Doosan MD Series Manual de usuario

PREFACE

•General information

This installation instruction is designed as a guide for the proper installation of DOOSAN

(Doosan Infracore Ltd. hereafter DOOSAN) marine diesel engines and to create conditions for

faultless operation of the entire system and to prevent installation related malfunctions and

possible consequential damage to the engine.

•Scope

This installation instruction applies to all DOOSAN engines for marine propulsion and marine

generator.

•Warranty

Warranty claims against DOOSAN Marine Engines will be accepted only if this installation

instruction has been complied with.

If any modification to the engine installation intended by DOOSAN is planned, DOOSAN must be

informed in writing, and a new inspection may necessary.

We reserve the right to make technical modifications in the course of further development.

•Validity

DOOSAN reserves the right to make changes at any time, without notice, in specifications and

models and also to discontinue models. The right is also reserved to change any specifications or

parts at any time without noticing any obligation to equip same on models manufactured prior to

date of such change.

The continuing accuracy of this manual cannot be guaranteed.

All illustrations used in this manual may not depict actual models or equipment and are intended

as representative views for reference only.

- a -

•Marine engine Recommendation on applications

The engine must be able to achieve rated engine speed when operated under fully

loaded conditions;

Secondary drive loads must be considered engine horse power which could be available to

drive the primary load. Therefore any such parasitic load requirements must be deducted when

sizing an engine for the primary load.

The engine must be used in accordance with the application guidelines for that

particular rating;

It is important to choose the proper engine rating to provide the optimum performance in a

given application. Ratings below show DOOSAN marine engine guidelines on applications.

(1) Heavy duty

•Operation hours : Unlimited per year

•Average load application : Up to 90%

•Percentages of time at full load : Up to 80%

•Typical gear box ratio : 2.5 ~ 6

(Application: Fishing trawler, Tug boat, Pushing vessel, Cago boat, Freighter, Ferry)

(2) Medium duty

•Operation hours : Up to 3,000hr per year

•Average load application : Up to 70%

•Percentages of time at full load : Up to 30%, 4hrs per 12 hour operation period

•Typical gear box ratio : 2 ~ 3.5

(Application:

Fishing boat, Pilot boat, Escort boat, Passenger boat, Ferry, Cruising Vessel

)

(3) Light duty

•Operation hours : Up to 1,000hr per year

•Average load application : Up to 50%

•Percentages of time at full load : Up to 20%, 2hrs per 12 hour operation period

•Typical gear box ratio : 1 ~ 2.5

(Application:

Fishing boat, Pilot boat, Escort boat, Passenger boat, Ferry, Cruising Vessel

)

- b -

•Other country regulation

Other country may apply additional internal regulation. Please follow their appropriate advice.

Korea : KR = Korean Resister of Shipping

Sweden : Navigation Office

Finland : Navigation Office

Norway : DNV = Det Norske Veritas

USA : ABS = American Bureau of shipping

Indonesia : BKI = Biro Klasifikasi Indonesia

USA : NMMA = National Marine Manufacturers Association

England : LR = Lloyds Register of Shipping

France : BV = Bureau Veritas

Germany : GL = Germanisher Lloyd

Italy : RINA = Regislro Italiano Navale

Bulgaria : BKP = Bulgarian Register of Shipping

China : CCS = China Classification Society

China Rep.(Taiwan) : CR = China Corporation Register of Shipping

Spain : FN = Fidenavis

Croatia : CRS = Croatian Register of shipping

India : IRS = Indian Register of Shipping

Japan : NK = Nippon Kaiji Kyokai

Poland : PRS = Polski Register Statkow

Portugal : RP = Rinave Portuguesa

Rumania : RNR = Registrul Naval Roman

Russia : MRS = Russian Maritime Register of Sipping

Turkey : TL = Turk Loydu Vakfi

- c -

CONTENTS

CHAPTER 1 Engine Room .............................................................................................................1

1.1. Engine Room Ventilation 1.4. Power Rating

1.2. Engine Foundation 1.5. Inclinations

1.3. Max. Permissible Engine Inclination

CHAPTER 2 Engine Mounting .......................................................................................................6

2.1. Flexible Mounting 2.3. Arrangement of Engine and Reduction Gear

2.2. Solid Mounting

CHAPTER 3 Front Power Take off...............................................................................................13

3.1. Marine Installation Requirements 3.3. Belt Drives

3.2. Front Power Take-off Clutches

CHAPTER 4 Exhaust System.......................................................................................................18

4.1. Marine Installation Requirements 4.4. Direction of Exhaust Outlet

4.2. Dry Exhaust Systems(without sea 4.5. Permissible Back Pressure

water injection) 4.6. Designing the Exhaust System

4.3. Wet Exhaust System(with sea water 4.7. Measuring the Pressure Drop

injection)

CHAPTER 5 Intake System ..........................................................................................................30

5.1. Air Intake 5.4. General Note on Air Guidance

5.2. Engine Room Ventilation 5.5. Clear Cross Section

5.3. Radiant Heat to be Removed

CHAPTER 6 Cooling System .......................................................................................................35

6.1. Marine Installation Requirements 6.5. Engine Coolant

6.2. Selection of Piping Materials 6.6. Sea Water Lines

6.3. Cooling Circuit 6.7. Keel Cooler

6.4. Engine Cooling System

CHAPTER 7 Lubricating System .................................................................................................55

7.1. Marine Installation Requirements 7.3. Lube Oil Drain Pump

7.2. Engine Blow- by Gas Vent 7.4. Oil Dipstick Level Gauge

CHAPTER 8 Fuel System ...........................................................................................................57

8.1. Fuel Circuit 8.2. Fuel Tank

- a.4 -

CHAPTER 9 Propulsion System..................................................................................................64

9.1. Marine Gear Ratio Selection 9.5. Designing of the Propeller

9.2. How to Select the Right Propeller System 9.6. Propeller Tip Clearance

9.3. Propeller selection 9.7. Propeller Rotation in Twin Engine Applications

9.4. Power Drive with Fixed Pitch Propeller

CHAPTER 10 Electrical System...................................................................................................75

10.1. Electric Circuit 10.2. Electric Components

•

Appendix ....................................................................................................................................81

•

Part & After service center

•

Applications for DOOSAN Engine

- a.5 -

CHAPTER 1 ENGINE ROOM

When installing the engine, ensure that there is sufficient space for regular maintenance work

and possible engine overhaul after prolonged periods of operation. It must be possible to carry

out the following jobs on engine and gearbox without obstruction;

•Removing heat exchanger and inter-cooler for cleaning

•Exchanging starter, alternator and water pump

•Filling up with fuel, oil and coolant

•Checking oil and coolant level

•Changing fuel, oil and air filter

•Setting valves, re-tightening cylinder head bolts

•Draining oil and coolant

•Re-tightening and exchanging V - belts

•Maintenance and exchange of battery

•Exchanging injection nozzles

•Changing the sea water pump impeller

•Changing the reduction gear

1.1. Engine Room Ventilation

Calculation of the air requirements for the dissipation of convection and radiation heat can be

simplified the following formula:

where

•

m Air mass flow rate in kg/h

•

Q Convection and radiation in MJ/h

CpSpecific heat capacity of air = 1 kJ/(kg x degree)

Δt Difference in temperature between heated waste air and cold intake air in degrees Celsius

In order to obtain the air volume flow (m3/h) the air mass flow (kg/h) must be divided by the air

density, which depends on the temperature.

Air density as a function of the temperature at the air pressure of 0.98kg/cm2(1000 mbar).

- 1 -

••

m=Q x 1000

Cpx Δt

Temperature in

C Density in kg/m3

0 1.28

10 1.23

20 1.19

30 1.15

40 1.11

50 1.08

The before-mentioned formula is based on the assumption that the engine room is a heat-tight

system, i.e. for the sake of simplicity it is assumed that no thermal energy whatever is

dissipated through the hull to the ambient air or water.

In practice, however, such heat losses are likely to occur and depend on the following factors:

•Size and surface area of the engine room

•Difference in temperature between the engine room and the ambient air

•Hull material (thermal conductivity) and hull thickness

•Heat dissipation via pipes (e.g. exhaust pipes)

This heat transfer is therefore hard to estimate qualitatively.

Note : The difference of engine room and ambient air temperature (

t) would be better

below than 15

C, but should not exceed maximum 20

Δt = (Air temperature of engine room ) - (Ambient temperature )

•Temperature

t(degree Celsius) = T(Kelvin) - 273

T(Kelvin) = t (degree Celsius ) +273

t (degree Fahrenheit) = 1.8 x t (degree Celsius) + 32

•Pressure

1 kilo-Pascal (kPa) = 10 millibar (mbar)

1 hecto-Pascal (hPa) = 1 millibar (mbar)

•Energy flow

Mega - Joule/hour (MJ/h) x 1000 = Kilocalories/hour (kcal/h)

4.187

Mega - Joule/hour (MJ/h) x 1 = Kilowatt (kW)

3.6

- 2 -

1.2. Engine Foundation

Requirements for the engine foundation are as following;

•The foundation in the vessel should be able to take up propeller thrust in both directions

(ahead & astern) and transmit it on to the hull.

•The weight of the drive system as well as all dynamic forces that occur in rough seas must

be safely taken up.

•The torsion of the hull owing to rough seas and the load status must not be transferred to

the engine. The engine foundation is to be connected to the hull on an area as large as

possible

EB0O1001

Engine bed

Stringer

Engine mounting bracket

EB0O9007

•Transverse cross bracing on the engine

bed and stringers should be used to

prevent lateral engine movement on solid

mounted systems.

•In order to properly support the weight of

the engine and marine gear, a six-point

mounting system is recommended on all

DOOSAN marine engines.

When using a six-point mounting system,

the engine should be aligned using the

mounts at the front and at the marine gear

at first. Once the alignment is complete,

the next flywheel housing mounts should

be added.

- 3 -

1.3. Max. Permissible Engine Inclination

The installation angle of the engine is an important factor in the construction of the sub-frame.

When the engine is to be installed in longitudinal direction, The maximum permissible inclination

must not be exceeded. The maximum permissible inclination is defined as the largest angle that

occurs in driving operation, ie, installation inclination plus the ship’s maximum trim angle.

The maximum installation angle of the engine is the maximum permissible inclination angle ( )

of the boat less the angle of the maximum trim( ) while the vessel is in motion. ie, the maximum

installation angle of the engine is( - ).

= max. permissible vessel inclination angle ; angle towards the flywheel end

= angle towards the non flywheel end

= trim of the vessel

Note : angle

The angle of 5

toward the non-flywheel and must occur only while the vessel

is in motion.

- 4 -

Water line

EB0O1003

Max. oil pan permissible Max. angle of

Engine model angle of inclination engine installation

to the rear : ( ) inclination : ( - )

L034 / L034TI 20

L066TI 30

L136 / L136T 17

L136TI / L086TI 17

L196T / L196TI / L126TI 17

V158TI 17

V180TI 25

V222TI 25

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