page 42.

2)
In accordance with power definition. A reduction in power is required at higher temperatures/lower pressures.
Table 35: Intake air (conditions before compressor of turbocharger)
Charge air (conditions within charge air pipe before cylinder)

Min. Max.
Charge air temperature cylinder inlet1) 43 °C 59 °C

1)
Aim for a higher value in conditions of high air humidity (to reduce condensate amount).
Table 36: Charge air (conditions within charge air pipe before cylinder)
HT cooling water – Engine

Min. Max.
HT cooling water temperature engine outlet1) 90 °C2) 95 °C3)
HT cooling water temperature engine inlet – Preheated before start 60 °C 90 °C
HT cooling water pressure engine inlet4) 3 bar 4 bar
Pressure loss engine (total, for nominal flow rate) - 1.35 bar
Only for information:

+ Pressure loss engine (without charge air cooler) 0.3 bar 0.5 bar
+ Pressure loss HT piping engine 0.2 bar 0.45 bar
+ Pressure loss charge air cooler (HT stage) 0.2 bar 0.4 bar
Pressure rise attached HT cooling water pump (optional) 3.2 bar 3.8 bar
1)
SaCoSone measuring point is jacket cooling outlet of the engine.
2)
Regulated temperature.
3)
Operation at alarm level.
4)
SaCoSone measuring point is jacket cooling inlet.
Table 37: HT cooling water – Engine

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HT cooling water – Plant

Min. Max.
Permitted pressure loss of external HT system (plant) - 1.85 bar
Minimum required pressure rise of free-standing HT cooling water stand-by pump 3.2 bar -
(plant)
Cooling water expansion tank

+ Pre-pressure due to expansion tank at suction side of cooling water pump 0.6 bar 0.9 bar
+ Pressure loss from expansion tank to suction side of cooling water pump - 0.1 bar
Table 38: HT cooling water – Plant
LT cooling water – Engine

Min. Max.
LT cooling water temperature charge air cooler inlet (LT stage) 32 °C1) 38 °C2)
LT cooling water pressure charge air cooler inlet (LT stage) 2 bar 4 bar
Pressure loss charge air cooler (LT stage, for nominal flow rate) - 0.6 bar
Only for information:
+ Pressure loss LT piping engine 0.2 bar 0.3 bar
+ Pressure loss charge air cooler (LT stage) 0.1 bar 0.3 bar
1)
2)
In accordance with power definition. A reduction in power is required at higher temperatures/lower pressures.
Table 39: LT cooling water – Engine
LT cooling water – Plant

Min. Max.
Permitted pressure loss of external LT system (plant) - 2.4 bar
Minimum required pressure rise of free-standing LT cooling water stand-by pump 3.0 bar -
(plant)
Cooling water expansion tank

+ Pre-pressure due to expansion tank at suction side of cooling water pump 0.6 bar 0.9 bar
+ Pressure loss from expansion tank to suction side of cooling water pump - 0.1 bar
Table 40: LT cooling water – Plant
Nozzle cooling water

Min. Max.
Nozzle cooling water temperature engine inlet 55 °C 70 °C1)
Nozzle cooling water pressure engine inlet

+ Open system 2 bar 3 bar
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+ Closed system 3 bar 5 bar
Pressure loss engine (fuel nozzles, for nominal flow rate) - 1.5 bar
1)
Table 41: Nozzle cooling water
Lube oil
Min. Max.
Lube oil temperature engine inlet 65 °C1) 70 °C2)
Lube oil temperature engine inlet – Preheated before start 40 °C 65 °C3)
Lube oil pressure (during engine operation)

– Engine inlet 4 bar 5 bar
– Turbocharger inlet 1.3 bar 2.2 bar
Prelubrication/postlubrication (duration ≤ 10 min) lube oil pressure

– Engine inlet 0.3 bar4) 5 bar
Prelubrication/postlubrication (duration > 10 min) lube oil pressure

– Engine inlet 0.3 bar4) 0.6 bar
Lube oil pump (attached, free-standing)

– Design pressure 7 bar -
– Opening pressure safety valve - 8 bar
1)
2)
3)
If higher temperatures of lube oil in system will be reached, e.g. due to lube oil separator operation, at engine start
this temperature needs to be reduced as quickly as possible below alarm level to avoid a start failure.
4)
Note: Oil pressure > 0.3 bar must be ensured also for lube oil temperatures up to 70 °C.
Table 42: Lube oil
Fuel
Min. Max.
Fuel temperature engine inlet

– MGO (DMA, DMZ) and MDO (DMB) according ISO 8217-2017 –10 °C1) 45 °C2)
– HFO according ISO 8217-2017 - 150 °C2)
Fuel viscosity engine inlet

– MGO (DMA, DMZ) and MDO (DMB) according ISO 8217-2017 1.9 cSt 14.0 cSt
– HFO according ISO 8217-2017, recommended viscosity 12.0 cSt 14.0 cSt
Fuel pressure engine inlet 5.0 bar 8.0 bar
Fuel pressure engine inlet in case of black out (only engine start idling) 0.6 bar -
Differential pressure (engine inlet/engine outlet) 1.0 bar -

Fuel return, fuel pressure engine outlet 2.0 bar -
Maximum pressure variation at engine inlet - ±0.5 bar
HFO supply system

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+ Minimum required pressure rise of free-standing HFO supply pump (plant) 7.0 bar -
+ Minimum required pressure rise of free-standing HFO circulating pump 7.0 bar -
(booster pumps, plant)
+ Minimum required absolute design pressure free-standing HFO circulating 10.0 bar -
pump (booster pumps, plant)
Min. Max.

MDO/MGO supply system
+ Minimum required pressure rise of free-standing MDO/MGO supply pump 10.0 bar -
(plant)
Fuel temperature within HFO day tank (preheating) 75 °C 90 °C3)

1)
Maximum viscosity not to be exceeded. “Pour point” and “Cold filter plugging point” have to be observed.
2)
Not permissible to fall below minimum viscosity.
3)
If flash point is below 100 °C, than the limit is: 10 degrees distance to the flash point.
Table 43: Fuel
Compressed air in the starting air system

Min. Max.
Starting air pressure within vessel/pressure regulating valve inlet 10.0 bar 30.0 bar
Table 44: Compressed air in the starting air system
Compressed air in the control air system

Min. Max.
Control air pressure engine inlet 5.5 bar1) 8.0 bar

1)
Table 45: Compressed air in the control air system
Crankcase pressure (engine)

Min. Max.
Pressure within crankcase –2.5 mbar 3.0 mbar

Table 46: Crankcase pressure (engine)
Setting
Safety valve attached to the crankcase (opening pressure) 50 – 70 mbar

Table 47: Safety valve
Exhaust gas
Min. Max.
Exhaust gas temperature turbine outlet (normal operation under tropic conditions) - 415 °C
Exhaust gas temperature turbine outlet (with SCR within regeneration mode) 360 °C 400 °C
Exhaust gas temperature turbine outlet (emergency operation – According classifi- - 546 °C
cation rules – One failure of TC)
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Recommended design exhaust gas temperature turbine outlet for layout of 450 °C1) -
exhaust gas line (plant)
Minimum exhaust gas temperature after recooling due to exhaust gas heat utiliza- 190 °C2) -
tion
Min. Max.
2.16 Filling volumes
Exhaust gas back pressure after turbocharger (static) - 50 mbar3)

1)
Project specific evaluation required, figure given as minimum value for guidance only.
2)
To avoid sulfur corrosion in exhaust gas line (plant).
3)
If this value is exceeded by the total exhaust gas back pressure of the designed exhaust gas line, sections Derat-
ing, definition of P Operating, Page 24 and Increased exhaust gas pressure due to exhaust gas after treatment instal-
lations, Page 25 need to be considered.
Table 48: Exhaust gas
2.15 Leakage rate
Max. leak rate Max. leakage rate injection nozzle Burst leakage rate in case of pipe
break (for max. 1 min)
l/cyl. x h l/cyl. x h l/min
HFO MGO/MDO HFO MGO/MDO HFO, MGO/MDO
0.4 1.0 0.02 0.04 4.0
Table 49: Leakage rate – MAN 32/40 GenSet with SP injection pumps
Note:
▪ A high flow of dirty leakage oil will occur in case of a pipe break, for short
time only (< 1 min).
Engine will run down immediately after a pipe break alarm.
This leakage can be reused, if the entire fuel treatment of separation and
filtration is done.
▪ The operating leakage (clean) includes the leakage amount of the high-
pressure pumps, injection valves and valve groups, which occur during
normal operation due to their function. This leakage can be reused, if the
entire fuel treatment of separation and filtration is done.
▪ All other leakage amounts (dirt fuel oil from filters or from engine drains)
have to be discharged into the sludge tank.
Cooling water and oil volume – Turbocharger at counter coupling side1)

No. of cylinders 6 7 8 9
HT cooling water2) approximately litre 151 175 202 226
LT cooling water3) approximately 46 49 51 52

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Lube oil within base frame of GenSet 3,100 3,500 3,900 4,300
1)
Be aware: This is just the amount inside the engine. By this amount the level in the service or expansion tank will be
lowered when media systems are put in operation.
2)
HT water volume engine: HT part of charge air cooler, cylinder unit, piping.
3)
LT water volume engine: LT part of charge air cooler, piping.
Table 50: Cooling water and oil volume of engine

Service tanks Installation1) Minimum effective capacity
height
m m3
No. of cylinders 6 7 8 9
Cooling water cylinder 6–9 0.5
Required diameter for expansion pipeline - ≥ DN50 2)

1)
Installation height refers to tank bottom and crankshaft centre line.
2)
Cross sectional area should correspond to that of the venting pipes.
Table 51: Service tanks capacities

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2.17 Internal media systems – Exemplary
Internal fuel system – Exemplary

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Figure 23: Internal fuel system – Exemplary
Note:
The drawing shows the basic internal media flow of the engine in general.
Project-specific drawings thereof don´t exist.
Internal cooling water system – Exemplary

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Figure 24: Internal cooling water system – Exemplary
Note:
Internal lube oil system – Exemplary

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Figure 25: Internal lube oil system – Exemplary
Note:
Internal starting air system – Exemplary

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Figure 26: Internal starting air system – Exemplary
Note:
2.18 Venting amount of crankcase and turbocharger
2.18 Venting amount of crankcase and turbocharger
A ventilation of the engine crankcase and the turbochargers is required, as

described in section Crankcase vent and tank vent, Page 165.
For the layout of the ventilation system guidance is provided below:
Due to normal blow-by of the piston ring package small amounts of combus-
tion chamber gases get into the crankcase and carry along oil dust.
▪ The amount of crankcase vent gases is approximately 0.1 % of the
engine´s air flow rate.
▪ The temperature of the crankcase vent gases is approximately 5 K higher
than the oil temperature at the engine´s oil inlet.
▪ The density of crankcase vent gases is 1.0 kg/m³ (assumption for calcu-
lation).
In addition, the sealing air of the turbocharger needs to be vented.
▪ The amount of turbocharger sealing air is approximately:
– For single-stage turbocharged engines 0.2 % of the engine´s air flow
rate.
– For two-stage turbocharged engines 0.4 % of the engine´s air flow
rate.
▪ The temperature of turbocharger sealing air is approximately 5 K higher
than the oil temperature at the engine´s oil inlet.
▪ The density of turbocharger sealing air is 1.0 kg/m³ (assumption for cal-
culation).
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2.19 Exhaust gas emission

2.19.1 Maximum permissible NOx emission limit value IMO Tier II
IMO Tier II: Engine in standard version1

Rated speed 720 rpm 750 rpm
NOx 1) 2) 3)
IMO Tier II cycle D2/E2/E3 9.68 g/kWh4) 9.59g/kWh4)
Note:
The engine´s certification for compliance with the NOxlimits will be carried out during factory acceptance test as a
single or a group certification.
1)
Cycle values as per ISO 8178-4: 2007, operating on ISO 8217 DM grade fuel (marine distillate fuel: MGO or MDO).
2)
Calculated as NO2.
D2: Test cycle for "constant-speed auxiliary engine application".
E2: Test cycle for "constant-speed main propulsion application" including electric propulsion and all controllable pitch
propeller installations.
E3: Test cycle for "propeller-law-operated main and propeller-law-operated auxiliary engine” application.
3)
Based on a LT charge air cooling water temperature of max. 32 °C at 25 °C seawater temperature.
4)
Maximum permissible NOx emissions for marine diesel engines according to IMO Tier II:
130 ≤ n ≤ 2,000 → 44 * n–0.23 g/kWh (n = rated engine speed in rpm).
Table 52: Maximum permissible NOx emission limit value
1
Marine engines are guaranteed to meet the revised International Convention
for the Prevention of Pollution from Ships, "Revised MARPOL Annex VI (Reg-
ulations for the Prevention of Air Pollution from Ships), Regulation 13.4
(Tier II)" as adopted by the International Maritime Organization (IMO).
2.19.2 Smoke emission index (FSN)

Smoke index FSN for engine loads ≥ 25 % load well below limit of visibility
(0.4 FSN).
Valid for normal engine operation.
2.19.3 Exhaust gas components of medium-speed four-stroke diesel engines

The exhaust gas of a medium-speed four-stroke diesel engine is composed
of numerous constituents. These are derived from either the combustion air
and fuel oil and lube oil used, or they are reaction products, formed during
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the combustion process see table below. Only some of these are to be con-
sidered as harmful substances.
For a typical composition of the exhaust gas of an MAN Energy Solutions
four-stroke diesel engine without any exhaust gas treatment devices see
table below.
Main exhaust gas constituents Approx. [% by volume] Approx. [g/kWh]

Nitrogen N2 74.0 – 76.0 5,020 – 5,160
Oxygen O2 11.6 – 13.2 900 – 1,030
Carbon dioxide CO2 5.2 – 5.8 560 – 620
Steam H2O 5.9 – 8.6 260 – 370
Inert gases Ar, Ne, He... 0.9 75
Total > 99.75 7,000
Additional gaseous exhaust gas con- Approx. [% by volume] Approx. [g/kWh]

stituents considered as pollutants
Sulphur oxides SOx1) 0.07 10.0
Nitrogen oxides NOx2) 0.07 – 0.15 8.0 – 16.0
Carbon monoxide CO3) 0.006 – 0.011 0.4 – 0.8
Hydrocarbons HC4) 0.1 – 0.04 0.4 – 1.2
Total < 0.25 26
Additionally suspended exhaust gas Approx. [mg/Nm ] 3

Approx. [g/kWh]
constituents, PM5)
Operating on Operating on
MGO 6)
HFO 7)
MGO 6)
HFO7)
Soot (elemental carbon)8) 50 50 0.3 0.3
Fuel ash 4 40 0.03 0.25
Lube oil ash 3 8 0.02 0.04
Note:
At rated power and without exhaust gas treatment.
1)
SOx according to ISO 8178 or US EPA method 6C, with a sulphur content in the fuel oil of 2.5 % by weight.
2)
NOx according to ISO 8178 or US EPA method 7E, total NOx emission calculated as NO2.
3)
CO according to ISO 8178 or US EPA method 10.
4)
HC according to ISO 8178 or US EPA method 25 A.
5)
PM according to VDI 2066, EN-13284, ISO 9096 or US EPA method 17; in-stack filtration.
6)
Marine gas oil DM-A grade with an ash content of the fuel oil of 0.01 % and an ash content of the lube oil of 1.5 %.
7)
Heavy fuel oil RM-B grade with an ash content of the fuel oil of 0.1 % and an ash content of the lube oil of 4.0 %.
8)
Pure soot, without ash or any other particle-borne constituents.
Table 53: Exhaust gas constituents of the engine (before an exhaust gas aftertreatment installation) for
liquid fuel (for guidance only)
Carbon dioxide CO2

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Carbon dioxide (CO2) is a product of combustion of all fossil fuels.

Among all internal combustion engines the diesel engine has the lowest spe-
cific CO2 emission based on the same fuel quality, due to its superior effi-
ciency.
Sulphur oxides SOx
2.20 Noise
Sulphur oxides (SOx) are formed by the combustion of the sulphur contained
in the fuel.
Among all systems the diesel process results in the lowest specific SOx emis-
sion based on the same fuel quality, due to its superior efficiency.
Nitrogen oxides NOx (NO + NO2)

The high temperatures prevailing in the combustion chamber of an internal
combustion engine cause the chemical reaction of nitrogen (contained in the
combustion air as well as in some fuel grades) and oxygen (contained in the
combustion air) to nitrogen oxides (NOx).
Carbon monoxide CO
Carbon monoxide (CO) is formed during incomplete combustion.
In MAN Energy Solutions four-stroke diesel engines, optimisation of mixture
formation and turbocharging process successfully reduces the CO content of
the exhaust gas to a very low level.
Hydrocarbons HC
The hydrocarbons (HC) contained in the exhaust gas are composed of a
multitude of various organic compounds as a result of incomplete combus-
tion.
Due to the efficient combustion process, the HC content of exhaust gas of
MAN Energy Solutions four-stroke diesel engines is at a very low level.
Particulate matter PM
Particulate matter (PM) consists of soot (elemental carbon) and ash.
2.20 Noise
2.20.1 Airborne noise
L engine
Sound pressure level Lp
Measurements
Approximately 20 measuring points at 1 metre distance from the engine sur-

face are distributed evenly around the engine according to ISO 6798. The
noise at the exhaust outlet is not included, but provided separately in the fol-
lowing sections.
Octave level diagram
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The expected sound pressure level Lp is below 107 dB(A) at 100 % MCR.
The octave level diagram below represents an envelope of averaged meas-
ured spectra for comparable engines at the testbed and is a conservative
spectrum consequently. No room correction is performed. The data will
change depending on the acoustical properties of the environment.
Blow-off noise
Blow-off noise is not considered in the measurements, see below.

2.20 Noise
Figure 27: Airborne noise – Sound pressure level Lp – Octave level diagram L engine
2.20.2 Intake noise
L engine
Sound power level Lw
Measurements
The (unsilenced) intake air noise is determined based on measurements at
the turbocharger test bed and on measurements in the intake duct of typical
engines at the test bed.
The expected sound power level Lw of the unsilenced intake noise in the
intake duct is below 143 dB at 100 % MCR.

ured spectra for comparable engines and is a conservative spectrum conse-
quently. The data will change depending on the acoustical properties of the
environment.
Charge air blow-off noise
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Charge air blow-off noise is not considered in the measurements, see below.
These data are required and valid only for ducted air intake systems. The
data are not valid if the standard air filter silencer is attached to the turbo-
charger.
2.20 Noise
Figure 28: Unsilenced intake noise – Sound power level Lw – Octave level diagram L engine
2.20.3 Exhaust gas noise
L engine
Measurements
The (unsilenced) exhaust gas noise is measured according to internal MAN
Energy Solutions guidelines at several positions in the exhaust duct.
The sound power level Lw of the unsilenced exhaust gas noise in the
exhaust pipe is shown at 100 % MCR.
ured spectra for comparable engines and is a conservative spectrum conse-

quently. The data will change depending on the acoustical properties of the
environment.
Acoustic design
To ensure an appropriate acoustic design of the exhaust gas system, the
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yard, MAN Energy Solutions, supplier of silencer and where necessary

acoustic consultant have to cooperate.
Waste gate blow-off noise
Waste gate blow-off noise is not considered in the measurements, see
below.
2.20 Noise
Figure 29: Unsilenced exhaust gas noise – Sound power level Lw – Octave level diagram L engine
2.20.4 Blow-off noise example

Measurements
The (unsilenced) charge air blow-off noise is measured according to DIN
45635, part 47 at the orifice of a duct.
Throttle body with bore size 135 mm
Expansion of charge air from 3.4 bar to ambient pressure at 42 °C
The sound power level Lw of the unsilenced charge air blow-off noise is
approximately 141 dB for the measured operation point.
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2.20 Noise
Figure 30: Unsilenced charge air blow-off noise – Sound power level Lw – Octave level diagram
2.20.5 Noise and vibration – Impact on foundation
Noise and vibration is emitted by the engine to the surrounding (see figure
Noise and vibration – Impact on foundation, Page 80). The engine impact
transferred through the engine mounting to the foundation is focused subse-
quently.

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2.20 Noise
Figure 31: Noise and vibration – Impact on foundation

The foundation is excited to vibrations in a wide frequency range by the
engine and by auxiliary equipment (from engine or plant). The engine is
vibrating as a rigid body. Additionally, elastic engine vibrations are superim-
posed. Elastic vibrations are either of global (e.g. complete engine bending)
or local (e.g. bending engine foot) character. If the higher frequency range is
involved, the term "structure borne noise" is used instead of "vibrations".
Mechanical engine vibrations are mainly caused by mass forces of moved
drive train components and by gas forces of the combustion process. For
structure borne noise, further excitations are relevant as well, e.g. impacts
from piston stroke and valve seating, impulsive gas force components, alter-
nating gear train meshing forces and excitations from pumps.
For the analysis of the engine noise- and vibration-impact on the surround-
ing, the complete system with engine, engine mounting, foundation and plant
has to be considered.
Engine related noise and vibration reduction measures cover e.g. counterbal-
ance weights, balancing, crankshaft design with firing sequence, component
design etc. The remaining, inevitable engine excitation is transmitted to the

surrounding of the engine – but not completely in case of a resilient engine
mounting, which is chosen according to the application-specific require-
ments. The resilient mounting isolates engine noise and vibration from its sur-
rounding to a large extend. Hence, the transmitted forces are considerably
reduced compared with a rigid mounting. Nevertheless, the engine itself is
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vibrating stronger in the low frequency range in general – especially when

driving through mounting resonances.
In order to avoid resonances, it must be ensured that eigenfrequencies of
foundation and coupled plant structures have a sufficient safety margin in
relation to the engine excitations. Moreover, the foundation has to be
designed as stiff as possible in all directions at the connections to the engine.
Thus, the foundation mobility (measured according to ISO 7262) has to be as
2.20 Noise
low as possible to ensure low structure borne noise levels. For low frequen-
cies, the global connection of the foundation with the plant is focused for that
matter. The dynamic vibration behaviour of the foundation is mostly essential
for the mid frequency range. In the high frequency range, the foundation
elasticity is mainly influenced by the local design at the engine mounts. E.g.
for steel foundations, sufficient wall thicknesses and stiffening ribs at the con-
nection positions shall be provided. The dimensioning of the engine founda-
tion also has to be adjusted to other parts of the plant. For instance, it has to
be avoided that engine vibrations are amplified by alternator foundation vibra-
tions. Due to the scope of supply, the foundation design and its connection
with the plant is mostly within the responsibility of the costumer. Therefore,
the customer is responsible to involve MAN Energy Solutions for consultancy
in case of system-related questions with interaction of engine, foundation
and plant. The following information is available for MAN Energy Solutions
customers, some on special request:
▪ Residual external forces and couples (Project Guide)
Resulting from the summation of all mass forces from the moving drive
train components. All engine components are considered rigidly in the
calculation. The residual external forces and couples are only transferred
completely to the foundation in case of a rigid mounting, see above.
▪ Static torque fluctuation (Project Guide)
Static torque fluctuations result from the summation of gas and mass
forces acting on the crank drive. All components are considered rigidly in
the calculation. These couples are acting on the foundation dependent
on the applied engine mounting, see above.
▪ Mounting forces (project-specific)
The mounting dimensioning calculation is specific to a project and
defines details of the engine mounting. Mounting forces acting on the
foundation are part of the calculation results. Gas and mass forces are
considered for the excitation. The engine is considered as one rigid body
with elastic mounts. Thus, elastic engine vibrations are not implemented.
▪ Reference measurements for engine crankcase vibrations according to
ISO 10816‑6 (project-specific)
▪ Reference test bed measurements for structure borne noise (project-
specific)
Measuring points are positioned according to ISO 13332 on the engine
feet above and below the mounting elements. Structure borne noise lev-
els above elastic mounts mainly depend on the engine itself. Whereas
structure borne noise levels below elastic mounts strongly depend on the
foundation design. A direct transfer of the results from the test bed foun-
dation to the plant foundation is not easily possible – even with the con-
sideration of test bed mobilities. The results of test bed foundation mobi-
lity measurements according to ISO 7626 are available as a reference on
request as well.
▪ Dynamic transfer stiffness properties of resilient mounts (supplier infor-
mation, project-specific)
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Beside the described interaction of engine, foundation and plant with transfer
through the engine mounting to the foundation, additional transfer paths
need to be considered. For instance with focus on the elastic coupling of the
drive train, the exhaust pipe, other pipes and supports etc. Besides the
engine, other sources of noise and vibration need to be considered as well
(e.g. auxiliary equipment, propeller, thruster).
2.22 Arrangement of attached pumps
2.21 Moments of inertia – Engine, damper, flywheel
To be defined.
2.22 Arrangement of attached pumps
Figure 32: Attached pumps L engine
A 314 or 355 1) C 510 or 550 1)
B 555 – 964 1)
1)
Depending from pump type.
Note:
The final arrangement of the lube oil and cooling water pumps will be made
at inquiry or order.
An attached LT CW pump is not available for the MAN L32/40 auxiliary Gen-
Set.
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2.23 Foundation
2.23 Foundation
2.23.1 Resilient mounting of GenSets
Resilient mounting of GenSets

On resilient mounted GenSets, the diesel engine and the alternator are
placed on a common rigid base frame mounted on the ship's/erection hall's
foundation by means of resilient supports, type conical.
All connections from the GenSet to the external systems should be equipped
with flexible connections, and pipes, gangway etc. must not be welded to
the external part of the installation.
Resilient support
A resilient mounting of the GenSet is made with a number of conical mount-
ings. The number and the distance between them depend on the size of the
plant. These conical mountings are bolted to brackets on the base frame see
figure Resilient mounting of GenSets, Page 83.
The setting from unloaded to loaded condition is normally between 5 – 11
mm for the conical mounting.
The exact setting can be found in the calculation of the conical mountings for
the plant in question. The support of the individual conical mounting can be
made in one of the following three ways:
1. The support between the foundation and the base casting of the conical
mounting is made with a loose steel shim. This steel shim is machined to
an exact thickness (min. 40 mm) for each individual conical mounting.
2. The support can also be made by means of two steel shims, at the top a
loose shim of at least 40 mm and below a shim of approximately 10 mm
which are machined for each conical mounting and then welded to the
foundation.
3. Finally, the support can be made by means of chockfast. It is recommen-
ded to use two steel shims, the top shim should be loose and have a
minimum thickness of 40 mm, the bottom shim should be cast in chock-
fast with a thickness of at least 10 mm. 2 Engine and operation
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Figure 33: Resilient mounting of GenSets
Irrespective of the method of support, it is recommended to use a loose steel

2.23 Foundation
shim to facilitate a possible future replacement of the conical mountings.
Check of crankshaft deflection

The resilient mounted GenSet is normally delivered from the factory with
engine and alternator mounted on the common base frame. Eventhough
engine and alternator have been adjusted by the engine builder, with the
alternator rotor placed correctly in the stator and the crankshaft deflection of
the engine (autolog) within the prescribed tolerances, it is recommended to
check the crankshaft deflection (autolog) before starting up the GenSet.
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Figure 34: Support of conicals
2.23 Foundation
2.23.2 General requirements for engine foundation
Plate thicknesses
The stated material dimensions are recommendations, calculated for steel
plates. Thicknesses smaller than these are not permissible. When using other
materials (e.g. aluminium), a sufficient margin has to be added.
Top plates
Before or after having been welded in place, the bearing surfaces should be
machined and freed from rolling scale. Surface finish corresponding to Ra
3.2 peak-to-valley roughness in the area of the chocks shall be accom-
plished.
The thickness given is the finished size after machining.
Downward inclination outwards, not exceeding 0.7 %.
Prior to fitting the chocks, clean the bearing surfaces from dirt and rust that
may have formed. After the drilling of the foundation bolt holes, spotface the
lower contact face normal to the bolt hole.
Foundation girders
The distance of the inner girders must be observed. We recommend that the
distance of the outer girders (only required for larger types) is observed as
well.
The girders must be aligned exactly above and underneath the tank top.
Floor plates
No manholes are permitted in the floor plates in the area of the box-shaped
foundation. Welding is to be carried out through the manholes in the outer
girders.
Top plate supporting

Provide support in the area of the frames from the nearest girder below.
Dynamic foundation requirements

The eigenfrequencies of the foundation and the supporting structures,
including GenSet weight (without engine) shall be higher than 20 Hz. Occa-
sionally, even higher foundation eigenfrequencies are required. For further
information refer to section Noise and vibration – Impact on foundation, Page
79.
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3 Engine automation
3.1 SaCoSone GENSET system overview

The monitoring and safety system SaCoSone GENSET serves for complete
engine operation, control, monitoring and safety of GenSets. Therefore all
sensors and operating devices are wired to the system.
The SaCoSone design is based on high reliable and approved components as
well as modules specially designed for installation on medium speed engines.
The used components are harmonised to a homogenously system. The
whole system is attached to the engine cushioned against vibration.
Control Unit
The Control Unit includes a highly integrated Control Module S for engine
control, monitoring and alarm system (alarm limits and delay). The module
collects engines measuring data and transfers most measurements and data
to the ship alarm system via Modbus. Furthermore, the Control Unit is equip-
ped with a Display Module. This module consists of a touchscreen and an
integrated PLC for the safety system. The Display Module also acts as safety
system for over speed, low lube oil pressure and high cooling water temper-
ature.
The Display Module provides the following functions:
▪ safety system
▪ visualisation of measured values and operating values on a touchscreen
▪ engine operation via touchscreen
The safety system is electrically separated from the control system due to
requirements of the classification societies. For engine operation, additional
hardwired switches are available for relevant functions. The system configu-
ration can be edited via an Ethernet interface at the Display Module. Addi-
tionally, the Control Unit contains the terminal blocks for the connection to
external systems, such as the ship alarm system and the optional crankcase
monitoring. It is the central connecting and distribution point for the 24VDC
power supply of the whole system.
3 Engine automation
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Figure 35: Control Unit

3 Engine automation
Multifunction Monitoring System (optional)

The Multifunction Monitoring System (MMS) is part of the alarm and safety
system and is connected via the redundant CAN bus to the Control Module
S.
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1 Indication lamp “POWER ON”, green
Figure 36: Multifunction Monitoring System
System bus
SaCoSone GENSET is equipped with a redundant bus based on CAN. The
bus connects all system modules. This redundant bus system provides the
basis data exchange between the modules. The Control Module S operates
directly with electro-hydraulic actuator.
3 Engine automation
2019-09-19 - 1.4
Figure 37: System bus diagram
3.2 Power supply and distribution
3.2 Power supply and distribution

The plant has to provide electric power for the automation and monitoring
system. In general an uninterrupted 24 V DC power supply is required for
SaCoSone.
For marine main engines, an uninterrupted power supply (UPS) is required
which must be provided by two individual supply networks. According to
classification requirements it must be designed to guarantee the power sup-
ply to the connected systems for a sufficiently long period if both supply net-
works fail.
3 Engine automation
Figure 38: Power supply diagram
Required power supplies

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Voltage Consumer Notes

24 V DC Control Unit All SaCoSone components
24 V DC Multifunction Monitoring System All components

Table 54: Required power supplies
3.4 Functionality
3.3 Operation
Control Station Changeover

The operation and control can be done from both operating panels. Selec-
tion and activation of the control stations is possible at the Local Operating
Panel. On the touchscreens, all the measuring points acquired by means of
SaCoSone can be shown in clearly arranged drawings and figures. It is not
necessary to install additional speed indicators separately.
The operating rights can be handed over to an external automatic system.
Speed setting
In case of operating with one of the SaCoSone panels, the engine speed set-
ting is carried out manually by a decrease/increase switch button. If the oper-
ation is controlled by an external system, the speed setting can be done
either by means of binary contacts (e.g. for synchronisation) or by an active
4 – 20 mA analogue signal alternatively. The signal type for this is to be
defined in the project planning period.
Operating modes
For alternator applications:
▪ Droop (5-percent speed increase between nominal load and no load)
The operating mode is pre-selected via the SaCoS interface and has to be
defined during the application period.
Details regarding special operating modes on request.
3.4 Functionality
Safety system
Safety functions The safety system monitors all operating data of the engine and initiates the
required actions, i.e. engine shutdown, in case the limit values are exceeded.
The safety system is integrated the Display Module. The safety system
directly actuates the emergency shutdown device and the stop facility of the
speed governor.
Auto shutdown Auto shutdown is an engine shutdown initiated by any automatic supervision
of engine internal parameters.
Emergency stop Emergency stop is an engine shutdown initiated by an operator manual
3 Engine automation
action like pressing an emergency stop button. An emergency stop button is

placed at the Control Unit on engine.
Engine shutdown If an engine shutdown is triggered by the safety system, the emergency stop
signal has an immediate effect on the emergency shut-down device and the
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speed control. At the same time the emergency stop is triggered, SaCoSone
issues a signal resulting in the alternator switch to be opened.
Shutdown criteria ▪ Engine overspeed
▪ Failure of both engine speed sensors
▪ Lube oil pressure at engine inlet low
▪ HT cooling water temperature outlet too high
▪ High bearing temperature/deviation from Multifunction Monitoring Sys-

tem (optional)
3.4 Functionality
▪ High alternator winding temperature from Multifunction Monitoring Sys-

tem (optional)
▪ High splash-oil temperature/deviation from Multifunction Monitoring Sys-
tem (optional)
▪ High oilmist concentration in crankcase (optional)
▪ Remote Shutdown (optional)
– Differential protection (optional)
– Earth connector closed (optional)
– Gas leakage (optional)
Load reduction request SaCoSone GENSET requests a load reduction from PMS in case of VIT errors.
The load reduction has to be carried out by the PMS. For safety reason
SaCoSone GENSET will not reduce the load by itself.
Alarm/monitoring system
Alarming The alarm function of SaCoSone supervises all necessary parameters and
generates alarms to indicate discrepancies when required. The alarms will be
transferred to ship alarm system via Modbus data communication.
Self-monitoring SaCoSone carries out independent self-monitoring functions. Thus, for exam-
ple the connected sensors are checked constantly for function and wire
break. In case of a fault SaCoSone reports the occurred malfunctions in single
system components via system alarms.
Control SaCoSone controls all engine-internal functions as well as external compo-
nents, for example:
▪ Start/stop sequences:
Local and remote start/stop sequence for the GenSet. Activation of start
device. Control (auto start/stop signal) regarding prelubrication oil pump.
Monitoring and control of the acceleration period.
▪ Jet system:
For air fuel ratio control purposes, compressed air is lead to the turbo-
charger at start and at load steps.
▪ Control signals for external functions:
– Nozzle cooling water pump (only engine type MAN L32/40)
– HT cooling water preheating unit
– Prelubrication oil pump control
– Variable injection timing
▪ Redundant shutdown functions:
3 Engine automation
– Engine overspeed
– Low lube oil pressure inlet engine
– High cooling water temperature outlet engine
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Speed Control System

Governor The engine electronic speed control is realised by the Control Module. As
standard, the engine is equipped with an electro-hydraulic actuator. Engine
speed indication is carried out by means of redundant pick-ups at the cam-
shaft.
Speed adjustment Local, manual speed setting is possible at the Control Unit with a turn switch.
3.5 Interfaces
Remote speed setting is either possible via 4–20 mA signal or by using hard-
wired lower/raise commands.
Speed adjustment range Between –5 % and +10 % of the nominal speed at idle running.
Droop Adjustable by parameterisation tool from 0–5 % droop.
Load distribution By droop setting.
Engine stop Engine stop can be initiated local at the Display Module and remote via a
hardware channel or the bus interface.
3.5 Interfaces
Data machinery interface

This interface serves for data exchange to ship alarm systems or integrated
automation systems (IAS).
The status messages, alarms and safety actions, which are generated in the
system, can be transferred. All measuring values and alarms acquired by
SaCoSone GENSET are available for transfer.
The following Modbus protocols are available:
▪ Modbus RTU (Standard)
▪ Modbus ASCII
The Modbus RTU protocol is the standard protocol used for the communica-
tion from the GenSet. For the integration in older automation system, also
Modbus ASCII is available.
Modbus RTU protocol

The Modbus RTU protocol is the standard protocol used for the communica-
tion from the GenSet.
The bus interface provides a serial connection. The protocol is implemented
according to the following definitions:
▪ Modbus application protocol specification, Modbus over serial line speci-
fication and implementation guide
There are two serial interface standards available:
▪ RS422 – Standard, 4 + 2 wire (cable length <= 100 m), cable type as
specified in the circuit diagram, line termination: 150 Ohms
▪ RS485 – Standard, 2 + 2 wire (cable length <= 100 m), cable type as
specified in the circuit diagram, line termination: 150 Ohms
Settings The communication parameters are set as follows:
3 Engine automation
Modbus slave SaCoS

Modbus master Machinery alarm system
Slave ID (default) 1
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Data rate (default) 57,600 baud
Data rate (optionally available) 4,800 baud

9,600 baud
19,200 baud
38,400 baud
115,200 baud
Modbus slave SaCoS

3.5 Interfaces
Data bits 8
Stop bits 1
Parity None
Transmission mode Modbus RTU

Table 55: Settings for Modbus RTU
Function codes The following function codes are available to gather data from the SaCoSone
controllers:
Function code Function code Description
hexadecimal
1 0x01 read coils
3 0x03 read holding registers
5 0x05 write coil
6 0x06 write single register
15 0x0F write multiple coils
16 0x10 write multiple registers
22 0x16 mask write register
23 0x17 read multiple registers

Table 56: Functions codes
Message frame separation Message frames shall be separated by a silent interval of at least 4 character
times.
Provided data Provided data includes measured values and alarm or state information of
the engine.
Measured values are digitised analogue values of sensors, which are stored
in a fixed register of the control module S. Measured values include media
values (pressures, temperatures) where, according to the rules of classifica-
tion, monitoring has to be done by the machinery alarm system. The data
type used is signed integer of size 16 bit. Measured values are scaled by a
constant factor in order to provide decimals of the measured.
Pre-alarms, shutdowns and state information from the SaCoSone system are
available as single bits in fixed registers. The data type used is unsigned of
size 16 bit. The corresponding bits of alarm or state information are set to the
binary value „1“, if the event is active.
3 Engine automation
Contents of List of Signals For detailed information about the transferred data, please refer to the ”List
of Signals“ of the engine’s documentation set. This list contains the following
information:
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Field Description
Address The address (e.g.: MW15488) is the software address used in
the control module small.
HEX The hexadecimal value (e.g.: 3C80) of the software address

that has to be used by the MODBUS master when collecting
the specific data.
Field Description
3.5 Interfaces
Bit Information of alarms, reduce load, shutdown, etc. are availa-
ble as single bits. Bits in each register are counted 0 to 15.
Meas. Point The dedicated denomination of the measuring point or limit

value as listed in the „list of measuring and control devices“.
Description A short description of the measuring point or limit value.
Unit Information about how the value of the data has to be evalu-
ated by the Modbus master (e.g. „°C/100“ means: Reading a
data value of „4156“ corresponds to 41.56 °C)
Origin Name of the system where the specific sensor is connected

to, or the alarm is generated.
Signal The range of measured value.

Table 57: Content of List of Signals
Live bit In order to enable the alarm system to check whether the communication
with SaCoSone is working, a live bit is provided in the list of signals. This bit is
alternated every 4 seconds by SaCoSone.Thus, if it remains unchanged for
more than 4 seconds, the communication is down.
Modbus ASCII
General The communication setup is: 9,600 baud, 8 databits, 1 stopbit, no parity.
The Modbus protocol accepts one command (Function code 03) for reading
analogue and digital input values one at a time, or as a block of up to 32
inputs.
The following section describes the commands in the Modbus protocol,
which are implemented, and how they work.
Protocol description The ASCII and RTU version of the Modbus protocol is used, where the
CMS/DM works as Modbus slave.
All data bytes will be converted to 2-ASCII characters (hex-values). Thus,
when below is referred to “bytes“ or “words“, these will fill out 2 or 4 charac-
ters, respectively in the protocol. The general “message frame format“ has
the following outlook:
[:] [SLAVE] [FCT] [DATA] [CHECKSUM] [CR] [LF]
▪ [:]
1 char. Begin of frame
▪ [SLAVE]
2 char. Modbus slave address (Selected on DIP-switch at Display Mod-
ule)
3 Engine automation
▪ [FCT]
2 char. function code
▪ [DATA]
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n X 2 char. data
▪ [CHECKSUM]
2 char. checksum (LRC)
▪ [CR]
1 char. CR
▪ [LF]
1 char. LF (end of frame)
The following function codes (FCT) are accepted:

3.5 Interfaces
▪ 03H: Read n words at specific address

▪ 10H: Write n words at specific address
In response to the message frame, the slave (CMS) must answer with ap-
propriate data. If this is not possible, a package with the most important bit
in FCT set to 1 will be returned, followed by an exception code, where the
following is supported:
▪ 01: Illegal function
▪ 02: Illegal data address
▪ 03: Illegal data value
▪ 06: BUSY. Message rejected
FCT = 03H: Read words
The master transmits an inquiry to the slave (CMS) to read a number (n) of
datawords from a given address. The slave (CMS) replies with the required
number (n) of datawords. To read a single register (n) must be set to 1. To
read block type register (n) must be in the range 1...32.
Request (master):
[DATA] = [ADR][n]
[ADR]=Word stating the address in HEX.
[n]=Word stating the number of words to be read.
Answer (slave-CMS):
[DATA] = [bb][1. word][2. word]....[n. word]
[bb]=Byte, stating number of subsequent bytes.
[1. word]=1. dataword
[n. word]=No n. dataword
FCT = 10H: Write words
The master sends data to the slave (CMS/DM) starting from a particular ad-
dress. The slave (CMS/DM) returns the written number of bytes, plus echoes
the address.
Write data (master):
[DATA] = [ADR][n] [bb][1. word][2. word]....[n word]
[ADR] = Word that gives the address in HEX.
[n] = Word indicating number of words to be written.
[bb] = Byte that gives the number of bytes to follow (2*n)
Please note that 8bb9 is byte size!
3 Engine automation

Answer (slave-CMS/DM):
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[DATA] = [ADR][bb*2]
[ADR]= Word HEX that gives the address in HEX
[bb*2]=Number of words written.
Data format
3.5 Interfaces
Example for data format MW113 71 0 F Signal fault ZS82 : Emergency stop SF=1 CMS binary
(pushbutton)
1 F Signal fault ZS75 : Turning gear dis- SF=1 CMS binary
engaged
2 F Signal fault SS84 : Remote stop SF=1 CMS binary
3 F Signal fault SS83 : Remote start SF=1 CMS binary
4 F Signal fault LAH28 : Lube oil level SF=1 CMS binary

high
5 F Signal fault LAL28 : Lube oil level SF=1 CMS binary

low
6 F Signal fault LAH42 : Fuel oil leakage SF=1 CMS binary

high
7 F Signal fault ZS97 : Remote switch SF=1 CMS binary
8 F Signal fault LAH92 : OMD alarm SF=1 CMS binary
9 F Signal fault TAH 29-27 : CCMON SF=1 CMS binary

alarm
10 F Signal fault : Remote reset SF=1 CMS binary
11 F Signal fault LAH98 : Alternator cool- SF=1 CMS binary

ing water leakage alarm
12 F Signal fault : Emergency alternator SF=1 CMS binary

mode
13 F Signal fault : Speed raise SF=1 CMS binary
14 F Signal fault : Speed lower SF=1 CMS binary
15 F Signal fault : Switch isochronous/ SF=1 CMS binary

droop mode
Table 58: Extract from Modbus ASCII list
For this example we assume that the following alarms have been triggered:
▪ Signal fault SS83 : Remote start,
▪ Signal fault LAL28 : Lube oil level low,
▪ Signal fault ZS97 : Remote switch,
▪ Signal fault LAH92 : OMD alarm,
▪ Signal fault TAH 29-27 : CCMON alarm,
3 Engine automation
▪ Signal fault : Emergency alternator mode,

▪ Signal fault : Switch isochronous/droop mode
Bit 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
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Value 0 0 0 1 0 1 0 1 1 1 0 0 1 0 0 1
Table 59: Bit sample of MW113
In Modbus ASCII these 16 bits are grouped in 4 groups each containing 4

bits and then translated from binary format to hexadecimal format (0 – 9, A –
F)
- Binary Hex
3.5 Interfaces
Bit 0-3 0001 1
Bit 4-7 0101 5
Bit 8-11 1100 C
Bit 12-15 1001 9

Table 60: Translation from binary to hexadecimal format
The next step these hexadecimal values are interpreted as ASCII-signs (ex-
tract from ASCII table)
Hexadecimal ASCII
30 0
31 1
32 2
33 3
34 4
35 5
36 6
37 7
38 8
39 9
40 A
41 B
42 C
43 D
44 E
45 F
Table 61: Interpretation of hexadecimal values as ASCII
In this example the letter (ASCII letter) 1 will be translated hexadecimal value
31 and so on:
1 --> 31
5 --> 35
3 Engine automation
C --> 43
9 --> 39
When the ship alarm system recalls MW113, it receives the following data
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embedded in the Modbus message: 31 35 43 39
Interfaces to external systems

Alternator control SaCoSone GENSET provides inputs for all temperature signals for the temper-
atures of the alternator bearings and alternator windings.
Power management Hardwired interface for remote start/stop, speed setting, alternator circuit
3.7 Installation requirements

breaker trip etc.
Remote control For remote control several digital inputs are available.
Ethernet interface The ethernet interface at the Display Module can be used for the connection
of SaCoSone EXPERT.
Serial interface The serial RS485 interface is used for the connection to the CoCoS-EDS.
Multifunction Monitoring SaCoSone GENSET provides an interface to a Multifunction Monitoring Sys-
System tem. The Multifunction Monitoring System is delivered as extra control cabi-
net.
External Governor SaCoSone GENSET provides a Power Output signal (release signal) to the
actuator of the external mechanical or electronical governor. As long as the
signal is closed, the speed governor is not releasing any fuel amount.
For the actuator of the electronical mechanical governor an analogue 4…20
mA signal (to avoid black smoke during operation, e.g. during load up of the
engine, a charge air limiter) and a digital input (healthy output / major alarm,
which is closed, as long as there is no failure within the governor) is provided.
3.6 Technical data
Control Unit
L engine
Width 380 mm
Height 1000 mm
Depth 210 mm
Depth overall 250 mm
Weight 75 kg
Multifunction Monitoring System

L engine
Width 380 mm
Height 380 mm
Depth 210 mm
Depth overall 250 mm
Weight 50 kg
3 Engine automation

The cables for the connection of sensors and actuators which are not moun-
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ted on the engine are not included in the scope of MAN Energy Solutions
supply. Shielded cables have to be used for the cabling of sensors. For elec-
trical noise protection, an electric ground connection must be made from the
Control Unit to earthing.
All wiring to external systems should be carried out without conductor
sleeves.
The redundant CAN cables are MAN Energy Solutions scope of supply. If the
customer provides these cables, the cable must have a characteristic impe-
dance of 120 Ω.
3 Engine automation
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4 Specification for engine supplies
4.1 Explanatory notes for operating supplies – Diesel

engines
4.1 Explanatory notes for operating supplies – Diesel engines
Temperatures and pressures stated in section Planning data, Page 57 must
be considered.
4.1.1 Lube oil
Main fuel Lube oil type Viscosity class Base No. (BN)
MGO (class DMA or DMZ) Doped (HD) + additives SAE 40 10 – 16 mg KOH/g Depending on
sulphur content
MDO (ISO-F-DMB) 10 – 20 mg KOH/g
HFO Medium-alkaline + 20 – 55 mg KOH/g

additives
Table 62: Main fuel/lube oil type
Selection of the lube oil must be in accordance with the relevant sections.
The lube oil must always match the worst fuel oil quality.
A base number (BN) that is too low is critical due to the risk of corrosion.
A base number that is too high, could lead to deposits/sedimentation.
4.1.2 Fuel
The engine is designed for operation with HFO, MDO (DMB) and MGO (DMA,
DMZ) according to ISO 8217-2017 in the qualities quoted in the relevant sec-
tions.
Additional requirements for HFO before engine:
▪ Water content before engine: Max. 0.2 %
▪ Al + Si content before engine: Max. 15 mg/kg
Engine operation with DM-grade fuel according to ISO 8217-2017, viscosity

≥ 2 cSt at 40 °C
A) Short-term operation, Engines that are normally operated with heavy fuel, can also be operated
max. 72 hours with DM-grade fuel for short periods.
Boundary conditions:
▪ DM-grade fuel in accordance with stated specifications and a viscosity of
≥ 2 cSt at 40 °C.
▪ MGO-operation maximum 72 hours within a two-week period (cumula-
tive with distribution as required).
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▪ Fuel oil cooler switched on and fuel oil temperature before engine
≤ 45 °C. In general, the minimum viscosity before engine of 1.9 cSt must
not be undershoot!
B) Long-term (> 72 h) or For long-term (> 72 h) or continuous operation with DM-grade fuel special
continuous operation engine- and plant-related planning prerequisites must be set and special
actions are necessary during operation.
Following features are required on engine side:
▪ Valve seat lubrication with possibility to be turned off and on manually.

4.1 Explanatory notes for operating supplies – Diesel
engines
▪ In case of conventional injection system, injection pumps with sealing oil

system, which can be activated and cut off manually, are necessary.
Following features are required on plant side:
▪ Layout of fuel system to be adapted for low-viscosity fuel (capacity and
design of fuel supply and booster pump).
▪ Cooler layout in fuel system for a fuel oil temperature before engine of
≤ 45 °C (min. permissible viscosity before engine 1.9 cSt).
▪ Nozzle cooling system with possibility to be turned off and on during
engine operation.
Boundary conditions for operation:
▪ Fuel in accordance with MGO (DMA, DMZ) and a viscosity of ≥ 2 cSt at
40 °C.
▪ Fuel oil cooler activated and fuel oil temperature before engine ≤ 45 °C.
In general the minimum viscosity before engine of 1.9 cSt must not be
undershoot!
▪ Valve seat lubrication turned on.
▪ In case of conventional injection system, sealing oil of injection pumps
activated.
▪ Nozzle cooling system switched off.
Continuous operation with MGO (DMA, DMZ):
▪ Lube oil for diesel operation (BN10-BN16) has to be used.
Operation with heavy fuel oil of a sulphur content of < 1.5 %

Previous experience with stationary engines using heavy fuel of a low sulphur
content does not show any restriction in the utilisation of these fuels, provi-
ded that the combustion properties are not affected negatively.
This may well change if in the future new methods are developed to produce
low sulphur-containing heavy fuels.
If it is intended to run continuously with low sulphur-containing heavy fuel,
lube oil with a low BN (BN30) has to be used. This is required, in spite of
experiences that engines have been proven to be very robust with regard to
the continuous usage of the standard lube oil (BN40) for this purpose.
Instruction for minimum admissible fuel temperature

▪ In general the minimum viscosity before engine of 1.9 cSt must not be
undershoot.
▪ The fuel specific characteristic values “pour point” and “cold filter plug-
ging point” have to be observed to ensure pumpability respectively filter-
ability of the fuel oil.
▪ Fuel temperatures of approximately minus 10 °C and less have to be
avoided, due to temporarily embrittlement of seals used in the engines
fuel oil system and as a result their possibly loss of function.
2019-09-19 - 1.4
4.2 Specification of lubricating oil (SAE 40) for operation

with MGO/MDO and biofuels
4.1.3 Nozzle cooling
The quality of the engine cooling water required in relevant section has to be
ensured.
Nozzle cooling system activation
Kind of fuel Activated
MGO (DMA, DMZ) No, see section Fuel, Page 101
MDO (DMB) No
HFO Yes
Table 63: Nozzle cooling system activation
4.1.4 Intake air

The quality of the intake air as stated in the relevant sections has to be
ensured.
4.2 Specification of lubricating oil (SAE 40) for operation with MGO/MDO and
biofuels
General
The specific output achieved by modern diesel engines combined with the
use of fuels that satisfy the quality requirements more and more frequently
increase the demands on the performance of the lubricating oil which must
therefore be carefully selected.
Doped lubricating oils (HD oils) have a proven track record as lubricants for
the drive, cylinder, turbocharger and also for cooling the piston. Doped lubri-
cating oils contain additives that, amongst other things, ensure dirt absorp-
tion capability, cleaning of the engine and the neutralisation of acidic com-
bustion products.
Only lubricating oils that have been approved by MAN Energy Solutions may
be used. These are listed in the tables below. 4 Specification for engine supplies
Specifications
Base oil The base oil (doped lubricating oil = base oil + additives) must have a narrow
distillation range and be refined using modern methods. If it contains paraf-
fins, they must not impair the thermal stability or oxidation stability.
The base oil must comply with the following limit values, particularly in terms
of its resistance to ageing.
Properties/Characteristics Unit Test method Limit value
2019-09-19 - 1.4
Make-up – – Ideally paraffin based
Low-temperature behaviour, still flowable °C ASTM D 2500 –15
Flash point (Cleveland) °C ASTM D 92 > 200
Ash content (oxidised ash) Weight % ASTM D 482 < 0.02
Coke residue (according to Conradson) Weight % ASTM D 189 < 0.50

Ageing tendency following 100 hours of heating – MAN Energy Solu- –

up to 135 °C tions ageing oven1)
Insoluble n-heptane Weight % ASTM D 4055 < 0.2

or DIN 51592
Evaporation loss Weight % - <2
Spot test (filter paper) – MAN Energy Solu- Precipitation of resins or

tions test asphalt-like ageing products
must not be identifiable.
1)
Works' own method
Table 64: Target values for base oils
Compounded lubricating oils The base oil to which the additives have been added (doped lubricating oil)
(HD oils) must have the following properties:
Additives The additives must be dissolved in the oil, and their composition must ensure
that as little ash as possible remains after combustion.
The ash must be soft. If this prerequisite is not met, it is likely the rate of dep-
osition in the combustion chamber will be higher, particularly at the outlet
valves and at the turbocharger inlet housing. Hard additive ash promotes pit-
ting of the valve seats, and causes valve burn-out, it also increases mechani-
cal wear of the cylinder liners.
Additives must not increase the rate, at which the filter elements in the active
or used condition are blocked.
Washing ability The washing ability must be high enough to prevent the accumulation of tar
and coke residue as a result of fuel combustion.
Dispersion capability The selected dispersibility must be such that commercially-available lubricat-
ing oil cleaning systems can remove harmful contaminants from the oil used,
i.e. the oil must possess good filtering properties and separability.
Neutralisation capability The neutralisation capability (ASTM D2896) must be high enough to neutral-
ise the acidic products produced during combustion. The reaction time of
the additive must be harmonised with the process in the combustion cham-
ber.
Evaporation tendency The evaporation tendency must be as low as possible as otherwise the oil
consumption will be adversely affected.
Additional requirements The lubricating oil must not contain viscosity index improver. Fresh oil must
not contain water or other contaminants.
Lubricating oil selection

Engine SAE class
16/24, 21/31, 27/38, 28/32S, 32/40, 32/44, 35/44DF, 40/54, 40
45/60, 48/60, 58/64, 51/60DF
2019-09-19 - 1.4
Table 65: Viscosity (SAE class) of lubricating oils
Doped oil quality We recommend doped lube oils (HD oils) according to the international spec-
ifications MIL-L 2104 or API-CD with a base number of BN 10–16 mg
KOH/g. Lube oils according to the military specification O-278 can be used if
they are included in the current list of approved lube oils under https://corpo-

rate.man-es.com/lubrication. Lube oils not included in the list may only be
used following consultation with MAN Energy Solutions.
The operating conditions of the engine and the quality of the fuel determine
the additive fractions the lube oil should contain. If marine diesel oil with a
high sulfur content of 1.0 up to 1.5 weight % is used, a base number (BN) of
approx. 20 should be selected. However, the operating results that ensure
the most efficient engine operation ultimately determine the additive content.
Cylinder lubricating oil In engines with separate cylinder lubrication systems, the pistons and cylin-
der liners are supplied with lubricating oil via a separate lubricating oil pump.
The quantity of lubricating oil is set at the factory according to the quality of
the fuel to be used and the anticipated operating conditions.
Use a lubricating oil for the cylinder and lubricating circuit as specified above.
Oil for mechanical/hydraulic Multigrade oil 5W40 should ideally be used in mechanical-hydraulic control-
speed governors lers with a separate oil sump, unless the technical documentation for the
speed governor specifies otherwise. If this oil is not available when filling,
15W40 oil may be used instead in exceptional cases. In this case, it makes
no difference whether synthetic or mineral-based oils are used.
The military specification applied for these oils is NATO O-236.
Experience with the drive engine L27/38 has shown that the operating tem-
perature of the Woodward controller UG10MAS and corresponding actuator
for UG723+ can reach temperatures higher than 93 °C. In these cases, we
recommend using synthetic oil such as Castrol Alphasyn HG150.
Lubricating oil additives The use of other additives with the lubricating oil, or the mixing of different
brands (oils by different manufacturers), is not permitted as this may impair
the performance of the existing additives which have been carefully harmon-
ised with each another, and also specially tailored to the base oil.
Selection of lubricating oils/ Most of the oil manufacturers are in close regular contact with engine manu-
warranty facturers, and can therefore provide information on which oil in their specific
product range has been approved by the engine manufacturer for the partic-
ular application. Irrespective of the above, the lubricating oil manufacturers
are in any case responsible for the quality and characteristics of their prod-
ucts. If you have any questions, we will be happy to provide you with further
information.
Oil during operation There are no prescribed oil change intervals for MAN Energy Solutions 4 Specification for engine supplies
medium speed engines. The oil properties must be analysed monthly. As
long as the oil properties are within the defined threshold values, the oil may
be used further. See table Limit values for used lube oil, Page 110.
The quality can only be maintained if it is purified via a separator or an other-
wise suitable device.
Temporary operation with Due to current and future emission regulations, heavy fuel oil cannot be used
gas oil in designated regions. Low-sulphur diesel fuel must be used in these regions
instead.
If the engine is operated with low-sulphur diesel fuel for less than 1,000 h, a
2019-09-19 - 1.4
lubricating oil which is suitable for HFO operation (BN 30 – 55 mg KOH/g)

can be used during this period.
If the engine is operated provisionally with low-sulphur diesel fuel for more
than 1,000 h and is subsequently operated once again with HFO, a lubricat-
ing oil with a BN of 20 must be used. If the BN 20 lubricating oil from the
same manufacturer as the lubricating oil is used for HFO operation with
higher BN (40 or 50), an oil change will not be required when effecting the
changeover. It will be sufficient to use BN 20 oil when replenishing the used

lubricating oil.
If you wish to operate the engine with HFO once again, it will be necessary to
change over in good time to lubricating oil with a higher BN (30 – 55). If the
lubricating oil with higher BN is by the same manufacturer as the BN 20 lubri-
cating oil, the changeover can also be effected without an oil change. In
doing so, the lubricating oil with higher BN (30 – 55) must be used to replen-
ish the used lubricating oil roughly 2 weeks prior to resuming HFO operation.
Tests
A monthly analysis of lube oil samples is mandatory for safe engine opera-
tion. We can analyse fuel for customers in the MAN Energy Solutions Prime-
ServLab.
Note:
If operating fluids are improperly handled, this can pose a danger to health,
safety and the environment. The relevant safety information by the supplier of
operating fluids must be observed.
Manufacturer Base number (10) 12 – 16 (mgKOH/g)
CASTROL Castrol MLC 40 / MHP 154
CHEVRON Delo 1000Marine 40

(Texaco, Caltex) Delo SHP40
EXXONMOBIL Mobilgard 412 / Mobilgard 1SHC

Mobilgard ADL 40 1)
Delvac 1640 1)
PETROBRAS Marbrax CCD-410

Marbrax CCD-415
REPSOL Neptuno NT 1540
SHELL Gadinia 40
Gadinia AL40
Gadinia S3
Sirius X40 1)
STATOIL MarWay 1040 1)
TOTAL Lubmarine Caprano M40

Disola M4015
1)
With sulphur content in the fuel of less than 1 %
Table 66: Lube oils approved for use in MAN Energy Solutions four-stroke
engines that run on gas oil and diesel fuel
The current releases are available at https://corporate.man-es.com/lubrica-

tion.
2019-09-19 - 1.4
Note:
MAN Energy Solutionsdoes not assume liability for problems that occur
when using these oils.
Limit value Procedure
4.3 Specification of lubricating oil (SAE 40) for heavy fuel

operation (HFO)
Viscosity at 40° C 110 – 220 mm²/s ASTM D7042, ASTM D445,
DIN EN 16896 or ISO 3104
Base number (BN) at least 50% of the fresh oil ISO 3771
Flash point (PM) min. 185°C ISO 2719
Water content max. 0.2% (max. 0.5% for brief peri- DIN 51777 or ASTM D6304
ods)
n-heptane insoluble max. 1.5% DIN 51592 or IP 316
Metal content dependent on engine type and oper- –

ating conditions
Guide value only .

Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm ASTM D5185 or DIN 51399-1
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
For operation with bio-fuels: max. 12% FT-IR

proportion of bio-fuel
Table 67: Limit values for used lubricating oil
4.3 Specification of lubricating oil (SAE 40) for heavy fuel operation (HFO)
General
The specific output achieved by modern diesel engines combined with the
use of fuels that satisfy the quality requirements more and more frequently
increase the demands on the performance of the lubricating oil which must
therefore be carefully selected.
Medium alkalinity lubricating oils have a proven track record as lubricants for
the moving parts and turbocharger cylinder and for cooling the pistons.
Lubricating oils of medium alkalinity contain additives that, in addition to 4 Specification for engine supplies
other properties, ensure a higher neutralization reserve than with fully com-
pounded engine oils (HD oils).
International specifications do not exist for medium alkalinity lubricating oils.
A test operation is therefore necessary for a corresponding long period in
accordance with the manufacturer's instructions.
Only lubricating oils that have been approved by MAN Energy Solutions may
be used.
Specifications
2019-09-19 - 1.4
Base oil The base oil (doped lubricating oil = base oil + additives) must have a narrow
distillation range and be refined using modern methods. If it contains paraf-
fins, they must not impair the thermal stability or oxidation stability.
The base oil must comply with the limit values in the table below, particularly
in terms of its resistance to ageing:

operation (HFO)
Make-up – – Ideally paraffin based
Low-temperature behaviour, still flowable °C ASTM D 2500 –15
Flash point (Cleveland) °C ASTM D 92 > 200
Ash content (oxidised ash) Weight % ASTM D 482 < 0.02
Coke residue (according to Conradson) Weight % ASTM D 189 < 0.50
Ageing tendency following 100 hours of heating – MAN Energy Solu- –

up to 135 °C tions ageing oven1)
Insoluble n-heptane Weight % ASTM D 4055 < 0.2

or DIN 51592
Evaporation loss Weight % - <2
Spot test (filter paper) – MAN Energy Solu- Precipitation of resins or

tions test asphalt-like ageing products
must not be identifiable.
1)
Works' own method
Table 68: Target values for base oils
Medium alkalinity lubricating The prepared oil (base oil with additives) must have the following properties:
oil
Additives The additives must be dissolved in the oil and their composition must ensure
that after combustion as little ash as possible is left over, even if the engine is
provisionally operated with distillate oil.
The ash must be soft. If this prerequisite is not met, it is likely the rate of dep-
osition in the combustion chamber will be higher, particularly at the outlet
valves and at the turbocharger inlet housing. Hard additive ash promotes pit-
ting of the valve seats, and causes valve burn-out, it also increases mechani-
cal wear of the cylinder liners.
Additives must not increase the rate, at which the filter elements in the active
or used condition are blocked.
Washing ability The washing ability must be high enough to prevent the accumulation of tar
and coke residue as a result of fuel combustion.

The lubricating oil must not absorb the deposits produced by the fuel.
Dispersion capability The selected dispersibility must be such that commercially-available lubricat-
ing oil cleaning systems can remove harmful contaminants from the oil used,
i.e. the oil must possess good filtering properties and separability.
Neutralisation capability The neutralisation capability (ASTM D2896) must be high enough to neutral-
ise the acidic products produced during combustion. The reaction time of
the additive must be harmonised with the process in the combustion cham-
ber.
For tips on selecting the base number, refer to the table entitled Base num-
2019-09-19 - 1.4
ber to be used for various operating conditions, Page 109.

Evaporation tendency The evaporation tendency must be as low as possible as otherwise the oil
consumption will be adversely affected.
Additional requirements The lubricating oil must not contain viscosity index improver. Fresh oil must
not contain water or other contaminants.
Lube oil selection

operation (HFO)
Engine SAE class
16/24, 21/31, 27/38, 28/32S, 32/40, 32/44, 35/44DF, 40/54, 40
45/60, 48/60, 58/64, 51/60DF
Table 69: Viscosity (SAE class) of lubricating oils
Neutralisation properties Lubricating oils with medium alkalinity and a range of neutralization capabili-
(BN) ties (BN) are available on the market. At the present level of knowledge, an
interrelation between the expected operating conditions and the BN number
can be established. However, the operating results are still the overriding fac-
tor in determining which BN number provides the most efficient engine oper-
ation.
Table Base number to be used for various operating conditions, Page 109
indicates the relationship between the anticipated operating conditions and
the BN number.
Approx. BN Engines/operating conditions
of fresh oil
(mg KOH/g oil)
20 Marine diesel oil (MDO) of a lower quality and with a high sulfur content or heavy fuel oil with a
sulfur content of less than 0.50 %
30 generally 23/30H and 28/32H. 23/30A, 28/32A and 28/32S under normal operating conditions.
For engines 16/24, 21/31, 27/38, 32/40, 32/44CR, 32/44K, 40/54, 48/60 as well as 58/64 and
51/60DF operating with 100% HFO with a sulfur content < 1.5 % only.
40 Under unfavourable operating conditions and where the corresponding requirements for the oil
service life and cleaning capacity exist, 23/30A, 28/32A and 28/32S.
In general 16/24, 21/31, 27/38, 32/40, 32/44CR, 32/44K, 40/54, 48/60 as well as 58/64 and
51/60DF for operation with heavy fuel oil, provided the sulfur content is over 1.5 %.
50 32/40, 32/44CR, 32/44K, 40/54, 48/60 and 58/64, if the oil service life or engine cleanliness is
insufficient with a BN number of 40 (high sulfur content of fuel, extremely low lube oil consump-
tion).
Table 70: Base number to be used for various operating conditions
Operation with low-sulphur

fuel
To comply with the emissions regulations, the sulphur content of fuels used
nowadays varies. Fuels with low-sulphur content must be used in environ-
mentally-sensitive areas (e.g. SECA). Fuels with higher sulphur content may
be used outside SECA zones. In this case, the BN number of the lube oil
selected must satisfy the requirements for operation using fuel with high-sul-
phur content. A lube oil with low BN number may only be selected if fuel with
a low sulphur content is used exclusively during operation.
However, the practical results demonstrate that the most efficient engine
operation is the factor ultimately determining the permitted additive content.
Cylinder lubricating oil In engines with separate cylinder lubrication systems, the pistons and cylin-
der liners are supplied with lubricating oil via a separate lubricating oil pump.
2019-09-19 - 1.4
The quantity of lubricating oil is set at the factory according to the quality of
the fuel to be used and the anticipated operating conditions.
Use a lubricating oil for the cylinder and lubricating circuit as specified above.
Oil for mechanical/hydraulic Multigrade oil 5W40 should ideally be used in mechanical-hydraulic control-
operation (HFO)
speed governors lers with a separate oil sump, unless the technical documentation for the
speed governor specifies otherwise. If this oil is not available when filling,
15W40 oil may be used instead in exceptional cases. In this case, it makes
no difference whether synthetic or mineral-based oils are used.
The military specification applied for these oils is NATO O-236.
Experience with the drive engine L27/38 has shown that the operating tem-
perature of the Woodward controller UG10MAS and corresponding actuator
for UG723+ can reach temperatures higher than 93 °C. In these cases, we
recommend using synthetic oil such as Castrol Alphasyn HG150.
Lubricating oil additives The use of other additives with the lubricating oil, or the mixing of different
brands (oils by different manufacturers), is not permitted as this may impair
the performance of the existing additives which have been carefully harmon-
ised with each another, and also specially tailored to the base oil.
Selection of lubricating oils/ Most of the oil manufacturers are in close regular contact with engine manu-
warranty facturers, and can therefore provide information on which oil in their specific
product range has been approved by the engine manufacturer for the partic-
ular application. Irrespective of the above, the lubricating oil manufacturers
are in any case responsible for the quality and characteristics of their prod-
ucts. If you have any questions, we will be happy to provide you with further
information.
Oil during operation There are no prescribed oil change intervals for MAN Energy Solutions
medium speed engines. The oil properties must be analysed monthly. As
long as the oil properties are within the defined threshold values, the oil may
be used further. See table Limit values for used lube oil, Page 110.
The quality can only be maintained if it is purified via a separator or an other-
wise suitable device.
Temporary operation with Due to current and future emission regulations, heavy fuel oil cannot be used
gas oil in designated regions. Low-sulphur diesel fuel must be used in these regions
instead.
If the engine is operated with low-sulphur diesel fuel for less than 1,000 h, a
lubricating oil which is suitable for HFO operation (BN 30 – 55 mg KOH/g)
can be used during this period.
If the engine is operated provisionally with low-sulphur diesel fuel for more
than 1,000 h and is subsequently operated once again with HFO, a lubricat-
ing oil with a BN of 20 must be used. If the BN 20 lubricating oil from the
same manufacturer as the lubricating oil is used for HFO operation with
higher BN (40 or 50), an oil change will not be required when effecting the
changeover. It will be sufficient to use BN 20 oil when replenishing the used
lubricating oil.
If you wish to operate the engine with HFO once again, it will be necessary to
change over in good time to lubricating oil with a higher BN (30 – 55). If the
lubricating oil with higher BN is by the same manufacturer as the BN 20 lubri-
cating oil, the changeover can also be effected without an oil change. In
doing so, the lubricating oil with higher BN (30 – 55) must be used to replen-
2019-09-19 - 1.4
ish the used lubricating oil roughly 2 weeks prior to resuming HFO operation.
Viscosity at 40 °C 110 – 220 mm²/s ISO 3104 or ASTM D 445
Base number (BN) at least 50 % of fresh oil ISO 3771

operation (HFO)
Flash point (PM) At least 185 °C ISO 2719
Water content max. 0.2 % (max. 0.5 % for brief peri- ISO 3733 or ASTM D 1744
ods)
n-heptane insoluble max. 1.5 % DIN 51592 or IP 316
Metal content depends on engine type and operat- –

ing conditions
Guide value only

Fe max. 50 ppm
Cr max. 10 ppm –
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
Table 71: Limit values for used lubricating oil
Tests
A monthly analysis of lube oil samples is mandatory for safe engine opera-
tion. We can analyse fuel for customers in the MAN Energy Solutions Prime-
ServLab.
Base Number (mgKOH/g)
Manufacturer
20–25 30 40 50–55
AEGEAN – Alfamar 430 Alfamar 440 Alfamar 450
AVIN OIL S.A. – AVIN ARGO S 30 SAE AVIN ARGO S 40 SAE AVIN ARGO S 50 SAE
40 40 40
CASTROL TLX Plus 204 TLX Plus 304 TLX Plus 404 TLX Plus 504
CEPSA – Troncoil 3040 Plus Troncoil 4040 Plus Troncoil 5040 Plus
CHEVRON Taro 20DP40 Taro 30DP40 Taro 40XL40 Taro 50XL40

(Texaco, Caltex) Taro 20DP40X Taro 30DP40X Taro 40XL40X Taro 50XL40X
EXXONMOBIL Mobilgard M420 Mobilgard M430 Mobilgard M440 Mobilgard M50 4 Specification for engine supplies
Gulf Oil Marine GulfSea Power 4020 GulfSea Power 4030 GulfSea Power 4040 GulfSea Power 4055
Ltd. MDO Gulfgen Supreme 430 Gulfgen Supreme 440 Gulfgen Supreme 455
Gulfgen Supreme 420
Idemitsu Kosan Daphne Marine Oil Daphne Marine Oil Daphne Marine Oil –
Co.,Ltd. SW30/SW40/MV30/ SA30/SA40 SH40
MV40
LPC S.A. – CYCLON POSEIDON CYCLON POSEIDON CYCLON POSEIDON

HT 4030 HT 4040 HT 4050
2019-09-19 - 1.4
LUKOIL Navigo TPEO 20/40 Navigo TPEO 30/40 Navigo TPEO 40/40 Navigo TPEO 50/40
Navigo TPEO 55/40
Motor Oil Hellas – EMO ARGO S 30 SAE EMO ARGO S 40 SAE EMO ARGO S 50 SAE
S.A. 40 40 40
PETROBRAS Marbrax CCD-420 Marbrax CCD-430 Marbrax CCD-440 –
Base Number (mgKOH/g)

4.4 Specification of gas oil/diesel oil (MGO)
Manufacturer
20–25 30 40 50–55
PT Pertamina Medripal 420 Medripal 430 Medripal 440 Medripal 450/455
(PERSERO)
REPSOL Neptuno NT 2040 Neptuno NT 3040 Neptuno NT 4040 –
SHELL Argina S 40 Argina T 40 Argina X 40 Argina XL 40

Argina S2 40 Argina S3 40 Argina S4 40 Argina S5 40
Sinopec Sinopec TPEO 4020 Sinopec TPEO 4030 Sinopec TPEO 4040 Sinopec TPEO 4050
TOTAL LUBMAR- Aurelia TI 4020 Aurelia TI 4030 Aurelia TI 4040 Aurelia TI 4055
INE
Table 72: Approved lube oils for heavy fuel oil-operated MAN Energy Solutions four-stroke engines
Note:
MAN Energy Solutionsdoes not assume liability for problems that occur
when using these oils.
Diesel oil
Other designations Gas oil, marine gas oil (MGO), diesel oil
Gas oil is a crude oil medium distillate and therefore must not contain any
residual materials.
Military specification
Diesel fuels that satisfy the NATO F-75 or F-76 specifications may be used if
they adhere to the minimum viscosity requirements.
Specification
The suitability of fuel depends on whether it has the properties defined in this
specification (based on its composition in the as-delivered state).
The DIN EN 590 standard and the ISO 8217 standard (Class DMA or Class
DMZ) in the current version have been extensively used as the basis when
defining these properties. The properties correspond to the test procedures
stated.
Properties Unit Test procedure Typical value
Density at 15 °C kg/m 3
ISO 3675 ≥ 820.0
≤ 890.0
Kinematic viscosity at 40 °C mm2/s (cSt) ISO 3104 ≥2

≤ 6.0
Filtering capability 1)
2019-09-19 - 1.4
in summer and °C DIN EN 116 must be indicated

in winter °C DIN EN 116
Flash point in enclosed crucible °C ISO 2719 ≥ 60
Sediment content (extraction method) weight % ISO 3735 ≤ 0.01
Water content Vol. % ISO 3733 ≤ 0.05
Properties Unit Test procedure Typical value

Sulphur content ISO 8754 ≤ 1.5
Ash ISO 6245 ≤ 0.01

weight %
Coke residue (MCR) ISO CD 10370 ≤ 0.10
Hydrogen sulphide mg/kg IP 570 <2
Acid number mg KOH/g ASTM D664 < 0.5
Oxidation stability g/m3 ISO 12205 < 25
Lubricity μm ISO 12156-1 < 520

(wear scar diameter)
Content of biodiesel (FAME) % (v/v) EN 14078 not permissible
Cetane index and cetane number – ISO 4264 ≥ 40

ISO 5165
Other specifications:
ASTM D 975 – – 1D/2D

1)
It must be ensured that the fuel can be used under the climatic conditions in the area of application.
Table 73: Properties of Diesel Fuel (MGO) to be maintained
Additional information
Use of diesel oil If distillate intended for use as heating oil is used with stationary engines
instead of diesel oil (EL heating oil according to DIN 51603 or Fuel No. 1 or
no. 2 according to ASTM D 396), the ignition behaviour, stability and behav-
iour at low temperatures must be ensured; in other words the requirements
for the filterability and cetane number must be satisfied.
Viscosity To ensure sufficient lubrication, a minimum viscosity must be ensured at the
fuel pump. The maximum temperature required to ensure that a viscosity of
more than 1.9 mm2/s is maintained upstream of the fuel pump, depends on
the fuel viscosity. In any case, the fuel temperature upstream of the injection
pump must not exceed 45 °C.
The pour point indicates the temperature at which the oil stops flowing. To
ensure the pumping properties, the lowest temperature acceptable to the 4 Specification for engine supplies
fuel in the system should be about 10 ° C above the pour point.
Lubricity Normally, the lubricating ability of diesel oil is sufficient to operate the fuel
injection pump. Desulphurisation of diesel fuels can reduce their lubricity. If
the sulphur content is extremely low (< 500 ppm or 0.05%), the lubricity may
no longer be sufficient. Before using diesel fuels with low sulphur content,
you should therefore ensure that their lubricity is sufficient. This is the case if
the lubricity as specified in ISO 12156-1 does not exceed 520 μm.
You can ensure that these conditions will be met by using motor vehicle die-
sel fuel in accordance with EN 590 as this characteristic value is an integral
part of the specification.
2019-09-19 - 1.4
Note:
Analyses
4.5 Specification of diesel oil (MDO)
Analysis of fuel oil samples is very important for safe engine operation. We
can analyse fuel for customers at MAN Energy Solutions laboratory Prime-
ServLab.
Marine diesel oil

Other designations Marine diesel oil, marine diesel fuel.
Origin Marine diesel oil (MDO) is supplied as heavy distillate (designation ISO-F-
DMB) exclusively for marine applications. MDO is manufactured from crude
oil and must be free of organic acids and non-mineral oil products.
Specification
The suitability of a fuel depends on the engine design and the available
cleaning options as well as compliance with the properties in the following
table that refer to the as-delivered condition of the fuel.
The properties are essentially defined using the ISO 8217 standard in the
current version as the basis. The properties have been specified using the
stated test procedures.
Properties Unit Test procedure Designation
ISO-F specification – – DMB
Density at 15 °C kg/m3 ISO 3675 < 900
Kinematic viscosity at 40 °C mm2/s ≙ cSt ISO 3104 > 2.0

< 11 1)
Pour point, winter grade °C ISO 3016 <0
Pour point, summer grade °C ISO 3016 <6
Flash point (Pensky Martens) °C ISO 2719 > 60
Total sediment content weight % ISO CD 10307 0.10

Water content Vol. % ISO 3733 < 0.3
Sulphur content weight % ISO 8754 < 2.0
Ash content weight % ISO 6245 < 0.01
Coke residue (MCR) weight % ISO CD 10370 < 0.30
Cetane index and cetane number - ISO 4264 > 35

ISO 5165
Hydrogen sulphide mg/kg IP 570 <2
Acid number mg KOH/g ASTM D664 < 0.5

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Oxidation stability g/m3 ISO 12205 < 25
Lubricity μm ISO 12156-1 < 520

(wear scar diameter)
Other specifications:
Properties Unit Test procedure Designation

ASTM D 975 – – 2D
ASTM D 396 – – No. 2

Table 74: Properties of Marine Diesel Oil (MDO) to be maintained
1)
For engines 27/38 with 350 resp. 365 kW/cyl the viscosity must not
exceed 6 mm2/s @ 40 °C, as this would reduce the lifetime of the injection
system.
During reloading and transfer, MDO is treated like residual oil. It is possible
that oil is mixed with high-viscosity fuel or heavy fuel oil, for example with res-
idues of such fuels in the bunker vessel, which can markedly deteriorate the
properties. Admixtures of biodiesel (FAME) are not permissible!
Lubricity Normally, the lubricating ability of diesel oil is sufficient to operate the fuel
injection pump. Desulphurisation of diesel fuels can reduce their lubricity. If
the sulphur content is extremely low (< 500 ppm or 0.05%), the lubricity may
no longer be sufficient. Before using diesel fuels with low sulphur content,
you should therefore ensure that their lubricity is sufficient. This is the case if
the lubricity as specified in ISO 12156-1 does not exceed 520 μm.
You can ensure that these conditions will be met by using motor vehicle die-
sel fuel in accordance with EN 590 as this characteristic value is an integral
part of the specification.
The fuel must be free of lubricating oil (ULO – used lubricating oil, old oil).
Fuel is considered as contaminated with lubricating oil when the following
concentrations occur:
Ca > 30 ppm and Zn > 15 ppm or Ca > 30 ppm and P > 15 ppm.
The pour point specifies the temperature at which the oil no longer flows. The
lowest temperature of the fuel in the system should be roughly 10 °C above
the pour point to ensure that the required pumping characteristics are main-
tained.
A minimum viscosity must be observed to ensure sufficient lubrication in the
fuel injection pumps. The temperature of the fuel must therefore not exceed
45 °C. 4 Specification for engine supplies
Seawater causes the fuel system to corrode and also leads to hot corrosion
of the exhaust valves and turbocharger. Seawater also causes insufficient
atomisation and therefore poor mixture formation accompanied by a high
proportion of combustion residues.
Solid foreign matters increase mechanical wear and formation of ash in the
cylinder space.
We recommend the installation of a separator upstream of the fuel filter. Sep-
aration temperature: 40 – 50°C. Most solid particles (sand, rust and catalyst
particles) and water can be removed, and the cleaning intervals of the filter
2019-09-19 - 1.4
elements can be extended considerably.

Note:
Analyses
4.6 Specification of heavy fuel oil (HFO)
Analysis of fuel oil samples is very important for safe engine operation. We
ServLab.
Prerequisites
Four-stroke diesel engines from MAN Energy Solutions can be powered with
any heavy fuel oil recovered from crude oil that fulfils the requirements speci-
fied in the table Properties of heavy fuel oil, Page 117, provided that the
engine and the fuel management system are designed accordingly. In order
to ensure a favourable ratio between fuel costs, spare parts and also repair
and maintenance expenditure, we recommend observing the following
points.
Heavy fuel oil (HFO)

Origin/Refinery process The quality of the heavy fuel oil largely depends on the quality of crude oil
and on the refining process used. This is why the properties of heavy fuel oils
with the same viscosity may vary considerably depending on the bunker
positions. Heavy fuel oil is normally a mixture of residual oil and distillates.
The components of the mixture are normally obtained from modern refinery
processes, such as Catcracker or Visbreaker. These processes can
adversely affect the stability of the fuel as well as its ignition and combustion
properties. The processing of the heavy fuel oil and the operating result of
the engine also depend heavily on these factors.
Bunker positions with standardised heavy fuel oil qualities should preferably
be used. If oils need to be purchased from independent dealers, also ensure
that these also comply with the international specifications. The engine oper-
ator is responsible for ensuring that suitable heavy fuel oils are chosen.
Specifications Fuels that can be used in an engine must satisfy the specifications to ensure
adequate quality. The limit values for heavy fuel oils are specified in the table
Specifications for heavy fuel oils, Page 117. The entries in the last column of
this table contain important background information and must therefore be

observed.
The relevant international specification is ISO 8217 in the respectively appli-
cable version. The fuel may only be used if it fully complies with the standard.
All qualities in these specifications up to K700 can be used, provided the fuel
management system has been designed for these fuels. To use fuels that do
not comply with these specifications (e.g. crude oil), consultation with the
technical service from MAN Energy Solutions Augsburg is required. Heavy
fuel oils with a maximum density of 1,010 kg/m3 may only be used if up-to-
date separators are installed.
Important Even if they fulfil the aforementioned specifications, the fuel properties speci-
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fied in the table Specifications for heavy fuel oils, Page 117 may possibly not
be adequate to determine the ignition and combustion properties and also
the stability of the fuel. This means that the operating behaviour of the engine
can depend on properties that are not defined in the specification. This par-
ticularly applies to the oil property that causes formation of deposits in the
combustion chamber, injection system, gas ducts and exhaust system. A
number of fuels have a tendency towards incompatibility with lubricating oil
which leads to deposits being formed in the fuel pumps that can cause a

blockage of the pumps. It may therefore be necessary to exclude specific
fuels that could cause problems.
Blends The addition of engine oils (old lubricating oil, ULO – used lubricating oil) and
additives that are not manufactured from mineral oils, (coal-tar oil, for exam-
ple), and residual products of chemical or other processes such as solvents
(polymers or chemical waste) is not permitted. Some of the reasons for this
are as follows: abrasive and corrosive effects, unfavourable combustion
characteristics, poor compatibility with mineral oils and, last but not least,
adverse effects on the environment. The order for the fuel must expressly
state what is not permitted as the fuel specifications that generally apply do
not include this limitation.
If engine oils (old lubricating oil, ULO – used lubricating oil) are added to fuel,
this poses a particular danger as the additives in the lubricating oil act as
emulsifiers that cause dirt, water and catfines to be transported as fine sus-
pension. They therefore prevent the necessary cleaning of the fuel. In our
experience (and this has also been the experience of other manufacturers),
this can severely damage the engine and turbocharger components.
The addition of chemical waste products (solvents, for example) to the fuel is
prohibited for environmental protection reasons according to the resolution
of the IMO Marine Environment Protection Committee passed on 1st January
1992.
Leak oil collector Leak oil collectors that act as receptacles for leak oil, and also return and
overflow pipes in the lube oil system, must not be connected to the fuel tank.
Leak oil lines should be emptied into sludge tanks.
Characteristic Unit Limit value1) Standard2)
Viscosity (at 50 °C)3) mm2/s (cSt) Max. 700 ISO 3104, ASTM D7042;
ASTM D445, DIN EN 16896
Viscosity (at 100 °C)3) mm2/s (cSt) Max. 55
Density (at 15 °C) kg/m3 Max. 1010 ISO 3675, ISO 12185,
DIN 51757
Flashpoint4) °C Min. 60 ISO 2719
Pour point5) °C Max. 30 ISO 3016
Acid value mg KOH/g Max. 2.5 ASTM D664 4 Specification for engine supplies
Aluminium and silicon mg/kg max. 156) IP 501, IP 470, ISO 10478
Total sediment (aged) % (m/m) max. 0.10 ISO 10307-2
Coke residue (Conradson) % (m/m) max. 20 DIN EN ISO 10370
Sulphur % (m/m) max. 5.07) ISO 8754, ISO 14596
Ash % (m/m) max. 0.15 ISO 6245
Vanadium mg/kg max. 450 IP 501, IP 470, ISO 14597,

DIN 51790-4
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Water % (v/v) max. 0.208) DIN 51777; ASTM D6304
CCAI 870 ISO 8217
Asphaltene content % (m/m) Max. 2/3 of the coke residue factory standard, DIN 51595
(Conradson)
Characteristic Unit Limit value1) Standard2)

Sodium mg/kg max. Na < 1/3 Vn, Na < 100 IP 501, IP 470, DIN 51399-1
Used oil9) mg/kg max. Ca < 30 and Zn < 15 or IP 501, IP 470, IP 500,
Ca < 30 and P < 15 DIN 51399-1
Hydrogen sulphide mg/kg max. 2 IP 570

1)
Requirement at motor inlet: Additional parameters to ISO 8217. The entire document ISO 8217 in its current ver-
sion is binding.
2)
Always consult the latest version.
3)
Follow specific requirements for the injection system.
4)
SOLAS standard: Applications not regulated by the SOLAS standard may have a lower flashpoint.
5)
The operator must set the pour point according to the specifications of the fuel system and usage conditions.
6)
The maximum Al and Si content in the bunker product (before purification) must not exceed 60 mg/kg.
7)
Local laws and regulations supersede the maximum allowed sulphur content.
8)
The maximum water content in the bunker product (before purification) must not exceed 0.50%.
9)
The fuel must generally not contain used oil. If thresholds are exceeded, this indicates used oil contamination.
Table 75: Characteristics of heavy fuel oil
Please see section ISO 8217-2017 Specification of HFO, Page 127.
The purpose of the following information is to show the relationship between
the quality of heavy fuel oil, heavy fuel oil processing, the engine operation
and operating results more clearly.
Selection of heavy fuel oil Economical operation with heavy fuel oil within the limit values specified in
the table Specifications for heavy fuel oil, Page 117 is possible under normal
operating conditions provided the system is working properly and regular
maintenance is carried out. If these requirements are not satisfied, shorter
maintenance intervals, higher wear and increased spare parts requirement is
to be expected. The required maintenance intervals and operating results
determine which quality of heavy fuel oil should be used.

It is an established fact that the price advantage decreases as viscosity
increases. It is therefore not always economical to use the fuel with the high-
est viscosity as in many cases the quality of this fuel will not be the best.
Viscosity/injection viscosity Heavy fuel oils with a high viscosity may be of an inferior quality. The maxi-
mum permissible viscosity depends on the preheating system installed and
the capacity (flow rate) of the separator.
The prescribed injection viscosity of 12 – 14 mm2/s (for GenSets, L16/24,
L21/31, L23/30H, L27/38, L28/32H: 12 – 18 cSt) and corresponding fuel
temperature upstream of the engine must be observed. This is the only way
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to ensure efficient atomisation and mixture formation and therefore low-resi-

due combustion. This also prevents mechanical overloading of the injection
system. For the prescribed injection viscosity and/or the required fuel oil tem-
perature upstream of the engine, refer to the viscosity temperature diagram.
Heavy fuel oil processing Whether or not problems occur with the engine in operation depends on how
carefully the heavy fuel oil has been processed. Particular care should be
taken to ensure that highly-abrasive inorganic foreign matter (catalyst parti-
cles, rust, sand) are effectively removed. It has been shown in practice that

wear as a result of abrasion in the engine increases considerably if the alumi-
num and silicium content is higher than 15 mg/kg.
Viscosity and density influence the cleaning effect. This must be taken into
account when designing and making adjustments to the cleaning system.
Settling tank The heavy fuel oil is pre-cleaned in the settling tank. This pre-cleaning is
more effective the longer the fuel remains in the tank and the lower the vis-
cosity of the heavy fuel oil (maximum preheating temperature 75 °C in order
to prevent the formation of asphalt in the heavy fuel oil). One settling tank is
suitable for heavy fuel oils with a viscosity below 380 mm2/s at 50 °C. If the
heavy fuel oil has high concentrations of foreign material or if fuels according
to ISO-F-RM, G/K380 or K700 are used, two settling tanks are necessary,
one of which must be designed for operation over 24 hours. Before transfer-
ring the contents into the service tank, water and sludge must be drained
from the settling tank.
Separators A separator is particularly suitable for separating material with a higher spe-
cific density – such as water, foreign matter and sludge. The separators must
be self-cleaning (i.e. the cleaning intervals must be triggered automatically).
Only new generation separators should be used. They are extremely effective
throughout a wide density range with no changeover required, and can sep-
arate water from heavy fuel oils with a density of up to 1.01 g/ml at 15 °C.
Table Table_ Achievable contents of foreign matter and water, Page 120
shows the prerequisites that must be met by the separator. These limit val-
ues are used by manufacturers as the basis for dimensioning the separator
and ensure compliance.
The manufacturer's specifications must be complied with to maximize the
cleaning effect.
Application in ships and stationary use: parallel installation

One separator for 100% flow rate One separator (reserve) for 100%
flow rate
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Figure 39: Arrangement of heavy fuel oil cleaning equipment and/or separator
The separators must be arranged according to the manufacturers' current
recommendations (Alfa Laval and Westphalia). The density and viscosity of
the heavy fuel oil in particular must be taken into account. If separators by
other manufacturers are used, MAN Energy Solutions should be consulted.
If the treatment is in accordance with the MAN Energy Solutions specifica-

tions and the correct separators are chosen, it may be assumed that the
results stated in the table entitled Achievable contents of foreign matter and
water, Page 120 for inorganic foreign matter and water in heavy fuel oil will
be achieved at the engine inlet.
Results obtained during operation in practice show that the wear occurs as a
result of abrasion in the injection system and the engine will remain within
acceptable limits if these values are complied with. In addition, an optimum
lube oil treatment process must be ensured.
Definition Particle size Quantity
Inorganic foreign matter < 5 µm < 20 mg/kg
including catalyst particles
Al+Si content – < 15 mg/kg
Water content – < 0.2 vol.%

Table 76: Achievable contents of foreign matter and water (after separation)
Water It is particularly important to ensure that the water separation process is as

thorough as possible as the water takes the form of large droplets, and not a
finely distributed emulsion. In this form, water also promotes corrosion and
sludge formation in the fuel system and therefore impairs the supply, atomi-
sation and combustion of the heavy fuel oil. If the water absorbed in the fuel
is seawater, harmful sodium chloride and other salts dissolved in this water
will enter the engine.
Water-containing sludge must be removed from the settling tank before the
separation process starts, and must also be removed from the service tank
at regular intervals. The tank's ventilation system must be designed in such a
way that condensate cannot flow back into the tank.
Vanadium/Sodium If the vanadium/sodium ratio is unfavourable, the melting point of the heavy
fuel oil ash may fall in the operating area of the exhaust-gas valve which can
lead to high-temperature corrosion. Most of the water and water-soluble
sodium compounds it contains can be removed by pretreating the heavy fuel
oil in the settling tank and in the separators.
The risk of high-temperature corrosion is low if the sodium content is one
third of the vanadium content or less. It must also be ensured that sodium
does not enter the engine in the form of seawater in the intake air.
If the sodium content is higher than 100 mg/kg, this is likely to result in a
higher quantity of salt deposits in the combustion chamber and exhaust-gas
system. This will impair the function of the engine (including the suction func-
tion of the turbocharger).
Under certain conditions, high-temperature corrosion can be prevented by
using a fuel additive that increases the melting point of heavy fuel oil ash (also
see Additives for heavy fuel oils, Page 124).
Ash Fuel ash consists for the greater part of vanadium oxide and nickel sulphate
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(see above section for more information). Heavy fuel oils containing a high
proportion of ash in the form of foreign matter, e.g. sand, corrosion com-
pounds and catalyst particles, accelerate the mechanical wear in the engine.
Catalyst particles produced as a result of the catalytic cracking process may
be present in the heavy fuel oils. In most cases, these catalyst particles are
aluminium silicates causing a high degree of wear in the injection system and
the engine. The aluminium content determined, multiplied by a factor of

between 5 and 8 (depending on the catalytic bond), is roughly the same as
the proportion of catalyst remnants in the heavy fuel oil.
Homogeniser If a homogeniser is used, it must never be installed between the settling tank
and separator as otherwise it will not be possible to ensure satisfactory sepa-
ration of harmful contaminants, particularly seawater.
Flash point (ASTM D 93) National and international transportation and storage regulations governing
the use of fuels must be complied with in relation to the flash point. In gen-
eral, a flash point of above 60 °C is prescribed for diesel engine fuels.
Low-temperature behaviour The pour point is the temperature at which the fuel is no longer flowable
(ASTM D 97) (pumpable). As the pour point of many low-viscosity heavy fuel oils is higher
than 0 °C, the bunker facility must be preheated, unless fuel in accordance
with RMA or RMB is used. The entire bunker facility must be designed in
such a way that the heavy fuel oil can be preheated to around 10 °C above
the pour point.
Pump characteristics If the viscosity of the fuel is higher than 1000 mm2/s (cSt), or the temperature
is not at least 10 °C above the pour point, pump problems will occur. For
more information, also refer to paragraph Low-temperature behaviour (ASTM
D 97, Page 121.
Combustion properties If the proportion of asphalt is more than two thirds of the coke residue (Con-
radson), combustion may be delayed which in turn may increase the forma-
tion of combustion residues, leading to such as deposits on and in the injec-
tion nozzles, large amounts of smoke, low output, increased fuel consump-
tion and a rapid rise in ignition pressure as well as combustion close to the
cylinder wall (thermal overloading of lubricating oil film). If the ratio of asphalt
to coke residues reaches the limit 0.66, and if the asphalt content exceeds
8%, the risk of deposits forming in the combustion chamber and injection
system is higher. These problems can also occur when using unstable heavy
fuel oils, or if incompatible heavy fuel oils are mixed. This would lead to an
increased deposition of asphalt (see paragraph Compatibility, Page 124).
Ignition quality Nowadays, to achieve the prescribed reference viscosity, cracking-process
products are used as the low viscosity ingredients of heavy fuel oils although
the ignition characteristics of these oils may also be poor. The cetane num-
ber of these compounds should be > 35. If the proportion of aromatic hydro-
carbons is high (more than 35 %), this also adversely affects the ignition
quality. 4 Specification for engine supplies
The ignition delay in heavy fuel oils with poor ignition characteristics is longer;
the combustion is also delayed which can lead to thermal overloading of the
oil film at the cylinder liner and also high cylinder pressures. The ignition delay
and accompanying increase in pressure in the cylinder are also influenced by
the end temperature and compression pressure, i.e. by the compression
ratio, the charge-air pressure and charge-air temperature.
The disadvantages of using fuels with poor ignition characteristics can be
limited by preheating the charge air in partial load operation and reducing the
output for a limited period. However, a more effective solution is a high com-
2019-09-19 - 1.4
pression ratio and operational adjustment of the injection system to the igni-
tion characteristics of the fuel used, as is the case with MAN Energy Solu-
tions piston engines.
The ignition quality is one of the most important properties of the fuel. This
value appears as CCAI in ISO 8217. This method is only applicable to

"straight run" residual oils. The increasing complexity of refinery processes
has the effect that the CCAI method does not correctly reflect the ignition
behaviour for all residual oils.
A testing instrument has been developed based on the constant volume
combustion method (fuel combustion analyser FCA), which is used in some
fuel testing laboratories (FCA) in conformity with IP 541.
The instrument measures the ignition delay to determine the ignition quality
of a fuel and this measurement is converted into an instrument-specific
cetane number (ECN: Estimated Cetane Number). It has been determined
that heavy fuel oils with a low ECN number cause operating problems and
may even lead to damage to the engine. An ECN >20 can be considered
acceptable.
As the liquid components of the heavy fuel oil decisively influence the ignition
quality, flow properties and combustion quality, the bunker operator is
responsible for ensuring that the quality of heavy fuel oil delivered is suitable
for the diesel engine. Also see illustration entitled Nomogram for determining
the CCAI – assigning the CCAI ranges to engine types, Page 123.
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V Viscosity in mm2/s (cSt) A Normal operating condi-
at 50° C tions
D Density [in kg/m3] at 15° B The ignition characteris-
C tics can be poor and
require adapting the
engine or the operating
conditions. 4 Specification for engine supplies
CCAI Calculated Carbon C Problems identified may
Aromaticity Index lead to engine damage,
even after a short period
of operation.
1 Engine type 2 The CCAI is obtained
from the straight line
through the density and
viscosity of the heavy fuel
oils.
The CCAI can be calculated using the following formula:
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CCAI = D - 141 log log (V+0.85) - 81
Figure 40: Nomogram for determining the CCAI and assigning the CCAI ranges to
engine types
Sulphuric acid corrosion The engine should be operated at the coolant temperatures prescribed in the
operating handbook for the relevant load. If the temperature of the compo-
nents that are exposed to acidic combustion products is below the acid dew
point, acid corrosion can no longer be effectively prevented, even if alkaline
lube oil is used.
The BN values specified in section Specification of lubricating oil (SAE 40) for
heavy fuel operation (HFO), Page 107 are sufficient, providing the quality of
lubricating oil and the engine's cooling system satisfy the requirements.
Compatibility The supplier must guarantee that the heavy fuel oil is homogeneous and
remains stable, even after the standard storage period. If different bunker oils
are mixed, this can lead to separation and the associated sludge formation in
the fuel system during which large quantities of sludge accumulate in the
separator that block filters, prevent atomisation and a large amount of resi-
due as a result of combustion.
This is due to incompatibility or instability of the oils. Therefore heavy fuel oil
as much as possible should be removed in the storage tank before bunker-
ing again to prevent incompatibility.
Blending the heavy fuel oil If heavy fuel oil for the main engine is blended with gas oil (MGO) or other
residual fuels (e.g. LSFO or ULSFO) to obtain the required quality or viscosity
of heavy fuel oil, it is extremely important that the components are compati-
ble (see section Compatibility, Page 124). The compatibility of the resulting
mixture must be tested over the entire mixing range. Reduced long-term sta-
bility due to consumption of the stability reserve can be a result. A p-value >
1.5 as per ASTM D7060 is required. Due to the infinite number of fuel mix-
tures on the market, it is not possible to make a general statement regarding
the compatibility of residual fuels. In order to avoid compatibility issues, it is
generally recommended not to mix fuels. If heavy fuel oil is supposed to be
mixed with distillate fuels in order to perform a switch-over process, the
heavy fuel oil must have a p-value of > 2.5 according to ASTM D7060.
Additives for heavy fuel oils MAN Energy Solutions engines can be operated economically without addi-
tives. It is up to the customer to decide whether or not the use of additives is
beneficial. The supplier of the additive must guarantee that the engine opera-
tion will not be impaired by using the product.
The use of heavy fuel oil additives during the warranty period must be avoi-
ded as a basic principle.
Additives that are currently used for diesel engines, as well as their probable
effects on the engine's operation, are summarised in the table below Addi-
tives for heavy fuel oils and their effects on the engine operation, Page 124.
Precombustion additives ▪ Dispersing agents/stabilisers

▪ Emulsion breakers
▪ Biocides
Combustion additives ▪ Combustion catalysts
(fuel savings, emissions)
Post-combustion additives ▪ Ash modifiers (hot corrosion)
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▪ Soot removers (exhaust-gas system)

Table 77: Additives for heavy fuel oils and their effects on the engine
operation
Heavy fuel oils with low From the point of view of an engine manufacturer, a lower limit for the sul-

sulphur content phur content of heavy fuel oils does not exist. We have not identified any
problems with the low-sulphur heavy fuel oils currently available on the mar-
ket that can be traced back to their sulphur content. This situation may
change in future if new methods are used for the production of low-sulphur
heavy fuel oil (desulphurisation, new blending components). MAN Energy
Solutions will monitor developments and inform its customers if required.
If the engine is not always operated with low-sulphur heavy fuel oil, corre-
sponding lubricating oil for the fuel with the highest sulphur content must be
selected.
Note:
Tests
Sampling In order to check whether the stated specifications and/or required delivery
conditions have been met, we recommend keeping at least one sample of
each bunker oil (at least for the warranty period of the engine). In order to
ensure that the sample is a representative sample of the bunkered oil, the
sample should be taken from the transfer line during start-up, after half the
operating time, as well as at the end of the bunkering period.
Analysis of samples To ensure sufficient cleaning of the fuel via the separator, perform regular
functional check by sampling up- and downstream of the separator.
Analysis of HFO samples is very important for safe engine operation. We can
analyse fuel for customers at MAN Energy Solutions laboratory PrimeServ-
Lab.

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2019-09-19 - 1.4

4.6.1 ISO 8217:2017 Specification of HFO
Characteristic Unit Limit Category ISO-F- Test method
RMA RMB RMD RME RMG RMK
10a 30 80 180 180 380 500 700 380 500 700
Kinematic mm2/s Max. 10.00 30.00 80.00 180.0 180.0 380.0 500.0 700.0 380.0 500.0 700.0 ISO 3104
viscosity
at 50 °Cb
MAN L32/40 GenSet IMO Tier II, Project Guide – Marine, EN
Density at 15 °C kg/m3 Max. 920.0 960.0 975.0 991.0 991.0 1010.0 See 7.1
ISO 3675 or
ISO 12185
CCAI – Max. 850 860 860 860 870 870 See 6.3 a)
Sulfurc % (m/m) Max. Statutory requirements See 7.2

ISO 8754
ISO 14596
Flash point °C Min. 60.0 60.0 60.0 60.0 60.0 60.0 See 7.3
ISO 2719
Hydrogen sulfide mg/kg Max. 2.00 2.00 2.00 2.00 2.00 2.00 See 7.11
IP 570
Acid numberd mg Max. 2.5 2.5 2.5 2.5 2.5 2.5 ASTM D664
KOH/g
Total sediment % (m/m) Max. 0.10 0.10 0.10 0.10 0.10 0.10 See 7.5
aged ISO 10307-2
Carbon residue: % (m/m) Max. 2.50 10.00 14.00 15.00 18.00 20.00 ISO 10370
micro method
4 Specification for engine supplies 4.6.1 ISO 8217:2017 Specification of HFO

127 (284)
4
128 (284)
4 Specification for engine supplies 4.6.1 ISO 8217:2017 Specification of HFO
4
Characteristic Unit Limit Category ISO-F- Test method
RMA RMB RMD RME RMG RMK
10a 30 80 180 180 380 500 700 380 500 700
Pour point
(upper)e
MAN L32/40 GenSet IMO Tier II, Project Guide – Marine, EN
Winter quality °C Max. 0 0 30 30 30 30 ISO 3016

Summer quality
°C Max. 6 6 30 30 30 30 ISO 3016
Water % (V/V) Max. 0.30 0.50 0.50 0.50 0.50 0.50 ISO 3733
Ash % (m/m) Max. 0.040 0.070 0.070 0.070 0.100 0.150 ISO 6245
Vanadium mg/kg Max. 50 150 150 150 350 450 see 7.7
IP 501, IP 470
or ISO 14597
Sodium mg/kg Max. 50 100 100 50 100 100 see 7.8

IP 501, IP 470
Aluminium plus mg/kg Max. 25 40 40 50 60 60 see 7.9

silicon IP 501, IP 470
or ISO 10478
Used lubricating – The fuel shall be free from ULO. A fuel shall be considered to contain ULO when either one of the following condi- (see 7.10) IP
oils (ULO): tions is met: 501 or
calcium and zinc
or mg/kg calcium > 30 and zinc > 15 IP 470

calcium and
phosphorus or
mg/kg calcium > 30 and phosphorus > 15 IP 500
a This category is based on a previously defined distillate DMC category that was described in ISO 8217:2005, Table 1. ISO 8217:2005 has been withdrawn.
b 1mm2/s = 1 cSt
c The purchaser shall define the maximum sulfur content in accordance with relevant statutory limitations. See 0.3 and Annex C.
d See Annex H.
e Purchasers shall ensure that this pour point is suitable for the equipment on board, especially if the ship operates in cold climates.
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4.7 Viscosity-temperature diagram (VT diagram)

Explanations of viscosity-temperature diagram
Figure 41: Viscosity-temperature diagram (VT diagram)
In the diagram, the fuel temperatures are shown on the horizontal axis and
the viscosity is shown on the vertical axis.
The diagonal lines correspond to viscosity-temperature curves of fuels with
different reference viscosities. The vertical viscosity axis in mm2/s (cSt)
applies for 40, 50 or 100 °C.
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Determining the viscosity-temperature curve and the required preheating

temperature
Example: Heavy fuel oil with Prescribed injection viscosity Required temperature of heavy fuel oil
180 mm2/s at 50 °C in mm²/s at engine inlet1) in °C
≥ 12 126 (line c)
≤ 14 119 (line d)
1)
With these figures, the temperature drop between the last preheating device and
the fuel injection pump is not taken into account.
Table 78: Determining the viscosity-temperature curve and the required
preheating temperature
A heavy fuel oil with a viscosity of 180 mm2/s at 50 °C can reach a viscosity
of 1,000 mm2/s at 24 °C (line e) – this is the maximum permissible viscosity
of fuel that the pump can deliver.
A heavy fuel oil discharge temperature of 152 °C is reached when using a
recent state-of-the-art preheating device with 8 bar saturated steam. At
higher temperatures there is a risk of residues forming in the preheating sys-
tem – this leads to a reduction in heating output and thermal overloading of
the heavy fuel oil. Asphalt is also formed in this case, i.e. quality deterioration.
The heavy fuel oil lines between the outlet of the last preheating system and
the injection valve must be suitably insulated to limit the maximum drop in
temperature to 4 °C. This is the only way to achieve the necessary injection
viscosity of 14 mm2/s for heavy fuel oils with a reference viscosity of 700
mm2/s at 50 °C (the maximum viscosity as defined in the international specifi-
cations such as ISO CIMAC or British Standard). If heavy fuel oil with a low
reference viscosity is used, the injection viscosity should ideally be 12 mm2/s
in order to achieve more effective atomisation to reduce the combustion resi-
due.
The delivery pump must be designed for heavy fuel oil with a viscosity of up
to 1,000 mm2/s. The pour point also determines whether the pump is capa-
ble of transporting the heavy fuel oil. The bunker facility must be designed so
as to allow the heavy fuel oil to be heated to roughly 10 °C above the pour
point.
Note:
The viscosity of gas oil or diesel oil (marine diesel oil) upstream of the engine
must be at least 1.9 mm2/s. If the viscosity is too low, this may cause seizing
of the pump plunger or nozzle needle valves as a result of insufficient lubrica-
tion.
This can be avoided by monitoring the temperature of the fuel. Although the
maximum permissible temperature depends on the viscosity of the fuel, it
must never exceed the following values:
▪ 45 °C at the most with MGO (DMA) and MDO (DMB)
A fuel cooler must therefore be installed.
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If the viscosity of the fuel is < 2 cSt at 40 °C, consult the technical service of
MAN Energy Solutions in Augsburg.
4.8 Specification of engine cooling water

Preliminary remarks
An engine coolant is composed as follows: water for heat removal and cool-
ant additive for corrosion protection.
As is also the case with the fuel and lubricating oil, the engine coolant must
be carefully selected, handled and checked. If this is not the case, corrosion,
erosion and cavitation may occur at the walls of the cooling system in con-
tact with water and deposits may form. Deposits obstruct the transfer of heat
and can cause thermal overloading of the cooled parts. The system must be
treated with an anticorrosive agent before bringing it into operation for the
first time. The concentrations prescribed by the engine manufacturer must
always be observed during subsequent operation. The above especially
applies if a chemical additive is added.
Requirements
Limit values The properties of untreated coolant must correspond to the following limit
values:
Properties/Characteristic Properties Unit
Water type Distillate or fresh water, free of foreign mat- –
ter.
Total hardness max. 10 dGH1)
pH value 6.5 – 8 –
Chloride ion content max. 50 mg/l2)

Table 79: Properties of coolant that must be complied with
1 dGH (German
1)
≙ 10 mg CaO in litre of water ≙ 17.9 mg CaCO3/l
hardness)
≙ 0.357 mval/l ≙ 0.179 mmol/l
2)
1 mg/l ≙ 1 ppm
Testing equipment The MAN Energy Solutions water testing equipment incorporates devices
that determine the water properties directly related to the above. The manu-
facturers of anticorrosive agents also supply user-friendly testing equipment.
For information on monitoring cooling water, see section Cooling water
inspecting, Page 137.
Distillate If distilled water (from a fresh water generator, for example) or fully desalina-
ted water (from ion exchange or reverse osmosis) is available, this should
ideally be used as the engine coolant. These waters are free of lime and
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salts, which means that deposits that could interfere with the transfer of heat
to the coolant, and therefore also reduce the cooling effect, cannot form.
However, these waters are more corrosive than normal hard water as the
thin film of lime scale that would otherwise provide temporary corrosion pro-
tection does not form on the walls. This is why distilled water must be han-
dled particularly carefully and the concentration of the additive must be regu-
larly checked.
Hardness The total hardness of the water is the combined effect of the temporary and
permanent hardness. The proportion of calcium and magnesium salts is of

overriding importance. The temporary hardness is determined by the carbo-
nate content of the calcium and magnesium salts. The permanent hardness
is determined by the amount of remaining calcium and magnesium salts (sul-
phates). The temporary (carbonate) hardness is the critical factor that deter-
mines the extent of limescale deposit in the cooling system.
Water with a total hardness of > 10°dGH must be mixed with distilled water
or softened. Subsequent hardening of extremely soft water is only necessary
to prevent foaming if emulsifiable slushing oils are used.
Damage to the cooling water system

Corrosion Corrosion is an electrochemical process that can widely be avoided by
selecting the correct water quality and by carefully handling the water in the
engine cooling system.
Flow cavitation Flow cavitation can occur in areas in which high flow velocities and high tur-
bulence is present. If the steam pressure is reached, steam bubbles form
and subsequently collapse in high pressure zones which causes the destruc-
tion of materials in constricted areas.
Erosion Erosion is a mechanical process accompanied by material abrasion and the
destruction of protective films by solids that have been drawn in, particularly
in areas with high flow velocities or strong turbulence.
Stress corrosion cracking Stress corrosion cracking is a failure mechanism that occurs as a result of
simultaneous dynamic and corrosive stress. This may lead to cracking and
rapid crack propagation in water-cooled, mechanically-loaded components if
the coolant has not been treated correctly.
Processing of engine cooling water

Formation of a protective The purpose of treating the engine coolant using anticorrosive agents is to
film produce a continuous protective film on the walls of cooling surfaces and
therefore prevent the damage referred to above. In order for an anticorrosive
agent to be 100 % effective, it is extremely important that untreated water
satisfies the requirements in the paragraph Requirements, Page 131.
Protective films can be formed by treating the coolant with anticorrosive
chemicals or emulsifiable slushing oil.

Emulsifiable slushing oils are used less and less frequently as their use has
been considerably restricted by environmental protection regulations, and
because they are rarely available from suppliers for this and other reasons.
Treatment prior to initial Treatment with an anticorrosive agent should be carried out before the
commissioning of engine engine is brought into operation for the first time to prevent irreparable initial
damage.
Note:
The engine must not be brought into operation without treating the cooling
water first.
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Additives for cooling water

Only the additives approved by MAN Energy Solutions and listed in the
tables under the paragraph entitled Permissible cooling water additives may
be used.
Required release A coolant additive may only be permitted for use if tested and approved as

per the latest directives of the ICE Research Association (FVV) “Suitability test
of internal combustion engine cooling fluid additives.” The test report must
be obtainable on request. The relevant tests can be carried out on request in
Germany at the staatliche Materialprüfanstalt (Federal Institute for Materials
Research and Testing), Abteilung Oberflächentechnik (Surface Technology
Division), Grafenstraße 2 in D-64283 Darmstadt.
Once the coolant additive has been tested by the FVV, the engine must be
tested in a second step before the final approval is granted.
In closed circuits only Additives may only be used in closed circuits where no significant consump-
tion occurs, apart from leaks or evaporation losses. Observe the applicable
environmental protection regulations when disposing of coolant containing
additives. For more information, consult the additive supplier.
Chemical additives
Sodium nitrite and sodium borate based additives etc. have a proven track
record. Galvanised iron pipes or zinc sacrificial anodes must not be used in
cooling systems. This corrosion protection is not required due to the prescri-
bed coolant treatment and electrochemical potential reversal that may occur
due to the coolant temperatures which are usual in engines nowadays. If
necessary, the pipes must be deplated.
Slushing oil
This additive is an emulsifiable mineral oil with additives for corrosion protec-
tion. A thin protective film of oil forms on the walls of the cooling system. This
prevents corrosion without interfering with heat transfer, and also prevents
limescale deposits on the walls of the cooling system.
Emulsifiable corrosion protection oils have lost importance. For reasons of
environmental protection and due to occasional stability problems with emul-
sions, oil emulsions are scarcely used nowadays.
It is not permissible to use corrosion protection oils in the cooling water cir-
cuit of MAN Energy Solutions engines.
Anti-freeze agents
If temperatures below the freezing point of water in the engine cannot be 4 Specification for engine supplies
excluded, an antifreeze agent that also prevents corrosion must be added to
the cooling system or corresponding parts. Otherwise, the entire system
must be heated.
Sufficient corrosion protection can be provided by adding the products listed
in the table entitled Antifreeze agent with slushing properties, Page 137 (Mili-
tary specification: Federal Armed Forces Sy-7025), while observing the pre-
scribed minimum concentration. This concentration prevents freezing at tem-
peratures down to –22 °C and provides sufficient corrosion protection. How-
ever, the quantity of antifreeze agent actually required always depends on
the lowest temperatures that are to be expected at the place of use.
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Antifreeze agents are generally based on ethylene glycol. A suitable chemical

anticorrosive agent must be added if the concentration of the antifreeze
agent prescribed by the user for a specific application does not provide an
appropriate level of corrosion protection, or if the concentration of antifreeze
agent used is lower due to less stringent frost protection requirements and
does not provide an appropriate level of corrosion protection. Considering
that the antifreeze agents listed in the table Antifreeze agents with slushing
properties, Page 137 also contain corrosion inhibitors and their compatibility
with other anticorrosive agents is generally not given, only pure glycol may be
used as antifreeze agent in such cases.
Simultaneous use of anticorrosive agent from the table Nitrite-free chemical
additives, Page 136 together with glycol is not permitted, because monitor-
ing the anticorrosive agent concentration in this mixture is no more possible.
Antifreeze agents may only be added after approval by MAN Energy Solu-
tions.
Before an antifreeze agent is used, the cooling system must be thoroughly
cleaned.
If the coolant contains emulsifiable slushing oil, antifreeze agent may not be
added as otherwise the emulsion would break up and oil sludge would form
in the cooling system.
Biocides
If you cannot avoid using a biocide because the coolant has been contami-
nated by bacteria, observe the following steps:
▪ You must ensure that the biocide to be used is suitable for the specific
application.
▪ The biocide must be compatible with the sealing materials used in the
coolant system and must not react with these.
▪ The biocide and its decomposition products must not contain corrosion-
promoting components. Biocides whose decomposition products con-
tain chloride or sulphate ions are not permitted.
▪ Biocides that cause foaming of coolant are not permitted.
Prerequisite for effective use of an anticorrosive agent
Clean cooling system

As contamination significantly reduces the effectiveness of the additive, the
tanks, pipes, coolers and other parts outside the engine must be free of rust
and other deposits before the engine is started up for the first time and after
repairs of the pipe system.
The entire system must therefore be cleaned with the engine switched off
using a suitable cleaning agent (see section Cooling water system cleaning,
Page 138).
Loose solid matter in particular must be removed by flushing the system
thoroughly as otherwise erosion may occur in locations where the flow veloc-
ity is high.
The cleaning agents must not corrode the seals and materials of the cooling
system. In most cases, the supplier of the coolant additive will be able to
carry out this work and, if this is not possible, will at least be able to provide
suitable products to do this. If this work is carried out by the engine operator,
he should use the services of a specialist supplier of cleaning agents. The
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cooling system must be flushed thoroughly after cleaning. Once this has
been done, the engine coolant must be immediately treated with anticorro-
sive agent. Once the engine has been brought back into operation, the
cleaned system must be checked for leaks.
Regular checks of the coolant condition and coolant system

Treated coolant may become contaminated when the engine is in operation,
which causes the additive to loose some of its effectiveness. It is therefore
advisable to regularly check the cooling system and the coolant condition. To
determine leakages in the lube oil system, it is advisable to carry out regular
checks of water in the expansion tank. Indications of oil content in water are,
e.g. discoloration or a visible oil film on the surface of the water sample.
The additive concentration must be checked at least once a week using the
test kits specified by the manufacturer. The results must be documented.
Note:
The chemical additive concentrations shall not be less than the minimum
concentrations indicated in the table Nitrite-containing chemical additives,
Page 136.
Excessively low concentrations lead to corrosion and must be avoided. Con-
centrations that are somewhat higher do not cause damage. Concentrations
that are more than twice as high as recommended should be avoided.
Every 2 to 6 months, a coolant sample must be sent to an independent labo-
ratory or to the engine manufacturer for an integrated analysis.
If chemical additives or antifreeze agents are used, coolant should be
replaced after 3 years at the latest.
If there is a high concentration of solids (rust) in the system, the water must
be completely replaced and entire system carefully cleaned.
Deposits in the cooling system may be caused by fluids that enter the cool-
ant or by emulsion break-up, corrosion in the system, and limescale deposits
if the water is very hard. If the concentration of chloride ions has increased,
this generally indicates that seawater has entered the system. The maximum
specified concentration of 50 mg chloride ions per kg must not be exceeded
as otherwise the risk of corrosion is too high. If exhaust gas enters the cool-
ant, this can lead to a sudden drop in the pH value or to an increase in the
sulphate content.
Water losses must be compensated for by filling with untreated water that
meets the quality requirements specified in the paragraph Requirements,
Page 131. The concentration of anticorrosive agent must subsequently be
checked and adjusted if necessary.
Subsequent checks of the coolant are especially required if the coolant had
to be drained off in order to carry out repairs or maintenance.
Protective measures
Anticorrosive agents contain chemical compounds that can pose a risk to
health or the environment if incorrectly used. Comply with the directions in
the manufacturer's material safety data sheets.
Avoid prolonged direct contact with the skin. Wash hands thoroughly after
use. If larger quantities spray and/or soak into clothing, remove and wash
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clothing before wearing it again.

If chemicals come into contact with your eyes, rinse them immediately with
plenty of water and seek medical advice.
Anticorrosive agents are generally harmful to the water cycle. Observe the
relevant statutory requirements for disposal.
Auxiliary engines
If the same cooling water system used in a MAN Energy Solutions two-
stroke main engine is used in a marine engine of type 16/24, 21/ 31, 23/30H,
27/38 or 28/32H, the cooling water recommendations for the main engine
must be observed.
Analyses
Regular analysis of coolant is very important for safe engine operation. We
ServLab.
Permissible cooling water additives

Manufacturer Product designation Initial dosing Minimum concentration ppm
for 1,000 litres
Product Nitrite Na-Nitrite
(NO2) (NaNO2)
Drew Marine Liquidewt 15 l 15,000 700 1,050

Maxigard 40 l 40,000 1,330 2,000
Wilhelmsen (Unitor) Rocor NB Liquid 21.5 l 21,500 2,400 3,600

Dieselguard 4.8 kg 4,800 2,400 3,600
Nalfleet Marine Nalfleet EWT Liq 3l 3,000 1,000 1,500

(9-108)
Nalfleet EWT 9-111 10 l 10,000 1,000 1,500
Nalcool 2000 30 l 30,000 1,000 1,500
Nalco Nalcool 2000 30 l 30,000 1,000 1,500

TRAC 102 30 l 30,000 1,000 1,500
TRAC 118 3l 3,000 1,000 1,500
Maritech AB Marisol CW 12 l 12,000 2,000 3,000
Uniservice, Italy N.C.L.T. 12 l 12,000 2,000 3,000

Colorcooling 24 l 24,000 2,000 3,000
Marichem – Marigases D.C.W.T. - 48 l 48,000 2,400 -

Non-Chromate
Marine Care Caretreat 2 16 l 16,000 4,000 6,000
Vecom Cool Treat NCLT 16 l 16,000 4,000 6,000

Table 80: Nitrite-containing chemical additives
Nitrite-free additives (chemical additives)

Manufacturer Product designation Concentration range [Vol. %]
Chevron, Arteco Havoline XLI 7.5 – 11
Total WT Supra 7.5 – 11

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Q8 Oils Q8 Corrosion Inhibitor 7.5 – 11

Long-Life
Table 81: Nitrite-free chemical additives
Anti-freeze solutions with slushing properties
4.9 Cooling water inspecting

Manufacturer Product designation Concentration range Antifreeze agent range1)
BASF Glysantin G 48
Glysantin 9313
Glysantin G 05
Castrol Radicool NF, SF
Shell Glycoshell Min. 35 Vol. % Min. –20 °C

Max. 60 Vol. % 2) Max. –50 °C
Mobil Antifreeze agent 500
Arteco Havoline XLC
Total Glacelf Auto Supra

Total Organifreeze
Table 82: Antifreeze agents with slushing properties
Antifreeze agent acc. to

1)
35 Vol. % corresponds to approx. –
ASTMD1177 20 °C
55 Vol. % corresponds to approx. – (manufacturer's instructions)
45 °C
60 Vol. % corresponds to approx. –
50 °C
2)
Antifreeze agent concentrations higher than 55 vol. % are only permitted, if safe heat removal is ensured by a suffi-
cient cooling rate.
4.9 Cooling water inspecting
Summary
Acquire and check typical values of the operating media to prevent or limit
damage.
The freshwater used to fill the cooling water circuits must satisfy the specifi-
cations. The cooling water in the system must be checked regularly in
accordance with the maintenance schedule.
The following work/steps is/are necessary:
Acquisition of typical values for the operating fluid, evaluation of the operating
fluid and checking the concentration of the anticorrosive agent.
Tools/equipment required
Equipment for checking the The following equipment can be used:
fresh water quality ▪ The MAN Energy Solutions water testing kit, or similar testing kit, with all
necessary instruments and chemicals that determine the water hardness,
pH value and chloride content (obtainable from MAN Energy Solutions or
Mar-Tec Marine, Hamburg).
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Equipment for testing the When using chemical additives:

concentration of additives ▪ Testing equipment in accordance with the supplier's recommendations.
Testing kits from the supplier also include equipment that can be used to
determine the fresh water quality.
Testing the typical values of water

4.10 Cooling water system cleaning
Short specification
Typical value/property Water for filling Circulating water
and refilling (without additive) (with additive)
Water type Fresh water, free of foreign matter Treated coolant
Total hardness ≤ 10 dGH 1)

≤ 10 dGH1)
pH value 6.5 – 8 at 20 °C ≥ 7.5 at 20 °C
Chloride ion content ≤ 50 mg/l ≤ 50 mg/l2)

Table 83: Quality specifications for coolants (short version)
1)
dGH German hardness
1 dGH = 10 mg/l CaO
= 17.9 mg/l CaCO3
= 0.179 mmol/L
2)
1 mg/l = 1 ppm
Testing the concentration of anticorrosive agents

Short specification
Anticorrosive agent Concentration
Chemical additives According to the quality specification, see section Engine cooling water specifications,
Page 131.
Anti-freeze agents
Table 84: Concentration of the cooling water additive
Testing the concentration of The concentration should be tested every week, and/or according to the
chemical additives maintenance schedule, using the testing instruments, reagents and instruc-
tions of the relevant supplier.
Chemical slushing oils can only provide effective protection if the right con-
centration is precisely maintained. This is why the concentrations recommen-
ded by MAN Energy Solutions (quality specifications in section Engine cool-
ing water specifications, Page 131) must be complied with in all cases.
These recommended concentrations may be other than those specified by

the manufacturer.
Testing the concentration of The concentration must be checked in accordance with the manufacturer's
anti-freeze agents instructions or the test can be outsourced to a suitable laboratory. If in
doubt, consult MAN Energy Solutions.
Regular water samplings Small quantities of lube oil in coolant can be found by visual check during
regular water sampling from the expansion tank.
Regular analysis of coolant is very important for safe engine operation. We
ServLab.
2019-09-19 - 1.4
Summary
Remove contamination/residue from operating fluid systems, ensure/re-
establish operating reliability.
Cooling water systems containing deposits or contamination prevent effec-

tive cooling of parts. Contamination and deposits must be regularly elimina-
ted.
This comprises the following:
Cleaning the system and, if required removal of limescale deposits, flushing
the system.
Cleaning
The coolant system must be checked for contamination at regular intervals.
Cleaning is required if the degree of contamination is high. This work should
ideally be carried out by a specialist who can provide the right cleaning
agents for the type of deposits and materials in the cooling circuit. The clean-
ing should only be carried out by the engine operator if this cannot be done
by a specialist.
Oil sludge Oil sludge from lubricating oil that has entered the cooling system or a high
concentration of anticorrosive agents can be removed by flushing the system
with fresh water to which some cleaning agent has been added. Suitable
cleaning agents are listed alphabetically in the table entitled Cleaning agents
for removing oil sludge., Page 139 Products by other manufacturers can be
used providing they have similar properties. The manufacturer's instructions
for use must be strictly observed.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew HDE - 777 4 – 5% 4 h at 50 – 60 °C
Nalfleet MaxiClean 2 2 – 5% 4 h at 60 °C
Unitor Aquabreak 0.05 – 0.5% 4 h at ambient temperature
Vecom Ultrasonic 4% 12 h at 50 – 60 °C
Multi Cleaner
Table 85: Cleaning agents for removing oil sludge
Lime and rust deposits Lime and rust deposits can form if the water is especially hard or if the con-
centration of the anticorrosive agent is too low. A thin lime scale layer can be
left on the surface as experience has shown that this protects against corro-
sion. However, limescale deposits with a thickness of more than 0.5 mm
obstruct the transfer of heat and cause thermal overloading of the compo-
nents being cooled.
Rust that has been flushed out may have an abrasive effect on other parts of
the system, such as the sealing elements of the water pumps. Together with
the elements that are responsible for water hardness, this forms what is
known as ferrous sludge which tends to gather in areas where the flow
velocity is low.
Products that remove limescale deposits are generally suitable for removing
rust. Suitable cleaning agents are listed alphabetically in the table entitled
Cleaning agents for removing limescale and rust deposits., Page 140 Prod-
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ucts by other manufacturers can be used providing they have similar proper-
ties. The manufacturer's instructions for use must be strictly observed. Prior
to cleaning, check whether the cleaning agent is suitable for the materials to
be cleaned. The products listed in the table entitled Cleaning agents for
removing limescale and rust deposits, Page 140 are also suitable for stain-
less steel.
Manufacturer Product Concentration Duration of cleaning procedure/temperature

Drew SAF-Acid 5 – 10 % 4 h at 60 – 70 °C
Descale-IT 5 – 10 % 4 h at 60 – 70 °C
Ferroclean 10 % 4 – 24 h at 60 – 70 °C
Nalfleet Nalfleet 9 - 068 5% 4 h at 60 – 75 °C
Unitor Descalex 5 – 10 % 4 – 6 h at approx. 60 °C
Vecom Descalant F 3 – 10 % ca. 4 h at 50 – 60 °C

Table 86: Cleaning agents for removing lime scale and rust deposits
In emergencies only Hydrochloric acid diluted in water or aminosulphonic acid may only be used
in exceptional cases if a special cleaning agent that removes limescale
deposits without causing problems is not available. Observe the following
during application:
▪ Stainless steel heat exchangers must never be treated using diluted
hydrochloric acid.
▪ Cooling systems containing non-ferrous metals (aluminium, red bronze,
brass, etc.) must be treated with deactivated aminosulphonic acid. This
acid should be added to water in a concentration of 3 – 5 %. The tem-
perature of the solution should be 40 – 50 °C.
▪ Diluted hydrochloric acid may only be used to clean steel pipes. If hydro-
chloric acid is used as the cleaning agent, there is always a danger that
acid will remain in the system, even when the system has been neutral-
ised and flushed. This residual acid promotes pitting. We therefore rec-
ommend you have the cleaning carried out by a specialist.
The carbon dioxide bubbles that form when limescale deposits are dissolved
can prevent the cleaning agent from reaching boiler scale. It is therefore
absolutely necessary to circulate the water with the cleaning agent to flush
away the gas bubbles and allow them to escape. The length of the cleaning
process depends on the thickness and composition of the deposits. Values
are provided for orientation in the table entitled Cleaning agents for removing
limescale and rust deposits, Page 140.
Following cleaning The cooling system must be flushed several times once it has been cleaned
using cleaning agents. Replace the water during this process. If acids are
used to carry out the cleaning, neutralise the cooling system afterwards with
suitable chemicals then flush. The system can then be refilled with water that
has been prepared accordingly.
Note:
Start the cleaning operation only when the engine has cooled down. Hot
engine components must not come into contact with cold water. Open the
venting pipes before refilling the cooling water system. Blocked venting pipes
prevent air from escaping which can lead to thermal overloading of the
engine.
Note:
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The products to be used can endanger health and may be harmful to the
environment. Follow the manufacturer's handling instructions without fail.
The applicable regulations governing the disposal of cleaning agents or acids
must be observed.
4.11 Specification of intake air (combustion air)

4.11 Specification of intake air (combustion air)
General
The quality and condition of intake air (combustion air) have a significant
effect on the engine output, wear and emissions of the engine. In this regard,
not only are the atmospheric conditions extremely important, but also con-
tamination by solid and gaseous foreign matter.
Mineral dust in the intake air increases wear. Chemicals and gases promote
corrosion.
This is why effective cleaning of intake air (combustion air) and regular main-
tenance/cleaning of the air filter are required.
When designing the intake air system, the maximum permissible overall pres-
sure drop (filter, silencer, pipe line) of 20 mbar must be taken into considera-
tion.
Exhaust turbochargers for marine engines are equipped with silencers
enclosed by a filter mat as a standard. The quality class (filter class) of the
filter mat corresponds to the ISO Coarse 45 % quality in accordance with
DIN EN ISO 16890.
Requirements
Liquid fuel engines: As minimum, inlet air (combustion air) must be cleaned
by an ISO Coarse 45% class filter as per DIN EN ISO 16890, if the combus-
tion air is drawn in from inside (e.g. from the machine room/engine room). If
the combustion air is drawn in from outside, in the environment with a risk of
higher inlet air contamination (e.g. due to sand storms, due to loading and
unloading grain cargo vessels or in the surroundings of cement plants), addi-
tional measures must be taken. This includes the use of pre-separators,
pulse filter systems and a higher grade of filter efficiency class at least up to
ISO ePM10 50% according to DIN EN ISO 16890.
Gas engines and dual-fuel engines: As minimum, inlet air (combustion air)
must be cleaned by an ISO COARSE 45% class filter as per DIN EN ISO
16890, if the combustion air is drawn in from inside (e.g. from machine room/

engine room). Gas engines or dual-fuel engines must be equipped with a dry
filter. Oil bath filters are not permitted because they enrich the inlet air with oil
mist. This is not permissible for gas operated engines because this may
result in engine knocking. If the combustion air is drawn in from outside, in
the environment with a risk of higher inlet air contamination (e.g. due to sand
storms, due to loading and unloading grain cargo vessels or in the surround-
ings of cement plants) additional measures must be taken. This includes the
use of pre-separators, pulse filter systems and a higher grade of filter effi-
ciency class at least up to ISO ePM10 50% according to DIN EN ISO 16890.
In general, the following applies:
The inlet air path from air filter to engine shall be designed and implemented
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airtight so that no false air may be drawn in from the outdoor.

The concentration downstream of the air filter and/or upstream of the turbo-
charger inlet must not exceed the following limit values.
The air must not contain organic or inorganic silicon compounds.
Properties Limit Unit 1)

4.12 Specification of compressed air
Dust (sand, cement, CaO, Al2O3 etc.) max. 5 mg/Nm3
Chlorine max. 1.5
Sulphur dioxide (SO2) max. 1.25
Hydrogen sulphide (H2S) max. 5
Salt (NaCl) max. 1

1)
One Nm3 corresponds to one cubic meter of gas at 0 °C and 101.32 kPa.
Table 87: Typical values for intake air (combustion air) that must be complied
with
Note:
Intake air shall not contain any flammable gases. Make sure that the com-
bustion air is not explosive and is not drawn in from the ATEX Zone.
General
For compressed air quality observe the ISO 8573-1:2010. Compressed air
must be free of solid particles and oil (acc. to the specification).
Requirements
Compressed air quality of The starting air must fulfil at least the following quality requirements accord-
starting air system ing to ISO 8573-1:2010.
Purity regarding solid particles Quality class 6

Particle size > 40µm max. concentration < 5 mg/m3
Purity regarding moisture Quality class 7
Residual water content < 0.5 g/m3
Purity regarding oil Quality class X
Additional requirements are:

▪ The air must not contain organic or inorganic silicon compounds.
▪ The layout of the starting air system must ensure that no corrosion may
occur.
▪ The starting air system and the starting air receiver must be equipped
with condensate drain devices.
▪ By means of devices provided in the starting air system and via mainte-
nance of the system components, it must be ensured that any hazard-
ous formation of an explosive compressed air/lube oil mixture is preven-
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ted in a safe manner.

Compressed air quality in the Please note that control air will be used for the activation of some safety
control air system functions on the engine – therefore, the compressed air quality in this system
is very important.
Control air must meet at least the following quality requirements according to
ISO 8573-1:2010.
▪ Purity regarding solid particles Quality class 5

▪ Purity regarding moisture Quality class 4
▪ Purity regarding oil Quality class 3
For catalysts
The following specifications are valid unless otherwise defined by any other
relevant sources:
Compressed air quality for Compressed air for soot blowing must meet at least the following quality
soot blowing requirements according to ISO 8573-1:2010.

Compressed air quality for Compressed air for atomisation of the reducing agent must fulfil at least the
reducing agent atomisation following quality requirements according to ISO 8573-1:2010.

Note:
To prevent clogging of catalyst and catalyst lifetime shortening, the com-
pressed air specification must always be observed.

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5 Engine supply systems
5.1 Basic principles for pipe selection

5.1.1 Engine pipe connections and dimensions

The external piping systems are to be installed and connected to the engine
by the shipyard. Piping systems are to be designed in order to maintain the
pressure losses at a reasonable level. To achieve this with justifiable costs, it
is recommended to maintain the flow rates as indicated below. Nevertheless,
depending on specific conditions of piping systems, it may be necessary in
some cases to adopt even lower flow rates. Generally it is not recommended
to adopt higher flow rates.
Recommended flow rates (m/s)
Suction side Delivery side
Fresh water (cooling water) 1.0 – 2.0 1.5 – 3.0
Lube oil 0.5 – 1.0 1.5 – 2.5
Seawater 1.0 – 1.5 1.5 – 2.5
Diesel fuel 0.5 – 1.0 1.5 – 2.0
Heavy fuel oil 0.3 – 0.8 1.0 – 1.8
Natural gas (< 5 bar) - 5 – 10
Natural gas (> 5 bar) - 10 – 20
Compressed air for control air system - 2 – 10
Compressed air for starting air system - 25 – 30
Intake air 20 – 25
Exhaust gas 40
Table 88: Recommended flow rates
5.1.2 Specification of materials for piping
General
▪ The properties of the piping shall conform to international standards, e.g.
DIN EN 10208, DIN EN 10216, DIN EN 10217 or DIN EN 10305, DIN EN

13480-3.
▪ For piping, black steel pipe should be used; stainless steel shall be used
where necessary.
▪ Outer surface of pipes needs to be primed and painted according to the
specification – for stationary power plants it is recommended to execute
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painting according Q10.09028-5013.

▪ The pipes are to be sound, clean and free from all imperfections. The
internal surfaces must be thoroughly cleaned and all scale, grit, dirt and
sand used in casting or bending has to be removed. No sand is to be
used as packing during bending operations. For further instructions
regarding stationary power plants also consider Q10.09028-2104.
▪ In the case of pipes with forged bends care is to be taken that internal
surfaces are smooth and no stray weld metal left after joining.
▪ See also the instructions in our Work card 6682000.16-01E for cleaning
of steel pipes before fitting together with the Q10.09028-2104 for sta-
tionary power plants.
LT-, HT- and nozzle cooling water pipes

Galvanised steel pipe must not be used for the piping of the system as all
additives contained in the engine cooling water attack zinc. Moreover, there
is the risk of the formation of local electrolytic element couples where the zinc
layer has been worn off, and the risk of aeration corrosion where the zinc
layer is not properly bonded to the substrate.
Proposed material (EN)
P235GH, E235, X6CrNiMoTi17-12-2
Fuel oil pipes, lube oil pipes

Galvanised steel pipe must not be used for the piping of the system as acid
components of the fuel may attack zinc.
E235, P235GH, X6CrNiMoTi17-12-2
Urea pipes (for SCR only)

Galvanised steel pipe, brass and copper components must not be used for
the piping of the system.
X6CrNiMoTi17-12-2
Compressed air pipes

Galvanised steel pipe must not be used for the piping of the system.
E235, P235GH, X6CrNiMoTi17-12-2
Seawater pipes
Material depending on required flow speed and mechanical stress.
Proposed material
CuNiFe, glass fiber reinforced plastic, rubber lined steel
5.1.3 Installation of flexible pipe connections
Arrangement of hoses on resiliently mounted engine

Flexible pipe connections become necessary to connect GenSet with exter-
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nal piping systems. They are used to compensate the dynamic movements
of the GenSet in relation to the external piping system. For information about
the origin of the dynamic engine movements, their direction and identity in
principle see table Excursions of resiliently mounted L engines, Page 147.
Origin of static/ Engine rotations unit Coupling displacements unit Exhaust flange

dynamic (at the turbocharger)
movements
° mm mm
Axial Cross Vertical Axial Cross Vertical Axial Cross Vertical
direction direction direction
Rx Ry Rz X Y Z X Y Z
Pitching 0.0 ±0.026 0.0 ±0.95 0.0 ±1.13 ±2.4 0.0 ±1.1
Rolling ±0.22 0.0 0.0 0.0 ±3.2 ±0.35 ±0.3 ±16.2 ±4.25
Engine torque –0.045 0.0 0.0 0.0 0.35 (to 0.0 0.0 2.9 (to 0.9
(CCW) control control
side) side)
Vibration (±0.003) ~0.0 ~0.0 0.0 0.0 0.0 0.0 ±0.12 ±0.08
during normal
operation
Run out ±0.053 0.0 0.0 0.0 ±0.64 0.0 0.0 ±3.9 ±1.1
resonance
Table 89: Excursions of resiliently mounted L engines
Note:
The above entries are approximate values (±10 %); they are valid for the
standard design of the mounting.
Assumed sea way movements: Pitching ±7.5°/rolling ±22.5°.
The conical mounts (RD214B/X) are fitted with internal stoppers (clearances:
Δlat= ±3 mm, Δvert= ±4 mm); these clearances will not be completely utilised
by the above loading cases.

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Figure 42: Coordinate system

Generally flexible pipes (rubber hoses with steel inlet, metal hoses, PTFE-cor-
rugated hose-lines, rubber bellows with steel inlet, steel bellows, steel com-
pensators) are nearly unable to compensate twisting movements. Therefore
the installation direction of flexible pipes must be vertically (in Z-direction) if
ever possible. An installation in horizontal-axial direction (in X-direction) is not

permitted; an installation in horizontal-lateral (Y-direction) is not recommen-

ded.
The media connections (compensators) to and from the engine must be
highly flexible whereas the fixations of the compensators on the one hand
with the engine and on the other hand with the environment must be realised
as stiff as possible.
Flange and screw connections

Flexible pipes delivered loosely by MAN Energy Solutions are fitted with
flange connections, for sizes with DN32 upwards. Smaller sizes are fitted
with screw connections. Each flexible pipe is delivered complete with counter
flanges or, those smaller than DN32, with weld-on sockets.
Arrangement of the external piping system

Shipyard's pipe system must be exactly arranged so that the flanges or
screw connections do fit without lateral or angular offset. Therefore it is rec-
ommended to adjust the final position of the pipe connections after engine
alignment is completed.
Figure 43: Arrangement of pipes in system
Installation of hoses
In the case of straight-line-vertical installation, a suitable distance between
the hose connections has to be chosen, so that the hose is installed with a
sag. The hose must not be in tension during operation. To satisfy a correct
sag in a straight-line-vertically installed hose, the distance between the hose
connections (hose installed, engine stopped) has to be approximately 5 %

shorter than the same distance of the unconnected hose (without sag).
In case it is unavoidable (this is not recommended) to connect the hose in
lateral-horizontal direction (Y-direction) the hose must be installed preferably
with a 90° arc. The minimum bending radii, specified in our drawings, are to
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be observed.
Never twist the hoses during installation. Turnable lapped flanges on the
hoses avoid this.
Where screw connections are used, steady the hexagon on the hose with a
wrench while fitting the nut.
Comply with all installation instructions of the hose manufacturer.
Depending on the required application rubber hoses with steel inlet, metal

hoses or PTFE-corrugated hose lines are used.
Installation of steel compensators

Steel compensators are used for hot media, e.g. exhaust gas. They can
compensate movements in line and transversal to their centre line, but they
are absolutely unable to compensate twisting movements. Compensators
are very stiff against torsion. For this reason all kind of steel compensators
installed on resilient mounted engines are to be installed in vertical direction.
Note:
Exhaust gas compensators are also used to compensate thermal expansion.
Therefore exhaust gas compensators are required for all type of engine
mountings, also for semi-resilient or rigid mounted engines. But in these
cases the compensators are quite shorter, they are designed only to com-
pensate the thermal expansions and vibrations, but not other dynamic
engine movements.
Angular compensator for fuel oil

The fuel oil compensator, to be used for resilient mounted engines, can be
an angular system composed of three compensators with different charac-
teristics. Please observe the installation instruction indicated on the specific
drawing.
Supports of pipes
Flexible pipes must be installed as near as possible to the engine connection.
On the shipside, directly after the flexible pipe, the pipe is to be fixed with a
sturdy pipe anchor of higher than normal quality. This anchor must be capa-
ble to absorb the reaction forces of the flexible pipe, the hydraulic force of
the fluid and the dynamic force.
Example of the axial force of a compensator to be absorbed by the pipe
anchor:
▪ Hydraulic force
= (Cross section area of the compensator) x (Pressure of the fluid inside)
▪ Reaction force
= (Spring rate of the compensator) x (Displacement of the comp.)
▪ Axial force
= (Hydraulic force) + (Reaction force)
Additionally a sufficient margin has to be included to account for pressure

peaks and vibrations.
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Figure 44: Installation of hoses

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5.1.4 Condensate amount in charge air pipes and air vessels
Figure 45: Diagram condensate amount
The amount of condensate precipitated from the air can be considerablly

high, particularly in the tropics. It depends on the condition of the intake air
(temperature, relative air humidity) in comparison to the charge air after
charge air cooler (pressure, temperature).
It is important, that no condensed water of the intake air/charge air will be led
to the compressor of the turbocharger, as this may cause damages.
In addition the condensed water quantity in the engine needs to be mini-
mised. This is achieved by controlling the charge air temperature.

How to determine the amount of condensate:
First determine the point I of intersection in the left side of the diagram (intake
air), see figure Diagram condensate amount, Page 151 between the corre-
sponding relative air humidity curve and the ambient air temperature.
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Secondly determine the point II of intersection in the right side of the diagram
(charge air) between the corresponding charge air pressure curve and the
charge air temperature. Note that charge air pressure as mentioned in sec-
tion Planning data, Page 57 is shown in absolute pressure.
At both points of intersection read out the values [g water/kg air] on the verti-
cally axis.
The intake air water content I minus the charge air water content II is the
condensate amount A which will precipitate. If the calculations result is nega-

tive no condensate will occur.
For an example see figure Diagram condensate amount, Page 151. Intake air
water content 30 g/kg minus 26 g/kg = 4 g of water/kg of air will precipitate.
To calculate the condensate amount during filling of the starting air receiver
just use the 30 bar curve (see figure Diagram condensate amount, Page 151)
in a similar procedure.
Example how to determine the amount of water accumulating in the charge

air pipe
Parameter Unit Value
Engine output (P) kW 9,000
Specific air flow (le) kg/kWh 6.9
Ambient air condition (I):

Ambient air temperature °C 35
Relative air humidity % 80
Charge air condition (II):

Charge air temperature after cooler1) °C 56
Charge air pressure (over pressure) 1)
bar 3.0
Solution according to above diagram
Water content of air according to point of intersection (I) kg of water/kg of air 0.030
Maximum water content of air according to point of intersection (II) kg of water/kg of air 0.026
The difference between (I) and (II) is the condensed water amount (A)
A = I – II = 0.030 – 0.026 = 0.004 kg of water/kg of air
Total amount of condensate QA:

QA = A x le x P
QA = 0.004 x 6.9 x 9,000 = 248 kg/h
In case of two-stage turbocharging choose the values of the high-pressure TC and cooler (second stage of turbo-
1)
charging system) accordingly.

Table 90: Example how to determine the amount of water accumulating in the charge air pipe
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Example how to determine the condensate amount in the starting air
5.2 Lube oil system

receiver
Volumetric capacity of tank (V) litre 3,500
m3 3.5
Temperature of air in starting air receiver (T) °C 40

K 313
Air pressure in starting air receiver (p above atmosphere) bar 30

Air pressure in starting air receiver (p absolute) bar abs 31
31 x 105
Gas constant for air (R)

287
Ambient air temperature °C 35
Relative air humidity % 80
Weight of air in the starting air receiver is calculated as follows:
Solution according to above diagram
Water content of air according to point of intersection (I) kg of water/kg of air 0.030
Maximum water content of air according to point of intersection (III) kg of water/kg of air 0.002
The difference between (I) and (III) is the condensed water amount (B)
B = I – III
B = 0.030 – 0.002 = 0.028 kg of water/kg of air
Total amount of condensate in the vessel (QB)

QB = m x B
QB = 121 x 0.028 = 3.39 kg
Table 91: Example how to determine the condensate amount in the starting air receiver
5.2 Lube oil system
5.2.1 Lube oil system description

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The diagrams represent standard design of the external lube oil service sys-
tem. All moving parts of the engine are pressurised with oil circulating in the
build-on system, based on wet sump lubrication.
The lubrication of the cylinder liners is designed as a separate system

5.2 Lube oil system
attached to the engine but served by the inner lubrication system.
System flow
The lube oil service pump draws oil from the oil sump and pumps it through
the lube oil cooler and the lube oil automatic filter to the main lube oil pipe.
From there, it is distributed to the lubricating points of engine and turbo-
charger and returns by gravity to the oil sump inside the lube oil service tank.
Treatment systems, which are cleaning the lube oil continuously in a by-pass
stream, are installed on the GenSet and in the plant.
Lube oil consumption

For the lube oil consumption (SLOC) see table Total lube oil consumption,
Page 54. It should, however, be observed that during the running in period
the lube oil consumption may exceed the values stated.
The total lube oil consumption will be increased by the following processes
and influences:
▪ Desludging interval of the lube oil separator/automatic filter and lube oil
content of the discharged sludge (approximately 30 %).
▪ Lube oil evaporation.
▪ Leakages.
▪ Losses at lube oil filter exchange.
Requirements before commissioning of engine

The flushing of the lube oil system in accordance to the MAN Energy Solu-
tions specification (see the relevant working cards) demands before commis-
sioning of the engine, that all installations within the system are in proper
operation. Please be aware that special installations for commissioning are
required and the lube oil separator must be in operation from the very first
phase of commissioning.
Please contact MAN Energy Solutions or licensee if any uncertainties occur.
T-001/Lube oil service tank

The engine frame tank has the function of the lube oil service tank. The main
purpose is to separate air and particles from the lube oil, before being pum-
ped back to the engine. Even a low oil level should still permit the lube oil to
be drawn in free of air if the ship is pitching. The approximate quantities of oil
necessary for new engine, before starting up are given in the table Cooling
water and oil volume of engine, Page 66. Concerning the required lube oil
quality, see table Main fuel/lube oil type, Page 101.
It is recommended to use the separator suction pipe for draining of the lube
oil service tank. For all used reserve connections a siphon in the plant is rec-
ommended.
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H-002/Lube oil preheater

To fulfill the starting conditions (see section Starting conditions, Page 29)
preheating of the lube oil in the lube oil service tank is necessary. Therefore
the preheater of the separator is often used. The preheater must be enlarged
in size if necessary, so that it can heat up the content of the service tank to
≥ 40 °C, within 4 hours. If engines have to be kept in stand-by mode, the
lube oil of the corresponding engines always has to be in the temperature
5.2 Lube oil system

range of starting conditions. Means that also the maximum lube oil tempera-
ture limit should not be exceeded during engine start.
For arctic operation conditions the heater capacity has to be increased.
FIL-004/Lube oil suction strainer

The lube oil suction strainer protects the attached lube oil pumps against
larger dirt particles that may have accumulated in the tank.
P-001/Lube oil service pump

The main lube oil service pump is mounted on the free end of the engine and
is driven by means of the crankshaft through a gear. The pump gear is lubri-
cated by the engines oil flow. The oil pressure at engine inlet is controlled by
an adjustable spring loaded pressure relief valve (PCV-007). For the capacity
of the attached lube oil service pump, see table Nominal values for cooler
specification – Auxiliary GenSet, Page 57. If additional lube oil consumers
(e.g. alternator bearing or backflush filter) will be installed, which are supplied
by the service pump, please contact MAN Energy Solutions to check if the
lube oil capacity of the pump is still sufficient.
PCV-007/Pressure relief valve

By use of the pressure relief valve, a constant lube oil pressure before the
engine is adjusted.
The pressure relief valve is installed upstream of the lube oil cooler. The
return pipe (spilling pipe) from the pressure relief valve returns into the lube oil
service tank.
The control line of the pressure relief valve has to be connected to the engine
inlet. In this way the pressure losses of filters, pipes and cooler are compen-
sated automatically.
P-075/Cylinder lube oil pump

The engine is equipped with an electrically driven lube oil pump supplying
extra lubricant to the cylinder liners to handle specific demands. The pump
operates in the load range 50 – 100 % and for maintenance purposes. It is
activated from the automation system of the engine.
P-007/Prelubrication pump
The GenSet is as standard equipped with an electrically driven pump for pre-
lubrication before starting and also for postlubrication when the engine is
stopped. The prelubrication pump, which is of the gear pump type, is self pri-
ming and installed in parallel to the lube oil service pump. Its operation is
requested by the GenSet automation system, as long as required. The volt-
age for automatic control must be supplied from the emergency switchboard
in order to secure post- and prelubrication in case of a critical situation.
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In case of unintended engine stop (e.g. blackout) the postlubrication must be

started as soon as possible (latest within 20 min) after the engine has stop-
ped and must persist for minimum 15 min. This is required to cool down the
bearings of the turbocharger and hot inner components (see also section
Prelubrication/Postlubrication, Page 164).
For installed pump capacities see the following table.

5.2 Lube oil system
Delivery rate 50 Hz m3/h 27 27 43 43
60 Hz 33 33 52 52
Differential pressure - bar 3.5 3.5 3.5 3.5
E-motor capacity 50 Hz kW 8.0 8.0 17.3 17.3
60 Hz 10.4 10.4 15.0 15.0

Table 92: Technical data of the installed prelubrication/postlubrication pump
HE-002/Lube oil cooler

The lube oil cooler is of the plate type with LT cooling water as cooling
medium and is mounted at the front end of the base frame.
Heat data, flow rates and tolerances are indicated in section Planning data,
Page 57 and the following.
On the lube oil side the pressure drop shall not exceed 1.1 bar.
Rated heat capacity kW 433 552 631 710
Max. pressure drop (LO) bar max. 1.1
Max. pressure drop (LT CW) bar approx. 0.25 – 0.30

Table 93: Technical data of the installed lube oil cooler
TCV-001/Lube oil temperature control valve

The 3-way valve regulates the lube oil temperature at engine inlet by directing
the lube oil flow through the lube oil cooler or in by-pass to it. Wax-type ther-
mostatic elements ensure a constant temperature regulation.
No. of cylinders, config. L engines
Type1) Wax-type thermostat
Set point °C 63
Pressure drop bar 0.4

1)
Full open temperature of wax elements: Set point.
Control range of lube oil inlet temperature: Set point minus 10 K.
Table 94: Technical data of the lube oil temperature control valve
Lube oil treatment

The treatment of the circulating lube oil can be divided into two major func-
tions:
▪ Removal of contaminations to keep up the lube oil performance.
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▪ Retention of dirt to protect the engine.

The removal of combustion residues, water and other mechanical contami-
nations is the major task of separators/centrifuges (CF-001) installed in by-
pass to the main lube oil service system of the engine. The installation of a
lube oil separator per engine is recommended to ensure a continuous sepa-
ration during engine operation.
The lube oil filters integrated in the system protect the diesel engine in the
5.2 Lube oil system

main circuit retaining all residues which may cause a harm to the engine.
Depending on the filter design, the collected residues are to be removed
from the filter mesh by automatic back flushing, manual cleaning or changing
the filter cartridge. The retention capacity of the installed filter should be as
high as possible.
When selecting an appropriate filter arrangement, the customer request for
operation and maintenance, as well as the class requirements, have to be
taken in consideration.
FIL-002/Lube oil duplex filter

The lube oil duplex filter has the function of both, main filter and indicator fil-
ter. It is designed as duplex filter and the cartridges are of a paper filter type.
Each filter consists of a primary and a secondary filter stage. If one of the fil-
ters is clogged, switch-over to the second filter and cleaning must be carried
out manually. The pipe section between filter and engine inlet must be closely
inspected before installation.
Type - Duplex filter
Capacity m3/h 2 x 132
Cartridge type - Two stage paper cartridge
Filter mesh width (sphere passing mesh) µm 1st stage: 15

2nd stage: 60
Table 95: Technical data of lube oil duplex filter
CF-008/Lube oil centrifugal filter

The built-on by-pass filter is of a centrifugal type. It removes small impurities
and herewith serves as inspection device for checking the pureness of the
lube oil system.
Only a small part of the oil main stream is routed through the centrifuge. Its
flow pressure is operating the centrifuge itself. The centrifuge shall be instal-
led as close as possible to the pressure side of the lube oil pump for
improved centrifuge effect.
Type - Centrifugal filter with paper insert
Min. flow (at 3 bar) m3/h 3.1
Max. flow (at 7 bar) m3/h 4.5

Table 96: Technical data of lube oil centrifugal filter
External automatic filter (optional, not shown in lube oil diagram)

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Automatic filtration offers long filter service intervals. An external free-stand-

ing lube oil automatic filter can optionally be integrated in the lube oil supply
line. The back washing/flushing of the filter elements has to be arranged in a
way that the lube oil flow and pressure will not be affected. If an external
backflush filter without own supply pump is foreseen, please contact MAN
Energy Solutions to check, if the capacity of the lube oil service pump P-001
5.2 Lube oil system
is sufficient to serve the lube oil automatic filter additionally. The flushing dis-
charge is led into the lube oil service tank T-001.
TR-001/Condensate trap
See section Crankcase vent and tank vent, Page 165.
CF-001/Lube oil separator

The lube oil is intensively cleaned by separation in the by-pass thus relieving
the filters and allowing an economical design.
The lube oil separator should be of the self-cleaning type. The design is to be
based on a lube oil quantity of 1.0 l/kW. This lube oil quantity should be
cleaned in times within 24 hours.
The formula for determining the separator flow rate (Q) is:
Q [l/h] Separator flow rate
P [kW] Total engine output
n HFO = 7
MDO/MGO = 5
Gas (+ MDO/MGO for ignition only) = 5
With the evaluated flow rate the size of separator has to be selected accord-
ing to the evaluation table of the manufacturer. The separator rating stated
by the manufacturer should be higher than the flow rate (Q) calculated
according to the formula above.
Separator equipment
The lube oil preheater H-002 must always be able to heat the oil to 95 – 98
°C and the size is to be selected accordingly. In addition to a PI-temperature
control, which avoids a thermal overloading of the oil, silting of the preheater
must be prevented by high turbulence of the oil in the preheater.
Control accuracy ±1 °C.
Cruise ships operating in arctic waters require larger lube oil preheaters. In
this case the size of the preheater must be calculated with a Δt of 60 K.
The freshwater supplied must be treated as specified by the separator sup-
plier.
The supply pumps shall be of the free-standing type, i.e. not mounted on the
separator and are to be installed in the immediate vicinity of the lube oil serv-
ice tank.
This arrangement has three advantages:
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▪ Suction of lube oil without causing cavitation.

▪ The lube oil separator does not need to be installed in the vicinity of the
service tank but can be mounted in the separator room together with the
fuel oil separators.
▪ Better matching of the capacity to the required separator throughput.
As a reserve for the lube oil separator, the use of the diesel fuel oil separator
5.2 Lube oil system

is admissible. For reserve operation the diesel fuel oil separator must be con-
verted accordingly. This includes the pipe connection to the lube oil system
which must not be implemented with valves or spectacle flanges. The con-
nection is to be executed by removable change-over joints that will definitely
prevent MDO from getting into the lube oil circuit. See also rules and regula-
tions of classification societies.
Multi-engine plants
In principle one lube oil separator unit per engine in operation is recommen-
ded. But the experienced load profile for the majority of merchant vessels is
in average around 43 – 50 % of the installed auxiliary GenSet power.
Regarding this, it might be an economic solution to install one common sep-
arator for multi-engine plants. Requirement: One separator unit must not be
dedicated to more than 3 engines and there must always be one separator
unit in reserve. With three identical engines the time-related average power
demand corresponds to 1.3 – 1.5 times the power of one engine.
▪ Bulk carrier and tanker: f ~ 1.3

▪ Container vessel: f ~ 1.5
If the average load profile is well above 50 %, factor f or the number of sepa-
rators must be increased.
It must be ensured that during the switch-over from one to another GenSet,
the valves of the upstream and the downstream line (to and from the lube oil
service tank) are always switched simultaneously. Generally there is the risk,
that wear and dirt particles being transferred from one engine to another.
The switch-over times, respectively the time how long the lube oil separator
is connected to each engine, must be determined depending on the propor-
tional power generation. If there is no heater available to keep the lube oil of
stand-by engines at the right temperature, a periodical switch-over to these
engines must be considered as well. On the other hand, the heat input from
the cleaned lube oil into the service tank of the running engines must be limi-
ted to meet the right lube oil temperature at engine inlet.
Separator efficiency
Various operating parameters affect the separation efficiency. These include
temperature (which controls both, fuel oil viscosity and density), flow rate and
separator maintenance. Figure Separation efficiency dependence on particle

size, density difference, viscosity and flow rate, Page 160 shows, how the
operating parameters affect the separator efficiency.
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5.2 Lube oil system
Figure 46: Separation efficiency dependence on particle size, density difference, viscosity and flow rate
(reference: Diagram 1 – 3: "CIMAC Paper No. 51 - Onboard Fuel Oil Cleaning", CIMAC Congress, 2013)
Due to the fact that auxiliary generating sets often are operated with the
worst fuels available and in an unfavourable part load range, the lube oil can
pollute much earlier than this of comparable main propulsion engines. There-
fore it is recommended to run the lube oil separators within no more than 25
% of its nominal capacity. Separator manufacturers already may have con-
sidered a similar factor for choosing the optimum separator capacity.
T-006/Leakage oil collecting tank

Leaked fuel and lube oil is collected in this tank. The content must not be
added to the fuel, but led into the sludge tank.
T-021/Sludge tank
Separated impurities from the lube oil separator module and the content of
the leakage oil collecting tank T-006 are disposed into the sludge tank. The
sludge tank is also part of the fuel oil leakage system. See description in
paragraph T-021/Sludge tank, Page 192.
Withdrawal points for samples

Points for drawing lube oil samples are to be provided upstream and down-
stream of the filters and the separator, to verify the effectiveness of these
system components.
Piping system
It is recommended to use pipes according to the pressure class PN10.
In agreement with MAN Energy Solutions optional branches can be foreseen
for:
▪ External lube oil automatic filter.

▪ Pressure lubrication of alternator bearings.
P-012/Lube oil transfer pump

The lube oil transfer pump supplies fresh oil from the lube oil storage tank to
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the operating tank. Starting and stopping of the lube oil transfer pump should
preferably be done automatically by float switches fitted in the tank.
Lube oil system diagrams
5.2 Lube oil system

Figure 47: Lube oil system diagram, GenSet – Internal

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Engine components
P-001 Lube oil service pump (engine P-075 Cylinder lube oil pump
driven)
GenSet components
CF-008 Centrifuge (by-pass filter) P-007 Prelubrication pump

5.2 Lube oil system
FIL-002 Lube oil duplex filter PCV-007 Pressure relief valve
FIL-004 Lube oil suction strainer T-001 Lube oil service tank
HE-002 Lube oil cooler TCV-001 Lube oil temperature control valve
1, 2 NRV-001 Non return valve
Engine pipe connections
2171 Engine inlet 7772 Control line to pressure relief valve
2173 Oil pump inlet 9184 Dirty oil drain from crankcase
2175 Oil pump outlet 9187 Dirty oil drain from crankcase
C30/2598 Vent turbocharger 9197 Dirty oil drain from crankcase
2599 Drain from turbocharger 9199 Dirty oil drain from crankcase
C13/2898 Vent crankcase
GenSet pipe connections
C3/2076 From separator C9/2081 Flushing from automatic filter
C16/2076 Supply C15/2095 Overflow, optional
C4/2078 To separator
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5.2 Lube oil system

Figure 48: Lube oil system diagram, GenSet – External

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5.2 Lube oil system
C30/2598 Vent turbocharger 9187 Dirty oil drain from crankcase
2599 Drain from turbocharger 9197 Dirty oil drain from crankcase
C13/2898 Vent crankcase 9199 Dirty oil drain from crankcase
9184 Dirty oil drain from crankcase
C3/2076 From separator C9/2081 Inlet (optional)
C16/2076 Supply C15/2095 Overflow
C4/2078 To separator
Engine components
P-001 Lube oil service pump (engine driven)
GenSet components
CF-008 Filter centrifuge P-007 Prelubrication pump
FIL-002 Lube oil duplex filter T-001 Lube oil service tank
FIL-004 Lube oil suction strainer TCV-001 Lube oil temperature control valve
HE-002 Lube oil cooler
Engine room components
CF-001 Lube oil separator T-006 Leakage oil collecting tank
CF-003 Diesel fuel oil separator T-021 Sludge tank
H-002 Lube oil preheater 1, 2 TR-001 Condensate trap
P-012 Lube oil transfer pump
5.2.2 Prelubrication/postlubrication
Prelubrication
The prelubrication pump must be switched on at least 5 minutes before
engine start. The prelubrication pump serves to assist the engine attached
main lube oil pump, until this can provide a sufficient flow rate.
For design data of the prelubrication pump see section Planning data, Page
57 and paragraph Lube oil, Page 63.
During the starting process, the maximal temperature mentioned in section
Starting conditions, Page 29 must not be exceeded at engine inlet. There-
fore, a small LT cooling waterpump can be necessary if the lube oil cooler is
served only by an attached LT pump.
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Postlubrication
The prelubrication pump is also to be used for postlubrication after the
engine is turned off.
Postlubrication is effected for a period of 15 minutes.
5.2 Lube oil system

5.2.3 Crankcase vent and tank vent
Condensate traps
The condensate traps (TR-001) required for the vent pipes of the turbo-
charger, the engine crankcase and the service tank must be installed as
close as possible to the vent connections. This will prevent condensate
water, which has formed on the cold venting pipes, to enter the engine or
service tank.
Vent pipes
The vent pipes from engine crankcase and turbocharger are to be arranged
according to the sketch. The frame tank is vented through the vent pipes of
the engine. The pipe design must ensure a sufficient lube oil ventilation and
avoid a reduction of the cross section, caused from condensed water. The
required nominal diameters ND are stated in the chart following the diagram.
Note:
▪ The venting pipework must be kept separately for each engine.
▪ Condensate trap overflows are to be connected via siphone to drain pipe
and back to sludge tank.
▪ Specific requirements of the classification societies are to be strictly
observed.
▪ The pipe connection between engine and ventilation line must be flexible.
▪ The ventilation pipe must be made with continuous upward slope min
5°, even when the ship heel or trim (static inclination).

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Figure 49: Crankcase vent and turbocharger vent
Engine type Nominal diameter ND (mm)

5.3 Water systems
L engine A B C
125 125 50
Table 97: Crankcase vent and turbocharger vent
5.3 Water systems
5.3.1 General
During the combustion process in diesel and gas engines the fuels energy is
converted into heat. While one part is furthermore converted into mechanical
power, the other part remains as waste heat and must be dissipated. The
engines exhaust gas contains a large amount of heat, which is partly recov-
ered by the exhaust gas turbo charger and is led back into the power gener-
ating process. Another large heat quantity must be removed by cooling the
cylinder jackets, fuel injection valves, charge air and lube oil with circulating
water. Off the engine there are also heat loads to be dissipated, such from
cooling the alternator or diesel fuel. An additional but smaller amount of heat
is radiated by hot surfaces of engine, piping and other components.
Dissipating all the heat out of the system is the purpose of the cooling water
system.
The engine's cooling water system

The engine's cooling water system comprises a low temperature (LT) circuit
and a high temperature (HT) circuit. The systems are designed only for trea-
ted fresh water, which meets all requirements specified by MAN Energy Sol-
utions, see section Specification of engine cooling water, Page 131.
The LT cooling water system includes heat exchangers for charge air cooling
(stage 2), lubricating oil cooling, fuel injection nozzle cooling and alternator
cooling if the latter is water-cooled. It is designed for freshwater as cooling
medium. The LT cooling water temperature for the auxiliary GenSets is regu-
lated by the plant control system to 32 °C and must not drop below.
The HT cooling water system removes heat from charged air (stage 1), cylin-
der liners and cylinder heads. An engine outlet temperature of nearly 90 °C
ensures a perfect combustion in the entire load area. This temperature limits
thermal loads in the high-load area and avoids hot-corrosion in the combus-
tion area. In the low-load area, the temperature is sufficiently high to avoid
cold corrosion.
Piping
Coolant additives may attack a zinc layer. It is therefore imperative to avoid
using galvanised steel pipes. Treatment of cooling water as specified by
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MAN Energy Solutions will safely protect the inner pipe walls against corro-
sion.
Moreover, there is the risk of the formation of local electrolytic element cou-
ples where the zinc layer has been worn off, and the risk of aeration corro-
sion where the zinc layer is not properly bonded to the substrate.
See the instructions in our Work card 6682 000.16-01E for cleaning of steel
5.3 Water systems

pipes before fitting.
Pipes shall be manufactured and assembled in a way that ensures a proper
draining of all segments. Venting is to be provided at each high point of the
pipe system and drain openings at each low point.
Cooling water pipes are to be designed according to pressure values and
flow rates stated in section Planning data, Page 57 and the following sec-
tions. The engine cooling water connections have to be designed according
to PN10/PN16.
5.3.2 GenSet design and components – Water systems
The HT regulation and LT cooling water by-pass valve as well as the lube oil
cooler are already installed at the engine frame. If the alternator is water
cooled, this additional heat load and piping must be considered for the
design of the system. Piping and several instruments are installed on the
GenSet to minimise the installation costs and time at the shipyard. As stand-
ard the GenSet is equipped with 2-string piping. The following options can
be chosen additionally:
▪ Internal piping for 1-string cooling water system
The standard for the internal cooling water system is shown in figure Cooling
water system diagram, Page 169. This system has been constructed with a
view to full integration into the external system.
MOV-003/LT cooling water by-pass valve

Low temperature cooling During low load operation the control valve diverts the LT cooling water to
water system by-pass the charge air cooler HE-008 and directly to the lube oil cooler
HE-002. This affects a higher charge air temperature and thus a better com-
bustion. The valve is controlled by the engine control system.
Type - 3-way, electric/pneumatic
Switch point % load 20
Valve position - Low load (energised): 3 – 2

High load (de-energised): 3 – 1
Table 98: Technical data of LT cooling water by-pass valve
The regulation of the LT cooling water temperature takes place in the exter-
nal system by the LT cooling water temperature control valve MOV-016.
HE-002/Lube oil cooler

For the description of the lube oil cooler see section Lube oil system descrip-
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tion, Page 153.

5.3 Water systems
Type - Plate type heat exchanger
Material - Stainless steel
Pressure drop (water side) bar 0.20 – 0.35

Table 99: Technical data of lube oil cooler
For heat data, flow rates and tolerances see section Planning data, Page 57
and the following. For the description of the principal design criteria see para-
graph Cooler dimensioning, general, Page 176.
During postlubrication the cooler should be flown through by LT cooling
water and not be shut-off immediately after engine shut-off.
HE-008/Charge air cooler (stage 2)

The charged combustion air is further cooled by the LT cooling water, pass-
ing stage 2 of the charge air cooler. For permitted pressure, heat data and
flow rates see section Planning data, Page 57 and the following.
A-001/Alternator
Depending on the manufacturer’s design, the alternator may need to be
cooled with cooling water. If the alternator and/or the lubricating oil for the
alternator bearings are water cooled, the pipes for this can be integrated on
the GenSet. The additional LT cooling water flow rate must be considered for
the dimensioning of the LT cooling water pump P-076.
High temperature cooling P-002/HT cooling water service pump, attached
water system The HT cooling water service pump (attached) is of the centrifugal type and
mounted at the front cover of the engine. It is driven by the engine’s crank-
shaft through a resilient gear transmission.
Depending on the piping arrangement (1-string or 2-string) the discharge
head of the pump must carefully be chosen to avoid excessive pressure
upstream the engine. Generally a lower discharge pressure is required, if a 1-
string cooling water system is installed. For the auxiliary GenSet two pumps
are preset as standard, which must be selected according to the type of
cooling water system. It must be strictly ensured, that the chosen pump
matches to the executed cooling water system.
Type of cooling water system - 1-string 2-string
Discharge head bar 3.5 4.5
Volume flow m3/h 53 70

Table 100: Technical data of attached HT cooling water pump
The optimal operating point of the pump must be adjusted in any case by
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installing orifices or throttle valves. For permitted pressure, heat data and
flow rates see section Planning data, Page 57 and the following. The different
types of cooling water systems are described in section Cooling water sys-
tem diagrams, Page 170. Depending on the system design, it may be neces-
sary to use a pump with reduced delivery head. For further information or in
case of uncertainty please contact MAN Energy Solutions.
TCV-007/HT cooling water temperature control valve
5.3 Water systems

The HT cooling water control valve serves to maintain the cylinder cooling
water temperature constantly at 90 °C at the engine outlet, even in case of
frequent load changes and to protect the engine against excessive thermal
load. In order to fulfill these requirements a thermostatic valve with a suitable
nominal temperature must be installed. By default a wax type thermostatic
valve with a nominal temperature of 85 °C is used. Depending on the plant
design and its characteristic, a control valve with another nominal tempera-
ture may satisfy the requirements.
Type - 3-way, thermostatic wax
elements
Nominal temperature °C 85
Working range °C 82 – 91
Pressure drop bar 0.15 – 0.20

Table 101: Technical data of HT temperature control valve
The auxiliary GenSets are less suitable for heat recovery due to the low HT
cooling water temperature regulation.
Figure 50: Cooling water system diagram

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Instrumentation engine/GenSet
PT01 Pressure transmitter, inlet engine PT10 Pressure transmitter, inlet engine
(1PT 4170) (1PT 3170)
TE10 Temperature element, inlet engine TE12 Temperature element, outlet engine
(1TE 3170) (1TE 3180)

5.3 Water systems
F1/3173 HT cooling water inlet A7/3471 Nozzle cooling water inlet
F2/3190 HT cooling water outlet A8/3499 Nozzle cooling water outlet
F3/3198 Vent (+F5 inlet from external pre- F6/3673 Outlet to external preheater (option)
heater option)
B1/3263 Alternator inlet G1/4173 LT cooling water inlet
B2/3273 Alternator outlet G2/4190 LT cooling water outlet
Engine components
HE-008 Charge air cooler stage II (LT) D-001 Diesel engine (cylinder)
HE-010 Charge air cooler stage I (HT) P-002 HT cooling water service pump,
attached
GenSet components
P-047 Preheating cooling water pump HE-002 Lube oil cooler

(optional)
H-027 Preheater (optional) TCV-007 HT cooling water control valve
A-001 Alternator MOV-003 LT cooling water by-pass valve
3171 HT cooling water inlet 4171 LT cooling water inlet
3183 To preheater 4195 Drain charging air cooler
3199 HT cooling water outlet 4199 LT cooling water outlet
5.3.3 Cooling water system diagrams
Auxiliary GenSet plants

Auxiliary GenSet plants are installed together with main propulsion engines
(e.g. on container vessels) to support them and to ensure the electrical
power supply on board. A common LT cooling water system allows substan-
tial savings in operating costs. This is why LT central coolers and LT cooling
water supply pumps are often used by both, main and auxiliary engines, if
they have the same temperature and quality requirements.
1-string system A further possibility to lower installation and operating costs is to interconnect
the HT and the LT cooling system. In this cooling water system, called 1-
string cooling water system, there is no HT water cooler installed. The

attached HT cooling water pump draws the HT water feed flow directly out of
the LT water backflow. After absorbing the heat of charge air cooler and
engine, the HT water is pumped back into the LT circuit and the heat load
will be dissipated by the central LT cooler. The HT cooling water temperature
is adjusted by the thermostatic valve TCV-007.
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2-string system Arrangements with separate LT and HT circuits are called 2-string cooling
water systems. Both circuits do not get directly in contact. This may have
advantages in case of damage and contamination of the cooling water with
lube oil or fuel oil. Leakages can be detected more quickly. The 2-string sys-
tem also may have less pressure fluctuations, because there are no pumps
installed in series. However additional heat exchangers for the HT circuit are
necessary. Pumps and heat exchangers can be common for propulsion and
5.3 Water systems

GenSet engines, but a separate HT regulation for the GenSet engines is
highly recommended.

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Cooling water system diagrams

5.3 Water systems
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Figure 51: Cooling water system diagram 1-string
Engine components
5.3 Water systems

D-001 Diesel engine HE-010 HT charge air cooler (stage I)
HE-008 LT charge air cooler (stage II) P-002 HT cooling water service pump,
attached
GenSet components
HE-002 Lube oil cooler TCV-007 HT cooling water control valve
FIL-021 Strainer for commissioning MOV-016 LT cooling water temperature con-

trol valve
HE-005 Nozzle cooling water cooler 1,2 P-076 LT cooling water service pump set,
free-standing
HE-007 Fuel oil cooler 3 P-076 LT cooling water port service pump,
free-standing
1,2 HE-024 LT cooler T-039 Cooling water storage tank
MOD-004 HT cooling water preheating module T-075 LT cooling water expansion tank
MOD-005 Nozzle cooling water module
3171 HT cooling water inlet 3471 Nozzle cooling water inlet
3173 HT cooling water outlet (to pre- 3499 Nozzle cooling water outlet
heater)
3198 Engine cooling water ventilation/ 4171 LT cooling water inlet

preheating
3190 LT cooling water inlet 4175 LT cooling water outlet
4174 Alternator outlet 4176 Alternator inlet
Nozzle cooling water module pipe connections
N1 Nozzle cooling water inlet N4 LT cooling water outlet
N2 Nozzle cooling water outlet N7 Discharge

N3 LT cooling water inlet

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5.3 Water systems
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Figure 52: Cooling water system diagram 2-string
Engine components
5.3 Water systems

D-001 Diesel engine HE-010 HT charge air cooler (stage I)
HE-008 LT charge air cooler (stage II) P-002 HT cooling water service pump,
attached
GenSet components
HE-002 Lube oil cooler TCV-007 HT cooling water control valve
FIL-021 Strainer for commissioning MOV-016 LT cooling water temperature con-

trol valve
1,2 HE-003 Cooler für HT cooling water 1,2 P-076 LT cooling water service pump set,
free-standing
HE-005 Nozzle cooling water cooler 3 P-076 LT cooling water port service pump,
free-standing
HE-007 Fuel oil cooler T-002 HT cooling water expansion tank
1,2 HE-024 LT cooler T-039 Cooling water storage tank
MOD-004 HT cooling water preheating module T-075 LT cooling water expansion tank
MOD-005 Nozzle cooling water module
3171 HT cooling water inlet 3471 Nozzle cooling water inlet
3173 HT cooling water outlet (to pre- 3499 Nozzle cooling water outlet
heater)
3198 Engine cooling water ventilation/ 4171 LT cooling water inlet

preheating
3174 HT cooling water inlet 4174 Alternator outlet
3190 LT cooling water outlet 4175 LT cooling water outlet
3197 HT cooling water outlet 4176 Alternator inlet
Nozzle cooling water module pipe connections

N1 Nozzle cooling water inlet N4 LT cooling water outlet
N2 Nozzle cooling water outlet N7 Discharge
N3 LT cooling water inlet

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5.3 Water systems
5.3.4 Cooling water system description
The diagrams show the external cooling water systems for auxiliary generat-
ing sets (GenSets), which are integrated in the cooling water system of a
main propulsion engine. They comprise two different ways of installing the
cooling water circuits (1-string or 2-string) and several possible arrangements
of the cooling water preheating equipment.
Note:
The arrangement of the cooling water system shown here is only one of
many possible solutions. It is recommended to inform MAN Energy Solutions
in advance in case other arrangements should be desired.
For the design data of the system components shown in the diagram see
section Planning data, Page 57 and following sections.
The cooling water is to be conditioned using a corrosion inhibitor, see sec-
tion Specification of engine cooling water, Page 131.
Cooler dimensioning, general For coolers operated by seawater (not treated water), lube oil or MDO/MGO
on the primary side and treated freshwater on the secondary side, an addi-
tional safety margin of 10 % related to the heat transfer coefficient is to be
considered. If treated water is applied on both sides, MAN Energy Solutions
does not insist on this margin.
In case antifreeze is added to the cooling water, the corresponding lower
heat transfer is to be taken into consideration.
The cooler piping arrangement should include venting and draining facilities
for the cooler. In case coolers for lube oil, fuel oil or other environmental haz-
ardous fluids are operated by seawater, we strongly recommend to use dou-
ble wall plate type coolers. These coolers allow to detect leakage and pre-
vent the seawater from pollution by hazardous fluids.
Open/closed system
Open system Characterised by "atmospheric pressure" in the expansion tank. Pre-pres-
sure in the system, at the suction side of the cooling water pump is given by
the geodetic height of the expansion tank (standard value 6 – 9 m above
crankshaft of engine).
Closed system In a closed system, the expansion tank is pressurised and has no venting
connection to open atmosphere. This system is recommended in case the
engine will be operated at cooling water temperatures above 100 °C or an
open expansion tank may not be placed at the required geodetic height. Use
air separators to ensure proper venting of the system.
Venting Note:
Insufficient venting of the cooling water system prevents air from escaping
which can lead to thermal overloading of the engine.
The cooling water system needs to be vented at the highest point in the
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cooling system. Additional points with venting lines to be installed in the cool-
ing system according to layout and necessity.
If LT and HT string are separated, make sure that the venting lines are always
routed only to the associated expansion tank. The venting pipe must be con-
nected to the expansion tank below the minimum water level, this prevents
oxydation of the cooling water caused by "splashing" from the venting pipe.
5.3 Water systems

The expansion tank should be equipped with venting pipe and flange for fill-
ing of water and inhibitors.
Additional notes regarding venting pipe routing:
▪ The ventilation pipe should be continuously inclined (min. 5 degrees).
▪ No restrictions, no kinks in the ventilation pipes.
▪ Merging of ventilation pipes only permitted with appropriate cross-sec-
tional enlargement.
Draining At the lowest point of the cooling system a drain has to be provided. Addi-
tional points for draining to be provided in the cooling system according to
layout and necessity, e.g. for components in the system that will be removed
for maintenance.
LT cooling water system

General In general the LT cooling water passes through the following components:
▪ Stage 2 of the two-stage charge air cooler (HE-008)
▪ Lube oil cooler (HE-002)
▪ Nozzle cooling water cooler (HE-005)
▪ Fuel oil cooler (HE-007)
▪ Alternator cooler (if water cooled) (A-001)
▪ LT cooling water cooler (HE-024)
▪ Other components such as, e.g., main engine for propulsion.
The system components of the LT cooling water circuit are designed for a
maximum LT cooling water temperature of 38 °C with a corresponding sea-
water temperature of 32 °C (tropical conditions).
However, the capacity of the LT cooler (HE-024) is determined by the tem-
perature difference between seawater and LT cooling water. Due to this cor-
relation an LT freshwater temperature of 32 °C can be ensured at a seawater
temperature of 25 °C.
To meet the IMO Tier I/IMO Tier II regulations the set point of the LT cooling
water temperature control valve (MOV-016) is to be adjusted to 32 °C. How-
ever this temperature will fluctuate and reach at most 38 °C with a seawater
temperature of 32 °C (tropical conditions).
The charge air cooler stage 2 (HE-008) and the lube oil cooler (HE-002) are
installed in series to obtain a low delivery rate of the LT cooling water pump
(P-076).
P-076/LT cooling water Due to operational safety a set of at least two cooling water pumps, one for
pump service and one in stand-by, must be installed for sea operation. These
pumps are common for all engines, if they have the same requirements for
fresh water quality and temperature. In order to minimise the power con-
sumption, a smaller pump should be installed for port operation and thus
only for operating the auxiliary GenSets.
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The delivery rates of the pumps are mainly determined by the cooling water,
required for the charge air cooler (stage 2) and the other coolers. For the sys-
tem’s flowrates and heat loads see section Planning data, Page 57.
MOV-003/LT cooling water For details of the LT cooling water by-pass valve see section GenSet design
by-pass valve and components – Water systems, Page 167.
HE-002/Lube oil cooler, free- For the description see section Lube oil system description, Page 153. For
5.3 Water systems
standing heat data, flow rates and tolerances see section Planning data, Page 57 and
the following. For the description of the principal design criteria see para-
graph Cooler dimensioning, general, Page 176.
HE-024/Cooler for LT cooling For heat data, flow rates and tolerances of the heat sources see section
water Planning data, Page 57 and the following. For the description of the principal
design criteria for coolers see paragraph Cooler dimensioning, general, Page
176.
MOV-016/LT cooling water This is a motor-actuated three-way regulating valve with a linear characteris-
temperature control valve tic. It is to be installed as a mixing valve. It maintains the LT cooling water at
set point temperature (32 °C standard).
The three-way valve is to be designed for a pressure loss of 0.3 – 0.6 bar. It
is to be equipped with an actuator with low positioning speed. For adjust-
ment of the valve please follow instructions given in MAN Energy Solutions
planning documentation. The actuator must permit manual emergency
adjustment.
The actual LT flow temperature is measured by a temperature sensor,
directly downstream of the three-way mixing valve in the supply pipe to
charge air cooler stage 1.
This sensor has to be installed by the shipyard. To ensure instantaneous
measurement of the mixing temperature of the three-way mixing valve, the
distance to the valve should be 5 to 10 times the pipe diameter.
For single engine plants, the control function may be taken over by the
SaCoS control unit. For multi engine plants, MAN Energy Solutions can sup-
ply a suitable external controller.
Note:
For engine operation with reduced NOx emission, according to IMO
Tier I/IMO Tier II requirement, at 100 % engine load and a seawater tempera-
ture of 25 °C (IMO Tier I/IMO Tier II reference temperature), an LT cooling
water temperature of 32 °C before charge air cooler stage 2 (HE-008) is to
be maintained. For other temperatures, the engine setting has to be adap-
ted. For further details please contact MAN Energy Solutions.
FIL-021/Strainer for cooling In order to protect the engine and system components, several strainers are
water to be provided at the places marked in the diagram. We recommend a mesh
size of 1 – 2 mm depending on the pipe diameter.
HE-005/Nozzle cooling water The nozzle cooling water system is a separate and closed cooling circuit. It is
cooler cooled down by LT cooling water via the nozzle cooling water cooler
(HE-005).
Heat data, flow rates and tolerances are indicated in section Planning data,
Page 57 and the following. The principal design criteria for coolers has been
described before in paragraph Cooler dimensioning, general, Page 176. For
plants with two main engines only one nozzle cooling water cooler (HE-005)
is required. As an option a compact nozzle cooling water module (MOD-005)
can be delivered, see section Nozzle cooling water module, Page 188.
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HE-007/Fuel oil cooler This cooler is required to dissipate the heat of the fuel injection pumps during
MDO/MGO operation. For the description of the principal design criteria for
coolers see paragraph Cooler dimensioning, general, Page 176. For plants
with more than one engine, connected to the same fuel oil system, only one
MDO/MGO cooler is required.
In case fuels with very low viscosity are used (e.g. arctic diesel or military
5.3 Water systems

fuels), a chiller system may be necessary to meet the minimum required fuel
viscosity (see section Fuel oil system, Page 190). Please contact MAN
Energy Solutions in that case.
T-075/LT cooling water The expansion tank compensates changes in system volume and losses due
expansion tank to leakages. It is to be arranged in such a way, that the tank bottom is situ-
ated above the highest point of the system at any ship inclination.
The expansion pipe shall connect the tank with the suction side of the
pump(s), as close as possible. It is to be installed in a steady rise (minimum
5°) to the expansion tank, without any air pockets. Minimum required diame-
ter is DN 32 for L engines and DN 40 for V engines.
For the recommended installation height and the diameter of the connecting
pipe, see table Service tanks capacities, Page 66.
The tank must have the following equipment:
▪ Sight glass for level monitoring or other suitable device for continuous
level monitoring
▪ Low-level alarm switch
▪ Overflow and filling connection
▪ Inlet for corrosion inhibitor
▪ Venting pipe
To prevent oxidation of the cooling water caused by “splashing”, the venting
pipe must be connected to the tank below the minimum water level.
1-string system For plants with interconnected LT and HT systems, the minimum tank vol-
ume should be determined by the following equation, depending on the
number of cylinders:
V = 0.5 + Vexpansion * nengine [m3]
The expansion volume is given in table Cooling water expansion volume,
Page 179, below.
Number of cylinders - 6 7 8 9
Expansion volume (HT and litre 13 15 18 20

LT system)
Table 102: Cooling water expansion volume
2-string system The effective tank capacity should be high enough to keep approximately 2/3
of the tank content of T-002. In case of twin-engine plants with a common
cooling water system, the tank capacity should be by approximately 50 %

higher. The tanks T-075 and T-002 should be arranged side by side to facili-
tate installation. In any case the tank bottom must be installed above the
highest point of the LT system at any ship inclination.
HT cooling water system

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General The HT cooling water system consists of the following coolers and heat
exchangers:
▪ Charge air cooler stage 1 (HE-010)
▪ Cylinder and valve head cooling (D-001)
▪ Cooler for HT cooling water (HE-003)
▪ HT cooling water preheater (H-027)

5.3 Water systems
Each engine has its own attached HT cooling water pump. The outlet tem-
perature of the cylinder cooling water is regulated to 90 °C after the engine
by the temperature control valve TCV-007, which is installed on the GenSet
frame.
The shipyard is responsible for the correct cooling water distribution, ensur-
ing that each engine will be supplied with cooling water at the flow rates
required by the individual engines, under all operating conditions. To meet
this requirement, orifices, flow regulation valves, by-pass systems etc. are to
be installed where necessary. Check total pressure loss in HT circuit. The
delivery height of the attached pump must not be exceeded.
P-002/HT cooling water The engine is equipped with a HT cooling water service pump (attached). For
service pump, attached details see section GenSet design and components – Water systems, Page
167.
HE-003/Cooler for HT cooling If the engines cooling water system is installed as a 2-string system, a cooler
water for HT cooling water must be installed. The heat from the HT cooling water
can either be transferred to the LT cooling system or directly to the seawater.
For heat data, flow rates and tolerances of the heat sources see section
Planning data, Page 57 and the following. For the description of the principal
design criteria for coolers see paragraph Cooler dimensioning, general, Page
176.
T-002/HT cooling water The expansion tank compensates changes in system volume and losses due
expansion tank to leakages. It is to be arranged in such a way, that the tank bottom is situ-
2-string system ated above the highest point of the system at any ship inclination.
The expansion pipe shall connect the tank with the suction side of the
pump(s), as close as possible. It is to be installed in a steady rise (minimum
5°) to the expansion tank, without any air pockets. Minimum required diame-
ter is DN 32 for L engines and DN 40 for V engines.
For the required volume of the tank, the recommended installation height and
the diameter of the connection pipe, see table Service tanks capacites, Page
66.
Tank equipment:
▪ Sight glass for level monitoring or other suitable device for continuous
level monitoring
▪ Low-level alarm switch
▪ Overflow and filling connection
▪ Inlet for corrosion inhibitor
▪ Venting pipe
To prevent oxidation of the cooling water caused by “splashing”, the venting

pipe must be connected to the tank below the minimum water level.
FSH-002/Condensate Only for acceptance by Bureau Veritas:
monitoring tank (not The condensate deposition in the charge air cooler is drained via the con-
indicated in the diagram) densate monitoring tank. A level switch releases an alarm when condensate
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is flooding the tank.
Engine preheating
5.3 Water systems

To secure a perfect combustion and at the same time avoid cold corrosion,
the engine must be preheated, in stand-by mode or before starting on HFO.
One part is the preheating of the engine’s water jackets and valve heads by
the HT cooling water. The second part is the preheating of the charge air
right after starting by the LT cooling water by-pass valve MOV-003.
On figure Cooling water system diagram 1-string, Page 172, two different
arrangements of the preheating equipment are shown.
▪ External, installed in the plant, one for each single GenSet.
▪ External, installed in the plant, common for all GenSets.
At 1-string systems, the LT cooling water flow must be shut off to be able to
preheat the engine effectively. Usually that is done by automatically actuated
valves. Electrically or pneumatically driven valves shall be used. Valves actu-
ated by engine lube oil must not be used, because of the very real risk of
cooling water entering the lubricating oil system due to a broken actuator
diaphragm.
MOD-004/HT cooling water All preheating equipment can be integrated and installed as one single unit.
preheating module As an option MAN Energy Solutions can supply a compact HT cooling water
preheating module (MOD-004). Please contact MAN Energy Solutions to
check the hydraulic circuit and electric connections. Figure Example – Com-
pact HT cooling water preheating module, Page 181 shows an example of
such a preheating module.
The main components of the HT cooling water preheating module are the HT
cooling water preheating pump and the HT cooling water preheater.
P-047/HT preheating pump An electrically driven pump becomes necessary to circulate the HT cooling
water during preheating. The flow through each cylinder should be approxi-
mately 2.5 l/min with flow from top and downwards.
HE-027/Preheater The preheater must be designed to preheat the engine up to 60 °C. To pre-
vent a too quick and uneven heating of the engine, the preheating tempera-
ture of the HT cooling water at engine inlet must remain mandatory below 90
°C and the circulation amount may not exceed 30 % of the nominal flow. The
maximum heating power has to be calculated accordingly.
The preheater must be designed to preheat the engine up to 60 °C. To pre-
vent a too quick and uneven heating of the engine, the preheating tempera-
ture of the HT cooling water at engine inlet must remain mandatory below 90
°C and the circulation amount may not exceed 30 % of the nominal flow. The
maximum heating power has to be calculated accordingly.
For preheating the HT cooling water from 10 °C to 60 °C within 8 hours, the
capacity of the external preheater should be 2.5 to 3.0 kW per cylinder.

These values include the radiation heat losses from the outer surface of the
engine. Also a margin of 20 % for heat losses of the cooling system has been
considered.
For the quantity of cooling water inside the engine see table Cooling water
and oil volume of engine, Page 66.
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Please avoid an installation of the preheater in parallel to the engine driven

HT pump. In this case, the preheater may not be operated while the engine
is running. Preheaters operated on steam or thermal oil may cause alarms
since a post-cooling of the heat exchanger is not possible after engine start
(preheater pump is blocked by counter pressure of the engine driven pump).
5.3 Water systems
Figure 53: Example – Compact HT cooling water preheating module
1 Electric flow heater 5 Safety valve
2 Switch cabinet 6 Manometer (filled with glycerin)
3 Circulation pump A Cooling water inlet
4 Non-return valve B Cooling water outlet
Preheating of the main engine with surplus heat

The preheating of the main engine with cooling water from auxiliary engines
is also possible, provided that the cooling water is treated in the same way.
In that case, the expansion tanks of the two cooling systems have to be
installed at the same level. Furthermore, it must be checked, if the available
heat is sufficient to pre-heat the main engine. This depends on the number of
auxiliary engines in operation and their load. It is recommended to install a
separate preheater for the main engine, as the available heat from the auxili-
ary engines may be insufficient during operation in port.
Preheating of the auxiliary engines with surplus heat

As shown in the diagrams, the auxiliary engines are preheated in stand-by
position with surplus heat from the running engines. If the engines are pre-
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heated with reverse cooling water direction, from the top and downwards, an
optimal heat distribution is reached in the engine. This method is at the same
time more economical since the need for heating is less and the water flow is
reduced. Due to the pressure difference, the HT cooling water pumps of the
running engines provide, the GenSets are preheated automatically via the
venting pipe.
Preheating of charge air
5.3 Water systems

During low load operation the low temperature cooling water is by-passed on
LT side of charge air cooler and led directly to lube oil cooler. This is done to
raise charge air temperature and improve combustion. At the connection F3
for the expansion tank there is a non-return valve with Ø 3 mm hole. This is
for the internal connections of the engine to improve preheating of the engine
at stand-by.
Engine post-cooling
It is required to cool down the engine for a period of 15 minutes after shut-
down. For this purpose the standby pump can be used. In case that neither
an electrically driven HT cooling water pump nor an electrically driven
standby pump is installed (e.g. multi-engine plants with engine driven HT
cooling water pump without electrically driven HT standby pump, if applica-
ble by the classification rules), it is possible to cool down the engine by a
separate small preheating pump. If the optional HT cooling water preheating
module (MOD-004) with integrated circulation pump is installed, it is also
possible to cool down the engine with this small pump. However, the pump
used to cool down the engine, has to be electrically driven and started auto-
matically after engine shut-down.
5.3.5 Cooling water collecting and supply system
T-074/Cooling water collecting tank

The tank is to be dimensioned and arranged in such a way that the cooling
water content of the circuits of the cylinder, turbocharger and nozzle cooling
systems can be drained into it for maintenance purposes.
This is necessary to meet the requirements with regard to environmental pro-
tection (water has been treated with chemicals) and corrosion inhibition (re-
use of conditioned cooling water).
Volumes for the engine are listed in table Cooling water and oil volume of the
engine, Page 67.
P-031/Cooling water filling pump (not indicated in the diagram)

The content of the collecting tank can be discharged into the expansion
tanks by a freshwater transfer pump.
5.3.6 Turbine washing

Turbocharger washing equipment

The turbocharger of engines operating on heavy fuel oil must be cleaned at
regular intervals. This requires the installation of a freshwater supply line from
the sanitary system to the turbine washing equipment and dirty-water drain
pipes via a funnel (for visual inspection) to the sludge tank. Please provide a
fresh water connection DN 25 with shut-off valve, pressure reducing device
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(2 – 4 bar) with integrated filter and pressure gauge (0 – 6 bar).

The water lance must be removed after every washing process. This is a pre-
cautionary measure, which serves to prevent an inadvertent admission of
water to the turbocharger.
The compressor washing equipment is completely mounted on the turbo-
charger and is supplied with freshwater from a small tank.
For further information see the turbocharger Project Guide. You can also find
5.3 Water systems
the latest updates on our website https://turbocharger.man-es.com.

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Figure 54: Cleaning turbine
5.3 Water systems

5.3.7 Cleaning of charge air cooler (ultrasonic)
The cooler bundle can be cleaned without being removed. Prior to filling with
cleaning solvent, the charge air cooler and its adjacent housings must be iso-
lated from the turbocharger and charge air pipe using blind flanges.
▪ The casing must be filled and drained with a big firehose with shut-off
valve (see figure below). All piping dimensions DN 80.
▪ If the cooler bundle is contaminated with oil, fill the charge air cooler cas-
ing with freshwater and a liquid washing-up additive.
▪ Insert the ultrasonic cleaning device after addition of the cleaning agent in
default dosing portion.
▪ Flush with freshwater (quantity: Approximately 2x to fill in and to drain).
The contaminated water must be cleaned after every sequence and must be
drained into the dirty water collecting tank.
Recommended cleaning medium:
"PrimeServClean MAN C 0186"
Increase in differential pressure1) Degree of fouling Cleaning period (guide value)
< 100 mm WC Marginally fouled Cleaning not required
100 – 200 mm WC Slightly fouled Approx. 1 hour
200 – 300 mm WC Severely fouled Approx. 1.5 hour
> 300 mm WC Extremely fouled Approx. 2 hour

1)
Increase in differential pressure = actual condition – New condition (mm WC = mm water column).
Table 103: Degree of fouling of the charge air cooler
Note:
When using cleaning agents:
The instructions of the manufacturers must be observed. Particular the data
sheets with safety relevance must be followed. The temperature of these
products has, (due to the fact that some of them are inflammable), to be at
10 °C lower than the respective flash point. The waste disposal instructions
of the manufacturers must be observed. Follow all terms and conditions of
the Classification Societies.
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5.3 Water systems
Figure 55: Principle layout
1 Installation ultrasonic cleaning 4 Dirty water collecting tank.

Required size of dirty water collecting tank:
Volume at the least 4-multiple charge air cooler
volume.
2 Firehose with sprag nozzle 5 Ventilation

3 Firehose A Isolation with blind flanges
5.3.8 Nozzle cooling system

P-005/Nozzle cooling water The centrifugal (non self-priming) pump discharges cooling water via the noz-
pump zle cooling water cooler (HE-005) and the strainer for cooling water (FIL-021)
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to the header pipe on the engine and then to the individual injection valves.
HE-005/Nozzle cooling water The nozzle cooling water cooler is to be connected in the LT cooling water
cooler circuit according to schematic diagram. Cooling of the nozzle cooling water
is effected by the LT cooling water.
If an antifreeze is added to the cooling water, the resulting lower heat transfer
5.3 Water systems

rate must be taken into consideration. The cooler is to be provided with vent-
ing and draining facilities.
TCV-005/Nozzle cooling The nozzle cooling water temperature control valve with thermal-expansion
water temperature control elements regulates the flow through the cooler to reach the required inlet
valve temperature of the nozzle cooling water. It has a regulating range from
approximately 50 °C (valve begins to open the pipe from the cooler) to 60 °C
(pipe from the cooler completely open).
FIL-021/Strainer for cooling To protect the nozzles for the first commissioning of the engine a strainer for
water cooling water has to be provided. The mesh size is 0.25 mm.

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Figure 56: Nozzle cooling system diagram
Components
5.3 Water systems
D-001 Diesel engine P-005 Nozzle cooling water pump
FIL-021 Strainer for commissioning T-039 Cooling water storage tank
HE-005 Nozzle cooling water cooler T-076 Nozzle cooling water service tank
MOD-005 Nozzle cooling water module TCV-005 Nozzle cooling water temperature
control valve
Major engine connections
3471 Nozzle cooling water inlet 3494 Nozzle cooling water outlet
3495 Nozzle cooling water drain
Connections to the nozzle cooling module
N1 Nozzle cooling water return from N6 Filling connection

engine
N2 Nozzle cooling water outlet to N7 Discharge

engine
N3 Cooling water inlet N8 From savety valve
N4 Cooling water outlet 13 Expansion pot
N5 Check for "oil in water"
5.3.9 Nozzle cooling water module
General In HFO operation, the nozzles of the fuel injection valves are cooled by fresh-
water circulation, therefore a nozzle cooling water system is required. It is a
separate and closed system re-cooled by the LT cooling water system, but
not directly in contact with the LT cooling water. The separate nozzle cooling
water system ensures easy detection of damages at the nozzles. Even small
fuel leakages are visible via the sight glass. The closed system also prevents
the engine and other parts of the cooling water system from pollution by fuel
oil. Cleaning of the system is quite easy and only a small amount of contami-
nated water has to be discharged to the sludge tank. The nozzle cooling
water is to be treated with corrosion inhibitor according to MAN Energy Solu-
tions specification. For further information see section Specification of engine
cooling water, Page 131.
Note:
In diesel engines designed to operate prevalently on HFO the injection valves

are to be cooled during operation on HFO. In the case of MGO or MDO
operation exceeding 72 h, the nozzle cooling is to be switched off and the
supply line is to be closed. The return pipe has to remain open.
In diesel engines designed to operate exclusively on MGO or MDO (no HFO
operation possible), nozzle cooling is not required. The nozzle cooling system
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is omitted.
Design
The nozzle cooling water module consists of a storage tank, on which all
components required for nozzle cooling are mounted.
Figure 57: Example: Compact nozzle cooling water module 5.3 Water systems
Part list
1 Tank 11 Sight glass

2 Circulation pump 12 Flow switch set point
3 Plate heat exchanger 13 Valve with non-return
4 Inspection hatch 14 Temperature regulating valve
5 Safety valve 15 Expansion pot

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6 Automatic venting 16 Ball type cock
7 Pressure gauge 17 Ball type cock
8 Valve 18 Ball type cock
9 Thermometer 19 Ball type cock
10 Thermometer 20 Switch cabinet
Connections to the nozzle cooling module

5.4 Fuel oil system
N1 Nozzle cooling water return from engine N5 Check for "oil in water"
N2 Nozzle cooling water outlet to engine N6 Filling connection
N3 Cooling water inlet N7 Discharge
N4 Cooling water outlet
5.4 Fuel oil system
5.4.1 General
The fuel oil system must be designed and built to supply the diesel engine
with fuel oil, which meets all requirements specified by MAN Energy Solu-
tions. In order to achieve this purpose, plant equipment for storage, transfer,
purification, heating and cooling, measuring and monitoring installations as
well as piping and control systems are necessary. The shown system dia-
grams are for guidance only. Both, an integrated system according to the uni
fuel concept as well as a separated system for supplying the auxiliary
engines exclusively, are possible. They have to be adapted in each case to
the actual engine type, pipe layout and applicable classification rules.
Uni fuel concept

Auxiliary GenSet plants are installed together with the main propulsion
engines (e.g. on container vessels) to support them and to ensure the electri-
cal power supply on board. The fuel oil system can be designed as an uni
fuel system, indicating that the propulsion engine and the GenSets are run-
ning on the same fuel oil and are fed from a common fuel oil system.
Emergency MDO supply system

Always a separate and pure MDO supply system for the auxiliary engines is
installed. It ensures the independent fuel oil supply in case of an emergency
(e.g. fault within HFO system or blackout) or to flush the engines with distil-
late fuel before repair or maintenance. At multi-engine plants this system
allows to operate e.g one GenSet in MDO mode, while the other GenSets
are still running in HFO mode. The separate emergency MDO supply system
is not designed for continuous operation, but only for temporary emergency
operation.
Fuel types
Different local emission regulations on the one hand and economic reasons
on the other hand, require the storage of more and more different sorts of
fuel oil on board. Besides distillate fuel oils (DMA, DMB), high-viscosity and
heavy fuel oils (RMK fuels) are important to operate large vessels economi-
2019-09-19 - 1.4
cally.
Since January 2015 more strictly emission regulations concerning the sul-
phur content of fuels used within the so called „sulphur emission control
areas (SECAs)” apply. As a result several “ultra low sulphur” fuel oils are
offered. From an engine manufacturer’s point of view there is no lower limit
for the sulphur content of fuel oil. MAN Energy Solutions has not experienced
any trouble with the currently available low sulphur fuels, that is related to the
sulphur content. However new fuel production methods are applied (desul-
5.4 Fuel oil system

phurisation, uncommon blending components), which will challenge the
whole fuel oil system.
In the following section the abbreviation MDO (marine diesel oil) is used as
synonym for all distillate fuels, such as DMA (former MGO) and DMB, DMZ
(former MDO) acc. to ISO 8217. The abbreviation HFO (heavy fuel oil) will be
used generally for RM-fuels with high content of residual oils (RMA - RMK)
according to ISO 8217. Further information about all approved fuels is given
in section Specification for engine supplies, Page 101.
Mixing of fuels
Different fuels are mixed inevitably in tanks, pipes and engines. As a result
incompatibility reactions may occur and lead to damages of the engine and
the plant system. To avoid incompatibility reactions it is recommended to
check the compatibility between all handled fuels, especially between low
sulphur (LS)/ultra low sulphur (ULS) and conventional fuels, by lab (e.g. Pri-
meServLab) or with an onboard kit before bunkering. Test methods following
ASTM D2781, ASTM D4740 or ASTM D7060 may be suitable for rough esti-
mation of fuel compatibility.
Low mixture ratios between HFO and MDO normally effect no incompatibility
reactions:
▪ Max. MDO content in HFO: 5 % vol.
▪ Max. HFO content in MDO: 2 % vol.
However incompatibility reactions cannot be excluded completely, especially
when using HFO with high asphaltene content and less aromatic MDO.
Compatibility tests are required in any case.

Fuel oil sampling points are to be provided upstream and downstream of
each filter, to verify the effectiveness of these system components.
Piping
We recommend to use pipes according to PN16 for the fuel system (see
section Engine pipe connections and dimensions, Page 145).
Material
The casing material of pumps and filters should be EN-GJS (nodular cast
iron), in accordance to the requirements of the classification societies.
5.4.2 Marine diesel oil (MDO) treatment system
A prerequisite for safe and reliable engine operation with a minimum of serv-
icing is a properly designed and well-functioning fuel oil treatment system.
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The schematic diagram, see figure MDO treatment system diagram, Page
194 shows the system components required for fuel oil treatment for marine
diesel oil (MDO).
T-015/Diesel fuel oil storage tank

5.4 Fuel oil system
The minimum effective capacity of the tank should be sufficient for the opera-
tion of the propulsion plant, as well as for the operation of the auxiliary die-
sels for the maximum duration of voyage including the resulting sediments
and water. Regarding the tank design, the requirements of the respective
classification society are to be observed.
The diesel fuel oil storage tank should be provided with a sludge space with
a tank bottom inclination of preferably 10° and sludge drain valves at the
lowest point to drain the settled sludge at regular intervals.
Tank heating The tank heater must be designed so that the MDO temperature is at least
10 °C minimum above the pour point. The supply of the heating medium
must be automatically controlled as a function of the MDO temperature.
Fuel with biodiesel In case fuel oils with up to 7 % of biodiesel (FAME) are used, there is an
increased risk of degradation especially due to microbial activity which can
threaten engine performance. In order to minimise this risk, long storage peri-
ods of this fuel have to be avoided. Furthermore all distillate tanks are to be
supplied with a drainage system to prevent bacterial growth by water accu-
mulation.
T-021/Sludge tank
If disposal by an incinerator plant is not planned, the tank has to be dimen-
sioned so that it is capable of absorbing all residues which accumulate dur-
ing the operation in the course of a maximum duration of voyage. In order to
enable the emptying of the tank, it must be heated.
The heating is to be dimensioned so that the content of the tank can be
heated to approximately 40 °C. If the sludge tank is used for the disposal of
leakages or sludge of heavy fuel oil plants, the heating must be dimensioned
to heat the tank content up to 60 °C.
P-073/Diesel fuel oil separator feed pump

The supply pumps should always be electrically driven, i.e. not mounted on
the diesel fuel oil separator, as the delivery volume can be matched better to
the required throughput.
H-019/Fuel oil preheater

In order to achieve the separating temperature, a separator adapted to suit
the fuel oil viscosity should be fitted.
The fuel oil preheater must be able to heat the diesel oil up to 40 °C and the
size must be selected accordingly. However the medium temperature pre-

scribed in the separator manual must be observed and adjusted.
A reliable temperature control (offset ± 1 °C) even for variable fuel oil flow
rates must be installed.
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CF-003/Diesel fuel oil separator

A self-cleaning separator must be provided. The diesel fuel oil separator is
dimensioned in accordance with the separator manufacturers' guidelines.
The required flow rate (Q) can be roughly determined by the following equa-
tion:
5.4 Fuel oil system

be [g/kWh] Fuel oil consumption
ρ [g/l] Density at separating temp approximately 870 kg/m3 = g/dm3
With the evaluated flow rate, the size of the separator has to be selected
according to the evaluation table of the manufacturer. The separator rating
stated by the manufacturer should be higher than the flow rate (Q) calculated
according to the above formula.
For the first estimation of the maximum fuel oil consumption (be), increase the
specific table value by 15 %, see section Planning data, Page 57.
For project-specific values contact MAN Energy Solutions.
In the following, characteristics affecting the fuel oil consumption are listed
exemplary:
▪ Tropical conditions
▪ The engine-mounted pumps
▪ Fluctuations of the calorific value
▪ The consumption tolerance

each separator, to verify the effectiveness of these system components.
T-003/Diesel fuel oil service tank

See description in paragraph T-003/Diesel fuel oil service tank, Page 204.

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5.4 Fuel oil system
MDO treatment system diagram

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Figure 58: MDO treatment system diagram
Components
5.4 Fuel oil system

CF-003 Diesel fuel oil separator T-015 Diesel fuel oil storage tank
H-019 Fuel oil preheater T-021 Sludge tank
P-057 Diesel fuel oil transfer pump 1,2 T-003 Diesel fuel oil service tank
P-073 Diesel fuel oil separator feed pump
5.4.3 Heavy fuel oil (HFO) treatment system

A prerequisite for safe and reliable engine operation with a minimum of serv-
icing is a properly designed and well-functioning fuel oil treatment system.
The schematic diagram, see figure HFO treatment system diagram, Page
200 shows the system components required for fuel treatment of heavy fuel
oil (HFO).
Bunker fuel oil

Fuel compatibility problems are avoidable if mixing of newly bunkered fuel
with remaining fuel can be prevented by a suitable number of bunkers. Heat-
ing coils in bunkers need to be designed so that the HFO in it is at a temper-
ature of at least 10 °C minimum above the pour point.
P-038/Heavy fuel oil transfer pump

The heavy fuel oil transfer pump discharges fuel from the bunkers into the
heavy fuel oil settling tanks. Being a screw pump, it handles the fuel oil gen-
tly, thus prevent water being emulsified in the fuel oil. Its capacity must be
sized to fill the complete heavy fuel oil settling tank within ≤ 2 hours.
T-016/Heavy fuel oil settling tank

Two heavy fuel oil settling tanks should be installed, in order to obtain thor-
ough pre-cleaning and to allow fuels of different origin to be kept separate.
When using RM-fuels we recommend two heavy fuel oil settling tanks for
each fuel type (high sulphur HFO, low sulphur HFO).
Size Pre-cleaning by settling is the more effective the longer the solid material is
given time to settle. The storage capacity of the heavy fuel oil settling tank
should be designed to hold at least a 24-hour supply of fuel oil at full load
operation, including sediments and water the fuel oil contains.
The minimum volume (V) to be provided is:
V [m3] Minimum volume

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P [kW] Engine rating
Tank heating The heating surfaces should be dimensioned that the heavy fuel oil settling
tank content can be evenly heated to 75 °C within 6 to 8 hours. The heating
should be automatically controlled, depending on the fuel oil temperature.
In order to avoid:
▪ Agitation of the sludge due to heating, the heating coils should be

arranged at a sufficient distance from the tank bottom.
5.4 Fuel oil system
▪ The formation of asphaltene, the fuel oil temperature should not be per-
missible to exceed 75 °C.
▪ The formation of carbon deposits on the heating surfaces, the heat
transferred per unit surface must not exceed 1.1 W/cm2.
Design The heavy fuel oil settling tank is to be fitted with baffle plates in longitudinal
and transverse direction in order to reduce agitation of the fuel oil in the tank
in rough seas as far as possible. The suction pipe of the heavy fuel oil sepa-
rator must not reach into the sludge space. One or more sludge drain valves,
depending on the slant of the tank bottom (preferably 10°), are to be provi-
ded at the lowest point. The heavy fuel oil settling tank is to be insulated
against thermal losses.
Sludge must be removed from the heavy fuel oil settling tank before the sep-
arators draw fuel oil from it.
T-021/Sludge tank
If disposal by an incinerator plant is not planned, the tank has to be dimen-
sioned so that it is capable of absorbing all residues which accumulate dur-
ing the operation in the course of a maximum duration of voyage. In order to
enable the emptying of the tank, it must be heated.
The heating is to be dimensioned so that the content of the tank can be
heated to approximately 60 °C.
P-015/Heavy fuel oil separator feed pump

The supply pumps should preferably be of the free-standing type, i.e. not
mounted on the heavy fuel oil separator, as the delivery volume can be
matched better to the required throughput.
H-008/Heavy fuel oil preheater

To reach the separating temperature a heavy fuel oil preheater matched to
the fuel oil viscosity has to be installed.
A reliable temperature control (setpoint 98 °C ± 1 °C for HFO) for different
fuel oil flow rates must be installed.
CF-002/Heavy fuel oil separator

Main principle of separators as well as settling tanks is the density difference
between fuel oil, particles and water. Small particles will settle very slowly,
especially in RMK-fuels with high viscosity/high density.

Not only good quality fuels, but also poor quality and high viscosity fuels
might be used. For each HFO-type two new generation separators must be
installed, which are also capable of clean fuels with a density up to 1,010
kg/m³ (referring to 15 °C).
Recommended separator manufacturers and types:
2019-09-19 - 1.4
Alfa Laval: Alcap, type SU

Westfalia: Unitrol, type OSE
Separators must always be provided in sets of at least 2 of the same type
▪ 1 service separator
▪ 1 stand-by separator
of self-cleaning type.
5.4 Fuel oil system

The freshwater supplied to the heavy fuel oil separator must be treated as
specified by its manufacturer.
Mode of operation Optimising the operation parameters is to raises the heavy fuel oil separator
efficiency up to 98 %. Based on the separator makers recommendations and
guidelines the separator cleaning efficiency can be increased by several
options.
▪ Number of separators in operation
The stand-by separator is always to be put into service, to achieve the
best possible fuel cleaning effect with the separator plant as installed.
The piping of both heavy fuel oil separators is to be arranged in accord-
ance with the makers advice, preferably for both parallel and series oper-
ation.
Separator operation in parallel means each unit works with i.e. a 50 %-
flow rate of the separator design-flow (based on the 100 %-engine load
fuel oil consumption). More hints for the differences between design flow
and different possible operation flow can be found in the separator
maker manuals. The discharge flow of the separator supply pump is to
be split up equally between the two separators in parallel operation.
▪ Fuel temperature
The required fuel oil temperature at separator inlet is stated in the sepa-
rator manual and must be observed. When cleaning heavy fuel oil the
inlet temperature should be around 98 °C. A longer HFO residence time
in each separator in combination with a high separation temperature may
reduce the amount of small and light foreign particles (i.e. cat fines in the
range of 5 micron to 10 micron). Some separator manufacturers offer
fully automatic and so-called hot separation systems. These systems
raise the fuel oil temperature temporarily above 98 °C to make fine parti-
cles be separated more efficiently.
▪ Fuel flow rate
Generally the engines are not running all together and not always at
100 % load. Hence the current fuel oil consumption is lower than the
design flow rate of the separators.
The separator module and its control must allow a reduction of the flow-
rate, depending on the actual fuel oil consumption. This will increase the
separators efficiency. There are at least two options of reducing the flow-
rate through the separator:
1. Using only one feed pump for two separators to split the flow to 50 %
for each separator.
2. Using frequency controlled feed pumps, controlled by the separator
control in dependence of the continuously measured fuel oil consump-
tion.
▪ Homogenisation
As a result of emulsification or homogenisation the water contained in the
fuel will be dissipated in very small droplets, which can hardly be
removed by the separators. Furthermore cat fines are hydrophilic and will
create non-separable aggregates together with the water droplets. The
same applies when homogenising fuel in tanks, whereby the settling
2019-09-19 - 1.4
process will be hindered. Water and particles which normally shall settle
down at the bottom of the tank then get into the fuel supply system and
will not be removed.
Therefore, homogenisers must not be utilised if the homogenised fuel is
delivered to the heavy fuel oil separator or either directly or indirectly to
the heavy fuel oil settling or service tanks.
Various operating parameters affect the heavy fuel oil separation efficiency.
5.4 Fuel oil system
These include temperature (which controls both, fuel oil viscosity and den-
sity), flow rate and separator maintenance. Figure Separation efficiency
dependence on particle size, density difference, viscosity and flowrate, Page
198 shows, how the operating parameters affect the separator efficiency.
However all operating parameters have always be observed and adjusted
according to the separators operating manual.
Figure 59: Separation efficiency dependence on particle size, density difference, viscosity and flow rate
(reference: Diagram 1 – 3: "CIMAC Paper No. 51 - Onboard Fuel Oil Cleaning", CIMAC Congress, 2013)
Size The heavy fuel oil separators are dimensioned in accordance with the sepa-
rator manufacturers' guidelines. The required design flow rate (Q) can be
roughly determined by the following equation:
be [g/kWh] Fuel oil consumption
ρ [g/l] Density at separating temp approximately 930 kg/m3 = [g/l]
With the evaluated flow rate, the size of the separator has to be selected
according to the evaluation table of the manufacturer. The separator rating
stated by the manufacturer should be higher than the flow rate (Q) calculated
according to the above formula.
For the first estimation of the maximum fuel oil consumption (be), increase the
specific table value by 15 %, see section Planning data, Page 57.
For project-specific values contact MAN Energy Solutions.
In the following, characteristics affecting the fuel oil consumption are listed
exemplary:
▪ The engine-mounted pumps
▪ Fluctuations of the calorific value
2019-09-19 - 1.4
▪ The consumption tolerance

each separator, to verify the effectiveness of these system components.
T-022/Heavy fuel oil service tank
5.4 Fuel oil system

See description in paragraph T-022/Heavy fuel oil service tank, Page 204.

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HFO treatment system diagram

5.4 Fuel oil system
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Figure 60: HFO treatment system diagram
Components
5.4 Fuel oil system

1,2 CF-002 HFO fuel oil separator 1,2 P-038 HFO transfer pump
1,2 H-008 HFO preheater 1,2 T-016 HFO settling tank
MDO-008 Fuel oil module T-021 Sludge tank
1,2 P-015 HFO separator feed pump 1,2 T-022 HFO service tank
5.4.4 GenSet design and components – Fuel oil system
General
Some essential fuel oil cleaning and measuring equipment is already installed
at the engine itself or at the GenSet frame. Also completely installed is the
piping to the fuel oil duplex filter, from the filter to the engine as well as the
fuel oil return line and the leakage pipes from the engine to the plant. If the
engine is equipped with a leakage drain split piping or sealed plunger (SP)
injection pumps, two separate leakage connections exist at the GenSet: One
for the dirty leakage (lube oil and particle contaminated) and one for the clean
and reusable leakage.
FIL-013/Fuel oil duplex filter

The absolute mesh size of the fuel oil duplex filter is 25 µm (sphere passing
mesh). To keep the engine running, it is possible to switch over to the sec-
ond chamber, if one filter element is clogged and must be cleaned or
changed. If the filter elements are removed for cleaning, the filter chamber
must be emptied completely. This prevents dirt particles remaining in the fil-
ter casing from migrating to the clean oil side of the filter. The main design
criterion is the permissible filter area load, specified by the filter manufacturer.
Filter mesh size (sphere passing mesh) µm 25
Design pressure bar 16
Design temperature °C ≥ 150

Table 104: Design data
FSH-001/Leakage fuel oil monitoring tank

The monitoring tank is attached to the GenSet. High pressure pump over-
flow, leakages from fuel injectors and buffer pistons and escaping fuel from
burst control pipes is carried to the monitoring tank. To warm up the leak-
age, fuel oil supplied to the engine passes through the tank. The tank is
equipped with a level switch, which initiates an alarm in case of a larger leak-
age flow than normal. All parts of the monitored leakage system (pipes and
monitoring tank) have to be designed for a fuel rate of 6.7 l/min x cyl. Most
classification societies require the installation of monitoring tanks for unman-
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ned engine rooms, some for manned rooms as well.
Fuel oil system diagram

5.4 Fuel oil system
Figure 61: Fuel oil system diagram
5671 Fuel oil inlet 5694 Clean fuel oil leakage drain
5693 Dirty fuel oil leakage drain 5699 Fuel oil outlet
5271/A1 Fuel oil inlet 5684/A3A Clean fuel oil leakage drain*
5299/A2 Fuel oil outlet 5685/A3B Dirty fuel oil leakage drain*
5684/A3 Dirty fuel oil leakage drain

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GenSet equipments
FIL-013 Fuel oil duplex filter FSH-001 Leakage fuel oil monitoring tank
Option: Leakage drain spilt or engine equipped with sealed plunger (SP) pumps (pipe connections 5693 and 5694
*)
not interconnected).
5.4 Fuel oil system

5.4.5 Fuel oil supply system
General
Normally one or two main engines are connected to one fuel system. Auxili-
ary engines can be connected to the same fuel system as well, see figure Uni
fuel oil system diagram, Page 213. A separate and pure MDO supply system
for the auxiliary engines increases the availability of the GenSets. It is
designed for short time operation in case of an emergency or for mainte-
nance purposes.
MDO viscosity
At engine inlet the MDO-fuel viscosity must be > 2.0 and < 11 cSt (see sec-
tion Specification of diesel oil (MDO), Page 114). The fuel oil temperature has
to be adapted accordingly. It must be ensured, that the MDO fuel tempera-
ture of maximum 45 °C at engine inlet (for all MDO qualities) is not exceeded.
Therefore a tank heating and a cooler in the fuel return pipe are required.
HFO viscosity
To ensure that high-viscosity fuel oils (HFO) achieve the specified injection
viscosity between 12 and 14 cSt (see section Specification of heavy fuel oil
(HFO), Page 116 and Viscosity-temperature diagram (VT diagram), Page
129) a preheater must be installed. The preheating temperature of up to 150
°C, may cause degassing problems in conventional, pressureless systems.
A remedial measure is adopting a pressurised system in which the required
system pressure is 1 bar above the evaporation pressure of water.
Fuel Injection Temperature after Evaporation Required system
viscosity1) final heater HFO pressure pressure
mm2/50 °C mm2/s °C bar bar
180 12 126 1.4 2.4
320 12 138 2.4 3.4
380 12 142 2.7 3.7
420 12 144 2.9 3.9
500 14 141 2.7 3.7

700 14 147 3.2 4.2
For fuel viscosity depending on fuel temperature please see section Viscosity-temperature diagram (VT diagram),
1)
Page 129.
Table 105: Injection viscosity and temperature after final heater heavy fuel oil
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The indicated pressures are minimum requirements due to the fuel charac-
teristic. Nevertheless, to meet the required fuel pressure at the engine inlet
(see section Planning data, Page 57 and the following), the pressure in the
fuel oil mixing tank and booster circuit becomes significant higher as indica-
ted in this table.
T-003/Diesel fuel oil service tank

5.4 Fuel oil system
The classification societies specify that at least two service tanks for each
fuel type to be installed on board. One tank supplies the engines with purified
MDO, while the other tank receives purified MDO and allows remained parti-
cles to settle down to the tank bottom. The minimum tank capacity of each
tank should, in addition to the MDO consumption of other consumers, ena-
ble a full load operation of minimum eight operating hours for all engines
under all conditions.
The service tank should be provided with a sludge space with a tank bottom
inclination of preferably 10° and sludge drain valves at the lowest point to
drain the settled sludge at regular intervals. Overflow pipes from the diesel
fuel oil service tank T-003 to the diesel fuel oil storage tank T-015, with heat-
ing coils and insulation must be installed.
If DMB fuel with 11 cSt (at 40 °C) is used, the tank heating is to be designed
to keep the tank temperature at minimum 40 °C. For lighter types of MDO it
is recommended to heat the tank in order to reach a fuel oil viscosity of 11
cSt or less. Rules and regulations for tanks, issued by the classification soci-
eties, must be observed.
The required minimum MDO capacity of each service tank is:
VMDOST = (Qp x to x Ms )/(3 x 1000 l/m3)
Required min. volume of one diesel fuel oil service VMDOST m3

tank
Required supply pump capacity, MDO 45 °C Qp l/h

See paragraph P-008/Diesel fuel oil supply pump,
Page 215 and P-018/Fuel oil supply pump, Page
205.
Operating time to h
to = 8 h
Margin for sludge MS -

MS = 1.05
Table 106: Required minimum MDO capacity
In case more than one engine, or different engines are connected to the
same fuel system, the service tank capacity has to be increased accordingly.
Overflow To enable a continuous separator cleaning flow independent from the fuel oil
consumption, the diesel fuel oil service tank should be equipped with an
overflow pipe. The overflow pipe shall be installed from the bottom of the
service tank to the top of the settling tank. In this way heavy particles and
water collecting at the lower part of the service tank will recirculate into the
settling tank.
T-022/Heavy fuel oil service tank

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The heavy fuel oil cleaned in the heavy fuel oil separator is passed to the
service tank, and as the separators are in continuous operation, the tank is
always kept filled.
To fulfil this requirement it is necessary to fit the heavy fuel oil service tank
5.4 Fuel oil system

T-022 with overflow pipes, which are connected with the heavy fuel oil set-
tling tanks T-016. The tank capacity is to be designed for at least eight-
hours' fuel supply at full load so as to provide for a sufficient period of time
for separator maintenance.
The tank should have a sludge space with a tank bottom inclination of pref-
erably 10° with sludge drain valves at the lowest point and it is to be equip-
ped with heating coils.
The sludge must be drained from the service tank at regular intervals.
The heating coils are to be designed for a tank temperature of 75 °C.
The rules and regulations for tanks issued by the classification societies must
be observed.
HFO with high and low sulphur content must be stored in separate service
tanks.
Overflow To enable a continuous separator cleaning flow independent from the fuel oil
consumption, the diesel fuel oil service tank should be equipped with an
overflow pipe. The overflow pipe shall be installed from the bottom of the
service tank to the top of the settling tank. In this way heavy particles and
water collecting at the lower part of the service tank will recirculate into the
settling tank.
CK-002/Three-way valve for fuel oil changeover

This valve is used for changing over from MDO/MGO operation to heavy fuel
operation and vice versa. Normally it is operated manually, and it is equipped
with two limit switches for remote indication and suppression of alarms from
the viscosity measuring and control system during MDO/MGO operation.
STR-010/Suction strainer
To protect the fuel oil supply pumps, an approximately 0.5 mm gauge
(sphere-passing mesh) strainer is to be installed at the suction side of each
supply pump.
P-018/Fuel oil supply pump

The volumetric capacity must be at least 160 % of max. fuel oil consumption.
QP1= P1x br ISOx f4
Required supply pump delivery capacity with HFO at 90 °C QP1 l/h

Engine output at 100 % MCR P1 kW
Specific engine fuel oil consumption (ISO) at 100 % MCR brISO g/kWh
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Factor for pump dimensioning f4 l/g

5.4 Fuel oil system
▪ For diesel engines operating on main fuel HFO:

f4 = 2.00 x 10–3
Note:
The factor f4includes the following parameters:
▪ 160 % fuel oil flow
▪ Main fuel: HFO 380 mm2/50 °C
▪ Attached lube oil and cooling water pumps
▪ Realistic lower heating value
▪ Specific fuel oil weight at pumping temperature
▪ Tolerance
In case more than one engine is connected to the same fuel oil system, the pump capacity has to be increased
accordingly.
Table 107: Simplified fuel oil supply pump dimensioning
The delivery height of the fuel oil supply pump shall be selected according to
the required system pressure (see table Injection viscosity and temperature
after final heater heavy fuel oil, Page 209), the required pressure in the mixing
tank and the resistance of the automatic filter, flowmeter and piping system.
Injection system
bar
Positive pressure at the fuel module inlet due to tank level above fuel module level – 0.10
Pressure loss of the pipes between fuel module inlet and mixing tank inlet + 0.20
Pressure loss of the automatic filter + 0.80
Pressure loss of the fuel flow measuring device + 0.10
Pressure in the fuel oil mixing tank + 5.70
Operating delivery height of the supply pump = 6.70

Table 108: Example for the determination of the expected operating delivery height of the fuel oil supply
pump
It is recommended to install fuel oil supply pumps designed for the following
pressures:
Engines with conventional fuel oil injection system: Design delivery height
7.0 bar, design output pressure 7.0 bar.
Engines with common rail injection system: Design delivery height 8.0 bar,
design output pressure 8.0 bar.
HE-025/Fuel oil cooler, supply circuit

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If no fuel is consumed in the system while the pump is in operation, the fin-
ned-tube cooler prevents excessive heating of the fuel. Its cooling surface
must be adequate to dissipate the heat that is produced by the pump to the
ambient air.
In case of continuos MDO/MGO operation, a water cooled fuel oil cooler is
required to keep the fuel oil temperature below 45 °C.
PCV-009/Pressure limiting valve
5.4 Fuel oil system

This valve is used for setting the required system pressure and keeping it
constant. It returns in the case of
▪ engine shutdown 100 %, and of
▪ engine full load 37.5 % of the quantity delivered by the fuel oil supply
pump back to the pump suction side.
FIL-003/Fuel oil automatic filter, supply circuit

The fuel oil automatic filter (supply circuit) should be a type that causes no
pressure drop in the system during flushing sequence and must be equipped
with differential pressure indication and switches.
The design criterion relies on the filter surface load, specified by the filter
manufacturer.

A by-pass pipe in parallel to the fuel oil automatic filter (supply circuit) is
required. Only during maintenance on the automatic filter, the by-pass must
be opened; the fuel is then filtered by the automatic filter (booster circuit)
FIL-030. This operating mode is not permissible for continuous operation.
FQ-003/Fuel oil flowmeter

In case a fuel oil consumption measurement is required, a fuel oil flowmeter
must be installed downstream the fuel oil automatic filter (supply circuit)
FIL-003.
A by-pass line must be provided in case of flowmeter failure or maintenance.
T-011/Fuel oil mixing tank

The mixing tank compensates pressure surges which occur in the pressur-
ised part of the fuel system.
For this purpose, there has to be an air cushion in the tank. As this air cush-
ion is exhausted during operation, compressed air (max. 10 bar) has to be
refilled via the control air connection from time to time.
Before prolonged shutdowns the system is changed over to MDO/MGO

operation.
The tank volume shall be designed to achieve gradual temperature equalisa-
tion within 5 minutes in the case of half-load consumption.
The tank shall be designed for the maximum possible service pressure, usu-
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ally approximately 10 bar and is to be accepted by the classification society

in question.
The expected operating pressure in the fuel oil mixing tank depends on the
required fuel oil pressure at the inlet (see section Planning data, Page 57) and
the pressure losses of the installed components and pipes.
Injection system
5.4 Fuel oil system
bar
Required max. fuel oil pressure at engine inlet + 8.00
Pressure difference between fuel oil inlet and outlet engine – 2.00
Pressure loss of the fuel oil return pipe between engine outlet and mixing tank inlet, – 0.30
e.g.
Pressure loss of the flow balancing valve (to be installed only in multi-engine plants, – 0.00
pressure loss approximately 0.5 bar)
Operating pressure in the fuel oil mixing tank = 5.70

Table 110: Example for the determination of the expected operating pressure of the fuel oil mixing tank
This example demonstrates, that the calculated operating pressure in the fuel
oil mixing tank is (for all HFO viscosities) higher than the min. required fuel oil
pressure (see table Injection viscosity and temperature after final heater
heavy fuel oil, Page 209).
P-003/Fuel oil booster pump

To cool the engine mounted high pressure injection pumps, the capacity of
the booster pump has to be at least 300 % of maximum fuel oil consumption
at injection viscosity.
QP2= P1x br ISOx f5
Required booster pump delivery capacity with HFO at 145 °C QP2 l/h
Engine output at 100 % MCR P1 kW
Specific engine fuel oil consumption (ISO) at 100 % MCR brISO g/kWh
Factor for pump dimensioning f5 l/g

▪ For diesel engines operating on main fuel HFO:
f5 = 3.90 x 10–3
Note:
The factor f5includes the following parameters:
▪ 300 % fuel oil flow at 100 % MCR
▪ Main fuel: HFO 380 mm2/50 °C
▪ Attached lube oil and cooling water pumps
▪ Realistic lower heating value

▪ Specific fuel oil weight at pumping temperature
▪ Tolerance
In case more than one engine is connected to the same fuel oil system, the pump capacity has to be increased
accordingly.
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Table 111: Simplified fuel oil booster pump dimensioning
The delivery height of the fuel oil booster pump is to be adjusted to the total
resistance of the booster system.
Injection system
5.4 Fuel oil system

bar
Pressure difference between fuel inlet and outlet engine + 2.00
Pressure loss of the flow balancing valve (to be installed only in multi-engine + 0.00
plants, pressure loss approximately 0.5 bar)
Pressure loss of the pipes, mixing tank – Engine mixing tank, e.g. + 0.50
Pressure loss of the final heater heavy fuel oil max. + 0.80
Pressure loss of the indicator filter + 0.80
Operating delivery height of the booster pump = 4.10

Table 112: Example for the determination of the expected operating delivery height of the fuel oil booster
pump
It is recommended to install booster pumps designed for the following pres-

sures:
Engines with conventional fuel oil injection system: Design delivery height
7.0 bar, design output pressure 10.0 bar.
Engines common rail injection system: Design delivery height 10.0 bar,
design output pressure 14.0 bar.
To ensure that high-viscosity fuel oils achieve the specified injection viscosity,
a preheating temperature is necessary, which may cause degassing prob-
lems in conventional, pressureless systems.
A remedial measure is adopting a pressurised system in which the required
system pressure is 1 bar above the evaporation pressure of water.
Fuel Injection Temperature after Evaporation Min. required system

viscosity1) final heater HFO pressure pressure
mm2/50 °C mm2/s °C bar bar
180 12 126 1.4 2.4
320 12 138 2.4 3.4
380 12 142 2.7 3.7
420 12 144 2.9 3.9
500 14 141 2.7 3.7

700 14 147 3.2 4.2

1)
For fuel oil viscosity depending on fuel temperature please see section Viscosity-temperature diagram (VT diagram),
Page 129.
Table 113: Injection viscosity and temperature after final heater heavy fuel oil
The indicated pressures are minimum requirements due to the fuel charac-
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teristic. Nevertheless, to meet the required fuel pressure at the engine inlet
(see section Planning data, Page 57 and the following), the pressure in the
fuel oil mixing tank and booster circuit becomes significant higher than indi-
cated in this table.
VI-001/Viscosimeter
5.4 Fuel oil system
This device regulates automatically the heating of the final heater heavy fuel
oil depending on the viscosity of the circulating fuel oil, to reach the viscosity
required for injection.
H-004/Final heater heavy fuel oil

The capacity of the final heater shall be determined on the basis of the injec-
tion temperature at the nozzle, to which at least 4 K must be added to com-
pensate for heat losses in the piping. The piping for both heaters shall be
arranged for single and series operation.
Parallel operation with half the throughput must be avoided due to the risk of
sludge deposits.
HE-007/Fuel oil cooler

CK-003/Three-way valve (fuel oil cooler/by-pass)
The purpose of the fuel oil cooler is to ensure that the viscosity of MDO will
not become too low at engine inlet.
When switching from HFO to MDO operation, the three-way valve (fuel oil
cooler/by-pass) CK-003 must be actuated slowly to lead MDO through the
fuel oil cooler HE-007. It is then cooled by LT cooling water.
That way, the MDO which was heated while circulating via the injection
pumps, is cooled before it returns to the fuel oil mixing tank T-011.
The cooler should be opened only after flushing the system with MDO.
The cooling medium used for the fuel oil cooler is preferably fresh water from
the central cooling water system. Based on the fuel oils available on the mar-
ket with a viscosity ≥ 2.0 cSt at 40 °C, a fuel inlet temperature ≤ 40 °C is
expected to be sufficient to achieve 2.0 cSt at engine inlet. In such case, the
central cooling water/LT cooling water at 36 °C can be used as coolant. For
the lowest viscosity distillate fuels, a water cooled fuel oil cooler may be not
enough to sufficiently cool down the fuel to the required temperature. In this
case it is recommended to install a so-called “chiller” that removes heat
through vapor compression or an absorption refrigerant cycle.
The thermal design of the cooler is based on the following data:
Pc= P1x brISO1x f1
Qc= P1x brISO1x f2
Cooler outlet temperature MDO1) Tout °C

Tout = 45 °C
Dissipated heat of the cooler Pc kW
MDO flow for thermal dimensioning of the cooler2) Qc l/h
Engine output power at 100 % MCR P1 kW

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Specific engine fuel oil consumption (ISO) at 100 % MCR brISO1 g/kWh
Factor for heat dissipation: f1 -

f1= 2.68 x 10-5
Factor for MDO flow: f2 l/g
5.4 Fuel oil system

f2 = 2.80 x 10-3
Note:
In case more than one engine, or different engines are connected to the same fuel oil system, the cooler capacity has
to be increased accordingly.
1)
This temperature has to be normally max. 45 °C. Only for very light MGO fuel types this temperature has to be even
lower in order to preserve the min. admissible fuel oil viscosity in engine inlet (see section Viscosity-temperature dia-
gram (VT diagram), Page 129).
The max. MDO/MGO throughput is identical to the delivery quantity of the installed diesel fuel oil supply pump
2)
P-008.
Table 114: Calculation of cooler design
The delivery height of the fuel oil booster pump is to be adjusted to the total
resistance of the booster system.
Injection system
bar
Pressure difference between fuel inlet and outlet engine + 2.00
Pressure loss of the flow balancing valve (to be installed only in multi-engine + 0.00
plants, pressure loss approximately 0.5 bar)
Pressure loss of the pipes, mixing tank – Engine mixing tank, e.g. + 0.50
Pressure loss of the final heater heavy fuel oil max. + 0.80
Pressure loss of the indicator filter + 0.80
Operating delivery height of the booster pump = 4.10

Table 115: Example for the determination of the expected operating delivery height of the fuel oil booster
pump
The recommended pressure class of the fuel oil cooler is PN16.
T-008/Fuel oil damper tank

The injection nozzles cause pressure peaks in the pressurised part of the fuel
system. In order to protect the viscosity measuring and control unit, these
pressure peaks have to be equalised by a compensation tank. The volume of
the pressure peaks compensation tank is 20 I.
FIL-030/Automatic filter (booster circuit)

The automatic filter should be a type that causes no pressure drop in the
system during flushing sequence. The filter mesh size shall be 10 µm (sphere
passing mesh).
The automatic filter must be equipped with differential pressure indication
and switches.
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The design criterion relies on the filter surface load, specified by the filter
manufacturer.

5.4 Fuel oil system

A by-pass pipe in parallel to the automatic filter is required. Only during main-
tenance on the automatic filter, the by-pass is to be opened; the fuel is then
filtered by the fuel oil duplex filter FIL-013.
FBV-010/Flow balancing valve

The flow balancing valve at engine outlet is to be installed only (one per
engine) in multi-engine arrangements connected to the same fuel system. It
is used to balance the fuel flow through the engines. Each engine has to be
fed with its correct, individual fuel flow.
PCV-011/Fuel oil spill valve

The spill valve is only required for multi-engine arrangements, installed in by-
pass to each engine.
In case two or more engines are operated with one common fuel oil system,
it must be possible to separate one engine from the fuel circuit for mainte-
nance purposes, while the other engines keep running. In order to avoid
excessive pressure in the pressurised system, fuel which cannot circulate
through the shut-off engine, has to be rerouted via this valve to the return
pipe. This valve is adjusted to open in case the pressure, in comparison to
normal operation (multi-engine operation), is exceeded. This valve should be
designed as pressure relief valve, not as safety valve.
V-002/Shut-off cock
The stop cock is only required for multi-engine operation and is closed dur-
ing normal operation. When one engine is separated from the fuel circuit for
maintenance purposes, this cock has to be opened manually.
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Uni fuel oil system diagram
5.4 Fuel oil system

2019-09-19 - 1.4
Figure 62: Uni fuel oil system diagram
Engine room separate MDO system

5.4 Fuel oil system
CF-003 Diesel fuel oil separator P-008 Diesel fuel oil supply pump
CK-003 Three-way valve (fuel oil cooler/by- PCV-008 Pressure retaining valve
pass)
FIL-037 Fuel oil simplex filter T-003 Diesel fuel oil service tank
HE-007 Fuel oil cooler T-015 Diesel fuel oil storage tank
GenSet
FIL-013 Fuel oil duplex filter
Engine room
CK-002 Three-way valve for fuel oil change- FBV-010 Flow balancing valve
over
CK-006 Switching valve MDO and HFO (in) T-006 Leakage oil collecting tank
CK-007 Switching valve MDO and HFO (out) T-021 Sludge tank
Engine room uni fuel oil system
CF-002 Heavy fuel oil separator P-018 Fuel oil supply pump
CK-003 Three-way valve (fuel oil cooler/by- PCV-009 Pressure limiting valve
pass)
CK-004 Switching to MDO flushing PCV-011 Fuel oil spill valve
FIL-003 Fuel oil automatic filter, supply circuit STR-010 Suction strainer
FIL-030 Fuel oil automatic filter T-008 Damper tank
FQ-003 Fuel oil flowmeter T-011 Fuel oil mixing tank
H-004 Final heater heavy fuel oil T-016 Heavy fuel oil settling tank
HE-007 Fuel oil cooler T-022 Heavy fuel oil service tank
HE-025 Fuel oil cooler, supply circuit V-002 Shut-off cock
P-003 Fuel oil booster pump VI-001 Viscosimeter
5671/A1 Fuel oil inlet GenSet 5684/A3 Leakage fuel oil drain
5699/A2 Fuel oil outlet GenSet

5.4.6 Fuel oil supply at blackout conditions

As the main electrical grid is not available during a blackout, an alternative
energy source has to guarantee fuel oil supply. If a sufficient uninterruptible
power supply (UPS) system is available, it can be connected to the regular
fuel oil supply pumps and run them in spite of blackout.
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Alternatively an additional pneumatic pump can be installed. If this pump is

connected to a working air system, it must be ensured that this system can
always deliver sufficient compressed air required to outlast the blackout
operation.
Also the starting air system can be used, if the additional air is considered for
5.4 Fuel oil system

design of starting air receivers and the adequate control of the blackout
pump is implemented in the ship automation system. Background is that the
amount of compressed air required by class societies for engine starts must
not be affected. MAN Energy Solutions can design a suitable pneumatic
pump and calculate its compressed air consumption.
For a short time the engines can also run by use of a gravity fuel oil tank
(MDO/MGO) or in a HFO system by the air pressure cushion in the fuel oil
mixing tank (see required pressure in section Operating/service temperatures
and pressures, Page 62.
Duration of blackout operation

Duration of the blackout pump operation should last till the regular fuel sup-
ply is recovered:
▪ Duration of the emergency GenSet for connecting to the main electrical
grid
▪ Start-up time of the fuel oil module after main grid is restored
▪ Buffer time
On the other hand, the duration of the blackout pump operation should be
limited by the ship automation system due to:
▪ Reduction of UPS or compressed air consumption
▪ Consideration of engine related systems without power supply (e.g. cool-
ing water system might overheat)
Depending on engine load it can be advisable to schedule blackout operation
to maximum 90 seconds.
Integration in fuel oil system

In a diesel fuel oil supply system it is recommended to integrate the blackout
pump parallel to the regular fuel oil supply pumps. In order to reduce com-
pressed air consumption, it is possible to choose a downsized pump and
operate the engine in part load.
For a heavy fuel oil supply system a pneumatic pump delivers fuel oil from
MDO service tank into the mixing tank to guarantee low load operation. For
high-load operation please contact MAN Energy Solutions.
Note:
A fuel oil supply with cold MDO/MGO shortly after HFO-operation will lead to
temperature shocks in the injection system and has to be avoided under any
circumstances.
5.4.7 Emergency MDO supply system
The separate emergency MDO supply system supplies only the auxiliary
engines and is independent from the uni fuel system. It is designed to oper-
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ate only in case of emergency or for maintenance reasons.

Design and components of the emergency MDO supply system are shown in
figure Uni fuel oil system diagram, Page 213.
P-008/Diesel fuel oil supply pump
The supply pump shall keep sufficient fuel pressure before the engine.
5.4 Fuel oil system
The volumetric capacity must be at least 300 % of the maximum fuel oil con-
sumption of the engine, including margins for:
▪ Realistic heating value and
▪ Tolerance
To reach this, the diesel fuel oil supply pump has to be designed according
to the following formula:
Qp= P1x brISO1x f3
Required supply pump capacity with MDO 45 °C Qp l/h
Engine output power at 100 % MCR P1 kW
Specific engine fuel oil consumption (ISO) at brISO1 g/kWh

100 % MCR
Factor for pump dimensioning: f3 = 3.75 x 10-3 f3 l/g
Table 117: Formula to design the diesel fuel oil supply pump
In case more than one engine or different engines are connected to the same
fuel oil system, the pump capacity has to be increased accordingly.
The discharge pressure shall be selected with reference to the system losses
and the pressure required before the engine (see section Planning data,
Page 57 and the following). Normally the required discharge pressure is 10
bar.
FIL-037/MDO simplex filter

Filter design and size mainly depend on the filter surface load, specified by
the filter manufacturer.

A by-pass pipe in parallel to the filter is required. The system is only designed
for short time service.
HE-007/Fuel oil cooler

CK-003/Three-way valve (fuel oil cooler/by-pass)
See description in paragraph HE-007/Fuel oil cooler, CK-003/Three-way
valve (fuel oil cooler/by-pass), Page 210.
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5.4.8 Fuel oil leakage system

During the operation of diesel engines several leakages accrue. Waste and
leak oil from the compartments have separate outlets from each side of the
engine. Leakages from the pump bench or from conventional injection
pumps are dirty leakages (lube oil contaminated). If the GenSet only has one
single leakage drain outlet, all the leakage is dirty and shall be led into the
5.4 Fuel oil system

leakage oil collecting tank T-006 and then into the sludge tank T-021, as
shown in figures Uni fuel oil system diagram, Page 213 and Fuel oil leakage
system diagram, Page 218. It is prohibited to lead dirty leakages back into
settling or service tanks and to reuse it as fuel for the engines.
Some of the leakages are clean leakages, such as coming from the fuel
injection valves or buffer pistons. If the engine is equipped with sealed
plunger (SP) injection pumps, all clean leakages can be reused as fuel oil.
Clean leakages must be collected separately from dirty leakage and passing
the whole treatment system from the settling tank to the fuel oil separator
and fuel oil filters. As an option the GenSet has a separate clean leak oil out-
let, this leakage can be led into the clean leakage fuel oil tank T-071 as
shown in figure Fuel oil leakage system diagram, Page 218.
When operating on MDO a larger leak oil amount from fuel oil injection
pumps and fuel oil injection valves can be expected compared to operation
on HFO.
Leakage fuel oil flows unpressurised less (by gravity) from engine into tanks
(to be installed below the engine connections). Pipe clogging must be avoi-
ded by trace heating and sufficient slope downwards.
T-006/Leakage oil collecting tank

Leakage fuel oil from the injection pipes, leakage lubrication oil and dirt fuel
oil from the filters (to be discharged by gravity) are collected in the leakage oil
collecting tank (1T-006), as well as lube oil leakages (drain from crankcase).
The content of this tank has to be discharged into the sludge tank (T-021), or
it can be burned for instance in a waste oil incinerator. It is not permissible to
add the content of the tank to the fuel treatment system again, because of
contamination with lubrication oil.
For the dimensioning of the leakage oil collecting tank a total leakage (lube oil
and fuel oil) of max. 2.1 l/h x cyl. should be considered.
T-071/Clean leakage fuel oil tank

Clean leakage fuel oil escaping from the engines fuel oil system can be led
into an extra clean leakage fuel oil collecting tank. The tank must be heated
and insulated and its content must be pumped into the high sulphur (HS)
heavy fuel oil settling tank T-016. If an overflow pipe to the leakage oil col-
lecting tank T-006 is installed, a second unloading pump may be omitted.
The amount of clean leakage oil depends on the high pressure pump type,
its rate of wear, the fuel type and the operating temperatures. In case of a
pipe burst, a high flow of fuel oil leakage will occur for a short time (< 1 min.).
The engine will run down immediately after a pipe burst alarm.
For data regarding the leak rate, see table Leakage rate, Page 66.
T-021/Sludge tank
See description in paragraph T-021/Sludge tank, Page 196.
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Fuel oil leakage system diagram

5.4 Fuel oil system
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Figure 63: Fuel oil leakage system diagram for engines with sealed plunger pumps or GenSets with
leakage drain split only
GenSet pipe connection
5.4 Fuel oil system

5271/A1 Fuel oil inlet 5683/A3B Fuel oil leakage for disposal
5299/A2 Fuel oil outlet 5684/A3A Fuel oil leakage for reuse1)
Leakage fuel system components
T-006 Leakage oil collecting tank (dis- T-021 Sludge tank

posal)
1 T-016 Heavy fuel oil settling tank T-071 Clean leakage fuel oil tank
1)
Reuse only permissible, if engine is equipped with drain split piping (optional).
5.4.9 Fuel changeover

The following section give general information about the fuel changeover.
Additional and priority information about the fuel changeover procedure is
given in the engine operating instruction/manual section “Changeover from
diesel oil to heavy fuel oil and vice versa”.
Global fuel changeover

Global fuel changeover means that all GenSets are switched over to the
other type of fuel at the same time. This changeover is done by switching the
three-way valve for fuel oil changeover CK-002 and is permissible while the
engines are running.
Local fuel changeover

The GenSets can be supplied with MDO by the separate emergency MDO
supply system (see section Emergency MDO supply system, Page 215). It is
designed in such a way that the fuel type for the GenSets can be changed
independent of the fuel supply of the propulsion engine. A fuel changeover of
a single GenSet is called local changeover and must only be done at stop-
ped engine.
A local fuel changeover may be necessary if the GenSets have to be:
▪ Stopped for a prolonged period.
▪ Stopped for major repair of the fuel system, etc.
▪ In case of a blackout/emergency start.
The fuel oil system design must enable the performance of the following
steps for a local changeover from HFO to MDO:
▪ Flushing the stopped engine with MDO from separate emergency MDO
supply system. The flushing backflow should be lead to the high sulphur
(HS) heavy fuel oil service tank.
▪ Turning the engine crankshaft 3 – 4 times.
▪ Adjusting the fuel temperature upstream engine and the pump surface
temperature to about 45 °C.
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Approximately 50 minutes may elapse until a stable fuel oil temperature/

viscosity (depending on fuel system) is adjusted and the engine can be star-
ted.
The fuel oil temperature change gradient must not be higher than 2 K/min.
5.5 Compressed air system
5.5.1 General
To perform or control the following functions and systems, compressed air is
required:
▪ Engine start
▪ Emergency stop
▪ Oil mist detector
▪ Jet assist
▪ Turning gear
Each engine requires only one connection for compressed air. For the Gen-
Set internal piping see figure Compressed air system diagram – GenSet,
Page 221.
Piping
The pipes to be connected by the shipyard have to be supported immedi-
ately behind their connection to the engine. Further supports are required at
sufficiently short distance.
Flexible connections for starting air (steel tube type) have to be installed with
elastic fixation. The elastic mounting is intended to prevent the hose from
oscillating. For detail information please refer to planning and final documen-
tation and manufacturer manual.
Other air consumers for low pressure, auxiliary application (e.g. filter cleaning,
TC cleaning, pneumatic drives) can be connected to the start air system after
a pressure reduction unit.
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Compressed air system diagram

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Figure 64: Compressed air system diagram – GenSet
On engine connections
7171 Air inlet (Main starting valve) 7451 Air outlet from turning gear
7172 Control air and emergency stop 7461 Air inlet to turning gear
On GenSet connections
7161/K1 Starting air inlet on GenSet
5.5.2 Starting air system
Starting air system diagram

The compressed air supply to the engine plant requires starting air receivers
and starting air compressors of a capacity and air delivery rating which will
meet the requirements of the relevant classification society.
This external compressed air system should be common for both, propulsion
and auxiliary engines. Seperate tanks should only be installed in turbine
driven vessels or if the auxiliary engines are installed far away from the pro-
pulsion plant. Between the compressor and the air receivers an oil and water
separator should be installed in the line, equipped with automatic drain facili-
ties.
Figure 65: Compressed air system
Components
1,2 C-001 Starting air compressor 1,2 T-007 Starting air receiver
On GenSet connections
7161 Starting air inlet on GenSet
Installation
In order to protect the engine starting and control equipment against con-
densation water the following should be observed:
▪
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The air receiver(s) should always be installed with good drainage facilities.
Receiver(s) arranged in horizontal position must be installed with a slope
downwards of min. 3 – 5 degrees.
▪ Pipes and components should always be treated with rust inhibitors.
▪ The starting air pipes should be mounted with a slope towards the
receivers, preventing possible condensed water from running into the
compressors.
▪ Drain valves should be mounted at lowest position of the starting air

pipes and receivers.

The installation also has to ensure that during emergency discharging of the
safety valve no persons can be compromised.
It is not permissible to weld supports (or other) on the air receivers. The origi-
nal design must not be altered. Air receivers are to be bedded and fixed by
use of external supporting structures.
Other air consumers for low pressure, auxiliary application (e.g. filter cleaning,
TC cleaning, pneumatic drives) can be connected to the start air system after
a pressure reduction unit.
5.5.3 Starting air receivers, compressors
General requirements of classification societies

The equipment provided for starting the engines must enable the engines to
be started from the operating condition 'zero' with shipboard facilities, i. e.
without outside assistance.
1 C-001, 2 C-001/Starting air compressor

These are multi-stage compressor sets with safety valves, cooler for com-
pressed air and condensate traps.
The operational compressor is switched on by the pressure control at low
pressure then switched off when maximum service pressure is attained.
A max. service pressure of 30 bar is required. The standard design pressure
of the starting air receivers is 30 bar and the design temperature is 50 °C.
The service compressor is electrically driven, the auxiliary compressor may
also be driven by a diesel engine. The capacity of both compressors is identi-
cal.
Two or more starting air compressors must be provided. At least one of the
air compressors must be driven independently of the main engine and must
supply at least 50 % of the required total capacity.
The total capacity of the starting air compressors is to be calculated so that
the air volume necessary for the required number of starts is topped up from
atmospheric pressure within one hour.
The compressor capacities are calculated as follows:
P [Nm3/h] Total volumetric delivery capacity of the compressors

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V [litres] Total volume of the starting air receivers at 30 bar service pressure
As a rule, compressors of identical ratings should be provided. An emer-

gency compressor, if provided, is to be disregarded in this respect.
1 T-007, 2 T-007/Starting air receiver

The starting air supply must be split up into at least two starting air receivers
of the same size, which can be used independently of each other. Depend-
ing on the number of required starting manoeuvres and the consumption vol-
ume per manoeuvre, the size of the starting air receivers can be calculated
according to the given formula. The exact number of required starting
manoeuvres depends on the arrangement of the system and on the special
requirements of the classification society.
For the air consumption of the engine see table Starting air and control air
consumption, Page 55. Per each starting manoeuvre, the volume of one jet-
assist manoeuvre has to be considered. For more information concerning jet
assist, see section Jet assist, Page 225. The starting air consumption of an
alternator plant is approximately 50 % higher than stated for the single
engine.
Service pressure max. 30 bar

Minimum starting air pressure min. 10 bar
Calculation for starting air receiver of engines without jet assist and Slow
Turn:
Calculation for starting air receiver of engines with jet assist and Slow
Turn:
V [litre] Required receiver capacity
Vst [litre] Air consumption per nominal start1)
fDrive Factor for drive type (1.0 = diesel-mechanic, 1.5 = alternator drive)
zst Number of starts required by the classification society
zSafe Number of starts as safety margin
VJet [litre] Assist air consumption per jet assist1)
zJet Number of jet assist procedures2)

tJet [sec] Duration of jet assist procedures
Vsl Air consumption per Slow Turn litre1)
zsl Number of Slow Turn manoeuvres
pmax [bar] Maximum starting air pressure (normally 30 bar)

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pmin [bar] Minimum starting air pressure (10 bar)
Tabulated values see section Starting air and control air consumption, Page 55.
1)
The required number of jet manoeuvres has to be checked with yard or ship
2)
owner. To make a decision, consider the information in section Jet assist, Page
225.
If other consumers (i.e. auxiliary engines, ship air etc.) which are not listed in
5.6 Engine room ventilation and combustion air

the formula are connected to the starting air receiver, the capacity of starting
air receiver must be increased accordingly, or an additional separate air
receiver has to be installed.
5.5.4 Jet assist
General
Jet assist is a system for acceleration of the turbocharger. By means of noz-
zles in the turbocharger, compressed air is directed to accelerate the com-
pressor wheel. This causes the turbocharger to adapt more rapidly to a new
load condition and improves the response of the engine. Jet assist is working
efficiently with a pressure of 18 bar to max. 30 bar at the engine connection.
Jet assist activating time: 3 seconds to 10 seconds (5 seconds in average).
Air consumption
At each engine start the engine control system activates jet assist to acceler-
ate the start-up of the GenSet. Thus for each starting attempt the air volume
of one jet assist manoeuvre must be considered aditionally.
Auxiliary Genset
The data in following table is not binding. The required number of jet
manoeuvres for one engine has to be checked with yard or ship owner. For
decision see also section Start up and load application, Page 33.
The values shown in the following tables are based on diesel oil mode.
Application Recommended no. of jet assist with average duration, based on the
quantity of manoeuvres per hour
Auxiliary GenSet 3 x 5 sec.
Table 119: Values (for guidance only) for the number of jet assist manoeuvres
dependent on application
5.5.5 Slow turn

MAN L32/40 and MAN L32/44 auxiliary GenSets are not equipped with a
slow turn device.
5.6.1 General information
Engine room ventilation system

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Its purpose is:

▪ Supplying the engines and auxiliary boilers with combustion air.
▪ Carrying off the radiant heat from all installed engines and auxiliaries.
Combustion air
The combustion air must be free from spray water, snow, dust and oil mist.
This is achieved by:
▪ Louvres, protected against the head wind, with baffles in the back and
optimally dimensioned suction space so as to reduce the air flow velocity
to 1 – 1.5 m/s.
▪ Self-cleaning air filter in the suction space (required for dust-laden air,
e.g. cement, ore or grain carrier).
▪ Sufficient space between the intake point and the openings of exhaust
air ducts from the engine and separator room as well as vent pipes from
lube oil and fuel oil tanks and the air intake louvres (the influence of winds
must be taken into consideration).
▪ Positioning of engine room doors on the ship's deck so that no oil-laden
air and warm engine room air will be drawn in when the doors are open.
▪ Arranging the separator station at a sufficiently large distance from the
turbochargers.
As a standard, the engines are equipped with turbochargers with air intake
silencers and the intake air is normally drawn in from the engine room.
In tropical service a sufficient volume of air must be supplied to the turbo-
charger(s) at outside air temperature. For this purpose there must be an air
duct installed for each turbocharger, with the outlet of the duct facing the
respective intake air silencer, separated from the latter by a space of approxi-
mately 1.5 m (see figure Example: Exhaust gas ducting arrangement, Page
252). No water of condensation from the air duct must be permissible to be
drawn in by the turbocharger. The air stream must not be directed onto the
exhaust manifold.
If the ship operates at arctic conditions, an air preheater must be applied to
maintain the engine room temperature above 5° C. In order to reduce power
for air preheating, the engines can be supplied by a separate system directly
from outside, see section External intake air supply system, Page 227.
Air fans are to be designed so as to maintain a positive air pressure of 50 Pa
(5 mm WC) in the engine room.
Radiant heat
The heat radiated from the main and auxiliary engines, from the exhaust
manifolds, waste heat boilers, silencers, alternators, compressors, electrical
equipment, steam and condensate pipes, heated tanks and other auxiliaries
is absorbed by the engine room air.
The amount of air V required to carry off this radiant heat can be calculated
as follows:
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V [m3/h] Air required
Q [kJ/h] Heat to be dissipated
Δt [°C] Air temperature rise in engine room (10 – 12.5)
cp [kJ/kg*k] Specific heat capacity of air (1.01)
ρt [kg/m3] Air density at 35 °C (1.15)
Ventilator capacity

The capacity of the air ventilators (without separator room) must be large
enough to cover at least the sum of the following tasks:
▪ The combustion air requirements of all consumers.
▪ The air required for carrying off the radiant heat.
A rule-of-thumb applicable to plants operating on heavy fuel oil is 20 –
24 m3/kWh.
Moreover it is recommended to apply variable ventilator speed to regulate
the air flow. This prevents excessive energy consumption and cooling down
of engines in stand-by.
5.6.2 External intake air supply system
General recommendations for layout of intake air ducting

The design of the intake air system ducting is crucial for reliable operation of
the engine. The following points need to be considered:
▪ According to classification rules it may be required to install two air inlets
from the exterior, one at starboard and one at portside.
▪ It must be prevented that exhaust gas and oil dust is sucked into the
intake air duct as fast filter blocking will be the consequence.
▪ Suitable corrosion resistant materials like stainless steel should be
applied especially for hot surfaces. For some surfaces a corrosion pro-
tection class of C5 (according to EN ISO 12944-2) might be sufficient.
▪ Due to the flow and load changes, especially with high air velocities, the
intake air pipe is subject to vibrations. This has to be considered within
the overall layout.
▪ Besides the air duct and its components need to be insulated properly.
Especially a vapor barrier has to be applied to prevent atmospheric mois-
ture freezing in the insulation material.
▪ The overall pressure drop of intake air system ducting and its compo-
nents is to be limited to 20 mbar. If this requirement cannot be met,
increased fuel consumption must be considered or customised engine
matching is required. Moreover the differential pressure of the intake air
filter should be monitored to keep this requirement.
▪ The turbocharger as a flow machine is dependent on a uniform inflow.
Therefore, the ducting must enable an air flow without disturbances or
constrictions. For this, multiple deflections with an angle > 45° have to be
avoided.
▪ For engines with two turbochargers it needs to be ensured, that both tur-
bochargers have identical conditions for the air supply, otherwise this
would result in increased exhaust gas temperature.
▪ The intake air must not flow against the direction of the compressor rota-
tion, otherwise stalling could be recognized.
▪ It is recommended to optimize the layout of the intake air piping by CFD
calculations up to the entry of the compressor of the turbocharger.
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▪ The maximum specified air flow speed in connection pipes of 20 m/s

should not be exceeded at any location of the pipe.
Components of intake air ducting

The ambient air, which is led to engine by the intake air duct, needs to be
conditioned by several components as shown in figure External intake air
supply system for arctic conditions, Page 229. It needs to be cleaned
according to the requirements in section Specification of intake air (combus-
tion air), Page 141. This could be done by the following components:
▪ Section for cleaning of intake air (1 – 4 within figure External intake air
supply system for arctic conditions, Page 229)
Firstly a weather hood (1) and droplet separator (2) remove coarse dirt
ingress and water droplets. Subsequently an appropriate filter cleans the
intake air from particles (4). In case of arctic conditions, these compo-
nents might need to be heated as an anti-icing measure or for engine
operation (3). If more than one engine is to be supplied by external intake
air supply, redundancy should be considered.
▪ Combustion air silencer (5)
Noise emissions of engine inlet and charge air blow-off can be reduced
by a silencer in the intake air duct, see section Noise, Page 75 for data.
▪ Dirt and water separation
It is recommended to apply a mesh at the outlet of the silencer for pro-
tection of turbocharger against any loose parts (e.g. insulation material of
silencer, rust etc.) from the intake air duct. This mesh is to be applied
even if the silencer will not be supplied. Additionally calming zones and
dead space should be provided to separate dirt particles. A drain in close
to the turbocharger might be required to separate condensate water.
▪ Shut-off flap/blind plate (6)
It is recommended to install a shut-off flap to prevent cooling down of the
engine during longer standstills under arctic conditions.
▪ Charge air blow-off or recirculation (11)
For arctic conditions (see section Engine operation under arctic condi-
tions), Page 42 an increased firing pressure, which is caused by higher
density of cold air, is prevented by an additional valve, that blows off
charge air. A compensator (9 a/b) connects the engine with charge air
blow-off piping. Depending on engine type the blown-off air is taken in
front of (hot blow-off) or after (cold blow-off) the charge air cooler and
preferably circulated back in the intake air duct. A homogenous tempera-
ture profile and a correct measurement of intake air temperature in front
of compressor has to be achieved. For this a minimum distance of five
times the diameter of the intake air duct between inlet of blown-off air
and the measuring point should be kept. Alternatively blown-off air might
be led in the engine room or outside of the ship by an additional silencer
(13).
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Figure 66: External intake air supply system for arctic conditions
1 Weather hood 8 Transition piece

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2 Droplet separator 030.120.010 9a Expansion bellow – Cold blow-off
3 Preheater (if required) 9b Expansion bellow – Hot blow-off
4 Air intake filter 030.120.010 10 Charge air blow-off valve
5 Combustion air silencer 030.130.040 11 Charge air blow-off pipe
6 Blind plate/shut-off flap (for maintenance case) 12 Charge air blow-off silencer
5.7 Exhaust gas system
7 Expansion bellow combustion air 13 Waste gate (if required for relevant engine type)
5.7.1 General
Layout The flow resistance in the exhaust system has a very large influence on the
fuel consumption and the thermal load of the engine. The values given in this
document are based on an exhaust gas system which flow resistance does
not exceed 30 mbar. If the flow resistance of the exhaust gas system is
higher than 30 mbar, please contact MAN Energy Solutions for project-spe-
cific engine data.
The pipe diameter selection depends on the engine output, the exhaust gas
volume and the system back pressure, including silencer and SCR (if fitted).
The back pressure also being dependent on the length and arrangement of
the piping as well as the number of bends. Sharp bends result in very high
flow resistance and should therefore be avoided. If necessary, pipe bends
must be provided with guide vanes.
It is recommended not to exceed a maximum exhaust gas velocity of
approximately 40 m/s.
Installation When installing the exhaust system, the following points must be observed:
▪ The exhaust pipes of two or more engines must not be joined.
▪ Because of the high temperatures involved, the exhaust pipes must be
able to expand. The expansion joints to be provided for this purpose are
to be mounted between fixed-point pipe supports installed in suitable
positions. One compensator is required just after the outlet casing of the
turbocharger (see section Position of the outlet casing of the turbo-
charger, Page 253) in order to prevent the transmission of forces to the
turbocharger itself. These forces include those resulting from the weight,
thermal expansion or lateral displacement of the exhaust piping. For this
compensator/expansion joint one sturdy fixed-point support must be
provided.
▪ The exhaust piping should be elastically hung or supported by means of
dampers in order to prevent the transmission of sound to other parts of
the vessel.
▪ The exhaust piping is to be provided with water drains, which are to be
regularly checked to drain any condensation water or possible leak water
from exhaust gas boilers if fitted.
▪ During commissioning and maintenance work, checking of the exhaust

gas system back pressure by means of a temporarily connected measur-
ing device may become necessary. For this purpose, a measuring socket
is to be provided approximately 1 to 2 metres after the exhaust gas out-
let of the turbocharger, in a straight length of pipe at an easily accessed
position. Standard pressure measuring devices usually require a measur-
ing socket size of 1/2". This measuring socket is to be provided to
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ensure back pressure can be measured without any damage to the

exhaust gas pipe insulation.

5.7.2 Components and assemblies of the exhaust gas system
Exhaust gas silencer and exhaust gas boiler

Mode of operation The silencer operates on the absorption and resonance principle so it is
effective in a wide frequency band. The flow path, which runs through the
silencer in a straight line, ensures optimum noise reduction with minimum
flow resistance.
The silencer must be equipped with a spark arrestor.
Installation If possible, the silencer should be installed towards the end of the exhaust
line.
A vertical installation situation is to be preferred in order to avoid formations
of gas fuel pockets in the silencer. The cleaning ports of the spark arrestor
are to be easily accessible.
Note:
Water entry into the silencer and/or boiler must be avoided, as this can
cause damages of the components (e.g. forming of deposits) in the duct.
Exhaust gas boiler To utilise the thermal energy from the exhaust, an exhaust gas boiler produc-
ing steam or hot water may be installed.
Insulation The exhaust gas system (from outlet of turbocharger, boiler, silencer to the
outlet stack) is to be insulated to reduce the external surface temperature to
the required level.
The relevant provisions concerning accident prevention and those of the
classification societies must be observed.
The insulation is also required to avoid temperatures below the dew point on
the interior side. In case of insufficient insulation intensified corrosion and
soot deposits on the interior surface are the consequence. During fast load
changes, such deposits might flake off and be entrained by exhaust in the
form of soot flakes.
Insulation and covering of the compensator must not restrict its free move-
ment.

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6 Engine room planning
6.1 Installation and arrangement

6.1.1 General details

Apart from a functional arrangement of the components, the shipyard is to
provide for an engine room layout ensuring good accessibility of the compo-
nents for servicing.
The cleaning of the cooler tube bundle, the emptying of filter chambers and
subsequent cleaning of the strainer elements, and the emptying and cleaning
of tanks must be possible without any problem whenever required.
All of the openings for cleaning on the entire unit, including those of the
exhaust silencers, must be accessible.
There should be sufficient free space for temporary storage of pistons, cam-
shafts, turbocharger etc. dismounted from the engine. Additional space is
required for the maintenance personnel. The panels on the engine sides for
inspection of the bearings and removal of components must be accessible
without taking up floor plates or disconnecting supply lines and piping. Free
space for installation of a torsional vibration meter should be provided at the
crankshaft end.
A very important point is that there should be enough room for storing and
handling vital spare parts so that replacements can be made without loss of
time.
In planning marine installations with two or more engines driving one propel-
ler shaft through a multi-engine transmission gear, provision must be made
for a minimum clearance between the engines because the crankcase pan-
els of each engine must be accessible. Moreover, there must be free space
on both sides of each engine for removing pistons or cylinder liners.
Note:
MAN Energy Solutions delivered scope of supply is to be arranged and fixed
by proven technical experiences as per state of the art. Therefore the techni-
cal requirements have to be taken in consideration as described in the fol-
lowing documents subsequential:
▪ Order related engineering documents.
▪ Installation documents of our sub-suppliers for vendor specified equip-
ment.
▪ Operating manuals for diesel engines and auxiliaries.
▪ Project Guides of MAN Energy Solutions.

Any deviations from the principles specified in the aforementioned docu-
ments require a previous approval by MAN Energy Solutions.
Arrangements for fixation and/or supporting of plant related equipment devi-
ating from the scope of supply delivered by MAN Energy Solutions, not
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described in the aforementioned documents and not agreed with us are not
permissible.
For damages due to such arrangements we will not take over any responsi-
bility nor give any warranty.
6.1.2 Installation drawings

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Figure 67: Installation drawing 6L, 7L GenSet
For space requirements see sections: Space requirement for removal of

components, Page 246 and 3D Engine Viewer – A support programme to
configure the engine room, Page 240.

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Figure 68: Installation drawing 8L, 9L GenSet
For space requirements see sections: Space requirement for removal of

components, Page 246 and 3D Engine Viewer – A support programme to
configure the engine room, Page 240.
6.1.3 Removal dimensions of piston and cylinder liner
Figure 69: Piston removal – Lifting off the cylinder head with rocker arms – L engine

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Figure 70: Piston removal – Lifting off the cylinder head without rocker arms – L engine
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Figure 71: Piston removal – L engine

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Figure 72: Cylinder liner removal – L engine
6.1.4 Removal dimensions of intercooler, lube oil cooler, main filter and turbocharger
Figure 73: Charge air cooler removal – L engine
6.1.5 3D Engine Viewer – A support programme to configure the engine room

MAN Energy Solutions offers a free-of-charge online programme for the con-
figuration and provision of installation data required for installation examina-
tions and engine room planning: The 3D Engine Viewer and the 3D GenSet
Viewer.
Easy-to-handle selection and navigation masks permit configuration of the
required engine type, as necessary for virtual installation in your engine room.
In order to be able to use the 3D Engine, respectively GenSet Viewer, please
register on our website under:
https://extranet.mandieselturbo.com/Pages/Dashboard.aspx
After successful registration, the 3D Engine and GenSet Viewer is available
under:
https://extranet.mandieselturbo.com/content/appengineviewer/Pages/
Default.aspx
by clicking onto the requested application.
In only three steps, you will obtain professional engine room data for your fur-
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ther planning:
▪ Selection
Select the requested output, respectively the requested type.
▪ Configuration
Drop-down menus permit individual design of your engine according to

your requirements. Each of your configurations will be presented on the

basis of isometric models.
▪ View
The models of the 3D Engine Viewer and the 3D GenSet Viewer include
all essential geometric and planning-relevant attributes (e.g. connection
points, interfering edges, exhaust gas outlets, etc.) required for the inte-
gration of the model into your project.
The configuration with the selected engines can now be easily downloaded.
For 2D representation as .pdf or .dxf, for 3D as .dgn, .sat, .igs or 3D-dxf.
Figure 74: Selection of engine

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Figure 75: Preselected standard configuration
6.1.6 Lifting device

Lifting gear with varying lifting capacities are to be provided for servicing and
repair work on the engine, turbocharger and charge air cooler.
Engine
Component weights For servicing the engine an overhead traveling crane is required. The lifting
capacity shall be sufficient to handle the heaviest component that has to be
lifted during servicing of the engine and should foresee extra capacity e.g. to
overcome the break loose torque while lifting cylinder heads. The overhead
traveling crane can be chosen with the aid of the following table:
Components Unit Approximate weights
Cylinder head complete kg 580
Piston with piston pin and connecting rod 215

(for piston removal)
Cylinder liner 175
Charge air cooler 355

Table 120: Component weights
Crane arrangement
The rails for the crane are to be arranged in such a way that the crane can
cover the whole of the engine beginning at the exhaust pipe.
The hook position must reach along the engine axis, past the centreline of
the first and the last cylinder, so that valves can be dismantled and installed
without pulling at an angle. Similarly, the crane must be able to reach the tie
rod at the ends of the engine. In cramped conditions, eyelets must be wel-
ded under the deck above, to accommodate a lifting pulley.
The required crane capacity is to be determined by the crane supplier.
Crane design It is necessary that:
▪ There is an arresting device for securing the crane while hoisting if oper-
ating in heavy seas
▪ There is a two-stage lifting speed
Precision hoisting approximately = 0.5 m/min
Normal hoisting approximately = 2 – 4 m/min
Places of storage In planning the arrangement of the crane, a storage space must be provided
in the engine room for the dismantled engine components which can be
reached by the crane. It should be capable of holding two rocker arm cas-
ings, two cylinder covers and two pistons. If the cleaning and service work is
to be carried out here, additional space for cleaning troughs and work surfa-
ces should be planned.

Transport to the workshop Grinding of valve cones and valve seats is carried out in the workshop or in a
neighbouring room.
Transport rails and appropriate lifting tackle are to be provided for the further
transport of the complete cylinder cover from the storage space to the work-
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shop. For the necessary deck openings, see following figures and tables.
Turbocharger
Section Turbocharger assignments, Page 16 shows which turbocharger type
should be used for which engine variant.
Turbocharger dimensions

Figure 76: Exemplary illustration of NR turbocharger
Turbocharger L W H K F T A1 D A2 G
type [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
NR29/S min. min. min. max. min. min. min. min. min. min.
1,275 770 895 430 500 855 420 830 353.5 402.5
max. max. max. max. max. max. max. max. max.
1,275 820 965 570 855 420 830 353.5 707
NR34/S min. min. min. max. min. min. min. min. min. min.
1,574 853 935 510 600 1,030 544 1,220 440 450
max. max. max. max. max. max. max. max. max.
1,574 870 1,085 635 1,030 544 1,220 440 816
Table 121: Dimensions – NR turbocharger
Hoisting rail A hoisting rail with a mobile trolley is to be provided over the centre of the
turbocharger running parallel to its axis, into which a lifting tackle is suspen-
ded with the relevant lifting power for lifting the parts, which are mentioned in
the table(s) below, to carry out the operations according to the maintenance
schedule.
Turbocharger NR 29/S NR 34/S
Compressor casing kg 105 300
Gas admission casing 240 370
Silencer 85 300
Cartridge 190 245

Turbine rotor 45 60
Bearing case 145 185
Space for removal of silencer mm 210 330
See also table Space required for removal of turbocharger, Page 246.
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Table 122: Hoisting rail of the NR turbocharger
Withdrawal space The withdrawal space shown in section Removal dimensions, Page 240 and
dimensions in the table(s) in paragraph Hoisting rail, Page 243 is required for separating
the silencer from the turbocharger. The silencer must be shifted axially by this
distance before it can be moved laterally.
In addition to this measure, another 100 mm are required for assembly clear-
ance.
This is the minimum distance between silencer and bulkhead or tween-deck.
We recommend to plan additional 300 – 400 mm as working space.
Make sure that the silencer can be removed either downwards or upwards or
laterally and set aside, to make the turbocharger accessible for further servic-
ing. Pipes must not be laid in these free spaces.
Fan shafts
The engine combustion air is to be supplied towards the intake silencer in a
duct ending at a point 1.5 m away from the silencer inlet. If this duct impedes
the maintenance operations, for instance the removal of the silencer, the end
section of the duct must be removable. Suitable suspension lugs are to be
provided on the deck and duct.
Gallery
If possible the ship deck should reach up to both sides of the turbocharger
(clearance 50 mm) to obtain easy access for the maintenance personnel.
Where deck levels are unfavourable, suspended galleries are to be provided.
Charge air cooler

For cleaning of the charge air cooler bundle, it must be possible to lift it verti-
cally out of the cooler casing and lay it in a cleaning bath.
Exception MAN 32/40: The cooler bundle of this engine is drawn out at the
end. Similarly, transport onto land must be possible.
For lifting and transportation of the bundle, a lifting rail is to be provided
which runs in transverse or longitudinal direction to the engine (according to
the available storage place), over the centreline of the charge air cooler, from
which a trolley with hoisting tackle can be suspended.
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Figure 77: Air direction
Engine type Weight Length (L) Width (B) Height (H)

kg mm mm mm
L engine 450 520 712 1,014
Table 123: Weights and dimensions of charge air cooler bundle
6.1.7 Space requirement for maintenance

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Figure 78: Minimum centreline distance for twin engine installation
Number of cylinders 6L 7L 8L 9L
Turbocharger NR 29/S NR 29/S NR 34/S NR 34/S

H mm 4,622 4,622 4,840 4,840
P Free passage between the engines, width 600 mm and height 2,000 mm.
O Min. distance between the engines 2,835 mm (without gallery) and 3,220 (with gallery).
6.1.8 Space requirement for removal of components
Figure 79: Lube oil cooler removal
No. of cylinders, config 6L 7L 8L 9L

A min mm 200 227 250 277
A max 208 236 260 288
B approx. 645 745 795 895
Weight empty kg 1,133 1,133 1,190 1,190

Weight full 985 985 934 934
The dimension and numbers are given for guidance only.

Table 124: Dimension and weights for removal of lube oil cooler

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C mm 800 800 1,000 1,000

Table 125: Space required for removal of turbocharger

Figure 80: Main filter and intercooler removal

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6.1.9 Major spare parts

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6.2 Exhaust gas ducting
6.2.1 Example: Ducting arrangement

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Figure 81: Example: Exhaust gas ducting arrangement

6.2.2 Position of the outlet casing of the turbocharger
Figure 82: Position of the outlet casing of the turbocharger – 6+7L GenSet – NR 29/S

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Figure 83: Position of the outlet casing of the turbocharger – 8+9L GenSet – NR 34/S
Figure 84: Flange

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D mm 614 614 716 716
OD 754 754 856 856
T (max) 20 20 23 23

PCD 700 700 800 800
Hole thread M20 M20 M20 M20
Hole thread no. 20 20 24 24

Table 126: Dimension of flange – Turbocharger

D mm 614 614 716 716
OD 754 754 856 856
T 20 20 20 20
PCD 700 700 800 800
Hole size 22 22 22 22
Hole no. 20 20 24 24

Table 127: Dimension of connecting flange – Compensator, according to DIN 86044

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7 Annex
7.1 Safety instructions and necessary safety measures

The following list of basic safety instructions, in combination with further
engine documentation like user manual and working instructions, should
ensure a safe handling of the engine. Due to variations between specific
plants, this list does not claim to be complete and may vary with regard to
project-specific requirements.
7.1.1 General
There are risks at the interfaces of the engine, which have to be eliminated or
minimised in the context of integrating the engine into the plant system.
Responsible for this is the legal person which is responsible for the integra-
tion of the engine.
Following prerequisites need to be fulfilled:
▪ Layout, calculation, design and execution of the plant have to be state of
the art.
▪ All relevant classification rules, regulations and laws are considered, eval-
uated and are included in the system planning.
▪ The project-specific requirements of MAN Energy Solutions regarding the
engine and its connection to the plant are implemented.
▪ In principle, the more stringent requirements of a specific document is
applied if its relevance is given for the plant.
7.1.2 Safety equipment and measures provided by plant-side

▪ Proper execution of the work
Generally, it is necessary to ensure that all work is properly done accord-
ing to the task trained and qualified personnel.
All tools and equipment must be provided to ensure adequate accesible
and safe execution of works in all life cycles of the plant.
Special attention must be paid to the execution of the electrical equip-
ment. By selection of suitable specialised companies and personnel, it
has to be ensured that a faulty feeding of media, electric voltage and
electric currents will be avoided.
▪ Fire protection
A fire protection concept for the plant needs to be executed. All from
safety considerations resulting necessary measures must be implemen-
ted. The specific remaining risks, e.g. the escape of flammable media
from leaking connections, must be considered.
Generally, any ignition sources, such as smoking or open fire in the main-
tenance and protection area of the engine is prohibited.
Smoke detection systems and fire alarm systems have to be installed
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and in operation.
▪ Electrical safety
7 Annex
Standards and legislations for electrical safety have to be followed. Suita-

ble measures must be taken to avoid electrical short circuit, lethal electric
shocks and plant specific topics as static charging of the piping through
the media flow itself.
▪ Noise and vibration protection

The noise emission of the engine must be considered early in the plan-
ning and design phase. A soundproofing or noise encapsulation could be
necessary. The foundation must be suitable to withstand the engine
vibration and torque fluctuations. The engine vibration may also have an
impact on installations in the surrounding of the engine, as galleries for
maintenance next to the engine. Vibrations act on the human body and
may dependent on strength, frequency and duration harm health.
▪ Thermal hazards
In workspaces and traffic areas hot surfaces must be isolated or cov-
ered, so that the surface temperatures comply with the limits by stand-
ards or legislations.
▪ Composition of the ground
The ground, workspace, transport/traffic routes and storage areas have
to be designed according to the physical and chemical characteristics of
the excipients and supplies used in the plant.
Safe work for maintenance and operational staff must always be possi-
ble.
▪ Adequate lighting
Light sources for an adequate and sufficient lighting must be provided by
plant-side. The current guidelines should be followed (100 Lux is recom-
mended, see also DIN EN 1679-1).
▪ Working platforms/scaffolds
For work on the engine working platforms/scaffolds must be provided
and further safety precautions must be taken into consideration. Among
other things, it must be possible to work secured by safety belts. Corre-
sponding lifting points/devices have to be provided.
▪ Setting up storage areas
Throughout the plant, suitable storage areas have to be determined for
stabling of components and tools.
It is important to ensure stability, carrying capacity and accessibility. The
quality structure of the ground has to be considered (slip resistance,
resistance against residual liquids of the stored components, considera-
tion of the transport and traffic routes).
▪ Engine room ventilation
An effective ventilation system has to be provided in the engine room to
avoid endangering by contact or by inhalation of fluids, gases, vapours
and dusts which could have harmful, toxic, corrosive and/or acid effects.
▪ Venting of crankcase and turbocharger
The gases/vapours originating from crankcase and turbocharger are
ignitable. It must be ensured that the gases/vapours will not be ignited by
external sources. For multi-engine plants, each engine has to be ventila-
ted separately. The engine ventilation of different engines must not be
connected.
In case of an installed suction system, it has to be ensured that it will not
be stopped until at least 20 minutes after engine shutdown.
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▪ Intake air filtering

In case air intake is realised through piping and not by means of the tur-
7 Annex
bocharger´s intake silencer, appropriate measures for air filtering must be

provided. It must be ensured that particles exceeding 5 µm will be
restrained by an air filtration system.
▪ Quality of the intake air

It has to be ensured that combustible media will not be sucked in by the
engine.
Intake air quality according to the section Specification of intake air (com-
bustion air), Page 141 has to be guaranteed.
▪ Emergency stop system
The emergency stop system requires special care during planning, reali-
sation, commissioning and testing at site to avoid dangerous operating
conditions. The assessment of the effects on other system components
caused by an emergency stop of the engine must be carried out by
plant-side.
▪ Fail-safe 24 V power supply
Because engine control, alarm system and safety system are connected
to a 24 V power supply this part of the plant has to be designed fail-safe
to ensure a regular engine operation.
▪ Hazards by rotating parts/shafts
Contact with rotating parts must be excluded by plant-side (e.g. free
shaft end, flywheel, coupling).
▪ Safeguarding of the surrounding area of the flywheel
The entire area of the flywheel has to be safeguarded by plant-side.
Special care must be taken, inter alia, to prevent from: Ejection of parts,
contact with moving machine parts and falling into the flywheel area.
▪ Securing of the engine´s turning gear
The turning gear has to be equipped with an optical and acoustic warn-
ing device. When the turning gear is first activated, there has to be a cer-
tain delay between the emission of the warning device's signals and the
start of the turning gear. The gear wheel of the turning gear has to be
covered. The turning gear should be equipped with a remote control,
allowing optimal positioning of the operator, overlooking the entire hazard
area (a cable of approximately 20 m length is recommended). Uninten-
tional engagement or start of the turning gear must be prevented reliably.
It has to be prescribed in the form of a working instruction that:
– The turning gear has to be operated by at least two persons.
– The work area must be secured against unauthorised entry.
– Only trained personnel is permissible to operate the turning gear.
▪ Securing of the starting air pipe
To secure against unintentional restarting of the engine during mainte-
nance work, a disconnection and depressurisation of the engine´s start-
ing air system must be possible. A lockable starting air stop valve must
be provided in the starting air pipe to the engine.
▪ Securing of the turbocharger rotor
To secure against unintentional turning of the turbocharger rotor while
maintenance work, it must be possible to prevent draught in the exhaust
gas duct and, if necessary, to secure the rotor against rotation.
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▪ Consideration of the blow-off zone of the crankcase cover´s relief valves

During crankcase explosions, the resulting hot gases will be blown out of
7 Annex
the crankcase through the relief valves. This must be considered in the
overall planning.
▪ Installation of flexible connections

For installation of flexible connections follow strictly the information given

in the planning and final documentation and the manufacturer manual.
Flexible connections may be sensitive to corrosive media. For cleaning
only adequate cleaning agents must be used (see manufacturer manual).
Substances containing chlorine or other halogens are generally not per-
missible.
Flexible connections have to be checked regularly and replaced after any
damage or lifetime given in manufacturer manual.
▪ Connection of exhaust port of the turbocharger to the exhaust gas sys-
tem of the plant
The connection between the exhaust port of the turbocharger and the
exhaust gas system of the plant has to be executed gas tight and must
be equipped with a fire proof insulation.
The surface temperature of the fire insulation must not exceed 220 °C.
In workspaces and traffic areas, a suitable contact protection has to be
provided whose surface temperature must not exceed 60 °C.
The connection has to be equipped with compensators for longitudinal
expansion and axis displacement in consideration of the occurring vibra-
tions (the flange of the turbocharger reaches temperatures of up to
450 °C).
▪ Media systems
The stated media system pressures must be complied. It must be possi-
ble to close off each plant-side media system from the engine and to
depressurise these closed off pipings at the engine. Safety devices in
case of system over pressure must be provided.
▪ Drainable supplies and excipients
Supply system and excipient system must be drainable and must be
secured against unintentional recommissioning (EN 1037). Sufficient ven-
tilation at the filling, emptying and ventilation points must be ensured.
The residual quantities which must be emptied have to be collected and
disposed of properly.
▪ Spray guard has to be ensured for liquids possibly leaking from the
flanges of the plant´s piping system. The emerging media must be
drained off and collected safely.
▪ Charge air blow-off (if applied)
The piping must be executed by plant-side and must be suitably isola-
ted. In workspaces and traffic areas, a suitable contact protection has to
be provided whose surface temperature must not exceed 60 °C.
The compressed air is blown-off either outside the vessel or into the
engine room. In both cases, installing a silencer after blow-off valve is
recommended. If the blow-off valve is located upstream of the charge air
cooler, air temperature can rise up to 200 °C. It is recommended to
blow-off hot air outside the plant.
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7 Annex
▪ Signs
7.2 Programme for Factory Acceptance Test (FAT)

– Following figure shows exemplarily the risks in the area of a combus-
tion engine. This may vary slightly for the specific engine.
This warning sign has to be mounted clearly visibly at the engine as
well as at all entrances to the engine room.
Figure 85: Warning sign E11.48991-1108

– Prohibited area signs.
Depending on the application, it is possible that specific operating
ranges of the engine must be prohibited.
In these cases, the signs will be delivered together with the engine,
which have to be mounted clearly visibly on places at the engine
which allow intervention of the engine operation.
▪ Optical and acoustic warning device
Communication in the engine room may be impaired by noise. Acoustic
warning signals might not be heard. Therefore it is necessary to check
where at the plant optical warning signals (e.g. flash lamp) should be pro-
vided.
In any case, optical and acoustic warning devices are necessary while
using the turning gear and while starting/stopping the engine.

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According to quality guide line: Q10.09053-0013

Please see overleaf!
7 Annex
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7 Annex
Figure 86: Shop test of four-stroke marine diesel and dual fuel engines – Part 1

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7 Annex
Figure 87: Shop test of four-stroke marine diesel and dual fuel engines – Part 2
7.3 Engine running-in
Prerequisites
Engines require a running-in period in case one of the following conditions
applies:
▪ When put into operation on site, if
– after test run the pistons or bearings were dismantled for inspection
or
– the engine was partially or fully dismantled for transport.
▪ After fitting new drive train components, such as cylinder liners, pistons,
piston rings, crankshaft bearings, big-end bearings and piston pin bear-
ings.
▪ After the fitting of used bearing shells.
▪ After long-term low-load operation (> 500 operating hours).
Supplementary information
Operating Instructions During the running-in procedure the unevenness of the piston-ring surfaces
and cylinder contact surfaces is removed. The running-in period is comple-
ted once the first piston ring perfectly seals the combustion chamber. i.e. the
first piston ring should show an evenly worn contact surface. If the engine is
subjected to higher loads, prior to having been running-in, then the hot
exhaust gases will pass between the piston rings and the contact surfaces of
the cylinder. The oil film will be destroyed in such locations. The result is
material damage (e.g. burn marks) on the contact surface of the piston rings
and the cylinder liner. Later, this may result in increased engine wear and
high lube oil consumption.
The time until the running-in procedure is completed is determined by the
properties and quality of the surfaces of the cylinder liner, the quality of the
fuel and lube oil, as well as by the load of the engine and speed. The run-
ning-in periods indicated in following figures may therefore only be regarded
as approximate values.
Operating media
The running-in period may be carried out preferably using MGO (DMA, DMZ)
or MDO (DMB).
The fuel used must meet the quality standards see section Specification for
engine supplies, Page 101 and the design of the fuel system.
For the running-in of gas four-stroke engines it is best to use the gas which is
to be used later in operation.
Dual fuel engines are run in using liquid fuel mode with the fuel intended as
the pilot fuel.
Lube oil The running-in lube oil must match the quality standards, with regard to the
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fuel quality.
7 Annex
Engine running-in
Cylinder lubrication (optional) The cylinder lubrication must be switched to "Running In" mode during com-
pletion of the running-in procedure. This is done at the control cabinet or at
the control panel (under "Manual Operation"). This ensures that the cylinder
lubrication is already activated over the whole load range when the engine

starts. The running-in process of the piston rings and pistons benefits from
the increased supply of oil. Cylinder lubrication must be returned to "Normal
Mode" once the running-in period has been completed.
Checks Inspections of the bearing temperature and crankcase must be conducted
during the running-in period:
▪ The first inspection must take place after 10 minutes of operation at mini-
mum speed.
▪ An inspection must take place after operation at full load respectively
after operational output level has been reached.
The bearing temperatures (camshaft bearings, big-end and main bearings)
must be determined in comparison with adjoining bearings. For this purpose
an electrical sensor thermometer may be used as a measuring device.
At 85 % load and at 100 % load with nominal speed, the operating data
(ignition pressures, exhaust gas temperatures, charge air pressures, etc.)
must be measured and compared with the acceptance report.
Standard running-in Dependent on the application the running-in programme can be derived from
programme the figures in paragraph Diagram(s) of standard running-in, Page 266. During
the entire running-in period, the engine output has to be within the marked
output range. Critical speed ranges are thus avoided.
Running-in during Most four-stroke engines are subjected to a test run at the manufacturer´s
commissioning on site premises. As such, the engine has usually been run in. Nonetheless, after
installation in the final location, another running-in period is required if the pis-
tons or bearings were disassembled for inspection after the test run, or if the
engine was partially or fully disassembled for transport.
Running-in after fitting new If during revision work the cylinder liners, pistons, or piston rings are
drive train components replaced, a new running-in period is required. A running-in period is also
required if the piston rings are replaced in only one piston. The running-in
period must be conducted according to following figures or according to the
associated explanations.
The cylinder liner may be re-honed according to Work Card 050.05, if it is
not replaced. A transportable honing machine may be requested from one of
our Service and Support Locations.
Running-in after refitting When used bearing shells are reused, or when new bearing shells are instal-
used or new bearing shells led, these bearings have to be run in. The running-in period should be 3 to 5
(crankshaft, connecting rod hours under progressive loads, applied in stages. The instructions in the pre-
and piston pin bearings) ceding text segments, particularly the ones regarding the "Inspections", and
following figures must be observed.
Idling at higher speeds for long periods of operation should be avoided if at
all possible.
Running-in after low-load Continuous operation in the low-load range may result in substantial internal
operation pollution of the engine. Residue from fuel and lube oil combustion may cause
deposits on the top-land ring of the piston exposed to combustion, in the
piston ring channels as well as in the inlet channels. Moreover, it is possible
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that the charge air and exhaust pipes, the charge air cooler, the turbocharger
and the exhaust gas tank may be polluted with oil.
Since the piston rings have adapted themselves to the cylinder liner accord-
7 Annex
ing to the running load, increased wear resulting from quick acceleration and
possibly with other engine trouble (leaking piston rings, piston wear) should
be expected.
Therefore, after a longer period of low-load operation (≥ 500 hours of opera-

7.4 Definitions
tion) a running-in period should be performed again, depending on the

power, according to following figures.
Also for instruction see section Low-load operation, Page 30.
Note:
For further information, you may contact the MAN Energy Solutions cus-
tomer service or the customer service of the licensee.
Diagram of standard running-in
Figure 88: Standard running-in programme for engines operated with constant speed
7.4 Definitions
Auxiliary GenSet/auxiliary generator operation

A generator is driven by the engine, hereby the engine is operated at con-
stant speed. The generator supplies the electrical power not for the main
drive, but for supply systems of the vessel.
2019-09-19 - 1.4
Load profile with focus between 40 % and 80 % load. Average load: Up to

50 %.
7 Annex
Engine´s certification for compliance with the NOx limits according D2 Test
cycle. See within section Engine ratings (output) for different applications,
Page 23 if the engine is released for this kind of application and the corre-
sponding available output PApplication.
Blackout
7.4 Definitions
The classification societies define blackout on board ships as a loss of the
main source of electrical power resulting in the main and auxiliary machinery
to be out of operation and at the same time all necessary alternative energies
(e.g. start air, battery electricity) for starting the engines are available.
Dead ship condition

The classification societies define dead ship condition as follows:
▪ The main propulsion plant, boilers and auxiliary machinery are not in
operation due to the loss of the main source of electrical power.
▪ In restoring propulsion, the stored energy for starting the propulsion
plant, the main source of electrical power and other essential auxiliary
machinery is assumed not to be available.
▪ It is assumed that means are available to start the emergency generators
at all times. These are used to restore the propulsion.
Designation of engine sides

▪ Coupling side, CS
The coupling side is the main engine output side and is the side to which
the propeller, the alternator or other working machine is coupled.
▪ Free engine end/counter coupling side, CCS
The free engine end is the front face of the engine opposite the coupling
side.
Designation of cylinders
The cylinders are numbered in sequence, from the coupling side, 1, 2, 3 etc.
In V engines, looking on the coupling side, the left hand bank of cylinders is
designated A, and the right hand bank is designated B. Accordingly, the cyl-
inders are referred to as A1-A2-A3 or B1-B2-B3, etc.
2019-09-19 - 1.4
7 Annex
7.4 Definitions
Figure 89: Designation of cylinders
Direction of rotation
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7 Annex
Figure 90: Designation: Direction of rotation seen from flywheel end
Electric propulsion
7.4 Definitions
The generator being driven by the engine supplies electrical power to drive
an electric motor. The power of the electric motor is used to drive a control-
lable pitch or fixed pitch propeller, pods, thrusters, etc.
85 %.
Engine´s certification for compliance with the NOx limits according E2 Test
GenSet
The term "GenSet" is used, if engine and electrical alternator are mounted
together on a common base frame and form a single piece of equipment.
Gross calorific value (GCV)

This value supposes that the water of combustion is entirely condensed and
that the heat contained in the water vapor is recovered.
Mechanical propulsion with controllable pitch propeller (CPP)

A propeller with adjustable blades is driven by the engine.
The CPP´s pitch can be adjusted to absorb all the power that the engine is
capable of producing at nearly any rotational speed.
85 %.
Mechanical propulsion with fixed pitch propeller (FPP)

A fixed pitch propeller is driven by the engine. The FPP is always working
very close to the theoretical propeller curve (power input ~ n3). A higher tor-
que in comparison to the CPP even at low rotational speed is present.
85 %.
Multi-engine propulsion plant

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In a multi-engine propulsion plant at least two or more engines are available

for propulsion.
7 Annex
Net calorific value (NCV)

This value supposes that the products of combustion contain the water
vapor and that the heat in the water vapor is not recovered.
Offshore application
7.4 Definitions
Offshore construction and offshore drilling place high requirements regarding

the engine´s acceleration and load application behaviour. Higher require-
ments exist also regarding the permissible engine´s inclination.
Due to the wide range of possible requirements such as flag state regula-
tions, fire fighting items, redundancy, inclinations and dynamic positioning
modes all project requirements need to be clarified at an early stage.
Output
▪ ISO standard output (as specified in DIN ISO 3046-1)
Maximum continuous rating of the engine at nominal speed under
ISO conditions, provided that maintenance is carried out as specified.
▪ Operating-standard-output (as specified in DIN ISO 3046-1)
Maximum continuous rating of the engine at nominal speed taking in
account the kind of application and the local ambient conditions, provi-
ded that maintenance is carried out as specified. For marine applications
this is stated on the type plate of the engine.
▪ Fuel stop power (as specified in DIN ISO 3046-1)
Fuel stop power defines the maximum rating of the engine theoretical
possible, if the maximum possible fuel amount is used (blocking limit).
▪ Rated power (in accordance to rules of Germanischer Lloyd)
Maximum possible continuous power at rated speed and at defined
ambient conditions, provided that maintenances carried out as specified.
▪ Output explanation
Power of the engine at distinct speed and distinct torque.
▪ 100 % output
100 % output is equal to the rated power only at rated speed. 100 %
output of the engine can be reached at lower speed also if the torque is
increased.
▪ Nominal output
= rated power.
▪ MCR
Maximum continuous rating.
▪ ECR
Economic continuous rating = output of the engine with the lowest fuel
consumption.
Overload power (at FAT or SAT/sea trial)

Only if required by rules of classification societies, it is admitted to operate
the engine at 110 % of rated power for a maximum of 1 h in total as part of
the FAT or SAT/sea trial and in addition a maximum of 1 h in total as part of
the comissioning of the plant. Engine operation has to be done under super-
vision of trained MAN Energy Solutions personal.
2019-09-19 - 1.4
Single-engine propulsion plant

7 Annex
In a single-engine propulsion plant only one single-engine is available for pro-

pulsion.
Suction dredger application (mechanical drive of pumps)
7.5 Abbreviations
For direct drive of a suction dredger pump by the engine via gear box the
engine speed is directly influenced by the load on the suction pump.
The power demand of the dredge pump needs to be adapted to the operat-
ing range of the engine, particularly while start-up operation. Load profile with
focus between 80 % and 100 % load. Average load: Up to 85 %.
Engine´s certification for compliance with the NOx limits according C1 Test
Water jet application

A marine propulsion system that creates a jet of water that propels the ves-
sel. The water jet propulsion is always working close to the theoretical pro-
peller curve (power input ~ n3). With regard to its requirements the water jet
propulsion is identical to the mechanical propulsion with FPP.
85 %.
Weight definitions for SCR

▪ Handling weight (reactor only):
This is the "net weight" of the reactor without catalysts, relevant for trans-
port, logistics, etc.
▪ Operational weight (with catalysts):
That's the weight of the reactor in operation, that is equipped with a layer
of catalyst and the second layer empty – as reserve.
▪ Maximum weight structurally:
This is relevant for the static planning purposes maximum weight, that is
equipped with two layers catalysts.
7.5 Abbreviations
Abbreviation Explanation
BN Base number
CBM Condition based maintenance
CCM Crankcase monitoring system
CCS Counter coupling side

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CS Coupling side
ECR Economic continuous rating

7 Annex
EDS Engine diagnostics system
FAB Front auxiliary box
GCV Gross calorific value
Abbreviation Explanation
7.6 Symbols
GVU Gas Valve Unit
HFO Heavy fuel oil
HT CW High temperature cooling water
LT CW Low temperature cooling water
MCR Maximum continuous rating
MDO Marine diesel oil
MGO Marine gas oil
MN Methane number
NCV Net calorific value
OMD Oil mist detection
SaCoS Safety and control system
SAT Site acceptance test
SECA Sulphur emission control area
SP Sealed plunger
STC Sequential turbocharging
TAN Total acid number
TBO Time between overhaul
TC Turbocharger
TC Temperature controller
ULSHFO Ultra low sulphur heavy fuel oil
7.6 Symbols
Note:
The symbols shown should only be seen as examples and can differ from
the symbols in the diagrams.
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7 Annex
7.6 Symbols
Figure 91: Symbols used in functional and pipeline diagrams 1
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7 Annex
7.6 Symbols

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7 Annex
7.6 Symbols

2019-09-19 - 1.4
7 Annex
7.7 Preservation, packaging, storage
7.7.1 General
Introduction
Engines are internally and externally treated with preservation agent before
delivery. The type of preservation and packaging must be adjusted to the
means of transport and to the type and period of storage. Improper storage
may cause severe damage to the product.
Packaging and preservation of engine

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The type of packaging depends on the requirements imposed by means of

transport and storage period, climatic and environmental effects during
7 Annex
transport and storage conditions as well as on the preservative agents used.

As standard, the preservation and packaging of an engine is designed for a
storage period of 12 month and for sea transport.
Note:

The packaging must be protected against damage. It must only be removed
when a follow-up preservation is required or when the packaged material is
to be used. The condition of the packaging must be checked regularly and
repaired in case of damage. Especially a VCI packaging can only provide a
proper corrosion protection if it is intact and completely closed.
In addition, the engine interiors are protected by vapor phase corrosion pro-
tection. Inner compartments must not be opened while transportation and
storage. Otherwise, a re-preservation of the opened compartment will be
required.
If bare metal surfaces get exposed e.g. by disassembly of the coupling
device, the unprotected metal must be treated with agent f according to the
list of recommended anti-corrosion agents (https://corporate.man-es.com/
preservation).
Preservation and packaging of assemblies and engine parts

Unless stated otherwise in the order text, the preservation and packaging of
assemblies and engine parts must be carried out such that the parts will not
be damaged during transport and that the corrosion protection remains fully
intact for a period of at least 12 months when stored in a roofed dry room.
Transport
Transport and packaging of the engine, assemblies and engine parts must
be coordinated.
After transportation, any damage to the corrosion protection and packaging
must be rectified, and/or MAN Energy Solutions must be notified immedi-
ately.
7.7.2 Storage location and duration
Storage location
Storage location of engine As standard, the engine is packaged and preserved for outdoor storage.
The storage location must meet the following requirements:
▪ Engine is stored on firm and dry ground.
▪ Packaging material does not absorb any moisture from the ground.
▪ Engine is accessible for visual checks.
Storage location of Assemblies and engine parts must always be stored in a roofed dry room.
assemblies and engine parts The storage location must meet the following requirements:
▪ Parts are protected against environmental effects and the elements.
▪ The room must be well ventilated.
▪ Parts are stored on firm and dry ground.
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▪ Packaging material does not absorb any moisture from the ground.
▪ Parts cannot be damaged.
7 Annex
▪ Parts are accessible for visual inspection.

▪ An allocation of assemblies and engine parts to the order or requisition
must be possible at all times.
Note:
7.8 Engine colour
Packaging made of or including VCI paper or VCI film must not be opened or
must be closed immediately after opening.
Storage conditions
In general the following requirements must be met:
▪ Minimum ambient temperature: –10 °C
▪ Maximum ambient temperature: +60 °C
▪ Relative humidity: < 60 %
In case these conditions cannot be met, contact MAN Energy Solutions for
clarification.
Storage period
The permissible storage period of 12 months must not be exceeded.
Before the maximum storage period is reached:
▪ Check the condition of the stored engine, assemblies and parts.
▪ Renew the preservation or install the engine or components at their
intended location.
7.7.3 Follow-up preservation when preservation period is exceeded

A follow-up preservation must be performed before the maximum storage
period has elapsed, i.e. generally after 12 months.
Request assistance by authorised personnel of MAN Energy Solutions.
Note:
During storage and in case of a follow-up preservation the crankshaft must
not be turned. If the crankshaft is turned, usually for the first time after pres-
ervation this will be done during commissioning, the preservation is partially
removed. If the engine is to be stored again for a period thereafter, then ade-
quate re-preservation is required.
7.7.4 Removal of corrosion protection

Packaging and corrosion protection must only be removed from the engine
immediately before commissioning the engine in its installation location.
Remove outer protective layers, any foreign body from engine or component
(VCI packs, blanking covers, etc.), check engine and components for dam-
age and corrosion, perform corrective measures, if required.
The preservation agents sprayed inside the engine do not require any special
attention. They will be washed off by engine oil during subsequent engine
operation.
Contact MAN Energy Solutions if you have any questions.
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7.8 Engine colour

Engine standard colour according RAL colour table is RAL 7040 Window
7 Annex
grey. Other colours on request.
Index
A Blow-off 19
Blow-off device 19
Abbreviations 271
Additions to fuel consumption 53 19
Aging (Increase of S.F.C.) 56 Blow-off noise 78
Air Charge air cooler
Consumption (jet assist) 225 Condensate amount 151
Flow rates 57 151
Starting air consumption 53 Flow rates 57
55 Heat to be dissipated 57
Temperature 57 Colour of the engine 278
Air receivers Combustion air
Capacities 224 Flow rate 57
Air vessels Specification 101
Capacities 153 Common rail injection system 206
Condensate amount 151 Components
Airborne noise 75 Exhaust gas system 231
Composition of exhaust gas 73
76
Compressed air
Alternator
Specification 101
Reverse power protection 49
Compressed air system 220
Ambient conditions causes derat- 24
ing 222
Angle of inclination 18 Condensate amount
Approved applications 13 Air vessels 151
Arctic conditions 42 Charge air cooler 151
Arrangement 151
Attached pumps 82 Consumption
Attached pumps Control air 55
Arrangement 82 Fuel 53
Capacities 57 Fuel oil 53
Auxiliary generator operation Jet assist 225
Definiton 266 Lube oil 54
Auxiliary GenSet Control air
Planning data 57 Consumption 53
Auxiliary GenSet operation 55
Definition 266 Controllable pitch propeller
Available outputs Definition 269
Permissible frequency devia- 47 Cooler
tions Flow rates 57
Related reference conditions 23 Heat radiation 57
24 Heat to be dissipated 57
Specification, nominal values 57
B Temperature 57
Cooler dimensioning, general ° 176
Blackout
Cooling water
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Definition 267
Inspecting 101
C 137
Specification 101
Capacities
Index
Attached pumps 57 131

Pumps 57
Charge air
Specification for cleaning 101 Colour 278

137 Cross section 15
Definition of engine rating 22
138
Description 9
System description 176
Designation 16
System diagram 172
267
176
Equipment for various applica- 19
Crankcase vent and tank vent 165
tions
Crankshaft
Inclinations 18
Moments of inertia – Damper, 82
Main dimensions 17
flywheel
Noise 76
Cross section, engine 15
Operation under arctic condi- 42
Cylinder
tions
Designation 267
Outputs 21
Cylinder liner, removal of 237
Programme 9
240 Ratings 21
Ratings for different applications 23
D
24
Damper Room layout 233
Moments of inertia – Crank- 82 Running-in 264
shaft, flywheel Single-engine propulsion plant 270
Dead ship condition (Definition)
Definition 267 Speeds 21
Required starting conditions 29 Table of ratings 21
30 Weights 17
Definition of engine rating 22 Engine automation
Definitions Operation 91
Engine start 27 Supply and distribution 90
Derating Engine cooling water specifications 131
As a function of water tempera- 24 °
ture Engine pipe connections and 145
Due to ambient conditions 24 dimensions
Due to special conditions or 24 Engine ratings
demands Power, outputs, speeds 21
Design parameters 16 Suction dredger 271
Diagram Equipment for various applications 19
Lube oil system 161 Excursions of resiliently mounted L 147
Diagram condensate amount 151 engines
Diesel fuel see Fuel oil 54 Exhaust gas
Back pressure 24
E Composition 73
Ducting 252
Earthing
Emission 73
Bearing insulation 50
Flow rates 57
Measures 50
Flow rates, temperature 58
Welding 52
Pressure 24
ECR
Smoke emission index 73
Definition 270
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Electric operation 38
Temperature 57
Electric propulsion
Exhaust gas noise 77
Definition 269
Emissions 78
Index
Exhaust gas – IMO standard 73 Exhaust gas pressure

Engine Due to after treatment 25
3D Engine viewer 240 Exhaust gas system
Assemblies 231
Components 231 GenSet

Explanatory notes for operating 101 Definition 269
supplies 101 GenSet/electric propulsion
Operating range 46
F Grid parallel operation
Definition 270
Factory Acceptance Test (FAT) 261 Gross calorific value (GCV)
Filling volumes 66 Definition 269
Fixed pitch propeller
Definition 269 H
Flexible pipe connections
Installation 146 Heat radiation 57
Flow rates Heat to be dissipated 57
Air 57 Heavy fuel oil see Fuel oil 54
Cooler 57 HFO Operation 195
Exhaust gas 57 HFO see Fuel oil 54
Lube oil 57 HT-switching 30
Water 57
Flow resistances 66 I
Flywheel Idle speed 25
Moments of inertia – Crank- 82 IMO Marpol Regulation 54
shaft, damper
73
Follow-up preservation 278
IMO Tier II
Foundation
Definition 54
General requirements 85
Exhaust gas emission 73
Frequency deviations 47
Impact on foundation
Fuel
Noise and vibration 79
Consumption 53
Inclinations 18
55 Injection viscosity and temperature 209
Dependent on ambient condi- 55 after final heater heavy fuel oil
tions Installation
Diagram of HFO treatment sys- 200 Flexible pipe connections 146
tem 200 Installation drawings 234
HFO treatment 195 Intake air (combustion air)
MDO supply 203 Specification 141
Recalculation of consumption 55 Intake noise 76
Specification (HFO) 116 77
Specification (MDO) 114 ISO
Specification of gas oil (MGO) 112 Reference conditions 22
Stop power, definition 270 Standard output 21
Viscosity-diagram (VT) 129
24
Fuel oil
Consumption 53 270
Diagram of MDO treatment sys- 194
J
tem
MDO treatment 194 Jet assist
Specification for gas oil (MGO) 101 Air consumption 225
2019-09-19 - 1.4
G L
Gas oil Layout of pipes 145
Specification 101 Leakage rate 66
Lifting device 241
Index
112
Generator operation/electric propulsion Load
Power management 48 Low-load operation 30
Reduction 40
Load application MGO see Fuel oil 54

Auxiliary GenSet 38 Moments of inertia 82
Cold engine (only emergency 29 Multi-engine propulsion plant
case) 36 Definition 269
Electric propulsion 38
Electric propulsion plants 29 N
General remarks 33 Net calorific value (NCV)
Preheated engine 33 Definition 269
Ship electrical systems 38 Noise
Start-up time 33 Airborne 75
34 76
Load reduction Charge air blow-off 78
As a protective safety measure 42 Engine 76
Recommended 41 Exhaust gas 77
Stopping the engine 41
78
Sudden load shedding 40
Intake 76
Low-load operation 30
LT-switching 30 77
Lube oil Noise and vibration
Consumption 54 Impact on foundation 79
Flow rates 57 Nominal output
Specification (HFO) 107 Definition 270
Specification (MGO) 101 NOx
Specification (MGO/MDO) 103 IMO Tier II 73
System description 153 Nozzle cooling system 188
System diagram 161 Nozzle cooling water module 188
Temperature 57
O
M Offshore application
Main dimensions 17 Definition 13
Marine diesel oil (MDO) supply sys- 203 270
tem for diesel engines Oil mist detector 19
Marine diesel oil see Fuel oil 54 21
Marine gas oil Operating
Specification 101 Pressures 62
Marine gas oil see Fuel oil 54 Standard-output (definition) 270
MARPOL Regulation 53 Temperatures 62
54 Operating range
73 GenSet/electric propulsion 46
Materials Operating/service temperatures 62
Piping 145 and pressures
MCR Operation
Definition 270 Load application for ship electri- 38
MDO cal systems
Diagram of treatment system 194 Load reduction 40
MDO see Fuel oil 54 Low load 30
Mechanical propulsion with CPP Running-in of engine 264
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Definition 269 Output

Mechanical propulsion with FPP Available outputs, related refer- 23
Definiton 269 ence conditions 24
Medium-speed marine GenSets Definition 270
Index
Programme 9 Engine ratings, power, speeds 21

MGO (fuel oil)
Specification 101
ISO Standard 21 Room layout 233

23 Running-in 264
24
S
Permissible frequency devia- 47
tions Safety
Instructions 257
P Measures 257
Sealed Plunger injection pumps 12
Packaging 276
Separate MDO supply system 215
Part-load operation 30
Service tanks capacities 67
Permissible frequency deviations
Shut-off flap 19
Available outputs 47
Pipe dimensioning 145 19
Piping Slow turn 29
Materials 145 29
Planning data 30
Auxiliary GenSet 57 Smoke emission index 73
Flow rates of cooler 57 Space requirement for mainte- 245
Heat to be dissipated 57 nance 246
Temperature 57
Specification
Position of the outlet casing of the 253
Cleaning agents for cooling 101
turbocharger
water 138
Postlubrication 164
Power Combustion air 101
Engine ratings, outputs, speeds 21 Compressed air 101
Power drive connection 82 Cooling water inspecting 101
Power management 48 137
Preheated engine Cooling water system cleaning 101
Load application 33 137
Preheating
138
At starting 28
Diesel oil (MDO) 114
28 Engine cooling water 101
Prelubrication 164
131
Preservation 276
Fuel (Gas oil, Marine gas oil) 101
Pumps
Fuel (HFO) 116
Arrangement of attached 82
Fuel (MDO) 114
pumps
Fuel (MGO) 112
Capacities 57
Gas oil 112
Heavy fuel oil 116
R
Intake air (combustion air) 141
Rated power Lube oil (HFO) 107
Definition 270 Lube oil (MGO) 101
Ratings (output) for different appli- 23 Lube oil (MGO/MDO) 103
cations, engine 24 Viscosity-diagram 129
Reduction of load 40 Specification for intake air (com- 141
Reference conditions (ISO) 22 bustion air)
Removal Speed
Adjusting range 25
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Cylinder liner 237

Droop 25
240
Engine ratings 25
Piston 237
Engine ratings, power, outputs 21
240 Idling 25
Index
Removal of corrosion protection 278 Mimimum engine speed 25

Reverse power protection Speeds
Alternator 49 Clutch activation 25
Idling 25 Cooling water 57

Mimimum engine speed 25 Exhaust gas 57
Splash oil monitoring 19 Lube oil 57
21 Time limitation for low-load opera- 30
Stand-by operation capability 28 tion
Turbocharger assignments 16
28
Two-stage charge air cooler 19
Starting 28
20
28
Type of engine start 27
Starting air
/control air consumption 55
U
Consumption 53
55 Unloading the engine 40
Jet assist 225
receivers, compressors 223 V
System description 220 Variable Injection Timing (VIT) 19
222 21
Starting air receivers, compressors 223 Venting
Starting air system 220 Crankcase, turbocharger 72
222 Viscosity-temperature-diagram 129
Start-up time 34
Stopping the engine 41 W
Storage 276 Water
Storage location and duration 277 Flow rates 57
Suction dredger application Specification for engine cooling 101
Definition 271 water 131
Sudden load shedding 40
Water jet application
Supply system
Definition 271
Blackout conditions 214
Water systems
Switching: HT 30
Cooling water collecting and 183
Switching: LT 30
supply system
Symbols
Engine cooling 172
For drawings 272
Lube oil 153 Nozzle cooling 188
Turbine washing device 184
T Weights
Engine 17
Table of ratings 21 Lifting device 241
21 Welding
Temperature Earthing 52
Air 57 Works test 261
2019-09-19 - 1.4
Index

MAN L32/40 GenSet Project Guide – Marine
86224 Augsburg
P + 49 821 322- 0
F + 49 821 322-3382
www.man-es.com
MAN
L32/40
GenSet
All data provided in this document is non-binding.
This data serves informational purposes only
and is not guaranteed in any way. Depending on
the subsequent specific individual projects, the
relevant data may be subject to changes and
will be assessed and determined individually for
each project. This will depend on the particular
characteristics of each individual project,
especially specific site and operational conditions. Project Guide – Marine
Copyright © MAN Energy Solutions. Four-stroke diesel engine compliant with
D2366583EN-N1
Printed in Germany GGKMD-AUG-08180.5 IMO Tier II

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MAN Energy Solutions SE

Four-stroke diesel engine compliant with IMO Tier II

MAN L32/40 GenSet

Revision ............................................ 05.2017/1.4

MAN L32/40 GenSet IMO Tier II Project

MAN Energy Solutions SE

Copyright © 2019 MAN Energy Solutions

2 Engine and operation ........................................................................................................................... 13

2.11 GenSet operation ....................................................................................................................... 46

3 Engine automation ............................................................................................................................... 87

3.3 Operation ................................................................................................................................... 91

5 Engine supply systems ...................................................................................................................... 145

5.3.9 Nozzle cooling water module ............................................................................... 188

5.4.5 Fuel oil supply system .......................................................................................... 203

5.4.6 Fuel oil supply at blackout conditions ................................................................... 214

6 Engine room planning ........................................................................................................................ 233

7 Annex .................................................................................................................................................. 257

7.4 Definitions ............................................................................................................................... 266

7.7.3 Follow-up preservation when preservation period is exceeded ............................. 278

Index ................................................................................................................................................... 279

1.2 Engine description MAN L32/40 GenSet IMO Tier II

Figure 1: MAN Energy Solutions engine programme

1.2 Engine description MAN L32/40 GenSet IMO Tier II

Auxiliary GenSet concept

Figure 2: Auxiliary GenSet – Principle schema

by keeping lubricating oil consumption consistently low. Chromium ceramic

MAN Energy Solutions turbocharging system

1.2 Engine description MAN L32/40 GenSet IMO Tier II

Service friendly design

Device for variable injection timing (VIT)

Sealed Plunger injection pumps (SP injection pumps)

Core technologies in-house

Committed to the future

2 Engine and operation

2.1 Approved applications and destination/suitability of

Destination/suitability of the engine

Electric and electronic components attached to the engine –

Required engine room temperature

2.2 Engine design

2.2.1 Engine cross section

2 Engine and operation

2.2.2 Engine designations – Design parameters

Figure 4: Example to declare engine designations

Parameter Value Unit

Cylinder bore 320 mm

Piston stroke 400

Displacement per cylinder 32.17 litre

Distance between cylinder centres 530 mm

Crankshaft diameter at journal, 290

Crankshaft diameter at crank pin 290

2.2.3 Turbocharger assignments

No. of cylinders, config. GenSet

Table 2: Turbocharger assignments

2.2 Engine design

Engine MAN L32/40 GenSet

Figure 5: Main dimensions – L engine

No. of cylinders, Lenght C1) Lenght A Lenght B1) Height H Weight1)

7L 10,190 6,467 79.0

8L 11,398 6,997 4,401 4,840 87.0