MAN Energy Solutions

Technical Documentation

G70ME-C10.5-GA
Project guide

Project guide .................................... G70ME-C10.5-GA

Document No.................................... 7020-0276-11ppr April 2024
Revision............................................ 1.0
 MAN Energy Solutions
G70ME-C10.5-GA

MAN Energy Solutions

Teglholmsgade 41
DK-2450 Copenhagen SV
Phone +45 3385 1100
Fax +45 3385 1030
info-cph@man-es.com
https://marine.man-es.com
Copyright © MAN Energy Solutions
All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
MAN Energy Solutions

Preface

​
MAN B&W G70ME-C10.5-GA
Project Guide
Electronically Controlled
Dual Fuel Two-stroke Engines

This Project Guide is intended to provide the information necessary for the
layout of a marine propulsion plant.
The information is to be considered as preliminary. It is intended for the pro-
ject stage only and subject to modification in the interest of technical pro-
gress. The Project Guide provides the general technical data available at the
date of issue.
It should be noted that all figures, values, measurements or information about
performance stated in this project guide are for guidance only and should not
be used for detailed design purposes or as a substitute for specific drawings
and instructions prepared for such purposes.

Data Update
Data not finally calculated at the time of issue is marked ‘Available on re-
quest’. Such data may be made available at a later date, however, for a spe-
cific project the data can be requested. Pages and table entries marked ‘Not
applicable’ represent an option, function or selection which is not valid.
The latest, most current version of the individual Project Guide sections are
available on the Internet at: www.man-es.com --> 'Two stroke'.

Extent of Delivery
The final and binding design and outlines are to be supplied by our licensee,
the engine maker, see Chapter 20 of this Project Guide.
In order to facilitate negotiations between the yard, the engine maker and the
customer, a set of ‘Extent of Delivery’ forms is available in which the ‘Basic’
and the ‘Optional’ executions are specified.

Electronic versions
This Project Guide book and the 'Extent of Delivery' forms are available on the
internet at: www.man-es.com --> 'Two stroke'. where they can be down-
loaded.

Edition 1.0
April 2024
Preface

7020-0276-11ppr April 2024 3 (706)

 MAN Energy Solutions

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 subject to changes and will be assessed and determined individually
for each project. This will depend on the particular characteristics of each indi-
vidual project, especially specific site and operational conditions.

If this document is delivered in another language than English and doubts

arise concerning the translation, the English text shall prevail.

MAN Energy Solutions

Teglholmsgade 41
DK-2450 Copenhagen SV
Denmark
Telephone +45 33 85 11 00
Telefax +45 33 85 10 30
info-cph@man-es.com
www.man-es.com

Copyright 2024 © MAN Energy Solutions, branch of MAN Energy Solutions SE, Ger-
many, registered with the Danish Commerce and Companies Agency under CVR Nr.:
31611792, (herein referred to as "MAN Energy Solutions").
This document is the product and property of MAN Energy Solutions and is protec-
ted by applicable copyright laws. Subject to modification in the interest of technical
progress. Reproduction permitted provided source is given.
7020-0276-11ppr April 2024
Preface

4 (706) 7020-0276-11ppr April 2024

MAN Energy Solutions

Table of contents

Table of contents
01 Engine Design
The ME-GA dual-fuel engine ...................................................................................................... 1.00
Engine optimisation .................................................................................................................... 1.01
Engine type designation ............................................................................................................. 1.02
Power, speed and fuel oil ........................................................................................................... 1.03
Engine power range and fuel oil consumption ............................................................................ 1.04
Performance curves ................................................................................................................... 1.05
ME-GA engine description ......................................................................................................... 1.06
Engine cross section - TIII .......................................................................................................... 1.07

02 Engine Layout and Load Diagrams, SFOC, dot 5

Propeller layout and engine matching with margins .................................................................... 2.01
Optimum propeller speed .......................................................................................................... 2.02
Engine layout and load diagram ................................................................................................. 2.03
Special considerations for layout of propulsion plants with ME-GA engines ................................ 2.04
SFOC guarantee conditions ....................................................................................................... 2.05
Fuel consumption in an arbitrary operating point ........................................................................ 2.06

03 Turbocharger Selection & Exhaust Gas Bypass

Turbocharger selection .............................................................................................................. 3.01
Climate conditions and exhaust gas bypass .............................................................................. 3.02
Emission control ........................................................................................................................ 3.03

04 Electricity Production
Electricity production and hybrid solutions ................................................................................. 4.01
Power take-off solutions supplied by RENK ............................................................................... 4.02
Steps for obtaining approval of a PTO solution .......................................................................... 4.03
Power take off/gear constant ratio ............................................................................................. 4.04
G70ME-C10.5-GA

Waste heat recovery systems - TII ............................................................................................. 4.05

L16/24 GenSet Data .................................................................................................................. 4.06
L21/31 GenSet Data .................................................................................................................. 4.07
L23/30H Mk2 genset data ......................................................................................................... 4.08
L27/38 GenSet Data .................................................................................................................. 4.09

5 (10)
 MAN Energy Solutions

L28/32H Genset data ................................................................................................................ 4.10

Table of contents

GenSet Data .............................................................................................................................. 4.11

L23/30DF GenSet Data ............................................................................................................. 4.12
L28/32DF genset data ............................................................................................................... 4.13

05 Installation Aspects
Space requirements and overhaul .............................................................................................. 5.01
Space requirement .................................................................................................................... 5.02
Crane beam requirements - turbocharger and air cooler ............................................................ 5.03
Engine room cranes - requirements and applications ................................................................. 5.04
Engine outline, galleries and pipe connections ........................................................................... 5.05
Engine and gallery outline - TIII ................................................................................................... 5.06
Centre of gravity - TIII ................................................................................................................. 5.07
Water and oil calculation - TIII .................................................................................................... 5.08
Engine pipe connections - TIII .................................................................................................... 5.09
Counterflanges, Connections D and E ....................................................................................... 5.10
Engine seating and arrangement of holding down bolts ............................................................. 5.11
Epoxy chocks arrangement - TIII ................................................................................................ 5.12
Engine top bracing ..................................................................................................................... 5.13
Mechanical top bracing - TIII ...................................................................................................... 5.14
Hydraulic top bracing arrangement - TIII .................................................................................... 5.15
Components for engine control system ...................................................................................... 5.16
Shaftline earthing device ............................................................................................................ 5.17
MAN Alpha CPP and Alphatronic propulsion control .................................................................. 5.18

06 List of Capacities: Pumps, Coolers & Exhaust Gas

Calculation of List of Capacities ................................................................................................. 6.01
List of capacities for cooling water systems ............................................................................... 6.02
List of capacities ........................................................................................................................ 6.03
G70ME-C10.5-GA

Auxiliary machinery capacities derated engines .......................................................................... 6.04

07 Fuel
Fuel gas system - ME-GA engine ............................................................................................... 7.00
Fuel oil system ........................................................................................................................... 7.01
Fuel Oils ..................................................................................................................................... 7.02
Fuel Oil Pipes and Drain Pipes ................................................................................................... 7.03

6 (10)
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Insulation and heat tracing of fuel oil piping ................................................................................ 7.04

Table of contents
Components for Fuel Oil System ................................................................................................ 7.05
Water in fuel emulsification ......................................................................................................... 7.06
Fuel Gas Supply ........................................................................................................................ 7.07
Fuel gas supply systems ............................................................................................................ 7.08
Auxiliary systems for fuel gas supply system .............................................................................. 7.09

08 Lubricating Oil
Lubricating and cooling oil system ............................................................................................. 8.01
Hydraulic power supply unit ....................................................................................................... 8.02
Lubricating oil pipes for turbochargers ....................................................................................... 8.03
System oil list, consumption and cleaning .................................................................................. 8.04
Components and installation ...................................................................................................... 8.05
Lubricating oil tank ..................................................................................................................... 8.06
Venting and drain pipes ............................................................................................................. 8.07
Turbocharger lubricating oil system ............................................................................................ 8.08
Hydraulic control oil system ....................................................................................................... 8.09

09 Cylinder Lubrication
Cylinder oil specification and system description ........................................................................ 9.01
Alpha ACC cylinder lubrication system ....................................................................................... 9.02

10 Piston Rod Stuffing Box Drain Oil

Stuffing Box Drain Oil System .................................................................................................. 10.01

11 Low-temperature Cooling Water

Low-temperature Cooling Water System ................................................................................. 11.01
Central cooling water system ................................................................................................... 11.02
Components for central cooling water system ......................................................................... 11.03
Seawater Cooling System ........................................................................................................ 11.04
Components for Seawater Cooling System .............................................................................. 11.05
G70ME-C10.5-GA

Combined Cooling Water System ............................................................................................ 11.06

Components for Combined Cooling Water System .................................................................. 11.07
Cooling Water Pipes for Scavenge Air Cooler ........................................................................... 11.08

12 High-temperature Cooling Water

High-temperature cooling water system ................................................................................... 12.01

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Components ............................................................................................................................ 12.02

Table of contents

Jacket Cooling Water Pipes ..................................................................................................... 12.03

Liquid fuel gas vaporisation ...................................................................................................... 12.04

13 Starting and Control Air

Starting and control air systems ............................................................................................... 13.01
Components for Starting Air System ........................................................................................ 13.02
Piping ...................................................................................................................................... 13.03
Electric motor for turning gear .................................................................................................. 13.04

14 Scavenge Air
Scavenge Air System ............................................................................................................... 14.01
Auxiliary blowers ...................................................................................................................... 14.02
Scavenge air pipes .................................................................................................................. 14.03
Electric motor for auxiliary blower ............................................................................................. 14.04
Scavenge air cooler cleaning system ....................................................................................... 14.05
Scavenge air box drain system ................................................................................................ 14.06
Fire extinguishing systems for scavenge air space ................................................................... 14.07

15 Exhaust Gas
Exhaust gas system ................................................................................................................. 15.01
Piping and cleaning systems .................................................................................................... 15.02
Exhaust Gas System for Main Engine ....................................................................................... 15.03
System components ................................................................................................................ 15.04
Calculation of exhaust gas back-pressure ................................................................................ 15.05
Forces and moments at turbocharger ...................................................................................... 15.06
Diameter of exhaust gas pipes ................................................................................................. 15.07

16 Engine Control System

Dual-fuel engine control system ............................................................................................... 16.00
Units, layout and interfaces ...................................................................................................... 16.01
G70ME-C10.5-GA

Engine control system – second fuel extensions and interfaces ............................................... 16.02

17 Vibration Aspects
Vibration aspects ..................................................................................................................... 17.01
First and second order moments ............................................................................................. 17.02
Electrically Driven Moment Compensator ................................................................................. 17.03

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Power related unbalance ......................................................................................................... 17.04

Table of contents
Guide force moments .............................................................................................................. 17.05
Axial and torsional vibrations .................................................................................................... 17.06
External forces and moments, G70ME-C10.5-GA, layout point L1 ........................................... 17.07

18 Monitoring Systems and Instrumentation

Monitoring systems and instrumentation .................................................................................. 18.01
Engine Management Services .................................................................................................. 18.02
Condition Monitoring System CoCoS-EDS .............................................................................. 18.03
Slow down and shut down ...................................................................................................... 18.04
Local instruments .................................................................................................................... 18.05
Engine protection systems and alarms ..................................................................................... 18.06
Identification of instruments ..................................................................................................... 18.07
ME-GA safety aspects ............................................................................................................. 18.08

19 Dispatch Pattern, Testing, Spares and Tools

Dispatch pattern, testing, spares and tools .............................................................................. 19.01
Specification for Painting of main Engine .................................................................................. 19.02
Dispatch Pattern ...................................................................................................................... 19.03
Dispatch Pattern, List of Masses and Dimensions .................................................................... 19.04
Shop test ................................................................................................................................. 19.05
List of spare parts, unrestricted service .................................................................................... 19.06
Additional spares ..................................................................................................................... 19.07
Wearing Parts .......................................................................................................................... 19.08
Large spare parts, dimensions and masses ............................................................................. 19.09
List of standard tools for maintenance ..................................................................................... 19.10
Tool panels .............................................................................................................................. 19.11
Tools and special tools ............................................................................................................ 19.12

20 Project Support and Documentation

G70ME-C10.5-GA

Project support and documentation ......................................................................................... 20.01

CEAS application ..................................................................................................................... 20.02
Extent of delivery ..................................................................................................................... 20.03
Installation documentation ....................................................................................................... 20.04
ME-GA Installation documentation ........................................................................................... 20.05

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21 Appendix
Table of contents

Symbols for piping ................................................................................................................... 21.00

61395407755
G70ME-C10.5-GA

10 (10)
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
01 Engine Design

20 Project Support and Documentation

21 Appendix
61395409547

1 (1)
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01 Engine Design
 MAN Energy Solutions 199 14 58-2.0

The ME-GA dual-fuel engine

The development in fuel prices in combination with emission control regula-
tions has created a need for dual-fuel engines.
Although the ME-GA engine has been based on our ME engine technology, it
is an engine based on a pre-mixed gas principle, where pilot oil ignites an air-
fuel mixture.
In this project guide, second fuel, fuel gas or gas are the denominations for
methane. The fuel gas supply system (FGSS) delivers low-pressure gas to the
fuel gas admission system on the engine. This means that the engine runs on
pre-mixed gas in dual-fuel mode.
Based on the well-proven MAN dual-fuel design with minimal installation re-
quirements, the MAN B&W ME-GA engine uses an efficient ignition concept
and a gas admission system that gives a safe and reliable operation at the
lowest possible cost.
The ME-GA engine includes exhaust gas recirculation (EGR) as standard. This
ensures Tier III compliance in dual-fuel mode and in fuel-oil-only mode. EGR
also reduces methane slip emissions by up to 50% compared to two-stroke
Otto-cycle engines without EGR.

ME-GA admission system

By using a unique gas admission system, the ME-GA engine ensures minimal
installation and operating costs, and delivers best-in-class reliability. This is all
possible due to our patented engine design, including an on-engine gas regu-
lating valve and a bypass system, which enables depressurisation of the sys-
tem without a dedicated double-walled blow-off piping.
Different types of valves are used for the admission of fuel gas and the injec-
tion of pilot oil. The main subsystems required for both fuel oil and dual-fuel
operation are:
▪ On-engine fuel gas components
▪ Fuel oil (pilot oil supplied by the existing ME fuel oil system)
▪ Control oil for actuation of safe gas admission valves (SGAV)
▪ Sealing oil to separate gas and control oil. 1.00 The ME-GA dual-fuel engine
2022-03-29 - en

ME-GA engines 1 (5)

199 14 58-2.0 MAN Energy Solutions

Fig. 1.00.01: The ME-GA engine top with the gas regulating unit, SGAVs and
fuel gas pipes

ME-GA vs ME engine design

Although few technical differences separate fuel oil and fuel gas burning en-
gines, the ME-GA engine provides the optimal fuel flexibility.
The pre-mixed gas combustion principle of the ME-GA engine and the low-
pressure gas admission system facilitate the use of an FGSS at low CAPEX,
while offering Tier III compliant NOx levels.
1.00 The ME-GA dual-fuel engine

Fig. 1.00.01 shows the ME-GA engine design including the newly developed
gas regulating unit and the SGAV.
The ME-GA engine with one double-walled pipe installation with bi-directional
flow and SGAVs is developed to enhance engine operation and avoid poten-
tial gas leakages.
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The added systems and related functions for dual-fuel operation are:
▪ Fuel gas supply system for distributing low-pressure gas to the SGAV with
built-in window valve on each cylinder
▪ Leakage detection and ventilation system for detecting leakages and
venting the space between the inner and outer pipe of the double-walled
piping. Inlet air is taken from a non-hazardous area and exhausted outside
the engine room
▪ Sealing oil system, delivering sealing oil to the SGAV, separating control oil
and fuel gas. The system is fully integrated on the engine, the shipyard
does not need to consider this installation

2 (5) ME-GA engines

 MAN Energy Solutions 199 14 58-2.0

▪ Inert gas system that enables purging of the gas system on the engine
with inert gas
▪ Control and safety system, comprising a hydrocarbon analyser for check-
ing the space between the inner and outer pipe of the double-walled pip-
ing.

Engine operating modes

One main advantage of the ME-GA engine is its fuel flexibility. The control
concept comprises different fuel modes:
▪ dual-fuel operation with minimum pilot oil amount, see Fig. 1.00.02
▪ fuel-oil-only mode
▪ specified dual-fuel (SDF) mode.

1.00 The ME-GA dual-fuel engine

Fig. 1.00.02: Operating characteristics for the different fuel modes

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The dual-fuel operating mode is used for gas operation. It can only be started
manually by an operator on the main operating panel (MOP) in the control
room.
The ME-GA engine will be equipped with a dedicated pilot valve, the micro
booster injection valve (MBIV). The MBIV is based on our existing fuel booster
injection valve (FBIV) design. The pilot oil fraction is 0.5%, and the fuels are
0.5% VLSFO or MGO/MDO.
The MBIV shares the same fuel oil supply system as the main fuel oil injectors,
but on the engine, the fuel oil is split between the main injectors and the pilot
oil system.

ME-GA engines 3 (5)

199 14 58-2.0 MAN Energy Solutions

In general, if a failure occurs in the fuel gas system it will result in a fuel gas
shutdown and a return to the fuel-oil-only mode.
The fuel-oil-only mode is known from the ME engine. Operating the engine in
this mode can only be done on fuel oil, and the engine is considered gas safe.
The specified dual-fuel mode is based on economic considerations and the
decision to run the ME-GA engine on fuel oil or gas, and as such is applicable
for LNG carriers and LNG fuelled vessels. In principle, the operation can con-
tinue on either fuel oil or gas depending on availability and feasibility.
SDF-operation: The ME-GA engine runs on a mixture of gas and fuel oil. The
FGSS specifies a maximum limit of gas flow (“SF Load Limit signal”) to the
ME-ECS for propulsion. During SDF-operation, the amount of gas injected
can be adjusted to the available gas supply flow limit. If the required engine
load cannot be sustained within the “SF Load Limit”, the ECS will adjust the
gas injection amount according to the limit by increasing the fuel oil injection
amount.
The SDF mode can only be activated by the FGSS control system.
In cases, where the gas flow is insufficient at a specific engine load, fuel oil will
automatically be added to compensate the flow requirement.
The gas to fuel oil ratio must be kept within the SDF range to maintain a reli-
able combustion process. If the range is exceeded, the engine will automatic-
ally switch to the fuel-oil-only running mode, and gas stand by.
Currently, we expect that a gas to diesel ratio of 10-30% is realistic above
40% engine load.
SDF operation is a compromise compared to dual-fuel and/or fuel-oil opera-
tion. It means that the SDF mode is characterised by a reduced engine effi-
ciency, an increased methane slip, and increased NOx emissions. As such,
Tier III compliance is not guaranteed in SDF mode and in addition, this mode
is not IMO certified.
Once SDF is logged in the system, an alarm is released and the bridge re-
ceives an indication of lack of Tier III compliance. SDF should be specified in
the design specification order.

Safety
1.00 The ME-GA dual-fuel engine

The ME-GA control and safety system is designed to fail to safe condition. All
failures detected during fuel gas running result in a fuel gas stop and a
changeover to fuel oil operation. This condition applies also to failures of the
control system itself.
Following the changeover, the fuel gas pipes and the complete fuel gas sup-
2022-03-29 - en

ply system are blown out and freed from gas by purging.
The changeover to fuel-oil-mode is always done without any power loss of the
engine.

4 (5) ME-GA engines

 MAN Energy Solutions 199 14 58-2.0

Fuel gas supply systems

Different applications call for different fuel gas supply systems, and operators
and shipowners demand alternative solutions.
Therefore, MAN Energy Solutions aims to have a number of different fuel gas
supply systems prepared, tested and available. Section 7.08 shows examples
of fuel gas supply systems.
9007256678361227

1.00 The ME-GA dual-fuel engine

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ME-GA engines 5 (5)

199 14 58-2.0 MAN Energy Solutions

9007256678361227
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1.00 The ME-GA dual-fuel engine

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ME-GA engines
 MAN Energy Solutions 199 15 58-8.0

Engine optimisation
The ever valid requirement of ship operators is to obtain the lowest total oper-
ational costs, and especially the lowest possible specific fuel oil consumption
at any load, and under the prevailing operating conditions.
However, low-speed two-stroke main engines of the MC-C type, with a chain
driven camshaft, have limited flexibility with regard to fuel injection and ex-
haust valve activation, which are the two most important factors in adjusting
the engine to match the prevailing operating conditions.
A system with electronically controlled hydraulic activation provides the re-
quired flexibility, and such systems form the core of the ME Engine Control
System, described later in detail in Chapter 16.

Concept of the ME Engine

The ME engine concept consists of a hydraulic mechanical system for activa-
tion of the fuel injection and the exhaust valves. The actuators are electronic-
ally controlled by a number of control units forming the complete engine con-
trol system.
MAN Energy Solutions has specifically developed both the hardware and the
software in-house, in order to obtain an integrated solution for the engine con-
trol system.
The fuel pressure booster consists of a simple plunger powered by a hydraulic
piston activated by oil pressure. The oil pressure is controlled by an electron-
ically controlled proportional valve.
The exhaust valve is opened hydraulically by means of a two-stroke exhaust
valve actuator activated by the control oil from an electronically controlled pro-
portional valve. The exhaust valves are closed by the ‘air spring’.
In the hydraulic system, the normal lube oil is used as the medium. It is filtered
and pressurised by a hydraulic power supply unit mounted on the engine or
placed in the engine room.
The starting valves are opened pneumatically by electronically controlled ‘On/
Off’ valves, which make it possible to dispense with the mechanically activ-
ated starting air distributor.
By electronic control of the fuel injection and exhaust valves according to the
measured instantaneous crankshaft position, the Engine Control System fully
controls the combustion process.
System flexibility is obtained by means of different ‘Engine running modes’,
1.01 Engine optimisation

which are selected either automatically, depending on the operating condi-

tions, or manually by the operator to meet specific goals. The basic running
2022-01-20 - en

mode is ‘Fuel economy mode’ to comply with IMO NOx emission limitation.

Engine Design and IMO Regulation Compliance

The ME-C engine is the shorter, more compact version of the ME engine. It is
well suited wherever a small engine room is requested, for instance in con-
tainer vessels.
For MAN B&W ME/ME-C-TII designated engines, the design and performance
parameters comply with the International Maritime Organisation (IMO) Tier II
emission regulations.

95-35ME-GI/-LGI/-GA 1 (2)
199 15 58-8.0 MAN Energy Solutions

For engines built to comply with IMO Tier I emission regulations, please refer
to the Marine Engine IMO Tier I Project Guide.

Tier II Fuel Optimisation

NOx regulations place a limit on the SFOC on two-stroke engines. In general,
NOx emissions will increase if SFOC is decreased and vice versa. In the stand-
ard configuration, MAN B&W engines are optimised close to the IMO NOx limit
and, therefore, NOx emissions cannot be further increased.
The IMO NOx limit is given as a weighted average of the NOx emission at 25,
50, 75 and 100% load. This relationship can be utilised to tilt the SFOC profile
over the load range. This means that SFOC can be reduced at part load or
low load at the expense of a higher SFOC in the high-load range without ex-
ceeding the IMO NOx limit.
Optimisation of SFOC in the part-load (50-85%) or low-load (25-70%) range
requires implementation of the exhaust gas bypass (EGB) tuning method. This
tuning method makes it possible to optimise the fuel consumption at part- or
low-load, while maintaining the possibility of operating at high load when
needed.
The tuning method is available for all SMCR in the specific engine layout dia-
gram. The SFOC reduction potential of the EGB tuning method in partand
low-load is shown in Section 1.03.
For S40ME-B/GI and smaller, as well as for engine types 45 and larger with
conventional turbochargers, only high-load optimisation is applicable.
In this project guide, data is based on high-load optimisation unless explicitly
noted. For derated engines, calculations can be made in the CEAS application
described in Section 20.02.

Improved fuel consumption on gas fuel

In the ME-GI concept, NOx is reduced substantially on gas fuel compared to
diesel/HFO operation. As much as possible of this NOx margin is exchanged
for improved SFOC, while not exceeding the E3 NOx cycle value for the diesel
reference case. (Referring to the international standard for exhaust emission
measurement ISO 8178). This SFOC optimisation is available in the entire load
range..
Calculations of SFOC can be made in the CEAS application for engines with
and without EGB tuning installed.
9007252005776651
1.01 Engine optimisation

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2 (2) 95-35ME-GI/-LGI/-GA
 MAN Energy Solutions 198 38 24-3.11

Engine type designation

1.02 Engine type designation

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9007238558655371

All Engines 1 (1)

198 38 24-3.11 MAN Energy Solutions

9007238558655371
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1.02 Engine type designation

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All Engines
 MAN Energy Solutions 199 14 77-3.1

Power, speed and fuel oil

Fig. 1.03.01: Power, speed and fuel

9007254179875979

1.03 Power, speed and fuel oil

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G70ME-C10.5-GA 1 (1)
199 14 77-3.1 MAN Energy Solutions

9007254179875979
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1.03 Power, speed and fuel oil

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G70ME-C10.5-GA
 MAN Energy Solutions 199 18 94-2.0

Engine power range and fuel oil consumption

Engine Power
The following tables contain data regarding the power, speed and specific fuel
oil consumption of the engine.
Engine power is specified in kW for each cylinder number and layout points
L1, L2, L3 and L4.
For conversions between kW and metric horsepower, please note that 1 BHP
= 75 kpm/s = 0.7355 kW.
L1 designates nominal maximum continuous rating (nominal MCR), at 100%
engine power and 100% engine speed.
L2, L3 and L4 designate layout points at the other three corners of the layout
area, chosen for easy reference.

1.04 Engine power range and fuel oil consumption

Fig. 1.04.01: Layout diagram for engine power and speed

Overload corresponds to 110% of the power at MCR, and may be permitted

for a limited period of one hour every 12 hours.
The engine power figures given in the tables remain valid up to tropical condi-
tions at sea level as stated in IACS M28 (1978), i.e.:
Blower inlet temperature ................................ 45°C
Blower inlet pressure ............................1,000 mbar
Seawater temperature .................................... 32°C
Relative humidity ..............................................60%
2022-07-26 - en

Gas consumption
The gas consumption is governed by the heat rate required to be supplied
from the fuel for the engine to develop a given power. The pilot oil amount is
absolute per firing, so the gas consumption is determined by subtracting the
heat rate supplied by the pilot oil from the total heat rate and convert this into
g/kWh, considering the lower calorific value of the gas in question. An LCV of
50,000 k/kg is used as per standard for methane as related equivalent fuel
consumption, i.e. with all our usual figures.

ME-GA 1 (2)
199 18 94-2.0 MAN Energy Solutions

Example:
Heat rate at 75% load .......... 6618kJ/kWh
Ref. LCV of pilot fuel .............42,700 kJ
Ref LCV methane...................50,000 kJ/kg
Pilot oil consumption...............1.18 g/kWh
Pilot oil heat rate......................0.00118 x 42,700 = 50 kJ/kWh"
Gas heat rate...........................6,618 - 50 = 6,568 kJ/kWh
Gas consumption....................6,568 / 50,000 = 131.4 g/kWh
The heat rate is also referred to as the ‘Guiding Equivalent Energy Consump-
tion’.

Specific fuel oil consumption (SFOC)

The figures given in this folder represent the values obtained when the engine
and turbocharger are matched with a view to obtaining the lowest possible
SFOC values while also fulfilling the IMO NOX emmsion limitations.
The SFOC figures are given in g/kWh with a tolerance of 5% and are based
on the use of fuel with a lower calorific value of 42,700 kJ/kg (~10,200 kcal/
kg) at ISO conditions:
Ambient air pressure .............................1,000 mbar
Ambient air temperature ................................ 25°C
Cooling water temperature ............................ 25°C
Specific fuel oil consumption varies with ambient conditions and fuel oil lower
calorific value. For calculation of these changes, see Chapter 2.
For the otto cycle ME-GA engine, SFOC in oil mode is higher than the equival-
ent SFOC consumption (i.e. heat rate calculated into equivalent amount of
1.04 Engine power range and fuel oil consumption

MDO) in gas mode, as the process is optimised for gas mode.

Lubricating oil data

The cylinder oil consumption figures stated in the tables are valid under nor-
mal conditions.
During running-in periods and under special conditions, feed rates can be in-
creased. This is explained in Section 9.02.
61669019531

2022-07-26 - en

2 (2) ME-GA
 MAN Energy Solutions 198 53 31-6.2

Performance curves
Updated engine and capacities data is available from the CEAS program on
www.marine.man-es.com --> ’Two-Stroke’ --> ’CEAS Engine Calculations’.
9007250728817291

1.05 Performance curves

2022-11-16 - en

MC/MC-C, ME/ME-C/ME-B/-GI/-GA 1 (1)

198 53 31-6.2 MAN Energy Solutions

9007250728817291
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1.05 Performance curves

2022-11-16 - en

MC/MC-C, ME/ME-C/ME-B/-GI/-GA
 MAN Energy Solutions 199 18 17-7.0

ME-GA engine description

General
Engines built by MAN Energy Solutions' licensees are in accordance with our
drawings and standards. In certain cases, local standards may be applied but
all spare parts are interchangeable with parts designed by MAN Energy Solu-
tions.
Some components may differ from MAN Energy Solutions’ design because of
local production facilities, or the application of local standard components.
In the following, reference is made to item numbers specified in ‘Extent of De-
livery’ (EoD) forms, both for ‘Basic’ delivery and for some ‘Options’.

Bedplate and main bearing

The bedplate consists of high welded longitudinal girders and welded cross
girders with cast steel bearing supports. Long elastic holding-down bolts and
hydraulic tightening tools are used to fit the bedplate to the engine seating in
the ship. The bedplate is made with the thrust bearing in the aft end.
For engines mounted on epoxy chocks, the bedplate is made without taper.
An oil pan made of steel plate is welded to the bedplate. The oil pan, collects
return oil from the forced lubricating and cooling oil system. Oil outlets from
the oil pan are vertical as standard and provided with gratings.
The main bearings consist of thin-walled steel shells lined with white metal.
The main bearing bottom shell can be rotated out and in with special tools
and hydraulic tools for lifting the crankshaft. A bearing cap keeps the shells in
position.

Frame box
The frame box is welded. On the exhaust side of the frame box, a relief valve
is mounted for each cylinder. On the manoeuvring side, each cylinder has a
large hinged door. Crosshead guides are welded onto the frame box. The
frame box is bolted to the bedplate. Stay bolts tighten together bedplate,
frame box, and cylinder frame.
1.06 ME-GA engine description

Cylinder frame and stuffing box

The cylinder frame is cast and provided with access covers for:
2023-06-14 - en

▪ Cleaning the scavenge air space (if required)

▪ Inspection of scavenge ports and piston rings from the manoeuvring side.
The cylinder frame and cylinder liner forms the scavenge air space.
The cylinder frame is fitted with pipes for the piston cooling oil inlet. The scav-
enge air receiver, turbocharger, air cooler box, and gallery brackets are placed
on the cylinder frame. The bottom of the cylinder frame contains the piston
rod stuffing box with sealing rings for scavenge air, and oil scraper rings pre-
venting crankcase oil from entering the scavenge air space.
Scavenge air space and piston rod stuffing box drains are located in the bot-
tom of the cylinder frame.

ME-GA 1 (9)
199 18 17-7.0 MAN Energy Solutions

Cylinder liner
A cylinder liner made of alloyed cast iron is suspended in the cylinder frame
with a low-situated flange. The top of the cylinder liner is fitted with a cooling
jacket. The cylinder liner has scavenge ports, drilled holes for cylinder lubrica-
tion and gas admission.
On engines with bore sizes 95-80, the basic design includes cylinder liners
prepared for installation of temperature sensors. On all other engines, this liner
type is available as an option.

Cylinder cover
The cylinder cover of forged steel is made in one piece with bores for cooling
water. It has a central bore for the exhaust valve, bores for fuel valves, pilot
valves, starting valve, and indicator valve.
The bore for the indicator valve is also used for PMI Auto-tuning.

Crankshaft
The crankshaft is of the semi-built type made from forged or cast steel
throws. Depending on the number of cylinders, the crankshaft may be sup-
plied in two parts.
At the aft end, the crankshaft is provided with:
▪ Collar for thrust bearing
▪ Flange for gearwheel for step-up gear for the hydraulic power supply unit
(if fitted on the engine)
▪ Flange for turning wheel, and coupling bolts to the intermediate shaft.
At the front end, the crankshaft has a collar for an axial vibration damper and
a flange for fitting a tuning wheel. The flange can also be used for a potential
power take off installation. Normally, coupling bolts and nuts for joining the
crankshaft with the intermediate shaft are not supplied.

Thrust bearing
The propeller thrust is transferred through thrust collar, segments, and bed-
1.06 ME-GA engine description

plate to end chocks and engine seating, and to the ship’s hull.
A thrust bearing of the B&W-Michell type is located in the aft end of the en-
gine. It consists primarily of a thrust collar on the crankshaft, bearing support,
and segments of steel lined with white metal.
2023-06-14 - en

Engines with nine cylinders or more are specified with a 360-degree type
thrust bearing, while a 240-degree type is used for all other engines. The flex-
ible thrust cam design of MAN Energy Solutions' is used for the thrust collar
on a range of engine types.
The thrust shaft is an integrated part of the crankshaft, and it is lubricated by
the engine’s lubricating oil system.

2 (9) ME-GA
 MAN Energy Solutions 199 18 17-7.0

Step-up gear
For a mechanically engine-driven hydraulic power supply, the crankshaft
drives the main hydraulic oil pumps via a step-up gear. The main engine lub-
ricating oil system lubricates the step-up gear.

Turning gear and turning wheel

The turning wheel is fitted to the thrust shaft, and it is driven by a pinion on the
terminal shaft of the turning gear arrangement mounted on the bedplate. The
turning gear is driven by an electric motor with a built-in brake.
A blocking device prevents the main engine from starting when the turning
gear is engaged. Engagement and disengagement of the turning gear is done
manually by moving the pinion.
The basic design includes a control device for the turning gear, consisting of
starter and manual control box.

Axial vibration damper

The engine is fitted with an axial vibration damper mounted on the fore-end of
the crankshaft. The damper consists of a piston and a split-type housing loc-
ated forward of the foremost main bearing.
The piston is made as an integrated collar on the main crank journal, and the
housing is fixed to the main bearing support.
The vibration damper has a mechanical guide to enable a functional check, an
optionally electronic vibration monitor can be supplied.
Engines Mk. 9 and higher require an axial vibration monitor, which indicates
condition checks of the axial vibration damper, and terminals for alarm and
slowdown.

Tuning wheel / torsional vibration damper

Depending on the final torsional vibration calculations, it may be necessary to
order a tuning wheel or a torsional vibration damper, separately. 1.06 ME-GA engine description
Connecting rod
The connecting rod is made of forged or cast steel and provided with bearing
caps for the crosshead and crank pin bearings.
2023-06-14 - en

The crosshead and crank pin bearing caps are secured to the connecting rod
with studs and nuts tightened with hydraulic jacks.
The crosshead bearing consists of a set of thin-walled steel shells, lined with
bearing metal. The crosshead bearing cap is in one piece, with an angular cut
out for the piston rod.
The crank pin bearing is provided with thin-walled steel shells, lined with bear-
ing metal. Lubricating oil is supplied through ducts in the crosshead and con-
necting rod.

ME-GA 3 (9)
199 18 17-7.0 MAN Energy Solutions

Piston
The piston consists of a piston crown and a piston skirt. The piston crown is
made of heat-resistant steel. A piston cleaning ring located in the very top of
the cylinder liner scrapes off excessive ash and carbon formations on the pis-
ton topland.
The piston has three or four ring grooves which are hard-chrome plated on
both the upper and lower surfaces of the grooves. Three or four piston rings
are fitted depending on the engine type.
The uppermost piston ring is always a controlled pressure relief (CPR) ring
type, whereas the other two or three piston rings are either of the CPR type,
or have an oblique cut. Depending on the engine type, the uppermost piston
ring is higher than the others. All rings are alu-coated on the outer surface for
running-in.
The piston skirt is made of cast iron with a bronze band or molybdenum coat-
ing.

Piston rod
The piston rod is of forged steel and the running surface for the stuffing box is
surface hardened. The piston rod is connected to the crosshead with four
bolts. The piston rod has a central bore which, together with the cooling oil
pipe, forms the cooling oil inlet and outlet.

Crosshead
A crosshead of forged steel is provided with cast steel guide shoes with white
metal on the running surface. The guide shoe is of the low-friction type, and
the crosshead bearings are of the wide pad design. The telescopic pipe for oil
inlet and the pipe for oil outlet are mounted on the guide shoes.

Scavenge air system

The turbocharger draws air directly from the engine room through the tur-
bocharger intake silencer. From the turbocharger, the air is led via the char-
ging air pipe, air cooler, and scavenge air receiver to the scavenge ports of
1.06 ME-GA engine description

the cylinder liners, see Chapter 14. The scavenge air receiver has a D-shape
design.

Scavenge air cooler

2023-06-14 - en

Each turbocharger has a scavenge air cooler of the mono-block type.

The scavenge air cooler is most commonly cooled by freshwater from a cent-
ral cooling system. Alternatively, it can be cooled by seawater from a seawater
cooling system, or from a combined cooling system with separate seawater
and freshwater pumps. The working pressure is up to 4.5 bar.
The scavenge air cooler is designed to keep the temperature difference
between the scavenge air and the water inlet at about 6°C, at specified MCR.

4 (9) ME-GA
 MAN Energy Solutions 199 18 17-7.0

Auxiliary blower
The engine is provided with electrically-driven scavenge air blowers integrated
in the scavenge air cooler. The suction side of the blowers is connected to the
scavenge air space after the air cooler.
Between the air cooler and the scavenge air receiver, non-return valves are fit-
ted which automatically close when the auxiliary blowers supply the air.
To obtain a safe start, the auxiliary blowers start consecutively before the en-
gine is started to ensure sufficient scavenge air pressure.
Find more information in Chapter 14.

Exhaust gas system

From the exhaust valves, exhaust gas is led to the exhaust gas receiver where
the fluctuating pressure from the individual cylinders is equalised, and the total
volume of gas is led to the turbocharger(s). After the turbocharger(s), the gas
is led to the external exhaust pipe system.
Compensators are fitted between the exhaust valves and the receiver, and
between the receiver and the turbocharger(s).
The exhaust gas receiver and exhaust pipes are insulated and covered by gal-
vanised steel plating.
A protective grating is installed between the exhaust gas receiver and the tur-
bocharger.
For your information, the EGR system is mandatory on the ME-GA engine.

Exhaust turbocharger
The engines can be fitted with either MAN, Accelleron, or MHI turbochargers.
The turbocharger selection is described in Chapter 3, and the exhaust gas
system in Chapter 15.

Reversing
The engine is reversed electronically by the engine control system which
1.06 ME-GA engine description
changes the timing of fuel injection, exhaust valve activation, and starting air
valves.

2nd order moment compensators

2023-06-14 - en

In general, 2nd order moment compensators are relevant only for 5- and 6-
cylinder engines. The compensators can be mounted either on the aft end, or
on the fore and aft end of the engine.
The aft-end compensator consists of chain-driven balance weights. The fore-
end compensator consists of balance weights driven by the fore end of the
crankshaft.
Section 17.02 describes 2nd order moment compensators as well as the ba-
sic design and options.

ME-GA 5 (9)
199 18 17-7.0 MAN Energy Solutions

The hydraulic power supply

The hydraulic power supply (HPS) filters and pressurises the lube oil for the
hydraulic system. The HPS consists of either mechanically driven (by the en-
gine) main pumps with electrically driven start-up pumps or electrically driven
combined main and start-up pumps. The hydraulic pressure is 300 bar.
The engine driven HPS is mounted aft on the engine, for engines with the
chain drive placed aft (8 cylinders or less). For engines with the chain drive
located in the middle (9 cylinders or more), the HPS is placed in the middle.
Usually, the electrically driven HPS is mounted aft on the engine.
A combined HPS is available as an option, it is mechanically driven with elec-
trically driven start-up/back-up pumps with backup capacity.

Hydraulic cylinder unit

The hydraulic cylinder unit (HCU), one per cylinder, consists of a distributor
block mounted on a base plate. The distributor block has one or more accu-
mulators to ensure the necessary peak flow of hydraulic oil during the elec-
tronically controlled fuel injection.
The distributor block serves as mechanical support for the hydraulically activ-
ated fuel pressure booster and the hydraulically activated exhaust valve actu-
ator.

Fuel oil injection

The engine has one hydraulically activated fuel oil pressure booster for each
cylinder. fuel oil high-pressure pipes are of the double-wall type with built-in
conical support. The pipes are insulated, but not heated. A ‘fuel oil leakage’
system on detects leakages, and if a leakage is detected, it immediately stops
the injection on the affected cylinder.
On the ME-GA engine, two separate valves inject fuel oil and pilot oil. The in-
jection of fuel oil is activated by a multi-way valve termed either electronic fuel
injection (ELFI) or fuel injection valve actuation (FIVA). The pilot fuel is injected
by a self-contained micro-boosted injection valve (MBIV). The valves are elec-
tronically controlled by the cylinder control unit (CCU) of the engine control
system.
1.06 ME-GA engine description

An automatic vent slide in the fuel valve allows the fuel oil to circulate through
the fuel valve and high-pressure pipes when the engine is stopped. If the valve
spindle sticks, the vent slide also prevents the compression chamber from be-
ing filled with fuel oil. Oil from the vent slide and other drains is led away in a
2023-06-14 - en

closed system. Chapter 7 contains further information.

Gas admission
The gas valve train (GVT) supplies gas to a gas regulating unit (GRU) in the
gas chain pipe system. The GRU regulates the gas pressure in the chain pipe
which distributes gas to two safe gas admission valves (SGAV) on each cylin-
der The admission of gas is controlled by a window valve (WV) and a gas ad-
mission valve (GAV). The electronic window valve (ELWI) controls opening of
the window valve, and an electronic gas admission valve (ELGA) controls
opening of the gas admission valve.

6 (9) ME-GA
 MAN Energy Solutions 199 18 17-7.0

Gas pipes are double walled, with the outer shielding pipe designed to pre-
vent gas outflow to the machinery space if leakages occur, or if the inner gas
pipe ruptures.
A separate mechanical ventilation system with a capacity of 30 air changes
per hour vents the intervening gas pipe space, including the space around
valves, flanges, etc. Any gas leakage is led to the ventilated part of the
double-walled piping system where hydrocarbon (HC) sensors detect the
leakage.
The pressure in the intervening gas pipe space is kept below the engine room
pressure. The extractor fan motor is placed outside the duct and the ma-
chinery space. Ventilation inlet air must be drawn from a gas safe area and
exhausted to a safe place.
The gas pipes on the engine are designed for, and pressure tested at a pres-
sure, which is 50% higher than the normal working pressure. Gas pipes are
supported to avoid mechanical vibrations, and they should be protected
against drops of heavy items as well.
The chain piping to the individual cylinders is flexible to cope with mechanical
stress from the thermal expansion of the engine when going from cold to hot
conditions.
The gas pipe system is designed to avoid excessive gas pressure fluctuations
during operation.
The gas pipes must be connected to an inert gas purging system.

Purge block
The purge block is a square steel block bolted onto the end adapter block on
the last cylinder.
The purge block supplies nitrogen to the gas injection system during purging,
and a double block and bleed valve setup controls the purging sequences.
The purge block also contains the connection for ventilation air.

Starting Valves
Starting air is supplied to each cylinder by a solenoid valve which is controlled
by the CCUs of the engine control system.
1.06 ME-GA engine description
The starting air valve is opened by control air and closed by a spring. Opening
of the starting air valve is controlled by the CCU in the engine control system.
Before starting the engine, slow turning is initiated by a program incorporated
in the basic engine control system.
2023-06-14 - en

Section 13.01 describes the starting air system.

Exhaust valve
The exhaust valve consists of the valve housing with spindle guide, and the
valve spindle. The valve housing is an uncooled Millennium type of cast iron
with a water-cooled bottom piece of steel, which is flame-hardened and of the
Wide-seat type. The exhaust valve spindle is a DSA760-type.
The exhaust valve is tightened to the cylinder cover with studs and nuts. The
exhaust valve is opened hydraulically by the electronic valve activation system
and closed by an air spring.

ME-GA 7 (9)
199 18 17-7.0 MAN Energy Solutions

The exhaust valve is of the low-force design. Operation of the exhaust valve is
controlled by a multi-way valve (ELVA or FIVA). In operation, the valve spindle
rotates slowly, driven by the exhaust gas acting on a vane wheel fixed to the
spindle.
Sealing of the exhaust valve spindle guide is obtained with an oil bath, or con-
trolled oil level (COL), in the bottom of the air cylinder above the sealing ring.
This oil bath lubricates the exhaust valve spindle guide and sealing ring.

Indicator cock
The engine has an indicator cock for connection of the PMI pressure trans-
ducer.

MAN B&W alpha cylinder lubrication

The electronically controlled MAN B&W Alpha cylinder lubrication system is
applied to the ME engines, and controlled by the ME Engine Control System.
The main advantages of the MAN B&W Alpha cylinder lubrication system,
compared with the conventional mechanical lubricator, are:
• Improved injection timing
• Increased dosage flexibility
• Constant injection pressure
• Improved oil distribution in the cylinder liner
• Possibility for prelubrication before starting.
More details about the cylinder lubrication system can be found in Chapter 9.

Gallery arrangement
The engine is provided with gallery brackets, stanchions, railings, and plat-
forms (exclusive of ladders). The positions of the brackets are carefully chosen
to provide the best possible overhauling and inspection conditions.
Some of the main pipes for the engine are suspended from the gallery brack-
ets, and the topmost gallery platform on the manoeuvring side has holes for
overhauling pistons.
The engine is prepared for installation of top bracings on the exhaust side, or
on the manoeuvring side.
1.06 ME-GA engine description

Piping arrangement
The engine is delivered with piping arrangements for:
2023-06-14 - en

▪ Fuel oil
▪ Gas
▪ Inert Gas
▪ Heating fuel oil
▪ Lubricating oil, piston cooling oil and hydraulic oil
▪ Cylinder lubricating oil
▪ Cooling water to scavenge air cooler
▪ Jacket and turbocharger cooling water
▪ Cleaning of turbocharger

8 (9) ME-GA
 MAN Energy Solutions 199 18 17-7.0

▪ Fire extinguishing in scavenge air space

▪ Starting air
▪ Control air
▪ Various drain pipes.
All piping arrangements are made of steel piping, except the piping for control
air and steam heating of fuel pipes, which is of copper.
The piping has sockets for local instruments, alarm and safety equipment, and
several sockets for supplementary signal equipment.
Chapter 18 contains more information about instrumentation.
27021657234640395

1.06 ME-GA engine description

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ME-GA 9 (9)
199 18 17-7.0 MAN Energy Solutions

27021657234640395
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1.06 ME-GA engine description

2023-06-14 - en

ME-GA
 MAN Energy Solutions 199 17 24-2.0

Engine cross section - TIII

General

1.07 Engine cross section - TIII

2023-10-25 - en

Fig. 1.07.01: G70ME-C10.5-GA-EGRBP, Example of Engine cross section,

turbocharger(s) mounted on the exhaust side
18014454985483915

G70ME-C10.5-GA T-III 1 (1)

199 17 24-2.0 MAN Energy Solutions

18014454985483915
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1.07 Engine cross section - TIII

2023-10-25 - en

G70ME-C10.5-GA T-III
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water

02 Engine Layout and Load Diagrams, SFOC, dot 5

12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395532811

1 (1)
 MAN Energy Solutions

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02 Engine Layout and Load Diagrams, SFOC, dot 5
 MAN Energy Solutions 199 06 13-4.1

Propeller layout and engine matching with margins

The combination of speed and power obtained for the design condition of the
ship may be called the propeller design point (PD). PD is placed on the light
running propeller curve, in Fig. 2.01.01.
Some shipyards, and/or propeller manufacturers occasionally use an alternat-
ive propeller design point (PD’) for the propeller design. To reflect average
conditions at sea, PD’ incorporates all or part of the so-called sea margin de-
scribed later.

2.01 Propeller layout and engine matching with margins

Fig. 2.01.01: Light propeller curve with margins added to establish the spe-
cified MCR for propulsion (MP) within a layout area for a specific engine

The service propulsion point (SP) on the engine layout curve is obtained by
adding the sea margin, and the light running margin to the propeller design
2023-01-18 - en

point (PD).
The specified MCR for propulsion, attained by including all margins described
in the following sections, must be placed within the layout area. See the later
section "Engine layout limitations" for further information.

All engines 1 (4)

199 06 13-4.1 MAN Energy Solutions

Sea margin
As the sea is rarely completely calm and a wind often blows, the ship will ex-
perience increased resistance from wind and waves in average conditions.
When determining the necessary engine power it is normal practice to add a
power margin, the so-called sea margin. The sea margin ensures that the ship
can maintain the design speed in average conditions at sea.
Traditionally, the sea margin has been approximately 15% of the power re-
quired to achieve the design speed with a clean hull in calm weather (PD). As
ship design speeds reduce, it can be necessary to increase the sea margin
since the resistance experienced by the ship is not reduced. If allowed by the
EEDI regulation, it can be sensible to use a larger margin for ships often oper-
ating in heavy weather.

Engine margin
Often an engine owner will not permit 100% utilisation of engine power for
normal operation due to the increase of the fuel consumption and the reduc-
tion of the power reserve. Therefore an engine margin of 10 to 15% is in-
cluded to operate the engine at 90 or 85% load at the service propulsion
point. Higher margins have been experienced for specific trades or reasons. If
allowed by the EEDI regulation, a high engine margin is typically preferred for
ships in scheduled traffic to make it possible to catch up with delays.
2.01 Propeller layout and engine matching with margins

The engine margin can be increased for ships with a shaft generator, see the
later section 2.03.

Light running margin

When the ship has sailed for some time, the hull and propeller becomes
fouled. This will increase the hull resistance, and reduce the ship speed unless
the engine delivers more power to the propeller to maintain the speed. As a
result, the propeller will require more torque and the engine will be heavier
loaded and heavy running (HR), which requires an increased torque from the
engine.
When determining the necessary engine layout speed, the influence of a
heavy running propeller and operation with increased vessel resistance must
be considered. Therefore it is recommended to use a heavier propeller curve
for the layout of the engine. The propeller curve for clean hull, and calm
weather may then represent a "light running" (LR) propeller, whereas the en-
gine layout curve represents a propeller curve in heavy weather, or with heavy
fouling.
2023-01-18 - en

MAN Energy Solutions recommends using a light running margin (LRM) of

normally 4.0–7.0%, however, for special cases up to 10%. It means that for a
given engine power, the light running propeller rpm is 4.0–10.0% higher than
the rpm given on the engine layout curve. Or, conversely, the engine is spe-
cified to a speed 4.0–7.0% lower than given on the design light propeller
curve.
The point attained in the engine layout diagram, after shifting the propeller
curve (containing the sea and engine margins) by the light running margin, is
termed the “specified MCR for propulsion” point (MP).

2 (4) All engines

 MAN Energy Solutions 199 06 13-4.1

The high end of the range (7–10%) is primarily intended for vessels often op-
erating in adverse conditions with a heavy running propeller. Low-powered
EEDI ships such as tankers, and bulkers with blunt bows may also experience
an operational benefit from a relatively high light-running margin.
Vessels with shaft generators, or vessels with high ice classes can also benefit
from a light running margin in the high range, or in special cases even beyond
10%. It makes it possible to keep the shaft generator and power take-off
(PTO) in operation for longer periods at sea. See the later guidance on PTO
layout limits.
The SMCR values of engine power (SMCRpower) and speed (SMCRspeed )
when including the margins can be calculated using equations 2.01.01 and
2.01.02.

Eg. 2.01.01

Eg. 2.01.02

2.01 Propeller layout and engine matching with margins

The recommendation towards LRM is applicable to all draughts at which the
ship is intended to operate, whether ballast, design or scantling draught. The
recommendation is applicable to engine loads from 50 through 100%. If an
average of the measured values between 50% and 100% load is used for
verification of the attained light running margin, this will smoothen out the ef-
fect of measurement uncertainty and other variations.

Note on LRM
Light and heavy running, fouling, and sea margin are partially overlapping
terms. Light and heavy running of the propeller refers to hull and propeller de-
terioration, as well as heavy weather and the resulting shift of the propeller
curve towards the left in the load diagram. See for example Fig. 2.01.01. This
shift stems from the increased torque required by the propeller during en-
counters of added resistance on the hull, that is, a lower rpm output at the
same power.
2023-01-18 - en

The light running margin gives a margin towards engine limitations, see sec-
tion 2.03. This margin ensures that the ship can deliver maximum power in
conditions not as ideal as sea trial conditions. If the light running margin was
not included, this might not be the case.
The sea margin gives the power margin necessary to maintain the service
speed during average sea conditions with added wave and wind resistance.
The light running margin ensures that the necessary power is available.

All engines 3 (4)

199 06 13-4.1 MAN Energy Solutions

Within the recommendations for the light running margin, the degree of light
running must be decided based on experience from the actual trade, and the
hull design of the vessel. In general, slender designs with sharp bows require
smaller margins than full-body ships with blunt bows. The latter design results
in an increase of the added resistance in adverse weather.
For further information on the effects of engine heavy running, see the later
section: "Engine power and speed limits".
18014450035657099
2.01 Propeller layout and engine matching with margins

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4 (4) All engines

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Optimum propeller speed

Propeller diameter and pitch

In general, the following applies: the larger the propeller diameter, D, the lower
the optimum propeller speed and the power required for a certain design
draught and ship speed, see curve D in Fig. 2.02.01.

Fig. 2.02.01: Influence of propeller diameter (D) and pitch on propeller design
The maximum propeller diameter depends on the design draught of the ship
and the clearance needed between the propeller, the aft body hull, and the
keel.
Fig. 2.02.01 shows an example with an 80,000-dwt crude oil tanker with a
design draught of 12.2 m and a design speed of 14.5 knots.
When the propeller diameter is increased from 6.6 m to 7.2 m, the power de-
mand is reduced from approximately 9,290 kW to 8,820 kW. The optimum
2.02 Optimum propeller speed
propeller speed is reduced from 120 rpm to 100 rpm. This corresponds to the
constant ship speed coefficient α = 0.28. See the definition of α in the later
section “Definition of constant ship speed lines”.
Once a propeller diameter of maximum 7.2 m has been chosen, the corres-
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ponding optimum pitch in this point for the design speed of 14.5 knots is P/D
= 0.70.
However, if the optimum propeller speed of 100 r/min does not match the
preferred or selected main engine speed, a change of pitch away from the op-
timum will only cause a relatively small extra power demand. It will then be
possible to keep the same maximum propeller diameter:

▪ To increase engine revolutions from 100 rpm to 110 rpm (P/D = 0.62) re-
quires 8,900 kW, that is, an extra power demand of 80 kW
▪ To decrease engine revolutions from 100 rpm to 91 rpm (P/D = 0.81) re-
quires 8,900 kW, that is, an extra power demand of 80 kW.

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In both cases, the extra power demand is only 0.9%, and the corresponding
"equal speed curves" are α = +0.1, and α = -0.1, respectively. So there is a
certain interval of propeller speeds where the "power penalty" is limited. An in-
terval that can be utilised to accommodate the most fuel-efficient engine.
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Definition of constant ship speed lines

Fig. 2.02.02 shows the constant ship speed lines, α. These lines indicate the
power required at various propeller speeds to keep the same ship speed,
when an optimum pitch/diameter ratio is used.

Fig. 2.02.02: Layout diagram, and constant ship speed lines

Normally, if propellers with an optimum pitch are used, the following relation
between the necessary power, P, and the propeller speed, n, can be as-
2.02 Optimum propeller speed

sumed:

P2 = P1 × (n2 /n1)α
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where:
P is the propulsion power
n is the propeller speed
α is the constant ship speed coefficient.
18014450035666187

For any combination of power and speed, points on lines which are parallel to
the ship speed lines give the same ship speed. If a constant ship speed line is
drawn into the layout area through the specified propulsion MCR point, MP1,
then another specified propulsion MCR point, MP2, on this line will give the
same ship speed.

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Fig. 2.02.02 shows an example of the required power-speed point MP1

through which a constant ship speed curve α = 0.25 is drawn. Thereby, point
MP2 is obtained with a lower engine power, and a lower engine speed but
with the same ship speed.
Provided the optimum pitch is used for a given propeller diameter, the follow-
ing data applies when changing the propeller diameter:

▪ For general cargo, bulk carriers, and tankers: α = 0.20–0.30

▪ For container vessels, and roll-on/roll-off cargo: α = 0.15–0.25.

When changing the propeller speed by changing the pitch, the α-constant will
be different.
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2.02 Optimum propeller speed

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2.02 Optimum propeller speed

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Engine layout and load diagram

Engine layout limitations

As Fig. 2.03.01 shows, an engine's layout diagram is limited by:
1. Constant mean effective pressure (MEP) lines (L1– L3 and L2– L4)
2. Constant engine speed lines (L1– L2 and L3– L4).

Fig. 2.03.01: Engine layout diagram with limits

Within the layout area, there is complete freedom to select the engine’s spe-
cified maximum continuous rating (SMCR), point MP, which suits the ship’s
demand for power and speed.
The nominal maximum continuous rating (NMCR) of an engine design is equi-
valent to L1 in the layout area.
2.03 Engine layout and load diagram
The effective power, P, of a combustion engine is proportional to the mean ef-
fective pressure, pe, and engine speed, n. The expression for P, where c is a
constant, is:
P= c × pe × n
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For constant mean effective pressure (MEP), the power is proportional to the
speed:
P= c × n1 (for constant MEP)
When running with a fixed pitch propeller (FPP), the power can be expressed
according to the propeller law as:
P= c ∝ n3 (propeller law)
Although the proportionality, P ∝ k × V3. between the required power and the
cubic, i.e. ni = 3, of the speed is often referred to as a law, it is an assumption
valid only for frictional resistance. If the ship has sufficient engine power for

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operating at elevated speeds, the wave making resistance must be con-

sidered. At elevated ship speeds, V, the exponent can be higher, for example,
P ∝ k × V4.
Normally, estimates of the necessary propeller power and speed, n, are
based on theoretical calculations for the design condition of the ship, and of-
ten also on computer simulations along with experimental tank tests. Calcula-
tions and simulations are based on optimum operating conditions, that is, a
clean hull, good weather and calm seas.

Specified maximum continuous rating within the layout area

Based on the propulsion and engine running points, the layout diagram of the
relevant main engine can be drawn in a power-speed diagram like in Fig.
2.03.01. The SMCR, point MP, must be placed inside the limitation lines of
the layout diagram. Otherwise, the propeller speed has to be changed, or an-
other main engine type must be chosen. The selected SMCR influences the
mechanical design of the engine, for example, turbocharger, piston shims,
liners, and fuel valve nozzles.
Once the specified SMCR has been chosen, the engine design, and the capa-
cities of the auxiliary equipment will be adapted to the SMCR, as reflected in
CEAS reports.
If the SMCR is changed later on, it may involve a change of:
▪ shafting system
▪ vibrational characteristics
▪ pump and cooler capacities
▪ fuel valve nozzles
▪ piston shims
▪ cylinder liner cooling, and lubrication.
Furthermore, it may be necessary to re-match the turbocharger, or even to
change to a different size of turbocharger. Sometimes, such a change also re-
quires a piping system of larger dimensions. If the specification has to be pre-
pared for a later change of SMCR, it is important to consider this already at
the project stage. It can be an option to design the ship with a derated en-
2.03 Engine layout and load diagram

gine, and auxiliaries (coolers, pumps and pipe dimensions, shafting, and so
on) that are sufficient for a later uprating of the engine. This engine is termed a
dual-rated engine, which must be indicated in the Extent of Delivery (EoD).
Note, that EEDI regulations must permit this.
If a dual-rated engine is ordered, it is beneficial to carry out the testing neces-
sary to get the IMO technical file for the alternative SMCR during shop testing
of the engine. When testing is done before ship delivery, the more expensive
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in-ship testing of the engine is avoided. For all fuel variants of the ME-C en-
gines, the timing of fuel injection and the timing of exhaust valve activation are
electronically optimised over a wide operating range of the engine. For ME-B
engines, only the fuel injection (and not the exhaust valve activation) is elec-
tronically controlled over a wide operating range of the engine.
Various tunings are available for pure Tier II engines. These tunings allow op-
timisation of an engine for the specific needs of a project. There are no tun-
ings available for Tier III engines. See the later section “Example of SFOC
curves”.

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Engine load diagram and limitations

Definitions
A load diagram defines the power and speed limits for continuous and over-
load operation of the installed engine, see Fig. 2.03.02.

Fig. 2.03.02: Engine load diagram with adverse weather condition (AWC)
function for SMCR placed within the layout diagram (light blue)

The specified MCR, point MP, of the engine corresponds to the ship specific-
ation. The service points of the installed engine incorporate the engine power

2.03 Engine layout and load diagram

required for ship propulsion, and by the shaft generator.

Operating curves and limits

The lines on Fig. 2.03.02 describe the service range of the engine. We will
refer to these lines throughout section 2.03. The location of the SMCR point
within the layout diagram does not affect the appearance of the load diagram.
The SMCR point alone defines the load diagram, since all specifications utilise
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the maximum capabilities of the engine design. See the later section on “De-
rating for lower specific fuel oil consumption”.
Line 1:
Engine layout curve, per definition passing through 100% SMCR rpm, and
100% SMCR power. This curve coincides with the “heavy propeller curve”,
line 2. An engine without PTO will typically operate to the right of this curve
about 95% of the time.
Line 2:
Heavy propeller curve, the light propeller curve (line 6) shifted with the light
running margin to account for heavy weather, and fouled hull.

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Line 3:
Maximum rpm for continuous operation. For engines with an SMCR on the
line L1-L2 in the layout diagram, up to 105% of L1-rpm can be utilised. If the
SMCR is sufficiently speed derated, 110% of SMCR rpm, but no more than
105% of L1-rpm, can be utilised for standard engines. Torsional vibration con-
ditions must permit the rpm values.
If the SMCR (MP) is sufficiently speed derated, and if torsional vibration condi-
tions permit it, more than 110% speed is possible by choosing the “extended
load diagram”. The extended load diagram is described later in this chapter.
Line 4:
Torque/speed limit of the engine, limited mainly by the thermal load on the en-
gine.
Line 5:
Represents the maximum mean effective pressure (MEP) level acceptable for
continuous operation. Note, that this is only a limit at high loads, and engine
speeds. At lower speeds, line 4 is a stricter limit.
Line 6:
Light propeller curve for clean hull, and calm weather, often used for propeller
layout. The light running margin is the rpm margin (in percent) between the
engine layout curve (lines 1 and 2) and the light propeller curve.
Line 7:
Represents the maximum power for continuous operation. Note that when in-
creasing rpm towards lines 3 and 9, the maximum power for continuous oper-
ation cannot exceed 100%.
Line 8:
The area between lines 4, 5, 7 and line 8 represents the overload operation
limit of the engine. Overload running is possible only for limited periods, 1 hour
out of every 12 hours, as the resulting thermal load on the engine is high.
Line 9:
Maximum acceptable rpm at sea trial conditions with clean hull and propeller
in calm water. 110% of SMCR rpm, but no more than 107% of L1-rpm if per-
mitted by torsional vibrations.
If point M / the SMCR of the engine is sufficiently speed derated, more than
2.03 Engine layout and load diagram

110% speed is possible by choosing “Extended load diagram” which is de-

scribed later in this chapter.
Line 10:
PTO layout limit. This curve describes the maximum combined power re-
quired by the light propeller curve and the PTO at a given rpm with a shaft
generator/PTO. The PTO layout limit is to be considered when dimensioning
the system. This layout limit ensures operational margin to line 4, see the sub-
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sequent section “Shaft generator/PTO layout, governor stability and integra-

tion”.
Line 11.
Bollard pull propeller curve. The heaviest propeller curve possible at zero ad-
vance speed. The bollard pull curve is typically 15 to 20% heavier than the
light propeller curve, values may vary for individual designs.
AWC area
Extended overload operation limits of engines equipped with the adverse
weather conditions function, the AWC function. The AWC function increases
the percentage of engine power that can be developed with a heavy propeller,
as long as required in an emergency.

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When the function is activated, the electronic control of the ME engine alters
the cyclic process of the combustion to reduce the negative effects of devel-
oping a high engine torque at low rpm. It is done at the cost of an increased
specific fuel oil consumption. Due to the resulting SFOC increase, AWC is not
to be considered a replacement for an adequate light running margin. See the
later section “AWC function” for a further description of this function.

Limits for low-speed running

As the fuel injection for ME engines is automatically controlled over the entire
power range, the engine is able to operate down to approximately 15-20% of
the nominal L1 speed, depending on the actual propulsion system. Absolute
values of minimum speed must be determined at the sea trial.

Recommendation for operation

The area between lines 1, 3 and 7 is available for continuous operation
without limitation.
The area between lines 1, 4 and 5 is available for operation in shallow waters,
in heavy weather, and during acceleration, that is for non-steady operation
without any strict time limitation.
The area between lines 4, 5, 7 and 8 is available for overload operation for 1
out of every 12 hours.
After some time in operation, the ship’s hull and propeller will be fouled, res-
ulting in heavier running of the propeller. The propeller curve will move to the
left, (from line 6), towards line 2, and extra power is required for propulsion to
keep the same ship speed.
In calm weather conditions, the extent of heavy running of the propeller can
indicate the need for cleaning the hull, and/or polishing the propeller.

2.03 Engine layout and load diagram

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Passage of a barred speed range

If the engine and shaft line has a barred speed range (BSR), it is usually a
class requirement that it can be passed quickly. The quickest way to pass the
BSR is the following:
1. Set the rpm setting to a value just below the BSR
2. Wait while the ship accelerates to a ship speed corresponding to the rpm
setting
3. Increase the rpm setting to a value above the BSR.
Sometimes, for example in certain manoeuvring situations inside a harbour, or
at sea in adverse conditions, it may not be possible to follow the procedure
for passing the BSR. Either because there is no time to wait for the ship
speed to build up, or because high ship resistance makes it impossible to
achieve a ship speed corresponding to the engine rpm setting. In such cases,
it can be necessary to pass the BSR at low ship speed.
The most basic guidance on avoiding slow passing of the BSR is to avoid a
BSR that extends higher than 60% engine rpm, while specifying a light run-
ning margin within the recommendation. If so, it is normally possible to
achieve a sufficiently quick passage of the BSR in relevant conditions.
A more detailed approach is to ensure a BSR power margin, BSRPM, of at
least 10% in the design.
BSRPM = ((PL – PP)/PP*100
Here, PP is the power required by the bollard pull propeller curve at the upper
end of the BSR, whereas PL is the power limit for continuous operation within
the engine load diagram, line 4 in Fig. 2.03.02. As such, the BSRPM expresses
the excess engine power in the upper range of the BSR, and hereby the
ship’s capability to pass it.
If a ship faces challenges with passing the BSR, a special function termed the
"dynamic limiter function" (DLF) may be specified for diesel cycle engines. The
DLF can for shorter periods increase the index limits of the engine, and ensure
a faster passage of the BSR.
2.03 Engine layout and load diagram

For 5- and 6- cylinder engines with short shaft lines, such as on many bulkers
and tankers, the BSR may extend high up in the rpm range. Special attention
must be given to ensure that the BSR can be passed quickly. 5- and 6- cylin-
der engines are as standard delivered with the DLF functionality.
For support regarding passage of the BSR, contact MAN Energy Solutions,
Copenhagen at MarineProjectEngineering2s@man-es.com.
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Shaft generator/PTO layout, governor stability and integration

For the dimensioning and layout of a two-stroke propulsion plant with power
take-off (PTO)/shaft generator, two aspects are important to consider for the
design:
▪ PTO layout limit: prevention of engine overload
▪ Governor stability evaluation: prevention of engine speed hunting, and po-
tentially also engine overspeed
Both aspects and their interactions will be clarified in detail in the following
sections. See the flowchart in Fig. 2.03.03 for an overview of the considera-
tions needed for a specific plant.

2.03 Engine layout and load diagram

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Fig. 2.03.03: Flowchart for determining evaluations needed, depending on

plant characteristics

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It is a prerequisite for a successful governor stability evaluation that the criteria

of the PTO layout limit is fulfilled, and conversely. It is important to consider
both aspects as illustrated by the flowchart. At the end of this section, consid-
erations for the protection of the engine towards overload in service is given.

PTO layout limit

In the load diagram in Fig. 2.03.02, line 10 represents the "PTOlayout limit". Line
10 describes the maximum combined power required by the light propeller
curve and the PTO at a given speed, n, when a shaft generator/PTO is in-
stalled. The minimum value of the following three equations governs the
"PTOlayout limit". Observe the speed interval for which the second equation is ap-
plicable:

As marked in Fig. 2.03.02, the maximum design PTO power at a given speed
is the vertical difference between line 6 (the light propeller/combinator curve of
a propeller) and line 10 (the PTOlayout limit). PTO operation is not possible below
50% of SMCR-speed. Table 2.03.01 shows the relative PTO power available
when sea conditions allow operation along the light propeller curve. At engine
speeds above 50% of SMCR, the relative PTO power is given as a function of
the light running margin.
Designing the combined power of the PTO and propeller according to the
PTOlayout limit ensures that the PTO can be operated in conditions less ideal than
sea trial conditions. Note that neither the torque/speed limit (line 4) nor the
MEP limit (line 5) is used for the layout of the PTO capacity.
With increased heavy running, the electric power taken off with the PTO must
be decreased gradually not to push the operational point outside the engine
limits. In severe cases, fouling and sea conditions alone are enough to shift
2.03 Engine layout and load diagram

the propeller curve to line 4. It these cases, the PTO cannot be utilised without
overloading the engine, and the auxiliary engines must deliver all the electric
energy.
It can be beneficial to increase the SMCR power and/or the light running mar-
gin for ships with a large electrical consumption, which often operate at high
speeds/engine loads, or in areas with frequent encounters of adverse weather
conditions. This will increase the margin from the light propeller curve to the
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PTOlayout limit and ensure a higher availability of the PTO.

Increasing the SMCR power of the engine, while maintaining a constant pro-
peller pitch, results in an increase of the light running margin. See Table
2.03.01 at the end of this section. When evaluating the possibility for an in-
crease of SMCR power, compliance with EEDI regulations must be con-
sidered. See the application examples in main section “Examples of the use of
load diagrams”.
For information on PTO power available at a given propeller speed as a func-
tion of the propeller light running margin, see the later section "PTO layout
table".

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Governor stability for plants with PTO

A PTO connected to the electric grid will deliver constant power, and intro-
duce negative damping of the engine speed. If a vessel encounters, for ex-
ample, large waves, the speed through water and the engine speed will drop.
Therefore, the frequency drive will load the PTO with a higher torque to deliver
the same electrical power. The torque increase enhances the speed drop ex-
perienced, and conversely for a speed increase.
To ensure a stable engine speed during operation, MAN Energy Solutions has
established guidelines on governor stability for the maximum PTO power al-
lowed.
These guidelines must be considered along with the PTO layout limit. It means
that the maximum allowable PTO power to design for at any engine speed is
determined as the minimum of the two aspects.

First governor stability criteria

The first governor stability criteria depicted on Fig. 2.03.04 represents a min-
imum with respect to governor stability at lower speeds. The criteria are valid
for plants where the mechanical power of the PTO does not exceed 15%
SMCR power for fixed pitch propeller (FPP) plants and 10% SMCR power for
controllable pitch propeller (CPP) plants.
Fig. 2.03.04 shows three limits, which establish the first governor stability cri-
teria for:
▪ FPP plants (blue solid curve)
▪ CPP plants, and engines with bore sizes smaller than 80 cm (orange solid
curve)
▪ CPP, and 80-bore engines or larger (grey solid curve)

2.03 Engine layout and load diagram

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Fig. 2.03.04: First governor stability criteria for maximum mechanical PTO
which ensure an acceptable governor performance and stability without inter-
face option C. The limits relate to NMCR and are independent of the choice of
SMCR

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FPP CPP < 80 CPP >= 80

[%NMCR] [%NMCR] [%NMCR] [%NMCR] [%NMCR] [%NMCR]

100 15.0 100.0 10.0 100.0 10.0

60 15.0 61.5 10.0 60.0 10.0

57 13.2 60.0 9.0 57.0 10.0

50 9.0 57.0 7.8 50.0 7.0

47 7.8 50.0 5.0 47.0 5.0

40 5.0 48.6 4.6 45.0 3.5

47.0 2.6 43.5 2.4

45.0 0.0 42.0 0.0

Table 2.03.01: First governor stability criteria for maximum mechanical PTO
ensuring acceptable governor performance and stability without interface op-
tion C. The limits relate to NMCR and FPP plants, CPP plants and engines
with bore sizes smaller than 80 cm, and CPP plants with 80-bore engines or
larger

The limits in Fig. 2.03.04 are based on NMCR power and speed, not SMCR
power and speed. This is because stability is related closely to the actual
speed and the physical parameters of the engine, i.e., power and inertia,
rather than the choice of SMCR.
MAN Energy Solutions must be consulted for a plant-specific PTO layout and
design evaluation, if the maximum mechanical PTO load on the shaft is higher
than:
▪ 15% of SMCR power for FPP plants,
▪ or 10% for CPP plants,
▪ or if the plant does not fulfil the first governor stability criteria.

Interface option C described below is mandatory for these plants.

2.03 Engine layout and load diagram

For FPP plants, where the mechanical PTO power exceeds 10% of SMCR
power, Interface option C is recommended.
PTO operation is in any case not possible below 50% of SMCR speed.

Interface option C - integration between power management and engine

control system
For plants with a shaft generator more powerful than ordinary, Interface option
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C can be installed between the engine control system (ECS) and the power
management system (PMS) to increase the maximum PTO power. This inter-
face improves the integration of ECS and PMS, and enhances governor sta-
bility. A plant-specific evaluation is performed for each application of interface
option C. See also the next sections for other benefits of Interface option C.
The plant-specific PTO layout and design evaluation may lead to changes in
the control equipment. For example, an increase of signals from the plant and
requirements to the design of engine-driven mechanical components in the
form of turning and tuning wheels. The evaluation may also lead to changes in
the use of the PTO or set restrictions for the rotational speed while taking out
maximum power.

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Fixed pitch propellers

For plants with FPP, interface option C is:
▪ Required if the mechanical power of the PTO exceeds 15% of SMCR
▪ Recommended if the mechanical power of the PTO exceeds 10% of
SMCR
Application of Interface option C requires consultation of MAN Energy Solu-
tions for a plant-specific PTO layout and design evaluation. By applying Inter-
face option C, at least 20% of SMCR power is available for PTO within certain
speed limitations. An even larger ratio may be available for PTO and can be
investigated as part of a plant-specific PTO layout and design evaluation.

Controllable pitch propellers

For plants with CPP, further considerations are necessary regarding governor
stability, as when the propeller pitch is reduced. For CPP plants, Interface op-
tion C is:
▪ Required if the mechanical power of the PTO exceeds 10% of SMCR.
▪ Recommended if the mechanical power of the PTO exceeds 5% of SMCR
Based on a plant-specific evaluation, specific limits may be set to the min-
imum engine speed at which manoeuvring can be performed while sustaining
the maximum PTO power.
For plants, where the mechanical PTO power exceeds 10% of SMCR, a
plant-specific evaluation includes the risk of overspeed if a total electric load
loss occurs on the PTO during engine operation in constant speed mode.

Load sharing and overload protection in service

Designing according to the PTO layout limit does not protect the engine from
overload during PTO operation in combination with a fouled hull, or an en-
counter of heavy seas. With the standard interfaces between the engine and
remote control, it is the responsibility of the crew to balance the load between
PTO and gensets to avoid overload of the engine during conditions with in-
creased hull resistance.

2.03 Engine layout and load diagram

Besides ensuring governor stability, interface option C provides signals for the
PMS to automate load sharing between the main engine PTO and gensets.
The extended interface will help ensuring higher utilisation rates of the PTO,
thus reducing genset running hours. If supplying power solely by the PTO, it
will also reduce the risk of blackout without overloading the engine.
For support regarding layout of PTO/PTI and plant-specific evaluations, con-
tact MAN Energy Solutions, Copenhagen at MarineProjectEngineer-
2024-02-16 - en

ing2s@man-es.com.

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Options for accounting for PTO in the EEDI

Two options exist for including a PTO in the vessel EEDI, as described in the
EEDI guideline MEPC.364(79) and the IACS procedure PR38:
In option 1, the power of the main engine, PME, used for calculating the EEDI
is determined as:

PME = 0.75 x (PSMCR - PPTO), with the limitation that 0.75 x PPTO ≤ PAE.

Here, PPTO is the nameplate PTO power and PAE is the auxiliary power calcu-
lated as a percentage of PSMCR. For the alternative option 2, the power avail-
able for propulsion is limited to: PLIM, propulsion = PSMCR - PPTO, and PME used in the
EEDI calculation is 0.75 x PLIM, propulsion, see Fig. 2.03.05.
2.03 Engine layout and load diagram

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Fig. 2.03.05: The principle of PTO option 2 for the EEDI calculation
With an extension to PTO interface option C, it is possible for the engine con-
trol system (ECS) to support PTO option 2 in the EEDI calculation. The sup-
port of PTO option 2 is only performed by the ECS, and for a plant with PTO
interface option C, no further cabling or functionalities are necessary in the
power management system (PMS).

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The PMS sends the actual mechanical power of the PTO (PPTO, actual) to the
ECS. The ECS ensures that the actual total engine power (PLIM, engine) in service
is limited to the fixed limit for propulsion power (PLIM, propulsion) plus the actual
PTO power (PPTO, actual):

PLIM, engine = PLIM, propulsion + PPTO, actual

The value of the power limitation for maximum propulsion power (PLIM, propulsion)
is fixed and can in no circumstances be lifted or modified. When the PMS in-
forms the ECS that PTO operation is needed, and this is acknowledged by
the ECS, an engagement offset of approx. 5% of PSMCR is added to the actual
PLIM, engine to allow load transfer to the PTO. As long as the PTO is engaged, the
engagement offset is added to the PLIM, engine to allow load fluctuations for the
PTO. The combined power output of the engine, PPTO, actual and PLIM, propulsion, is
logged continuously. Since the engine can deliver the full PSMCR, when full PTO
power is exploited, the engine is certified as usual in accordance with PSMCR.
Furthermore, the SFOC of the engine is not affected by the application of PTO
option 2 for EEDI, and auxiliary capacities cannot be reduced as the engine
remains able to develop 100% power.
The engine load diagram in Fig. 2.03.06 is based on an SMCR with a fixed
limitation for propulsion power determined as: PLIM, propulsion = PSMCR - PPTO. In an
actual example of the PTO power in service (PPTO, actual), a variable limitation is
used for the total engine power: (PLIM, engine = PLIM, propulsion + PPTO, actual), thereby
ensuring that the fixed limitation for propulsion power (PLIM, propulsion) is not ex-
ceeded.

2.03 Engine layout and load diagram

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Fig. 2.03.06: Example of an engine load diagram based on an SMCR with a

fixed limitation for propulsion power

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Recommendations for designing propulsion plants for PTO option 2 for EEDI
The PTO layout guidance for this application deviates from MAN Energy Solu-
tions’ standard PTO layout guidance as described previously in Chapter 2:
The propulsion and PTO power in total is to be designed for 100% of PSMCR,
and not the maximum 95% of PSMCR recommended for standard PTO layouts.
The difference between the guidelines is reflected in the PTO layout limit for
option 2 in Fig. 2.03.06, where Nrel is the speed relative to the speed at SMCR
(NSMCR):
PTO layout limit for option 2 = 100 x (Nrel/100)2.4
The special PTO layout limit for option 2 is necessary since it is not possible to
exploit the 5% power margin of the standard guideline for heavy running of
the propeller, because the propulsion power will be limited to PLIM, propulsion re-
gardless of whether the propeller is heavy running or not.
Instead, the higher power allowed under the EEDI by applying PTO option 2
for plants with high PTO power capacities provides an inherent service margin
for PTO power.
The limitations for PTO power relative to PSMCR, as described previously in sec-
tion 2.03 of the Project Guide, prevail irrespective of the use of PTO option 2
for EEDI. It means that for fixed pitch propeller plants, a PTO power of up to
15% of PSMCR is possible without plant-specific evaluations, and up to 10% of
PSMCR for controllable pitch propellers.
If the amount of resistance added to the propeller makes it so heavy running
that the limited propulsion power (PLIM, propulsion) is encountered at a shaft speed
below SMCR (NSMCR), the engine cannot be loaded to 100% PSMCR. In this
case, the combined propulsion and PTO power will be subject to the limits for
continuous operation of the engine.
It is recommended to have a speed margin in the design for heavy running of
the propeller. The propeller light running margin can be increased to a level
where PLIM, propulsion, along the light propeller curve, and PPTO combined is
reached at speeds above NSMCR. Such a margin is included in the light pro-
peller curve for the example in Fig. 2.03.06, where PLIM, propulsion, along the light
propeller curve, + PPTO attains 100% engine load at 102% speed.
2.03 Engine layout and load diagram

The engine cannot necessarily attain 100% engine load in light sea trial condi-
tion as a result of the combined propulsion and PTO power. This will be the
case if the maximum allowable speed along the light propeller curve regarding
engine or torsional vibration conditions is below the speed at which PLIM, propulsion
is reached.
It is recommended to design the propeller and intermediate shaft to the full
torque of PSMCR. If a winding failure occurs on the PTO, or similar, which res-
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ults in a total load loss for the PTO, the shafting can instantaneously experi-
ence the full engine torque before the fuel index can be regulated to corres-
pond to PLIM, propulsion. The shafting system cannot be designed as for an engine
with an SMCR corresponding to PLIM, propulsion due to the higher torque available
from the higher power installed.
For examples on the application of PTO option 2 for EEDI, see the concluding
examples in the latter part of this section. For support regarding layout of
PTO/PTI, classification and application of PTO option 2 for EEDI, contact Mar-
ineProjectEngineering2s@man-es.com

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AWC functionality
The AWC functionality is only available for single fuel diesel engines equipped
with high-efficiency turbochargers. The AWC function is introduced for ME-C
10.5 and 9.7 engines. If the AWC function is installed, it can be activated by
pushing the “Increase limitation”-button, found on all ME-C engines.
There is no limitation on the duration of engine operation in the area of the
AWC function. As such, the increased power produced may be utilised when
evaluating a ship designs compliance with IMO minimum propulsion power re-
quirements.
Ice-classed ships are designed to operate in ice, and ice operation is therefore
not an emergency running condition. The AWC functionality is therefore not
applicable for compliance with ice-class power requirements, or similar re-
quirements that the ship is designed for (not emergency). For ice-classed
ships, the standard, or if selected, the rpm-extended load diagram, should be
applied as usual.
Based on the same argument as for ice-classed ships, the AWC functionality
does not increase the power available for PTO. The reason is that the opera-
tion of a PTO is not an emergency running condition. A PTO installation must
still comply with the PTO layout limits, and the governor stability criteria.
As a countermeasure to the temperature increase from heavy running, the
AWC functionality alters the cyclic process of the combustion by changing the
fuel injection timing and the exhaust valve timing. This improves thermal con-
ditions in the combustion chamber at a cost of an increased SFOC. The
SFOC penalty depends on the specific load conditions. Due to the increased
SFOC, the AWC functionality should not be considered a replacement for an
adequate light running margin.
When the engine is not running heavier than the normal load diagram, the
AWC functionality has no effect and does not affect the SFOC or emissions.
For ships frequently operating in adverse weather conditions, an increased
light running margin combined with an extended load diagram will ensure a
lower SFOC during (such) encounters of adverse weather than the AWC func-
tion. See the later section about extended load diagrams. For specific enquir-

2.03 Engine layout and load diagram

ies towards the availability of the AWC functionality, contact MarineProjectEn-
gineering2s@man-es.com. For specific projects applying AWC, send the tor-
sional vibration calculation (TVC) to MAN Energy Solutions, Copenhagen at
RDCPH@man-es.com.
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Rpm-extended load diagram

When a ship with fixed pitch propeller operates in normal sea service, it will in
general operate around the design/light propeller curve (line 6) as shown on
the standard load diagram in Fig. 2.03.07.

Fig. 2.03.07: Rpm-extended load diagram for a speed derated engine with an
extreme increase of the light running margin

Sometimes, when operating in heavy weather or ice, the performance of the

fixed pitch propeller will be characterised as more heavy running. For equal
power absorption of the propeller, the propeller speed will be lower, and the
propeller curve will move to the left.
2.03 Engine layout and load diagram

As the low-speed main engines are directly coupled to the propeller, the en-
gine has to follow a fixed pitch propeller also in heavy running propeller situ-
ations. For this type of operation, there is normally enough margin in the load
area between line 6 and the normal torque/speed limitation, line 4. It requires
that the light running margin is within recommendations, see Fig. 2.03.02.
For some ships and operating conditions, it would be an advantage – when
occasionally needed – to have a maximum margin for the torque increase
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from the light propeller curve (line 6) to the torque/speed limit (line 4).
If the vessel has a fixed pitch propeller which requires a high light running
margin, an rpm-extended load diagram is relevant. Torsional vibration condi-
tions must permit this, and the classification society in question must approve
the solution.
The high light running margin, and rpm-extended load diagram is especially
relevant when at least two of the listed cases apply to the ship:
▪ Sailing in areas with frequent encounters of heavy weather, especially for
low-powered ships with blunt bows
▪ Sailing for long periods in shallow or otherwise restricted waters

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▪ A high ice class

▪ Two fixed pitch propellers/two main engines, where one propeller/one en-
gine is declutched/stopped for some reason
▪ Large electric loads and according to PTO capacity.
See the examples in the following section about application of the rpm-exten-
ded load diagram.

Combinator curves for CPP propulsion plants

In principle, a controllable pitch propeller (CPP) can load the engine in any
point within the load diagram. It means that the engine can operate along a
combinator curve with optimised pitch settings and propeller speed, making it
possible to operate the total propulsion system with optimum efficiency.
There are three modes for operating a ship with a CPP, as reflected in Fig.
2.03.08:
▪ Constant engine speed (generator mode) – red line
▪ Fixed combinator curve – black curve (6)
▪ Adaptive combinator curve - this mode continuously adapts/controls pitch
and rpm, typically based on a combinator curve

2.03 Engine layout and load diagram

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Fig. 2.03.08: Combinator curve and engine load diagram. The constant rpm
curve can also be referred to as the generator curve. The exact speed of the
generator curve will depend on the gear ratio of the PTO

Recommendations will be given regarding:

▪ Two-stroke engines coupled directly with a CPP without PTO

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▪ Additional recommendation for two-stroke engines coupled directly with a

CPP and PTO

Controllable pitch propeller operating without PTO

Constant engine speed mode

For plants without PTO, the constant speed mode is typically used for, but not
limited to, manoeuvring as the ship approaches port. Operating the engine at
high speed and low pitch ensures the maximum margin to the load limitations
of the engine and the fastest response to any load change.
It is recommended avoiding continuous operation in the low-load area of the
engine and at high propeller speed close to SMCR speed, due to:
▪ Potential risk of erosive pressure side cavitation
▪ Relatively higher losses of propeller and engine

Fixed combinator curve

A fixed combinator curve implies that the engine operates at a certain speed
and the CPP load controller sets an associated pitch, depending on the set-
ting of the machinery telegraph. When operating along a combinator curve,
the shaft speed is reduced at lower loads. This will reduce the losses of the
propeller and the engine at lower loads and increase the propulsion plant effi-
ciency.
Fig. 2.03.09 shows a typical fixed combinator curve, which consists of two
constant speed parts and one combinator part
2.03 Engine layout and load diagram

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Fig. 2.03.09: Typical fixed combinator curves for controllable pitch propellers
without PTO

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The minimum constant speed part (point A to B) is typically placed after the
upper end of a barred speed range (BSR), if any. The maximum constant
speed part (point C to D) with an increased pitch is typically laid out as the
SMCR speed, so only the pitch is increased to attain 100% load. However, up
to 105% of the SMCR speed is available, as for an engine connected to a
fixed pitch propeller (FPP).
The combinator part (point B to C), is the part of the combinator curve that
connects the constant speed parts. Usually, the propeller design point is
within the range of the combinator part. The pitch can be constant along this
part, or it can follow a preset combination of speeds and different pitch set-
tings.
During the encounter of heavy weather, or fouling of the hull, the response
from a fixed combinator curve is similar to that of an FPP propeller curve.
The torque required from the propeller increases when the resistance of the
hull increases, which leads to a heavier running engine and higher SFOC. The
result is higher thermal loading of the engine. To achieve an adequate margin,
it is recommended that any arbitrary point along the fixed combinator curve
follows the recommendation of the FPP light running margin (LRM). This mar-
gin is 4–7%, and in special cases up to 10%, except for the pitch-in at SMCR
speed.
When reaching the engine limits for continuous operation, the propeller pitch
must be reduced, if the engine speed is not to be reduced.

Adaptive combinator curve

Typically, adaptive or dynamic combinator curves are based on fixed combin-
ator curves, and they can be applied to vessels experiencing resistance vari-
ations.
For long-term operation of plants with an adaptive combinator curve/propeller
pitch, it is recommended loading the engine no heavier than the engine layout
curve (line 1 or 2).
Short-term loading of the engine beyond the engine layout curve and up to
the limits of continuous operation (line 4) is available for acceleration, peak
wave resistance, etc., without adjusting the pitch. When reaching the limit for

2.03 Engine layout and load diagram

continuous operation, the pitch must be reduced to maintain the engine
speed.
The pitch adjustment capabilities of a CPP together with the adaptive combin-
ator curve enable an operating curve where the engine is not operated heavier
than given by the engine layout curve. Furthermore, the benefits are that the
SFOC does not increase as a result of engine heavy running, and that the
thermal load of the engine is reduced.
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Controllable pitch propeller operating with PTO

Constant engine speed mode (generator mode)

A constant engine speed is mainly relevant when operating a synchronous
PTO connected to a grid without a frequency converter, or for manoeuvring.
For plants with a PTO exceeding 10% of the SMCR power, the margin to-
wards engine overspeed during a total loss of shaft generator load at zero or
low pitch should be considered. See the section on governor stability, and for
further information contact MarineProjectEngineering2S@man-es.com.

Fixed combinator curve

For CPP propulsion plants with PTO and a fixed combinator curve, it is re-
commended designing the combinator curve so that the combined load of
propulsion power and maximum PTO output is within the PTO layout limit (line
10 in Fig. 2.03.08) at any speed.
For any combinator curve, the margin between the propulsion power design
points and the PTO layout limit should be large enough to cover the maximum
PTO mechanical power within the PTO layout limit at any speed. See Fig.
2.03.10.
2.03 Engine layout and load diagram

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Fig. 2.03.10: Typical fixed combinator curve for controllable pitch propellers
with PTO
Although the power of the intended PTO is within the PTO layout limit for a
combinator curve heavier than 4% LRM, the recommendation of a combin-
ator curve corresponding to at least 4% LRM prevails, for any point on the
combinator curve. Some CPP plants have a PTO capacity larger than required
at sea because the main engine driven PTO supplies power to the thrusters
during manoeuvring. In such cases, the maximum PTO power required at sea

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can be considered the margin between the combinator curve and the PTO
layout limit (line 10). However, the general recommendation of 4–7% LRM, up
to 10% in special cases, prevails.

Adaptive combinator curve

Assuming that the full PTO capacity at a given speed is not utilised for plants
with an adaptive combinator curve/propeller pitch. In this case, it is recom-
mended not to operate with a combined load of propeller and PTO, which is
heavier than the engine layout curve (line 1, 2 in Fig. 2.03.08).
Short-term loading of the engine beyond the layout curve and up to the limits
of continuous operation (line 4) is available for acceleration, start of heavy
electric consumers, etc., without adjusting the pitch.
The dynamic capabilities of the CP propeller can reduce the level of heavy
running by reducing the propeller torque to counter a torque increase of driv-
ing a PTO. This will reduce the SFOC not only for the power taken out for the
grid, but also for the power used to propel the vessel.

2.03 Engine layout and load diagram

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Examples of the use of load diagrams

In the following, various examples illustrate the flexibility of the layout and load
diagrams.

Example 1: Engine coupled to FPP without PTO

In this example, which represents a typical application of marine two-stroke
engines, typical values of 7%, engine margin, and 15% sea margin are in-
cluded. A light running margin in the higher range of the recommended 4–7%
(up to 10% in special cases) is displayed for the sake of the example.
The maximum speed acceptable for an engine with a standard load diagram
is the minimum value of 110% SMCR-speed or 105% L1-speed. If torsional vi-
bration conditions permit it, 107% of the SMCR-speed will be available for
continuous operation, even if the light propeller curve extends beyond the lay-
out diagram, see Fig. 2.03.11.
2.03 Engine layout and load diagram

Fig. 2.03.11: Engine coupled to a fixed pitch propeller without shaft generator.
The load diagram is the result of selecting the MP/SMCR within the layout
area, 15% sea margin, 10% engine margin, and 7% light running margin.
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Example 2: Engine coupled to FPP with PTO

In this example, the SMCR is determined by using the regular method for de-
termining PD and adding margins. Thereafter, it is investigated whether the
desired PTO of 9% of the SMCR can be accommodated within the PTO lay-
out limit.
As seen on Fig. 2.03.12, the power of the light propeller curve plus the power
of the PTO lies well within the PTO layout limit (line 10 in Fig. 2.03.08), which
is up to 102% of the SMCR speed (96% relative to L1 on Fig. 2.03.12). At a
shaft speed above this, the PTO output must be reduced.

Fig. 2.03.12: Engine coupled to a fixed pitch propeller, and shaft generator.
The load diagram is the result of selecting the MP/SMCR within the layout
area, the PTO layout limit, and light propeller curve plus PTO power (dashed).

2.03 Engine layout and load diagram

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Since the PTO power is less than 10% of the SMCR power, only first governor
stability criteria should be considered. There is no need for further considera-
tions about the impact of the PTO towards governor stability. As an example
of evaluating according to the first governor stability criteria, consider a
6S60ME-C10 engine and:
▪ NMCR (L1) of 14,940 kW at 105 rpm (80% of L1 as on Fig. 2.03.12)
▪ SMCR of 11,950 kW at 99.8 rpm (95% of L1 as on Fig. 2.03.12).

For a mechanical PTO power of:

▪ 9% of SMCR, which corresponds to: 0.09 x 11,905 = 1,070 kW
▪ available in a speed range from 80 - 102% of SMCR
which is: 80% x 95% = 76% to 102% x 95% = 97% of NMCR.
Absolute Relative to SMCR Relative to NMCR
Speed [rpm] Power [kW] Speed [%] Power [%] Speed [%] Power [%]

101.8 1070 102 9.0 97 7.2

79.8 1070 80 9.0 76 7.2

59.9 800 60 6.7 57 5.4

Table 2.03.02: Values of PTO realtive to an SMCR of 11950 kW at 99.8 rpm

relative to NMCR of 14940 kW at 105 rpm.
This is plotted relative to the first governor stability criteria, as this PTO power
represents 7.2% of the power at NMCR. The PTO is available down to 60% of
SMCR speed, and it delivers a constant torque between 60% and 80% of
SMCR speed. It means that the PTO delivers a reduced power proportional to
the speed reduction, compared to the speed at which the nominal PTO
power is available: 60%/80% x 1070 = 800 kW. This corresponds to 5.4% of
NMCR power and 60% x 95% = 57% of the NMCR speed. This is depicted in
Fig. 2.3.13.
2.03 Engine layout and load diagram

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Fig. 2.03.13: First governor stability criteria for maximum mechanical PTO and
PTO power in the example with an 6S60ME-C10, see table 2.

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Example 3: Engine coupled to FPP with PTO, and increased light running margin
In this example, a PTO of 18% of the SMCR is desired, which represents a
larger percentage of the SMCR power than considered in example 2.
To accommodate the larger PTO in a desired range of 80–100% of the
SMCR-speed (75–95% on Fig. 2.03.14), the light running margin is increased
to 9%. For the present SMCR located at 95% of the L1-speed, a 9% light run-
ning margin is still within the limit given by the minimum value of 110% SMCR-
speed, or 105% L1-speed.
As the PTO power exceeds 15% of the SMCR power, interface option C
between the power management system and the engine control system is a
prerequisite for applying the PTO to ensure sufficient governor stability. A
plant specific evaluation of the governor stability is part of the application of in-
terface option C.

2.03 Engine layout and load diagram

Fig. 2.03.14: Engine coupled to a fixed pitch propeller and shaft generator.
The load diagram is the result of selecting the MP/SMCR within the layout
area, the PTO layout limit (line 10), and the light propeller curve plus the PTO
power (dashed).

Example 4: Engine coupled to FPP with PTO, increased SMCR power, and rpm-extended load
diagram
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In this case, an increase of the PTO power to 24% of the SMCR power is
considered. If considering the same absolute propeller curve as in example 3,
the power cannot be accommodated within the PTO layout limit. For the sake
of example, it is not desirable to increase the propeller light running margin
further by decreasing the propeller pitch since it affects the propeller efficiency
negatively.
To accommodate the higher power of the PTO, the SMCR power is increased
by 7% while the SMCR-speed is maintained. This results in an engine that de-
livers a higher torque, see Fig. 2.03.15. The SMCR increase has the con-
sequence that the propeller light running margin at 100% of SMCR power
now corresponds to 11.5% - without changing the propeller pitch.

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Fig. 2.03.15: Engine coupled to a fixed pitch propeller, and a very large shaft
generator of 24% of SMCR. The load diagram is the result of selecting the
MP/SMCR within the layout area, the PTO layout limit (line 10), and the light
propeller curve plus the PTO power (dashed line).

In this example, the light propeller curve will deliver 100% power at 111.5% of
SMCR speed, or 106% of L1-speed. This is beyond the criteria of the min-
imum value of 110% of SMCR-speed, or 105% of L1-speed.
For speed-derated engines, it is possible to extend the maximum speed limit
to maximum 105% of the engine’s L1/L2 speed (line 3 in Fig. 2.03.08), but only
if the torsional vibration conditions permit this. Thus, with respect to torsional
vibrations, the shafting has to be approved by the classification society in
question, based on the selected extended maximum speed limit.
When choosing an increased light running margin, the load diagram area may
be extended from line 3 to line 3’, as shown in Fig. 2.03.07.
2.03 Engine layout and load diagram

The increased light propeller curve (line 6), may have a correspondingly in-
creased light running margin before exceeding the torque/speed limit (line 4).
In this example, the rpm extension of the load diagram will have limited effect.
Relative to the SMCR, 105% of L1-speed corresponds to 110.5%. Thereby,
100% power will not be available for continuous operation only by loading the
engine with the propeller and with the hull as in sea trial condition.
For further speed-derated engines, the effects of the rpm-extended load dia-
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gram will be greater.

As for sea trial, 107% of L1-speed is available for demonstrating full power, if
torsional vibration conditions permits, see Fig. 2.03.02. In this example, it cor-
responds to 112.5% of the SMCR. If 100% power is to be available only for
propeller load for continuous operation, the SMCR must be further speed de-
rated, that is, the SMCR point will be moved further to the left in the layout
diagram in Fig. 2.03.15.

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As the PTO power exceeds 15% of the SMCR power, interface option C
between the power management system and the engine control system is a
prerequisite for applying the PTO to ensure sufficient governor stability. A
plant specific evaluation of the governor stability is part of the application of in-
terface option C.

Example 5: Engine coupled to CPP without PTO

If a controllable pitch propeller (CPP) is applied, the combinator curve (of the
propeller) will normally be selected for a loaded ship including sea margin. For
a given propeller speed, the combinator curve may have a given propeller
pitch, and it may be heavy running in heavy weather like for a fixed pitch pro-
peller.
Therefore, it is recommended using a light running combinator curve ob-
serving the recommendations for the light running margin for a fixed pitch pro-
peller. For plants equipped with dynamic combinator curves adapting the pro-
peller pitch continuously, it is recommended to seeking an operational point
corresponding to the recommendations for the light running margin for fixed
pitch propellers.
See Fig. 2.03.16 for a typical combinator curve corresponding to 5% light run-
ning margin along the constant pitch part of the combinator curve. Even
without a PTO, some combinator curves are designed not to exceed 100% of
the SMCR-speed, as represented by the dashed line. The engine does not
prevent the combinator curve from continuing at constant pitch beyond 100%
of the SMCR-speed. However, the general speed limits of the engine must be
observed and torsional vibration conditions must permit it.
Sea and engine margins can in general be considered the same as for FP
propellers. However, as the pitch can be reduced in an encounter of adverse
weather conditions, there are no reasons for applying the AWC functionality.

2.03 Engine layout and load diagram

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Fig. 2.03.16: Engine coupled to a controllable pitch propeller without shaft

generator. The load diagram is the result of selecting the MP/SMCR within the
layout area.

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Example 6: Engine coupled to CPP with PTO

In this example, a PTO of 15% of the SMCR is desired which requires a com-
binator curve corresponding to 7% light running margin to accommodate the
PTO within the PTO layout limit, see Fig. 2.03.17.

Fig. 2.03.17: Engine coupled to a controllable pitch propeller with a shaft gen-
erator corresponding to 15% of the SMCR power. The load diagram is the
result of selecting the MP/SMCR within the layout area.

As for a fixed pitch propeller, the combined load of the combinator curve and
PTO power must lie within the PTO layout limit.
Even if the pitch of the CP propeller can be reduced to accommodate the
PTO, when full PTO power is needed, it may be an advantage to increase the
SMCR power as in example 4, if high ratios of PTO power are to be available.
2.03 Engine layout and load diagram

Especially if full utilisation of the PTO power is foreseen for the major part of
the operational time.
As the PTO power exceeds 10% of the SMCR power, interface option C
between the power management system and the engine control system is a
prerequisite for applying the PTO to ensure sufficient governor stability for a
CPP plant. A plant-specific evaluation of the governor stability is part of the
application of interface option C. For CPP plants, this evaluation also con-
siders the margin against overspeed if a total load loss takes place on the
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PTO, while the propeller is at zero pitch. This scenario can take place during
manoeuvring if the PTO drives the thrusters.
Contact Marine Project Engineering2S@man-es.com for enquires and assist-
ance with the layout of the engine.

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Example 7: Utilisation of PTO option 2 for EEDI on an LPG carrier

The following two examples consider the application and impact of applying
PTO option 2 for EEDI. Consider an LPG carrier with a 6G60ME-C10.5-LGIP
engine with:
▪ SMCR of 11,200 kW at 90 rpm
▪ 10% propeller light running margin
▪ PTO with 2,070 kWe power
▪ Considering a 90% efficiency, this results in: PPTO = 2,300 kW mechanic
load.

This example covers the basics of what is shown in the previous Fig. 2.03.06.

The SMCR of 11,200 kW and PPTO = 2,300 kW implies that:

PLIM, propulsion = PSMCR - PPTO = 11,200 - 2,300 = 8,900 kW

Whereby, PME used in the EEDI calculation is:

PME, opt. 2 = 0.75 x PLIM, propulsion = 6,675 kW

This can be compared to the value attained by applying option 1:

PME, opt. 1 = 0.75 x (PSMCR - PPTO)

↕
PME, opt. 1 = 0.75 x (PSMCR - PAE / 0.75) = 0.75 x (11,200 - 530 / 0.75 ) = 7,870
kW

Example 8: Utilisation of PTO option 2 for EEDI on a Kamsarmax (82k dwt) bulk carrier
Consider a Kamsarmax bulk carrier with a 6S60ME-C10.5 engine with: 2.03 Engine layout and load diagram
▪ SMCR in L4 of 9,000 kW at 84 rpm
▪ 7% propeller light running margin
▪ PTO with 900 kWe power, a replacement for one of the typically three
auxiliary engines
▪ Considering a 90% efficiency, this results in PPTO = 1,000 kW mechanic
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load.

The SMCR of 9,000 kW and PPTO = 1,000 kW imply that:

PLIM, propulsion = PSMCR - PPTO = 9,000 - 1,000 = 8,000 kW

PME, opt. 2 = 0.75 x PLIM, propulsion = 6,000 kW

All engines 29 (32)

199 06 11-0.1 MAN Energy Solutions

This can be compared to the value attained by applying option 1:

PME, opt. 1 = 0.75 x (PSMCR - PPTO)
↕
PME, opt. 1 = 0.75 x (PSMCR - PAE / 0.75) = 0.75 x (9,000 - 450 / 0.75 ) = 6,300 kW

If the vessel had to attain the same EEDI as per PTO option 2 for EEDI without
the PTO, the SMCR of the engine should be approx. 8,000 kW. However, this
rating would imply a change of engine selection to a 5S60ME-C10.5 with
SMCR of 8,000 kW at 84 rpm.
Fig. 2.03.18 shows the difference between limitations for continuous loading
for these two different ratings, when applying the same absolute propeller with
a light running margin of 7% to the original SMCR.
2.03 Engine layout and load diagram

Fig. 2.03.18: Difference in limits for continuous loading of engines with an

SMCR of 9,000 kW at 84 rpm relative to an SMCR of 8,000 kW at 84 rpm. By
2024-02-16 - en

applying PTO option 2 for EEDI for the high SMCR, it is possible to attain the
same EEDI value as for the low SMCR without PTO.
Furthermore, it illustrates that by applying PTO option 2 for EEDI, it is possible
to apply an engine with a higher rating than otherwise applicable. This would
enable a higher torque for the same EEDI value as without PTO, thereby en-
suring that there is a good margin for operation of the PTO in calm waters and
less ideal conditions alike. This allows for a high utilisation rate of the PTO in
service to the benefit of the overall plant efficiency. In this specific example,
the derating extent for the 6S60ME-C10.5 engine is furthermore greater than
for the 5S60ME-C10.5 engine, resulting in a lower SFOC.

30 (32) All engines

 MAN Energy Solutions 199 06 11-0.1

PTO layout table

Maximum (mechanical) PTO power [% of SMCR power] as a function of engine speed and propeller light running margin
Engine Propeller light running margin [%]
speed [% of
SMCR]

4% 5% 6% 7% 8% 9% 10%

50% 7.8 8.1 8.5 8.7 9.0 9.3 9.6

51% 8.1 8.4 8.7 9.0 9.3 9.6 9.9

52% 8.3 8.7 9.0 9.3 9.7 10.0 10.3

53% 8.6 8.9 9.3 9.6 10.0 10.3 10.6

54% 8.8 9.2 9.6 9.9 10.3 10.6 11.0

55% 9.0 9.4 9.8 10.2 10.6 11.0 11.3

56% 9.3 9.7 10.1 10.5 10.9 11.3 11.7

57% 9.5 10.0 10.4 10.8 11.2 11.6 12.0

58% 9.7 10.2 10.7 11.1 11.6 12.0 12.4

59% 9.9 10.4 10.9 11.4 11.9 12.3 12.8

60% 10.1 10.7 11.2 11.7 12.2 12.7 13.1

61% 10.4 10.9 11.5 12.0 12.5 13.0 13.5

62% 10.6 11.2 11.7 12.3 12.8 13.3 13.8

63% 10.8 11.4 12.0 12.6 13.1 13.7 14.2

64% 11.0 11.6 12.3 12.9 13.5 14.0 14.6

65% 11.1 11.8 12.5 13.1 13.8 14.4 14.9

66% 11.3 12.1 12.8 13.4 14.1 14.7 15.3

67% 11.5 12.3 13.0 13.7 14.4 15.0 15.6

68% 11.7 12.5 13.2 14.0 14.7 15.3 16.0 2.03 Engine layout and load diagram
69% 11.8 12.7 13.5 14.2 15.0 15.7 16.4

70% 12.0 12.9 13.7 14.5 15.3 16.0 16.7

71% 12.1 13.0 13.9 14.7 15.5 16.3 17.1

72% 12.3 13.2 14.1 15.0 15.8 16.6 17.4

2024-02-16 - en

73% 12.4 13.4 14.3 15.2 16.1 16.9 17.8

74% 12.5 13.5 14.5 15.5 16.4 17.3 18.1

75% 12.6 13.7 14.7 15.7 16.6 17.6 18.4

76% 12.7 13.8 14.9 15.9 16.9 17.9 18.8

77% 12.8 14.0 15.1 16.1 17.2 18.2 19.1

78% 12.9 14.1 15.2 16.3 17.4 18.4 19.4

79% 13.0 14.2 15.4 16.5 17.7 18.7 19.8

All engines 31 (32)

199 06 11-0.1 MAN Energy Solutions

Maximum (mechanical) PTO power [% of SMCR power] as a function of engine speed and propeller light running margin
80% 13.0 14.3 15.5 16.7 17.9 19.0 20.1

81% 13.1 14.4 15.7 16.9 18.1 19.3 20.4

82% 13.1 14.5 15.8 17.1 18.3 19.5 20.7

83% 13.1 14.5 15.9 17.3 18.6 19.8 21.0

84% 13.1 14.6 16.0 17.4 18.8 20.0 21.3

85% 13.1 14.7 16.1 17.6 19.0 20.3 21.6

86% 13.1 14.7 16.2 17.7 19.1 20.5 21.8

87% 13.0 14.7 16.3 17.8 19.3 20.7 22.1

88% 13.0 14.7 16.4 18.0 19.5 21.0 22.4

89% 12.9 14.7 16.4 18.1 19.6 21.2 22.6

90% 12.8 14.7 16.4 18.1 19.8 21.4 22.9

91% 12.8 14.6 16.5 18.2 19.9 21.6 23.1

92% 12.6 14.6 16.5 18.3 20.0 21.7 23.4

93% 12.5 14.5 16.5 18.4 20.2 21.9 23.6

94% 12.4 14.5 16.5 18.4 20.3 22.1 23.8

95% 12.2 14.4 16.4 18.4 20.4 22.2 24.0

96% 12.0 14.2 16.4 18.4 20.4 22.3 24.2

97% 11.0 13.3 15.5 17.6 19.7 21.7 23.6

98% 9.4 11.8 14.1 16.3 18.4 20.4 22.4

99% 7.8 10.2 12.6 14.8 17.0 19.1 21.2

100% 6.1 8.6 11.0 13.4 15.6 17.8 19.9

101% 3.4 6.0 8.5 10.9 13.2 15.4 17.6

102% 0.7 3.3 5.9 8.4 10.8 13.1 15.3

2.03 Engine layout and load diagram

103% 0.0 0.6 3.3 5.8 8.3 10.6 12.9

104% 0.0 0.0 0.6 3.2 5.7 8.1 10.5

105% 0.0 0.0 0.0 0.5 3.1 5.6 8.0

106% 0.0 0.0 0.0 0.0 0.5 3.0 5.5

107% 0.0 0.0 0.0 0.0 0.0 0.4 3.0

2024-02-16 - en

108% 0.0 0.0 0.0 0.0 0.0 0.0 0.4

109% 0.0 0.0 0.0 0.0 0.0 0.0 0.0

110% 0.0 0.0 0.0 0.0 0.0 0.0 0.0

72057645578026379

Table 2.03.03: Maximum (mechanical) PTO power (a percentage of SMCR

power) as a function of engine speed, and propeller light running margin
72057645578026379

32 (32) All engines

 MAN Energy Solutions 199 19 80-4.0

Special considerations for layout of propulsion plants with ME-GA engines

Unlike any other MAN B&W engine, the ME-GA engine applies the Otto-cycle
combustion with preadmission of gaseous fuel before compressing premixed
air and fuel. The engine load diagram and the overall principles governing the
layout of a propulsion plant described previously in this chapter also apply to
plants with ME-GA engines and FPP, with a few extra aspects to consider.
For general enquiries, and for enquiries about ME-GA engines combined with
a CPP, consult MAN Energy Solutions at
MarineProjectEngineering2S@man-es.com.

Fuel ratio control activation

The Otto process is sensitive to low air-fuel gas ratio conditions in the cylin-
der, which can cause preignition, high pressure rise, high maximum pressure,
etc. A low air-fuel gas ratio may occur during operating conditions such as ac-
celeration, heavy running, warm ambient conditions, etc.
The engine control system (ECS) for the ME-GA engine automatically detects
high and low air-fuel gas ratio conditions, and takes the necessary steps to
ensure that the ME-GA engine always operates within mechanical and ther-
modynamic design limits by controlling amongst others:

▪ Exhaust gas by-pass (EGB)

2.04 Special considerations for layout of propulsion plants

▪ Addition of diesel to the combustion
▪ Gas injection timing
▪ Cylinder mean pressure balance
▪ Governor index limitation
▪ Gas standby and gas shutdown

The combined concept is termed fuel ratio control (FRC). Sensor measure-
ments of engine speed, scavenge air pressure, oxygen content, and cylinder
pressure form the basis for evaluating several parameters like heavy/light run-
ning numbers, air-fuel gas ratio, preignition, and speed of combustion. If one
parameter exceeds the threshold value, the FRC applies suitable counter-
measures depending on the specific parameter to revert the process to the
operating window.
One example of the FRC countermeasure is to replace part of the gas admis-
sion with small amounts of diesel. In this way, the amount of fuel gas needed
is reduced. As a result, the air-fuel gas ratio is increased to an acceptable
level during the compression stroke, while the potential operating time in dual-
fuel mode is maximised, and the torque capabilities of the engine ensured.
2023-10-24 - en

Another measure of the FRC is to open the EGB.

with ME-GA engines

It is not possible to define the load at which the various FRC functionalities are
activated, since it depends on ambient conditions and their influence on scav-
enge air temperature, composition of air-fuel gas mixture, dynamic load vari-
ations, etc.
During shop test, tropical-like ambient conditions can activate the FRC to ob-
tain stable operating conditions during the performance measurement. This is
acceptable, and both NOX emissions and consumptions will be corrected in
the shop test report and the technical file.

ME-GA 1 (4)
199 19 80-4.0 MAN Energy Solutions

PTO layout and interface C

The PTO layout limit described in the previous section is applicable for the
ME-GA engine as well. To accommodate the added torque for driving the
PTO within the load limits of the engine, an adequate light running margin
considering the planned operation is important.
Due to the nature of the premixed combustion in the Ottocycle, the time
between admitting the fuel and the development of torque is inherently longer.
Therefore, the improved interface option C between the PMS and the ECS in-
troduced previously in this chapter, is a prerequisite for ME-GA engines with a
PTO power exceeding 5% of SMCR power. A feedforward signal from the
PMS to the ECS for the PTO load allows for an improved governor control
and acts to avoid speed instability.
When operating the ME-GA engine along the PTO layout limit, heavy running
in itself will not activate FRC but depending on ambient conditions and load
variations, other parameters exceeding their threshold values may activate
FRC.
For specific evaluations of ME-GA engines with PTO, consult MAN Energy
Solutions at MarineProjectEngineering2S@man-es.com.

Running modes and maximum speed

On the ME-GA engine, the EGR is active in all normal operating modes. The
ME-GA engine is Tier III compliant also with FRC activated. If any failures oc-
2.04 Special considerations for layout of propulsion plants

cur on the EGR system, it will be possible to continue operation in emergency

mode with load restrictions, and NOX emissions exceeding Tier III limits.
During normal operation of the ME-GA engine, the maximum speed in dual-
fuel mode is limited to 103%. If this speed is exceeded, gas operation will
stop, and the engine changed to fuel-oil-only mode.
For a sufficient margin towards gas shutdown, it is recommended to set the
maximum speed for normal operation to 100% of the SMCR speed.
During sea trial, the maximum speed in dual-fuel mode can be increased up
to 106%, if torsional vibration conditions permit this. FRC activation may oc-
cur, depending on ambient conditions. For sea trial of plants with a light run-
ning margin higher than 6%, it will, depending on sea conditions, not neces-
sarily be possible to demonstrate 100% propulsion power in dual-fuel mode.

Extended dual-fuel mode shutdown speed for speed-derated ME-GA plants

For speed-derated plants, where the speed of the specified MCR (SMCR) lies
sufficiently below the nominal MCR (NMCR) speed, maximum speed in fuel-
oil-only mode and shutdown speed in dual-fuel mode can be increased, if tor-
sional vibration conditions permit.
2023-10-24 - en
with ME-GA engines

An increase in the possible maximum speed is especially relevant for vessels

with a large power take-off (PTO) relative to SMCR power, see Fig. 2.04.01.
For these, up to 10% light running margin may be required for a sufficient
margin between the light propeller curve and the PTO layout limit for the PTO.
The propeller light running margin is defined as the propeller speed required to
develop the SMCR power relative to the SMCR speed, for further info see
“Basic principles of ship propulsion”.

2 (4) ME-GA
 MAN Energy Solutions 199 19 80-4.0

2.04 Special considerations for layout of propulsion plants

Fig. 2.04.01: Load diagram with a light propeller curve demonstrating a 7%
light running margin with possible variations of dual-fuel mode shutdown
speed, depending on the location of SMCR relative to NMCR
General requirements and recommendations for increasing maximum speed
It is a general prerequisite that torsional vibration conditions permits any in-
crease of the maximum speed.
For a sufficient margin towards dual-fuel mode shutdown, it is recommended
to set the maximum speed for normal operation on the machinery telegraph
to no more than 100% of the SMCR speed irrespective of the possible exten-
sions below.
In adverse weather conditions, it may be required to operate the engine at a
lower speed than for calm waters in both oil and dual-fuel modes. This is to
ensure a sufficient margin for variations in engine speed as the result of en-
2023-10-24 - en

countering heavy seas, dynamic propeller ventilation, etc.

with ME-GA engines

This is especially critical if the PTO is the sole provider of electric power on-
board, as in this case a main engine shutdown would result in a blackout as
well.
Fuel ratio control (FRC) may be activated depending on actual operation con-
ditions.

ME-GA 3 (4)
199 19 80-4.0 MAN Energy Solutions

Fuel-oil-only mode
If torsional vibration conditions permit it, the general speed limitations in fuel-
oil-only mode described in Section 2.03 prevails. This implies that the max-
imum speed in fuel-oil-only mode for continuous operation can be defined ac-
cordingly:

Fuel-oil only mode max. speed, maximum: Minimum value of 110% SMCR or 105%
NMCR
18014464041306123

Dual-fuel mode shutdown

If permitted by torsional vibration conditions, the maximum speed for dual-fuel
mode shutdown may be increased using a similar criteria:

Dual-fuel mode shutdown max. speed, maximum: Minimum 106% SMCR or 103%
NMCR
18014464041306123

The lower setting of dual-fuel mode shutdown is necessary to attain a similar

margin towards the safety system shutdown speed.
18014464041306123
2.04 Special considerations for layout of propulsion plants

2023-10-24 - en
with ME-GA engines

4 (4) ME-GA
 MAN Energy Solutions 1991524-1.0

SFOC guarantee conditions

The specific fuel oil consumption (SFOC) is given in g/kWh based on the refer-
ence ambient conditions stated in ISO 3046-1:2002(E) and ISO
15550:2002(E):
▪ 1,000 mbar ambient air pressure
▪ 25°C ambient air temperature
▪ 25°C scavenge air coolant temperature.
The SFOC is based on fuels with lower calorific values (LCV) as specified in
Table 2.05.01.

Fuel type (Engine type) LCV [kj/kg]

Diesel 42,700

Methane (GI) 50,000

Ethane (GIE) 47,500

Methanol (LGIM) 19,900

LPG (LGIP) 46,000

178 69 17-6.0.0

Table 2.05.01: Lower calorific values of fuels

For ambient conditions that are different from the ISO reference conditions,
the SFOC will be adjusted according to the conversion factors in Table
2.05.02.

With Without
Pmax Pmax
adjusted adjusted

Parameter Condition change SFOC SFOC

change change

Scav. air coolant temperature per 10°C rise +0.60% +0.41%

Blower inlet temperature per 10°C rise +0.20% +0.71%

Blower inlet pressure per 10 mbar rise -0.02% -0.05%

2.05 SFOC guarantee conditions
Fuel, lower calorific value per 1% -1.00% -1.00%

178 69 18-8.0.0

Table 2.05.02: Specific fuel oil consumption conversion factors

2023-01-18 - en

A 1°C increase of the scavenge air coolant temperature, results in a corres-

ponding 1°C increase of the scavenge air temperature, and if pmax is un-
changed SFOC increases 0.06%.

All Engines 1 (4)

1991524-1.0 MAN Energy Solutions

SFOC guarantee
The SFOC guarantee refers to the above ISO reference conditions, the lower
calorific values, and is valid for one running point only.
The energy efficiency design index (EEDI) has increased the focus on partload
SFOC. We therefore offer the option of selecting the SFOC guarantee at a
load point in the range between 50% and 100%, EoD: 4 02 002.
All engine design criteria, for example heat load, bearing load and mechanical
stresses on the construction, are defined at 100% load, independent of the
guarantee point selected. This means that turbocharger matching, engine ad-
justment and engine load calibration must also be performed at 100% load,
independent of the guarantee point. At 100% load, the tolerances are com-
pensated for by matching, adjustment and calibration, the SFOC tolerance is
5%.
When choosing an SFOC guarantee below 100%, the tolerances will affect
engine running at the lower SFOC guarantee load point. This includes toler-
ances on measurement equipment, engine process control, and turbocharger
performance.
Consequently, the SFOC guarantee depends on the selected guarantee point,
and it s given with a tolerance of:

Engine load SFOC tolerance

(% of SMCR)

100 - 85% 5%

<85 - 65% 6%

<65 - 50% 7%

Table 2.05.03: SFOC tolerance depending on engine load

Please note that the SFOC guarantee can only be given in one (1) load point.
2.05 SFOC guarantee conditions

2023-01-18 - en

2 (4) All Engines

 MAN Energy Solutions 1991524-1.0

Cooling water temperature during normal operation

In general, it is recommended to operate the main engine with the lowest pos-
sible cooling water temperature to the air coolers, as this will reduce the fuel
consumption of the engine and improve the engine performance.
When operating with 36°C cooling water temperature setpoint instead of, for
example, 10°C (to the air coolers), the SFOC will increase by approx. 2 g/
kWh.
With a lower cooling water temperature, the air cooler and water mist catcher
will remove more water from the compressed scavenge air. This has a posit-
ive effect on the cylinder condition as the humidity level in the combustion
gasses is lowered, and the tendency to condensation of acids on the cylinder
liner is thereby reduced.

Derating for lower specific fuel oil consumption

Fig. 2.05.01: Layout diagram showing MEP derating along L1-L2 (reduced
SFOC) and power and speed derating along L1-L3 (SFOC is unchanged)
The ratio between the maximum firing pressure (Pmax) and the mean effective
pressure (MEP) is influences the efficiency of a combustion engine. If the Pmax/
2.05 SFOC guarantee conditions
MEP ratio is increased, the SFOC will be reduced.
The engine is designed to withstand a certain Pmax and this Pmax is utilised by
the engine control system when other constraints do not apply.
The maximum MEP can be chosen in a range of values defined by the layout
2023-01-18 - en

diagram of the engine, and it is therefore possible to specify a reduced MEP

to achieve a reduced SFOC. This concept is known as MEP derating or
simply derating, see Fig. 2.05.01.
If the layout point is moved parallel to the constant MEP lines, SFOC is not re-
duced, see Fig. 2.05.01.
27021650211931531

All Engines 3 (4)

1991524-1.0 MAN Energy Solutions

Engine choices when derating

Due to requirements to ship speed and possibly shaft generator power out-
put, derating is often not achieved by reducing MCR power. Instead, if al-
lowed under the EEDI, a larger engine is selected to be able to choose a
lower MEP rating, for example an engine of the same type but with an extra
cylinder.
Derating reduces the overall SFOC level. The actual SFOC for a project will
also depend on other parameters such as:
▪ Engine tuning method
▪ Engine running mode (Tier II, Tier III)
▪ Operating curve (fixed pitch propeller, controllable pitch propeller)
▪ Actual engine load
▪ Ambient conditions.
The actual SFOC for an engine can be found using the CEAS application
available at www.man-es.com --> 'Planning Tools & Downloads' --> 'CEAS
Engines Calculations'
It is possible to use CEAS to investigate the effect of derating for a particular
engine by running CEAS for different engine ratings, for example the L1 rating
(not MEP derated) and the L2 rating (fully MEP derated). This information can
be used in the initial design work where the basic layout of the propulsion
plant is decided.

Example of SFOC curves

Fig. 2.05.02 shows examples of SFOC curves for high-load tuning, part-load
(EGB-PL) and low-load (EGB-LL) exhaust gas bypass tuning for a tier II engine
operating with a fixed pitch propeller.
2.05 SFOC guarantee conditions

2023-01-18 - en

Fig. 2.05.02: Influence on SFOC from engine tuning method and actual en-
gine load
As an example, Fig. 2.05.02 illustrates the relative changes in SFOC due to
the engine tuning method and the engine load. The graphs in this figure are
only examples. Use CEAS to get actual project values.
Tier III engines do not offer the option for load tuning while in tier II mode, as
the parameters controlling the combustion process are already fixed in order
to meet both Tier II and Tier III demands.
27021650211931531

4 (4) All Engines

 MAN Energy Solutions 199 06 14-6.0

Fuel consumption in an arbitrary operating point

Once the specified MCR (M) of the engine has been chosen, the specific fuel
oil consumption in an arbitrary point S1, S2 or S3, can be estimated based on
the SFOC in points ‘1’ and ‘2’. See Fig. 2.06.01.
The SFOC values in points ‘1’ and ‘2’ can be found by using our CEAS ap-
plication, for the propeller curve I and for the constant speed curve II, giving
the SFOC in points 1 and 2, respectively. See section 20.02.
Next the SFOC for point S1 can be calculated as an interpolation between the
SFOC in points ‘1’ and ‘2’, and for point S3 as an extrapolation.
The SFOC curve through points S2, on the left of point 1, is symmetric with re-
spect to point 1. It means that at speeds lower than that of point 1, the SFOC
will also increase.
The above-mentioned method provides only an approximate value. A more
precise indication of the expected SFOC at any load can be calculated. This is
a service which is available to our customers on request. Contact MAN En-
ergy Solutions, Copenhagen at MarineProjectEngineering2S@man-es.com.

2.06 Fuel consumption in an arbitrary operating point

Fig. 2.06.01: SFOC at an arbitrary load

9007250795523467
2023-01-18 - en

All Engines 1 (1)

199 06 14-6.0 MAN Energy Solutions

9007250795523467
This page is intentionally left blank
2.06 Fuel consumption in an arbitrary operating point

2023-01-18 - en

All Engines
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water

03 Turbocharger Selection & Exhaust Gas Bypass

12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395539595

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

03 Turbocharger Selection & Exhaust Gas Bypass
MAN Energy Solutions 199 15 87-5.0

Turbocharger selection

General
Updated turbocharger data based on the latest information from the tur-
bocharger makers are available from the Turbocharger selection program on
www.man-es.com --> 'Turbocharger selection'.
The data specified in the printed edition are valid at the time of publishing.
The MAN B&W engines are designed for the application of either MAN,
Accelleron or MHI turbochargers.
The turbocharger choice is made with a view to obtaining the lowest possible
Specific fuel oil consumption (SFOC) values at the nominal MCR by applying
high efficiency turbochargers.
The engines are, as standard, equipped with as few turbochargers as pos-
sible, see Table 3.01.01 & 3.01.02.
One more turbocharger can be applied, than the number stated in the tables,
if this is desirable due to space requirements, or for other reasons. Additional
costs are to be expected.
However, we recommend the ‘Turbocharger selection’ program on the Inter-
net, which can be used to identify a list of applicable turbochargers for a spe-
cific engine layout.
For information about turbocharger arrangement and cleaning systems, see
Section 15.01.

High efficiency turbochargers for the G70ME-C10.5-GA engines - L1 output

Cylinders MAN Accelleron MHI
5 1×TCT30 1×A260 1×MET42MBII
1×A170 1×MET53MBII

6 - 1×A165 1×MET48MBII
1×A270 1×MET60MBII
36028850201289099

Table 3.01.01: High efficiency turbochargers

36028850201289099
3.01 Turbocharger selection

G70ME-C10.5-GA 1 (1)
199 15 87-5.0 MAN Energy Solutions

36028850201289099
This page is intentionally left blank
3.01 Turbocharger selection

G70ME-C10.5-GA
 MAN Energy Solutions 198 45 93-4.7

Climate conditions and exhaust gas bypass

Extreme ambient conditions

As mentioned in Chapter 1, the engine power
figures are valid for tropical conditions at sea
level: 45 °C air at 1,000 mbar and 32 °C sea-
water, whereas the reference fuel consumption is given at ISO conditions: 25
°C air at 1,000 mbar and 25 °C charge air coolant temperature.
Marine diesel engines are, however, exposed to greatly varying climatic tem-
peratures winter and summer in arctic as well as tropical areas. These vari-
ations cause changes of the scavenge air pressure, the maximum combustion
pressure, the exhaust gas amount and temperatures as well as the specific
fuel oil consumption.
For further information about the possible
countermeasures, please refer to our publication titled:
Influence of Ambient Temperature Conditions
The publication is available at
www.man-es.com → ‘Marine’ → ‘Products’ → ‘Planning Tools and Downloads’
→ ’Technical Papers’.

Arctic running condition

For air inlet temperatures below -10 °C the precautions to be taken depend
very much on the operating profile of the vessel. The following alternative is
one of the possible countermeasures. The selection of countermeasures,
however, must be evaluated in each individual case.

3.02 Climate conditions and exhaust gas bypass

Exhaust gas receiver with variable bypass
Option: 4 60 118
Compensation for low ambient temperature can be obtained by using exhaust
gas bypass
system.
This arrangement ensures that only part of the exhaust gas goes via the tur-
bine of the turbocharger, thus supplying less energy to the compressor which,
in turn, reduces the air supply to the engine.
Please note that if an exhaust gas bypass is applied, the turbocharger size
and specification has to be determined by other means than
stated in this Chapter.
2023-03-27 - en

Emergency Running Condition

Exhaust gas receiver with total bypass flange and blank counterflange
Option: 4 60 119
Bypass of the total amount of exhaust gas round the turbocharger is only
used for emergency
running in the event of turbocharger failure on engines, see Fig. 3.02.01.

80-30MC/MC-C/ME-C/ME-B/-GI/-GA 1 (2)
198 45 93-4.7 MAN Energy Solutions

This enables the engine to run at a higher load with only one turbocharger un-
der emergency conditions. The engine’s exhaust gas receiver will in this case
be fitted with a bypass flange of approximately the same diameter as the inlet
pipe to the turbocharger. The emergency pipe is yard’s supply.

18014449383169675

Fig. 3.02.01: Total bypass of exhaust for

emergency running
18014449383169675
3.02 Climate conditions and exhaust gas bypass

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2 (2) 80-30MC/MC-C/ME-C/ME-B/-GI/-GA
 MAN Energy Solutions 198 84 47-2.2

Emission control

IMO Tier II NOx emission limits

As standard, all ME, ME-B and ME-C/-GI/-GA engines fulfill the IMO Tier II
NOx emission requirements, a speed-dependent NOx limit measured
according to ISO 8178 Test Cycles E2/E3 for Heavy Duty Diesel Engines.
The E2/E3 test cycles are referred to in the Extent of Delivery as EoD: 4 06
200 Economy mode with the options: 4 06 201 Engine test cycle E3, or 4 06
202 Engine test cycle E2.

NOx reduction methods for IMO Tier III

As adopted by IMO for future enforcement, the engine must fulfil the more re-
strictive IMO Tier III NOx requirements when sailing in a NOx emission control
area (NECA).
The Tier III NOx requirements can be met by exhaust gas recirculation (EGR), a
method which directly affects the combustion process by lowering the gener-
ation of NOx.
Alternatively, the required NOx level could be met by installing a selective cata-
lytic reduction (SCR) system, an aftertreatment system that reduces the emis-
sion of NOx already generated in the combustion process.
ME-GA engines which operate on gas supplied at low pressure during the
compression (Otto process) also comply with Tier III NOx requirements. The
engine is configured as an EGR engine which utilises the EGR process to pre-
vent knocking and to suppress the methane slip. When operating in fuel oil
mode, the engine operates according to the diesel process and applies the
EGR for Tier II and III compliance.
Details of MAN Energy Solutions' NOx reduction methods for IMO Tier III can
be found in our publication:
Emission Project Guide
The publication is available at www.man-es.com ’Project Guides’ -->’Other
Guides’.
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3.03 Emission control

ME-C/-GI/-GA and ME-B 1 (1)

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3.03 Emission control

ME-C/-GI/-GA and ME-B

MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
04 Electricity Production

18 Monitoring Systems and Instrumentation

19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395543819

1 (1)
 MAN Energy Solutions

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04 Electricity Production
 MAN Energy Solutions 199 12 73-5.1

Electricity production and hybrid solutions

Introduction
Hotel load and other electric consumptions are significant fuel consumers on
a vessel, second only to propulsion power. It is consistently necessary to pro-
duce most, if not all, of the electricity on board due to the long voyages. The
following machinery produces, running either alone or in parallel, the required
electricity:
1. Auxiliary diesel or dual-fuel generating sets
2. Main engine driven generators
3. Exhaust gas or steam driven turbo generators using exhaust gas waste
heat
4. Emergency diesel generating sets
5. Marine battery systems
6. Solar cells
The machinery installed should be selected based on the environmental im-
pact, and an economic evaluation of first cost, operating costs, spare part
costs, and the demand for work hours for maintenance.
The following sections give technical information about main engine driven
generators (power take-off), different PTO configurations with exhaust gas
and steam driven turbo generators, and auxiliary diesel generating sets pro-
duced by MAN Energy Solutions

Power take-off

4.01 Electricity production and hybrid solutions

A generator coupled to a power take-off (PTO) from the main engine enables
production of electrical power based on the main engine’s low specific fuel oil
and gas consumption (SFOC/SGC). As of 2020, the use of a PTO solution
has a positive effect on the attained EEDI, which can be evaluated according
to IMO rules. The PTO maximum service power should be evaluated regard-
ing two independent aspects:
1. Thermal overload of the engine and
2. Rpm stability/load change capability of the engine.
MAN Energy Solutions has developed guidelines to assist you with the layout
of systems with PTO. See the next paragraph ‘PTO maximum service power’
to assess thermal overload. Refer to section 17.06 ‘Governor stability evalu-
ation for special propulsion plants’ for evaluation of the rpm stability/load
2021-09-21 - en

change capability of the engine. Several standardised PTO systems are avail-
able; see the paragraph ‘Designation’ later in this chapter.

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PTO maximum service power

This document refers to the electrical output of the PTO as PTOE, the mech-
anical input to the PTO from the engine as PTOM and the PTO efficiency as
ηPTO. They are related according to the following law:

PTOE
PTOM = _____
ηPTO

Fig. 4.01.01 shows an example of maximum PTO service power (not neces-
sarily rated power) provided by the PTO maker, that is, how much power is
available for the specific machinery in the speed range. PM is the maximum
selected power of the PTO, and nM the maximum selected speed. PM cannot
coincide with the SMCR power of the engine, but nM can, though it is not al-
ways the case.
The designed maximum service power must observe the guideline of MAN
Energy Solutions. It means that the maximum service power must be within
the boundaries given by the light propeller curve and the PTO layout limit, see
section 2.03 ‘Engine Layout and Load Diagram’.
Due to the general shape of the PTO layout limit and the PTO characteristics,
it is sufficient to verify each corner of the operating range with equation 1,
equation 2, and equation 3 to avoid thermal overload. In Fig. 4.01.01, those
corners are located at 52.5%, 70%, and 100% of the engine speed.
4.01 Electricity production and hybrid solutions

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Fig. 4.01.01: Example of PTO maximum service power

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 MAN Energy Solutions 199 12 73-5.1

PSMCR and nSMCR is the power, and the engine speed of rotation at the SMCR
point, respectively. n is the specific engine speed of rotation at which the
mechanical PTO power is generated, LRM is the propeller light running mar-
gin, and EMP the engine margin for PTO operation (the minimum recommen-
ded margin is 5%).

4.01 Electricity production and hybrid solutions

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Designation
A PTO system can be designed in different way. MAN Energy Solutions cat-
egorises a design according to two classifications: engine-to-generator and
generator-to-grid.
The engine-to-generator classification relates to the position of the PTO sys-
tem, and the connection between the engine and the system. The generator-
to-grid classification relates to the frequency of the power fed to the grid, and
the systems between the generator and the grid.
The generator-to-grid classification relates to:
1. The frequency of the power fed to the grid but also to
2. The type of/composition of the systems between the generator and the
grid.
Two positions are available on the engine for the installation of a PTO system:
the aft end (towards the propeller) and the front end. Side-mounted systems
are currently not available. Front-end mounted generators can be mounted
on-engine or on-tank-top.
They can be connected either using an elastic coupling or directly coupled to
the crankshaft. Aft-end mounted generators are mounted either on the shaft
or through a tunnel-gear. Fig. 4.01.02 illustrates the options. It is important to
note that some of the PTO solutions might not be commercially available de-
pending on engine bore size
4.01 Electricity production and hybrid solutions

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Fig. 4.01.02: PTO layout

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 MAN Energy Solutions 199 12 73-5.1

The fluctuations in the frequency of the output electric current generated by

the shaft generator are proportional to the variation of the engine speed of ro-
tation that occurs during normal operation. Most of the electric equipment
cannot withstand large fluctuations of the current's frequency. As a result, the
system is either limited to a range in which the PTO can be operated, or a fre-
quency control system must be included.
Therefore, MAN Energy Solutions has defined two categories for PTO fre-
quency types, or generator-to-grid systems (Fig. 4.01.03). The first category is
systems with a frequency converter, and the second category is systems with
synchronous frequency. The latter has a possible sub-designation of floating
frequency (Fig. 4.01.04), which is further explained in ‘Floating Frequency Sys-
tem’.

Fig. 4.01.03: PTO frequency type

4.01 Electricity production and hybrid solutions

Fig. 4.01.04: PTO frequency type (optional)

On the design specification order (DSO), there are two spaces to fill in. The
2021-09-21 - en

PTO type, which refers to Fig. 4.01.02 and the PTO frequency type, which
consists of the three options displayed on Figs. 4.01.03 and Fig. 4.01.04.

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199 12 73-5.1 MAN Energy Solutions

Example

Fig. 4.01.05: Example of designation

4.01 Electricity production and hybrid solutions

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6 (8) All engines

 MAN Energy Solutions 199 12 73-5.1

Similarity between old and new PTO designations

MAN Energy Solutions has implemented a new way of designating PTO sys-
tems. For this reason, Fig. 4.01.06 shows the relation between old and new
designations. The figure also shows how RENK’s systems are designated.
Side-mounted PTO and RCF (RENK Constant Frequency) solutions are dis-
continued, and therefore no longer offered.

New designation Old designation RENK

FEG FC Not available IFPS

FEG SF BW I GCR RCF*

RCF*

FED FC DMG CFE

FED SF Not available

FTG FC Not available

FTG SF BW II GCR RCF*

RCF*

FTD FC Not available

FTD SF Not available

ASM FC SMG CFE

ASM SF Not available

ATG FC Not available

4.01 Electricity production and hybrid solutions

ATG SF BW IV GCR RCF*
RCF*

N/A BW III* GCR RCF*

RCF*

* Discontinued
Table 4.01.01: Equivalence between old and new PTO designations
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199 12 73-5.1 MAN Energy Solutions

Floating frequency systems

If most of the electrical equipment is suited for a supply with varying fre-
quency, for example between 50 - 60 Hz, a PTO/SF configuration can be the
economically and technically best solution. It consists of a constant gear ratio,
that is, the frequency follows the engine speed. However, the PTO will be able
to generate the required electricity within an engine load range of approxim-
ately 52% to 90% (80% to 97% of the SMCR speed). For the limited part of
equipment, which requires a fixed frequency, a smaller frequency converter
can be used.
Bulk carriers, tankers, and other vessels with low variations in cruise speed
will obtain the following advantages:
▪ It is simple and thereby reliable
▪ Simple electrical system
▪ Highest possible efficiency (approximately 95%)
▪ Relatively cheap.
▪ Lower electrical power consumption at part load due to the lower speed.
This will also function as an optimisation of auxiliary systems, since the re-
quired power automatically reduces at lower engine loads, whereas in a
normal system, the power required by auxiliary systems is constant.
On the other hand, parallel running of an auxiliary engine and the PTO system
is not possible with such systems, since it requires a frequency converter.
The installation of a PTO/SF system is restricted to a certain speed range, but
most likely, a speed range can be chosen according to the most typical en-
gine operating range. The electric equipment must be evaluated to establish
the correct dimensioning. As an example, the main engine lube oil pumps
4.01 Electricity production and hybrid solutions

must be dimensioned for the required flow at 50 Hz. Therefore, it is recom-

mended to use a centrifugal lube oil pump.
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 MAN Energy Solutions 199 07 97-8.0

Power take-off solutions supplied by RENK

PTO maker and supplier, RENK, provides two specific solutions: An integ-
rated front-end solution and a tunnel gearbox solution. These systems have
different layouts and characteristics. This chapter uses these as examples of
what is to be expected in the extent of delivery (EoD).

RENK IFPS© (Integrated Front-end Power System)

Fig. 1 shows the RENK IFPS. It features from one up to four generators con-
nected to the crankshaft via a single-step gearbox. The high-ratio gearbox is
designed for limited engine room space, and mounted on the engine fore end
without an additional foundation.

The IFPS system has been developed in cooperation with the German gear-
box manufacturer RENK. As standard, it is available for PTO powers of 500,
1000, 1500 and 2000 kW. The intermediate shaft is mounted directly on the
crankshaft and its gearbox housing is bolted on to a strengthened front-end
cover. The system is even compatible with a tuning wheel if required by tor-
sional vibration conditions. As an option, an angle encoder can be mounted
on the gearbox front side.

Extent of delivery for IFPS

▪ Gearbox incl. intermediate shaft
▪ Highly elastic coupling
▪ One to four generators
▪ IGBT active infeed frequency converter

4.02 Power take-off solutions supplied by RENK

▪ Transformer
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199 07 97-8.0 MAN Energy Solutions

Fig. 1: Components of the IFPS

4.02 Power take-off solutions supplied by RENK

The IFPS is designed for operation with full output PTO-power between 100%
and 70% specified speed, and with reduced power down to 50% of the en-
gine speed at specified MCR (see Fig. 2).

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Fig. 2: Operating range of the IFPS

2 (4) All engines

 MAN Energy Solutions 199 07 97-8.0

An IGBT active infeed converter provides the constant grid frequency. The
system can supply reactive power to the electric mains without a synchronous
condenser, and causes negligible harmonics to the grid.

Fig. 3: Diagram of IFPS with active infeed converters and transformer

With a small modification, the IFPS can be operated both as a generator

(PTO) and as a motor (PTI).

RENK MARHY© as auxiliary propulsion system/take-home system

Special applications require an auxiliary propulsion system/take-home system
capable of driving the propeller by using the shaft generator as an electric mo-
tor.
MAN Energy Solutions can provide a solution where the propeller is driven by
the alternator via a tunnel gearbox (RENK MARHY©). A number of gensets
produce the electric power for the propulsion mode.

4.02 Power take-off solutions supplied by RENK

The main engine is disengaged by a clutch (RENK PSC) which is made as an
integral part of the shafting. The clutch is installed between the tunnel gearbox
and the main engine. Torque transmission will be switched by a hydraulically
engaged backlash-free conical toothing. Equipped with a fully automatic PSC,
the RENK MARHY© system can quickly establish auxiliary propulsion, and
switch back to PTO operation from the engine control room and/or the
bridge, even with an unmanned engine room. The built-in thrust bearing trans-
fers the propulsion propeller thrust to the engine thrust bearing in both operat-
ing modes. In disengaged condition, a pair of sleeve bearings transmit the
bending moments and shear forces within the propeller shaft line.
To minimise the required power for auxiliary propulsion mode, a two-speed
tunnel gearbox can be used, which provides lower propeller speed, and thus
higher propeller efficiency in auxiliary propulsion mode.
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199 07 97-8.0 MAN Energy Solutions

Extent of delivery for RENK MARHY©

Included in the MARHY© system are:
▪ PSC clutch
▪ Tunnel gearbox
▪ Highly elastic coupling for gearbox input and output
▪ Generator/motor
▪ IGBT active infeed converter frequency converter
▪ Transformer
4.02 Power take-off solutions supplied by RENK

Fig. 4: Generic outline of the auxiliary propulsion system

9007250870772235

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4 (4) All engines

 MAN Energy Solutions 199 16 35-5.0

Steps for obtaining approval of a PTO solution

MAN Energy Solutions frequently receives enquiries about the different PTO
solutions described in Section 4.01. To facilitate the process of getting a pro-
ject approved, follow the necessary steps described here:
1. PTO layout guidance.
The sizing of the PTO generator must adhere to the layout guide from
MAN Energy Solutions. The guide stipulates the maximum PTO mechan-
ical power from the main engine in relation to the SMCR chosen. Sections
2.03 and 4.01 describe this in detail.
2. Governor stability evaluation for special propulsion plants (17.06)
When a PTO generator is connected to the ship’s electrical grid, it be-
comes important to evaluate whether the power management system and
the main engine can cope with the frequency converter’s inhered negative
damping on rpm stability. The sizing of the PTO generator must fulfil the
criteria of MAN Energy Solutions to prevent insufficient stability of the sys-
tem. Furthermore, MAN Energy Solutions can provide interface docu-
mentation for the connection between the main engine control system
and the ship’s power management system. For more information, see
Section (17.06).
3. Torsional vibration.
The entire propulsion train: Main engine, shafting, propeller, and PTO,
must fulfil class rules concerning torsional (and axial) vibrations. This must
be evaluated in each individual case, because every case deviates from
the other. If required, MAN Energy Solutions can assist with the analysis.
Otherwise, it is normally a matter of shipyard responsibility. It might be re-

4.03 Steps for obtaining approval of a PTO solution

quired, sometimes that a torsional vibration damper is installed.
4. Specifically for main engine front-end mounted PTO solutions.
For front-end mounted PTO solutions such as RENK IFPS or HHI EMG,
the interface between the main engine front end and the PTO system
must be identified to determine the scope of delivery together with that of
the main engine, and the PTO solution. The result of the torsional analysis
can involve installation of large tuning wheels and/or torsional dampers,
which will affect the scope of delivery. This can necessitate the installation
of an extra bearing on the main engine side to cope with the weight of
these parts. Be aware that such cases differ from one another, and that
MAN Energy Solutions can assist in the evaluation of whether direct
mounted PTO solutions can be accepted or not.
We strongly recommend that shipyards involve MAN Energy Solutions in the
design phase of a new ship with a PTO solution. It is important to choose the
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correct PTO size compared to the main engine size, and to comply with the
IMO EEDI rules. Figs. 1–4 show examples of different PTO solutions.
Figs. 1–4 show examples of different PTO solutions.

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199 16 35-5.0 MAN Energy Solutions

Fig. 1: Intermediate shaft mounted generator. A solution mostly used on large

container ships using high-power PTO generator sizes. Image of intermediate
shaft mounted generator for the EEE class synchronous motor/generator (by
Ccourtesy of Siemens).
4.03 Steps for obtaining approval of a PTO solution

Fig. 2: An example of a tunnel-geared PTO generator solution – RENK MAR-

HY®. The solution is used for many different ship types, but in particular for
ro-ro ships and container feeders (Courtesy of RENK).

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 MAN Energy Solutions 199 16 35-5.0

Fig. 3: Main engine front-end mounted PTO – RENK IFPS. The new PTO
solution allows for a short engine room due to the short total length of main
engine and PTO. The solution is particularly useful for tankers and bulk carri-
ers (. Courtesy of RENK).

Fig. 4: Main engine front-end mounted PTO – HHI EMG (Engine Mounted
Generator). The new PTO solution allows the maximum cargo capacity with its
short installation space, especially for tankers, LNGC carriers, and bulk carri-
ers (Courtesy of HHI).
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199 16 35-5.0 MAN Energy Solutions

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4.03 Steps for obtaining approval of a PTO solution

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All engines
 MAN Energy Solutions 198 43 16-8.9

Power take off/gear constant ratio

PTO type: BW II/GCR

Power Take Off/Gear Constant Ratio

The PTO system type BW II/GCR illustrated in Fig. 4.01.01 alternative 5 can
generate electrical power on board ships equipped with a controllable pitch
propeller, running at constant speed.
The PTO unit is mounted on the tank top at the fore end of the engine see
Fig. 4.04.01. The PTO generator is activated at sea, taking over the electrical
power production on board when the main engine speed has stabilised at a
level corresponding to the generator frequency required on board.
The installation length in front of the engine, and thus the engine room length
requirement, naturally exceeds the length of the engine aft end mounted shaft
generator arrangements. However, there is some scope for limiting the space
requirement, depending on the configuration chosen.

4.04 Power take off/gear constant ratio

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Fig. 4.04.01: Generic outline of Power Take Off (PTO) BW II/GCR

70-30ME-C/-ME-B/-GI/-LGI/-GA 1 (4)
198 43 16-8.9 MAN Energy Solutions

PTO type: BW IV/GCR

Power Take Off/Gear Constant Ratio

The shaft generator system, type PTO BW IV/ GCR, installed in the shaft line
(Fig. 4.01.01 alternative 6) can generate power on board ships equipped with
a controllable pitch propeller running at constant speed.
The PTO system can be delivered as a tunnel gear with hollow flexible coup-
ling or, alternatively, as a generator step-Žup gear with thrust bearing and flex-
ible coupling integrated in the shaft line.
The main engine needs no special preparation for mounting these types of
PTO systems as they are connected to the intermediate shaft.
The PTO system installed in the shaft line can also be installed on ships
equipped with a fixed pitch propeller or controllable pitch propeller running in
combinator mode. This will, however, require an additional Constant Fre-
quency gear (Fig. 4.01.01 alternative 2) or additional electrical equipment for
maintaining the constant frequency of the generated electric power.

Tunnel gear with hollow flexible coupling

This PTO system is normally installed on ships with a minor electrical power
take off load compared to the propulsion power, up to approximately 25% of
the engine power.
The hollow flexible coupling is only to be dimensioned for the maximum elec-
trical load of the power take off system and this gives an economic advantage
for minor power take off loads compared to the system with an ordinary flex-
ible coupling integrated in the shaft line.
The hollow flexible coupling consists of flexible segments and connecting
pieces, which allow replacement of the coupling segments without dismount-
ing the shaft line, see Fig. 4.04.02.
4.04 Power take off/gear constant ratio

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2 (4) 70-30ME-C/-ME-B/-GI/-LGI/-GA
 MAN Energy Solutions 198 43 16-8.9

Fig. 4.04.02: Generic outline of BW IV/GCR, tunnel gear

Generator step-up gear and flexible coupling integrated in the shaft line
For higher power take off loads, a generator stepŽ-up gear and flexible coup-
ling integrated in the shaft line may be chosen due to first costs of gear and
coupling.
The flexible coupling integrated in the shaft line will transfer the total engine
load for both propulsion and electrical power and must be dimensioned ac-
cordingly.
The flexible coupling cannot transfer the thrust from the propeller and it is,
therefore, necessary to make the gearŽbox with an integrated thrust bearing.
This type of PTO system is typically installed on ships with large electrical
power consumption, e.g. shuttle tankers.

Auxiliary Propulsion System/Take Home System

From time to time an Auxiliary Propulsion System/ Take Home System cap-
able of driving the CP propeller by using the shaft generator as an electric mo-
tor is requested.
MAN Energy Solutions can offer a solution where the CP propeller is driven by
the alternator via a twoŽ speed tunnel gear box. The electric power is pro-
duced by a number of GenSets. The main engine is disengaged by a clutch
(RENK PSC) made as an integral part of the shafting. The clutch is installed
between the tunnel gear box and the main engine, and conical bolts are used
to connect and disconnect the main engine and the shafting. See Figure
4.04.03.
A thrust bearing, which transfers the auxiliary propulsion propeller thrust to the
engine thrust bearing when the clutch is disengaged, is built into the RENK
PSC clutch. When the clutch is engaged, the thrust is transferred statically to
the engine thrust bearing through the thrust bearing built into the clutch.

4.04 Power take off/gear constant ratio

To obtain high propeller efficiency in the auxiliary propulsion mode, and thus
also to minimise the auxiliary power required, a twoŽ speed tunnel gear, which
provides lower propeller speed in the auxiliary propulsion mode, is used.
The two speed tunnel gear box is made with a friction clutch which allows the
propeller to be clutched in at full alternator/motor speed where the full torque
is available. The alternator/motor is started in the deŽclutched condition with a
start transformer.
The system can quickly establish auxiliary propulsion from the engine control
room and/or bridge, even with unmanned engine room.
2022-02-11 - en

ReŽestablishment of normal operation requires attendance in the engine room

and can be done within a few minutes.

70-30ME-C/-ME-B/-GI/-LGI/-GA 3 (4)
198 43 16-8.9 MAN Energy Solutions

Fig. 4.04.03: Auxiliary propulsion system

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4.04 Power take off/gear constant ratio

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4 (4) 70-30ME-C/-ME-B/-GI/-LGI/-GA
MAN Energy Solutions 199 16 64-2.0

Waste heat recovery systems - TII

General
Due to the increasing fuel prices seen from 2004 and onwards many
shipowners have shown interest in efficiency improvements of the power sys-
tems on board their ships. A modern two-stroke diesel engine has one of the
highest thermal efficiencies of today’s power systems, but even this high effi-
ciency can be improved by combining the diesel engine with other power sys-
tems.
One of the possibilities for improving the efficiency is to install one or more
systems utilising some of the energy in the exhaust gas after the two-stroke
engine, which in MAN Energy Solutions terms is designated as WHRS (Waste
Heat Recovery Systems).
WHRS can be divided into different types of subsystems, depending on how
the system utilises the exhaust gas energy. Choosing the right system for a
specific project depends on the electricity demand on board the ship and the
acceptable first cost for the complete installation. MAN Energy Solutions uses
the following designations for the current systems on the market:

• PTG (Power Turbine Generator):

An exhaust gas driven turbine connected to a generator via a gearbox.

• STG (Steam Turbine Generator):

A steam driven turbine connected to a generator via a gearbox. The steam is
produced in a large exhaust gas driven boiler installed on the main engine ex-
haust gas piping system.

• Combined Turbines:
A combination of the two first systems. The arrangement is often that the
power turbine is connected to the steam turbine via a gearbox and the steam
turbine is further connected to a large generator, which absorbs the power
from both turbines.

4.05 Waste heat recovery systems - TII

The PTG system will produce power equivalent to approx. 3.5% of the main
engine SMCR, when the engine is running at SMCR. For the STG system this
value is between 5 and 7% depending on the system installed. When combin-
ing the two systems, a power output equivalent to 10% of the main engine’s
SMCR is possible, when the engine is running at SMCR.
The WHRS output depends on the main engine rating and whether service
steam consumption must be deducted or not.
As the electrical power produced by the system needs to be used on board
the ship, specifying the correct size system for a specific project must be con-
sidered carefully. In cases where the electrical power consumption on board
the ship is low, a smaller system than possible for the engine type may be
considered. Another possibility is to install a shaft generator/motor to absorb
excess power produced by the WHRS. The main engine will then be un-
loaded, or it will be possible to increase the speed of the ship, without penal-
ising the fuel bill.
Because the energy from WHRS is taken from the exhaust gas of the main
engine, this power produced can be considered as ”free”. In reality, the main
engine SFOC will increase slightly, but the gain in electricity production on
board the ship will far surpass this increase in SFOC. As an example, the

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199 16 64-2.0 MAN Energy Solutions

SFOC of the combined output of both the engine and the system with power
and steam turbine can be calculated to be as low as 152 g/kWh (ref. LCV
42,700 kJ/kg).

Power turbine generator (PTG)

Fig. 4.05.01: PTG diagram

4.05 Waste heat recovery systems - TII

The power turbines of today are based on the different turbocharger suppli-
ers’ newest designs of high efficiency turbochargers, i.e. MAN TCA, ABB A-L
and Mitsubishi MET turbochargers.
MAN Energy Solutions offers PTG solutions called TCS-PTG in the range from
approx. 1,000 kW to 5,000 kW, see Fig. 4.05.02.
The power turbine basically is the turbine side of a normal high-efficient tur-
bocharger with some modifications to the bearings and the turbine shaft. This
is in order to be able to connect it to a gearbox instead of the normal connec-
tion to the compressor side. The power turbine will be installed on a separate
exhaust gas pipe from the exhaust gas receiver, which bypasses the tur-
bochargers.
The performance of the PTG and the main engine will depend on a careful
matching of the engine turbochargers and the power turbine, for which
reason the turbocharger/s and the power turbine need to be from the same
manufacturer. In Fig. 4.05.01, a diagram of the PTG arrangement is shown.
The newest generation of high efficiency turbochargers allows bypassing of
some of the main engine exhaust gas, thereby creating a new balance of the
air flow through the engine. In this way, it is possible to extract power from the
power turbine equivalent to 3.5% of the main engine’s SMCR, when the en-
gine is running at SMCR.

2 (10) G70ME-C10.5-GI/-GA
MAN Energy Solutions 199 16 64-2.0

Fig. 4.05.02: MAN Energy Solutions 1,500 kW TCS-PTG solution

4.05 Waste heat recovery systems - TII

G70ME-C10.5-GI/-GA 3 (10)
199 16 64-2.0 MAN Energy Solutions

Steam turbine generator (STG)

Fig. 4.05.03: STG system diagram

In most cases the exhaust gas pipe system of the main engine is equipped
with a boiler system. With this boiler, some of the energy in the exhaust gas is
utilised to produce steam for use on board the ship.
If the engine is WHR matched, the exhaust gas temperature will be between
50°C and 65°C higher than on a conventional engine, which makes it possible
4.05 Waste heat recovery systems - TII

to install a larger boiler system and, thereby, produce more steam. In short,
MAN Energy Solutions designates this system STG. Fig. 4.05.03 shows an
example of the STG diagram.
For WHR matching the engine, a bypass is installed to increase the temperat-
ure of the exhaust gas and improve the boiler output. The bypass valve is
controlled by the engine control system.
The extra steam produced in the boiler can be utilised in a steam turbine,
which can be used to drive a generator for power production on board the
ship. A STG system could be arranged as shown in Fig. 4.05.04, where a typ-
ical system size is shown with the outline dimensions.
The steam turbine can either be a single or dual pressure turbine, depending
on the size of the system. Steam pressure for a single pressure system is 7 to
10 bar, and for the dual pressure system the high-pressure cycle will be 9 to
10 bar and the low-pressure cycle will be 4 to 5 bar.

4 (10) G70ME-C10.5-GI/-GA
MAN Energy Solutions 199 16 64-2.0

Fig. 4.05.04: STG steam turbine generator arrangement with

condenser - typical arrangement

4.05 Waste heat recovery systems - TII

G70ME-C10.5-GI/-GA 5 (10)
199 16 64-2.0 MAN Energy Solutions

Full WHRS steam and power turbines combined

Fig. 4.05.05: Full WHRS with both steam and power turbines
Because the installation of the power turbine also will result in an increase of
the exhaust gas temperature after the turbochargers, it is possible to install
both the power turbine, the larger boiler and steam turbine on the same en-
gine. This way, the energy from the exhaust gas is utilised in the best way
possible by today’s components.
4.05 Waste heat recovery systems - TII

When looking at the system with both power and steam turbine, quite often
the power turbine and the steam turbine are connected to the same gener-
ator. In some cases, it is also possible to have each turbine on a separate
generator. This is, however, mostly seen on stationary engines, where the fre-
quency control is simpler because of the large grid to which the generator is
coupled.
For marine installations the power turbine is, in most cases, connected to the
steam turbine via a gearbox, and the steam turbine is then connected to the
generator. It is also possible to have a generator with connections in both
ends, and then connect the power turbine in one end and the steam turbine in
the other. In both cases control of one generator only is needed.
For dimensions of a typical full WHRS see Fig. 4.05.06.
As mentioned, the systems with steam turbines require a larger boiler to be in-
stalled. The size of the boiler system will be considerably bigger than the size
of an ordinary boiler system, and the actual boiler size has to be calculated
from case to case. Casing space for the exhaust boiler must be reserved in
the initial planning of the ship’s machinery spaces.

6 (10) G70ME-C10.5-GI/-GA
MAN Energy Solutions 199 16 64-2.0

Fig. 4.05.06: Full ST & PT full waste heat recovery unit arrangement with
condenser - typical arrangement

4.05 Waste heat recovery systems - TII

G70ME-C10.5-GI/-GA 7 (10)
199 16 64-2.0 MAN Energy Solutions

WHRS Generator Output

Guidance output of WHR for G70ME-C10.5-GI/-GA engine rated in L1at ISO conditions
Engine power PTG STG Full WHRS with
Cyl. combined turbines
% SMCR kW kWe kWe kWe
100 15,300 400 660 1,060
5
75 11,475 330 380 710

100 18,360 480 850 1,330

6
75 13,770 390 500 890

Note 1: The above given preliminary WHRS generator outputs is based on HP

service steam consumption of 0.3 ton/h and LP service steam consumption
of 0.7 ton/h for the ship at ISO condition.
Note 2: 75% SMCR is selected due to the EEDI focus on the engine load.
Because all the components come from different manufacturers, the final out-
put and the system efficiency have to be calculated from case to case.
However, Table 4.05.07 shows a guidance of possible outputs in L1 based on
theoretically calculated outputs from the system.
4.05 Waste heat recovery systems - TII

8 (10) G70ME-C10.5-GI/-GA
MAN Energy Solutions 199 16 64-2.0

WHRS output at a rating lower than L1

As engines are seldom rated in L1, it is recommended to contact MAN Energy
Solutions Copenhagen, department Marine Project Engineering,
e-mail: lee5@man-es.com for specific WHRS generator output.
In order to receive as correctly as possible an engine tuned for WHRS data,
please specify requested engine rating (power × rpm) and ship service steam
consumption (kg/hour).
Detailed information about the different WHRS systems is found in our public-
ation:

Waste Heat Recovery System (WHRS)

The publication is available at
www.man-es.com → ‘Marine’ → ‘Products’ → ‘Planning Tools and Downloads’
→ ’Technical Papers’.

Waste heat recovery element and safety valve

The boiler water or steam for power generator is preheated in the Waste Heat
Recovery (WHR) element, also called the first-stage air cooler.
The WHR element is typically built as a high-pressure water/steam heat ex-
changer which is placed on top of the scavenge air cooler, see Fig. 4.05.07.
Full water flow must be passed through the WHR element continuously when
the engine is running. This must be considered in the layout of the steam feed
water system (the WHR element supply heating). Refer to our ‘WHR element
specification’ which is available from MAN Energy Solutions, Copenhagen.

4.05 Waste heat recovery systems - TII

Fig. 4.05.07: WHR element on Scavenge air cooler

G70ME-C10.5-GI/-GA 9 (10)
199 16 64-2.0 MAN Energy Solutions

Safety valve and blow-Off

In normal operation, the temperature and pressure of the WHR element is in
the range of 140-150°C and 8-21 bar respectively.
In order to prevent leaking components from causing personal injuries or
damage to vital parts of the main engine, a safety relief valve will blow off ex-
cess pressure. The safety relief valve is connected to an external connection,
‘W’, see Fig. 4.05.08.
Connection ‘W’ must be passed to the funnel or another free space according
to the class rules for steam discharge from safety valve.
As the system is pressurised according to class rules, the safety valve must
be type approved.
4.05 Waste heat recovery systems - TII

Fig. 4.05.08: WHR safety valve blow-off through connection ‘W’ to the funnel
45036051991086859

10 (10) G70ME-C10.5-GI/-GA
 MAN Energy Solutions 198 82 80-4.2

L16/24 GenSet Data

Engine ratings
1000 rpm 1200 rpm
Engine type 1000 rpm Available turning 1200 rpm Available turning
No of cylinders direction direction
kW CW 1) kW CW 1)
5L16/24 450 Yes 500 Yes

6L16/24 570 Yes 660 Yes

7L16/24 665 Yes 770 Yes

8L16/24 760 Yes 880 Yes

9L16/24 855 Yes 990 Yes

1)
CW clockwise
Table 1: Engine ratings for emission standard - IMO Tier II

B10011_1689490-8.0

4.06 L16/24 GenSet Data

2022-07-12 - en

80-30ME-C/-ME-B/-GI/-LGI/-GA 1 (5)
198 82 80-4.2 MAN Energy Solutions

General

Cyl. no A (mm) * B (mm) * C (mm) H (mm) ** Dry weight

GenSet (t)
5 (1000 rpm) 2807 1400 4207 2337 9.5
5 (1200 rpm) 2807 1400 4207 2337 9.5

6 (1000 rpm) 3082 1490 4572 2337 10.5

6 (1200 rpm) 3082 1490 4572 2337 10.5

7 (1000 rpm) 3557 1585 5142 2337 11.4

7 (1200 rpm) 3557 1585 5142 2415 11.4

8 (1000 rpm) 3832 1680 5512 2415 12.4

8 (1200 rpm) 3832 1680 5512 2415 12.4

9 (1000 rpm) 4107 1680 5787 2415 13.1

9 (1200 rpm) 4107 1680 5787 2415 13.1

P Free passage between the engines, width 600 mm and height 2000 mm.
Q Min. distance between engines: 1800 mm.

* Depending on alternator
** Weight included a standard alternator
All dimensions and masses are approximate, and subject to changes without prior notice.
4.06 L16/24 GenSet Data

2022-07-12 - en

2 (5) 80-30ME-C/-ME-B/-GI/-LGI/-GA
 MAN Energy Solutions 198 82 80-4.2

Capacities
5L:90 kW/cyl., 6L-9L: 95 kW/cyl. at 1000 rpm 5 6 7 8 9
Engine output kW 450 570 665 760 855
Speed rpm 1000 1000 1000 1000 1000

Heat to be dissipated 3)
Cooling water cylinder kW 107 135 158 181 203
Charge air cooler; cooling water HT kW 138 169 192 213 234
Charge air cooler; cooling water LT kW 56 69 80 91 102
Lubricating oil cooler kW 98 124 145 166 187
Heat radiation engine kW 15 19 23 26 29

Flow rates 4)
Internal (inside engine)
HT circuit (cylinder + charge air cooler HT stage) m3/h 10.9 12.7 14.5 16.3 18.1
LT circuit (lub. oil + charge air cooler LT stage) m3/h 15.7 18.9 22 25.1 28.3
Lubrication oil m3/h 18 18 30 30 30
External (from engine to system)
HT water flow (at 40°C inlet) m3/h 5.2 6.4 7.4 8.3 9.2
LT water flow (at 38°C inlet) m3/h 15.7 18.9 22 25.1 28.3

Air data
Temperature of charge air at charge air cooler outlet °C 49 51 52 54 55
Air flow rate m3/h 5) 2721 3446 4021 4595 5169
kg/kWh 6.62 6.62 6.62 6.62 6.62
Charge air pressure bar 4.13 4.13 4.13 4.13 4.13
Air required to dissipate heat radiation (eng.) m3/h 4860 6157 7453 8425 9397
(t2-t1= 10°C)

Exhaust gas data 6)

Volume flow (temperature turbocharger outlet) m3/h 7) 5710 7233 8438 9644 10849
Mass flow t/h 3.1 3.9 4.5 5.2 5.8
Temperature at turbine outlet °C 375 375 375 375 375
Heat content (190°C) kW 170 216 252 288 324
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30 < 30
Permissible exhaust back pressure (SCR) mbar < 50 < 50 < 50 < 50 < 50

Pumps
External pumps 8)
Diesel oil pump (5 bar at fuel oil inlet A1) m3/h 0.32 0.40 0.47 0.54 0.60
Fuel oil supply pump (4 bar discharge pressure) m3/h 0.15 0.19 0.23 0.26 0.29
Fuel oil circulating pump 9) (8 bar at fuel oil inlet A1) m3/h 0.32 0.40 0.47 0.54 0.60
4.06 L16/24 GenSet Data

Starting air data

2022-07-12 - en

Air consumption per start, Nm3 0.47 0.56 0.65 0.75 0.84
incl. air for jet assist (IR/TDI)
Air consumption per start, incl. air for jet assist (Gali) Nm3 0.80 0.96 1.12 1.28 1.44

Capacities
5L:100 kW/cyl., 6L-9L: 110 kW/cyl. at 1200 rpm 5 6 7 8 9
Engine output kW 500 660 770 880 990
Speed rpm 1200 1200 1200 1200 1200

80-30ME-C/-ME-B/-GI/-LGI/-GA 3 (5)
198 82 80-4.2 MAN Energy Solutions

5L:100 kW/cyl., 6L-9L: 110 kW/cyl. at 1200 rpm 5 6 7 8 9

3)
Heat to be dissipated
Cooling water cylinder kW 100 132 154 177 199
Charge air cooler; cooling water HT kW 149 187 211 234 255
Charge air cooler; cooling water LT kW 66 83 96 109 122
Lubricating oil cooler kW 113 149 174 199 224
Heat radiation engine kW 17 23 26 30 34

Flow rates 4)
Internal (inside engine)
HT circuit (cylinder + charge air cooler HT stage) m3/h 13.1 15.2 17.4 19.5 21.6
LT circuit (lube oil + charge air cooler LT stage) m3/h 19.3 20.7 24.2 27.7 31.1
Lubrication oil m3/h 21 21 35 35 35
External (from engine to system)
HT water flow (at 40°C inlet) m3/h 5.7 7.3 8.4 9.4 10.4
LT water flow (at 38°C inlet) m3/h 19.1 20.7 24.2 27.7 31.1

Air data
Temperature of charge air at charge air cooler outlet °C 51 53 55 56 57
Air flow rate m3/h 5) 3169 4183 4880 5578 6275
kg/kWh 6.94 6.94 6.94 6.94 6.94
Charge air pressure bar 3.92 3.92 3.92 3.92 3.92
Air required to dissipate heat radiation (eng.) m3/h 5509 7453 8425 9721 11017
(t2-t1= 10°C)

Exhaust gas data 6)

Volume flow (temperature turbocharger outlet) m3/h 7) 6448 8511 9929 11348 12766
Mass flow t/h 3.6 4.7 5.5 6.3 7.1
Temperature at turbine outlet °C 356 356 356 356 356
Heat content (190°C) kW 178 235 274 313 352
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30 < 30
Permissible exhaust back pressure (SCR) mbar < 50 < 50 < 50 < 50 < 50

Pumps
External pumps 8)
Diesel oil pump (5 bar at fuel oil inlet A1) m3/h 0.35 0.47 0.54 0.62 0.70
Fuel oil supply pump (4 bar discharge pressure) m3/h 0.17 0.22 0.26 0.30 0.34
Fuel oil circulating pump 9) (8 bar at fuel oil inlet A1) m3/h 0.35 0.47 0.54 0.62 0.70

Starting air data

Air consumption per start, Nm3 0.47 0.56 0.65 0.75 0.84
incl. air for jet assist (IR/TDI)
Air consumption per start, incl. air for jet assist (Gali) Nm3 0.80 0.96 1.12 1.28 1.44
4.06 L16/24 GenSet Data

2022-07-12 - en

Remarks to capacities
1) HT cooling water flows first through HT stage charge air cooler, then through water jacket and cylinder head,
water temperature outlet engine regulated by mechanical thermostat.
2) LT cooling water flows first through LT stage charge air cooler, then through lube oil cooler, water temperature
outlet engine regulated by mechanical thermostat.
3) Tolerance: + 10% for rating coolers, - 15% for heat recovery.
4) Basic values for layout of the coolers.
5) Under above mentioned reference conditions.
6) Tolerance: quantity +/- 5%, temperature +/- 20°C.
Exhaust gas flow are calculated from given exhaust gas temperature at the Tropic reference condition.

4 (5) 80-30ME-C/-ME-B/-GI/-LGI/-GA
 MAN Energy Solutions 198 82 80-4.2

7) Tolerance of the pumps' delivery capacities must be considered by the manufactures.

8) In order to ensure sufficient flow through the engine fuel system the capacity of the fuel oil circulation pumps
9) must be minimum 3 times the full load consumption of the installed engines

D10050_3700002-9.2 & D10050_3700003-0.3

9007249803701131

4.06 L16/24 GenSet Data

2022-07-12 - en

80-30ME-C/-ME-B/-GI/-LGI/-GA 5 (5)
198 82 80-4.2 MAN Energy Solutions

9007249803701131
This page is intentionally left blank
4.06 L16/24 GenSet Data

2022-07-12 - en

80-30ME-C/-ME-B/-GI/-LGI/-GA
 MAN Energy Solutions 198 82 81-6.2

L21/31 GenSet Data

Engine ratings
900 rpm 1000 rpm
Engine type 900 rpm Available turning 1000 rpm Available turning
No of cylinders direction direction
kW CW 1) kW CW 1)
5L21/31 1000 Yes 1000 Yes

6L21/31 1320 Yes 1320 Yes

7L21/31 1540 Yes 1540 Yes

8L21/31 1760 Yes 1760 Yes

9L21/31 1980 Yes 1980 Yes

1)
CW clockwise
Table 1: Engine ratings for emission standard

B10011_1689496-9.0

General

1 bearing
4.07 L21/31 GenSet Data

Cyl. no A (mm) * B (mm) * C (mm) H (mm) ** Dry WEight

2021-11-12 - en

GenSet (t)
5 (900 rpm) 3959 1820 5779 3183 22.5
5 (1000 rpm) 3959 1870 5829 3183 22.5

6 (900 rpm) 4314 1870 6184 3183 26.0

6 (1000 rpm) 4314 2000 6314 3183 26.0

7 (900/1000 rpm) 4669 1970 6639 3289 29.5

80-26 engines 1 (4)

198 82 81-6.2 MAN Energy Solutions

2 bearings
Cyl. no A (mm) * B (mm) * C (mm) H (mm) ** Dry weight
GenSet (t)
5 (900/1000 rpm) 4507 2100 6607 3183 22.5

6 (900/1000 rpm) 4862 2100 6962 3183 26.0

7 (900/1000 rpm) 5217 2110 7327 3289 29.5

8 (900/1000 rpm) 5572 2110 7682 3289 33.0

9 (900/1000 rpm) 5927 2135 8062 3289 36.5

P Free passage between the engines, width 600 mm and height 2000 mm.
Q Min. distance between engines: 2400 mm (without gallery) and 2600 mm (with gallery)

* Depending on alternator
** Weight included a standard alternator
All dimensions and masses are approximate, and subject to changes without prior notice.
4.07 L21/31 GenSet Data

2021-11-12 - en

2 (4) 80-26 engines

 MAN Energy Solutions 198 82 81-6.2

Capacities
5L: 200 kW/cyl., 6L-9L: 220kW/cyl. at 900 rpm, 1-String 5 6 7 8 9
Engine output kW 1000 1320 1540 1760 1980
Speed rpm 900 900 900 900 900

External (from engine to system)

1-string cooling water (mix) °C 52.4 56.4 59.1 61.6 64.2

Heat to be dissipated 3)
Cooling water cylinder kW 208 289 347 405 464
Charge air cooler; cooling water HT kW 346 435 490 542 590
Charge air cooler; cooling water LT kW 198 244 274 303 332
Lubricating oil cooler kW 176 238 281 324 368
Heat radiation engine kW 49 65 76 87 98

Flow rates 4)
Internal (inside engine)
HT circuit (cylinder + charge air cooler HT stage) m3/h 55 55 55 55 55
LT circuit (lube oil + charge air cooler LT stage) m3/h 55 55 55 55 55
Lubrication oil m3/hh 31 31 41 41 41
External (from engine to system)
HT water flow (at 40°C inlet) m3/h 11.1 14.1 16.0 17.8 19.5
LT water flow (at 38°C inlet) m3/h 55 55 55 55 55

Air data
Temperature of charge air at charge air cooler outlet °C 52 56 58 60 62
Air flow rate m3/h 5) 6656 8786 10250 11714 13178
kg/kWh 7.28 7.28 7.28 7.28 7.28
Charge air pressure bar 4.58 4.61 4.63 4.64 4.66
Air required to dissipate heat radiation (eng.) m3/h 17980 23800 27600 31500 35300
(t2-t1= 10°C)

Exhaust gas data 6)

Volume flow (temperature turbocharger outlet) m3/h 7) 13484 17918 20981 24055 27130
Mass flow t/h 7.5 9.9 11.5 13.2 14.8
Temperature at turbine outlet °C 353 357 360 362 363
Heat content (190°C) kW 366 496 587 679 771
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30 < 30
Permissible exhaust back pressure (SCR) mbar < 50 < 50 < 50 < 50 < 50

Pumps
External pumps 8)
4.07 L21/31 GenSet Data

Diesel oil pump (5 bar at fuel oil inlet A1) m3/h 0.89 1.18 1.37 1.57 1.76
2021-11-12 - en

Fuel oil supply pump (4 bar discharge pressure) m3/h 0.30 0.39 0.46 0.52 0.59
Fuel oil circulating pump 9) (8 bar at fuel oil inlet A1) m3/h 0.89 1.18 1.37 1.57 1.76

Starting air data

Air consumption per start, incl. air for jet assist (TDI) Nm3 1.0 1.2 1.4 1.6 1.8
Air consumption per start, incl. air for jet assist (Gali) Nm3 1.8 2.1 2.4 2.7 3.0

D10050_1689479-1.5

80-26 engines 3 (4)

198 82 81-6.2 MAN Energy Solutions

Capacities
5L:200 kW/cyl., 6L-9L: 220 kW/cyl. at 1000 rpm, 1-String 5 6 7 8 9
External (from engine to system)
1-String coding water (mix) °C 50.6 54.1 56.4 58.6 60.8

Engine output kW 1000 1320 1540 1760 1980

Speed rpm 1000 1000 1000 1000 1000

Heat to be dissipated 3)
Cooling water cylinder kW 206 285 342 399 456
Charge air cooler; cooling water HT kW 321 404 455 503 548
Charge air cooler; cooling water LT kW 192 238 266 294 321
Lubricating oil cooler kW 175 236 279 322 365
Heat radiation engine kW 49 65 76 87 98

Flow rates 4)
Internal (inside engine)
HT circuit (cylinder + charge air cooler HT stage) m3/h 61 61 61 61 61
LT circuit (lube oil + charge air cooler LT stage) m3/h 61 61 61 61 61
Lubrication oil m3/h 34 34 46 46 46
External (from engine to system)
HT water flow (at 40°C inlet) m3/h 10.7 13.5 15.4 17.1 18.8
LT water flow (at 38°C inlet) m3/h 61 61 61 61 61

Air data
Temperature of charge air at charge air cooler outlet °C 51 55 57 59 60
Air flow rate m3/h 5) 6647 8774 10237 11699 13161
kg/kWh 7.27 7.27 7.27 7.27 7.27
Charge air pressure bar 4.25 4.28 4.29 4.30 4.31
Air required to dissipate heat radiation (eng.) m3/h 17980 23800 27600 31500 35300
(t2-t1= 10°C)

Exhaust gas data 6)

Volume flow (temperature turbocharger outlet) m3/h 7) 13730 18235 21348 24468 27594
Mass flow t/h 7.5 9.9 11.5 13.2 14.8
Temperature at turbine outlet °C 365 369 372 373 375
Heat content (190°C) kW 394 532 628 725 823
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30 < 30
Permissible exhaust back pressure (SCR) mbar < 50 < 50 < 50 < 50 < 50

Pumps
External pumps 8)
4.07 L21/31 GenSet Data

Diesel oil pump (5 bar at fuel oil inlet A1) m3/h 0.89 1.18 1.37 1.57 1.76
2021-11-12 - en

Fuel oil supply pump (4 bar) m3/h 0.30 0.39 0.46 0.52 0.59
Fuel oil circulating pump 9) (8 bar) m3/h 0.89 1.18 1.37 1.57 1.76

Starting air data

Air consumption per start, incl. air for jet assist (TDI) Nm3 1.0 1.2 1.4 1.6 1.8
Air consumption per start, incl. air for jet assist (Gali) Nm3 1.8 2.1 2.4 2.7 3.0

D10050_1689499-4.5
9007250128455307

4 (4) 80-26 engines

 MAN Energy Solutions 199 05 30-6.0

L23/30H Mk2 genset data

Engine ratings
720 rpm 750 rpm 900 rpm
Engine type 720 rpm Available turning 750 rpm Available turning 900 rpm Available turning
No of cylinders direction direction direction
kW CW 1) kW CW 1) kW CW 1)
5L23/30H Mk2 ECR 580 Yes 580 Yes – –

5L23/30H Mk2 710 Yes 740 Yes – –

6L23/30H Mk2 852 Yes 888 Yes 1050 Yes

7L23/30H Mk2 994 Yes 1036 Yes 1225 Yes

8L23/30H Mk2 1136 Yes 1184 Yes 1400 Yes

1)
CW clockwise
Table 1: Engine ratings for emission standard IMO Tier II.

B10011_3700292-7.1

4.08 L23/30H Mk2 genset data

80-30 engines 1 (6)

199 05 30-6.0 MAN Energy Solutions

General

Cyl. no A (mm) * B (mm) * C (mm) H (mm) ** Dry weight

GenSet (t)
5 (720 rpm) 3369 2155 5524 2402 18.0
5 (750 rpm) 3369 2155 5524 2402 17.6

6 (720 rpm) 3738 2265 6004 2402 19.7

6 (750 rpm) 3738 2265 6004 2402 19.7
6 (900 rpm) 3738 2265 6004 2466 21.0

7 (720 rpm) 4109 2395 6504 2466 21.4

7 (750 rpm) 4109 2395 6504 2466 21.4
7 (900 rpm) 4109 2395 6504 2466 22.8

8 (720 rpm) 4475 2480 6959 2466 23.5

8 (750 rpm) 4475 2480 6959 2466 22.9
8 (900 rpm) 4475 2340 6815 2466 24.5

P Free passage between the engines, width 600 mm and height 2000 mm.
Q Min. distance between engines: 2250 mm

* Depending on alternator
** Weight included a standard alternator
4.08 L23/30H Mk2 genset data

All dimensions and masses are approximate, and subject to changes without prior notice.

2 (6) 80-30 engines

MAN Energy Solutions 199 05 30-6.0

Capacities
5-8L23/30H Mk 2: 142 kW/Cyl., 720 rpm 5 6 7 8
Engine output kW 710 852 994 1136
Speed rpm 720 720 720 720

Heat to be dissipated 3)
Cooling water cylinder kW 217 262 302 347
Charge air cooler; cooling water HT
(1 stage cooler: no HT-stage) kW - - - -
Charge air cooler; cooling water LT kW 351 407 505 563
Lubricating oil cooler kW 67 81 94 107
Heat radiation engine kW 30 36 42 48

Air data
Charge air temp. at charge air cooler outlet, max. °C 54 56 53 54
Air flow rate m3/h 5) 5430 6516 7602 8688
kg/kWh 8.03 8.03 8.03 8.03
Charge air pressure bar (abs) 3.39 3.40 3.39 3.39
Air required to dissipate heat radiation (eng.)
(t2-t1=10°C) m3/h 9756 11708 13659 15610

Exhaust gas data 6)

Volume flow (temperature turbocharger outlet) m3/h 7) 10086 12069 14138 16121
Mass flow t/h 5.85 7.00 8.20 9.35
Temperature at turbine outlet °C 324 325 323 324
Heat content (190°C) kW 234 283 325 374
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30
Permissible exhaust back pressure (SCR) mbar < 50 < 50 < 50 < 50

Pumps
Engine driven pumps 4)
HT cooling water pump 1-2.5 bar m3/h 36 36 36 36
LT cooling water pump 1-2.5 bar m3/h 55 55 55 55
Lubrication oil 3-5 bar m3/h 16 16 16 16
External pumps 8)
Diesel oil pump 4 bar at fuel oil inlet A1 m3/h 0.52 0.62 0.73 0.83
Fuel oil supply pump 4 bar discharge pressure m3/h 0.26 0.31 0.36 0.41
Fuel oil circulating pump 9) 8 bar at fuel oil inlet A1 m3/h 0.51 0.62 0.72 0.82
Cooling water pumps
4.08 L23/30H Mk2 genset data
"Internal cooling water
system 1"
LT cooling water pump 1-2.5 bar m3/h 35 42 48 55
"Internal cooling water
system 2"
HT cooling water pump 1-2.5 bar m3/h 20 24 28 32
LT cooling water pump 1-2.5 bar m3/h 35 42 48 55
Lubricating oil pump 3-5 bar m3/h 14 15 16 17

Starting air system

Air consumption per start (10 bar starter) Nm3 1.40 1.43 1.50 1.54

1) Tolerance: + 10 % for rating coolers, - 15 % for heat recovery

2) LT cooling water flows in parallel through one-stage charge air cooler and lube oil cooler HT cooling water
flows only through water jacket and cylinder head, water temperature outlet engine regulated by mechanical
thermostat

80-30 engines 3 (6)

199 05 30-6.0 MAN Energy Solutions

3) Basic values for layout of the coolers

4) Under above mentioned reference conditions
5) Tolerance: quantity +/- 5%, temperature +/- 20°C
6) Under below mentioned temperature at turbine outlet and pressure according above mentioned reference
conditions
7) Tolerance of the pumps delivery capacities must be considered by the manufactures
8) To compensate for built on pumps, ambient condition, calorific value and adequate circulations flow. The ISO
fuel oil consumption is multiplied by 1.45.

D10050_3700220-9.0
4.08 L23/30H Mk2 genset data

4 (6) 80-30 engines

MAN Energy Solutions 199 05 30-6.0

Capacities
6-8L23/30H Mk 2: 175 kW/Cyl., 900 rpm 6 7 8
Engine output kW 1050 1225 1400
Speed rpm 900 900 900

Heat to be dissipated 3)
Cooling water cylinder kW 298 349 402
Charge air cooler; cooling water HT
1 stage cooler: no HT-stage kW - - -
Charge air cooler; cooling water LT kW 441 604 672
Lubricating oil cooler kW 122 143 164
Heat radiation engine kW 42 49 56

Air data
Temp. of charge air at charge air cooler outlet, max. °C 54 55 56
Air flow rate m3/h 5) 8020 9357 10693
kg/kWh 8.02 8.02 8.02
Charge air pressure bar (abs) 3.60 3.61 3.61
Air required to dissipate heat radiation (eng.) m3/h 13669 15947 18225
(t2-t1=10°C)

Exhaust gas data 6)

Volume flow (temperature turbocharger outlet) m3/h 7) 15636 18364 20909
Mass flow t/h 8.60 10.10 11.50
Temperature at turbine outlet °C 354 355 356
Heat content (190°C) kW 423 497 571
Permissible exhaust back pressure mbar < 30 < 30 < 30
Permissible exhaust back pressure (SCR) mbar < 50 < 50 < 50

Pumps
Engine driven pumps 4)
HT cooling water pump 1-2.5 bar m3/h 45 45 45
LT cooling water pump 1-2.5 bar m3/h 69 69 69
Lubrication oil 3-5 bar m3/h 20 20 20
External pumps 8)
Diesel oil pump 4 bar at fuel oil inlet A1 m3/h 0.78 0.91 1.04
Fuel oil supply pump 4 bar discharge pressure m3/h 0.38 0.45 0.51
Fuel oil circulating pump 9) 8 bar at fuel oil inlet A1 m3/h 0.77 0.90 1.03
Cooling water pumps
4.08 L23/30H Mk2 genset data
"Internal cooling water system
1"
LT cooling water pump 1-2.5 bar m3/h 52 61 70
"Internal cooling water system
2"
HT cooling water pump 1-2.5 bar m3/h 30 35 40
LT cooling water pump 1-2.5 bar m3/h 52 61 70
Lubricating oil pump 3-5 bar m3/h 17 18 19

Starting air system

Air consumption per start (10 bar starter) Nm3 1.43 1.50 1.54

1) Tolerance: + 10 % for rating coolers, - 15 % for heat recovery

2) LT cooling water flows in parallel through one-stage charge air cooler and lube oil cooler HT cooling water
flows only through water jacket and cylinder head, water temperature outlet engine regulated by mechanical
thermostat

80-30 engines 5 (6)

199 05 30-6.0 MAN Energy Solutions

3) Basic values for layout of the coolers

4) Under above mentioned reference conditions
5) Tolerance: quantity +/- 5%, temperature +/- 20°C
6) Under below mentioned temperature at turbine outlet and pressure according above mentioned reference
conditions
7) Tolerance of the pumps delivery capacities must be considered by the manufactures
8) To compensate for built on pumps, ambient condition, calorific value and adequate circulations flow. The ISO
fuel oil consumption is multiplied by 1.45.
9007252393293195

D10050_3700221-0.0
9007252393293195
4.08 L23/30H Mk2 genset data

6 (6) 80-30 engines

 MAN Energy Solutions 198 82 84-1.1

L27/38 GenSet Data

Engine ratings
720 rpm 750 rpm 720/750 MGO
Engine type
720 rpm Available turning 750 rpm Available turning 720/750 Available turning
No of cylinders
direction direction rpm direction

kW CW 1) kW CW 1) kW CW 1)

5L27/38 1,500 Yes 1,600 Yes - -

6L27/38 1,980 Yes 1,980 Yes 2,100 Yes

7L27/38 2,310 Yes 2,310 Yes 2,450 Yes

8L27/38 2,640 Yes 2,640 Yes 2,800 Yes

9L27/38 2,970 Yes 2,970 Yes 3,150 Yes

1)
CW clockwise

B10011-1689467-1.0

General

Cyl. no A (mm) * B (mm) * C (mm) H (mm) ** Dry weight

GenSet (t)
4.09 L27/38 GenSet Data

5 (720 mm) 4,346 2,486 6,832 3,712 40.0

5 (750 mm) 4,346 2,486 6,832 3,712 40.0
2022-05-02 - en

6 (720 mm 4,791 2,766 7,557 3,712 44.5

6 (750 mm) 4,791 2,766 7,557 3,712 44.5

7 (720 mm) 5,236 2,766 8,002 3,899 50.4

7 (750 mm) 5,236 2,766 8,002 3,899 50.4

8 (720 mm) 5,681 2,986 8,667 3,899 58.2

8 (750 mm) 5,681 2,986 8,667 3,899 58.2

9 (720 mm) 6,126 2,986 9,112 3,899 64.7

9 (750 mm) 6,126 2,986 9,112 3,899 64.7

98-35MC/MC-C/ME-C/-GI/-GA, 60-30ME-B/-GI/-LGI 1 (6)

198 82 84-1.1 MAN Energy Solutions

P Free passage between the engines, width 600 mm and height 2,000 mm.
Q Min. distance between engines: 2,900 mm (without gallery) and 3,100 mm
(with gallery)
* Depending on alternator
** Weight included a standard alternator
All dimensions and masses are approximate, and subject to changes without
prior notice.

Capacities
5L27/38: 300 kW/cyl., 720 rpm, 6-9L27/38: 330 kW/cyl., 720 rpm

Reference condition : Tropic

Air temperature °C 45
LT-water temperature inlet engine (from system) °C 38
Air pressure bar 1
Relative humidity % 50

Temperature basis:

Setpoint HT cooling water engine outlet 1) °C 79°C nominal

(Range of mech. thermostatic element 77-85°C)
Setpoint LT cooling water engine outlet 2) °C 35°C nominal
(Range of mech. thermostatic element 29°-41°C)
Setpoint Lube oil inlet engine °C 66°C nominal
(Range of mech. thermostatic element 63-72°C)

Number of cylinders 5 6 7 8 9

Engine output kW 1,500 1,980 2,310 2,640 2,970

Speed rpm 720

Heat to be dissipated 3)

Cooling water (C.W.) Cylinder kW 256 330 385 440 495

Charge air cooler; cooling water HT kW 466 594 675 750 820
Charge air cooler; cooling water LT kW 178 216 242 268 297
Lube oil (L.O.) cooler kW 224 279 325 372 418
Heat radiation engine kW 63 83 97 111 125
4.09 L27/38 GenSet Data

Flow rates4)
Internal (inside engine)
2022-05-02 - en

HT circuit (cylinder + charge air cooler HT stage) m3/h 58 58 58 58 58

LT circuit (lube oil + charge air cooler LT stage) m3/h 58 58 58 58 58
3
Lube oil m /h 64 64 92 92 92

External (from engine to system)

HT water flow (at 40°C inlet) m3/h 16 20.2 23 25.5 28

3
LT water flow (at 38°C inlet) m /h 58 58 58 58 58

Air data

2 (6) 98-35MC/MC-C/ME-C/-GI/-GA, 60-30ME-B/-GI/-LGI

 MAN Energy Solutions 198 82 84-1.1

Temperature of charge air at charge air cooler outlet °C 50 53 55 56 57

3 5)
Air flow rate m /h 9,137 12,061 14,071 16,082 18,092
Charge air pressure kg/kWh 6.67 6.67 6.67 6.67 6.67

Air required to dissipate heat radiation (eng.)(t2-t1= bar 4.01 4.01 4.01 4.01 4.01
3
10°C) m /h 20,414 26,895 31,431 35,968 40,504

Exhaust gas data 6)

Volume flow (temperature turbocharger outlet) m3/h 7) 19,203 25,348 29,572 33,797 38,021
Mass flow t/h 10.3 13.6 15.9 18.1 20.4
Temperature at turbine outlet °C 376 376 376 376 376
Heat content (190°C) k/W 575 759 886 1,012 1,139
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30 < 30

Pumps

External pumps 8)
Diesel oil pump (5 bar at fuel oil inlet A1) m3/h 1.06 1.40 1.63 1.87 2.10
3
Fuel oil supply pump (4 bar discharge pressure) m /h 0.51 0.67 0.79 0.90 1.01
3
Fuel oil circulating pump (8 bar at fuel oil inlet A1) m /h 1.06 1.40 1.63 1.87 2.10

Starting air data

Air consumption per start, incl. air for jet assist (IR/TDI) Nm3 2.5 2.9 3.3 3.8 4.3

1) HT cooling water flows first through HT stage charge air cooler, then through
water jacket and cylinder head, water temperature outlet engine regulated
by mechanical thermostat.
2) LT cooling water flows first through LT stage charge air cooler, then through
lube oil cooler, water temperature outlet engine regulated by mechanical
thermostat.
3) Tolerance: + 10% for rating coolers, - 15% for heat recovery.
4) Basic values for layout of the coolers.
5) Under above mentioned reference conditions.
6) Tolerance: quantity +/- 5%, temperature +/- 20°C.
7) Under below mentioned temperature at turbine outlet and pressure accord-
ing above mentioned reference conditions.
8) Tolerance of the pumps delivery capacities must be considered by the man-
4.09 L27/38 GenSet Data

ufactures.
2022-05-02 - en

D10050_1689471-7.3

98-35MC/MC-C/ME-C/-GI/-GA, 60-30ME-B/-GI/-LGI 3 (6)

198 82 84-1.1 MAN Energy Solutions

Capacities
5L27/38: 320 kW/cyl., 750 rpm, 6-9L27/38: 330 kW/cyl., 750 rpm

Reference condition : Tropic

Air temperature °C 45
LT-water temperature inlet engine (from system) °C 38
Air pressure bar 1
Relative humidity % 50

Temperature basis:

Setpoint HT cooling water engine outlet 1) °C 79°C nominal

(Range of mech. thermostatic element 77-85°C)
Setpoint LT cooling water engine outlet 2) °C 35°C nominal
(Range of mech. thermostatic element 29°-41°C)
Setpoint Lube oil inlet engine °C 66°C nominal
(Range of mech. thermostatic element 63-72°C)

Number of cylinders 5 6 7 8 9

Engine output kW 1,600 1,980 2,310 2,640 2,970

Speed rpm 750

3)
Heat to be dissipated

Cooling water (C.W.) Cylinder kW 263 330 385 440 495

Charge air cooler; cooling water HT kW 488 587 666 741 811
Charge air cooler; cooling water LT kW 194 225 252 280 307
Lube oil (L.O.) cooler kW 230 279 325 372 418
Heat radiation engine kW 67 83 97 111 125
4)
Flow rates
Internal (inside engine)

HT circuit (cylinder + charge air cooler HT stage) m3/h 69 69 69 69 69

3
LT circuit (lube oil + charge air cooler LT stage) m /h 69 69 69 69 69
3
Lube oil m /h 66 66 96 96 96

External (from engine to system)

4.09 L27/38 GenSet Data

HT water flow (at 40°C inlet) m3/h 16.8 20.3 23 25.7 28.2
2022-05-02 - en

3
LT water flow (at 38°C inlet) m /h 69 69 69 69 69

Air data

Temperature of charge air at charge air cooler outlet °C 51 53 55 56 57

3 5)
Air flow rate m /h 9,951 12,314 14,367 16,419 18,472
kg/kWh 6.81 6.81 6.81 6.81 6.81

Charge air pressure bar 4.04 4.04 4.04 4.04 4.04

3
Air required to dissipate heat radiation (eng.)(t2-t1= 10°C) m /h 21,710 26,895 31,431 35,968 40,504

Exhaust gas data 6)

4 (6) 98-35MC/MC-C/ME-C/-GI/-GA, 60-30ME-B/-GI/-LGI

 MAN Energy Solutions 198 82 84-1.1

Volume flow (temperature turbocharger outlet) m3/h 7) 20,546 25,426 29,664 33,901 38,139
Mass flow t/h 11.2 13.9 16.2 18.5 20.8
Temperature at turbine outlet °C 365 365 365 365 365
Heat content (190°C) k/W 589 729 850 972 1,093
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30 < 30

Pumps

External pumps 8)
Diesel oil pump (5 bar at fuel oil inlet A1) m3/h 1.13 1.40 1.63 1.87 2.10
3
Fuel oil supply pump (4 bar discharge pressure) m /h 0.54 0.67 0.79 0.90 1.01

Fuel oil circulating pump (8 bar at fuel oil inlet A1) m3/h 1.13 1.40 1.63 1.87 2.10

Starting air data

Air consumption per start, incl. air for jet assist (IR/TDI) Nm3 2.5 2.9 3.3 3.8 4.3

1) HT cooling water flows first through HT stage charge air cooler, then through
water jacket and cylinder head, water temperature outlet engine regulated
by mechanical thermostat.
2) LT cooling water flows first through LT stage charge air cooler, then through
lube oil cooler, water temperature outlet engine regulated by mechanical
thermostat.
3) Tolerance: + 10% for rating coolers, - 15% for heat recovery.
4) Basic values for layout of the coolers.
5) Under above mentioned reference conditions.
6) Tolerance: quantity +/- 5%, temperature +/- 20°C.
7) Under below mentioned temperature at turbine outlet and pressure accord-
ing above mentioned reference conditions.
8) Tolerance of the pumps delivery capacities must be considered by the man-
ufactures.

D10050_1689472-9.3

General
4.09 L27/38 GenSet Data
2022-05-02 - en

98-35MC/MC-C/ME-C/-GI/-GA, 60-30ME-B/-GI/-LGI 5 (6)

198 82 84-1.1 MAN Energy Solutions

Cyl. no A (mm) * B (mm) * C (mm) H (mm) ** Dry weight

GenSet (t)
5 (720 rpm) 4346 2486 6832 3705 42.0
5 (750 rpm) 4346 2486 6832 3705 42.3

6 (720 rpm) 4791 2766 7557 3717 45.8

6 (750 rpm) 4791 2766 7557 3717 46.1

7 (720 rpm) 5236 2766 8002 3717 52.1

7 (750 rpm) 5236 2766 8002 3717 52.1

8 (720 rpm) 5681 2986 8667 3717 56.5

8 (750 rpm) 5681 2986 8667 3717 58.3

9 (720 rpm) 6126 2986 9112 3797 61.8

9 (750 rpm) 6126 2986 9112 3797 63.9

P Free passage between the engines, width 600 mm and height 2000 mm.
Q Min. distance between engines: 2900 mm (without gallery) and 3100 mm (with gallery)

* Depending on alternator
** Weight included a standard alternator

All dimensions and masses are approximate, and subject to changes without
prior notice.

Engine ratings
720 rpm 750 rpm 720/750 MGO
Engine type 720 rpm Available turning 750 rpm Available turning 720/750 Available turning
No of cylinders direction direction rpm direction
kW CW 1) kW CW 1) kW CW 1)
5L27/38 1500 Yes 1600 Yes – –

6L27/38 1980 Yes 1980 Yes 2100 Yes

7L27/38 2310 Yes 2310 Yes 2450 Yes

8L27/38 2640 Yes 2640 Yes 2800 Yes

9L27/38 2970 Yes 2970 Yes 3150 Yes

1)
CW clockwise
4.09 L27/38 GenSet Data

Table 1: Engine ratings for emission standard - IMO Tier II.

2022-05-02 - en

9007251845516683

6 (6) 98-35MC/MC-C/ME-C/-GI/-GA, 60-30ME-B/-GI/-LGI

 MAN Energy Solutions 198 82 85-3.1

L28/32H Genset data

Engine Ratings
720 rpm 750 rpm
Engine type
720 rpm Available turning dir- 750 rpm Available turning dir-
No of cylinders
ection ection

kW CW 1) kW CW 1)

5L28/32 1,050 Yes 1,100 Yes

6L28/32 1,260 Yes 1,320 Yes

7L28/32 1,470 Yes 1,540 Yes

8L28/32 1,680 Yes 1,760 Yes

9L28/32 1,890 Yes 1,980 Yes

1)
CW clockwise

B10011-3700014-9.0

General

Cyl. no A (mm) * B (mm) * C (mm) H (mm) ** Dry weight

4.10 L28/32H Genset data

GenSet (t)
2022-01-19 - en

5 (720 mm) 4,279 2,400 6,679 3,184 32.6

5 (750 mm) 4,279 2,400 6,679 3,184 32.6

6 (720 mm 4,759 2,510 7,269 3,184 36.3

6 (750 mm) 4,759 2,510 7,269 3,184 36.3

7 (720 mm) 5,499 2,680 8,179 3,374 39.4

7 (750 mm) 5,499 2,680 8,179 3,374 39.4

8 (720 mm) 5,979 2,770 8,749 3,374 40.7

8 (750 mm) 5,979 2,770 8,749 3,374 40.6

9 (720 mm) 6,199 2,690 8,889 3,534 47.1

9 (750 mm) 6,199 2,690 8,889 3,534 47.1

All engines 1 (5)

198 82 85-3.1 MAN Energy Solutions

P Free passage between the engines, width 600 mm and height 2,000 mm.
Q Min. distance between engines: 2,655 mm (without gallery) and 2,850 mm
(with gallery)
* Depending on alternator
** Weight included a standard alternator
All dimensions and masses are approximate, and subject to changes without
prior notice.

Capacities
5L-9L: 210 kW/Cyl. at 720 rpm

Reference condition : Tropic

Air temperature °C 45
LT water temperature inlet engine (from system) °C 38
Air pressure bar 1
Relative humidity % 50

Number of cylinders 5 6 7 8 9
Engine output kW 1,050 1,260 1,470 1,680 1,890
rpm 720 720 720 720 720
Speed

Heat to be dissipated 1)

Cooling water (C.W.) Cylinder kW 234 281 328 375 421

Charge air cooler; cooling water HT kW 0 0 0 0 0
(Single stage charge air cooler)
Charge air cooler; cooling water LT kW 355 397 500 553 592

Lube oil (L.O.) cooler kW 191 230 268 306 345

Heat radiation engine kW 26 31 36 42 47

kW

Flow rates 2)
Internal (inside engine)

HT cooling water cylinder m3/h 37 45 50 55 60

3
LT cooling water lube oil cooler * m /h 7.8 9.4 11 12.7 14.4
LT cooling water lube oil cooler ** m3/h 28 28 40 40 40
4.10 L28/32H Genset data

LT cooling water charge air cooler m3/h 37 45 55 65 75

2022-01-19 - en

Air data

Temperature of charge air at charge air cooler outlet °C 51 52 51 52 53

3 3)
Air flow rate m /h 7,355 8,826 10,297 11,768 13,239
kg/kWh 7.67 7.67 7.67 7.67 7.67
Charge air pressure bar 2.97 2.97 2.97 2.97 2.97
3
Air required to dissipate heat radiation (engine) (t2-t1= m /h 8,425 10,045 11,665 13,609 15,230
10°C)

Exhaust gas data 4)

2 (5) All engines

 MAN Energy Solutions 198 82 85-3.1

Volume flow (temperature turbocharger outlet) m3/h5 14,711 17,653 20,595 23,537 26,479
Mass flow t/h 8.3 9.9 11.6 13.2 14.9
Temperature at turbine outlet °C 347 347 347 347 347
Heat content (190°C) kW 389 467 545 623 701
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30 < 30

Starting air system

Air consumption per start Nm3 2.5 2.5 2.5 2.5 2.5

Pumps
Engine driven pumps

Fuel oil feed pump (5.5-7.5 bar) m3/h 1.4 1.4 1.4 1.4 1.4
HT circuit cooling water (1.0-2.5 bar) m3/h 45 45 60 60 60
LT circuit cooling water (1.0-2.5 bar) m3/h 45 60 75 75 75
3
Lube oil (3.0-5.0 bar) m /h 24 24 34 34 34
6)
External pumps

Diesel oil pump (4 bar at fuel oil inlet A1) m3/h 0.74 0.89 1.04 1.19 1.34
3
Fuel oil supply pump (4 bar discharge pressure) m /h 0.36 0.43 0.50 0.57 0.64
3
Fuel oil circulating pump (8 bar at fuel oil inlet A1) m /h 0.74 0.89 1.04 34 34
3
HT circuit cooling water (1.0-2.5 bar) m /h 37 45 50 55 60
3
LT circuit cooling water (1.0-2.5 bar) * m /h 45 54 65 77 89
3
LT circuit cooling water (1.0-2.5 bar) ** m /h 65 73 95 105 115
3
Lube oil (3.0-5.0 bar) m /h 22 23 35 27 28

1) Tolerance: + 10% for rating coolers, - 15% for heat recovery.

2) Basic values for layout of the coolers.
3) Under above mentioned reference conditions.
4) Tolerance: quantity +/- 5%, temperature +/- 20°C.
5) Under below mentioned temperature at turbine outlet and pressure accord-
ing above mentioned reference conditions.
6) Tolerance of the pumps delivery capacities must be considered by the man-
ufactures.
* Only valid for engines equipped with internal basic cooling water system no.
4.10 L28/32H Genset data

1 and 2.
2022-01-19 - en

** Only valid for engines equipped with combined coolers, internal basic cool-
ing water system no. 3

D10050_3700075-9.0

All engines 3 (5)

198 82 85-3.1 MAN Energy Solutions

Capacities
5L-9L: 220 kW/Cyl. at 750 rpm

Reference condition : Tropic

Air temperature °C 45
LT water temperature inlet engine (from system) °C 38
Air pressure bar 1
Relative humidity % 50

Number of cylinders 5 6 7 8 9

Engine output kW 1,100 1,320 1,540 1,760 1,980

Speed rpm 750 750 750 750 750

Heat to be dissipated 1)

Cooling water (C.W.) Cylinder kW 245 294 343 392 442

Charge air cooler; cooling water HT kW 0 0 0 0 0
(Single stage charge air cooler)
Charge air cooler; cooling water LT kW 387 435 545 587 648

Lube oil (L.O.) cooler kW 201 241 281 321 361

Heat radiation engine kW 27 33 38 44 49

Flow rates 2)
Internal (inside engine)

HT cooling water cylinder m3/h 37 45 50 55 60

3
LT cooling water lube oil cooler * m /h 7.8 9.4 11 12.7 14.4
3
LT cooling water lube oil cooler ** m /h 28 28 40 40 40
3
LT cooling water charge air cooler m /h 37 45 55 65 75

Air data

Temperature of charge air at charge air cooler outlet °C 52 54 52 52 55

3 3)
Air flow rate m /h 7,826 9,391 10,956 12,521 14,087
kg/kWh 7.79 7.79 7.79 7.79 7.79
Charge air pressure bar 3.07 3.07 3.07 3.07 3.07
3
Air required to dissipate heat radiation (engine) (t2-t1= m /h 8,749 10,693 12,313 14,257 15,878
4.10 L28/32H Genset data

10°C)
2022-01-19 - en

Exhaust gas data 4)

Volume flow (temperature turbocharger outlet) m3/h5 15,520 18,624 21,728 24,832 27,936
Mass flow t/h 8.8 10.5 12.3 14.1 15.8
Temperature at turbine outlet °C 342 342 342 342 342
Heat content (190°C) kW 401 481 561 641 721
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30 < 30
9007251868540683

Starting air system

Air consumption per start Nm3 2.5 2.5 2.5 2.5 2.5

4 (5) All engines

 MAN Energy Solutions 198 82 85-3.1

Pumps
Engine driven pumps

Fuel oil feed pump (5.5-7.5 bar) m3/h 1.4 1.4 1.4 1.4 1.4
3
HT circuit cooling water (1.0-2.5 bar) m /h 45 45 60 60 60
3
LT circuit cooling water (1.0-2.5 bar) m /h 45 60 75 75 75
3
Lube oil (3.0-5.0 bar) m /h 24 24 34 34 34
6)
External pumps

Diesel oil pump (4 bar at fuel oil inlet A1) m3/h 0.78 0.93 1.09 1.24 1.40
3
Fuel oil supply pump (4 bar discharge pressure) m /h 0.37 0.45 0.52 0.60 0.67
3
Fuel oil circulating pump (8 bar at fuel oil inlet A1) m /h 0.78 0.93 1.09 1.24 1.40
3
HT circuit cooling water (1.0-2.5 bar) m /h 37 45 50 55 60
3
LT circuit cooling water (1.0-2.5 bar) * m /h 45 54 65 77 89
3
LT circuit cooling water (1.0-2.5 bar) ** m /h 65 73 95 105 115
3
Lube oil (3.0-5.0 bar) m /h 22 23 25 27 28
9007251868540683

1) Tolerance: + 10% for rating coolers, - 15% for heat recovery.

2) Basic values for layout of the coolers.
3) Under above mentioned reference conditions.
4) Tolerance: quantity +/- 5%, temperature +/- 20°C.
5) Under below mentioned temperature at turbine outlet and pressure accord-
ing above mentioned reference conditions.
6) Tolerance of the pumps delivery capacities must be considered by the man-
ufactures.
* Only valid for engines equipped with internal basic cooling water system no.
1 and 2.
** Only valid for engines equipped with combined coolers, internal basic cool-
ing water system no. 3
9007251868540683

D10050_3700076-0.0
9007251868540683
4.10 L28/32H Genset data
2022-01-19 - en

All engines 5 (5)

198 82 85-3.1 MAN Energy Solutions

9007251868540683
This page is intentionally left blank
4.10 L28/32H Genset data

2022-01-19 - en

All engines
 MAN Energy Solutions 199 05 64-2.0

GenSet Data
2021-11-17 - en

4.11 GenSet Data

56369989003

1 (1)
199 05 64-2.0 MAN Energy Solutions

56369989003
This page is intentionally left blank

2021-11-17 - en
4.11 GenSet Data
MAN Energy Solutions 199 17 18-3.0

L23/30DF GenSet Data

4.12 L23/30DF GenSet Data

9007255624742411

1 (1)
199 17 18-3.0 MAN Energy Solutions

9007255624742411
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4.12 L23/30DF GenSet Data
 MAN Energy Solutions 1990533-1.0

L28/32DF genset data

Engine ratings
720 rpm Available turning 750 rpm Available turning
Engine type direction direction
No of cylinders kW CW 1) kW CW 1)
5L28/32DF 1000 Yes 1000 Yes

6L28/32DF 1200 Yes 1200 Yes

7L28/32DF 1400 Yes 1400 Yes

8L28/32DF 1600 Yes 1600 Yes

9L28/32DF 1800 Yes 1800 Yes

1)
CW clockwise

B10011_3700283-2.1

4.13 L28/32DF genset data

2022-03-02 - en

95-50ME-GI, 60-35ME-B-GI, 70ME-GA 1 (6)

1990533-1.0 MAN Energy Solutions

General

Cyl. no A (mm) * B (mm) * C (mm) H (mm) ** Dry weight

GenSet (t)
5 (720 rpm) 4321 2400 6721 2835 32.6
5 (750 rpm) 4321 2400 6721 2835 32.3

6 (720 rpm) 4801 2510 7311 3009 36.3

6 (750 rpm) 4801 2510 7311 3009 36.3

7 (720 rpm) 5281 2680 7961 3009 39.4

7 (750 rpm) 5281 2680 7961 3009 39.4

8 (720 rpm) 5761 2770 8531 3009 40.7

8 (750 rpm) 5761 2770 8531 3009 40.6

9 (720 rpm) 6241 2690 8931 3009 47.1

9 (750 rpm) 6241 2690 8931 3009 47.1

P Free passage between the engines, width 600 mm and height 2000 mm.
Q Min. distance between engines: 2655 mm (without gallery) and 2850 mm (with gallery).

* Depending on alternator
** Weight included a standard alternator
4.13 L28/32DF genset data

All dimensions and masses are approximate, and subject to changes without
prior notice.
2022-03-02 - en

B10011_3700300-1.0

2 (6) 95-50ME-GI, 60-35ME-B-GI, 70ME-GA

 MAN Energy Solutions 1990533-1.0

Capacities
5L-9L: 200 kW/Cyl. at 720 rpm 5 6 7 8 9
Engine output kW 1000 1200 1400 1600 1800
Speed rpm 720 720 720 720 720

Heat to be dissipated 3)
Cooling water cylinder kW 234 281 328 375 421
Charge air cooler; cooling water HT kW 0 0 0 0 0
(Single stage charge air cooler)
Charge air cooler; cooling water LT kW 355 397 500 553 592
Lubricating oil cooler kW 191 230 268 306 345
Heat radiation engine kW 26 31 36 42 47

Flow rates 4)
Internal (inside engine)
HT cooling water cylinder m3/h 37 45 50 55 60
LT cooling water lube oil cooler m3/h 7.8 9.4 11 12.7 14.4
LT cooling water charge air cooler m3/h 37 45 55 65 75

Air data
Temperature of charge air at charge air cooler outlet °C 51 52 51 52 53
Air flow rate m3/h 5) 7355 8826 10297 11768 13239
kg/kWh 7.67 7.67 7.67 7.67 7.67
Charge air pressure bar 2.97 2.97 2.97 2.97 2.97
Air required to dissipate heat radiation (engine) m3/h 8425 10045 11665 13609 15230
(t2-t1= 10°C)

Exhaust gas data 6)

Volume flow (temperature turbocharger outlet) m3/h 7) 14711 17653 20595 23537 26479
Mass flow t/h 8.3 9.9 11.6 13.2 14.9
Temperature at turbine outlet °C 347 347 347 347 347
Heat content (190°C) kW 389 467 545 623 701
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30 < 30
Permissible exhaust back pressure (SCR) mbar < 50 < 50 < 50 < 50 < 50

Starting air system

Air consumption per start Nm3 2.5 2.5 2.5 2.5 2.5

Pumps
Engine driven pumps
Fuel oil feed pump (5.5-7.5 bar) m3/h 1.4 1.4 1.4 1.4 1.4
m3/h
4.13 L28/32DF genset data

HT circuit cooling water (1.0-2.5 bar) 45 45 60 60 60

LT circuit cooling water (1.0-2.5 bar) m3/h 45 60 75 75 75
Lube oil (3.0-5.0 bar) m3/h 24 24 34 34 34
2022-03-02 - en

External pumps 8)
Diesel oil pump (4 bar at fuel oil inlet A1) m3/h 0.74 0.89 1.04 1.19 1.34
Fuel oil supply pump (4 bar discharge pressure) m3/h 0.36 0.43 0.50 0.57 0.64
Fuel oil circulating pump 9) (8 bar at fuel oil inlet A1) m3/h 0.74 0.89 1.04 1.19 1.34
HT circuit cooling water (1.0-2.5 bar) m3/h 37 45 50 55 60
LT circuit cooling water (1.0-2.5 bar) m3/h 45 54 65 77 89
Lube oil (3.0-5.0 bar) m3/h 22 23 25 27 28

1) Tolerance: + 10 % for rating coolers, - 15 % for heat recovery

2) Basic values for layout of the coolers
3) Under above mentioned reference conditions

95-50ME-GI, 60-35ME-B-GI, 70ME-GA 3 (6)

1990533-1.0 MAN Energy Solutions

4) Tolerance: quantity +/- 5%, temperature +/- 20°C

5) Under below mentioned temperature at turbine outlet and pressure according above mentioned reference
conditions
6) Tolerance of the pumps delivery capacities must be considered by the manufactures
* Only valid for engines equipped with internal basic cooling water system no. 1 and 2.
** Only valid for engines equipped with combined coolers, internal basic cooling water system no. 3

D10050_3700325-3.0
4.13 L28/32DF genset data

2022-03-02 - en

4 (6) 95-50ME-GI, 60-35ME-B-GI, 70ME-GA

 MAN Energy Solutions 1990533-1.0

Capacities
5L-9L: 200 kW/Cyl. at 750 rpm 5 6 7 8 9
Engine output kW 1000 1200 1400 1600 1800
Speed rpm 750 750 750 750 750

Heat to be dissipated 3)
Cooling water cylinder kW 245 294 343 392 442
Charge air cooler; cooling water HT kW 0 0 0 0 0
(Single stage charge air cooler)
Charge air cooler; cooling water LT kW 387 435 545 587 648
Lubricating oil cooler kW 201 241 281 321 361
Heat radiation engine kW 27 33 38 44 49

Flow rates 4)
Internal (inside engine)
HT cooling water cylinder m3/h 37 45 50 55 60
LT cooling water lube oil cooler m3/h 7.8 9.4 11 12.7 14.4
LT cooling water charge air cooler m3/h 37 45 55 65 75

Air data
Temperature of charge air at charge air cooler outlet °C 52 54 52 52 55
Air flow rate m3/h 5) 7826 9391 10956 12521 14087
kg/kWh 7.79 7.79 7.79 7.79 7.79
Charge air pressure bar 3.07 3.07 3.07 3.07 3.07
Air required to dissipate heat radiation (engine) m3/h 8749 10693 12313 14257 15878
(t2-t1= 10°C)

Exhaust gas data 6)

Volume flow (temperature turbocharger outlet) m3/h 7) 15520 18624 21728 24832 27936
Mass flow t/h 8.8 10.5 12.3 14.1 15.8
Temperature at turbine outlet °C 342 342 342 342 342
Heat content (190°C) kW 401 481 561 641 721
Permissible exhaust back pressure mbar < 30 < 30 < 30 < 30 < 30
Permissible exhaust back pressure (SCR) mbar < 50 < 50 < 50 < 50 < 50

Starting air system

Air consumption per start Nm3 2.5 2.5 2.5 2.5 2.5

Pumps
Engine driven pumps
Fuel oil feed pump (5.5-7.5 bar) m3/h 1.4 1.4 1.4 1.4 1.4
m3/h
4.13 L28/32DF genset data

HT circuit cooling water (1.0-2.5 bar) 45 45 60 60 60

LT circuit cooling water (1.0-2.5 bar) m3/h 45 60 75 75 75
Lubrication oil (3.0-5.0 bar) m3/h 24 24 34 34 34
2022-03-02 - en

External pumps 8)
Diesel oil pump (4 bar at fuel oil inlet A1) m3/h 0.78 0.93 1.09 1.24 1.40
Fuel oil supply pump (4 bar discharge pressure) m3/h 0.37 0.45 0.52 0.60 0.67
Fuel oil circulating pump 9) (8 bar at fuel oil inlet A1) m3/h 0.78 0.93 1.09 1.24 1.40
HT circuit cooling water (1.0-2.5 bar) m3/h 37 45 50 55 60
LT circuit cooling water (1.0-2.5 bar) m3/h 45 54 65 77 89
Lubrication oil (3.0-5.0 bar) m3/h 22 23 25 27 28

1) Tolerance: + 10 % for rating coolers, - 15 % for heat recovery

2) Basic values for layout of the coolers
3) Under above mentioned reference conditions

95-50ME-GI, 60-35ME-B-GI, 70ME-GA 5 (6)

1990533-1.0 MAN Energy Solutions

4) Tolerance: quantity +/- 5%, temperature +/- 20°C

5) Under below mentioned temperature at turbine outlet and pressure according above mentioned reference
conditions
6) Tolerance of the pumps delivery capacities must be considered by the manufactures
* Only valid for engines equipped with internal basic cooling water system no. 1 and 2.
** Only valid for engines equipped with combined coolers, internal basic cooling water system no. 3
27021614067287179

D10050_3700324-1.0
27021614067287179
4.13 L28/32DF genset data

2022-03-02 - en

6 (6) 95-50ME-GI, 60-35ME-B-GI, 70ME-GA

MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
05 Installation Aspects

18 Monitoring Systems and Instrumentation

19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395555083

1 (1)
 MAN Energy Solutions

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05 Installation Aspects
 MAN Energy Solutions 198 43 75-4.8

Space requirements and overhaul

General
The latest version of the Installation Drawings of this section is available for
download at www.marine.man-es.com--> 'Two -Stroke' --> 'Installation
Drawings'. Specify engine and accept the ‘Conditions for use’ before clicking
on ‘Download Drawings’.

Space requirements for the engine

The space requirements stated in Section 5.02 are valid for engines rated at
nominal MCR (L1).
The additional space needed for engines equipped with PTO is stated in
Chapter 4.
If, during the project stage, the outer dimensions of the turbocharger seem to
cause problems, it is possible, for the same number of cylinders, to use tur-
bochargers with smaller dimensions by increasing the indicated number of
turbochargers by one, see Chapter 3.

Overhaul of engine
The distances stated from the centre of the crankshaft to the crane hook are
for the normal lifting procedure and the reduced height lifting procedure (in-
volving tilting of main components). The lifting capacity of a normal engine
room crane can be found in Fig. 5.04.01.
The area covered by the engine room crane shall be wide enough to reach
any heavy spare part required in the engine room.
A lower overhaul height is, however, available by using the MAN B&W
Double”Jib crane, built by Danish Crane Building A/S, shown in Figs. 5.04.02
and 5.04.03.

5.01 Space requirements and overhaul

Please note that the distance ‘E’ in Fig. 5.02.01, given for a double”jib crane is
from the centre of the crankshaft to the lower edge of the deck beam.
A special crane beam for dismantling the turbocharger must be fitted. The lift-
ing capacity of the crane beam for dismantling the turbocharger is stated in
Section 5.03.
The overhaul tools for the engine are designed to be used with a crane hook
according to DIN 15400, June 1990, material class M and load capacity 1Am
and dimensions of the single hook type according to DIN 15401, part 1.
2023-09-12 - en

The total length of the engine at the crankshaft level may vary depending on
the equipment to be fitted on the fore end of the engine, such as adjustable
counterweights, tuning wheel, moment compensators or PTO.
18014451173989515

ME-B, MC/MC-C, ME/ME-C/-GI/-LGI/-GA 1 (1)

198 43 75-4.8 MAN Energy Solutions

18014451173989515
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5.01 Space requirements and overhaul

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ME-B, MC/MC-C, ME/ME-C/-GI/-LGI/-GA

 MAN Energy Solutions 199 13 27-6.0

Space requirement

Engine space requirement turbocharger(s) mounted on the exhaust side

Minimum access conditions around the engine to be used for an escape route
is 600 mm.
The dimensions are given in mm, and are for guidance only. If the dimensions
cannot be fulfilled, please contact MAN Energy Solutions or our local repres-
entative.
* To avoid human injury from rotating turning wheel, the turning wheel has to
be shielded or access protected (Yard supply).
Fig. 5.02.01: Space requirement for the engine, turbocharger(s) mounted on
the exhaust side, 4 59 122
5.02 Space requirement
2023-10-23 - en

G70ME-C10.5/-GI/-GA 1 (3)
2 (3)
5.02 Space requirement

199 13 27-6.0
Dimensions of exhaust side
Cylinder No. 5 6
A 1,044 Cylinder distance. See drawing 'Outline drawing'

B 1,800 Distance from crankshaft centre line to foundation. See drawing ‘Engine seating’

B1 800 Distance from crankshaft centre line to floor. See drawing ‘Outline drawing’

C 4,217 4,272 The dimension includes a cofferdam of 600 mm and must fulfil minimum height to tank top according to classification
rules. See drawing ‘Lub. oil bottom tank’

8,487 8,487 MAN TCA/TCR/TCT

G70ME-C10.5/-GI/-GA

8,072 8,072 Accelleron A100/A200 Dimensions according to turbocharger choice at nominal MCR in Tier II mode. See
D *) drawing 'Outline drawing' for the specified dimensions in Tier II or III mode.
8,202 MHI MET

E *) See text Height of exhaust pipe is according to engine room design.

F See text See drawing: ‘Engine Top Bracing’, if top bracing fitted on camshaft side

5,712 5,712 MAN TCA/TCR/TCT The required space to the engine room casing includes mechanical top bracing.
Dimensions according to turbocharger choice at nominal MCR in Tier II mode.
5,712 5,712 Accelleron A100/A200
G See drawing ‘Top bracing’ for the specified dimensions in Tier II or III mode.
5,712 MHI MET

H1 *) DI/GI=13,625 / GA=13,800 Minimum overhaul height, normal lifting procedure. See drawing ‘Engine room crane’

I 2,235 Length from crankshaft centre line to outer side bedplate. See drawing ‘Engine seating’

MAN Energy Solutions

J 460 Space for tightening control of holding down bolts. See drawing ‘Engine seating’

K See text K must be equal to or larger than the propeller shaft, if the propeller shaft is to be drawn into the engine room

L *) 8,387 9,192 Minimum length of a basic engine, without 2nd order moment compensators. See drawing 'Outline drawing'

M ≈ 800 Free space in front of engine

N 5,462 Distance between outer foundations girders. See drawing ‘Engine seating’

O 2,600 Minimum crane operation area. See drawing 'Outline drawing'

P See text See drawing ‘Crane beam for Turbocharger’ for overhaul of turbocharger

2023-10-23 - en
 2023-10-23 - en

Cylinder No. 5 6

MAN Energy Solutions

Q See text Recommended crane operation area. See drawing 'Outline drawing'

V 0°, 15°, 30°, 45°, 60°, 75°, 90° Maximum 30° when engine room has minimum headroom above the
turbocharger
27021645722730635

593 97 21-9.2.0
27021645722730635

*) The minimum engine room crane height is i.e. dependent on the choice of crane, see the actual heights 'H1'
The minimum engine room height is dependent on 'H1' or 'E+D'.
Maximum length of engine see the engine outline drawing.
Length of engine with PTO see corresponding space requirement.
27021645722730635

Table 5.02.01: Space requirement for the engine, turbocharger(s) mounted on the exhaust side
27021645722730635
G70ME-C10.5/-GI/-GA

199 13 27-6.0
5.02 Space requirement
3 (3)
 5.02 Space requirement

199 13 27-6.0
G70ME-C10.5/-GI/-GA

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MAN Energy Solutions

2023-10-23 - en
 MAN Energy Solutions 199 20 15-4.0

Crane beam requirements - turbocharger and air cooler

General
If the travelling area of the engine room crane covers the recommended area
in the Engine Room Crane drawing, Fig. 5.04.01, crane beams can be omit-
ted for the overhaul of turbocharger. If not, a crane beam with trolleys is re-
quired at each end of the turbocharger(s).

Crane beam and trolleys

Two trolleys are to be available at the compressor end and one trolley is
needed at the gas inlet end:
▪ Crane beam no. 1 is for dismantling of turbocharger components
▪ Crane beam no. 2 is for transporting turbocharger components
as indicated in Figs. 5.03.01 and 5.03.02.

Lifting capacity
The crane beams are used and dimensioned for lifting the following compon-
ents:
▪ Exhaust gas inlet casing
▪ Turbocharger inlet silencer

5.03 Crane beam requirements - turbocharger and air

▪ Compressor casing
▪ Turbine rotor with bearings.
The crane beams are to be placed in relation to the turbocharger(s) so that
the components around the gas outlet casing can be removed in connection
with overhaul of the turbocharger(s).
The crane beam can be bolted to brackets that are fastened to the ship struc-
ture or to columns that are located on the top platform of the engine.
The lifting capacity of the crane beam for the heaviest component ‘W’, is in-
dicated in table 5.03.01 for the various turbocharger makes and types.
The crane beam shall be dimensioned for lifting the weight ‘W’ with a deflec-
tion of some 5 mm only.

Relative position of the crane hook

HB indicates the position of the crane hook in the vertical plane related to the
2024-03-29 - en

centre of the turbocharger. HB and b also specifies the minimum space for
dismantling.
For engines with the turbocharger(s) located on the exhaust side, EoD: 4 59
122, the letter ‘a’ indicates the distance between vertical centrelines of the en-
gine and the turbocharger.
cooler

All engines 1 (8)

199 20 15-4.0 MAN Energy Solutions

Fig. 5.03.01: Required height and distance

5.03 Crane beam requirements - turbocharger and air

MAN
Turbocharger W HB b
kg mm mm
TCR18 1,500 760 500

TCR20 1,500 1,000 500

TCR22 1,500 1,200 500

TCA44 1,000 1,200 500

TCA55 1,000 1,384 600

TCA66 1,200 1,608 700

TCA77 2,000 1,700 800

TCA88 3,080 2,040 1,000

TCT30 500 1,200 700

2024-03-29 - en

TCT40 500 1,300 800

TCT50 750 1,450 900

TCT60 1,000 1,600 1,000

TCT70 1,500 1,750 1,100

TCT80 2,000 1,950 1,250

cooler

2 (8) All engines

 MAN Energy Solutions 199 20 15-4.0

Accelleron
Turbocharger W HB b
kg mm mm

A165-L 750 1,250 800

A170-L 1,000 1,450 950

A175-L 1,470 1,750 1,100

A180-L 1,950 2,000 1,250

A185-L 2,550 2,200 1,400

A255-L 530 1,025 700

A260-L 530 1,200 700

A265-L 750 1,475 800

A270-L 1,000 1,750 950

A275-L 1,470 2,000 1,100

A280-L 1,950 2,225 1,250

Mitsubishi (MHI)
Turbocharger W HB b
kg mm mm
MET18 1,000 1,000 500

5.03 Crane beam requirements - turbocharger and air

MET22 1,000 1,000 500

MET26 1,000 1,500 500

MET30 1,000 1,500 500

MET33 1,000 1,500 600

MET37 1,000 1,500 600

MET42 1,000 1,500 600

MET48 1,000 1,500 700

MET53 1,000 1,500 700

MET60 1,000 1,600 700

MET66 1,500 1,800 800

MET71 1,800 1,800 800

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MET83 2,700 2,000 1,000

MET90 3,500 2,200 1,000

079 43 38-0.9.0b

The figures ‘a’ are stated in the ‘Engine and gallery outline’ drawing, Section
5.06.
Table 5.03.01: Required height, distance and weight
cooler

All engines 3 (8)

199 20 15-4.0 MAN Energy Solutions

Crane beam for turbochargers

5.03 Crane beam requirements - turbocharger and air

2024-03-29 - en

Fig. 5.03.02: Crane beam for turbocharger

cooler

4 (8) All engines

 MAN Energy Solutions 199 20 15-4.0

Crane beam for overhaul of EGR cooler, turbocharger on exhaust side

Overhaul/exchange of scavenge air and EGR cooler.
Valid for air cooler design for the following engines with more than one tur-
bochargers mounted on the exhaust side.
1. Dismantle all the pipes in the area around the cooler.
2. Dismantle all the pipes around the inlet cover for the cooler.
3. Take out the cooler insert by using the above placed crane beam moun-
ted on the engine.
4. Turn the cooler insert to an upright position.
5. Dismantle the platforms below the air cooler.
6. Lower down the cooler insert between the gallery brackets and down to
the engine room floor.
Make sure that the cooler insert is supported, e.g. on a wooden support.
7. Move the cooler insert to an area covered by the engine room crane us-
ing the lifting beam mounted below the lower gallery of the engine.
8. By using the engine room crane the cooler insert can be lifted out of the
engine room.

5.03 Crane beam requirements - turbocharger and air

2024-03-29 - en

cooler

Fig. 5.03.03a: Crane beam for overhaul of EGR cooler, turbochargers located
on exhaust side of the engine

All engines 5 (8)

199 20 15-4.0 MAN Energy Solutions

Overhaul/exchange of scavenge air and EGR cooler.

The text and figure are for guidance only.

Fig. 5.03.03b: Crane beam for overhaul of EGR cooler, turbochargers located
on exhaust side of the engine
5.03 Crane beam requirements - turbocharger and air

2024-03-29 - en
cooler

Fig. 5.03.03c: Crane beam for overhaul of EGR cooler, turbochargers located
on exhaust side of the engine

6 (8) All engines

 MAN Energy Solutions 199 20 15-4.0

Overhaul/exchange of scavenge air and EGR cooler.

The text and figure are for guidance only.

5.03 Crane beam requirements - turbocharger and air

Fig. 5.03.03d: Crane beam for overhaul of EGR cooler, turbochargers located
on exhaust side of the engine
2024-03-29 - en

cooler

Fig. 5.03.03e: Crane beam for overhaul of EGR cooler, turbochargers located
on exhaust side of the engine

All engines 7 (8)

199 20 15-4.0 MAN Energy Solutions

Crane beam for overhaul of air cooler, turbocharger on aft end

This information is only applicable for 50-30 bore engines.

Overhaul/exchange of scavenge air and EGR cooler.

The text and figures are for guidance only
Valid for all engines with aft mounted turbocharger.
1. Dismantle all the pipes in the area around the air cooler.
2. Dismantle all the pipes around the inlet cover for the cooler.
3. Take out the cooler insert by using the above placed crane beam moun-
ted on the engine.
4. Turn the cooler insert to an upright position.
5. By using the engine room crane the air cooler insert can be lifted out of
the engine room.
5.03 Crane beam requirements - turbocharger and air

2024-03-29 - en

Fig. 5.03.04: Crane beam for overhaul of air cooler, turbocharger located on
aft end of the engine
72800847371
cooler

8 (8) All engines

 MAN Energy Solutions 199 13 72-9.0

Engine room cranes - requirements and applications

General
For the main engine components the crane hook travelling area must cover at
minimum the full length of the engine and a width in accordance with dimen-
sion A given on the drawing. The crane hook should at minimum be able to
reach down to a level corresponding to the centre line of the crankshaft.
It is recommended, (see cross-hatched area) in order also to cover overhaul
of turbocharger(S), air coolers, EGR component, SCR component, etc., that
the crane hook travelling area covers at minimum the full length of the engine
and a width to the center line of the before mentioned components.
If the crane hook travelling area is not covering the recommended area, trolley
mounted chain hoists must be installed on separate crane beams or, alternat-
ively, in combination with the engine room crane structure for the before men-
tioned components. See separate drawing with information about the re-
quired lifting capacity for overhaul of turbochargers.
The recommended area is also covering that the engine room crane can be
used for transport of heavy spare parts from the engine room hatch to the en-
gine. The placement of heavy spare parts and the engine room hatch are for
guidance only

5.04 Engine room cranes - requirements and applications

2023-10-05 - en

G70ME-C10.5/-GI/-LGI/-GA 1 (3)
199 13 72-9.0 MAN Energy Solutions
5.04 Engine room cranes - requirements and applications

1) The lifting tools for the engine are designed to fit together with a standard crane hook with a lifting
capacity in accordance with the figure stated in the table. If a larger crane hook is used, it may not fit
directly to the overhaul tools, and the use of an intermediate shackle or similar between the lifting tool
and the crane hook will affect the requirements for the minimum lifting height in the engine room
(dimension H1).
2023-10-05 - en

3) MDT crane interval is the following in ton:

Normal crane : 0.63, 1.0, 1.25, 2.0, 3.2, 4.0, 5.0, 6.3, 8.0, 10.0 & 12.5
If a larger or smaller crane capacity than specified is used, we recommend to use a crane with
minimum capacity corresponding to the heaviest component +5% or max +200 kg.
4) For the Description of H1, see drawing 5887764-6

Fig. 5.04.01: Engine room cranes - requirements and applications

2 (3) G70ME-C10.5/-GI/-LGI/-GA
 MAN Energy Solutions 199 13 72-9.0

Dimensions of engine room crane

Crane capacity Normal Crane
in tons selected Crane operating Height to crane hook in mm for: 4)
in accordance Normal lifting procedure
Mass in kg including lifting tools with DIN and JIS width in mm
(vertical lifting)
Engine Type standard capa-
cities 1) & 3)
H1
B C D E A G I
G70ME-C10.5-DI 4,000 4,850 2,675 6.3 2,600 13,625 13,425

G70ME-C10.5-GI 4,500 4,850 2,675 6.3 2,600 13,625 13,425

G70ME-C10.5-LGI X X X 6.3 X X X

G70ME-C10.5-GA X X X 6.3 X 13,800 13,450

90072041237487755

A Minimum distance from center line crankshaft B Cylinder cover complete with exhaust valve
to the overhaul piston hole on the gallery
C Cylinder liner with cooling jacket D Piston with rod and stuffing box
E Normal crane G Above cylinder cover studs
H1 Minimum height from centre line crankshaft to I Without cylinder cover studs
centre line crane hook

5.04 Engine room cranes - requirements and applications

90072041237487755

589 16 58-8.7.0
90072041237487755

Table. 5.04.01: Engine room cranes - requirements and applications

90072041237487755
2023-10-05 - en

G70ME-C10.5/-GI/-LGI/-GA 3 (3)
199 13 72-9.0 MAN Energy Solutions

90072041237487755
This page is intentionally left blank
5.04 Engine room cranes - requirements and applications

2023-10-05 - en

G70ME-C10.5/-GI/-LGI/-GA
 MAN Energy Solutions 198 47 15-8.3

Engine outline, galleries and pipe connections

Engine outline
The total length of the engine at the crankshaft level may vary depending on
the equipment to be fitted on the fore end of the engine, such as adjustable
counterweights, tuning wheel, moment compensators or PTO, which are
shown as alternatives in Section 5.06

Engine masses and centre of gravity

The partial and total engine masses appear from Section 19.04, ‘Dispatch
Pattern’, to which the masses of water and oil in the engine, Section 5.08, are
to be added. The centre of gravity is shown in Section 5.07, in both cases in-
cluding the water and oil in the engine, but without moment compensators or
PTO.

Gallery outline
Section 5.06 show the gallery outline for engines rated at nominal MCR (L1).

Engine pipe connections

The positions of the external pipe connections on the engine are stated in
Section 5.09, and the corresponding lists of counterflanges for pipes and tur-
bocharger in Section 5.10.

5.05 Engine outline, galleries and pipe connections

The flange connection on the turbocharger gas outlet is rectangular, but a
transition piece to a circular form can be supplied as an option: 4 60 601.
45036048943205899
2023-09-12 - en

ME-B, MC/MC-C, ME/ME-C/-GI/-LGI/-GA 1 (1)

198 47 15-8.3 MAN Energy Solutions

45036048943205899
This page is intentionally left blank
5.05 Engine outline, galleries and pipe connections

2023-09-12 - en

ME-B, MC/MC-C, ME/ME-C/-GI/-LGI/-GA

MAN Energy Solutions 199 16 52-2.0

Engine and gallery outline - TIII

SCR

5.06 Engine and gallery outline - TIII

Fig. 5.06.01a: 5G70ME-C10.5-GA SCR, Example of Engine and gallery out-

line with one MET66MB turbocharger(s) on exhaust side

G70ME-C10.5-GA T-III 1 (5)

199 16 52-2.0 MAN Energy Solutions
5.06 Engine and gallery outline - TIII

Fig. 5.06.01b: 5G70ME-C10.5-GA SCR, Example of Engine and gallery out-

line with one MET66MB turbocharger(s) on exhaust side

2 (5) G70ME-C10.5-GA T-III

MAN Energy Solutions 199 16 52-2.0

5.06 Engine and gallery outline - TIII

Fig. 5.06.01c: 5G70ME-C10.5-GA SCR, Example of Engine and gallery out-

line with one MET66MB turbocharger(s) on exhaust side

G70ME-C10.5-GA T-III 3 (5)

199 16 52-2.0 MAN Energy Solutions
5.06 Engine and gallery outline - TIII

Fig. 5.06.01d: 5G70ME-C10.5-GA SCR, Example of Engine and gallery out-

line with one MET66MB turbocharger(s) on exhaust side

4 (5) G70ME-C10.5-GA T-III

MAN Energy Solutions 199 16 52-2.0

Dimensions of turbocharger on exhaust side

TC Type a b c d
MAN TCA77 3,520 8,487 1,901
5,300
A175-L/A275-L 3,337 8,072 1,946
Accelleron A170-L
Available on request
A260-L

MET66MB 3,412 8,202 1,972 5,300

MHI MET53MBII
Available on request
MET42MBII
27021652987762955

e f g h i
Without moment compensator. 1,051
Without additional bearing
1,909 983
Without moment compensator. 1,051
With additional bearing due to HTW

With moment compensator. 1,659

Without additional bearing
2,650 1,674
With moment compensator. 1,659
With additional bearing due to HTW
27021652987762955

602 12 01-6.3.0
27021652987762955

Table 5.06.01: 5G70ME-C10.5-GA SCR, Example of Engine and gallery out-

line with turbocharger(s) on exhaust side
Please note that the latest version of the dimensioned drawing is available for
download at www.marine.man-es.com --> 'Two-Stroke' --> 'Installation
Drawings'. First choose engine series, then engine type and select ‘Outline
drawing’ for the actual number of cylinders and type of turbocharger installa-
tion in the list of drawings available for download.
5.06 Engine and gallery outline - TIII
27021652987762955

G70ME-C10.5-GA T-III 5 (5)

199 16 52-2.0 MAN Energy Solutions

27021652987762955
This page is intentionally left blank
5.06 Engine and gallery outline - TIII

G70ME-C10.5-GA T-III
 MAN Energy Solutions 199 17 25-4.0

Centre of gravity - TIII

General

Fig.5.07.01:Centre of gravity
5.07 Centre of gravity - TIII
2023-11-01 - en

G70ME-C10.5-GA T-III 1 (3)

199 17 25-4.0 MAN Energy Solutions

Distances and engine configurations: EGRBP

No. of cylinders 5 6
Distance X mm 187

Distance Y mm 2,324
Available on request
Distance Z mm 2,928

DMT *) 534

Engine configuration:

Engine divided NA

TC configuration 1×A265-L

Chain case position - Center NA

Chain case position - Aft With

nd
2 order moment compensator Fore With

2nd order moment compensator Aft With

Tuning wheel 40,000 Kgm2

Turning wheel 16,408 Kgm2

TVD NA Available on request

EGR High sulphur NA

EGR Low sulphur With

EGR Configuration 1×RTU24

1× HOWDEN LOW SPEED

Waste heat recovery system NA

HPSCR NA

Cooler type 1×LKMX - C2/2201

1× EGR - D2/1584

Electrical driven HPS NA

Engine driven HPS With

27021654275045387

628 76 19-3.0.0
5.07 Centre of gravity - TIII

27021654275045387

All values stated are approximate.

2023-11-01 - en

Data for engines with a different engine configuration is available on request.

*) Dry mass tonnes
Table 5.07.01: G70ME-C10.5-GA-EGRBP, Centre of gravity, turbocharger(s)
mounted on the exhaust side

2 (3) G70ME-C10.5-GA T-III

 MAN Energy Solutions 199 17 25-4.0
27021654275045387

5.07 Centre of gravity - TIII

2023-11-01 - en

G70ME-C10.5-GA T-III 3 (3)

199 17 25-4.0 MAN Energy Solutions

27021654275045387
This page is intentionally left blank
5.07 Centre of gravity - TIII

2023-11-01 - en

G70ME-C10.5-GA T-III
 MAN Energy Solutions 199 17 33-7.0

Water and oil calculation - TIII

Masses and engine configuration: EGRBP

No. of cylinders 5 6
Total mass of water, kg 2,620 2,840

- Jacket cooling water, kg 900 940

- Scavenge air cooling water, kg 960 1,150

- Cooling water in EGR , kg 760 750

Total mass of oil, kg 3,150 3,600

- Oil in engine system, kg 1,900 2,250

- Oil pan, kg 840 920

- Hydraulic system oil, kg 410 430

Engine configuration:

TC configuration 1xA165-L 1xA270-L

L connection position fore/aft Fore Fore

K connection position fore/aft Fore Fore

Auto filter - Kanagawa NA NA

Auto filter - Boll filter type 6.64 NA NA

Auto filter – Boll filter type 6.49 With With

Auto filter - Boll filter new type 8.48 NA NA

Separate hydraulic oil NA NA

Separate T/C NA NA

2nd order moment compensator / position fore With With

nd
2 order moment compensator / position aft With With

EGR High sulphur NA NA 5.08 Water and oil calculation - TIII

EGR Low sulphur With With

EGR Configuration 1xRTU24 1xRTU24

1xHowden Low Speed 1xHowden

Waste heat recovery system NA NA

2023-10-30 - en

Cooler type 1xLKMX-C2/2201 1xLKMX-C2/2201

1xEGR-D2/1584 1xEGR-D2/1834

Electrical driven HPS NA NA

Engine driven HPS With With

HPS Center NA NA

HPS Aft With With

18014455221432971

629 09 34-5.0.0 /614 01 77-1.0.0

18014455221432971

Table 5.08.01: G70ME-C10.5-GA-EGRBP, Water and oil in engine

G70ME-C10.5-GA T-III 1 (2)

199 17 33-7.0 MAN Energy Solutions
18014455221432971
5.08 Water and oil calculation - TIII

2023-10-30 - en

2 (2) G70ME-C10.5-GA T-III

MAN Energy Solutions 199 16 53-4.0

Engine pipe connections - TIII

EGR

5.09 Engine pipe connections - TIII

The letters refer to list of ‘Counterflanges’, Fig. 5.10.01.

Fig. 5.09.01a: Example of Engine pipe connections, 5G70ME-C10.5-GA
EGR with one turbocharger mounted on the exhaust side

G70ME-C10.5-GA T-III 1 (5)

199 16 53-4.0 MAN Energy Solutions
5.09 Engine pipe connections - TIII

The letters refer to list of ‘Counterflanges’, Fig. 5.10.01.

Fig. 5.09.01b: Example of Engine pipe connections, 5G70ME-C10.5-GA
EGR with one turbocharger mounted on the exhaust side

2 (5) G70ME-C10.5-GA T-III

MAN Energy Solutions 199 16 53-4.0

5.09 Engine pipe connections - TIII

The letters refer to list of ‘Counterflanges’, Fig. 5.10.01.

Fig. 5.09.01c: Example of Engine pipe connections, 5G70ME-C10.5-GA EGR
with one turbocharger mounted on the exhaust side

Dimensions of turbochargers on exhaust side

MAN

TC type TCT40-ML TCT50-ML TCT60-ML TCA66

a 3,500 3,596

G70ME-C10.5-GA T-III 3 (5)

199 16 53-4.0 MAN Energy Solutions

b 7,862 8,137

c 3,345 3,372

d 9,064

e 3,805

n Available on Request 2,974

h 8,303
Available on
s Request 3,848

k
Available on
i
Request
f
9007254502611339

ABB

TC type A165-L/A265-L A170-L/A270-L A175-L/A275-L

a 3500 3,515

b 7852 7,939

c 3380 3,337

d 8359 8,463

e 3636 3,818

n 3274 3,254 Available on

h 8271 8,403 Request

s 3232 4,042

k
Available on Request
i

f
5.09 Engine pipe connections - TIII

9007254502611339

4 (5) G70ME-C10.5-GA T-III

MAN Energy Solutions 199 16 53-4.0

MHI

TC type MET48MB MET48MBII MET53MB MET53MBII MET60MB MET60MBII

a 3,537 3,537

b 8,107 8,107

c 3,283 3,283

d 8,783 8,731

e 3,718 3,897

n Available on 3,088 Available on 3,077 Available on

h Request 8,556 Request 8,567 Request

s 3,639 3,705

k 2,977 2,909

i 8,257 8,275

f 3,669 3,654
9007254502611339

Dimension With Moment compensator Without moment compensator

eey 2,303 2,103

eoy 2,485 2,285

ahy 2,948 1,857

aby 1,820 1,620

ruy 2,385 2,185

9007254502611339

Filter g p

Boll & Kirch 905

Kanagawa 990
9007254502611339

5.09 Engine pipe connections - TIII

Table 5.09.01: Engine pipe connections, G70ME-C10.5-GA EGR with one
turbocharger mounted on the exhaust side
Please note that the latest version of the dimensioned drawing is available for
download at www.marine.man-es.com --> 'Two-Stroke' --> 'Installation
Drawings'. First choose engine series, then engine type and select ‘Outline
drawing’ for the actual number of cylinders and type of turbocharger installa-
tion in the list of drawings available for download.
9007254502611339

G70ME-C10.5-GA T-III 5 (5)

199 16 53-4.0 MAN Energy Solutions

9007254502611339
This page is intentionally left blank
5.09 Engine pipe connections - TIII

G70ME-C10.5-GA T-III
 MAN Energy Solutions 198 66 70-0.12

Counterflanges, Connections D and E

MAN Type TCA44-88

Type TCA series – Rectangular type

TC L W IL IW A B C D E F G N O

TCA44 1,054 444 949 340 1,001 312 826 408 1,012 104 118 24 ø13.5

TCA55 1,206 516 1,080 390 1,143 360 1,000 472 1,155 120 125 26 ø17.5

TCA66 1,433 613 1,283 463 1,358 420 1,200 560 1,373 140 150 26 ø17.5

TCA77 1,694 720 1,524 550 1,612 480 1,440 664 1,628 160 160 28 ø22

TCA88 2,012 855 1,810 653 1,914 570 1,710 788 1,934 190 190 28 ø22

TCA99 2,207 938 1,985 717 2100 624 1,872 866 2,120 208 208 28 ø22

5.10 Counterflanges, Connections D and E

2023-11-01 - en

All engines 1 (13)

198 66 70-0.12 MAN Energy Solutions

MAN Type TCR

Type TCR series – Round type

TC Dia 1 Dia 2 PCD N O

TCR18 425 310 395 12 ø22

TCR20 540 373 495 16 ø22

TCR22 703 487 650 20 ø22

Fig. 5.10.01a and b: Turbocharger MAN TCA and TCR, exhaust outlet, con-
nection D
5.10 Counterflanges, Connections D and E

2023-11-01 - en

2 (13) All engines

 MAN Energy Solutions 198 66 70-0.12

ABB Type A100/A200-L

Type A100/200-L series – Rectangular type

TC L W IL IW A B C D F G N O

A255-L Available on request

A260-L

A165/A265-L 1,114 562 950 404 1,050 430 900 511 86 100 32 ø22

A170/A270-L 1,280 625 1,095 466 1,210 450 1,080 568 90 120 32 ø22

A175/A275-L 1,523 770 1,320 562 1,446 510 1,260 710 170 140 28 ø30

A180/A280-L 1,743 856 1,491 634 1,650 630 1,485 786 150 135 36 ø30

A185-L 1,955 958 1,663 707 1,860 725 1,595 886 145 145 36 ø30

Fig. 5.10.01c: Turbocharger Accelleron A100/200-L, exhaust outlet, connec-

tion D

5.10 Counterflanges, Connections D and E

2023-11-01 - en

All engines 3 (13)

198 66 70-0.12 MAN Energy Solutions

MHI Type MET

Type MET – Rectangular type

TC L W IL IW A B C D F G N O

Series MB

MET33 Available on request

MET37 999 353 909 263 969 240 855 323 80 95 28 ø15

MET42 1,094 381 1,004 291 1,061 261 950 351 87 95 30 ø15

MET48 1,240 430 1,140 330 1,206 300 1,070 396 100 107 30 ø15

MET53 1,389 485 1,273 369 1,340 330 1,200 440 110 120 30 ø20

MET60 1,528 522 1,418 410 1,488 330 1,320 482 110 110 34 ø20

MET66 1,713 585 1,587 459 1,663 372 1,536 535 124 128 34 ø20

MET71 1,837 617 1,717 497 1,792 480 1,584 572 120 132 36 ø20

MET83 2,163 731 2,009 581 2,103 480 1,920 671 160 160 34 ø24
5.10 Counterflanges, Connections D and E

MET90 2,378 801 2,218 641 2,318 525 2,100 741 175 175 34 ø24

Series MA

MET33 700 310 605 222 670 180 550 280 90 110 18 ø15

MET42 883 365 793 275 850 240 630 335 80 90 24 ø15

MET53 1,122 465 1,006 349 1,073 300 945 420 100 105 28 ø20

MET60 1,230 500 1,120 388 1,190 315 1,050 460 105 105 30 ø20

MET66 1,380 560 1,254 434 1,330 345 1,200 510 115 120 30 ø20
2023-11-01 - en

MET71 1,520 600 1,400 480 1,475 345 1,265 555 115 115 34 ø20

MET83 1,740 700 1,586 550 1,680 450 1,500 640 150 150 30 ø24

MET90 1,910 755 1,750 595 1,850 480 1,650 695 160 165 30 ø24

Fig. 5.10.01d: Turbocharger MHI MET MB and MA, exhaust outlet, connec-
tion D

4 (13) All engines

 MAN Energy Solutions 198 66 70-0.12

Counterflanges, Connection E

MAN Type TCA

TC Dia/ISO Dia/JIS OD PCD N O Thickness of

flanges

TCA44 61 77 120 90 4 ø14 14

9007251756623499

5.10 Counterflanges, Connections D and E

TC Dia/ISO Dia/JIS L W N O Thickness of

flanges
2023-11-01 - en

TCA55 61 77 86 76 4 ø14 16

TCA66 90 90 110 90 4 ø18 16

9007251756623499

Fig. 5.10.01e and f: Turbocharger MAN TCA, venting of lube oil discharge
pipe, connection E

All engines 5 (13)

198 66 70-0.12 MAN Energy Solutions

TC Dia/ISO Dia/JIS L W N O Thickness of

flanges

TCA77 115 115 126 72 4 ø18 18

TCA88 141 141 150 86 4 ø18 18

TCA99 141 141 164 94 4 ø22 24

9007251756623499

Fig. 5.10.01g: Turbocharger MAN TCA, venting of lube oil discharge pipe,
connection E
5.10 Counterflanges, Connections D and E

2023-11-01 - en

6 (13) All engines

 MAN Energy Solutions 198 66 70-0.12

ABB Type A100/A200-L

TC Dia 1 PCD L=W N O Thickness of

flanges

A255-L Available on request

A260-L

A165/A265-L 43 100 106 8 ø8.5 18

A170/A270-L 77 100 115 8 ø11 18

A175/A275-L 77 126 140 8 ø11 18

A180/A280-L 90 142 158 8 ø13 18

A185-L 115 157 178 8 ø13 18

Fig. 5.10.01h: Turbocharger Accelleron A100/200-L, venting of lube oil dis-

charge pipe, connection E

5.10 Counterflanges, Connections D and E

2023-11-01 - en

All engines 7 (13)

198 66 70-0.12 MAN Energy Solutions

MHI Type MET MB

TC L=W Dia 2 PCD N O Thickness

of flanges
(A)

MET33MB Available on request

MET42MB 105 61 105 4 ø14 14

MET48MB 125 77 130 4 ø14 14

MET53MB 125 77 130 4 ø14 14

MET60MB 140 90 145 4 ø18 14

MET66MB 140 90 145 4 ø18 14

5.10 Counterflanges, Connections D and E

2023-11-01 - en

TC Dia 1 Dia 2 PCD N O Thickness

of flanges
(A)

MET71MB 180 90 145 4 ø18 14

MET83MB 200 115 165 4 ø18 16

MET90MB 200 115 165 4 ø18 16

Fig. 5.10.01i and j: Turbocharger MHI MET MB, venting of lube oil discharge
pipe, connection E

8 (13) All engines

 MAN Energy Solutions 198 66 70-0.12

MHI Type MET MA

TC L=W Dia 2 PCD N O Thickness

of flanges
(A)

MET33MA Available on request

MET42MB 105 61 105 4 ø14 14

MET53MB 125 77 130 4 ø14 14

MET60MB 140 90 145 4 ø18 14

MET66MB 140 90 145 4 ø18 14

MET71MB 140 90 145 4 ø18 14

MET90MB 155 115 155 4 ø18 14

5.10 Counterflanges, Connections D and E

2023-11-01 - en

All engines 9 (13)

198 66 70-0.12 MAN Energy Solutions

TC Dia 1 Dia 2 PCD N O Thickness

of flanges
(A)

MET83MB 180 90 145 4 ø18 148

Fig. 5.10.01k and l: Turbocharger MHI MET MA, venting of lube oil discharge
pipe, connection E
5.10 Counterflanges, Connections D and E

2023-11-01 - en

10 (13) All engines

 MAN Energy Solutions 198 66 70-0.12

Counterflanges, connection EB
9007251756623499

MHI Type MET MB

TC Dia 1 Dia 2 PCD N O Thickness

of flanges
(A)

MET42MB 95 43 75 4 ø12 10

MET60MB 120 49 95 4 ø14 12

MET66MB 120 49 95 4 ø14 12

MET71MB 120 49 95 4 ø14 12

MET83MB 120 49 95 4 ø14 12

9007251756623499

5.10 Counterflanges, Connections D and E

2023-11-01 - en

All engines 11 (13)

198 66 70-0.12 MAN Energy Solutions

TC L=W Dia 2 PCD N O Thickness

of flanges
(A)

MET48MB 95 49 95 4 ø14 12

MET53MB 95 49 95 4 ø14 12

MET90MB 125 77 130 4 ø14 14

9007251756623499

198 70 27-3.5.0
9007251756623499

Fig. 5.10.01m and n: Turbocharger MHI MB, cooling air, connection EB

5.10 Counterflanges, Connections D and E

2023-11-01 - en

12 (13) All engines

 MAN Energy Solutions 198 66 70-0.12
9007251756623499

5.10 Counterflanges, Connections D and E

2023-11-01 - en

All engines 13 (13)

198 66 70-0.12 MAN Energy Solutions

9007251756623499
This page is intentionally left blank
5.10 Counterflanges, Connections D and E

2023-11-01 - en

All engines
MAN Energy Solutions 198 41 76-5.13

Engine seating and arrangement of holding down bolts

General
The latest version of the Installation Drawings of this section is available for
download at www.marine.man-es.com --> 'Two-Stroke' --> Installation Draw-
ings'. Specify engine and accept the ‘Conditions for use’ before clicking on
‘Download Drawings’.
The dimensions of the seating stated in Figs. 5.12.01 and 5.12.02 are for
guidance only.
The engine is designed for mounting on epoxy chocks, EoD: 4 82 102, in
which case the underside of the bedplate’s lower flanges has no taper.
The epoxy types approved by MAN Energy Solutions are:
▪ ‘Chockfast Orange PR 610 TCF’
and ‘Epocast 36’ from ITW Philadelphia Resins Corporation, USA.
▪ ‘Durasin’ from
Daemmstoff Industrie Korea Ltd.
▪ ‘EPY’ from
Marine Service Jaroszewicz S.C., Poland.
▪ ‘Loctite Fixmaster Marine Chocking’, Henkel.

5.11 Engine seating and arrangement of holding down bolts

▪ 'CMP Liner Blue' from
Chugoku Marine Paints Ltd, Japan.
18014451011425931

All engines 1 (1)

198 41 76-5.13 MAN Energy Solutions

18014451011425931
This page is intentionally left blank
5.11 Engine seating and arrangement of holding down bolts

All engines
MAN Energy Solutions 199 13 48-0.0

Epoxy chocks arrangement - TIII

General

5.12 Epoxy chocks arrangement - TIII

Fig. 5.12.01: Arrangement of epoxy chocks and holding down bolts

For details of chocks and bolts see special drawings. For securing of support-
ing chocks see special drawing.

Preparing holes for holding down bolts

1) The engine builder drills the holes for holding down bolts in the bedplate
while observing the toleranced locations indicated on MAN Energy Solutions'
drawings for machining the bedplate
2) The shipyard drills the holes for holding down bolts in the top plates while
observing the toleranced locations given on the present drawing
3) The holding down bolts must be made in accordance with MAN Energy
Solutions' drawings of these bolts.

G70ME-C10.5/-GI/-GA T-III 1 (4)

199 13 48-0.0 MAN Energy Solutions

Engine seating profile

5.12 Epoxy chocks arrangement - TIII

Holding down bolts, option: 4 82 602 include:

1. Protecting cap 4. Distance pipe
2. Spherical nut 5. Round nut
3. Spherical washer 6. Holding down bolt

Fig. 5.12.02a: Profile of engine seating with vertical lubricating oil outlet

2 (4) G70ME-C10.5/-GI/-GA T-III

MAN Energy Solutions 199 13 48-0.0

End chock bolts, option: 4 82 610 includes:

1. Stud for end chock bolt
2. Round nut
3. Round nut
4. Spherical washer
5. Spherical washer
6. Protecting cap

End chock liner, option: 4 82 612 includes:

7. Liner for end chock

End chock brackets, option: 4 82 614 includes: 5.12 Epoxy chocks arrangement - TIII
8. End chock bracket

Fig. 5.12.02b: Profile of engine seating, end chocks,

option: 4 82 610

G70ME-C10.5/-GI/-GA T-III 3 (4)

199 13 48-0.0 MAN Energy Solutions

Side chock brackets, option: 4 82 622 includes:

1. Side chock brackets

Side chock liners, option: 4 82 620 includes:
2. Liner for side chock
3. Lock plate
4. Washer
5. Hexagon socket set screw
36028845465060491

Fig. 5.12.02c: Profile of engine seating, side view, side chocks,

option: 4 82 620
36028845465060491
5.12 Epoxy chocks arrangement - TIII

4 (4) G70ME-C10.5/-GI/-GA T-III

 MAN Energy Solutions 199 04 83-8.1

Engine top bracing

General
The so-called guide force moments are caused by the transverse reaction
forces acting on the crossheads due to the connecting rod and crankshaft
mechanism. When the piston of a cylinder is not exactly in its top or bottom
position the gas force from the combustion, transferred through the connect-
ing rod, will have a component acting on the crosshead and the crankshaft
perpendicularly to the axis of the cylinder. Its resultant is acting on the guide
shoe and together they form a guide force moment.
The moments may excite engine vibrations moving the engine top athwart
ships and causing a rocking (excited by H-moment) or twisting (excited by X-
moment) movement of the engine. For engines with less than seven cylinders,
this guide force moment tends to rock the engine in the transverse direction,
and for engines with seven cylinders or more, it tends to twist the engine.
The guide force moments are harmless to the engine except when resonance
vibrations occur in the engine/double bottom system. They may, however,
cause annoying vibrations in the superstructure and/or engine room, if proper
countermeasures are not taken.
As a detailed calculation of this system is normally not available, MAN Energy
Solutions recommends that top bracing is installed between the engine’s up-
per platform brackets and the casing side.
However, the top bracing is not needed in all cases. In some cases the vibra-
tion level is lower if the top bracing is not installed. This has normally to be
checked by measurements, i.e. with and without top bracing.
If a vibration measurement in the first vessel of a series shows that the vibra-
tion level is acceptable without the top bracing, we have no objection to the
top bracing being removed and the rest of the series produced without top
bracing. It is our experience that especially the 7-cylinder engine will often
have a lower vibration level without top bracing.
Without top bracing, the natural frequency of the vibrating system comprising
engine, ship’s bottom, and ship’s side is often so low that resonance with the
excitation source (the guide force moment) can occur close to the normal
speed range, resulting in the risk of vibration.
With top bracing, such a resonance will occur above the normal speed range,
as the natural frequencies of the double bottom/main engine system will in-
crease. The impact of vibration is thus lowered.
The top bracing system is installed either as a mechanical top bracing (typic-
5.13 Engine top bracing
2023-12-11 - en

ally on smaller engine types) or a hydraulic top bracing (typically on larger en-
gine types). Both systems are described below.
The top bracing is normally installed on the exhaust side of the engine, but hy-
draulic top bracing can alternatively be installed on the manoeuvring side. A
combination of exhaust side and manoeuvring side installation of hydraulic top
bracing is also possible.

All engines 1 (3)

199 04 83-8.1 MAN Energy Solutions

Mechanical top bracing

The mechanical top bracing comprises stiff connections between the engine
and the hull.
The top bracing stiffener consists of a double bar tightened with friction shims
at each end of the mounting positions. The friction shims allow the top bra-
cing stiffener to move in case of displacements caused by thermal expansion
of the engine or different loading conditions of the vessel. Furthermore, the
tightening is made with a well-defined force on the friction shims, using disc
springs, to prevent overloading of the system in case of an excessive vibration
level.
The mechanical top bracing is to be made by the shipyard in accordance with
MAN Energy Solutions instructions.

Fig. 5.13.01: Mechanical top bracing stiffener.

Option: 4 83 112

Hydraulic top bracing

The hydraulic top bracing is an alternative to the mechanical top bracing used
mainly on engines with a cylinder bore of 50 or more. The installation normally
features two, four or six independently working top bracing units.
The top bracing unit consists of a single-acting hydraulic cylinder with a hy-
draulic control unit and an accumulator mounted directly on the cylinder unit.
The top bracing is controlled by an automatic switch in a control panel, which
5.13 Engine top bracing

activates the top bracing when the engine is running. It is possible to pro-
2023-12-11 - en

gramme the switch to choose a certain rpm range, at which the top bracing is
active. For service purposes, manual control from the control panel is also
possible.
When active, the hydraulic cylinder provides a pressure on the engine in pro-
portion to the vibration level. When the distance between the hull and engine
increases, oil flows into the cylinder under pressure from the accumulator.
When the distance decreases, a non-return valve prevents the oil from flowing
back to the accumulator, and the pressure rises. If the pressure reaches a
preset maximum value, a relief valve allows the oil to flow back to the accu-
mulator, hereby maintaining the force on the engine below the specified value.

2 (3) All engines

 MAN Energy Solutions 199 04 83-8.1

By a different pre-setting of the relief valve, the top bracing is delivered in a

low-pressure version (26 bar) or a high-pressure version (40 bar).
The top bracing unit is designed to allow displacements between the hull and
engine caused by thermal expansion of the engine or different loading condi-
tions of the vessel.

5.13 Engine top bracing

2023-12-11 - en

Fig. 5.13.02: Outline of a hydraulic top bracing unit. The unit is installed with
the oil accumulator pointing either up or down. Option: 4 83 123
18014451011756427

All engines 3 (3)

199 04 83-8.1 MAN Energy Solutions

18014451011756427
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5.13 Engine top bracing

2023-12-11 - en

All engines
 MAN Energy Solutions 199 17 36-2.0

Mechanical top bracing - TIII

EGRBP

5.14 Mechanical top bracing - TIII

2024-02-27 - en

Horisontal distance (mm) between top bracing fix point and centreline cylinder 1
a = 522 d = 3,654 f = 5,742
b = 1,566 e = 4,698

Fig. 5.14.01: G70ME-C10.5-GA-EGRBP, Example of Mechanical top bracing

arrangement, turbocharger(s) mounted on the exhaust side, top bracings in-
stalled on the exhaust side

G70ME-C10.5-GA T-III 1 (2)

199 17 36-2.0 MAN Energy Solutions

Dimensions of turbocharger(s) on exhaust side

Turbocharger Q R
TCT40 4,905 5,850

TCT50 Available on request

MAN
TCA66 4,905 5,850

TCA77 4,905 5,850

A260-L Available on request

A165 / A265-L 4,905 5,850

Accelleron
A170 / A270-L 4,905 5,850

A175 / A275-L 4,905 5,850

MET42MBII Available on request

MET48MB 4,905 5,850

MET48MBII Available on request

MHI
MET53MB 4,905 5,850

MET53MBII Available on request

MET60MB 4,905 5,850

MET60MBII Available on request

9007256035324811

Table 5.14.01: G70ME-C10.5-GA-EGRBP, Mechanical top bracing arrange-

ment, turbocharger(s) mounted on the exhaust side, top bracings installed on
the exhaust side
Horizontal vibrations on top of the engine are caused by the guide force mo-
ments. For 4-7 cylinder engines the H-moment is the major excitation source
and for larger cylinder numbers the X-moment is the major excitation source.
For engines with vibrations excited by the X-moment, bracings at the centre
of the engine are of only minor importance.
5.14 Mechanical top bracing - TIII

Top bracings should only be installed on one side, either the exhaust side or
the manoeuvring side. If the top bracing has to be installed on the manoeuv-
ring side, please contact MAN Energy Solutions.
If the minimum built-in length can not be fulfilled, please contact MAN Energy
Solutions or our local representative.
2024-02-27 - en

The complete arrangement to be delivered by the shipyard.

9007256035324811

2 (2) G70ME-C10.5-GA T-III

MAN Energy Solutions 199 16 54-6.0

Hydraulic top bracing arrangement - TIII

EGR

5.15 Hydraulic top bracing arrangement - TIII

Fig. 5.15.01: 6G70ME-C10-GA-EGR, Example of Hydraulic top bracing ar-

rangement,
turbocharger(s) mounted on the exhaust side

G70ME-C10.5-GA T-III 1 (2)

199 16 54-6.0 MAN Energy Solutions
5.15 Hydraulic top bracing arrangement - TIII

Fig. 5.15.02: Hydraulic top bracing data

As the rigidity of the casing structure to which the top bracing is attached is
most important, it is recommended that the top bracing is attached directly
into a deck.
Required rigidity of the casing side point A:
In the axial direction of the hydraulic top bracing:
Force per bracing: 127 kN
Max. corresponding deflection of casing side: 0.51 mm
In the horizontal and vertical direction of the hydraulic top bracing:
Force per bracing: 22 kN
Max. corresponding deflection of casing side : 2.00 mm
9007254570620171

2 (2) G70ME-C10.5-GA T-III

 MAN Energy Solutions 199 15 50-3.0

Components for engine control system

Installation of ECS in the Engine Control Room

The following items are to be installed in the ECR (Engine Control Room):
▪ 2 pcs EICU (Engine Interface Control Unit)
(1 pcs only for ME-B engines)
▪ 1 pcs ECS MOP-A (Main Operating Panel)
EC-MOP with touch display, 15”
▪ 1 pcs ECS MOP-B
EC-MOP with touch display, 15”
▪ 1 pcs EMS MOP with system software Display,
24” marine monitor PC unit
▪ 1 pcs Managed switch and VPN router with firewall

The EICU functions as an interface unit to ECR related systems such as AMS
(Alarm and Monitoring System), RCS (Remote Control System) and Safety
System. On ME-B engines the EICU also controls the HPS.
MOP-A and -B are redundant and are the operator’s interface to the ECS. Via
both MOPs, the operator can control and view the status of the ECS. Via the
EMS MOP PC, the operator can view the status and operating history of both
the ECS and the engine, EMS is decribed in Section 18.01.
The PMI Auto-tuning application is run on the EMS MOP PC. PMI Auto-tuning
is used to optimize the combustion process with minimal operator attendance
and improve the efficiency of the engine. See Section 18.01.
CoCoS-EDS ME Basic is included as an application in the Engine Manage-
ment Services as part of the standard software package installed on the EMS
MOP PC. See Section 18.01.

5.16 Components for engine control system

2022-10-12 - en

ME/ME-C/ME-B/-GI/-GA/-LGI 1 (4)
199 15 50-3.0 MAN Energy Solutions

Abbreviations: # Yard Supply

AMS: Alarm Monitoring Systems
EICU: Engine Interface Control ¤ Ethernet, 10 m patch cable supplied with
Unit switch. Type:
EMS: Engine Management Ser- RJ45, STP (Shielded Twisted Pair), CAT 5.
vices
MOP: Main Operating Panel In case 10 m cable is not enough, this be-
comes Yard supply.

Fig. 5.16.01 Network and PC components for the ME/ME-B Engine Control
System

EC-MOP
▪ Integrated PC unit and touch display,
15”
▪ Direct dimming control (0-100%)
▪ USB connections at front
▪ IP20 resistant front
▪ Dual Arcnet

Pointing Device
5.16 Components for engine control system

▪ Keyboard model
▪ UK version, 104 keys
▪ USB connection
▪ Trackball mouse
▪ USB connection

EMS MOP PC
2022-10-12 - en

▪ Standard industry PC with MS Win-

dows
operating system, UK version

2 (4) ME/ME-C/ME-B/-GI/-GA/-LGI
 MAN Energy Solutions 199 15 50-3.0

Marine Monitor for EMS MOP PC

▪ LCD (MVA) monitor 24”
▪ Projected capacitive touch
▪ Resolution 1,920x1,080,
WSXGA+
▪ Direct dimming control
(0-100%)
▪ IP54 resistant front
▪ For mounting in panel

▪ Bracket for optional mounting on

desktop, with hinges (5° tilt, adjustable
95°) or without hinges (10° tilt, not ad-
justable

Network Components
▪ Managed switch and VPN router with
firewall

5.16 Components for engine control system

Fig. 5.16.02 MOP PC equipment for the ME/ME-B Engine Control System
2022-10-12 - en

ME/ME-C/ME-B/-GI/-GA/-LGI 3 (4)
199 15 50-3.0 MAN Energy Solutions

EICU Cabinet
▪ Engine interface control cabinet for
ME-ECS for installation in ECR (re-
commended) or ER

Fig. 5.16.03: The network printer and EICU cabinet unit for the ME Engine
Control System

Engine Control Room Console

▪ Recommended outline of Engine Control Room console with ME equipment
5.16 Components for engine control system

2022-10-12 - en

* Yard supply

Oil mist detector equipment depending on supplier/maker

BWM: Bearing Wear Monitoring
18014451190197515

Fig. 5.16.04: Example of Engine Control Room console

18014451190197515

4 (4) ME/ME-C/ME-B/-GI/-GA/-LGI
 MAN Energy Solutions 198 49 29-2.4

Shaftline earthing device

Scope and field of application

A difference in the electrical potential between the hull and the propeller shaft
will be generated due to the difference in materials and to the propeller being
immersed in sea water.
In some cases, the difference in the electrical potential has caused spark
erosion on the thrust, main bearings and journals of the crankshaft of the en-
gine.
In order to reduce the electrical potential between the crankshaft and the hull
and thus prevent spark erosion, a highly efficient shaftline earthing device
must be installed.
The shaftline earthing device should be able to keep the electrical potential
difference below 50 mV DC. A shaft-to-hull monitoring equipment with a mV-
meter and with an output signal to the alarm system must be installed so that
the potential and thus the correct function of the shaftline earthing device can
be monitored.
Note that only one shaftline earthing device is needed in the propeller shaft
system.

5.17 Shaftline earthing device

2023-10-26 - en

All engines 1 (3)

198 49 29-2.4 MAN Energy Solutions

Design description
The shaftline earthing device consists of two silver slip rings, two arrange-
ments for holding brushes including connecting cables and monitoring equip-
ment with a mV-meter and an output signal for alarm.
The slip rings should be made of solid silver or back-up rings of copper with a
silver layer all over. The expected life span of the silver layer on the slip rings
should be minimum 5 years.
The brushes should be made of minimum 80% silver and 20% graphite to en-
sure a sufficient electrical conducting capability.
Resistivity of the silver should be less than 0.1μ Ohm x m. The total resistance
from the shaft to the hull must not exceed 0.001 Ohm.
Cabling of the shaftline earthing device to the hull must be with a cable with a
cross section not less than 45 mm2. The length of the cable to the hull should
be as short as possible.
Monitoring equipment should have a 4-20 mA signal for alarm and a mV-
meter with a switch for changing range. Primary range from 0 to 50 mV DC
and secondary range from 0 to 300 mV DC.
When the shaftline earthing device is working correctly, the electrical potential
will normally be within the range of 10-50 mV DC depending of propeller size
and revolutions.
The alarm set-point should be 80 mV for a high alarm. The alarm signals with
an alarm delay of 30 seconds and an alarm cut-off, when the engine is
stopped, must be connected to the alarm system.
Connection of cables is shown in the sketch, see Fig. 5.17.01.
5.17 Shaftline earthing device

2023-10-26 - en

Fig. 5.17.01: Connection of cables for the shaftline earthing device

2 (3) All engines

 MAN Energy Solutions 198 49 29-2.4

Shaftline earthing device installations

The shaftline earthing device slip rings must be mounted on the foremost in-
termediate shaft as close to the engine as possible, see Fig. 5.17.02

Fig. 5.17.02: Installation of shaftline earthing device in an engine plant without

shaft-mounted generator
When a generator is fitted in the propeller shaft system, where the rotor of the
generator is part of the intermediate shaft, the shaftline earthing device must
be mounted between the generator and the engine, see Fig. 5.17.03

5.17 Shaftline earthing device

2023-10-26 - en

Fig. 5.17.03: Installation of shaftline earthing device in an engine plant with

shaft-mounted generator
27021650275972491

All engines 3 (3)

198 49 29-2.4 MAN Energy Solutions

27021650275972491
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5.17 Shaftline earthing device

2023-10-26 - en

All engines
 MAN Energy Solutions 199 15 80-2.0

MAN Alpha CPP and Alphatronic propulsion control

MAN Alpha controllable pitch propeller

On MAN Energy Solutions' MAN Alpha VBS type controllable pitch (CP) pro-
peller, the propeller hub contains a hydraulic servomotor which sets the pitch.
A range of different propeller hub sizes is available to select an optimum hub
for any given combination of engine power and revolution, and ice class of the
vessel.

VBS type CP propeller designation and range

The VBS type CP propellers are designated according to the diameter of their
hubs, for example ‘VBS2150’ which indicates a propeller hub diameter of
2,150 mm.
Fig. 5.18.01 shows the standard VBS type CP propeller programme, the pro-
peller diameters and the engine power range covered.

5.18 MAN Alpha CPP and Alphatronic propulsion control

2024-04-03 - en

Fig. 5.18.01: Range of MAN Alpha controllable pitch propellers type VBS Mk
5
As standard VBS Mk 5 versions are four-bladed but five-bladed versions are
available on request. The standard blade and hub materials are Ni-Al-bronze,
with stainless steel available as an option. The propellers are based on no ice
class but are available up to the highest ice classes.
The servo oil system controlling the setting of the propeller blade pitch is dis-
cussed in the later Section 'Servo oil system for VBS type CP propeller'.

70-30 engines 1 (13)

199 15 80-2.0 MAN Energy Solutions

Data sheet for propeller

Fig. 5.18.02 and Table 5.18.01 define the dimensions and information neces-
sary for propeller design purposes.

Identification: _______________________________
5.18 MAN Alpha CPP and Alphatronic propulsion control

Fig. 5.18.02: Dimension sketch for propeller design purposes

For propeller design purposes, provide us with the following information:

Type of vessel: ______________________________

1. S: (See Fig. 5.18.02) __________ mm
W: (See Fig. 5.18.02) __________ mm
I: (See Fig. 5.18.02) __________ mm
2. Stern tube and shafting arrangement layout
3. Propeller aperture drawing
4. Complete set of reports from model tank tests (resistance test, self propulsion
test and wake measurement). If a model test is not available, fill inTable 5.18.02
with main dimensions
2024-04-03 - en

5. Drawing of lines plan

6. Classification society: __________
Ice class notation: __________
7. Maximum rated power of shaft generator: __________ kW
8. Optimisation condition for the propeller: To obtain the highest propeller effi-
ciency, state the most common service condition for the vessel.
Ship speed: __________ kn
Engine service load: __________ %

2 (13) 70-30 engines

 MAN Energy Solutions 199 15 80-2.0

Service/sea margin: __________ %

Shaft generator service load: __________ kW
Draft: __________ m
9. Comments: __________

Table 5.18.01: Data sheet for propeller design purposes

Main dimensions
If a model test is not available, fill in Table 5.18.02 which contains an addi-
tional data sheet for propeller design purposes.

Symbol Unit Ballast Loaded

Length between perpendiculars LPP m

Length of load water line LWL m

Breadth B m

Draft at forward perpendicular TF m

Draft at aft perpendicular TA m

Displacement o m3

Block coefficient (LPP) CB

5.18 MAN Alpha CPP and Alphatronic propulsion control

Midship coefficient CM

Waterplane area coefficient CWL

Wetted surface with appendages S m2

Centre of buoyancy forward of LPP/2 LCB m

Propeller centre height above baseline H m

Bulb section area at forward perpendicular AB m2

178 22 97-0.0

Table 5.18.02: Additional data sheet for propeller design purposes when a
model test is not available
2024-04-03 - en

70-30 engines 3 (13)

199 15 80-2.0 MAN Energy Solutions

Propeller clearance
To reduce pressure impulses and vibrations emitted from the propeller to the
hull, MAN Energy Solutions recommends a minimum tip clearance as shown
in Fig. 5.18.03.

Fig. 5.18.03: Propeller clearance

For ships with slender aft body and favourable inflow conditions, use the lower
values of Table 5.18.03, whereas for ships with full aft body and large vari-
ations in wake field, the upper values have to be used.
In twin-screw ships, the blade tip may protrude below the base line.

Hub High-skew Non-skew Baseline

5.18 MAN Alpha CPP and Alphatronic propulsion control

Dismantling of cap propeller propeller clearance

X [mm] Y [mm] Y [mm] Z [mm]

VBS 860 170

VBS 940 185

VBS 1020 200

VBS 1100 215

VBS 1180 230

VBS 1260 245

VBS 1350 265 15-20% 20-25% Min.

of D of D 50-100
VBS 1460 280

VBS 1550 300

VBS 1640 320

2024-04-03 - en

VBS 1730 340

VBS 1810 355

VBS 1890 370

VBS 1970 385

VBS 2060 405

VBS 2150 425

Table 5.18.03: Clearances

4 (13) 70-30 engines

 MAN Energy Solutions 199 15 80-2.0

Servo oil system for VBS type CP propeller

Fig. 5.18.04 shows the design principle of the servo oil system for MAN En-
ergy Solutions' MAN Alpha VBS type CP propeller.
The VBS system consists of a servo oil tank unit, which is the hydraulic power
unit, and coupling flange with electrical pitch feedback box and oil distributor
ring.
The electrical pitch feedback box continuously measures the position of the
pitch feedback ring and compares this signal with the pitch order signal.
If a deviation occurs, a proportional valve is actuated. Hereby, high-pressure
oil is fed to one or the other side of the servo piston via the oil distributor ring,
until the desired propeller pitch has been reached.
The pitch setting is normally remote controlled, but local emergency control is
possible.

5.18 MAN Alpha CPP and Alphatronic propulsion control

Fig. 5.18.04: Servo oil system for MAN Alpha VBS type CP propeller
2024-04-03 - en

Hydraulic power unit

The servo oil tank unit is the hydraulic power unit for MAN Energy Solutions'
MAN Alpha CP propeller.
The servo oil tank unit in Fig. 5.18.05 consists of an oil tank with all compon-
ents mounted on top to facilitate installation at the yard.

70-30 engines 5 (13)

199 15 80-2.0 MAN Energy Solutions
5.18 MAN Alpha CPP and Alphatronic propulsion control

Fig. 5.18.05: Hydraulic power unit for MAN Alpha CP propellers

Two electrically driven pumps draw oil from the oil tank through a suction filter
and deliver high-pressure oil to the proportional valve.
One of two pumps will be in service during normal operation, while the
second will start up at powerful manoeuvring.
A servo oil pressure adjusting valve ensures minimum servo oil pressure at
any time, hereby minimising the electrical power consumption.
The maximum system pressure is set on the safety valve.
Return oil is led back to the tank via a thermostatic valve, cooler and paper fil-
ter.
The servo oil unit is equipped with alarms according to requirements of classi-
fication societies and necessary pressure and temperature indicators.
2024-04-03 - en

If the servo oil unit cannot be placed so that there is a maximum oil level be-
low the oil distribution ring, the system must incorporate an extra, small drain
tank complete with pump. This drain tank must be placed at a suitable level,
below the oil distributor ring drain lines.

Alphatronic 3000 propulsion control system

Description
The system offers three levels of propulsion control:
▪ 'Normal control' with automatic load control

6 (13) 70-30 engines

 MAN Energy Solutions 199 15 80-2.0

▪ 'Backup control' from bridge and ECR

▪ Independent telegraph system for communicating from the bridge to the
machinery space.
The system is based on a modular panel design concept to elegantly fit any
ship console layout. A configurable touch screen in the propulsion control
panel meets a wide range of customer specific functions.
A thrust command can be issued in different control levels from the propulsion
control station: In ‘Normal control' from the control lever in a handle panel, in
‘Backup control' as an order from one of the display panels, or indirectly via
telegraph orders from a navigator on the bridge to an engineer in the ma-
chinery space.

Controllable pitch propeller applications

In single and twin propeller installations, applications with non-reversible two-
stroke low speed engines are controlled by the Alphatronic 3000 system. The
system comprises remote start and stop of engines from the display panels,
and control of engine speed from the handle panel, see Fig. 5.18.06.

5.18 MAN Alpha CPP and Alphatronic propulsion control

2024-04-03 - en

Fig. 5.18.06: Control system architecture – two-stroke propulsion package ex-

ample with CP propeller

70-30 engines 7 (13)

199 15 80-2.0 MAN Energy Solutions

Bridge control station layout for a single propeller plant

Fig. 5.18.07 shows the bridge control station layout, including the different
panels, for a single CP propeller plant.

Fig. 5.18.07: Bridge control station layout with propulsion control panel,
manoeuvre handle panel, emergency stop panel and telegraph order panel
5.18 MAN Alpha CPP and Alphatronic propulsion control

Manoeuvre handle panels

The manoeuvre handle panel (MHP) in Fig. 5.18.08 is the primary control
device for the main propeller.

2024-04-03 - en

Fig. 5.18.08: Single-handle version – MHP – for CPP plants

The panel is always located on the ship’s bridge, normally also in the ECR,
and optionally on the bridge wings and aft bridge. A control station will com-
prise one, and only one, manoeuvre handle panel in a suitable version for the
actual propulsion plant. The stepper motor(s) of the MHP is built into the
spherically shaped handle body - requiring very limited installation space and
console depth, see Fig. 5.18.08.

8 (13) 70-30 engines

 MAN Energy Solutions 199 15 80-2.0

On CPP plants, the lever will control thrust and thrust direction via speed and
pitch settings.
The single-handle panel is used for single propeller applications, and the
double-handle panel shown in Fig. 5.18.09 is used for twin-propeller plants.
The double-handle version is for independent control of the two shaft lines via
two separate electric circuits.

Fig. 5.18.09: Double-handle version – MHP – for CPP plants

5.18 MAN Alpha CPP and Alphatronic propulsion control

All handles comprise a stepper motor for alignment (electric shaft system) of
the levers according to the commands from the lever in command.

Propulsion control panel

The propulsion control panel (PCP) comprises a touch screen with soft keys
for handling transfer of control responsibility and setup of propulsion power. In
addition to propulsion setup, the display handles general monitoring and
alarms for the propulsion control system, see Fig. 5.18.10.
2024-04-03 - en

Fig. 5.18.10: Propulsion control panel – PCP – for CPP plants

70-30 engines 9 (13)

199 15 80-2.0 MAN Energy Solutions

The control function in the engine safety system related to ‘shutdown’ and
‘load reduction’ is also available in the display panel. One PCP per propeller
shaft must be available on the bridge control location and in the ECR.
The PCP provides two levels of control. ‘Normal control’ with thrust com-
mands from the selected manoeuvre handle and ‘Backup control’ with thrust
commands from a soft key menu in the display panel. The PCP can be selec-
ted for all bridge control stations, if a setup of propulsion power is necessary
on other bridge control stations besides the main control station on the bridge
centre.

Telegraph order panel

The telegraph order panel (TOP) in Fig. 5.18.11 operates independent of the
propulsion remote control system.
5.18 MAN Alpha CPP and Alphatronic propulsion control

2024-04-03 - en

Fig. 5.18.11: Telegraph order panel (TOP)

According to SOLAS requirements, at least one telegraph panel per propeller
shaft must be available on the bridge control location and in the ECR. How-
ever, the telegraph panel can be placed on any bridge control station where
the telegraph order communication is expected to be relevant.

10 (13) 70-30 engines

 MAN Energy Solutions 199 15 80-2.0

The telegraph can be used for issuing orders from the bridge to the machinery
space independent of the propulsion remote control system. In the ECR, con-
trol telegraph orders are available in control level ‘Normal’ and ‘Backup’. If
local control is chosen in the engine room, the telegraph panel is connected
to the local operating panel in the engine room (CPP only) used for telegraph
order acknowledgement and setting of corresponding local thrust commands.

Local operating panel with telegraph

The local operating panel for the propeller (LOP-P) is located in the engine
room close to the local operating panel for the engine. In addition to local con-
trol and monitoring functionality for the propeller system, the panel is used for
telegraph order acknowledgement, see Figs. 5.18.12 and 5.18.13.

5.18 MAN Alpha CPP and Alphatronic propulsion control

Fig. 5.18.12: LOP-P with telegraph receiver and propeller pitch control
2024-04-03 - en

Fig. 5.18.13: Zooming in on the LOP-P display shows the additional sub-
menus available, for example for monitoring bearing temperatures in stern
tube and intermediate shaft line

70-30 engines 11 (13)

199 15 80-2.0 MAN Energy Solutions

Emergency stop panel

The function of the propulsion power emergency stop panel (ESP) in Fig.
5.18.14 is totally independent of the propulsion remote control system.

Fig. 5.18.14: Emergency stop panel - ESP

According to regulations, at least one emergency stop panel per propeller
shaft must be available on the bridge control location and in the ECR. For
5.18 MAN Alpha CPP and Alphatronic propulsion control

safety reasons, it is recommended to incorporate an emergency stop panel

on all control stations.

Control station for engine control room

The control station configuration comprises a display panel, a handle panel, a
telegraph panel and an emergency stop panel, see Fig. 5.18.15.

2024-04-03 - en

Fig. 5.18.15: ECR control station with optional EHP panel for a two-stroke en-
gine with CP propeller

12 (13) 70-30 engines

 MAN Energy Solutions 199 15 80-2.0

For two-stroke low speed engines, an additional optional engine handle panel
(EHP) can be added for independent start, stop and speed setting of the en-
gine from the ECR, see Fig. 5.18.16.

Fig. 5.18.16: Two-stroke engine handle panel – EHP

The EHP comprises basic control functions: a push button for command

5.18 MAN Alpha CPP and Alphatronic propulsion control

take-over, and lever for engine start, stop and speed setting.

Further information
For further information and details of the many options available from the
Alphatronic 3000 propulsion control systems - see our publication:
https://www.man-es.com/docs/default-source/document-sync/alphat-
ronic-30004f3f7c5cbd654eff86735e7cd5a16a45.pdf?sfvrsn=ac5a32e6_1
36028850157554315
2024-04-03 - en

70-30 engines 13 (13)

199 15 80-2.0 MAN Energy Solutions

36028850157554315
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5.18 MAN Alpha CPP and Alphatronic propulsion control

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70-30 engines
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil

06 List of Capacities: Pumps, Coolers & Exhaust Gas

11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395569547

1 (1)
 MAN Energy Solutions

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06 List of Capacities: Pumps, Coolers & Exhaust Gas
 MAN Energy Solutions 199 04 08-6.1

Calculation of List of Capacities

Updated engine and capacities data is available from the CEAS application at
www.marine.man-es.com -->’ Two-Stroke’ --> ’CEAS engine calculations’.
This chapter describes the necessary auxiliary machinery capacities to be
used for a nominally rated engine. The capacities given are valid for seawater
cooling system and central cooling water system, respectively.
For a derated engine, i.e. with a specified MCR different from the nominally
rated MCR point, the list of capacities will be different from the nominal capa-
cities.
Furthermore, among others, the exhaust gas data depends on the ambient
temperature conditions.
For a derated engine, calculations of:
▪ Derated capacities
▪ Available heat rate, for example for freshwater production
▪ Exhaust gas amounts and temperatures
can be made in the CEAS application available at the above link.

Nomenclature
In the following description and examples of the auxiliary machinery capacities
in Section 6.02, the below nomenclatures are used:

Engine ratings Point / Index Power Speed

Nominal maximum continuous rating (NMCR) L1 PL1 nL1

Specified maximum continuous rating (SMCR) M PM nM

Normal continuous rating (NCR) S PS nS

Table. 6.01.01: Nomenclature of basic engine ratings

Parameters Cooler index Flow index

M = Mass flow air = scavenge air cooler exh = exhaust gas

Table. 6.01.02: Nomenclature of coolers and volume flows, etc. 6.01 Calculation of List of Capacities

Engine Configurations Related to SFOC

The engine type is available in the following version with respect to the effi-
ciency of the turbocharger(s) alone:
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High efficiency turbocharger, the basic engine design (EoD: 4 59 104)

Conventional turbocharger, (option: 4 59 107) for both of which the lists of ca-
pacities Section 6.03 are calculated.
9007250805478923

95-30 engines dot 5 and higher 1 (1)

199 04 08-6.1 MAN Energy Solutions

9007250805478923
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6.01 Calculation of List of Capacities

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95-30 engines dot 5 and higher

 MAN Energy Solutions 198 95 12-4.0

List of capacities for cooling water systems

The List of Capacities contain data regarding the necessary capacities of the
auxiliary machinery for the main engine only, and refer to NMCR. Complying
with IMO Tier II NOx limitations.
The heat dissipation figures include 10% extra margin for overload running ex-
cept for the scavenge air cooler, which is an integrated part of the diesel en-
gine.

Cooling Water Systems

The capacities given in the tables are based on tropical ambient reference
conditions and refer to engines with high efficiency/conventional turbocharger
running at NMCR for:
▪ Seawater cooling system,
See diagram, Fig. 6.02.01 and nominal capacities in Fig. 6.03.01

Fig. 6.02.01: Diagram for seawater cooling system

▪ Central cooling water system,
See diagram, Fig. 6.02.02 and nominal capacities in Fig. 6.03.01

6.02 List of capacities for cooling water systems

Fig. 6.02.02: Diagram for central cooling water system

The capacities for the starting air receivers and the compressors are stated in
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Fig. 6.03.01.

Heat Radiation
The radiation and convection heat losses to the engine room is around 1% of
the engine power at NMCR.

G/S95-50ME-C9/10/-GI, G/S50ME-B9 1 (2)

198 95 12-4.0 MAN Energy Solutions

Flanges on Engine, etc.

The location of the flanges on the engine are shown in: ‘Engine pipe connec-
tions’, and the flanges are identified by reference letters stated in the list of
‘Counter flanges’; both can be found in Chapter 5.
The diagrams use the ‘Basic symbols for piping’, the symbols for instrumenta-
tion are according to ‘ISO 1219-1’ / ‘ISO 1219-2’ and the instrumentation list
both found in Appendix A.
9007250982665355
6.02 List of capacities for cooling water systems

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2 (2) G/S95-50ME-C9/10/-GI, G/S50ME-B9

 MAN Energy Solutions 199 19 65-0.0

List of capacities
Download an engine report with capacities for pumps, coolers, auxiliary sys-
tem, etc., for your specific engine type by using our online engine calculation
tool CEAS at:
https://www.man-es.com/marine/products/planning-tools-and-downloads/
ceas-engine-calculations

Fig. 6.03.01: The browser-based CEAS calculation system

64876580235
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6.03 List of capacities

All engines 1 (1)

199 19 65-0.0 MAN Energy Solutions

64876580235
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6.03 List of capacities

All engines
 MAN Energy Solutions 199 15 93-4.0

Auxiliary machinery capacities derated engines

Further to the auxiliary machinery capacities for a nominally rated engine
shown in Section 6.03, the dimensioning of heat exchangers (coolers) and
pumps for derated engines as well as calculating the:
▪ List of capacities for derated engine
▪ Available heat to be removed, for example for freshwater production
▪ Exhaust gas amounts and temperatures
can be made in the CEAS application descibed in Section 20.02.
The CEAS application is available at www.marine.man-es.com --> 'Two
stroke' --> 'CEAS Engine Calculations' .

Pump Pressure and Temperatures

The pump heads stated in the table below are for guidance only and depend
on the actual pressure drop across coolers, filters, etc. in the systems.

Pump head, bar Maximum working temp. °C

Fuel oil supply pump 4 100

Fuel oil circulating pump 6 150

Lubricating oil pump 4.5 70

Seawater pump, for seawater cooling system 2.5 50

Seawater pump, for central cooling water system 2.0 50

6.04 Auxiliary machinery capacities derated engines

Central cooling water pump 2.5 80

Jacket water pump 3.0 100

Flow Velocities
For external pipe connections, we prescribe the following maximum velocities:
Marine diesel oil ......................................... 1.0 m/s
Heavy fuel oil .............................................. 0.6 m/s
Lubricating oil ............................................. 1.8 m/s
Cooling water ............................................. 3.0 m/s
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G70-60ME-C9/10/-GI/-GA/-LGI 1 (4)
199 15 93-4.0 MAN Energy Solutions

Centrifugal Pump Selection

6.04 Auxiliary machinery capacities derated engines

Fig. 6.04.01: Location of the specified nominal duty point (SNDP) on the
pump QH curve
When selecting a centrifugal pump, it is recommended to carefully evaluate
the pump QH (capacity/ head) curve in order for the pump to work properly
both in normal operation and under changed conditions. But also for ensuring
that the maximum pipe design pressure is not exceeded.
The following has to be evaluated:
▪ Location of the specified nominal duty point (SNDP) on the pump QH
curve
▪ Pump QH curve slope
▪ Maximum available delivery pressure from the pump.
9007252659909003

Location of the Duty Point on the Pump QH

Particularly important is the location of the specified nominal duty point
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(SNDP) on the pump QH curve: the SNDP is equal to the intersection of the
pump QH curve and the pipe system pressure characteristic, which is defined
at the design stage.
The SNDP must be located in the range of 45 to 85% of the pump’s max-
imum capacity, see Fig. 6.04.01.
Thus, the pump will be able to operate with slightly lower or higher pipe sys-
tem pressure characteristic than specified at the design stage, without the risk
of cavitation or too big variations in flow.

2 (4) G70-60ME-C9/10/-GI/-GA/-LGI
 MAN Energy Solutions 199 15 93-4.0

Pump QH Curve Slope

At the location of the SNDP, the pump capacity should not decrease by more
than 10% when the pressure is increased by 5%, see Fig. 6.04.02.
This way, the flow stays acceptable even if the pipe system pressure is higher
than expected and the flow does not change too much, for example when a
thermostatic valve changes position.

6.04 Auxiliary machinery capacities derated engines

Fig. 6.04.02: Pump QH curve slope
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G70-60ME-C9/10/-GI/-GA/-LGI 3 (4)
199 15 93-4.0 MAN Energy Solutions

Maximum Available Pump Delivery Pressure

It is important to evaluate, if the maximum available delivery pressure from the
pump contributes to exceeding the maximum allowable design pressure in
the pipe system.
The maximum available delivery pressure from the pump will occur e.g. when
a valve in the system is closed, see Fig. 6.04.03.
The maximum allowable pipe system design pressure must be known in order
to make the pressure rate sizing for equipment and other pipe components
correctly.
6.04 Auxiliary machinery capacities derated engines

Fig. 6.04.03: Maximum available pump delivery pressure

9007252659909003

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4 (4) G70-60ME-C9/10/-GI/-GA/-LGI
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395575051
07 Fuel

1 (1)
 MAN Energy Solutions

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07 Fuel
 MAN Energy Solutions 199 16 43-8.0

Fuel gas system - ME-GA engine

The ME-GA engine is a dual-fuel engine based on a pre-mixed gas principle.
The engine combusts a fuel-air mixture ignited by pilot oil in dual-fuel mode.
The fuel gas admission on the engine is described in the present Section
7.00.
In this project guide, second fuel or fuel gas is the denomination for methane.
A fuel gas supply system (FGSS) delivers low-pressure gas to the fuel gas ad-
mission system on the engine.
The ME-GA engine has two fuel oil injection systems, a main system and a
separate pilot oil system. The main system is comparable to the system used
for engines combusting fuel-oil only.
The fuel oil and pilot oil systems are described in Section 7.01, the FGSS and
auxiliary systems in Sections 7.07 - 7.09.

The ME-GA specific engine parts

The fuel gas admission system on the engine contains a gas regulating unit
(GRU), optimised gas piping arrangement and safe gas admission valves
(SGAV) in each cylinder. The SGAVs are located in the cylinder liner.
Each SGAV contains a window valve, which is activated by a solenoid valve,
and a gas admission valve (GAV), also operated by its own solenoid valve.
The fuel gas accumulator volume is provided in the fuel gas piping.
The ME-GA engine is equipped with a dedicated pilot valve, the micro booster
injection valve (MBIV).
Sealing oil is supplied to the window/shutdown valve and SGAV to separate
the control oil and the fuel gas.
Apart from these systems on the engine, the engine auxiliaries will comprise
some new units, the most important ones being:
▪ If the fuel gas supply is natural gas (NG), it requires a cryogenic com-
pressor, including a cooler, to supply the required engine inlet pressure in
the range of 5.5-12 barg, depending on engine load and rating.

7.00 Fuel gas system - ME-GA engine

▪ If the fuel gas supply is liquefied natural gas (LNG), it requires a cryogenic
pump and vaporiser solution
▪ ME-GA engine control system (ME-ECS)
▪ Leakage detection and ventilation system
▪ Flow switches
▪ Gas valve unit (GVU) with a double block and bleed function
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▪ Gas regulating unit (GRU), which enables depressurisation of the system

without an expensive dedicated blow-off piping. The engine-mounted
design gives a fast-reacting fuel gas pressure control.
▪ Heat traced and insulated fuel gas supply pipes
▪ Inert gas system for purging the fuel gas supply system, and the gas sys-
tem on the engine, with inert gas
▪ Purge block mounted on the engine, which enables purging without a
dedicated blow-off piping

ME-GA 1 (7)
199 16 43-8.0 MAN Energy Solutions

Fuel gas piping on the engine

Fig. 7.00.01: Layout of the double-walled piping system for fuel gas
The layout of the double-walled piping system for fuel gas is shown in Fig.
7.00.01. The fuel gas from the compressor unit, or the cryogenic pumps and
vaporiser, passes through the main pipe, the GVU and the GRU, before it is
7.00 Fuel gas system - ME-GA engine

distributed to the SGAVs on each cylinder.

The piping design includes gas pipes with bellows that has two important
functions:
▪ Separate the cylinder units from each other, in terms of gas dynamics,
due to the application of the well-proven design philosophy from the ME
engine fuel oil system.
▪ Act as flexible connections between engine structures, and safeguard
2022-03-02 - en

against extra stress in the fuel gas supply pipes caused by the inevitable
differences in thermal expansion of the gas pipe system and the engine
structure.

2 (7) ME-GA
 MAN Energy Solutions 199 16 43-8.0

Fuel admission system on the ME-GA engine

Fig. 7.00.02a: Fuel gas admission and combustion for the ME-GA engine 7.00 Fuel gas system - ME-GA engine
Low-pressure fuel gas is supplied to the GVU at approximately 13 bar. The
GVU design is similar to the GVT design for the ME-GI engine, but adapted to
the lower fuel gas pressure. The ME-ECS controls all functions of the GVU.
From the GVU, the fuel gas is led via double-walled pipes, where applicable,
to the GRU mounted on the engine.
2022-03-02 - en

From the GRU, the fuel gas is passed on to the SGAVs, see Fig. 7.00.02a.
The SGAV is controlled by the control oil system, which, in principle, consists
of the ME hydraulic control oil system and an electronic gas admission valve
(ELGA). The ELGA valve controls the timing of the fuel gas admission by ad-
mitting high-pressure control oil to the SGAV to open it.
In the fuel supply system, the micro booster injection valve (MBIV) pressurises
the pilot oil during dual-fuel operation.
In the ME-ECS it is possible to operate the engine in various modes: Dual-fuel
mode with minimum pilot oil amount and the fuel-oil-only mode.

ME-GA 3 (7)
199 16 43-8.0 MAN Energy Solutions

Pilot oil injection amount versus engine load

Dual-fuel operation is possible down to 5% engine load.
The minimum pilot oil amount in dual-fuel mode is 0.5% at MCR (in L1), see
Fig. 7.00.02b. If the engine is derated, the pilot amount is relatively higher as
calculated in CEAS, see Section 20.02.
The engine output with minimum pilot oil amount can be obtained even with
an LCV of the fuel gas as low as 38 MJ/kg. Below 38 MJ/kg, a higher pilot oil
amount might be required.
The guaranteed specific gas consumption (SGC) on test bed requires an LCV
of minimum 50 MJ/kg with a tolerance of -7%.

Fig. 7.00.02b: Dual-fuel operation and pilot oil amount

Condition of the fuel gas delivery to the engine

The following data is based on natural gas as the fuel gas.

Pressure
7.00 Fuel gas system - ME-GA engine

Operating pressure See Fig. 7.07.04

Safety relief valve 16 barg
Pulsation limit +0.6 bar

Flow
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The maximum flow requirement is specified at 100% SMCR, depending on

the pressure, see Fig. 7.07.04.

Maximum / minimum requirement Refer to (*

Minimum flow requirement in standby 0 kg/h

The maximum flow requirement must also be achievable close to the overhaul
interval of the FGSS.
In case of a specific LCV requirement, please inform MAN Energy Solutions.
Under certain circumstances, modification of the SGAV may be required to
accommodate fuel gas with a different LCV.

4 (7) ME-GA
 MAN Energy Solutions 199 16 43-8.0

(* ‘List of Capacities’, or CEAS report

Temperature
Temp. inlet to engine 5 to 55°C
Shut down 0°C

The specified engine inlet temperature takes into account the following:
▪ reduces condensation on the outer wall of the inner pipe of the double-
walled piping
▪ the performance of the engine is not adversely affected
▪ reduces thermal loads on the gas piping itself
▪ provides uniform gas density
▪ the gas temperature during blow-off will still be within the temperature lim-
its of the materials selected for piping and components

Guiding fuel gas specification

Designation Unit Limit Value Test method refer-
ence *)
(Latest edition to be
applied)

Net calorific value MJ/Nm3 Min. 27 ISO 6976 (or GPA

(NCV) 2172)

Net calorific value MJ/Nm3 Mix. 41 ISO 6976 (or GPA

(NCV) 2172)

Methane number (MN) No unit Min. 64 for 100% EN 16726 or Pro-

engine pane Knock Index
power PKI. The applied test
60 for 85% method shall be
engine given as MN (PKI) or

7.00 Fuel gas system - ME-GA engine

power MN (EN 16726).

Methane (CH4) % (mol) Min. 70 ISO 6974-3 (all parts)

Hydrogen sulphide mg/Nm3 Max. 5 ISO 19739

(H2S)

Water mg/m3 Max. 0.7 ISO 10101

Gas cleanliness - - Liquid or

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solid con-
taminants
must be re-
moved from
the LNG.
See text.

Ethane (C2H6) % (mol) - report ISO 6974 (all parts)

Propane (C3H8) % (mol) - report ISO 6974 (all parts)

n-Butane (C4H10) % (mol) - report ISO 6974 (all parts)

i-Butane

ME-GA 5 (7)
199 16 43-8.0 MAN Energy Solutions

Pentane (C5H12) and % (mol) - report ISO 6974 (all parts)

higher

Nitrogen (N2) % (mol) - report ISO 6974 (all parts)

3
Density ( at temperat- kg/m - report8 ISO 6578
ure of the liquid phase)

*) ISO standards methods are the highest level of international methods and
are therefore recommended. Equivalent methods from ASTM, GPA and IP
can also be used. It is recommended to consistently use methods from one
of the standard organisations, for example ISO or GPA.

604 23 42-0.0

Table 7.00.01: Guiding fuel gas specification

Natural gas (NG) is a hydrocarbon gas mixture consisting primarily of methane
(CH4) and higher hydrocarbons like ethane and propane. The composition of
NG is varying worldwide. ME-GA engines are able to operate on a wide range
of gas qualities.
The values in the guiding fuel gas specification, Table 7.00.01, refer to the hy-
drocarbon mixture as delivered to the ship. It is assumed that the gas has un-
dergone a liquefaction process at some point before being bunkered.

Liquefied natural gas

Liquefied natural gas (LNG) has been cooled down to –162 °C. Due to the re-
quirements of the liquefaction process, the composition of the hydrocarbon
mixture will be within rather narrow limits. More importantly, impurities such as
water (H2O), ammonia (NH3) chloride (Cl), fluorine (F) and carbon dioxide (CO2)
are removed to the extent possible. Higher-order hydrocarbons are also re-
moved.

Influence of boil-off gas from fuel gas tanks

7.00 Fuel gas system - ME-GA engine

LNG in the ships’ tanks will change composition and properties over time.
This is due to the unavoidable heat-influx from the surroundings, which will
cause vaporisation of lighter compounds, like nitrogen (N2) and methane. This
process is called ageing and the gas produced is referred to as boil-off gas
(BOG). BOG contains a higher amount of nitrogen compared to the LNG
bunkered.
The remaining LNG will have an increased percentage of higher hydrocar-
bons. The composition of the LNG bunkered will, hence, not necessarily be
2022-03-02 - en

the same as the composition of the fuel gas delivered to the engine.
Please contact your MAN Energy Solutions two-stroke representative for
more information.

Fuel gas bunkering

Liquid or solid contaminants such as metal shavings, welding debris, insula-
tion (i.e. perlite), sand, wood, cloth and oil must be removed from the LNG. It
is generally considered as good engineering and operating practice to have
LNG cargo strainers in the loading and discharge lines in order to minimise
particulate contamination of the LNG and subsequent tanks and equipment.

6 (7) ME-GA
 MAN Energy Solutions 199 16 43-8.0

It is recommended that the filter is controlled by a surveyor after the bunkering

to establish the contamination degree. It is important to note that the quality
and impurity degree can vary among the suppliers due to production and
handling differences and the type of bunkering/transfer process (for example:
terminal tank to vessel, truck to vessel, vessel to vessel, portable tank trans-
fer).
MAN Energy Solutions strongly recommends installing filters in the bunkering
line and a filtration setup might be included in the FGSS, see Section 7.07.
198 87 55-1.3

Sealing oil system

The sealing oil system is a pressurised hydraulic oil system with a constant
differential pressure, approximately 3 bar higher than the fuel gas pressure,
which prevents fuel gas from entering the hydraulic oil system.
The sealing oil is applied to the SGAV and the window/shutdown valve in the
space between the gas on one side and the hydraulic oil on the other side.
The sealing oil pump unit is connected to the SGAV and the window/shut-
down valve with double-walled pipes.
The sealing oil system consists of a reduction station, which reduces the ME-
C servo hydraulic oil pressure to the sealing oil pressure. The sealing oil sys-
tem is installed on the engine.
The consumption of sealing oil is small, as calculated in CEAS, see Section
20.02. The sealing oil will be injected with the fuel gas into the combustion
chamber.
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ME-GA 7 (7)
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7.00 Fuel gas system - ME-GA engine

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ME-GA
 MAN Energy Solutions 199 15 01-3.0

Fuel oil system

The system is so arranged that both diesel oil and heavy fuel oil can be used,
see Fig. 7.01.01.
From the service tank the fuel is led to an electrically driven supply pump by
means of which a pressure of approximately 4 bar can be maintained in the
low pressure part of the fuel circulating system, thus avoiding gasification of
the fuel in the venting box in the temperature ranges applied.
The venting box is connected to the service tank via an automatic deaerating
valve, which will release any gases present, but will retain liquids.
From the low pressure part of the fuel system the fuel oil is led to an electric-
ally-driven circulating pump, which pumps the fuel oil through a heater and a
full flow filter situated immediately before the inlet to the engine.
The fuel injection is performed by the electronically controlled pressure
booster located on the Hydraulic Cylinder Unit (HCU), one per cylinder, which
also contains the actuator for the electronic exhaust valve activation.
The Cylinder Control Units (CCU) of the Engine Control System (described in
Section 16.01) calculate the timing of the fuel injection and the exhaust valve
activation.
To ensure ample filling of the HCU, the capacity of the electrically-driven circu-
lating pump is higher than the amount of fuel consumed by the diesel engine.
Surplus fuel oil is recirculated from the engine through the venting box.
To ensure a constant fuel pressure to the fuel injection pumps during all en-
gine loads, a spring loaded overflow valve is inserted in the fuel oil system on
the engine.
The fuel oil pressure measured on the engine (at fuel pump level) should be
7-8 bar, equivalent to a circulating pump pressure of 10 bar.

Fuel Considerations
When the engine is stopped, the circulating pump will continue to circulate
heated heavy fuel through the fuel oil system on the engine, thereby keeping
the fuel pumps heated and the fuel valves deaerated. This automatic circula-
tion of preheated fuel during engine standstill is the background for our re-
commendation: constant operation on heavy fuel.
In addition, if this recommendation was not followed, there would be a latent
risk of diesel oil and heavy fuels of marginal quality forming incompatible
blends during fuel change over or when operating in areas with restrictions on
sulphur content in fuel oil due to exhaust gas emission control.
2023-03-28 - en

In special circumstances a change-over to diesel oil may become necessary –

and this can be performed at any time, even when the engine is not running.
7.01 Fuel oil system

Such a change-over may become necessary if, for instance, the vessel is ex-
pected to be inactive for a prolonged period with cold engine e.g. due to:
▪ docking
▪ stop for more than five days
▪ major repairs of the fuel system, etc.

95-60 ME/ME-C/ME-B/-GI/-GA/-LGI 1 (7)

199 15 01-3.0 MAN Energy Solutions

The built-on overflow valves, if any, at the supply pumps are to be adjusted to
5 bar, whereas the external bypass valve is adjusted to 4 bar. The pipes
between the tanks and the supply pumps shall have minimum 50% larger
passage area than the pipe between the supply pump and the circulating
pump.
If the fuel oil pipe ‘X’ at inlet to engine is made as a straight line immediately at
the end of the engine, it will be necessary to mount an expansion joint. If the
connection is made as indicated, with a bend immediately at the end of the
engine, no expansion joint is required.

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7.01 Fuel oil system

2 (7) 95-60 ME/ME-C/ME-B/-GI/-GA/-LGI

 MAN Energy Solutions 199 15 01-3.0

Fuel Oil System

2023-03-28 - en

7.01 Fuel oil system

95-60 ME/ME-C/ME-B/-GI/-GA/-LGI 3 (7)

199 15 01-3.0 MAN Energy Solutions

1) MDO/MGO Cooler
For low-viscosity distillate fuels like marine gas oil (MGO), it is necessary to have
a cooler to ensure that the viscosity at engine inlet is above 2 cSt.
Location of cooler: As shown or, alternatively, anywhere before inlet to engine.
2) Fuel oil flowmeter (Optional)
Flow rate: See ‘List of Capacities’ (same as fuel supply pump).
Type: In case a damaged flow meter can block the fuel supply, a safety bypass
valve is to be placed across the flowmeter.
3) 0.23 litre/kWh in relation to certified Flow Rate (CFR); the engine SMCR can be
used to determine the capacity. The separators should be capable of removing
cat fines (Al+Si) from 80 ppm to a maximum level of 15 ppm Al+Si but preferably
lower.
Inlet temperature: Min. 98°C.
4) Valve in engine drain pipe
Valve in engine drain pipe is not acceptable. If the drain is blocked, the pressure
booster top cover seal will be damaged.
In case a valve between the engine connection AD and the drain tank is required,
the valve should be locked in open position and marked with a text, indicating
that the valve must only be closed in case of no fuel oil pressure to the engine. In
case of non-return valve, the opening pressure for the valve has to be below 0.2
bar.
5) MDO/MGO Cooler (Optional)
For protection of supply pumps against too warm oil and thus too low viscosity.
6) Transfer pump (Optional)
The transfer pump has to be able to return part of the content of the service tank
to the settling tank to minimize the risk of supplying fuel to the engine with a high
content of settled particles, e.g. cat fines, if the service tank has not been used
for a while.
7) Name of flange connection
AF for engines with a bore of 60 cm and above
AE for engines with a bore of 50 cm and below
a) Tracing, fuel oil lines: By jacket cooling water
b) Tracing, drain lines: By jacket cooling water
– only for engines with bore of 60 cm and above
*) Optional installation
The letters refer to the list of ‘Counterflanges’
2023-03-28 - en
7.01 Fuel oil system

079 95 01-2.3.1

Fig. 7.01.01: Fuel oil system

4 (7) 95-60 ME/ME-C/ME-B/-GI/-GA/-LGI

 MAN Energy Solutions 199 15 01-3.0

Heavy Fuel Oil Tank

This type of tank should be used for any residual fuel usage. (It can also be
used for distillate fuel). The tank must be designed as high as possible and
equipped with a sloping bottom in order to collect the solid particles settling
from the fuel oil.
The tank outlet to the supply pumps must be placed above the slope to pre-
vent solid particles to be drawn into the heavy fuel oil supply pumps. An over-
flow pipe must be installed inside the tank below the pump outlet pipe to en-
sure that only ‘contaminated’ fuel is pumped back to settling tank.
A possibility of returning the day tank content to the settling tank must be in-
stalled for cases where the day tank content have not been used for some
time.

Drain of Clean Fuel Oil from HCU, Pumps, Pipes

The HCU Fuel Oil Pressure Booster has a leakage drain of clean fuel oil from
the umbrella sealing through ‘AD’ to the fuel oil drain tank.
The drain amount in litres per cylinder per hour is approximately as listed in
Table 7.01.02.
This drained clean oil will, of course, influence the measured SFOC, but the oil
is not wasted, and the quantity is well within the measuring accuracy of the
flowmeters normally used.

Engine bore, ME/ME-C, ME-B Flow rate,

(incl. -GI & -LGI versions) litres/cyl./hr.

98 On request

95, 90 1.7

80 2.1

70, 65 1.5

60 1.2

Table 7.01.02: Drain amount from fuel oil pump umbrella seal, figures for guid-
ance

Leakage Oil Amount Dependencies

Due to tolerances in the fuel pumps, the table figures may vary and are there-
2023-03-28 - en

fore for guidance only. In fact, the leakage amount relates to the clearance
between plunger and barrel in the third power. Thus, within the drawing toler-
7.01 Fuel oil system

ances alone, the table figures can vary quite a lot.

The engine load, however, has little influence on the drain amount because
the leakage does not originate from the high-pressure side of the fuel pump.
For the same reason, the varying leakage amount does not influence the in-
jection itself.
The figures in Table 7.01.02 are based on fuel oil with 12 cSt viscosity. In
case of distillate fuel oil, the figures can be up to 6 times higher due to the
lower viscosity.

95-60 ME/ME-C/ME-B/-GI/-GA/-LGI 5 (7)

199 15 01-3.0 MAN Energy Solutions

Fuel Oil Drains in Service and for Overhaul

The main purpose of the drain ‘AD’ is to collect fuel oil from the fuel pumps.
The drain oil is led to an overflow tank and can be pumped to the heavy fuel
oil (HFO) tank or to the settling tank. In case of ultra low sulphur (ULSFO) or
distillate fuel oil, the piping should allow the fuel oil to be pumped to the ultra
low sulphur or distillate fuel oil tank.
As a safety measure for the crew during maintenance, an overhaul drain from
the umbrella leads clean fuel oil from the umbrella directly to drain ‘AF’ and
further to the sludge tank. Also washing water from the cylinder cover and the
baseplate is led to drain ‘AF’.
The ‘AF’ drain is provided with a box for giving alarm in case of leakage in a
high pressure pipe.
The size of the sludge tank is determined on the basis of the draining inter-
vals, the classification society rules, and on whether it may be vented directly
to the engine room.
Drains ‘AD’, ‘AF’ and the drain for overhaul are shown in Fig. 7.03.01.

Drain of Contaminated Fuel etc.

Leakage oil, in shape of fuel and lubricating oil contaminated with water, dirt
etc. and collected by the HCU Base Plate top plate (ME only), as well as tur-
bocharger cleaning water etc. is drained off through the bedplate drains ‘AE’.
Drain ‘AE’ is shown in Fig. 8.07.02.

Heating of Fuel Drain Pipes

Owing to the relatively high viscosity of the heavy fuel oil, it is recommended
that the drain pipes and the fuel oil drain tank are heated to min. 50°C, but
max. 100°C.
The drain pipes between engine and tanks can be heated by the jacket water,
as shown in Fig. 7.01.01 ‘Fuel oil system’ as flange ‘BD’. (Flange BD and the
tracing line are not applicable on MC/ MC-C engines type 42 and smaller).

Fuel Oil Flow Velocity and Viscosity

For external pipe connections, we prescribe the following maximum flow vel-
cities:
Marine diesel oil .......................................... 1.0 m/s
2023-03-28 - en

Heavy fuel oil ............................................... 0.6 m/s

7.01 Fuel oil system

The fuel viscosity is influenced by factors such as emulsification of water into

the fuel for reducing the NOx emission.

Cat Fines
Cat fines is a by-product from the catalytic cracking used in fuel distillation.
Cat fines is an extremely hard material, very abrasive and damaging to the en-
gine and fuel equipment. It is recommended always to purchase fuel with as
low cat fines content as possible.

6 (7) 95-60 ME/ME-C/ME-B/-GI/-GA/-LGI

 MAN Energy Solutions 199 15 01-3.0

Cat fines can to some extent be removed from the fuel by means of a good
and flexible tank design and by having optimum conditions for the separator in
terms of flow and high temperature.
Further information about fuel oil specifications and other fuel considerations
is available in our publications:
Guidelines for Fuels and Lubes Purchasing
0.50% S fuel operation - 2020
The publications are available at www.man-es.com → ‘Marine’ → ‘Products’ →
‘Planning Tools and Downloads’ → ’Technical Papers’.
18014452939457291
2023-03-28 - en

7.01 Fuel oil system

95-60 ME/ME-C/ME-B/-GI/-GA/-LGI 7 (7)

199 15 01-3.0 MAN Energy Solutions

18014452939457291
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2023-03-28 - en
7.01 Fuel oil system

95-60 ME/ME-C/ME-B/-GI/-GA/-LGI
 MAN Energy Solutions 198 38 80-4.7

Fuel Oils

Marine Diesel Oil:

Marine diesel oil ISO 8217, Class DMB
British Standard 6843, Class DMB
Similar oils may also be used

Heavy Fuel Oil (HFO)

Most commercially available HFO with a viscosity below 700 cSt at 50°C
(7,000 sec. Redwood I at 100°F) can be used.
For guidance on purchase, reference is made to ISO 8217:2012, British
Standard 6843 and to CIMAC recommendations regarding requirements for
heavy fuel for diesel engines, fourth edition 2003, in which the maximum ac-
ceptable grades are RMH 700 and RMK 700. The above“mentioned ISO and
BS standards supersede BSMA 100 in which the limit was M9.
The data in the above HFO standards and specifications refer to fuel as de-
livered to the ship, i.e. before on-board cleaning.
In order to ensure effective and sufficient cleaning of the HFO, i.e. removal of
water and solid contaminants, the fuel oil specific gravity at 15°C (60°F)
should be below 0.991, unless modern types of centrifuges with adequate
cleaning abilities are used.
Higher densities can be allowed if special treatment systems are installed.
Current analysis information is not sufficient for estimating the combustion
properties of the oil. This means that service results depend on oil properties
which cannot be known beforehand. This especially applies to the tendency
of the oil to form deposits in combustion chambers, gas passages and tur-
bines. It may, therefore, be necessary to rule out some oils that cause diffi-
culties.

Guiding Heavy Fuel Oil Specification

Based on our general service experience we have, as a supplement to the
above mentioned standards, drawn up the guiding HFO specification shown
below.
Heavy fuel oils limited by this specification have, to the extent of the commer-
cial availability, been used with satisfactory results on MAN B&W two“stroke
low speed diesel engines.
2021-06-22 - en

The data refers to the fuel as supplied i.e. before any on-board cleaning.

Guiding specification (maximum values)

Density at 15°C kg/m3 ≤ 1.010*

7.02 Fuel Oils

Kinematic viscosity
at 100°C cSt ≤ 55
at 50°C cSt ≤ 700

Flash point °C ≥ 60

Pour point °C ≤ 30

MC/MC-C, ME/ME-C/ME-GI/ME-GA/ME-B 1 (2)

198 38 80-4.7 MAN Energy Solutions

Carbon residue % (m/m) ≤ 20

Ash % (m/m) ≤ 0.15

Total sediment potential % (m/m) ≤ 0.10

Water % (v/v) ≤ 0.5

Sulphur % (m/m) ≤ 4.5

Vanadium mg/kg ≤ 450

Aluminum + Silicon mg/kg ≤ 60

Equal to ISO 8217:2010 - RMK 700 / CIMAC recommendation No. 21 - K700

* Provided automatic clarifiers are installed

m/m = mass
v/v = volume
51728870155

If heavy fuel oils with analysis data exceeding the above figures are to be
used, especially with regard to viscosity and specific gravity, the engine
builder should be contacted for advice regarding possible fuel oil system
changes.
51728870155

2021-06-22 - en
7.02 Fuel Oils

2 (2) MC/MC-C, ME/ME-C/ME-GI/ME-GA/ME-B

 MAN Energy Solutions 198 91 13-4.3

Fuel Oil Pipes and Drain Pipes

7.03 Fuel Oil Pipes and Drain Pipes

2023-01-04 - en

The letters refer to list of ‘Counterflanges’

The item nos. refer to ‘Guidance values automation’
Fig. 7.03.01: Fuel oil and drain pipes
9007240651931147

G/S95-60ME-C10/9/-GI/-GA/-LGI,S/L80-60ME-C8-GI/-LGI 1 (1)
198 91 13-4.3 MAN Energy Solutions

9007240651931147
This page is intentionally left blank
7.03 Fuel Oil Pipes and Drain Pipes

2023-01-04 - en

G/S95-60ME-C10/9/-GI/-GA/-LGI,S/L80-60ME-C8-GI/-LGI
 MAN Energy Solutions 199 15 05-0.0

Insulation and heat tracing of fuel oil piping

Insulation of fuel oil pipes and fuel oil drain pipes should not be carried out un-
til the piping systems have been subjected to the pressure tests specified and
approved by the respective classification society and/or authorities, Fig.
7.04.01.
The directions mentioned below include insulation of hot pipes, flanges and
valves with a surface temperature of the complete insulation of maximum
55°C at a room temperature of maximum 38°C. As for the choice of material
and, if required, approval for the specific purpose, reference is made to the re-
spective classification society.

Fuel Oil Pipes

The pipes are to be insulated with 20 mm mineral wool of minimum 150 kg/
m3 and covered with glass cloth of minimum 400 g/m2.

Fuel Oil Pipes and Heating Pipes Together

Two or more pipes can be insulated with 30 mm wired mats of mineral wool
of minimum 150 kg/m3 covered with glass cloth of minimum 400 g/m2.

Flanges and Valves

The flanges and valves are to be insulated by means of removable pads.
Flange and valve pads are made of glass cloth, minimum 400 g/m2, contain-
ing mineral wool stuffed to minimum 150 kg/m3.
Thickness of the pads to be:

7.04 Insulation and heat tracing of fuel oil piping

Fuel oil pipes ................................................20 mm
Fuel oil pipes and heating pipes together ....30 mm
The pads are to be fitted so that they lap over the pipe insulating material by
the pad thickness. At flanged joints, insulating material on pipes should not be
fitted closer than corresponding to the minimum bolt length.

Mounting
Mounting of the insulation is to be carried out in accordance with the sup-
plier’s instructions.
2022-01-18 - en

95-60 engines 1 (4)

199 15 05-0.0 MAN Energy Solutions

Fig. 7.04.01: Details of fuel oil pipes insulation, option: 4 35 121. Example
from 98-50 MC engine

Heat Loss in Piping

7.04 Insulation and heat tracing of fuel oil piping

2022-01-18 - en

Fig. 7.04.02: Heat loss/Pipe cover

2 (4) 95-60 engines

 MAN Energy Solutions 199 15 05-0.0

Fuel Oil Pipe Heat Tracing

The steam tracing of the fuel oil pipes is intended to operate in two situations:

1. When the circulation pump is running, there will be a temperature loss in the pip-
ing, see Fig. 7.04.02. This loss is very small, therefore tracing in this situation is
only necessary with very long fuel supply lines.
2. When the circulation pump is stopped with heavy fuel oil in the piping and the
pipes have cooled down to engine room temperature, as it is not possible to
pump the heavy fuel oil. In this situation the fuel oil must be heated to pumping
temperature of about 50˚C.
To heat the pipe to pumping level we recommend to use 100 watt leaking/meter
pipe.
9007251454685451

7.04 Insulation and heat tracing of fuel oil piping

Fig. 7.04.03: Fuel oil pipe heat tracing
9007251454685451

Fuel Oil and Lubricating Oil Pipe Spray Shields

To fulfill IMO regulations, fuel and oil pipe assemblies are to be secured by
spray shields.
The shields can be made either by a metal flange cover according to IMO
MSC/Circ.647 or antisplashing tape wrapped according to makers instruction
for Class approval, see examples shown in Fig. 7.04.04a and b.
To ensure tightness, the spray shields are to be applied after pressure test of
2022-01-18 - en

the pipe system.

95-60 engines 3 (4)

199 15 05-0.0 MAN Energy Solutions

Fig. 7.04.04a: Metal flange cover and clamping band

Fig. 7.04.04b: Anti-splashing tape (FN tape)

9007251454685451
7.04 Insulation and heat tracing of fuel oil piping

2022-01-18 - en

4 (4) 95-60 engines

 MAN Energy Solutions 198 39 51-2.10

Components for Fuel Oil System

Fuel Oil Separator

The manual cleaning type of separators are not to be recommended. Separ-
ators must be self-cleaning, either with total discharge or with partiadischarge.
Distinction must be made between installations for:
▪ Specific gravities < 0.991 (corresponding to ISO 8217: RMA-RMD grades
and British Standard 6843 from RMA to RMH, and CIMAC from A to H-
grades)
▪ Specific gravities > 0.991 (corresponding to ISO 8217: RME-RMK grades
and CIMAC K-grades).
For the latter specific gravities, the manufacturers have developed special
types of separators, e.g.:
Alfa Laval ........................................................Alcap
Westfalia .......................................................Unitrol
Mitsubishi ..............................................E-Hidens II
MAN Energy Solutions also recommends using high-temperature separators,
which will increase the efficiency.
The separator should be able to treat approximately the following quantity of
oil:

0.23 litres/kWh in relation to CFR (certified flow rate)

This figure includes a margin for:

▪ water content in fuel oil
▪ possible sludge, ash and other impurities in the fuel oil
▪ increased fuel oil consumption, in connection with other conditions than
ISO standard condition
▪ purifier service for cleaning and maintenance.
The Specified MCR can be used to determine the capacity. The separator ca-
pacity must always be higher than the calculated capacity.
Inlet temperature to separator, minimum .......98°C
7.05 Components for Fuel Oil System
CFR according to CEN, CWA 15375
The size of the separator has to be chosen according to the supplier’s table
valid for the selected viscosity of the Heavy Fuel Oil and in compliance with
CFR or similar. Normally, two separators are installed for Heavy Fuel Oil (HFO),
2021-08-10 - en

each with adequate capacity to comply with the above recommendation.

A separator for Marine Diesel Oil (MDO) is not a must. However, MAN Energy
Solutions recommends that at least one of the HFO separators can also treat
MDO.
If it is decided after all to install an individual purifier for MDO on board, the ca-
pacity should be based on the above recommendation, or it should be a sep-
arator of the same size as that for HFO.
It is recommended to follow the CIMAC Recommendation 25:
Recommendations concerning the design of heavy fuel treatment plants for
diesel engines.

All engines 1 (8)

198 39 51-2.10 MAN Energy Solutions

Fuel Oil Supply Pump

Fuel oil viscosity, specified ....up to 700 cSt at 50°C
Fuel oil viscosity, maximum ....................... 700 cSt
Fuel oil viscosity, minimum ............................ 2 cSt
Pump head ................................................... 4 bar
Fuel oil flow ........................ see ‘List of Capacities’
Delivery pressure ........................................... 4 bar
Working temperature, maximum ............. 110°C *)
*) If a high temperature separator is used, higher working temperature related
to the separator must be specified.
The capacity stated in ‘List of Capacities’ is to be fulfilled with a tolerance of:
–0% to +15% and shall also be able to cover the back-flushing, see ‘Fuel oil
filter’.

Fuel Oil Circulating Pump

This is to be of the screw or gear wheel type.
Fuel oil viscosity, specified ....up to 700 cSt at 50°C
Fuel oil viscosity normal ............................... 20 cSt
Fuel oil viscosity, maximum ....................... 700 cSt
Fuel oil viscosity, minimum ............................ 2 cSt
Fuel oil flow ......................... see ‘List of Capacities’
Pump head ................................................... 6 bar
Delivery pressure ..........................................10 bar
Working temperature .................................. 150°C
The capacity stated in ‘List of Capacities’ is to be fulfilled with a tolerance of:
–0% to +15% and shall also be able to cover the back-flushing, see ‘Fuel oil
filter’.
Pump head is based on a total pressure drop in filter and preheater of max-
imum 1.5 bar.
7.05 Components for Fuel Oil System

2021-08-10 - en

2 (8) All engines

 MAN Energy Solutions 198 39 51-2.10

Fuel Oil Heater

The heater is to be of the tube or plate heat exchanger type.
The required heating temperature for different oil viscosities will appear from
the ‘Fuel oil heating chart’, Fig. 7.05.01. The chart is based on information

7.05 Components for Fuel Oil System

from oil suppliers regarding typical marine fuels with viscosity index 70-80.
Fig. 7.05.01: Fuel oil heating chart
Since the viscosity after the heater is the controlled parameter, the heating
temperature may vary, depending on the viscosity and viscosity index of the
fuel.
Recommended viscosity meter setting is 10-15 cSt.
2021-08-10 - en

Fuel oil viscosity specified ... up to 20 cSt at 150°C fuel oil circulating pump
Heat dissipation ................. see ‘List of Capacities’ Pressure drop on fuel oil
side, maximum ..................................... 1 bar at 15 cSt
Working pressure ..........................................10 bar
Fuel oil outlet temperature ...........................150°C
Steam supply, saturated ..........................7 bar abs
To maintain a correct and constant viscosity of the fuel oil at the inlet to the
main engine, the steam supply shall be automatically controlled, usually based
on a pneumatic or an electrically controlled system.

All engines 3 (8)

198 39 51-2.10 MAN Energy Solutions

Fuel Oil Filter

The filter can be of the manually cleaned duplex type or an automatic filter
with a manually cleaned bypass filter.
If a double filter (duplex) is installed, it should have sufficient capacity to allow
the specified full amount of oil to flow through each side of the filter at a given
working temperature with a max. 0.3 bar pressure drop across the filter (clean
filter).
If a filter with backflushing arrangement is installed, the following should be
noted. The required oil flow specified in the ‘List of capacities’, i.e. the delivery
rate of the fuel oil supply pump and the fuel oil circulating pump, should be in-
creased by the amount of oil used for the backflushing, so that the fuel oil
pressure at the inlet to the main engine can be maintained during cleaning.
In those cases where an automatically cleaned filter is installed, it should be
noted that in order to activate the cleaning process, certain makers of filters
require a greater oil pressure at the inlet to the filter than the pump pressure
specified. Therefore, the pump capacity should be adequate for this purpose,
too.
Alternatively positioned in the supply circuit after the supply pumps, the filter
has the same flow rate as the fuel oil supply pump. In this case, a duplex
safety filter has to be placed in the circulation circuit before the engine. The
absolute fineness of the safety filter is recommended to be maximum 60 μm
and the flow rate the same as for the circulation oil pump.
The fuel oil filter should be based on heavy fuel oil of: 130 cSt at 80°C = 700
cSt at 50°C = 7,000 sec Redwood I/100°F.
Fuel oil flow ............................see ‘Capacity of fuel oil circulating pump’
Working pressure ..........................................10 bar
Test pressure ..................... according to Class rule
Absolute fineness, maximum ........................10 μm
Working temperature, maximum .................150°C
Oil viscosity at working temperature, Oil viscosity at working temperature,
maximum ...................................................20 cSt
Pressure drop at clean filter,
7.05 Components for Fuel Oil System

maximum ..................................................0.3 bar

Filter to be cleaned at a pressure
drop of ......................................................0.5 bar
Note:
Some filter makers refer the fineness of the filters to be ‘nominal fineness’.
Thus figures will be approximately 40% lower than the ‘absolute fineness’ (6
μm nominal).
2021-08-10 - en

The filter housing shall be fitted with a steam jacket for heat tracing.
Further information about cleaning heavy fuel oil and other fuel oil types is
available in MAN Energy Solutions' most current Service Letters on this sub-
ject.
The Service Letters are available at www.marine.man-es.com --> ’Service
Letters’.

4 (8) All engines

 MAN Energy Solutions 198 39 51-2.10

Fuel Oil Filter (Option)

Located as shown in drawing or alternatively in the supply circuit after the
supply pumps. In this case, a duplex safety filter has to be placed in the circu-
lation circuit before the engine, with an absolute fineness of maximum 60 μm.

Pipe Diameter ‘D’ & ‘d’

The pipe (D) between the service tank and the supply pump is to have min-
imum 50% larger passage area than the pipe (d) between the supply pump
and in the circulating pump. This ensures the best suction conditions for the
supply pump (small pressure drop in the suction pipe).

Overflow Valve
See ‘List of Capacities’ (fuel oil supply oil pump).

Flushing of the Fuel Oil System

Before starting the engine for the first time, the system on board has to be
flushed in accordance with MAN Energy Solutions recommendations:
Flushing of Fuel Oil System
which is available from MAN Energy Solutions, Copenhagen.

Fuel Oil Venting Box

The design of the fuel oil venting box is shown in Fig. 7.05.02. The size is
chosen according to the maximum flow of the fuel oil circulation pump, which
is listed in section 6.03.
The venting tank has to be placed at the top service tank. If the venting tank is
placed below the top of the service tank, the drain pipe from the automatic
venting valve has to be led to a tank placed lower than the venting valve. The

7.05 Components for Fuel Oil System

lower tank can be a ‘Fuel oil over flow tank’, if this tank has venting to deck.
2021-08-10 - en

All engines 5 (8)

198 39 51-2.10 MAN Energy Solutions

Flow Dimensions in mm
m3/h Q
D1 D2 D3 H1 H2 H3 H4 H5
(max.)*

1.3 150 32 15 100 600 171.3 1,000 550

2.1 150 40 15 100 600 171.3 1,000 550

5.0 200 65 15 100 600 171.3 1,000 550

7.05 Components for Fuel Oil System

8.4 400 80 15 150 1,200 333.5 1,800 1,100

11.5 400 90 15 150 1,200 333.5 1,800 1,100

19.5 400 125 15 150 1,200 333.5 1,800 1,100

29.4 500 150 15 150 1,500 402.4 2,150 1,350

43.0 500 200 15 150 1,500 402.4 2,150 1,350

2021-08-10 - en

* The maximum flow of the fuel oil circulation pump

Fig. 07.05.02: Fuel oil venting box

Cooling of Distillate Fuels

The external fuel systems (supply and circulating systems) have a varying ef-
fect on the heating of the fuel and, thereby, the viscosity of the fuel when it
reaches the engine inlet.
Today, external fuel systems on-board are often designed to have an op-
timum operation on HFO, which means that the temperature is kept high.

6 (8) All engines

 MAN Energy Solutions 198 39 51-2.10

For low-viscosity distillate fuels like marine diesel oil (MDO) and marine gas oil
(MGO), however, the temperature must be kept as low as possible in order to
ensure a suitable viscosity at engine inlet.
9007250990787211

Fuel Oil Viscosity at Engine Inlet

The recommended fuel viscosity range for MAN B&W two-stroke engines at
engine inlet is listed in Table 7.05.03.

The lower fuel viscosity limit is 2 cSt

However, 3 cSt or higher is preferable as this will minimise the risk of having
problems caused by wear for instance.
For low-viscosity fuel grades, care must be taken not to heat the fuel too
much and thereby reduce the viscosity.

Range Fuel viscosity at engine inlet, cSt

Minimum 2

Normal, distillate 3 or higher

Normal, HFO 10-15

Maximum 20

Table 7.05.03: Recommended fuel viscosity at engine inlet

Information about temperature – viscosity relationship of marine fuels is avail-
able in our publication:
Guidelines for Operation on Fuels with less than 0.1% Sulphur, SL2014-593
The publication is available at www.marine.man-es.com -->'Service Letters'.

Impact of Fuel Viscosity on Engine Operation

Many factors influence the actually required minimum viscosity tolerance dur-
ing start-up and lowload operation:
▪ engine condition and maintenance

7.05 Components for Fuel Oil System

▪ fuel pump wear
▪ engine adjustment (mainly starting index)
▪ actual fuel temperature in the fuel system
Although achievable, it is difficult to optimize all of these factors at the same
time. This situation complicates operation on fuels in the lowest end of the vis-
cosity range.
2021-08-10 - en

Fuel Oil Cooler

To build in some margin for safe and reliable operation and to maintain the re-
quired viscosity at engine inlet, installation of a cooler will be necessary as
shown in Fig. 7.01.01.

All engines 7 (8)

198 39 51-2.10 MAN Energy Solutions

Viscosity Requirements of Fuel Pumps etc.

The fuel viscosity does not only affect the engine. In fact, most pumps in the
external system (supply pumps, circulating pumps, transfer pumps and feed
pumps for the separator) also need viscosities above 2 cSt to function prop-
erly.
MAN Energy Solutions recommends contacting the actual pump maker for
advice.
9007250990787211
7.05 Components for Fuel Oil System

2021-08-10 - en

8 (8) All engines

 MAN Energy Solutions 199 04 63-5.0

Water in fuel emulsification

General

7.06 Water in fuel emulsification

2023-09-22 - en

1 (2)
199 04 63-5.0 MAN Energy Solutions
7.06 Water in fuel emulsification

2023-09-22 - en

9007252743704203

2 (2)
 MAN Energy Solutions 199 15 90-9.0

Fuel Gas Supply

Fig. 7.07.01: Gas supply system placed outside the engine room for ME-GA
single-engine plants
The ME-GA engine requires fuel gas at a load-dependent pressure and a tem-
perature as specified in Section 7.00. This requirement is met by a gas supply
system consisting of:
▪ fuel gas supply system (FGSS), see examples in Section 7.08
▪ gas valve unit (GVU) for control of the fuel gas flow to the engine
▪ auxiliary systems for leakage detection and ventilation as well as inert gas,
see Section 7.09.
Fig. 7.07.01 shows the systems placed outside the engine room for a single-
engine plant.
Normally, the individual shipyard/contractor carries out the detailed design of
the gas supply system (FGSS and auxiliary systems). Therefore, the gas sup-
ply system is not subject to the type approval of the engine.
2022-01-27 - en

7.07 Fuel Gas Supply

ME-GA 1 (8)
199 15 90-9.0 MAN Energy Solutions

Gas valve unit

Fig. 7.07.02: Tank, FGSS and gas valve unit

The GVU is available as a single unit block component from MAN Energy
Solutions, option: 4 37 601.
Fig. 7.07.02 shows the configuration of the supply system, including GVU and
piping.

Location of the GVU above or below the deck

For mounting in a hazardous zone, either on deck or in a ventilated space, the
GVU can be arranged as a single-walled unit.
For mounting in a non-hazardous zone, such as a machinery space, the GVU
must be arranged as a ventilated unit, that is with a ventilated barrier between
the fuel gas system and the non-hazardous zone. Specific projects might re-
quire ventilated units in hazardous zones as well.
For vessels under the IGC Code the GVU is preferred to be mounted in a
ventilated space or alternatively installed in the cargo area where a separate
gas tight enclosure is required.
2022-01-27 - en
7.07 Fuel Gas Supply

2 (8) ME-GA
 MAN Energy Solutions 199 15 90-9.0

Gas supply system key components

Fig. 7.07.03: Gas valve unit schematic

Filters
A filter of the simplex type must be fitted at the FGSS outlet if an LNG pump is
installed. Particulate matter may not affect BOG compressor applications to a
great extent, therefore an exception of the filter requirement is allowed.
If a filter is installed, it must have the capacity to allow the maximum fuel flow
at the working pressure and temperature of the fuel gas, with minimum pres-
sure drop.

Maximum absolute filter fineness 10 μm

Maximum pressure drop 0.5 bar

Filters must be fitted with differential pressure transmitters for monitoring and
alarm tripping.
The GVU inlet contains a safety filter with the purpose of protecting the GVU
and the ME-GA engine from foreign particles that could damage the sealing of
2022-01-27 - en

the gas valves.

7.07 Fuel Gas Supply

For further information about filters for the FGSS, contact

MAN Energy Solutions, Copenhagen at MarineInstallation2S@man-es.com

Gas valve unit

Basically, the GVU is a double block and bleed system which separates the
FGSS from the ME-GA engine during shutdown. Furthermore, the GVU con-
tains shutdown valves, redundant blow-off valves, a non-permanent connec-

ME-GA 3 (8)
199 15 90-9.0 MAN Energy Solutions

tion for purging and pressure testing functions. As an option, and subject to
class approval, the GVU can also function as the master gas valve, see Fig.
7.07.02.
The engine control system controls the GVU, and they are closely linked. Fig.
7.07.03 illustrates the working principles of the GVU. Fig. 16.02.03 shows the
valve control signal interface.
The GVU contains valves for safe isolation of the engine and as it represents
the ME-GA interface to the external systems, it can only be delivered by sup-
pliers approved by MAN Energy Solutions.

Gas piping
For delivery of second fuel to the ME-GA main engine, double-walled fuel gas
pipes can be used in both open and enclosed spaces and for interior piping it
is a requirement.
Moreover, the double-walled fuel gas pipe requires ventilation of the annular
space as described in Section 7.09.
The single-walled fuel gas piping can only be used in areas/rooms classified
as hazardous zone 0 or 1. In all other locations, a double-walled piping is re-
quired.

Outer pipe of double-walled piping

The outer pipe must be designed to withstand local peak pressures and low
temperatures arising from a rupture of the inner pipe. The tangential mem-
brane stress of a straight pipe should not exceed the tensile strength divided
by 1.5 (Rm/1.5) when subjected to the critical pressure. The pressure ratings
of all other piping components shall reflect the same level of strength as the
straight pipe.

Temperature range -25 °C to 60 °C

The maximum total pressure loss must comply with the ventilation specifica-
tion of MAN Energy Solutions, see Section 7.09, General data for ventilation
system.

Inner pipe maximum working pressure 16 bar

Design/test pressure 9 bar
According to the local instantaneous peak pressure in case of an inner pipe rupture.
2022-01-27 - en

Outer pipe material

7.07 Fuel Gas Supply

The recommended materials are stainless steel 304L (EN 1.4306) or 316L (EN
1.4404). The selection of these materials is based on sufficient corrosion res-
istance, required strength, low-temperature fracture toughness, and resist-
ance to stress corrosion chloride cracking. By using these materials, long
maintenance intervals and a long service life can be offered.

The piping should be cold-worked in order to reduce the internal surface roughness.
Maximum surface roughness 280 μm

4 (8) ME-GA
 MAN Energy Solutions 199 15 90-9.0

Sizing
Pipe sizes are selected based on common standard sizes as per ASME
B36.10 and B36.19.
Tables 7.07.01 a & b provide pipe dimension guidelines based on standard
pipe sizes for EN 1.4306 and EN 1.4404.

Engine NPS Pipe OD Sch Thickness, t Test

type pressure
DN Inch

[-] [mm] [-] [mm] [-] [mm] [barg]

5/6G70 150 6 168.3 10 3.40 9

Table 7.07.01a: Pipe dimension guideline EN 1.4306 and EN 1.4404 - Fuel

gas outer pipe

Engine NPS Pipe OD Sch Thickness, t Test

type pressure
DN Inch

[-] [mm] [-] [mm] [-] [mm] [barg]

5/6G70 100 4 114.3 10 3.05 9

Table 7.07.01b: Pipe dimension guideline EN 1.4306 and EN 1.4404 - Ventila-

tion inlet pipe

Single-walled and inner pipe

The following specification applies to the single-walled pipe and the inner pipe
of the double-walled fuel gas piping, delivering fuel gas to the ME-GA main
engine.

Design pressure 16 bar

Temperature range -25 °C to 60 °C
Total pressure loss (max) 0.2 bar
Lower calorific value (LCV) 50 MJ/kg

* This refers to the maximum allowable pressure loss in the total length of the
supply piping from the FGSS to the main engine connection.
Design calculations for the pipe are performed using the above design as-
sumptions, and the formula specified in chapter 5.11 of the IGC code for cal-
2022-01-27 - en

culation of the pipe thickness. Pipe strengths for different pipe sizes are selec-
7.07 Fuel Gas Supply

ted based on manufacturer information according to ASME B31.3.

The demand made on the maximum total pressure loss also applies to pro-
jects using gas with a specific LCV. It means that for a higher flow, a larger
pipe diameter is required to comply with the demand on maximum pressure
loss.

ME-GA 5 (8)
199 15 90-9.0 MAN Energy Solutions

Total pressure loss

The total pressure loss from the gas supply system to the ME-GA main engine
should be as low as low as possible. The shipyard calculates the pressure
loss using:
PTotal = PPiping + PGVU + POther

Single-walled and inner pipe material

The recommended materials are stainless steel 304L (EN 1.4306), 316L (EN
1.4404), Duplex 2205 (EN 1.4462), Super Duplex (EN 1.4410) and Inconel
625 (EN 2.4856).
The selection of these materials is based on sufficient corrosion resistance, re-
quired strength, low temperature fracture toughness, resistance to stress cor-
rosion chloride cracking. By using these materials, long maintenance intervals
and a long service life can be offered
The piping should be cold-worked in order to reduce internal surface rough-
ness.

Maximum surface roughness 20 μm

Sizing of single-walled and inner pipe

The guidelines in Table 7.07.02 can be used for dimensioning the piping.
The pressure loss calculation is based on the length of the piping from the
FGSS to the main engine inlet flange. It is shown in Table 7.07.02.
It is recommended to use a design with welded bends and a minimum radius
as per DIN 13480-3, Chapter 6.2 and 6.3.

Engine Max flow NPS Pipe OD Sch Thick- Test pres- Pressure loss
type ness, t sure
DN Inch 50m 100m

[-] [kg/h] [mm] [-] [mm] [-] [mm] [barg] [bar]

5G70 2,260 100 4 114.3 10 3.05 25 0.02 0.04

6G70 3,190 100 4 114.3 10 3.05 25 0.04 0.08

Table 7.07.02: Dimension guidelines, EN 1.4306 and EN 1.4404

2022-01-27 - en
7.07 Fuel Gas Supply

Fuel gas pressure

The FGSS can generate the fuel gas pressure in different ways depending on
the storage condition of the gas.
▪ gas compressor, including coolers, pulsation dampers, condensate sep-
arator, etc.
▪ cryogenic pump to deliver LNG to an evaporator
▪ a combination of the above solutions.
Section 7.08. describes examples of fuel gas supply systems.

6 (8) ME-GA
 MAN Energy Solutions 199 15 90-9.0

Control of fuel gas supply systems

Section 16.02 gives a description of the ME-GA engine control system (ME-
GA-ECS).
The fuel pressure is controlled by the gas supply pressure set point, and the
actual fuel gas load specified by the GA-ECS.
Fig. 16.02.03 shows the control signal interface and Fig. 7.07.03 shows the
diagram of the GVU.

Gas supply pressure range

Fig. 7.07.04: Gas pressure at engine inlet (GRU) for each engine load, engine
rating and fuel quality
The FGSS must be designed and manufactured in such a way, that it can op-
2022-01-27 - en

erate within the margins of the gas supply pressure range presented in Fig.
7.07 Fuel Gas Supply

7.07.04.
The ME-ECS in combination with the overall propulsion system setup determ-
ines the actual operating profile.

ME-GA 7 (8)
199 15 90-9.0 MAN Energy Solutions

Safety standards for the gas supply system

All equipment must comply with but not necessarily be limited to the following:
1. Full class requirements for UMS notation and ACCU notation, etc.
(ABS, LRS and DNV)
2. IGF Code and/or IGC Code as applicable

IGF code: International Code of Safety for Ships Using Gases or other
Low-Flashpoint Fuels

IGC Code: International Code for the Construction and Equipment of

Ships Carrying Liquefied Gases in Bulk
3. SOLAS and Flag State requirements for fire safety and detection sys-
tems
4. other standards to be fulfilled:

DNV Rules Part 6 Chapter 13 Gas Fuelled Engine Installations

ABS applicable sections in their guidelines for propulsion and auxiliary

for gas-fuelled ships

ALPEMA SE 2000 or latest, Standards for Plate-fin Heat Exchangers

ASME VIII div 1 Plate-fin Heat Exchangers

ASME BPVC-VIII-3 Construction of High Pressure Vessels

IEC 60092 Electrical installations in ships Certified according to ATEX

directives.

18014451845572363

2022-01-27 - en
7.07 Fuel Gas Supply

8 (8) ME-GA
 MAN Energy Solutions 199 16 47-5.0

Fuel gas supply systems

Examples of fuel gas supply systems

Fig. 7.08.01: Three most commonly used fuel gas supply systems

Fuel gas supply system requirements

The requirements for the fuel gas supply system (FGSS) on board bulk carri-
ers, oil tankers and container vessels differ from those on LNG carriers.
LNG carriers have LNG on board, and the challenge for this ship type is to
design an efficient FGSS that can handle boil-off gas (BOG). The fuel supply
system should be able to handle BOG from the tanks, and deliver it to the
main engine and dual-fuel gensets. Furthermore, if a tank pressure becomes
too high, the fuel supply system should direct the BOG to the gas combustion
unit (GCU) to protect the tank.
Gas-fuelled bulk carriers, oil tankers and container vessels require an LNG
bunker tank. Therefore LNG bunker tanks are installed together with an FGSS
supplying LNG to the ME-GA engine and the dual-fuel gensets. The challenge
7.08 Fuel gas supply systems
is to make a ship design with sufficient space for installing tanks without losing
any space for bulk, oil and containers. Cryogenic compressors are not re-
quired, when LNG bunker tanks are installed. The FGSS will consist of a cryo-
genic pump and vaporiser only, see Fig. 7.08.04a and Fig. 7.08.04b.
2021-09-22 - en

In short, different applications call for different gas supply systems and operat-
ors and shipowners demand alternative solutions. Therefore, MAN Energy
Solutions aims to have a number of different fuel supply systems prepared,
tested and available for MAN B&W ME-GA engine plants.
The three fuel supply solutions most commonly considered for the ME-GA en-
gine are:
▪ LNG with a cryogenic compressor
▪ LNG with a cryogenic pump
▪ compressed natural gas (CNG) with a cryogenic compressor.

ME-GA 1 (4)
199 16 47-5.0 MAN Energy Solutions

The first two solutions can be combined with a reliquefaction system for BOG
as shown in Fig. 7.08.01.

Fuel supply systems and reliquefaction plants

Table 7.08.01 lists fuel supply systems for the MAN B&W ME-GA engine.

Manufacturer Type

MAN Cryo
TGE Gas Engineering
Hyundai Heavy Industries Fuel supply systems
Daewoo Shipbuilding & Marine Engineer-
ing
Mitsubishi Heavy Industries
Samsung Heavy Industries
DongHwa Entec

Cryostar
Kobelco Cryogenic compressors
Atlas Copco

Table 7.08.01: FGSS examples

Fig. 7.08.02 to Fig. 7.08.04 show examples of plant layouts and process de-
scriptions for supply systems and reliquefaction plants.

Capacities and dimensions of the FGSS

For capacities and dimensions of the FGSS and reliquefaction plant (if in-
stalled), confer with the documentation of the manufacturer.
Further information about the FGSS is available in our publication:
ME-GA Dual Fuel MAN B&W Engines
The publication is available at marine.man-es.com/two-stroke/technical-pa-
pers
7.08 Fuel gas supply systems

2021-09-22 - en

2 (4) ME-GA
 MAN Energy Solutions 199 16 47-5.0

Fig. 7.08.02: Combined reliquefaction plant and cryogenic LNG pump supply
system delivering fuel gas to the ME-GA engine (Cryostar SAS)

Fig. 7.08.03: Integrated compressor and reliquefaction system with Laby®-GI

compressor (Hamworthy plc and Burckhardt Compression AG)

7.08 Fuel gas supply systems

2021-09-22 - en

Fig. 7.08.04a: Example of an FGSS with cryogenic pump and vaporiser for
LNG-fuelled merchant vessels. Vacuum-insulated LNG tanks, type C, best
feasible for smaller vessels.

ME-GA 3 (4)
199 16 47-5.0 MAN Energy Solutions

Fig. 7.08.04b: Example of an FGSS with cryogenic pump and vaporiser for
LNG-fuelled merchant vessels. Foam-insulated LNG tanks, type C, best feas-
ible for medium-sized vessels.
27021652687618315
7.08 Fuel gas supply systems

2021-09-22 - en

4 (4) ME-GA
 MAN Energy Solutions 199 14 54-5.0

Auxiliary systems for fuel gas supply system

Fig. 7.09.01: ME-GA fuel supply auxiliary systems

ME-GA auxiliary systems, for the ME-GA engine fuel gas supply system,

7.09 Auxiliary systems for fuel gas supply system

include:
▪ leakage detection and ventilation system, which ventilates the outer pipe
of the double-walled piping completely and incorporates leakage detec-
tion
▪ nitrogen system, which purges the fuel gas supply on the engine and the
fuel gas supply pipe, from the main engine to the GVU, with nitrogen
Fig. 7.09.01 shows the fuel supply auxiliary systems and how they are con-
nected to the ME-GA engine.

Capacities of ME-GA auxiliary systems

The capacities of the ME-GA fuel supply auxiliary systems are listed in the
CEAS report for the actual project, see section 20.02.
2023-02-03 - en

Leakage detection and ventilation system

The purpose of the leakage detection and ventilation system is to ensure that
the outer pipe of the double-walled gas pipe system is constantly ventilated
by air. At least 30 air changes per hour are needed, according to require-
ments set by the applicable codes and regulations.
The ME-GA engine and all double-walled gas piping require ventilation.

ME-GA 1 (6)
199 14 54-5.0 MAN Energy Solutions

General data for ventilation systems

Designation Value

Medium Air

Ventilation air According to ISO 8573-1: 1-4

supply quality

Particle size Class 7 according to ISO 8573-1 max. allowed particle

size 40 μm

Oil content Class 4 according to ISO 8573-1 max. allowed content 5

mg/m3

Dew point Should be ≤ –8 ˚C (condition should apply for tropical am-

temperature bient conditions at atmospheric pressure)

Pressure range –20 mbarg to 0 barg

Air changes Minimum 30 air changes per hour Maximum 45 air

changes per hour

Table 7.09.01: General data for ventilation systems

Starting air from the starting air receiver can be used for ventilating the ME-GA
system. Alternative air supply systems can be installed if they comply with the
specification in table 7.09.01.
A reduction valve regulates the supply inlet pressure to slightly above atmo-
spheric pressure in order to maintain a slight overflow of air at the ventilation
air box. See section 13.00.
7.09 Auxiliary systems for fuel gas supply system

The design of the air box ensures, at all times and under all operating condi-
tions, that there cannot be an overpressure at the ventilation air inlet, accord-
ing to existing rules and legislations.

Temperature of the ventilation air

Take ambient temperatures into consideration when designing the ventilation
system.
Temperatures below the prescribed dew point will lead to frost formation and
should be avoided.
For specific projects, the ventilation piping might require insulation or heat tra-
cing to ensure that the ventilation air is always within the specification.
2023-02-03 - en

Ventilation air fan capacity

To decide the necessary capacity for the fan, the volume of the intermediate
spaces of the pipe system must be calculated. The complete volume consists
of:
▪ the volume of annular spaces in the main pipes
▪ the vented volume in the gas control block
▪ the single-walled inlet and outlet pipes of the ventilation system.
For further information regarding pipe sizes and venting volume in the gas
block for a specific engine type, contact MAN Energy Solutions.

2 (6) ME-GA
 MAN Energy Solutions 199 14 54-5.0

Based on the calculated volume, the capacity must ensure a minimum of 30

air changes per hour.

Fan requirements and installation guidelines

Ventilation is achieved by means of an electrically driven extractor fan placed
on deck. The fan must work independently of any other fan installation in the
engine room/power plant.
The electric fan motor as well as the starters have to be located outside the
ventilated pipe.
The parts of the rotating body and of the casing have to be of a spark-free
material with antistatic properties. Installation of the ventilation units has to be
carried out in a way that ensures bonding to the structure/hull of the unit.

7.09 Auxiliary systems for fuel gas supply system

2023-02-03 - en

Fig. 7.09.02: Leakage detection and ventilation system for the double-walled
piping
The ventilation inlet must be located in open air away from ignition sources,
and away from the ventilation outlet. Inlet and outlet must be considered as
hazardous zone 1.

ME-GA 3 (6)
199 14 54-5.0 MAN Energy Solutions

Venting air fan control

The GA Extension, see Fig. 16.02.03 controls the fan with reference to signals
going to and coming from the leakage detection and ventilation system for the
double-walled piping.
Two flow switches must be installed in the venting air intake to monitor that air
is flowing through the ventilation system. Fig. 7.09.02 shows the locations of
the flow switches.

Leakage detection
To detect any gas leaks into the annular space of the double-walled piping,
two hydrocarbon (HC) sensors must be installed in the outlet of the ventilation
system. Fig. 7.09.02 shows the locations of the HC sensors.

Safety standards for the leakage detection and ventilation system

All equipment and designs must comply with but not necessarily be limited to
the following:
▪ Current International Gas Code (IGC) and current International Gas Fuel
for ships (IGF) requirements
▪ Classification requirements from the specified classification society
▪ SOLAS and flag state requirements for fire safety and detection systems
▪ IEC 60092 Electrical Installations in Ships.
Further information about the gas ventilation system and a calculation of the
capacity of the venting fan are available from MAN Energy Solutions, Copen-
7.09 Auxiliary systems for fuel gas supply system

hagen.

Nitrogen system
A purging sequence is performed in order to dilute the remaining gas in the
gas system after an engine stop. The dilution is done by pressurising the gas
volume with nitrogen, and then releasing the methane/nitrogen-mixture
through the blow-off pipe.
The sequence is performed a consecutive number of times in order to reach a
safe gas concentration level in the system (below the lower explosion limit
(LEL)). The sequential procedure will be continued for a predefined number of
purges determined by parameter settings in the ECS. See the diagram for
FGSS auxiliary systems in Fig 7.09.01.
2023-02-03 - en

The FGSS also requires nitrogen for purging, which can either be supplied
from a common nitrogen system, or a separate standalone system. This de-
pends on the individual installation.
A sufficient quantity of nitrogen must be available on board prior to gas opera-
tion.

4 (6) ME-GA
 MAN Energy Solutions 199 14 54-5.0

General data for the nitrogen system

Minimum quality 95% N2
Minimum purging pressure 5 barg
Minimum buffer tank pressure 7 barg
Purging temperature ambient
Minimum number of purging sequences 4

Control of the nitrogen system

After a gas shutdown, the engine control system (ECS) initiates purging of the
gas systems. The ECS will as a minimum perform four purging sequences,
the actual number depends on the nitrogen system layout. Prior to gas start,
nitrogen is used for the verification test.

Purging volume and storage capacity

The purging storage volume must be designed for a number of consecutive
starts on fuel gas, each including a number of purging sequences, as well as
for purging prior to and after engine operation on fuel gas.
In order to calculate the purging volume, the total volume of piping being
purged must be calculated. The purging sequence is described in the follow-
ing.
The complete system purge volume includes:

7.09 Auxiliary systems for fuel gas supply system

▪ Nitrogen system and nitrogen supply piping
▪ Gas supply pipe from the main engine to the GVU
▪ Gas volume on the engine
The on-engine purge volume is available from the CEAS report under the Ni-
trogen system section for ME-GA type engines, see Section 20.02.

Buffer tank volume

The minimum required storage volume for the nitrogen system can be calcu-
lated as follows:
2023-02-03 - en

where
Vbuffer = Minimum buffer tank volume [m3]
Vpurge = Complete system purge volume [m3]
Pbuffer = Buffer tank storage pressure [bar(g)]
Ppurge = Minimum purge pressure [bar(g)]
n = Runs of purge sequences after gas stop [-]
Z = Number of consecutive gas starts [-]

ME-GA 5 (6)
199 14 54-5.0 MAN Energy Solutions

The ship designer decides the value of Z.

MAN Energy Solutions recommends that Z is minimum 6 consecutive gas
starts.
In addition, the nitrogen system and buffer tank must provide enough nitrogen
for tightness testing.

Nitrogen generator
Since the nitrogen buffer tank pressure decreases due to nitrogen consump-
tion, the nitrogen generator must be able to uphold a minimum capacity.
The nitrogen generator capacity must be designed to meet the required flow
per minute as follows:

where
Qgen = Volume flow of the nitrogen generator [Nm3/min]

The minimum nitrogen generator capacity depends on the nitrogen buffer

tank volume, and the nitrogen consumption per purging sequence. The de-
signer should evaluate the overall nitrogen system setup, and assess the most
optimal balance between nitrogen buffer tank size, and nitrogen generator ca-
pacity, while complying with MAN Energy Solutions' minimum requirements
for the nitrogen system.

Nitrogen booster requirements

7.09 Auxiliary systems for fuel gas supply system

A nitrogen booster/compressor (N2 booster) should be fitted for the purpose

of tightness testing the gas systems. During commissioning and after disas-
sembly of components in the gas system, a tightness test must be performed
by pressurising the engine with nitrogen to the maximum working pressure.
This is done to verify that the components have been assembled properly and
that gas pressure can be safely applied.
The requirements for the tightness test are:

Tightness testing pressure: 12 to 14 bar

Maximum period before reaching tightness testing pres- 3 hours
sure:
27021647946722571

The time it takes the system to reach the required tightness testing pressure,
2023-02-03 - en

after opening the nitrogen buffer tank, determines the capacity of the N2
booster.

An uninterrupted and sufficient nitrogen supply should be provided to ensure

that the N2 booster operation complies with manufacturer specifications and
the time requirement of MAN Energy Solutions.
MAN Energy Solutions does not require Ex approved N2 boosters but the
equipment must comply with the hazardous zone requirements of the room
where it is installed, if any.
The N2 booster can be either electrically driven or air driven. It should be
noted, however, that the outlet capacity of an air driven booster drops as out-
let pressure increases.
27021647946722571

6 (6) ME-GA
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
08 Lubricating Oil

20 Project Support and Documentation

21 Appendix
61395583755

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

08 Lubricating Oil
 MAN Energy Solutions 199 20 56-1.0

Lubricating and cooling oil system

System oil is the common designation of a lubricating oil used for different
purposes in systems in and on the engine. The system oil is used as:

1. Circulating oil
▪ Lubrication of crosshead bearings, crankshaft bearings, main and thrust
bearings
▪ Cooling of pistons
▪ Turbochargers
▪ Axial vibration damper

2. Hydraulic oil
▪ Hydraulic power supply unit (HPS)
▪ Exhaust valves
▪ Hydraulic cylinder unit (HCU)
▪ Moment compensator (if installed)
▪ Torsional vibration damper (if installed)

3. Control oil
▪ Activates (control) valves, etc.

4. Sealing oil in dual-fuel engines

▪ Confines low-flashpoint (LF) fuel in LF-systems (various systems and
types).

Two different lubricating and cooling oil system arrangements are available,
depending on whether the lubricating oil pump is a submerged centrifugal
deep-well pump (Fig. 8.01.01), or a positive displacement pump
(Fig. 8.01.02).

8.01 Lubricating and cooling oil system

2023-11-08 - en

All engines 1 (5)

199 20 56-1.0 MAN Energy Solutions

Fig. 8.01.01: Lubricating and cooling oil system arrangement with a sub-
merged centrifugal deep-well lubricating oil pump and cofferdam below the
lubricating oil bottom tank
8.01 Lubricating and cooling oil system

2023-11-08 - en

Fig. 8.01.02: Lubricating and cooling oil system arrangement with a positive
displacement lubricating oil pump and cofferdam below the lubricating oil bot-
tom tank

2 (5) All engines

 MAN Energy Solutions 199 20 56-1.0

The main lubricating oil pump pumps lubricating oil from a bottom tank to the
lubricating oil cooler, through a full-flow filter, to engine inlet ‘RU’, see Figs.
8.01.01–8.01.02. From the engine, the oil collects in the oil pan from where it
is drained off to the lubricating oil bottom tank through engine outlet ´S`. For
the design of the lubricating oil bottom tank, see Chapter 8.06.
If there is limited space below the engine, and the necessary space for a cof-
ferdam is not available (subject to classification approval), the arrangement in
Fig. 8.01.03 must be used.

Fig. 8.01.03: Lubricating and cooling oil system arrangement with a positive
displacement lubricating oil pump but no cofferdam below the lubricating oil

8.01 Lubricating and cooling oil system

bottom tank
If the lubricating oil tank gets damaged, the arrangement in Fig. 8.01.03 en-
ables emergency suction for both the lubricating oil pump and the separator
pump from the lubricating oil bottom tank.
Fig. 8.07.01 shows vent arrangement for engine crankcase, turbochargers,
and lubricating oil bottom tank.
For external pipe connections, we prescribe a maximum oil velocity of
1.8 m/s.
2023-11-08 - en

Notes on Figs. 8.01.01 – 8.01.03 are described in the following.

Orifice (Note 1 on Fig. 8.01.01)

An orifice should be installed if the inlet pressure to the engine exceeds the
figure for “Normal service high” given in the “Guidance Values for Automa-
tion”. Size, refer to document No.: 5774354-8 “Orifice sizes”.

Lubricating oil outlet (Note 2 on Figs. 8.01.01, 8.01.02 and 8.01.03)

Refer to a separate document for the specific engine design specification.

All engines 3 (5)

199 20 56-1.0 MAN Energy Solutions

Manual deaerating valve (Note 3 on Figs. 8.01.01, 8.01.02 and 8.01.03)

A manual venting arrangement with a small diameter should be installed at the
highest point. The location can be after or before the lubricating oil cooler.

Backflushing drain (Note 4 on Figs. 8.01.01, 8.01.02 and 8.01.03)

The backflushing line must terminate in the lubricating oil bottom tank close to
the separator pump suction line.

Lubricating oil sample connection

(Note 5 on Figs. 8.01.01, 8.01.02 and 8.01.03)
DN25 valve connection for oil sample purposes during flushing/flow cleaning
of the lubricating oil system at the shipyard and during normal operation.

Lubricating oil sample connection

(Note 7 on Figs. 8.01.01, 8.01.02 and 8.01.03)
DN10 valve connection for oil sample purposes.

Drain from turbocharger

(Note 9 on Figs. 8.01.01, 8.01.02 and 8.01.03)
As return oil is pressurised by sealing air from the turbocharger, the outlet in
the lubricating oil bottom tank must release the air above the oil level as
shown in one of the examples in Fig. 8.01.04.
8.01 Lubricating and cooling oil system

Fig. 8.01.04: Oil drain from turbocharger

Thermostatic valve location (Note 10 on Figs. 8.01.01, 8.01.02 and 8.01.03)

If the lubricating oil cooler is seawater cooled, the valve must be located on
2023-11-08 - en

the lubricating oil side.

Venting pipe routing, inclination

(Note 12 on Fig. 8.01.01, 8.01.02 and 8.01.03)
Refer to Project Guide Section 8.07.

RW connection (Note 13 on Figs. 8.01.01, 8.01.02 and 8.01.03)

The connection is only used when either Alfa Laval or Hydac type hydraulic
control oil (HCO) filter is installed at the engine.

4 (5) All engines

 MAN Energy Solutions 199 20 56-1.0

AB1 connection (Note 14 on Figs. 8.01.01, 8.01.02 and 8.01.03)

Connection only used when MAN exhaust gas recirculation (EGR) blowers are
installed for EGR engines.
73005929099

8.01 Lubricating and cooling oil system

2023-11-08 - en

All engines 5 (5)

199 20 56-1.0 MAN Energy Solutions

73005929099
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8.01 Lubricating and cooling oil system

2023-11-08 - en

All engines
 MAN Energy Solutions 199 20 59-7.0

Hydraulic power supply unit

A hydraulic power supply (HPS) unit supplies hydraulic power for the ME hy-
draulic-mechanical system for activation of fuel injection and exhaust valves.
Normal lubricating oil from the main lubricating oil system of the engine (as
standard) is used as hydraulic oil. The HPS unit filters the lubricating oil.

HPS connection to lubricating oil system

Internally on the engine, the lubricating oil inlet ‘RU’ is connected to the HPS
unit which supplies hydraulic oil to hydraulic cylinder units (HCU). See Figs.
8.01.01–8.01.03, 16.01.02a and 16.01.02b.
‘RW’ is the lubricating oil outlet from the automatic backflushing filter.
Hydraulic oil is supplied to the HCU at each cylinder where it is distributed to
two multi-way valves: Electronic fuel injection (ELFI) and electronic valve actu-
ation (ELVA), these carry out the fuel injection and open the exhaust valve, re-
spectively. The exhaust valve is closed by a conventional air spring.
The engine control system (ECS) controls the multi-way valves, see Chapter
16.

HPS configurations
The HPS pumps are driven either mechanically by the engine (via a step-up
gear from the crankshaft) or electrically. The HPS unit is mounted on the en-
gine, regardless of how the pumps are driven. For mechanically driven
pumps, the HPS unit (Fig. 8.02.01) consists of:
▪ an automatic and a redundant filter
▪ three to five engine driven main pumps
▪ two electrically driven start-up pumps
▪ a safety and accumulator block

8.02 Hydraulic power supply unit

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Fig. 8.02.01: Engine driven hydraulic power supply unit and lubricating oil
pipes
For electrically driven pumps, the HPS unit has three or more pumps which
function as combined main and start-up pumps.

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Altogether, two HPS configurations are available:

▪ STANDARD mechanically driven HPS, EOD: 4 40 160, with mechanically
driven main pumps and start-up pumps with a capacity sufficient to de-
liver the start-up pressure only. The engine cannot run with all engine-
driven main pumps out of operation. If one main pump is out, 66% engine
load is available.
▪ COMBINED mechanically driven HPS unit, EOD: 4 40 167 with electrically
driven start-up pumps with back-up capacity. If all engine-driven pumps
are out of operation, at least 15% engine power is available as back-up
power.

Motor start method

Direct online start (DOL) is required for all electric motors for the HPS pumps
to ensure proper operation under all conditions, including a start-up against
maximum pressure in the system.
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Lubricating oil pipes for turbochargers

8.03 Lubricating oil pipes for turbochargers

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System oil list, consumption and cleaning

System oil – a versatile lubricating oil used for many purposes

System oil is the common designation of a lubricating oil used for different
purposes in systems in and on the engine. As mentioned in Section 8.01, the
system oil is used as:
1. Circulating oil
2. Hydraulic oil
3. Control oil
4. Sealing oil in dual-fuel engines.

List of system oils

MAN Energy Solutions recommends using system oils (circulating oil) with the
following main properties:
▪ SAE 30 viscosity grade
▪ BN level 5 - 10
▪ high corrosion protection
▪ good anti-oxidant properties
▪ high detergency and dispersancy.
Adequate dispersion and detergent properties will keep the crankcase and
piston cooling spaces clean of deposits.
Table 1 lists major international system oil brands tested in service, and which
have passed the testing procedure and obtained a No Objection Letter (NOL).
Do not consider this list to be complete, as other system oils with NOLs from

8.04 System oil list, consumption and cleaning

MAN Energy Solutions can be equally suitable. System oils are recommended
for all MAN B&W two-stroke engines, independent of Mark number.

Company Circulating oil

SAE 30, BN 5 - 10
Castrol Castrol CDX 30

Chevron Lubricants Veritas 800 Marine 30

ENEOS Corporation Marine S30

ExxonMobil Mobilgard 300 C

Gulf Marine GulfSea Superbear 3006

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Shell Shell Melina S 30

Sinopec Lubricant co. System Oil 3005

SK Lubricants SK Supermar AS

TotalEnergies Lubmarine Atlanta Marine D3005

Table 1: Examples of international system oil brands that have an NOL from
MAN Energy Solutions
Do not consider the list complete, as oils from other companies can be
equally suitable. Further information can be obtained from the engine builder
or MAN Energy Solutions, Copenhagen.

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System oil consumption

The system oil consumption depends on factors like backflushing from
separators and drain from stuffing boxes.
Furthermore, the consumption varies for different engine sizes as well as op-
erational and maintenance patterns.

System oil offline cleaning

Automatic separators with total or partial discharge must be used.
Fig. 8.04.01 shows a typical system oil cleaning system.
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Fig. 8.04.01: Cleaning system

The nominal capacity of the separator must be according to the supplier’s re-
commendation for system oil, based on the figure:
0.136 litre/kWh
The nominal MCR is used as the total installed power.

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Recommendations of engine lubrication are available in the most current Ser-

vice Letters on this subject at www.marine.man-es.com --> 'Two-Stroke' -->
'Service Letters'.

Notwithstanding the foregoing, it remains the responsibility of the owner/oper-

ator of an engine to ensure that suitable fuels and lubes are conditioned and
used in order to prevent damage to the engine and other equipment on
board. MAN Energy Solutions disclaims any and all liability and cannot be held
responsible for any damage to the engine, engine components or other
equipment on board that may be caused by the use of the mentioned lubric-
ants.
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Components and installation

Lubricating oil pump

The lubricating oil pump can be a submerged centrifugal deep well pump or,
alternatively, a positive displacement type which requires one of the arrange-
ments shown in Fig. 8.01.01 and Fig. 8.01.02.

Flow rate
The flow capacity must be within a range from 100% to 112% of the capacity
stated in the CEAS report, see Section 6.03. Note that the given capacity
does not normally consider capacities of internal components such as tor-
sional vibration damper, gearbox, filter backflushing, etc.

Pump head (Ph)

The value given by MAN Energy Solutions is a preliminary guidance based on
a maximum pressure drop across cooler and filter of 1.0 bar, and a required
inlet pressure at the engine, which is specified at a reference location 1,800
mm above the crankshaft centre.
The actual pump head of the pumps must be based on required inlet pres-
sure to the engine, hydrostatic lifting height, and total actual pressure drop
across the lubricating oil system pipe components, specified by the shipyard,
at the specified flow rate.
If an automatically cleaned filter is installed, note that to activate the cleaning
process, certain makes of filters require a higher oil pressure at the filter inlet
than the pump pressure specified. Therefore, the pump capacity should be
adequate for this purpose, too.

Engine inlet pressure

The required inlet pressure to the engine must be according to “Guidance val-
ues for automation” for the specific engine type. The reference location for the
pressure is 1,800 mm above crankshaft centre.

Operating conditions 8.05 Components and installation

Lubricating oil viscosity, specified: 75 cSt at 50°C
Lubricating oil viscosity, maximum: 400 cSt, corresponding to a start of the
pump with cold lubricating oil
Maximum working temperature: 60° C.
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Centrifugal pump selection guideline, see Section 6.04.

Lubricating oil cooler

The lubricating oil cooler must be of either the plate type, or the shell and tube
type, and if the lubricating oil cooler is seawater (SW) cooled, it must be made
of Titanium.

Lubricating oil flow rate: See “flow rate” for the lubricating oil
pump

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Lubricating oil viscosity, specified: 75 cSt at 50°C

Working pressure: Pump head, Ph
Test pressure: According to class rules
Heat dissipation: Stated in the CEAS report
Max. differential pressure, lubricating oil 0.5 bar
side:
Lubricating oil outlet temperature: 45°C
The cooling water flow is stated in the CEAS report. The flow capacity must be within
a range from 100% to 110% of the capacity stated.
Max. differential pressure cooling side: 0.2 bar
Cooling water temp. inlet, SW cooled: minimum 10°C, maximum 32°C
Cooling water temp. inlet, freshwater (FW) minimum 10°C, maximum 36°C
cooled:

Lubricating oil full-flow filter

The filter should be either a manual or an automatic Duplex filter. A sufficient
capacity must be provided to allow the specified full amount of oil to flow
through each side of the filter at the working temperature and the differential
pressure across the filter, as stated below:

Lubricating oil flow rate: See “flow rate” for lubricating oil pump
Working pressure: Pump head (Ph)
Test pressure: According to class rules
Working temperature: Approximately 45°C
Absolute fineness: 50 μm or 40 μm (engine type dependent)
Clean filter differential pressure: Maximum 0.2 bar
Filter cleaning at differential pressure: Maximum 0.5 bar
Location: As close as possible to the main engine.
8.05 Components and installation

Lubricating oil bottom tank

The design must comply with the specific engine type, engine seating, and re-
commendation given in Section 8.06.
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Lubricating oil storage tank

The number, capacity, arrangement, and design must be according to owner/
classification society request, and normal shipyard standard.

Separator
An automatic separator type must be used, either with total discharge or par-
tial discharge.

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The nominal capacity of the separator must be according to the supplier’s re-
commendation for cleaning of lubricating oil based on the figure: 0.136 litre/
kWh. The engine NMCR must be used as the total installed power.

Preheater for separator

Type: Plate, or shell and tube
The nominal flow rate must be in accordance with the separator capacity and sup-
plier’s recommendation
Lubricating oil outlet temperature: 90°C, or in accordance with the recom-
mendation of the separator supplier
Lubricating oil inlet temperature: 45°C

Separator pump
Type: Positive displacement type
The nominal flow rate must be in accordance with the separator capacity and sup-
plier recommendation.

Filter for separator pump

The type, size, and necessity of the filter must be in accordance with the re-
commendation of the separator pump supplier.

Flushing of lubricating oil components and piping system at the shipyard

During installation of the lubricating oil system for the main engine, it is import-
ant to minimise or eliminate foreign particles in the system. This is done as a
final step on board the vessel, before starting the engine, by flushing the lub-
ricating oil components and piping system of MAN B&W two-stroke engines.
At the shipyard, the following main points should be observed during handling
and flushing of the lubricating oil components and piping system.
8.05 Components and installation
Before and during installation
Components delivered from sub-suppliers, such as pumps, coolers and fil-
ters, are expected to be clean and rust protected. However, these must be
spot-checked before being connected to the piping system.
All piping must be finished in the workshop before mounting on board, i.e. all
2023-11-15 - en

internal welds must be ground and piping must be acid-treated followed by

neutralisation, cleaning, and corrosion protection.
Both ends of all pipes must be closed/sealed during transport.
Before the final installation, carefully check the inside of the pipes for rust and
other kinds of foreign particles.
Never leave a pipe end uncovered during assembly.

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Bunkering and filling system

Tanks must be cleaned manually and inspected before filling these with oil.
When filling the oil system, MAN Energy Solutions recommends that new oil is
bunkered through a 6 μm fine filter, or that a purifier system is used. New oil is
normally delivered with a cleanliness level of XX/23/19 according to ISO 4406
and, therefore, requires further cleaning to meet our specification.

Flushing the piping with engine bypass

When flushing the system, the first step is to bypass the main engine oil sys-
tem. Through temporary piping and/or hosing, the oil is circulated through the
vessel’s system and directly back to the main engine oil sump tank.
If the system has been out of operation, or unused for a long time, it may be
necessary to spot-check for signs of corrosion in the system. Remove end
covers, bends, and so on, and inspect accordingly.
During flushing, it is important to keep the oil warm, approx. 60˚C, and the
flow of oil as high as possible. For that reason it may be necessary to run two
pumps at the same time.

Filtering and removing impurities

To remove dirt and impurities from the oil, it is essential to run the purifier sys-
tem during the complete flushing period and/or use a bypass unit with a 6 μm
fine filter and sump-to-sump filtration, see Fig. 8.05.01.
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Fig. 8.05.01: Lubricating oil system with temporary hosing/piping for flushing
at the shipyard

Furthermore, it is recommended to reduce the filter mesh size of the main filter
unit to 10-25 μm (to be changed again after sea trial) and use the 6 μm fine fil-
ter already installed in the auto-filter for this temporary installation, see Fig.
8.05.01. This can lead to a reduction of the flushing time.

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The flushing time depends on the system type, the condition of the piping and
the experience of the yard. 15–26 hours should be expected.

Cleanliness level, measuring kit and flushing log

MAN Energy Solutions specifies ISO 4406 XX/16/13 as the accepted cleanli-
ness level for ME hydraulic oil systems and second fuel hydraulic oil systems,
and ISO 4406 XX/19/15 for the remaining part of the lubricating oil systems.
The amount of contamination contained in system samples can be estimated
with the Pall Fluid Contamination Comparator combined with the Portable
Analysis Kit, HPCA-Kit-0, which is used by MAN Energy Solutions. This kit
and the comparator included is supplied by Pall Corporation, USA
(www.pall.com).
It is important to record the flushing condition in statements to all inspectors
involved. The MAN Energy Solutions ‘Flushing Log form’, which is available on
request, or a similar form is recommended for this purpose.

Flushing the engine oil system

The second step of flushing the system is to flush the complete engine oil sys-
tem. The procedure depends on the engine type and the condition in which
the engine is delivered from the engine builder. For detailed information, we
recommend contacting the engine builder or MAN Energy Solutions.

Inspection and recording in operation

Inspect the filters before and after the sea trial.
During operation of the oil system, check the performance and behaviour of
all filters, and note down any abnormal conditions. If any abnormal condition
is observed, take immediate action. For example, if a high differential pressure
occurs at short intervals, or in the case of abnormal backflushing, check the
filters and take appropriate action.
Further information and recommendations regarding flushing, the specified
cleanliness level and how to measure it, and how to use the NAS 1638 oil
cleanliness code as an alternative to ISO 4406, are available in our publica-
tion: Filtration Handbook.
The publication is available at www.man-es.com → ‘Marine’ → ‘Products’ 8.05 Components and installation
→‘Planning Tools and Downloads’ → ’Technical Papers’.
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Lubricating oil outlet

If required by class rules, a protecting ring, position 1–4 in Fig. 8.05.02,
should be installed.

Fig. 8.05.02: Lubricating oil outlet

The ring should be placed loose on the tank top guided by the hole in the
flange.
In the vertical direction, it is secured with a screw (position 4) to prevent wear
of the rubber plate.
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Lubricating oil tank

Fig. 8.06.01, Tables 8.06.01 and 8.06.02 show the lubricating oil tank and the
different dimensions.

Fig. 8.06.01: Dimensions of lubricating oil tank, with cofferdam

8.06 Lubricating oil tank

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G70ME-C10/-GI/-GA 1 (2)
199 12 07-8.0 MAN Energy Solutions

Cyl. Drain at D0 D1 D3 H0 H1 H2 H3 W L OL Q m3
No. cyl. No.

5 2-5 275 2x425 2x200 1,085 425 85 400 500 7,200 985 22.1

6 2-6 300 2x450 2x225 1,140 450 90 400 600 8,000 1,040 26.0

Table 8.06.01: Dimensions of lubricating oil tank with cofferdam referring to

Fig. 8.06.01

However, if space is limited other solutions are possible.

Table 8.06.02 shows the minimum lubricating oil bottom tank volume (m3).

5 cyl. 6 cyl.

20.0 23.9

Table 8.06.02: Minimum lubricating oil bottom tank volume in cubic metre

Note:
When calculating tank heights, allowance has not been made for the possibil-
ity that a quantity of oil in the lubricating oil system outside the engine may be
returned to the bottom tank, when the pumps are stopped. If the system out-
side the engine is designed so that an amount of lubricating oil is drained
back to the tank when the pumps are stopped, the height of the bottom tank
shown in Table 8.06.01 has to be increased to include this quantity.

Lubricating oil tank operating conditions

The lubricating oil bottom tank complies with the rules of classification
societies when operating under the conditions in Table 8.06.03.

Angle of inclination, degrees

Athwartships Fore and aft

Static Static

15 5
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Table 8.06.03: Operating conditions

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2 (2) G70ME-C10/-GI/-GA
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Venting and drain pipes

General
Fig. 8.07.01 shows venting arrangements for engine crankcase, turbocharger,
and lubricating oil bottom tank.

Fig. 8.07.01: Venting arrangement for engine crankcase, turbocharger, and

lubricating oil bottom tank
Notes on Fig. 8.07.01 are described in the following.

Crankcase venting line

8.07 Venting and drain pipes

The crankcase venting line must be made with a drain cowl as indicated in
Fig. 8.07.01 and detail 1, for draining of a potential build-up of condensate in
the venting line. This drain cowl must be located as close as possible to the
engine flange for crankcase venting.
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Hydrocarbon sensor (note 6)

1. Engine type: ME, fuel oil only

▪ A hydrocarbon (HC) sensor and a special vent outlet location are not rel-
evant.

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2. Engine type: ME-GI/-GA/-GIE/-LGIM/-LGIP

▪ A hydrocarbon sensor and a special vent outlet location are not relevant
but this can be overruled by the applicable flag state authority, who might
require the following:
– Tank venting: The venting outlet constitutes a hazardous zone and has
to be placed outside a safe area. The outside hazardous zone must be
according to flag state/classification society requirement.
– Monitoring: A hydrocarbon alarm sensor should be installed in the vent
line.

The piping must be terminated in open air:

See ‘Routing of vent pipes’ (Note 11)
Pipe routing: See ‘Venting pipe routing, inclination’ (Note 12)

Lubricating oil bottom tank venting lines

The lubricating oil bottom tank must be provided with sufficient venting. The
venting pipes should be arranged at the corners of the tank or, as a minimum,
at each end of the tank, to secure venting at any trim of the ship. The venting
pipe sizes from tanks are subject to classification society rules.
A drain system with a design as shown in note 6 and detail 2 in Fig. 8.07.01
can be installed for each of the air venting pipes from the lubricating oil bot-
tom tank. This gives the possibility to drain condensate and foreign particles
from venting pipes and, thereby, not contaminate the oil in the lubricating oil
bottom tank.
Drain valves must be opened and closed frequently during:
▪ Flushing procedure before initial engine start-up
▪ Sea-trial.
The piping must be terminated in open air:
See ‘Routing of vent pipes’ (Note 11)
Pipe routing: See ‘Venting pipe routing, inclination’ (Note 12)

Turbocharger vent line

A turbocharger vent line must be made going from the turbochargers to the
atmosphere. If more than one turbocharger vent line is connected to the same
vent line manifold, it is important that the vent pipe is connected to the bottom
of the manifold pipe, otherwise oil mist will accumulate in the pipe. Further-
8.07 Venting and drain pipes

more, the cross-sectional area of the vent pipe must be increased before con-
necting it to a common line. This is shown in Fig. 8.07.01, detail 3.
The piping must be terminated in open air:
2023-11-16 - en

See ‘Routing of vent pipes’ (Note 11)

Pipe routing: See ‘Venting pipe routing, inclination’ (Note 12)

Routing of vent pipes (Note 11 on Fig. 8.07.01)

It is recommended that each vent line from the various engine connections is
routed separately to the open air outside the engine room. They should not be
connected to each other or be connected to a common vent chamber.

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Venting pipe routing, inclination

(Note 12 on Figs. 8.01.01, 8.01.02, 8.01.03 and 8.07.01)
The vent piping routing has to be steadily ascending so no potential pipe
pockets can occur according to the vessel static longitudinal and transverse
inclination. In general, the longitudinal inclination used must be min. 5° (might
be smaller based on the length of the vessel and applicable classification soci-
ety rules) and the transverse inclination min. 15°. If for some reason a pipe
pocket cannot be avoided, a special drain pipe connection to the sludge or
waste oil tank must be installed in the bottom part of each pipe pocket to
avoid an oil-filled pocket.
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Turbocharger lubricating oil system

As an option, the engine can be prepared for a separate turbocharger (TC)
lubricating oil system, see Fig. 8.08.01.

8.08 Turbocharger lubricating oil system

Fig. 8.08.01: Separate TC lubricating oil system

The turbocharger lubricating oil system can be a separate unit, or it can be in-
tegrated in the engine room with the various components placed and
fastened to the steel structure of the engine room.
The design and dimensioning of the various components gives a reliable sys-
tem capable of supplying lubricating oil to the inlet of the engine-mounted tur-
bocharger at a constant pressure, both at engine stand-by and at various en-
gine loads.
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Initial filling and topping up (Note 1 on Fig. 8.08.01)

For all operations involving adding oil, oil filling must be done via the TC lubric-
ating oil fine filter unit.

Turbocharger lubricating oil return to tank (Note 2 on Fig. 8.08.01)

Return pipe outlets inside the tank must be placed near the tank side to avoid
formation of air bubbles in the turbocharger lubricating oil.

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Turbocharger lubricating oil

MAN Energy Solutions recommends the use of turbocharger lubricating oil
with the following main properties:
▪ SAE 30 viscosity grade
▪ BN level: 5–10
For further details, reference is made to drawing no. 5832509-5.

Turbocharger lubricating oil system components

Turbocharger lubricating oil tank

The tank must be designed as a separate loose tank (mild steel plate) or as
part of the ship structure. The tank must be made with a sloped bottom. The
tank should be placed at least 1 m below the turbocharger lubricating oil out-
let flange “AB” on Fig. 8.08.01.
The tank volume must be 10% of the pump flow rate given in the
CEAS report. The calculated tank volume is the volume between high- and
low-level alarms.
The design pressure must be according to class rules for tanks vented to the
atmosphere.
The low-level alarm must be placed at a level above the minimum level for
pump suction, including considerations of vessel athwartships and fore/aft in-
clinations (according to classification society rules). The low-level alarm must
be according to the document “Guidance Value – Automation”, sensor name
“LS 8130 AL”.
The optional high-level alarm must be placed so that the tank can receive the
TC lubricating oil drain amount from the engine without overflowing.

Cleaning
8.08 Turbocharger lubricating oil system

Before using the tank, it must be cleaned properly:

▪ Any slag (and other impurities) after welding must be removed mechanic-
ally
▪ Clean all visible impurities
▪ Treat scale on the surface with a descaling agent
▪ If rust is found, treat the surface with a rust-removing agent
▪ Use a vacuum cleaner to remove small particles from the surface and
corners
2024-02-16 - en

▪ Wash the surface with grease-dissolving liquid. Cleaned areas must be

protected with an antirust agent immediately after they have been cleaned
to provide protection until the system is filled up. The agent must be of a
type that can be mixed with lubricating oil.

Paint and protection

It is very important to ensure that the paint, if any, and other protecting
products used in the tank are oil resistant, and that the application method
has been thoroughly carried out, considering that a bad quality of paint may
be worse than no paint at all.
In general, it is recommended to coat the tank with clean oil.

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Turbocharger lubricating oil pump

The turbocharger lubricating oil pump should be a positive displacement type
pump with a build-in overflow safety valve.
The flow rate is stated in the CEAS report. The flow capacity must be within a
range from 100% to 112% of the capacity stated.

Pump head (Ph): 4 bar

Max. pump discharge pressure: 5 barg
TC lubricating oil viscosity, specified: 75 cSt at 50°C
TC lubricating oil viscosity, maximum: 400 cSt, corresponding to start of pump
with cold lubricating oil
Maximum temperature: 70°C
Classification and pressure test: According to class rules
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Turbocharger lubricating oil cooler

Type: Plate or shell and tube
Material: Titanium, if seawater cooled
TC lubricating oil flow rate: See “flow rate” for the turbocharger lub-
ricating oil pump
TC lubricating oil viscosity, specified: 75 cSt at 50°C
Working pressure: Max. pump discharge pressure 5 barg
Classification and pressure test: According to class rules
Heat dissipation: Stated in the CEAS report
Max. differential pressure TC lubricating 0.5 bar
oil side:
TC lubricating oil outlet setpoint temper- 45°C

8.08 Turbocharger lubricating oil system

ature:
Cooling water flow: Stated in the CEAS report
Max. differential pressure cooling side: 0.2 bar
Cooling water temp. inlet, FW cooled: Minimum 0°C, maximum 36°C
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Control pressure valve

The function of the valve is to create a constant supply pressure to the TC
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lubricating oil system independent of the engine load. The valve is the engine
builder scope of supply.

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Turbocharger lubricating oil full-flow filter

The filter should be either a manual or an automatic Duplex filter. A sufficient
capacity must be provided to allow the specified full amount of oil to flow
through each side of the filter at the working temperature and the differential
pressure across the filter, as stated below:

Lubricating oil flow rate: See “flow rate” for the lubricating oil
pump
Working pressure: Pump head (Ph)
Test pressure: According to class rules
Working temperature: Approximately 45°C
Absolute fineness: 50 μm
Clean filter differential pressure: Maximum 0.2 bar
Filter cleaning at differential pressure: Maximum 0.5 bar
Location: As close as possible to the main engine.
18014471648864651

Offline fine filter unit

A continuously running offline filtration must be performed to remove particles
and oil degradation products in the separate TC lubricating oil system. This is
performed by a fine filter unit, including a pump and filter. Furthermore, the
offline filtration unit must be able to clean bunkered TC lubricating oil before
the new oil enters the tank.
The capacity Q of the TC lubricating oil fine filter unit must correspond to
cleaning of 1/5 of the tank volume per hour.

Q (l/h) = Vtank (m3) x 1/5 (h-1) x 1000 (l/m3)

Example: Vtank = 2 m3, Q = 400 l/h
8.08 Turbocharger lubricating oil system

Fine filter filtration type: Deep-bed cartridge filtration

Filter fineness: 3 µm (absolute)
18014471648864651

Turbocharger lubricating oil backflushing filter (optional)

Fine filter filtration type: Deep-bed cartridge filtration
Filter fineness: 3 μm (absolute)
18014471648864651
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 MAN Energy Solutions 199 20 65-6.0

Thermostatic regulating valve

Freshwater flow: See CEAS report and cooling water flow
for “turbocharger lubricating oil cooler”
TC lubricating oil outlet, setpoint temper- 45°C
ature:
TC lubricating oil temperature range and alarm must be according to values stated in
the document “Guidance Value – Automation”, sensor name “TE 8112 I-AH-Al-Y”.
Max. working temperature: Up to 60 °C
Max. pressure drop: 0.3 bar
Actuator type: Electric or pneumatic
Recommended leak rate: Less than 0.5% of nominal flow
18014471648864651

8.08 Turbocharger lubricating oil system

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18014471648864651
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8.08 Turbocharger lubricating oil system

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All engines
 MAN Energy Solutions 199 20 68-1.0

Hydraulic control oil system

As an option, the engine can be prepared for a separate hydraulic control oil
(HCO) system, see Fig. 8.09.01.

Fig. 8.09.01: Hydraulic control oil system

The hydraulic control oil system can be a separate unit, or it can be integrated
in the engine room with the various components placed and fastened to the
steel structure of the engine room.
8.09 Hydraulic control oil system
The design and dimensioning of the various components gives a reliable sys-
tem capable of supplying low-pressure oil to the inlet of the engine-mounted
high-pressure hydraulic control oil pumps at a constant pressure, both at en-
gine standby, and at various engine loads.
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Initial filling and topping up (Note 1 on Fig. 8.09.01)

All oil added during the initial filling and topping up must be filtered through a
filter with a fineness of min. 3 µm (absolute).

Hydraulic control oil return to tank (Note 2 on Fig. 8.09.01)

Return pipe outlets inside the tank must be placed near the tank side to avoid
formation of air bubbles in the hydraulic control oil.

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Hydraulic control oil and cleanliness

MAN Energy Solutions recommends the use of HCO with the following main
properties:
▪ SAE 30 viscosity grade
▪ BN level: 5–10.
For further details, reference is made to drawing no. 5832509-5.
The hydraulic control oil must fulfil the cleanliness level ISO 4406 XX/16/13
equivalent to NAS 1638 Code 8.
MAN Energy Solutions can supply information and recommendations for:
▪ Flushing
▪ The specified cleanliness level and how it is measured
▪ Applying the NAS 1638 oil cleanliness code as an alternative to ISO 4406.

Hydraulic control oil system components

Hydraulic control oil tank

The tank must be designed as a separate loose tank (mild steel plate) or as
part of the ship structure. The tank must be made with a sloped bottom. The
tank should be placed at least 1 m below the hydraulic outlet flange “RZ” on
Fig. 8.09.01.
The tank volume must be 10% of the pump flow rate given in the
CEAS report. The calculated tank volume is the volume between high- and
low-level alarms.
The design pressure must be according to class rules for tanks vented to the
atmosphere.
The low-level alarm must be placed at a level above the minimum level for
pump suction, including considerations of vessel athwartships and fore/aft in-
clinations (according to classification society rules). The low-level alarm must
be according to the document “Guidance Value – Automation”, sensor name
“LS 1320 AL”.
The optional high-level alarm must be placed so that the tank can receive the
8.09 Hydraulic control oil system

HCO drain amount from the engine without overflowing.

Cleaning
Before using the tank, it must be cleaned properly:
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▪ Any slag (and other impurities) after welding must be removed mechanic-
ally
▪ Clean all visible impurities
▪ Treat scale on the surface with a descaling agent
▪ If rust is found, treat the surface with rust-removing agent
▪ Use a vacuum cleaner to remove small particles from the surface and
corners

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 MAN Energy Solutions 199 20 68-1.0

▪ Wash the surface with grease-dissolving liquid. Cleaned areas must be

protected with an antirust agent immediately after they have been cleaned
to provide protection until the system is filled up. The agent must be of a
type that can be mixed with lubricating oil.

Paint and protection

It is very important to ensure that the paint, if any, and other protecting
products used in the tank are oil resistant, and that the application method
has been thoroughly carried out, considering that a bad quality of paint may
be worse than no paint at all.
In general, it is recommended to coat the tank with clean oil.

Hydraulic control oil pump

The hydraulic control oil pump should be a positive displacement type pump
with a build-in overflow safety valve.
The flow rate is stated in the CEAS report. The flow capacity must be within a
range from 100% to 112% of the capacity stated.

Pump head (Ph): 4 bar

Max. pump discharge pressure: 5 barg
HCO viscosity, specified: 75 cSt at 50°C
HCO viscosity, maximum: 400 cSt, corresponding to start of pump
with cold HCO
Maximum temperature: 70°C
Classification and pressure test: According to class rules
9007272415940363

Hydraulic control oil cooler

Type: Plate or shell and tube
HCO flow rate: See “flow rate” for HCO pump
HCO viscosity, specified: 75 cSt at 50°C
Working pressure: Max. pump discharge pressure 5 barg 8.09 Hydraulic control oil system
Classification and pressure test: According to class rules
Heat dissipation: Stated in the CEAS report
Max. differential pressure HCO side: 0.5 bar
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HCO outlet setpoint temperature: 45°C

Cooling water flow: Stated in the CEAS report
Max. differential pressure cooling side: 0.2 bar
Cooling water temp. inlet, FW cooled: Minimum 0°C, maximum 36°C
9007272415940363

Control pressure valve

The function of the valve is to create a constant supply pressure to the HCO
system independent of the engine load. The valve is the engine builder scope
of supply.

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Hydraulic control oil filter

The filter is an automatic self-cleaning and backflushing type. See the filter
quality specification in the document 0744631-6.
Engine builder filter supplier options: Boll & Kirch, Alfa Laval, and Hydac

Offline fine filter unit

A continuously running offline filtration must be performed to remove particles
and oil degradation products in the separate HCO system. This can be per-
formed by a fine filter unit, including a pump and filter. Furthermore, the offline
filtration unit must be able to clean an HCO bunker, before the new oil enters
into the tank.
The HCO fine filter unit capacity “Q” must correspond to cleaning of 1/5 of the
tank volume per hour.

Q (l/h) = Vtank (m3) x 1/5 (h-1) x 1000 (l/m3)

Example: Vtank = 2 m3, Q = 400 l/h
Fine filter filtration type: Deep-bed cartridge filtration
Filter fineness: Max. 3 µm (absolute)
9007272415940363

Thermostatic regulating valve

Water flow: See CEAS report and cooling water flow
for HCO cooler
HCO outlet setpoint temperature: 45°C
HCO temperature range and alarm must be according to stated values in the docu-
ment “Guidance Value – Automation”, sensor name “TE 1310 AH-Y”.
Max. working temperature: Up to 60 °C
Max. pressure drop: 0.3 bar
Actuator type: Electric or pneumatic
Recommended leak rate: Less than 0.5% of nominal flow.
9007272415940363
8.09 Hydraulic control oil system

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4 (4) All engines

MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
09 Cylinder Lubrication

18 Monitoring Systems and Instrumentation

19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395592459

1 (1)
 MAN Energy Solutions

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09 Cylinder Lubrication
 MAN Energy Solutions 199 18 11-6.0

Cylinder oil specification and system description

Cylinder lubricators
Each cylinder liner has a number of lubricating quills through which oil is intro-
duced by MAN B&W Alpha Cylinder Lubricators, see Section 9.02.
Cylinder lubricating oil is pumped into the cylinder (via non-return valves) when
the piston rings pass the lubricating orifices during the upward stroke.
The control of the lubricators is integrated in the engine control system (ME-
ECS). Fig. 9.02.02b shows an overview of the cylinder lubricating oil control
system.

Cylinder lubrication strategy

The general lubrication strategy is to match the cylinder oil with the fuel type
and its sulphur content.
When operating on liquid natural gas (LNG), ethane liquid petroleum gas
(LPG) or methanol, the same cylinder oil is used as for <0.10 ULSFO (ultra-
low-sulphur fuel oil) to <0.5 VLSFO (very-low-sulphur fuel oil) operation.
For specific lubrication guidelines, please refer to the most recent lubrication
guideline for your specific engine type, for example service letters and circular
letters. Service letters are publicly available.
Circular letters are only distributed to customers with specific engine types.

9.01 Cylinder oil specification and system description

Cylinder oil
MAN Energy Solutions is continously improving the engine design. Highly fuel-
efficient engines with higher pressures and higher temperatures require lubric-
ants with matching performance. Cylinder oils must be designed to:
▪ lubricate pistons and liners
▪ reduce friction
▪ introduce wear protection
▪ minimise risk of seizures
▪ neutralise acids and oxidation products in accordance with the engine re-
quirement,
▪ and keep pistons, piston rings, ring grooves, ringlands, and liners clean.
The cylinder oils are divided into two performance categories, Cat. I and Cat.
II, of which Cat. II is the overall higher performing category.
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MAN Energy Solutions recommends using cylinder oils with the following main
properties:
▪ kinematic viscoity
– minimum 18.5 cSt at 100°C
– maximum 21.9 cSt at 100°C
▪ viscosity index (VI): min. 95
▪ high detergency
▪ alkalinity or base number (BN).

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Category II cylinder oils – all MAN B&W engines and recommended for Mk. 9
and higher
Cat. II cylinder oils have an excellent overall performance with a special focus
on cleaning ability. In order to receive this status, the cylinder oil must com-
plete extensive testing. The lubricants awarded Cat. II status are 40 BN, 100
BN, and 140 BN cylinder oils. Cylinder oils with 100 and 140 BN are mainly
used for high-sulphur fuel applications. The Cat. II 40 BN oils can be used for
operation on <0.10-0.50%S fuels and LNG, ethane, methanol, and LPG.
Table 9.01.01 lists major international system oil brands tested in service with
acceptable results, and which have passed the testing procedure and ob-
tained an No Objection Letter (NOL). Do not consider this list to be complete,
as other Cat. II cylinder oils with NOLs from MAN Energy Solutions can be
equally suitable.

Category II cylinder oils as stated in SL2022-728*

Company Cylinder oils

140 BN 100 BN 40 BN

Castrol Cyltech 140 Cyltech 100 Cyltech 40 XDC

Chevron Taro Ultra 140 Taro Ultra 100 Taro Ultra Ad-
vanced 40

ExxonMobil Mobilgard 5145 Mobilgard 5100 Mobilgard 540 AC

9.01 Cylinder oil specification and system description

Gulf Oil Marine Gulfsea Cylcare Gulfsea Cylcare Gulfsea Cylcare XP

50140X 50100X 5040X

ENEOS Corpora- ENEOS Marine

tion C1005S

Shell Shell Alexia 140 Shell Alexia 100 Shell Alexia 40XC

Sinopec Lubricant Sinopec Marine

co. Cylinder Oil 50100

TotalEnergies Lub- Talusia HR 140 Talusia Universal Talusia HD 40

marine 100

*Cat. II cylinder oils suitable for all MAN B&W two-stroke engines and recom-
mended for Mark 9 and higher. Examples of international cylinder oils for
which an NOL has been granted Cat. II status by MAN Energy Solutions.
Table 9.01.01: Cat. II cylinder oils
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 MAN Energy Solutions 199 18 11-6.0

Category I cylinder oils – MAN B&W engines Mk. 8 and lower

Table 9.01.02 lists major international cylinder oil brands tested in service with
acceptable results, and which have passed the testing procedure and ob-
tained an NOL. Do not consider this list to be complete, as other Cat. I cylin-
der oils with NOLs from MAN Energy Solutions can be equally suitable.

Category I cylinder oils as stated in SL2022-728**

Company Cylinder oils

100BN - 140BN 70 BN 40 BN

Castrol Cyltech 70 Cyltech 40SX*

Cyltech 40

Chevron Lubricants Taro Ultra 70 Taro Ultra 40

ExxonMobil Mobilgard 570 Mobilgard 540

Mobilgard 540 X*

Gulf Oil Marine Gulfsea Cylcare Gulfsea Cylcare

DCA 5070X DCA 5040X

ENEOS Corp. Marine C705 Marine 405Z

Shell Shell Alexia 70 Shell Alexia 40

Sinopec Lubricant Sinopec Marine Sinopec Marine Sinopec Marine

co. Cylinder Oil 50140 Cylinder OIl 5070S Cylinder Oil 5040

9.01 Cylinder oil specification and system description

SK lubricants SK Supermar Cyl SK Supermar Cyl SK Supermar Cyl
140 / SK Supermar 70 Plus 40 Plus
Cyl 100

TotalEnergies Lub- Talusia HR 70 Talusia LS 40

marine

* Also tested according to the new Cat. I requirements.

** Cat. I cylinder oils suitable for MAN B&W two-stroke engines Mk. 8 and
lower. Examples of international cylinder oils with an NOL from MAN Energy
Solutions.
Table 9.01.02: Cat. I cylinder oils

Notwithstanding the foregoing, it remains the responsibility of the owner/oper-

ator of an engine to ensure that suitable fuels and lubes are conditioned and
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used in order to prevent damage to the engine and other equipment on

board. MAN Energy Solutions disclaims any and all liability and cannot be held
responsible for any damage to the engine, engine components or other
equipment on board that may be caused by the use of the mentioned
lubricants.

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Description of cylinder oil systems

The general cylinder lubrication strategy for MAN B&W engines is to match
the cylinder oil with the fuel type, its sulphur content, and the dependency on
detergent. This match can be achieved by the two cylinder oil lubricating sys-
tems available, both of which require access to two cylinder oils.
The two cylinder oil lubrication systems are – options 1 and 2:
▪ Option 1 - Automated cylinder oil switching system (ACOS2) is the stand-
ard system for most engines, whereas
▪ Option 2 - Automated cylinder oil mixing system (ACOM) is a more ad-
vanced system designed for engine operation which places demands on
the change of cylinder oil.
Engine type ME-B/ME-C

Fuel type low sulphur high sulphur HS Tier II HS and spe-

(LS) (HS) LS Tier III cified dual-fuel
(SDF) operation

Option 1- standard standard standard N/A

ACOS2

Option 2 - N/A option option standard

ACOM

Table 9.01.01: Lubrication systems for all engines

9.01 Cylinder oil specification and system description

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 MAN Energy Solutions 199 18 11-6.0

Option 1 – Automated cylinder oil switching system

ACOS2 is a simple system securing fully acceptable conditions when a longer
changeover period is available. Fig. 9.01.01 shows Option 1 – the ACOS2
system.

9.01 Cylinder oil specification and system description

Fig. 9.01.01: Option 1 – ACOS2 system – standard system for most engines
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Option 2 – Automated cylinder oil mixing system

ACOM is specified for engine operation and the need for a faster responding
system when switching fuels. Fig. 9.01.02 shows Option 2 – the ACOM sys-
tem.
9.01 Cylinder oil specification and system description

Fig. 9.01.02: Option 2 - ACOM system

Cylinder oil feed rate (dosage)

The minimum cylinder oil feed rate can be found in the latest official guideline
issued in our most current Service Letter on this subject. Download Service
Letters from our website here. The minimum feed rate is the amount of oil
needed to lubricate all parts sufficiently.
Continuously monitoring the cylinder condition and analysing drain oil samples
are important to:
1. optimise cylinder oil feed rate and consumption, and
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2. safeguard the engine against wear.

Further information about cylinder lubrication is available in ’ most current Ser-
vice Letters on this subject.

Option 1 – Automated cylinder oil switching system

The ACOS2 system automatically switches between two grades of cylinder
oil, for example, cylinder lubricating oils with a high and a low BN. In general,
the cylinder oil storage and/or service tanks should be arranged separately for
the two cylinder oils.

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Switching between the two types of cylinder lubricating oil is based on several
factors, some are mentioned below:
▪ Engine load (fuel oil and dual-fuel (DF) operation)
▪ Amount of pilot fuel in the combusted fuel (only for DF operation on )
▪ Sulphur content in the pilot fuel (only for DF operation on )
▪ Cylinder oil detergency to control cylinder cleanliness.
The sulphur content in the combusted fuel is called the sulphur equivalent.
The ACOS2 system automatically calculates the sulphur equivalent based on
input about the sulphur content of the pilot fuel, which the crew enters on the
main operating panel (MOP).

Control modes
The engine control system (ECS) controls the ACOS2 system and the supply
of cylinder oils via a three-way valve.
See Fig. 9.01.01, and the control modes in Table 9.01.02.

Control mode Description

Auto Cylinder lubrication will switch to high-BN

cylinder oil in dual-fuel operation, and
low-BN cylinder oil when running on fuel
oil only. This switch occurs automatically
based on a feed rate threshold value.

High BN Only high-BN oil is used for cylinder lub-

rication

9.01 Cylinder oil specification and system description

Low BN Only low-BN oil is used for cylinder lubric-
ation

Table 9.01.02: Control modes

The three-way ball valve is activated pneumatically by control air and in failsafe
position, a spring forces the valve to switch to the high-BN oil.

Timer control of High- and Low-BN control modes

A timer with two timer functions (Max. and Force) can be enabled to control
how many days the engine will run on low-BN and high-BN oils.
The values entered into the timer and, therefore, the shift between cylinder
oils, give the possibility to address cylinder cleanliness.
The “Max.” timer depends on the low-BN feed rate or the days entered in the
timer.
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If the low-BN feed rate is bigger than an engine-dependant threshold value, it

will switch to high-BN oil. Likewise, if the number of days entered in the timer
has elapsed, it will switch to high-BN oil. Only one of the criteria has to be ful-
filled and the timer switches to high-BN oil.
The “Force” timer depends on the low-BN feed rate and the days entered in
the timer.
If the low-BN feed rate is lower than an engine-dependant threshold value and
the timer is done, it will switch to high-BN oil. Both criteria have to be fulfilled
before the timer switches to high-BN oil.

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Option 2 - Automated cylinder oil mixing system (ACOM)

The automated cylinder oil mixing (ACOM) is a cylinder oil delivery system
which automatically mixes to two fully formulated cylinder oils to the optimum
BN, depending on the sulphur content of the fuel.
In general, the cylinder oil storage and/or service tanks should be arranged
separately for the two cylinder oils.
' ACOM system mixes commercially available cylinder oils to the BN value re-
quired. The resulting BN of the cylinder oil supplied to the liners is in the range
of the BN values of the two cylinder oils stored on board.
The basic principle is to mix a cylinder lubricating oil with an optimal BN. At a
certain sulphur content level, the engine has to run on a high-BN cylinder oil.

ACOM working principle

The ME-ECS controls the ACOM system and the mixing of cylinder oils based
on an input about the sulphur content of the fuel combusted. In dual-fuel op-
eration, the sulphur content of the fuel combusted depends on:
▪ engine load
▪ amount of pilot oil in the combusted fuel
▪ sulphur content in the pilot fuel.
The sulphur content of fuel is called the sulphur equivalent. The ACOM system
automatically calculates the sulphur equivalent.
The ACOM system can be controlled automatically or manually, see Table
9.01 Cylinder oil specification and system description

9.01.03.

Control mode Description

Auto The system automatically calculates the

ordered BN value based on the sulphur
percentage of the fuel oil.

Manual The operator manually enters the ordered

BN value

Table 9.01.03: Control modes

The engine control systems of ME-C/-GI/-LGI/-GA and ME-B-GI/-LGI engines
contain the ACOM functionality, and the crew must input the sulphur content
of the pilot fuel on the MOP.
On the ME-B engine, ACOM is a stand-alone installation controlled from an
ACOM operating panel separate to the engine control system (ME-B ECS).
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The ship’s alarm system handles alarms.

The cylinder oil mixing volumes are kept small to enable a fast changeover
from one cylinder oil BN to another.

Two-tank cylinder lubrication system with ACOM

The ACOM design enables measurement of the daily consumption of cylinder
lubricating oil, which eliminates the need for two cylinder oil service/day tanks.
Furthermore, compared to Option 1 – the ACOS2 system in Fig. 9.01.01, the
ACOM system also eliminates the need for a heating tank.

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The cylinder lubricating oil is fed from the storage tanks to the ACOM system
by gravity. The ACOM system is located in the engine room near to and
above the cylinder lubricating oil inlet flange, AC, in a vertical distance of min-
imum 2 m. Fig. 9.01.04 shows the layout of the ACOM system.

9.01 Cylinder oil specification and system description

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Fig. 9.01.04: Automated cylinder oil mixing system (ACOM) in a single-rack

version for installation in the engine room

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Components for the cylinder oil lubricating systems

The next section describes the recommendations and requirements to the
components of the cylinder lubricating oil systems.

1. Cylinder oil storage tanks and/or service tanks

a) Combined storage and service tank design
It is recommended that the tank design is tall and slim to optimise settling in
the tank. The tank bottom must be sloped for easy water drainage.
b) Separate service tank design
It is recommended that the tank design is tall and slim to optimise settling in
the tank and the accuracy of readings for calculating the consumption. The
recommended length, width, and height aspect ratio is 1:1:3. The tank bot-
tom must be sloped for easy water drainage.
Capacity
The tank capacities must be determined based on hourly cylinder oil con-
sumption and the needed operating storage time. The storage time will differ
from project to project according to the time between bunkering of cylinder oil
estimated by the vessel operator. If separate cylinder oil storage tanks are in-
stalled, MAN Energy Solutions normally recommends that the capacity for the
service tanks is defined as one day.

Hourly consumption [m3/h] =

9.01 Cylinder oil specification and system description

Feed rate [g/kWh] x PowerSMCR [kW] x fsafe/(1000 [g/kg] x Density [kg/m3])

▪ Feed rate [g/kWh] = ACC x S [%], the feed rate used must not be less
than 0.6 g/kWh.
▪ ACC [g/kWh] = 0.4, as the design (normally between 0.2–0.4)
▪ S [%] is the sulphur content of the fuel oil
▪ PowerSMCR [kW] is engine power at SMCR
▪ fsafe is a safety factor, fsafe = 1.2
▪ Density [kg/m3] = 900.

Location
The supply line must be located minimum 1000 mm above the top of the cyl-
inder oil heating tanks and the ACOM system.
Minimum cylinder oil temperature in the tank
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The design minimum cylinder oil temperature in the tank is 25°C.

If the holding temperature is lower, the size of the heating element in the heat-
ing tank and the pipe dimension from the service tank to the heating tank
must be increased.
Outlet pipe dimension
Min. DN32 (min. DN40 if 0°C is the minimum cylinder oil temperature design
criteria)

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2. Filter
Fineness (absolute): 250 μm

3. Cylinder oil heating tanks and ACOM tanks

Capacity: Approx. 40 litres
Location
The bottom of the heating tank must be minimum 2000 mm above the engine
connection 'AC'.
Heating element size
Can be calculated as: Heat [W] = PowerSMCR [kW] x fheat [W/kW]
▪ PowerSMCR [kW] is engine power at SMCR
▪ fheat25 [W/kW] = 0.0078 for low-sulphur (0.5% S) engines (based on service
tank holding temperature, Th = 25°C)
▪ fheat25 [W/kW] = 0.0183 for high-sulphur (3.5% S) engines (based on ser-
vice tank holding temperature, Th = 25°C)
If a lower holding temperature is considered, fheat must be:
fheat = (45-Th act) x fheat25/20
Where Th act [°C] is the actual service tank holding temperature.
▪ Inlet pipe dimension: Min. DN32 (min. DN40, if 0°C service tank holding
temperature is the design criteria)
▪ Outlet pipe dimension: Min. DN32
▪ Vent pipe dimension: Min. DN32

9.01 Cylinder oil specification and system description

▪ Level alarm low switch: Guidance values for automation (GVA) tag no. LS
8212 AL

4. Electrical heat tracing and insulation

Location
The entire pipeline from heating tank to engine must be fitted with insulation
and electrical heat tracing.
Electrical tracing cable connection
The electrical tracing cable (shipyard supply) must be connected to the ter-
minal box installed internally at the engine. Fig. 9.01.05 shows the arrange-
ment.
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Fig 9.01.05: Electrical tracing cable arrangement

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5. Automatic cylinder oil switch – ACOS2

▪ Type: three-way ball valve (L-bored)
▪ Actuator: Pneumatic single acting type with spring return to position “High
BN cylinder oil”
▪ Solenoid valve: 3/2 type with silencer
▪ Controlled by: Engine control system – control signal XC8260 (24 V DC),
closed contact = “Low BN cylinder oil”
▪ Valve position feed-back to: engine control system - feed-back signal
ZS8261 (potential free contact) - “Low BN cylinder oil”
▪ Engine control system - feed-back signal ZS8262 (potential free contact) -
“High BN cylinder oil”
▪ Valve location: Must be located as close as possible to the heating tank.

6. Cylinder oil storage tanks (Optional)

Purpose
If for some reason, for example owner requirement, or if it is not possible to
locate the needed storage capacity in the service tanks at the required vertical
elevation level, independent storage tanks can be used.
Tank design
It is recommended that the tank design is tall and slim to optimise settling in
the tank. The tank bottom must be sloped for easy water drainage.
Capacity
The capacities of the tanks must be determined based on hourly cylinder oil
9.01 Cylinder oil specification and system description

consumption and the needed operating storage time. The needed storage
time will differ from project to project according to the time between bunker-
ing of cylinder oil estimated by the vessel operator.
For calculating hourly consumption [m3/h], reference is made to section “Cyl-
inder oil storage tanks and/or service tanks” – “Capacity”.

7. Cylinder oil transfer pumps (Optional)

Purpose
To transfer the cylinder oil between storage tanks and service tanks.
Option
If one transfer pump is used for pumping both cylinder oils, it has to be se-
cured that the pump suction/discharge valves are interlocked with each other
to avoid unintended blending of the two cylinder oils with different BN values.
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8. Flowmeter (Optional)
Location
Installation options:
▪ Located between service tank and cylinder oil heating tank *)
▪ Located between cylinder oil heating tank and engine. Only a Coriolis type
can be used *)
▪ Located between storage tanks and service tanks.
*) These flowmeter locations can result in unreliable measurements because
of the very low flow.

12 (13) All engines

 MAN Energy Solutions 199 18 11-6.0

Type
A mass flowmeter of the Coriolis type can be recommended based on: low
differential pressure, no built-in non-return function, and it provides mass flow
results (not a volumetric result).
Vent pipes for twin engine plants (Note 1):
▪ ACOS2 system: A separate vent pipe must be used from each engine
heating tank
▪ ACOM system: A separate vent pipe must be used from each engine
ACOM BN mixing tank.
72057652346586763

9.01 Cylinder oil specification and system description

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All engines 13 (13)

199 18 11-6.0 MAN Energy Solutions

72057652346586763
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9.01 Cylinder oil specification and system description

2024-04-03 - en

All engines
 MAN Energy Solutions 199 15 83-8.0

Alpha ACC cylinder lubrication system

The MAN B&W Alpha cylinder lubrication system, see Figs. 9.02.02a, 02b and
02c, is designed to supply cylinder oil intermittently, for instance every 2, 4 or
8 engine revolutions with electronically controlled timing and dosage at a
defined position.

Traditional two-tank cylinder lubrication system

Separate storage and service tanks are installed for each of the different Base
Number (BN) cylinder oils used onboard ships operating on both high- and
low-sulphur fuels, see Fig. 9.02.02a.
The cylinder lubricating oil is pumped from the cylinder oil storage tank to the
service tank, the size of which depends on the owner’s and the yard’s re-
quirements, – it is normally dimensioned for about one week’s cylinder lubric-
ating oil consumption.

Oil feed to the Alpha cylinder lubrication system

Cylinder lubricating oil is fed to the Alpha cylinder lubrication system by gravity
from the service tank or ACOM.
The oil fed to the injectors is pressurised by the Alpha Lubricator which is
placed on the hydraulic cylinder unit (HCU) and equipped with small multi-pis-
ton pumps.
The oil pipes fitted on the engine are shown in Fig. 9.02.04.
The whole system is controlled by the Cylinder Control Unit (CCU) which con-
trols the injection frequency based on the engine-speed signal given by the
tacho signal and the fuel index.
Prior to start-up, the cylinders can be pre-lubricated and, during the running-
in period, the operator can choose to increase the lubricating oil feed rate to a

9.02 Alpha ACC cylinder lubrication system

max. setting of 200%.
The MAN B&W Alpha Cylinder Lubricator is preferably to be controlled in ac-
cordance with the Alpha ACC (Adaptable Cylinder Oil Control) feed rate sys-
tem.
The yard supply should be according to the items shown in Fig. 9.02.02a
within the broken line.
Regarding the filter and the small tank for heater, please see Fig. 9.02.05.

Alpha Lubricator variants

2023-03-28 - en

Since the Alpha Lubricator on ME and ME-B engines are controlled by the en-
gine control system, it is also referred to as the ME lubricator on those en-
gines.
A more advanced version with improved injection flexibility, the Alpha Lubric-
ator Mk 2, is being introduced on the G95/50/45/40ME-C9 and S50MEC9 in-
cluding their GI dual fuel variants.
Further information about the Alpha Lubricator Mk 2 is available in our public-
ation:
Service Experience MAN B&W Two-stroke Engines

95-60ME-GI/-LGI engines 1 (8)

199 15 83-8.0 MAN Energy Solutions

The publication is available at www.man-es.com → ‘Marine’ → ‘Products’ →

‘Planning Tools and Downloads’ → ’Technical Papers’.

Alpha Adaptive Cylinder Oil Control (Alpha ACC)

It is a well-known fact that the actual need for cylinder oil quantity varies with
the operational conditions such as load and fuel oil quality. Consequently, in
order to perform the optimal lubrication – cost’effectively as well as technically
– the cylinder lubricating oil dosage should follow such operational variations
accordingly.
The Alpha lubricating system offers the possibility of saving a considerable
amount of cylinder lubricating oil per year and, at the same time, to obtain a
safer and more predictable cylinder condition.
Alpha ACC (Adaptive Cylinder-oil Control) is the lubrication mode for MAN
B&W two-stroke engines, i.e. lube oil dosing proportional to the engine load
and proportional to the sulphur content in the fuel oil being burnt.

Working Principle
The feed rate control should be adjusted in relation to the actual fuel quality
and amount being burnt at any given time.
The following criteria determine the control:
▪ The cylinder oil dosage shall be proportional to the sulphur percentage in
the fuel
▪ The cylinder oil dosage shall be proportional to the engine load (i.e. the
amount of fuel entering the cylinders)
▪ The actual feed rate is dependent of the operating pattern and determined
based on engine wear, cylinder condition and BN of the cylinder oil.
The implementation of the above criteria will lead to an optimal cylinder oil
dosage.
9.02 Alpha ACC cylinder lubrication system

Specific Minimum Dosage with Alpha ACC

The recommendations are valid for all plants, whether controllable pitch or
fixed pitch propellers are used. The specific minimum dosage at lowersulphur
fuels is set at 0.6 g/kWh.
After a running-in period of 500 hours, the feed rate sulphur proportional
factor is 0.20 - 0.40 g/kWh × S%. The actual ACC factor will be based on cyl-
inder condition, and preferably a cylinder oil feed rate sweep test should be
applied. The ACC factor is also referred to as the Feed Rate Factor (FRF).
2023-03-28 - en

Examples of average cylinder oil consumption based on calculations of the

average worldwide sulphur content used on MAN B&W two-stroke engines
are shown in Fig. 9.02.01a and b.

2 (8) 95-60ME-GI/-LGI engines

 MAN Energy Solutions 199 15 83-8.0

Fig. 9.02.01a: FRF = 0.20 g/kWh × S% and BN 100 cylinder oil – average
consumption less than 0.65 g/kWh

9.02 Alpha ACC cylinder lubrication system

Fig. 9.02.01b: FRF = 0.26 g/kWh × S% and BN 100 cylinder oil – average
consumption less than 0.7 g/kWh
Further information about cylinder oil dosage is available in MAN Energy Solu-
tions' most current Service Letters on this subject available at www.mar-
ine.man-es.com --> ’Two-Stroke’ --> ’Service Letters’.

Cylinder oil pipe heating

2023-03-28 - en

In case of low engine room temperature, it can be difficult to keep the cylinder
oil temperature at 45 °C at the MAN B&W Alpha Lubricator, mounted on the
hydraulic cylinder.
Therefore the cylinder oil pipe from the two small tanks for heater element in
the vessel, Fig. 9.02.02a, or from the ACOM, Fig. 9.02.02b, and the main cyl-
inder oil pipe on the engine is insulated and electricallly heated.
The engine builder is to make the insulation and heating of the main cylinder
oil pipe on the engine. Moreover, the engine builder is to mount the terminal
box and the thermostat on the engine, see Fig. 9.02.03.

95-60ME-GI/-LGI engines 3 (8)

199 15 83-8.0 MAN Energy Solutions

The ship yard is to make the insulation of the cylinder oil pipe in the engine
room. The heating cable is to be mounted from the small tank for heater ele-
ment or the ACOM to the terminal box on the engine, see Figs. 9.02.02a and
02b.
9.02 Alpha ACC cylinder lubrication system

Fig. 9.02.02a: Cylinder lubricating oil system with dual storage and service
tanks and ACOS (behind AC1 and AC2)
2023-03-28 - en

4 (8) 95-60ME-GI/-LGI engines

 MAN Energy Solutions 199 15 83-8.0

9.02 Alpha ACC cylinder lubrication system

Fig. 9.02.02b: Cylinder lubricating oil system with dual storage or service
tanks and ACOM
2023-03-28 - en

95-60ME-GI/-LGI engines 5 (8)

199 15 83-8.0 MAN Energy Solutions

Fig. 9.02.02c: Cylinder lubricating oil system. Example from 80/70/65ME-C/-

GI/-LGI engines
9.02 Alpha ACC cylinder lubrication system

2023-03-28 - en

Fig. 9.02.03: Electric heating of cylinder oil pipes

6 (8) 95-60ME-GI/-LGI engines

 MAN Energy Solutions 199 15 83-8.0

The item no. refer to ‘Guidance Values Automation’. The letters refer to list of
‘Counterflanges’
Fig. 9.02.04a: Cylinder lubricating oil pipes, Alpha/ME lubricator

9.02 Alpha ACC cylinder lubrication system

2023-03-28 - en

The item no. refer to ‘Guidance Values Automation’. The letters refer to list of
‘Counterflanges’
Fig. 9.02.04b: Cylinder lubricating oil pipes, Alpha Mk 2 lubricator

95-60ME-GI/-LGI engines 7 (8)

199 15 83-8.0 MAN Energy Solutions
9.02 Alpha ACC cylinder lubrication system

Fig. 9.02.05: Suggestion for small heating tank with filter (for engines without
ACOM)
18014452359063435

2023-03-28 - en

8 (8) 95-60ME-GI/-LGI engines

MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas 10 Piston Rod Stuffing Box Drain Oil
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395596683

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

10 Piston Rod Stuffing Box Drain Oil
 MAN Energy Solutions 198 83 45-3.1

Stuffing Box Drain Oil System

For engines running on heavy fuel, it is important that the oil drained from the
piston rod stuffing boxes is not led directly into the system oil, as the oil
drained from the stuffing box is mixed with sludge from the scavenge air
space.
The performance of the piston rod stuffing box on the engines has proved to
be very efficient, primarily because the hardened piston rod allows a higher
scraper ring pressure.
The amount of drain oil from the stuffing boxes is typically about 10 - 15 litres/
24 hours per cylinder during normal service. In the running-in period, it can be
higher. The drain oil is a mixture of system oil from the crankcase, used cylin-
der oil, combustion residues and water from humidity in the scavenge air.
The relatively small amount of drain oil is led to the general oily waste drain
tank or is burnt in the incinerator, Fig. 10.01.01. (Yard’s supply).

10.01 Stuffing Box Drain Oil System

2022-06-16 - en

Fig. 10.01.01: Stuffing box drain oil system

36028848765613451

95-65ME/ME-C/-GI/-LGI/-GA 1 (1)
198 83 45-3.1 MAN Energy Solutions

36028848765613451
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10.01 Stuffing Box Drain Oil System

2022-06-16 - en

95-65ME/ME-C/-GI/-LGI/-GA
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas 11 Low-temperature Cooling Water
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395600267

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

11 Low-temperature Cooling Water
 MAN Energy Solutions 199 03 92-7.4

Low-temperature Cooling Water System

The low-temperature (LT) cooling water system supplies cooling water for the
lubricating oil, jacket water and scavenge air coolers.
The LT cooling water system can be arranged in several configurations like a:
▪ Central cooling water system being the most common system choice and
the basic execution for MAN B&W engines, EoD: 4 45 111
▪ Seawater cooling system being the most simple system and available as
an option: 4 45 110
▪ Combined cooling water system with seawater cooled scavenge air
cooler but freshwater cooled jacket water and lubricating oil cooler, avail-
able as an option: 4 45 117.
Principle diagrams of the above LT cooling water systems are shown in Fig.
11.01.01a, b and c and descriptions are found later in this chapter.
Further information and the latest recommendations concerning cooling water
systems are found in MAN Energy SolutionsService Letters available at
www.marine.man-es.com --> 'Two-Stroke' --> 'Service Letters'.

Chemical Corrosion Inhibition

Various types of inhibitors are available but, generally, only nitrite-borate
based inhibitors are recommended.
Where the inhibitor maker specifies a certain range as normal concentration,
we recommend to maintain the actual concentration in the upper end of that
range.
MAN Energy Solutions recommends keeping a record of all tests to follow the
condition and chemical properties of the cooling water and notice how it de-
velops. It is recommended to record the quality of water as follows:

11.01 Low-temperature Cooling Water System

▪ Once a week:
Take a sample from the circulating water during running, however not
from the expansion tank nor the pipes leading to the tank. Check the con-
dition of the cooling water. Test kits with instructions are normally avail-
able from the inhibitor supplier.
▪ Every third month:
Take a water sample from the system during running, as described above
in ‘Once a week’. Send the sample for laboratory analysis.
▪ Once a year:
Empty, flush and refill the cooling water system. Add the inhibitor. For fur-
ther information please refer to our recommendations for treatment of the
jacket water/ freshwater. The recommendations are available from MAN
2021-06-22 - en

Energy Solutions, Copenhagen.

Cooling System for Main Engines with EGR

For main engines with exhaust gas recirculation (EGR), a central cooling sys-
tem using freshwater as cooling media will be specified.
Further information about cooling water systems for main engines with EGR is
available from MAN Energy Solutions, Copenhegan.

Engines dot 5 and higher 1 (2)

199 03 92-7.4 MAN Energy Solutions

Fig. 11.01.01a: Principle diagram of central cooling water system

Fig. 11.01.01b: Principle diagram of seawater cooling system

11.01 Low-temperature Cooling Water System

Sea water
Central cooling Freshwater
Jacket pumps
water
cooler

Aux. Central
equipment cooler

Scav. air Lubr. oil

cooler cooler
Set point:
10-36°C
2021-06-22 - en

Tin ≥ 0 °C
Sea water pumps

568 25 97-1.0.1c

Fig. 11.01.01c: Principle diagram of combined cooling water system

51991246731

2 (2) Engines dot 5 and higher

 MAN Energy Solutions 199 05 50-9.2

Central cooling water system

The central cooling water system is characterized by having only one heat ex-
changer cooled by seawater. The other coolers, including the jacket water
cooler, are then cooled by central cooling water.

Cooling water temperature

To achieve an optimal engine performance regarding fuel oil consumption and
cylinder condition, it is important to ensure the lowest possible cooling water
inlet temperature at the scavenge air cooler.
MAN Energy Solutions therefore recommends or requires (depending on the
engine type) that the temperature control valve in the central cooling water cir-
cuit is to be set to minimum 10°C. Alternatively, if flow control of the seawater
pumps is used, the setpoint is to be approximately 4°C above the seawater
temperature but not lower than a temperature of 10°C.
In this way, the temperature follows the outboard seawater temperature when
the central cooling water temperature exceeds 10°C, see note 1 in
Fig. 11.02.01.

Standard, recommended setpoint: 10°C

ME-GA engine type, required setpoint: 10°C
EGR and EcoEGR, required setpoint: 10°C

11.02 Central cooling water system

2023-11-08 - en

Fig. 11.02.01: Central cooling water system

All engines 1 (2)

199 05 50-9.2 MAN Energy Solutions

Cooling water pump capacities

The pump capacities listed by MAN Energy Solutions cover the requirement of
the main engine only.
For any given plant, the specific capacities have to be determined according
to the actual plant specification and the number of auxiliary equipment. Such
equipment include GenSets, starting air compressors, provision compressors,
airconditioning compressors, etc.
A guideline for selecting centrifugal pumps is given in Section 6.04.

Cooling water piping

Orifices (or lockable adjustable valves for instance) must be installed in order
to create:
▪ the proper distribution of flow between each of the central cooling water
consumers, see note 2)
▪ a differential pressure identical to that of the central cooler at nominal
central cooling water pump capacity, see note 3).
References are made to Fig. 11.02.01.
For external pipe connections, we prescribe the following maximum water ve-
locities:

Central cooling water 3.0 m/s

Seawater 3.0 m/s

Expansion tank volume

The expansion tank must be designed as open to atmosphere. Venting pipes
entering the tank must terminate below the lowest possible water level, i.e.
below the low-level alarm.
The expansion tank volume has to be 10% of the total central cooling water
amount in the system.
11.02 Central cooling water system

The 10% expansion tank volume is defined as the volume between the lowest
level (at the low-level alarm sensor) and the overflow pipe or high-level alarm
sensor.
If the pipe system is designed with possible air pockets, these have to be ven-
ted to the expansion tank.
9007251246027403
2023-11-08 - en

2 (2) All engines

 MAN Energy Solutions 199 03 97-6.1

Components for central cooling water system

Seawater cooling pumps

The pumps are to be of the centrifugal type.

Seawater flow see CEAS application

Pump head 2.0 bar
Test pressure according to class rules
Working temperature, normal 0-32°C
Working temperature maximum 50°C

The flow capacity must be within a range from 100 to 110% of the capacity
stated.
The pump head of the pumps is to be determined based on the total actual
pressure drop across the seawater cooling water system.
A guideline for selecting centrifugal pumps is given in Section 6.04.

Central cooler
The cooler is to be of the shell and tube, or plate heat exchanger type, made
of seawater resistant material.

Heat dissipation see CEAS application

11.03 Components for central cooling water system

Central cooling water flow see CEAS application
Central cooling water temperature, outlet 36°C
Pressure drop on central cooling side max. 0.7 bar
Seawater flow see CEAS application
Seawater temperature, inlet 32°C
Pressure drop on seawater side maximum 1.0 bar

The pressure drop may be larger, depending on the actual cooler design.
The heat dissipation and the seawater flow figures are based on MCR output
at tropical conditions, i.e. a seawater temperature of 32°C and an ambient air
temperature of 45°C.
Overload running at tropical conditions will slightly increase the temperature
level in the cooling system, and will also slightly influence the engine perform-
2023-11-08 - en

ance.

Central cooling water pumps

The pumps are to be of the centrifugal type.

Central cooling water flow see CEAS application

Pump head 2.5 bar
Delivery pressure depends on location of expansion tank
Test pressure according to Class rules

All engines 1 (3)

199 03 97-6.1 MAN Energy Solutions

Working temperature 80°C

Design temperature 100°C

The flow capacity must be within a range from 100 to 110% of the capacity
stated.
The CEAS application covers the main engine only. The pump head of the
pumps is to be determined based on the total actual pressure drop across
the central cooling water system.
A guideline for selecting centrifugal pumps is given in Section 6.04.

Central cooling water thermostatic valve

The low temperature cooling system is to be equipped with a three-‹way
valve, mounted as a mixing valve, which bypasses all or part of the freshwater
around the central cooler.
The sensor is to be located at the outlet pipe from the thermostatic valve.

Lubricating oil cooler thermostatic valve

The lubricating oil cooler is to be equipped with a three-way valve, mounted
as a mixing valve, which bypasses all or part of the freshwater around the lub-
ricating cooler.
The sensor is to be located at the lubricating oil outlet pipe from the lubricat-
ing oil cooler and is set to keep a lubricating oil temperature of 45°C.
11.03 Components for central cooling water system

Chemical corrosion inhibitor and dosing tank

In order to properly mix the inhibitor into the central cooling water system cir-
cuit, the tank must be designed to receive a small flow of jacket cooling water
through the tank from the jacket water pumps. The tank must be suitable for
mixing inhibitors on both powder and liquid form.

Recommended tank size 0.3 m3

Design pressure max. central cooling water system pressure
Suggested inlet orifice size ø10 mm

Lubricating oil cooler

See Chapter 8 ‘Lubricating oil’.
2023-11-08 - en

Jacket water cooler

See Chapter 12 ‘High-temperature cooling water’.

2 (3) All engines

 MAN Energy Solutions 199 03 97-6.1

Scavenge air cooler

The scavenge air cooler is an integrated part of the main engine.

Heat dissipation see CEAS application

Central cooling water flow see CEAS application
Central cooling water temperature, inlet 36°C
Pressure drop on low-temperature freshwater side 0.3-0.8 bar

Cooling water pipes for scavenge air cooler

Diagrams of cooling water pipes for the scavenge air cooler are shown in
Fig. 11.08.01.
9007251246046603

11.03 Components for central cooling water system

2023-11-08 - en

All engines 3 (3)

199 03 97-6.1 MAN Energy Solutions

9007251246046603
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11.03 Components for central cooling water system

2023-11-08 - en

All engines
 MAN Energy Solutions 199 03 98-8.2

Seawater Cooling System

The seawater cooling system is an option for cooling the main engine lubricat-
ing oil cooler, the jacket water cooler and the scavenge air cooler by seawa-
ter, see Fig. 11.04.01. The seawater system consists of pumps and a thermo-
static valve.

Cooling Water Temperature

The capacity of the seawater pump is based on the outlet temperature of the
seawater being maximum 50°C after passing through the main engine lubric-
ating oil cooler, the jacket water cooler and the scavenge air cooler.
With an inlet temperature of maximum 32°C (tropical conditions), the max-
imum temperature increase is 18°C.
In order to prevent the lubricating oil from stiffening during cold services, a
thermostatic valve is to be installed. The thermostatic valve recirculates all or
part of the seawater to the suction side of the pumps. A set point of 10°C en-
sures that the cooling water to the cooling consumers will never fall below this
temperature, see note 1 in Fig. 11.04.01.

11.04 Seawater Cooling System

2021-06-22 - en

Fig. 11.04.01: Seawater cooling system

Cooling Water Pump Capacities

The pump capacities listed by MAN Energy Solutions cover the requirement
for the main engine only.

Engines dot 5 and higher 1 (2)

199 03 98-8.2 MAN Energy Solutions

For any given plant, the specific capacities have to be determined according
to the actual plant specification and the number of auxiliary equipment. Such
equipment include GenSets, starting air compressors, provision compressors,
airconditioning compressors, etc.
A guideline for selecting centrifugal pumps is given in Section 6.04.

Cooling Water Piping

In order to create the proper distribution of flow between each of the cooling
water consumers, orifices (or lockable adjustable valves for instance) must be
installed, see note 2) in Fig. 11.04.01.
For external pipe connections, we prescribe the following maximum water ve-
locities:
Seawater .....................................................3.0 m/s
If the pipe system is designed with possible air pockets, these have to be ven-
ted to the expansion tank.
51991401355
11.04 Seawater Cooling System

2021-06-22 - en

2 (2) Engines dot 5 and higher

 MAN Energy Solutions 199 04 00-1.1

Components for Seawater Cooling System

Seawater Cooling Pumps

The pumps are to be of the centrifugal type.
Seawater flow .....................see ‘List of Capacities’
Pump head ...................................................2.5 bar
Test pressure ......................according to class rule
Working temperature ....................maximum 50°C
The flow capacity must be within a range from 100 to 110% of the capacity
stated.
The pump head of the pumps is to be determined based on the total actual
pressure drop across the seawater cooling water system.
A guideline for selecting centrifugal pumps is given in Section 6.04.

Seawater Thermostatic Valve

The temperature control valve is a three-way mixing valve. The sensor is to be
located at the seawater inlet to the lubricating oil cooler, and the temperature
set point must be +10 °C.
Seawater flow .....................see ‘List of Capacities’
Temperature set point ..................................+10°C

Lubricating Oil Cooler

See Chapter 8 ‘Lubricating Oil’.

11.05 Components for Seawater Cooling System

Jacket Water Cooler
See Chapter 12 ‘High-temperature Cooling Water’.

Scavenge Air Cooler

The scavenge air cooler is an integrated part of the main engine.
Heat dissipation .................see ‘List of Capacities’
Seawater flow ....................see ‘List of Capacities’
Seawater temperature, for seawater cooling inlet, max..................32°C
Pressure drop on cooling water side .... 0.3-0.8 bar
The heat dissipation and the seawater flow are based on an MCR output at
2021-06-22 - en

tropical conditions, i.e. seawater temperature of 32°C and an ambient air tem-
perature of 45°C.

Cooling Water Pipes for Air Cooler

Diagrams of cooling water pipes for scavenge air cooler are shown in Figs.
11.08.01.
51991404555

Engines dot 5 and higher 1 (1)

199 04 00-1.1 MAN Energy Solutions

51991404555
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11.05 Components for Seawater Cooling System

2021-06-22 - en

Engines dot 5 and higher

 MAN Energy Solutions 199 04 71-8.2

Combined Cooling Water System

The combined cooling water system is characterized by having one heat ex-
changer and the scavenge air cooler cooled by seawater. The other coolers,
including the jacket water cooler, are then cooled by central cooling water.
In this system, the cooling water to the scavenge air cooler will always be ap-
prox. 4°C lower than in a central cooling water system.

Cooling Water Temperature

The capacity of the seawater pumps, central cooler pumps are based on the
outlet temperature of the freshwater being maximum 54°C after passing
through the main engine lubricating oil cooler.
With an inlet temperature of maximum 36°C (tropical conditions), the max-
imum temperature increase is 18°C.
The temperature control valve in the central cooling water circuit can be set to
minimum 10°C and maximum 36°C, see note 1 in Fig. 11.06.01.
Freshwater Fresh water
filling Seawater
*) Lubrication oil
*) Internal piping
Level Expansion LAH
Control line
indicator tank LAL
*) Optional installation

5) TI TI
2) 2)
NC 1)
Set point
10°C 36°C Lubricating TI
Central *3) oil cooler
TE 8423 I AH
cooler Set TI
Filling P AS
point
ø10 45°C
*)
Inhibitor N
PI TI
PI TI PI TI PI TI dosing
tank TE 8422 I AH
Various Various
4) Central auxiliary auxiliary PT 8421 I AH AL
Drain Jacket
Seawater cooling equipment equipment water TI Main engine
pumps water cooler
pumps
Cooling water

11.06 Combined Cooling Water System

PI drain air cooler
High sea
chest
Seawater Sample
inlet
Drain
Seawater
inlet
Low sea chest

*) optional installation
The letters refer to list of ‘Counterflanges’
The item no. refer to ‘Guidance Values Automation’
2023-01-04 - en

079 95 03-6.0.0

Fig. 11.06.01: Combined cooling water system

Alternatively, in case flow control of the seawater pumps is applied, the set
point is to be approximately 4°C above the seawater temperature but not
lower than 10°C.
In order to avoid seawater temperatures below 0°C at the scavenge air cooler
inlet, a manual by-pass valve is installed in the seawater circuit, see note 5) in
Fig. 11.06.01. The valve recirculates all or part of the seawater to the suction
side of the pumps.

Engines dot 5 and higher 1 (2)

199 04 71-8.2 MAN Energy Solutions

Cooling Water Pump Capacities

The pump capacities listed by MAN Energy Solutions cover the requirement
for the main engine only.
For any given plant, the specific capacities have to be determined according
to the actual plant specification and the number of auxiliary equipment. Such
equipment include GenSets, starting air compressors, provision compressors,
airconditioning compressors, etc.
In fig. 11.06.01, note 4 both seawater pumps for main engine scavenge air
cooler and for central cooling water system are shown. Alternative common
seawater pumps serving both systems can be installed.
A guideline for selecting centrifugal pumps is given in Section 6.04.

Cooling Water Piping

Orifices (or lockable adjustable valves for instance) must be installed in order
to create:
▪ the proper distribution of flow between each of the central cooling water
consumers, see note 2)
▪ a differential pressure identical to that of the central cooler at nominal
central cooling water pump capacity, see note 3).
References are made to Fig. 11.08.01.
For external pipe connections, we prescribe the following maximum water ve-
locities:
Central cooling water ..................................3.0 m/s
Seawater .....................................................3.0 m/s

Expansion Tank Volume

The expansion tank shall be designed as open to atmosphere. Venting pipes
entering the tank shall terminate below the lowest possible water level i.e. be-
11.06 Combined Cooling Water System

low the low level alarm.

The expansion tank volume has to be 10% of the total central cooling water
amount in the system. The 10% expansion tank volume is defined as the
volume between the lowest level (at the low level alarm sensor) and the over-
flow pipe or high level alarm sensor.
If the pipe system is designed with possible air pockets, these have to be ven-
ted to the expansion tank.
9007251246249227
2023-01-04 - en

2 (2) Engines dot 5 and higher

 MAN Energy Solutions 199 04 73-1.1

Components for Combined Cooling Water System

Seawater Cooling Pumps

The pumps are to be of the centrifugal type.
Seawater flow .....................see ‘List of Capacities’
Pump head ...................................................2.0 bar
Test pressure ....................according to Class rules
Working temperature, normal .....................0‰32°C
Working temperature ....................maximum 50°C
The flow capacity must be within a range from 100 to 110% of the capacity
stated.
The pump head of the pumps is to be determined based on the total actual
pressure drop across the seawater cooling water system.
A guideline for selecting centrifugal pumps is given in Section 6.04.

Central Cooler
The cooler is to be of the shell and tube or plate heat exchanger type, made
of seawater resistant material.
Heat dissipation .................see ‘List of Capacities’
Central cooling water flow .. see ‘List of Capacities’
Central cooling water temperature, outlet .......36°C

11.07 Components for Combined Cooling Water System

Pressure drop on
central cooling side ........................max. 0.7 bar
Seawater flow .....................see ‘List of Capacities’
Seawater temperature, inlet ...........................32°C
Pressure drop on
seawater side ..........................maximum 1.0 bar
The pressure drop may be larger, depending on the actual cooler design.
The heat dissipation and the seawater flow figures are based on MCR output
at tropical conditions, i.e. a seawater temperature of 32°C and an ambient air
temperature of 45°C.
Overload running at tropical conditions will slightly increase the temperature
level in the cooling system, and will also slightly influence the engine perform-
ance.

Central Cooling Water Pumps

2021-08-13 - en

The pumps are to be of the centrifugal type.

Central cooling water
flow ................................see ‘List of Capacities’
Pump head ...................................................2.5 bar
Delivery pressure ...............depends on location of expansion tank
Test pressure ....................according to Class rules
Working temperature .....................................80°C
Design temperature ......................................100°C
The flow capacity must be within a range from 100 to 110% of the capacity
stated.

Engines dot 5 and higher 1 (2)

199 04 73-1.1 MAN Energy Solutions

The ‘List of Capacities’ covers the main engine only. The pump head of the
pumps is to be determined based on the total actual pressure drop across
the central cooling water system.
A guideline for selecting centrifugal pumps is given in Section 6.04.

Central Cooling Water Thermostatic Valve

The low temperature cooling system is to be equipped with a three‰-way
valve, mounted as a mixing valve, which bypasses all or part of the freshwater
around the central cooler.
The sensor is to be located at the outlet pipe from the thermostatic valve and
is set to keep a temperature of minimum 10 °C and maximum 36°C.

Lubricating Oil Cooler Thermostatic Valve

The lubricating oil cooler is to be equipped with a three-way valve, mounted
as a mixing valve, which bypasses all or part of the freshwater around the lub-
ricating cooler.
The sensor is to be located at the lubricating oil outlet pipe from the lubricat-
ing oil cooler and is set to keep a lubricating oil temperature of 45°C.

Chemical Corrosion Inhibitor and Dosing Tank

In order to properly mix the inhibitor into the combined cooling water system
11.07 Components for Combined Cooling Water System

circuit, the tank shall be designed to receive a small flow of jacket cooling wa-
ter through the tank from the jacket water pumps. The tank shall be suitable
for mixing inhibitors in form of both powder and liquid.
Recommended tank size ..............................0.3 m3
Design pressure ......max. combined cooling water system pressure
Suggested inlet orifice size ........................ø10 mm

Lubricating Oil Cooler

See Chapter 8 ‘Lubricating Oil’.

Jacket Water Cooler

See Chapter 12 ‘High-temperature Cooling Water’.

Scavange Air Cooler

2021-08-13 - en

The scavenge air cooler is an integrated part of the main engine.

Heat dissipation .................see ‘List of Capacities’
Seawater flow .....................see ‘List of Capacities’
Central cooling temperature, inlet ..................32°C
Pressure drop on seawater side ........... 0.3-0.8 bar

Cooling Water Pipes for Air Cooler

Diagrams of cooling water pipes for scavenge air cooler are shown in Figs.
11.08.01.
51991652875

2 (2) Engines dot 5 and higher

 MAN Energy Solutions 199 04 01-3.4

Cooling Water Pipes for Scavenge Air Cooler

Fig. 11.08.01a: Cooling water pipes for engines with two or more turbochar-
gers

11.08 Cooling Water Pipes for Scavenge Air Cooler

2022-08-09 - en

Fig. 11.08.01b: Cooling water pipes with waste heat recovery for engines with
two or more turbochargers
9007251246252427

G95ME-C10/-GI/-LGI, S90ME-C10/-GI/-LGI, G80ME-C9/-GI/-LGI, G70ME-

C10/9/-GI/-GA/-LGI, S70ME-C10/8/-GI/-LGI, S65ME-C8/-GI/LGI, G60ME-C9/-
GI/-LGI, S60ME-C8/-GI/-LGI 1 (1)
199 04 01-3.4 MAN Energy Solutions

9007251246252427
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11.08 Cooling Water Pipes for Scavenge Air Cooler

2022-08-09 - en

G95ME-C10/-GI/-LGI, S90ME-C10/-GI/-LGI, G80ME-C9/-GI/-LGI, G70ME-

C10/9/-GI/-GA/-LGI, S70ME-C10/8/-GI/-LGI, S65ME-C8/-GI/LGI, G60ME-C9/-
GI/-LGI, S60ME-C8/-GI/-LGI
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas 12 High-temperature Cooling Water
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395608971

1 (1)
 MAN Energy Solutions

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12 High-temperature Cooling Water
 MAN Energy Solutions 199 17 29-1.0

High-temperature cooling water system

The high-temperature (HT) cooling water system, also known as the jacket
cooling water (JCW) system, is used for cooling the cylinder unit components
of the main engine and heating of the fuel oil drain pipes, see Fig. 12.01.01 to
12.01.04.
The jacket water pump draws water from the jacket water cooler outlet
through a deaerating tank, and delivers it to the engine.
A thermostatically controlled regulating valve is located at the inlet, or alternat-
ively at the outlet from the cooler. The regulating valve keeps the main engine
cooling water outlet at a fixed temperature level, independent of the engine
load.
A deaerating tank alarm device is installed between the deaerating tank and
the expansion tank. The purpose of the alarm device is to sound an alarm if a
large amount of gas is detected in the JCW circuit, for example caused by a
cylinder liner rupture.
An expansion tank is installed to create a sufficient static pressure in the JCW
system and to provide space for the water to expand and contract. The ex-
pansion tank must be placed at least 15 m above the top of the main engine
exhaust gas valves.
The engine jacket water must be carefully treated, maintained and monitored
to avoid corrosion, corrosion fatigue, cavitation and scale formation. There-
fore, it is recommended installing a chemical corrosion inhibitor dosing tank
and a means to take water samples from the JCW system.

Chemical corrosion inhibition

Various types of inhibitors are available but, generally, only nitrite-borate
based inhibitors are recommended.

12.01 High-temperature cooling water system

Where the inhibitor maker specifies the normal concentration as a specific
range, MAN Energy Solutions recommends maintaining the actual concentra-
tion in the upper end of that range.
MAN Energy Solutions recommends keeping a record of all tests to follow the
condition and chemical properties of the cooling water, and notice how it de-
velops. It is recommended recording the quality of water as follows:
▪ Once a week:
Take a sample from the circulating water during running, however, not
from the expansion tank or the pipes leading to the tank. Check the con-
dition of the cooling water. Test kits with instructions are normally avail-
able from the inhibitor supplier.
2023-04-21 - en

▪ Every third month:

Take a water sample from the system during running, as described above
in "Once a week". Send the sample for laboratory analysis.
▪ Once a year:
Empty, flush and refill the cooling water system. Add the inhibitor.
For further information, refer to our recommendations for treatment of the
jacket water/freshwater. The recommendations are available from MAN En-
ergy Solutions, Copenhagen.

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199 17 29-1.0 MAN Energy Solutions

Cooling water drain for maintenance

For maintenance of the main engine, a drain arrangement is installed at the
engine. By this drain arrangement, the jacket cooling water can be drained to,
for example, a freshwater drain tank for possible reuse of the chemical corro-
sion inhibitor-treated water.

Preheater system
During short stays in port (that is, less than 4-5 days), it is recommended that
the engine is kept preheated. The purpose is to prevent temperature vari-
ations in the engine structure and corresponding variations in thermal expan-
sion and possible leakages.
The jacket cooling water outlet temperature should be kept as high as pos-
sible and should (before starting up) be increased to at least 50°C. Preheating
could be provided by a built-in preheater in the jacket cooling water system,
by means of cooling water from the auxiliary engines, or a combination of the
two.
Preheating procedure
To protect the engine and to avoid corrosive attacks on the cylinder liners dur-
ing starting, minimum temperature restrictions must be considered before
starting the engine.
Normal engine start, fixed pitch propeller
A minimum engine jacket water temperature of 50°C is recommended before
starting the engine and gradually running it up to 80-90% SMCR speed
(SMCR rpm) during a 30 minute period.
To run up the engine to 90-100% SMCR rpm, it is recommended increasing
12.01 High-temperature cooling water system

the speed slowly during a period of 60 minutes.

Start of cold engine, fixed pitch propeller
In exceptional circumstances where it is not possible to comply with the
above recommendation, a minimum temperature of 20°C can be accepted
before the engine is started and slowly run up to 80% SMCR rpm.
Before exceeding 80% SMCR rpm, a minimum jacket water temperature of
50°C should be obtained before the above described normal load-up proced-
ure for starting the engine can be continued.
Note:
The above considerations for starting a cold engine are based on the as-
sumption that the engine has already been well run in.
2023-04-21 - en

For further information, see our publication:

Influence of Ambient Temperature Conditions

Freshwater generator
A freshwater generator can be installed in the JCW circuit for utilising the heat
radiated to the jacket cooling water from the main engine.

2 (11) All engines

 MAN Energy Solutions 199 17 29-1.0

Jacket cooling water piping - ME/-LGI engines (fuel sulphur content <= 0.5%)

12.01 High-temperature cooling water system

Fig. 12.01.01: Jacket cooling water system for ME/-LGI engines (fuel sulphur
content <=0.5%)

Notes:
1. Orifices (or lockable adjustable valves) to be installed to create a differen-
tial pressure identical to that of the jacket water cooler/freshwater gener-
ator at nominal jacket water pump capacity.
2. (Optional) Install orifices to create a minimum inlet pressure at engine inlet
2023-04-21 - en

connection "K" (at sensor PT 8401) which is higher than the minimum
pressure stated in "Guidance Values Automation" (GVA).
3. Flow restriction: Install an orifice with a small hole to avoid jacket water
flow through the expansion tank.
4. Temperature setpoint for thermostatic regulating valves
Thermostatic regulating valve for jacket water cooler: Setpoint: 87°C if a
thermostatic regulating valve is installed for the freshwater generator, oth-
erwise 85°C.
Thermostatic regulating valve for freshwater generator cooler: Setpoint:
83°C.

All engines 3 (11)

199 17 29-1.0 MAN Energy Solutions

5. IEC Ex proof equipment classification

Sensor type: Type according to applicable classification society require-
ment.
6. Deaeration of cooling water manifold of exhaust gas valve
Engine connection M: Venting pipe has to be arranged in fore or aft end
of the cooling water manifold discharge pipe from the exhaust gas valve
(opposite end of discharge to jacket water pump). An automatic deaerat-
ing valve located at the engine for expansion tank design option A can re-
place the vent pipe.
The letters refer to list of "Counterflanges"
For external pipe connections, we prescribe the following maximum water ve-
locity:
Jacket cooling water ................................... 3.0 m/s
12.01 High-temperature cooling water system

2023-04-21 - en

4 (11) All engines

 MAN Energy Solutions 199 17 29-1.0

Jacket cooling water piping - ME/-LGI engines (fuel sulphur content >0.5%)

12.01 High-temperature cooling water system

Fig. 12.01.02: Jacket cooling water system for ME/-LGI engines (fuel sulphur
content >0.5%)

Notes:
1. Orifices (or lockable adjustable valves) to be installed to create a differen-
tial pressure identical to that of the jacket water cooler/freshwater gener-
ator at nominal jacket water pump capacity.
2. (Optional) Install orifices to create a minimum inlet pressure at engine inlet
connection "K" (at sensor PT 8401) which is higher than the minimum
2023-04-21 - en

pressure stated in "Guidance Values Automation" (GVA).

3. Flow restriction: Install an orifice with a small hole to avoid jacket water
flow through the expansion tank.
4. IEC Ex proof equipment classification
Sensor type: Type according to applicable classification society require-
ment.
5. Deaeration of cooling water manifold of exhaust gas valve
Engine connection M: Venting pipe has to be arranged in fore or aft end
of the cooling water manifold discharge pipe from the exhaust gas valves

All engines 5 (11)

199 17 29-1.0 MAN Energy Solutions

(opposite end of discharge to jacket water pump). An automatic deaerat-

ing valve located at the engine for expansion tank design option A can re-
place the vent pipe.
The letters refer to list of "Counterflanges"
For external pipe connections, we prescribe the following maximum water ve-
locity:
Jacket cooling water ................................... 3.0 m/s
12.01 High-temperature cooling water system

2023-04-21 - en

6 (11) All engines

 MAN Energy Solutions 199 17 29-1.0

Jacket cooling water piping - ME-GI engines

12.01 High-temperature cooling water system

Fig. 12.01.03: Jacket cooling water system for ME-GI engines

Notes:
1. (Optional) Orifices (or lockable adjustable valves) to be installed to create
a differential pressure identical to that of the jacket water cooler/freshwa-
2023-04-21 - en

ter generator at nominal jacket water pump capacity.

2. (Optional) Install orifices to create a minimum inlet pressure at engine inlet
connection "K" (at sensor PT 8401), which is higher than the minimum
pressure stated in "Guidance Values Automation" (GVA).
3. Flow restriction: Install an orifice with a small hole to avoid jacket water
flow through the expansion tank.
4. Temperature setpoint for thermostatic regulating valves
Thermostatic regulating valve for jacket water cooler: Setpoint: 87°C if a
thermostatic regulating valve is installed for freshwater generator, other-

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199 17 29-1.0 MAN Energy Solutions

wise 85°C.
Thermostatic regulating valve for freshwater generator cooler: Setpoint:
83°C.
5. IEC Ex proof equipment classification
Sensor type: Type according to applicable classification society require-
ment.
6. Deaeration of cooling water manifold of exhaust gas valve
Engine connection M: Venting pipe has to be arranged in fore or aft end
of cooling water manifold discharge pipe from the exhaust gas valve (op-
posite end of discharge to jacket water pump). An automatic deaerating
valve located at the engine for expansion tank design option A can re-
place the vent pipe..
The letters refer to list of "Counterflanges"
For external pipe connections, we prescribe the following maximum water ve-
locity:
Jacket cooling water ................................... 3.0 m/s
12.01 High-temperature cooling water system

2023-04-21 - en

8 (11) All engines

 MAN Energy Solutions 199 17 29-1.0

Jacket cooling water piping - ME-GA engines

12.01 High-temperature cooling water system

Fig. 12.01.04: Jacket cooling water system for ME-GA engines

Notes:
1. Orifices (or lockable adjustable valves) to be installed to create a differen-
tial pressure identical to that of the jacket water cooler / freshwater gen-
erator at nominal jacket water pump capacity.
2. (Optional) Install orifices to create a minimum inlet pressure at engine inlet
connection "K" (at sensor PT 8401), which is higher than the minimum
pressure stated in "Guidance Values Automation" (GVA).
2023-04-21 - en

3. Flow restriction: Install an orifice with a small hole to avoid jacket water
flow through the expansion tank.
4. Temperature setpoint
Thermostatic regulating valve for jacket water cooler: Setpoint: 87°C if a
thermostatic regulating valve is installed for the freshwater generator, oth-
erwise 85°C.
Freshwater generating cooler thermostatic regulation valve: Setpoint:
83°C.
5. IEC Ex proof equipment classification
Sensor type: IECEx approved

All engines 9 (11)

199 17 29-1.0 MAN Energy Solutions

6. Vent pipe routing inclination

Vent pipes has to be routed steadily ascending so possible air in the sys-
tem easily can escape according to the vessel static longitudinal and
transverse inclination. In general a longitudinal inclination shall be taken
as min. 5° (might be smaller based on length of vessel and applicable
classification society rules) and a transverse inclination shall be taken as
min. 15°.
The letters refer to list of "Counterflanges"
For external pipe connections, we prescribe the following maximum water ve-
locity:
Jacket cooling water ................................... 3.0 m/s
12.01 High-temperature cooling water system

2023-04-21 - en

10 (11) All engines

 MAN Energy Solutions 199 17 29-1.0
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12.01 High-temperature cooling water system

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All engines 11 (11)

199 17 29-1.0 MAN Energy Solutions

9007255891909387
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12.01 High-temperature cooling water system

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All engines
 MAN Energy Solutions 199 15 77-9.0

Components

Jacket water cooling pump

The pumps should be of the centrifugal type.

Pump flow rate/jacket water flow see ‘List of capacities’

Pump head (see below note) 3.0 bar
Delivery pressure depends on the location of the expansion
tank
Test pressure according to Class rules
Working temperature 85°C
Max. temperature (design purpose) 100°C

The flow capacity must be within the range from 100 to 110% of the capacity
stated.
The pump head of the pumps should be determined based on the actual total
pressure drop across the cooling water system, i.e. the pressure drop across
main engine, jacket water cooler, three-way valve, valves, and other pipe
components.
Section 6.04 contains a guideline for selecting centrifugal pumps.

Jacket water cooler

Often the jacket water cooler is of the plate heat exchanger type, but it could
also be of the shell and tube type.

Heat dissipation see ‘List of capacities’

Jacket water flow see ‘List of capacities’
Jacket water temperature, inlet 85°C
Max. working temperature up to 100°C
Max. pressure drop on jacket water side 0.5 bar

Cooling water flow see ‘List of capacities’

Cooling water inlet temp., SW cooled ~38°C
Cooling water inlet temp., FW cooled ~43°C
Max. pressure drop on cooling side 0.5 bar
2023-06-01 - en

The following materials should be used for the cooler:

12.02 Components

Seawater cooled SW resistant (for example, titanium or

copper alloy for tube coolers)
Freshwater cooled stainless steel

The heat dissipation and flow are based on SMCR output at tropical condi-
tions, i.e. a seawater temperature of 32°C and an ambient air temperature of
45°C.

70-50 engines 1 (7)

199 15 77-9.0 MAN Energy Solutions

Jacket water thermostatic regulating valve

The main engine cooling water outlet temperature should be kept at a fixed
temperature of 85°C, independent of the engine load. This is done by a three-
way thermostatic regulating valve.
The controller of the thermostatically controlled regulating valve must be able
to receive a remote, variable set-point given by the main engine control sys-
tem (ECS). The variable set-point corresponds to the main engine jacket water
inlet temperature required for keeping the main engine outlet temperature at
the specified 85°C.
The reference measurement temperature sensor must be located after the
water has been mixed, i.e. between the cooler/cooler bypass and the jacket
water pumps as indicated in Fig. 12.01.01.

Jacket water flow see ‘List of capacities’

Max. working temperature up to 100°C
Max. pressure drop ~0.3 bar
Actuator type electric or pneumatic is recommended
Leak rate less than 0.5% of nominal flow

Note:
A low valve leak rate specified for the valve port against the cooler will provide
better utilisation of the heat available for the freshwater production.
Valve controller specification:

Remote set-point signal standard 4-20 mA

Range 0-4 mA = 65°C; 20 mA = 95°C

Expansion tank
The expansion tank must be designed as an open tank towards the atmo-
sphere. Venting pipes entering the tank must terminate below the lowest pos-
sible water level, i.e. below the low-level alarm.
The expansion tank must be located at least 15 m above the top of the main
engine exhaust gas valves.
The expansion tank volume has to be at least 10% of the total jacket cooling
water (JWC) amount in the system.
The 10% expansion tank volume is defined as the volume between the lowest
2023-06-01 - en

level (at the low-level alarm sensor) and the overflow pipe or high-level alarm
sensor.
12.02 Components

De-aerating tank and alarm device

Design and dimensions of the de-aerating tank are shown in Fig. 12.02.01
and the corresponding alarm device is shown in Fig. 12.02.02.

2 (7) 70-50 engines

 MAN Energy Solutions 199 15 77-9.0

Blackout overflow prevention unit (only for ME-GA engines)

The unit prevents the expansion tank from overflowing during a vessel black-
out.

Unit consist of:

Pressure sustain valve (not a safety valve), minimum DN25.
Set-pressures for the pressure sustain valve:
▪ Sustain set-pressure: 2.5 barg, when located in the range of 10-20 meter
above the engine exhaust gas valve.
▪ Sustain set-pressure: 3.5 barg, when located in the range of 1-10 meter
above the engine exhaust gas valve.
Purpose: To keep and maintain a pressure without exceeding the pipe system
design pressure.

Non-return valve, minimum DN25.

Purpose: To allow the water to implode at engine start-up after blackout.

Orifice with a 3 mm hole.

Purpose: To secure that the jacket water system is well vented and free from
air and to allow the water pressure to build up if there has been a blackout
scenario.

Shut-off valve – normally closed, minimum DN25.

Purpose: When filling or emptying water to or from the system, the valve must
be open – otherwise closed.

Chemical corrosion inhibitor and dosing tank

In order to properly mix the inhibitor into the JCW system, the tank must be
designed to receive a small flow of JCW through the tank from the jacket wa-
ter pumps. The tank must be suitable for mixing inhibitors in both powder and
liquid form.

Recommended tank size 0.3 m3

Design pressure max. JCW system pressure
2023-06-01 - en

Suggested inlet orifice size ø10 mm

12.02 Components

Other dosing point options, besides the above dosing tank proposal, are
available. If the following requirements are met, the expansion tank can be
used, for example.
▪ The expansion tank must be designed as an open tank towards the en-
gine room
▪ A continuous small jacket water flow is established through the tank. This
means that there is a pipe connection from the jacket water pump dis-
charge side via the expansion tank to the suction side of the jacket water
pump.

70-50 engines 3 (7)

199 15 77-9.0 MAN Energy Solutions

De-aerating tank

Fig. 12.02.01: De-aerating tank, option: 4 46 640

De-aerating tank dimensions

Tank size 0.05 m3 0.16 m3

Max. jacket water capacity 120 m3/h 300 m3/h

Dimensions in mm
2023-06-01 - en

Max. nominal diameter 125 200

12.02 Components

A 600 800

B 125 210

C 5 5

D 150 150

E 300 500

F 910 1,195

4 (7) 70-50 engines

 MAN Energy Solutions 199 15 77-9.0

G 250 350

øH 300 500

øI 320 520

øJ ND 50 ND 80

øK ND 32 ND 50

ND: Nominal diameter

Working pressure is according to actual piping arrangement.
In order not to impede the rotation of water, the pipe connection must end
flush with the tank, so that no internal edges are protruding.

Fig. 12.02.02: De-aerating tank, and alarm device, option: 4 46 645

Preheater components
When a preheater system is installed like in Fig. 12.01.01, the components
must be specified as follows.
2023-06-01 - en

Preheater pump (Optional)

12.02 Components

The pump should be of the centrifugal type.

Pump flow rate 10% of the JCW flow, see ‘List of capa-
cities’
Working temperature 50-85°C
Pump flow rate 10% of the JCW flow, see ‘List of capa-
cities’
Max. working temperature up to 100°C

70-50 engines 5 (7)

199 15 77-9.0 MAN Energy Solutions

Section 6.04 contains a guideline for selcting centrifugal pumps.

The preheater must be relocated if no preheater pump is installed.

Preheater
Heating flow rate 10% of the JCW flow, see ‘List of capa-
cities’
Heating capacity see the note below *)
Preheater type steam, thermal, oil, or electrical
Working temperature 50-85°C
Max. working temperature up to 100 °C
Max. pressure drop on jacket water side ~0.2 bar

*) The preheater heating capacity depends on the required preheating time

and the required temperature increase of the engine jacket water. Fig.
12.02.03 shows the temperature and time relations. In general, a temperature
increase of about 35°C (from 15°C to 50°C) is required, and a preheating time
of 12 hours requires a preheater capacity of about 1% of the engine NMCR
power.

2023-06-01 - en
12.02 Components

Fig. 12.02.03: Jacket water preheater, example

Freshwater generator installation

If a generator is installed in the ship for production of freshwater by utilising
the heat in the jacket water cooling system, it should be noted that the actual
available heat in the jacket water system is lower than indicated by the heat
dissipation figures in ‘List of capacities‘.

6 (7) 70-50 engines

 MAN Energy Solutions 199 15 77-9.0

The reason is that the latter figure is used for dimensioning the jacket water
cooler and therefore incorporates a safety margin which can be needed when
the engine is operating under conditions such as overload. Normally, this mar-
gin is 10% at SMCR.
The calculation of the heat actually available at SMCR for a derated diesel en-
gine can be made in the CEAS application described in Section 20.02.
A freshwater generator installation is shown in Fig. 12.01.01.

Calculation method
When using a normal freshwater generator of the single-effect vacuum evap-
orator type, the freshwater production (based on the available JCW heat for
design purpose, Qd-jw) can, for guidance, be estimated as 0.03 t/24h/kW heat:
Mfw = 0.03 × Qd-jw t/24h
Where:
Mfw: Freshwater production (tonnes per 24 hours)
Qd-jw = Qjw50% × Tol.-15% (kW)
Where
Qjw50[%]: Jacket water heat at 50% SMCR engine load at ISO condition (kW)
Tol.-15[%]: Minus tolerance of 15% = 0.85
If more heat is utilised than the heat available at 50% SMCR and/or when us-
ing the freshwater generator below 50% engine load, a special temperature
control system must be incorporated. The purpose is to ensure that the JWC
temperature at the outlet from the engine does not fall below a certain level.
Such a temperature control system may consist of a thermostatic three-way
valve as shown in Fig. 12.01.01 or a special built-in temperature control in the
freshwater generator, e.g. an automatic start/stop function, or similar.
If more heat is utilised than the heat available at 50% SMCR, the freshwater
production may for guidance be estimated as:
Mfw = 0.03 × Qd-jw t/24h
Where
Mfw : Freshwater production (tonness per 24 hours)
Qd-jw = QjwNCR × Tol.-15% (kW)
Where
QjwNCR: Jacket water heat at NCR engine load at ISO condition (kW)
Tol.-15%: Minus tolerance of 15% = 0.85
27021650823664139
2023-06-01 - en

12.02 Components

70-50 engines 7 (7)

199 15 77-9.0 MAN Energy Solutions

27021650823664139
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2023-06-01 - en
12.02 Components

70-50 engines
 MAN Energy Solutions 199 09 16-6.0

Jacket Cooling Water Pipes

12.03 Jacket Cooling Water Pipes

2021-07-02 - en

The letters refer to list of ‘Counterflanges’

The item no. refer to ‘Guidance values automation’
Fig.12.03.01: Jacket cooling water pipes
53517480203

G90/70ME-C10.5/.6/-GI/-GA/-LGI, S80-60ME-C10.5/.6/-GI/-LGI 1 (1)

199 09 16-6.0 MAN Energy Solutions

53517480203
This page is intentionally left blank
12.03 Jacket Cooling Water Pipes

2021-07-02 - en

G90/70ME-C10.5/.6/-GI/-GA/-LGI, S80-60ME-C10.5/.6/-GI/-LGI
 MAN Energy Solutions 199 16 08-1.0

Liquid fuel gas vaporisation

A liquid gas vaporising system is normally designed as a closed glycol circula-
tion system. It basically consists of a glycol circulation pump, a glycol heat ex-
changer and a gas vaporiser. The glycol system is considered as part of the
fuel gas supply system.
Most likely the heat available from the jacket water system is used for the
glycol heat exchanger because this energy is free. Other heat options are also
available such as steam and thermal oil.
When utilising the heat in the jacket water cooling system, the following
should be noted:
▪ A backup heat exchanger shall be incorporated in either the glycol system
or the jacket water system when the jacket water heat is used as the main
heat source. The purpose is to ensure that the high-pressure gas temper-
ature will be higher than the minimum required inlet temperature to the en-
gine during operation under very low load and during engine load change
(increasing the engine load)
▪ In the jacket water system showed in Fig. 12.04.01, the backup heat ex-
changer is located in the glycol circuit. Where as in Fig. 12.04.02, the
backup heat exchanger is located in the jacket water system as a pre-
heater/ hot water loop heater.
▪ Utilising both the jacket water heat for gas vaporization and freshwater
production, special attendance has to be made when calculating the
freshwater production. The calculation shall be based on the excess of
heat available after the necessary heat for gas vaporization has been
used.
▪ The actual available heat in the jacket water system is lower than indic-
ated by the heat dissipation figures given in the ‘List of capacities‘. The
reason is that the latter figure is used for dimensioning the jacket water
cooler.

The figure therefore incorporates a safety margin which could be needed

when the engine is operating under conditions such as for instance over-
load. Normally, this margin is 10% at SMCR
▪ The calculation of the heat actually available at SMCR and part loads for a
derated diesel engine can be made in the CEAS application described in
Section 20.02 12.04 Liquid fuel gas vaporisation
2022-01-25 - en

G95-50ME-C10.5/9.6/9.5-GI/-GA/-LGI, S70-50ME-C10.5/9.7/9.5-GI/-GA/-LGI 1 (3)

199 16 08-1.0 MAN Energy Solutions

1) (Optional) Orifices (or lockable adjustable valves) to be installed in order to create a differential pressure indentical
to that of the jacket water cooler / freshwater generator at nominal jacket water pump capacity.
2) (Optional) Orifices (or lockable adjustable valves to be installed in order to create a min. inlet pressure indicated
at sensor PT 8401 above the min. pressure stated in the Guidance Values Automation (GVA) at engine
inlet connection “K” and besides ensuring a correct flow from the jacket water pump.
12.04 Liquid fuel gas vaporisation

3) Orifices with small size hole to be installed for avoiding jacket water flow through the expansion tank.
9007253162553227

Fig. 12.04.01: Gas vaporization by heat from the jacket water – with backup
heat exchanger in the glycol system
2022-01-25 - en

2 (3) G95-50ME-C10.5/9.6/9.5-GI/-GA/-LGI, S70-50ME-C10.5/9.7/9.5-GI/-GA/-LGI

 MAN Energy Solutions 199 16 08-1.0

1) (Optional) Orifices (or lockable adjustable valves) to be installed in order to create a differential pressure indentical
to that of the jacket water cooler / freshwater generator at nominal jacket water pump capacity.
2) (Optional) Orifices (or lockable adjustable valves to be installed in order to create a min. inlet pressure indicated
at sensor PT 8401 above the min. pressure stated in the Guidance Values Automation (GVA) at engine
inlet connection “K” and besides ensuring a correct flow from the jacket water pump.
3) Orifices with small size hole to be installed for avoiding jacket water flow through the expansion tank.
9007253162553227

Fig. 12.04.02: Gas vaporization by heat from the jacket water – with backup
heat exchanger in the jacket water system
9007253162553227

12.04 Liquid fuel gas vaporisation

2022-01-25 - en

G95-50ME-C10.5/9.6/9.5-GI/-GA/-LGI, S70-50ME-C10.5/9.7/9.5-GI/-GA/-LGI 3 (3)

199 16 08-1.0 MAN Energy Solutions

9007253162553227
This page is intentionally left blank
12.04 Liquid fuel gas vaporisation

2022-01-25 - en

G95-50ME-C10.5/9.6/9.5-GI/-GA/-LGI, S70-50ME-C10.5/9.7/9.5-GI/-GA/-LGI
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
13 Starting and Control Air

17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395615115

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

13 Starting and Control Air
 MAN Energy Solutions 198 39 98-0.7

Starting and control air systems

The starting air of 30 bar is supplied by the starting air compressors to the
starting air receivers and from these to the main engine inlet ‘A’.
Through a reduction station, filtered compressed air at 7 bar is supplied to the
control air for exhaust valve air springs, through engine inlet ‘B’
Through a reduction valve, compressed air is supplied at approx. 7 bar to
‘AP’ for turbocharger cleaning (soft blast), and a minor volume used for the
fuel valve testing unit. The specific air pressure required for turbocharger
cleaning is subject to make and type of turbocharger.
Please note that the air consumption for control air, safety air, turbocharger
cleaning, sealing air for exhaust valve, for fuel valve testing unit and venting of
gas pipes are momentary requirements of the consumers.
The components of the starting and control air systems are further described
in Section 13.02.
For information about a common starting air system for main engines and
MAN Energy Solutions auxiliary engines, please refer to our publication:
Uni-concept Auxiliary Systems for Two-Stroke Main Engines and Four-Stroke
Auxiliary Engines
The publication is available at man-es.com/ --> 'Two-Stroke --> 'Technical
Papers'.

13.01 Starting and control air systems

2021-09-30 - en

Fig. 13.01.01: Starting and control air systems

9007250239407115

80-70ME-C 1 (1)
198 39 98-0.7 MAN Energy Solutions

9007250239407115
This page is intentionally left blank
13.01 Starting and control air systems

2021-09-30 - en

80-70ME-C
 MAN Energy Solutions 198 89 73-1.3

Components for Starting Air System

Starting Air Compressors

The starting air compressors are to be of the water-cooled, two-stage type
with intercooling.
More than two compressors may be installed to supply the total capacity
stated.
Air intake quantity:
Reversible engine,
for 12 starts .................... see ‘List of capacities’
Nonreversible engine,
for 6 starts ...................... see ‘List of capacities’
Delivery pressure ........................................ 30 bar

Starting Air Receivers

The volume of the two receivers is:
Reversible engine,
for 12 starts .................... see ‘List of capacities’ *)
Nonreversible engine,
for 6 starts ...................... see ‘List of capacities’ *)
Working pressure ........................................ 30 bar
Test pressure .................... according to class rule
*) The volume stated is at 25°C and 1,000 mbar

Reduction Station for Control and Safety Air

In normal operating, each of the two lines supplies one engine inlet. During
maintenance, three isolating valves in the reduction station allow one of the

13.02 Components for Starting Air System

two lines to be shut down while the other line supplies both engine inlets, see
Fig. 13.01.01.

Reduction.....................from 30-10 bar to 7 bar (Tolerance ± 10%)

Flow rate, free air .............. 2,100 Normal liters/min equal to 0.035 m3/s
Filter, fineness ............................................. 40 μm

Reduction Valve for Turbocharger Cleaning etc

2021-08-11 - en

Reduction............from 30-10 bar to approx. 7 bar *)

*) Subject to make and type of TC (Tolerance ±10%)
Flow rate, free air.............2,600 Normal liters/min equal to 0.043 m3/s

Reduction Valve for Venting Air for Gas Piping

Reduction ........................ from 30-10 bar to 1.5 bar (Tolerance ±10%)
Flow rate, free air ............... 1,000 Normal liters/min equal to 0.015 m3/s

95-60ME-GI/-GA/-LGI 1 (2)
198 89 73-1.3 MAN Energy Solutions

The consumption of compressed air for control air, exhaust valve air springs
and safety air as well as air for turbocharger cleaning, fuel valve testing and
venting of gas piping is covered by the capacities stated for air receivers and
compressors in the list of capacities.

Starting and Control Air Pipes

The piping delivered with and fitted onto the main engine is shown in the fol-
lowing figures in Section 13.03:
Fig. 13.03.01 Starting air pipes
Fig. 13.03.02 Air spring pipes, exhaust valves

Turning Gear
The turning wheel has cylindrical teeth and is fitted to the thrust shaft. The
turning wheel is driven by a pinion on the terminal shaft of the turning gear,
which is mounted on the bedplate.
Engagement and disengagement of the turning gear is effected by displacing
the pinion and terminal shaft axially. To prevent the main engine from starting
when the turning gear is engaged, the turning gear is equipped with a safety
arrangement which interlocks with the starting air system.
The turning gear is driven by an electric motor with a built-in gear and brake.
Key specifications of the electric motor and brake are stated in Section 13.04.
54216585355
13.02 Components for Starting Air System

2021-08-11 - en

2 (2) 95-60ME-GI/-GA/-LGI
 MAN Energy Solutions 199 15 14-5.0

Piping
The starting air pipes, Fig. 13.03.01, contain a main starting valve (a ball valve
with actuator), a nonreturn valve, a solenoid valve and a starting valve. The
main starting valve is controlled by the Engine Control System. Slow turning
before start of engine, EoD: 4 50 141, is included in the basic design.
The Engine Control System regulates the supply of control air to the starting
valves in accordance with the correct firing sequence and the timing.
Please note that the air consumption for control air, turbocharger cleaning and
for fuel valve testing unit are momentary requirements of the consumers. The
capacities stated for the air receivers and compressors in the ‘List of Capacit-
ies’ cover all the main engine requirements and starting of the auxiliary en-
gines.
For information about a common starting air system for main engines and
auxiliary engines, please refer to our publication:
Uni-concept Auxiliary Systems for Two-Stroke Main Engines and Four-Stroke
Auxiliary Engines
The publication is available at man-es.com/marine --> 'Two-Stroke' -->
'Technical Papers'.

Fig. 13.03.01: Starting air pipes

Exhaust Valve Air Spring Pipes

The exhaust valve is opened hydraulically by the Proportional Exhaust Valve
Actuator (PEVA) valve, which is activated by the Engine Control System.
2022-01-24 - en

The closing force is provided by an ‘air spring’ which leaves the valve spindle
free to rotate.
The compressed air is taken from the control air supply, see Fig. 13.03.02.
13.03 Piping

95-60ME-C/-GI/-GA/-LGI 1 (2)
199 15 14-5.0 MAN Energy Solutions

The item nos. refer to ‘Guidance values automation’

The piping is delivered with and fitted onto the engine
Fig. 13.03.02: Air spring pipes for exhaust valves
9007251497822475

2022-01-24 - en
13.03 Piping

2 (2) 95-60ME-C/-GI/-GA/-LGI
MAN Energy Solutions 199 13 68-3.0

Electric motor for turning gear

General
MAN Energy Solutions delivers a turning gear with built-in disc brake, option
4 80 101.
A turning gear with an electric motor of another protection or insulation class
can be ordered, option 4 80 103. Information about the alternative executions
is available on request.
Two basic executions are available for power supply frequencies of 60 and 50
Hz respectively. Nominal power and current consumption of the motors are
listed below.

Electric motor and brake, voltage 3 x 440-480V

Electric motor and brake, frequency 60 Hz
Protection, electric motor and brake IP 44
Insulation class F
27021646397570315

Electric motor
Number of cylinders Nominal power, Nominal current,
kW A

5-6 6.6 - 4P 10.1

27021646397570315

Electric motor and brake, voltage 3 x 380-415V

Electric motor and brake, frequency 50 Hz
Protection, electric motor and brake IP 44
Insulation class F
27021646397570315

Electric motor
Number of cylinders Nominal power, Nominal current, 13.04 Electric motor for turning gear
kW A

5-6 5.5 - 4P 11.7

27021646397570315

536 71 03-2.3.0
27021646397570315

Table 13.04.01: Electric motor for turning gear, option: 4 80 103

27021646397570315

G70ME-C9.5/10.5/-GI/-GA 1 (1)
199 13 68-3.0 MAN Energy Solutions

27021646397570315
This page is intentionally left blank
13.04 Electric motor for turning gear

G70ME-C9.5/10.5/-GI/-GA
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
14 Scavenge Air

20 Project Support and Documentation

21 Appendix
61395620619

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

14 Scavenge Air
 MAN Energy Solutions 198 40 04-1.5

Scavenge Air System

Scavenge air is supplied to the engine by one or more turbochargers, located
on the exhaust side of the engine.
The compressor of the turbocharger draws air from the engine room, through
an air filter, and the compressed air is cooled by the scavenge air cooler, one
per turbocharger. The scavenge air cooler is provided with a water mist
catcher, which prevents condensate water from being carried with the air into
the scavenge air receiver and to the combustion chamber.
The scavenge air system (see Figs. 14.01.01 and 14.02.01) is an integrated
part of the main engine
The engine power figures and the data in the list of capacities are based on
MCR at tropical conditions, i.e. a seawater temperature of 32°C, or freshwater
temperature of 36°C, and an ambient air inlet temperature of 45°C.

14.01 Scavenge Air System

2024-01-12 - en

Fig. 14.01.01: Scavenge Air System

18014450629816715

80-60ME-C/-GI/-LGI/-GA 1 (1)
198 40 04-1.5 MAN Energy Solutions

18014450629816715
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14.01 Scavenge Air System

2024-01-12 - en

80-60ME-C/-GI/-LGI/-GA
 MAN Energy Solutions 199 15 51-5.0

Auxiliary blowers
The engine is provided with a minimum of two electrically driven auxiliary
blowers, the actual number depending on the number of cylinders as well as
the turbocharger make and amount.
The auxiliary blowers are integrated in the reversing chamber below the scav-
enge air cooler. Between the scavenge air cooler and the scavenge air re-
ceiver, non-return valves are fitted which close automatically when the auxili-
ary blowers start supplying the scavenge air.

Auxiliary Blower Operation

The auxiliary blowers start operating consecutively before the engine is started
and will ensure complete scavenging of the cylinders in the starting phase,
thus providing the best conditions for a safe start.
During operation of the engine, the auxiliary blowers will start automatically
whenever the blower inlet pressure drops below a preset pressure, corres-
ponding to an engine load of approximately 25-35%.
The blowers will continue to operate until the blower inlet pressure again ex-
ceeds the preset pressure plus an appropriate hysteresis (i.e. taking recent
pressure history into account), corresponding to an engine load of approxim-
ately 30-40%.

Emergency Running
If one of the auxiliary blowers is out of function, the other auxiliary blower will
function in the system, without any manual adjustment of the valves being ne-
cessary.

14.02 Auxiliary blowers

2022-07-05 - en

Fig. 14.02.01: Scavenge air system, integrated blower

95-60ME-C/-GI/-GA/-LGI 1 (3)
199 15 51-5.0 MAN Energy Solutions

Control of the Auxiliary Blowers

The control system for the auxiliary blowers is integrated in the Engine Control
System. The auxiliary blowers can be controlled in either automatic (default) or
manual mode.
In automatic mode, the auxiliary blowers are started sequentially at the mo-
ment the engine is commanded to start. During engine running, the blowers
are started and stopped according to preset scavenge air pressure limits.
When the engine stops, the blowers are stopped after 30 minutes to prevent
overheating of the blowers. When a start is ordered, the blower will be started
in the normal sequence and the actual start of the engine will be delayed until
the blowers have started.
In manual mode, the blowers can be controlled individually from the ECR (En-
gine Control Room) panel irrespective of the engine condition.
Referring to Fig. 14.02.02, the Auxiliary Blower Starter Panels control and pro-
tect the Auxiliary Blower motors, one panel with starter per blower.
The starter panels with starters for the auxiliary blower motors are not in-
cluded, they can be ordered as an option: 4 55 653. (The starter panel design
and function is according to MAN Energy Solutions’s diagram, however, the
physical layout and choice of components has to be decided by the manufac-
turer).
Heaters for the blower motors are available as an option: 4 55 155.

Scavenge Air Cooler Requirements

The data for the scavenge air cooler is specified in the description of the cool-
ing water system chosen.
For further information, please refer to our publication titled: MAN Energy
Solutions Influence of Ambient Temperature Conditions
The publication is available at man-es.com/marine → ’Two-Stroke’ → ’Tech-
nical Papers’.
14.02 Auxiliary blowers

2022-07-05 - en

2 (3) 95-60ME-C/-GI/-GA/-LGI
 MAN Energy Solutions 199 15 51-5.0

Fig. 14.02.02: Diagram of auxiliary blower control system

9007251935396619

14.02 Auxiliary blowers

2022-07-05 - en

95-60ME-C/-GI/-GA/-LGI 3 (3)
199 15 51-5.0 MAN Energy Solutions

9007251935396619
This page is intentionally left blank
14.02 Auxiliary blowers

2022-07-05 - en

95-60ME-C/-GI/-GA/-LGI
 MAN Energy Solutions 198 40 13-6.5

Scavenge air pipes

The item No. refer to ‘Guidance Values Automation’

*) Option, see Fig. 15.02.05: Soft blast cleaning of turbine side
Fig. 14.03.01: Scavenge air pipes
15376938763

14.03 Scavenge air pipes

2021-10-04 - en

98-60MC-C, 98-60ME/ME-C/ME-B/-GI/-GA 1 (1)

198 40 13-6.5 MAN Energy Solutions

15376938763
This page is intentionally left blank
14.03 Scavenge air pipes

2021-10-04 - en

98-60MC-C, 98-60ME/ME-C/ME-B/-GI/-GA
 MAN Energy Solutions 198 88 03-1.1

Electric motor for auxiliary blower

General
The number of auxiliary blowers in a propulsion plant may vary depending on
the actual amount of turbochargers as well as space requirements.

Motor start method and size

Direct Online Start (DOL) is required for all auxiliary blower electric motors to
ensure proper operation under all conditions.
For typical engine configurations, the installed size of the electric motors for
auxiliary blowers are listed in Table 14.04.01.

Special operating conditions

For engines with Dynamic Positioning (DP) mode in manoeuvring system, op-
tion: 4 06 111, larger electric motors are required. This is in order to avoid
start and stop of the blowers inside the load range specified for dynamic posi-
tioning. The actual load range is to be decided between the owner and the
yard.
Engine plants with waste heat recovery exhaust gas bypass and engines with
low-and part-load exhaust gas bypass may require less blower capacity,
please contact MAN Energy Solutions, Copenhagen.

Number of Cylinder Number of Number of Installed Power/

Turbocharger Auxiliary Blower Blower kW

5 1 2 65

6 1 2 75

6 2 2 75

14.04 Electric motor for auxiliary blower

7 1 2 90

7 2 2 90

8 2 2 90
60882940171

The installed power of the electric motors are based on a voltage supply of
3x440V at 60Hz.
The electric motors are delivered with and fitted onto the engine.
Table 14.04.01: Electric motor for auxiliary blower
2022-06-23 - en

60882940171

G70ME-C9.2/.5/-GI 1 (1)
198 88 03-1.1 MAN Energy Solutions

60882940171
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14.04 Electric motor for auxiliary blower

2022-06-23 - en

G70ME-C9.2/.5/-GI
 MAN Energy Solutions 199 13 70-5.0

Scavenge air cooler cleaning system

General

The letters refer to list of 'Counterflanges'. The item nos. refer to 'Guidance
values automation'.
Fig. 14.05.01: Air cooler cleaning pipes, two or more air coolers, for EGR
The air side of the scavenge air cooler can be cleaned by injecting a grease
dissolving media through ‘AK’ to a spray pipe arrangement fitted to the air

14.05 Scavenge air cooler cleaning system

chamber above the air cooler element.

Drain from water mist catcher

Sludge is drained through ‘AL’ to the drain water collecting tank and the pol-
luted grease dissolvent returns from ‘AM’, through a filter, to the chemical
cleaning tank. The cleaning must be carried out while the engine is at stand-
still.
Dirty water collected after the water mist catcher is drained through ‘DX’ and
led to the bilge tank via an open funnel, see Fig. 14.05.02.
2023-09-29 - en

The ‘AL’ drain line is, during running, used as a permanent drain from the air
cooler water mist catcher. The water is led through an orifice to prevent major
losses of scavenge air.
The system is equipped with a drain box with a level switch, indicating any ex-
cessive water level.
The piping delivered with and fitted on the engine is shown in Fig 14.05.01.

G/S95-60ME-C/-GI/-GA/-LGI 1 (3)
199 13 70-5.0 MAN Energy Solutions

Auto pump overboard system

It is common practice on board to lead drain water directly overboard via a
collecting tank. Before pumping the drain water overboard, it is recommended
to measure the oil content. If above 15ppm, the drain water should be lead to
the clean bilge tank / bilge holding tank.
If required by the owner, a system for automatic disposal of drain water with
oil content monitoring could be built as outlined in Fig. 14.05.02.

198 76 84-9.2

The letters refer to list of 'Counterflanges'.

Fig. 14.05.02: Suggested automatic disposal of drain water, if required by
owner (not a demand from MAN Energy Solutions)
14.05 Scavenge air cooler cleaning system

2023-09-29 - en

2 (3) G/S95-60ME-C/-GI/-GA/-LGI
 MAN Energy Solutions 199 13 70-5.0

Air cooler cleaning unit

Engine type No. of cylinders Chemical tank capacity, m3 Circulation pump capacity at 3 bar, m3/h
5 0.3 1

14.05 Scavenge air cooler cleaning system

G60ME-C
6-8 0.6 2

5 0.3 1
S60ME-C
6-8 0.6 2

G70ME-C 5-6 0.6 2

5-7 0.6 2
S70ME-C
8 0.9 3

6-7 0.6 2
G80ME-C
2023-09-29 - en

8-9 0.9 3

6-8 0.9 3
G90ME-C
9-12 1.5 5

6-8 0.9 3
G95ME-C
9-12 1.5 5
45036044938601483

Fig. 14.05.03: Air cooler cleaning system with air cooler cleaning unit,
option: 4 55 665
45036044938601483

G/S95-60ME-C/-GI/-GA/-LGI 3 (3)
199 13 70-5.0 MAN Energy Solutions

45036044938601483
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14.05 Scavenge air cooler cleaning system

2023-09-29 - en

G/S95-60ME-C/-GI/-GA/-LGI
 MAN Energy Solutions 198 40 32-7.7

Scavenge air box drain system

The scavenge air box is continuously drained through ‘AV’ to a small pressur-
ised drain tank, from where the sludge is led to the sludge tank. Steam can be
applied through ‘BV’, if required, to facilitate the draining. See Fig. 14.06.01.
The continuous drain from the engine scavenge air area must not be directly
connected to the sludge tank due to the pressure level.
The drain tank shall be designed according to the pressurised system con-
nected to the BV connection as one of the following:
▪ Steam maximum working pressure
▪ Compressed air maximum working pressure
It is recommended that the drain tank is placed close to the engine to avoid
lon piping between engine and drain tank and thereby minimize the risk of the
pipe being blocked by sludge.

14.06 Scavenge air box drain system

The letters refer to list of ‘Counterflanges’

2021-10-12 - en

No. of cylinders: 5-6 7-9 10-12 14

3
Drain tank capacity, m 0.5 0.7 0.9 1.1
55654791819

079 61 03-0.9.0
55654791819

Fig. 14.06.01: Scavenge air box drain system

55654791819

70-60MC/MC-C/ME-B/ME-C/-GI/-GA/-LGI 1 (1)
198 40 32-7.7 MAN Energy Solutions

55654791819
This page is intentionally left blank
14.06 Scavenge air box drain system

2021-10-12 - en

70-60MC/MC-C/ME-B/ME-C/-GI/-GA/-LGI
 MAN Energy Solutions 199 13 65-8.0

Fire extinguishing systems for scavenge air space

General

14.07 Fire extinguishing systems for scavenge air space

Fig. 14.07.01: Fire extinguishing system for scavenge air space
Fire in the scavenge air space can be extinguished by steam, this being the
basic solution, or, optionally, by water mist or CO2.
The external system, pipe and flange connections are shown in Fig. 14.07.01
2023-11-20 - en

and the piping fitted onto the engine in Fig. 14.07.02.

In the Extent of Delivery, the fire extinguishing system for scavenge air space
is selected by the fire extinguishing agent:
▪ basic solution: 4 55 140 Steam
▪ option: 4 55 142 Water mist
▪ option: 4 55 143 CO2
The key specifications of the fire extinguishing agents are:

Steam fire extinguishing for scavenge air space

Steam pressure: 3-10 bar

70ME-C/-GI/-GA 1 (3)
199 13 65-8.0 MAN Energy Solutions

Steam quantity, approx.: 4.3 kg/cyl.

Water mist fire extinguishing for scavenge air space

Freshwater pressure: min. 3.5 bar
Freshwater quantity, approx.: 3.4 kg/cyl.

CO2 fire extinguishing for scavenge air space

CO2 test pressure: 150 bar
CO2 quantity, approx.: 8.5 kg/cyl.

Fire extinguishing pipes in scavenge air space

14.07 Fire extinguishing systems for scavenge air space

The letters refer to 'List of flanges'.

The item no. refer to 'Guidance Values Automation'.
Fig. 14.07.02: Fire extinguishing pipes in scavenge air space
2023-11-20 - en

2 (3) 70ME-C/-GI/-GA
 MAN Energy Solutions 199 13 65-8.0

Scavenge air space, drain pipes

The letters refer to 'List of flanges'.

14.07 Fire extinguishing systems for scavenge air space

Fig. 14.07.03: Scavenge air space, drain pipes
54043244145837195
2023-11-20 - en

70ME-C/-GI/-GA 3 (3)
199 13 65-8.0 MAN Energy Solutions

54043244145837195
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14.07 Fire extinguishing systems for scavenge air space

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70ME-C/-GI/-GA
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
15 Exhaust Gas

20 Project Support and Documentation

21 Appendix
61395628043

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

15 Exhaust Gas
 MAN Energy Solutions 198 40 47-2.8

Exhaust gas system

The exhaust gas is led from the cylinders to the exhaust gas receiver where
the fluctuating pressures from the cylinders are equalised and from where the
gas is led further on to the turbocharger at a constant pressure. See fig.
15.01.01.
Compensators are fitted between the exhaust valve housings and the exhaust
gas receiver and between the receiver and the turbocharger. A protective
grating is placed between the exhaust gas receiver and the turbocharger. The
turbocharger is fitted with a pick-up for monitoring and remote indication of
the turbocharger speed.
The exhaust gas receiver and the exhaust pipes are provided with insulation,
covered by steel plating

Turbocharger Arrangement and Cleaning System

The turbochargers are located on the exhaust side of the engine.
The engine is designed for the installation of the MAN turbocharger type TCA,
option: 4 59 101, Accelleron turbocharger type A-L, option: 4 59 102, or MHI
turbocharger type MET, option: 4 59 103.
All makes of turbochargers are fitted with an arrangement for water washing
of the compressor side, and soft blast cleaning of the turbine side, see Figs.
15.02.02, 15.02.03 and 15.02.04. Washing of the turbine side is only applic-
able on MAN turbochargers, though not for dual fuel engines.

15.01 Exhaust gas system

2022-09-23 - en

95-65MC/MC-C/ME/ME-C/-GI/-GA/G/S/L60ME-C/-GI 1 (2)
198 40 47-2.8 MAN Energy Solutions

Fig. 15.01.01: Exhaust gas system on engine

18014451230655499
15.01 Exhaust gas system

2022-09-23 - en

2 (2) 95-65MC/MC-C/ME/ME-C/-GI/-GA/G/S/L60ME-C/-GI
 MAN Energy Solutions 199 12 30-0.0

Piping and cleaning systems

Fig. 15.02.01: Exhaust gas pipes

Cleaning Systems

15.02 Piping and cleaning systems

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95-60 engines 1 (2)

199 12 30-0.0 MAN Energy Solutions

Fig. 15.02.02: MAN TCA turbocharger, water washing of turbine side

Fig. 15.02.03: Soft blast cleaning of turbine side and water washing of com-
pressor side for ABB turbochargers

Soft Blast Cleaning Systems

15.02 Piping and cleaning systems

2022-01-24 - en

Fig. 15.02.04: Soft blast cleaning of turbine side, basic

9007251935401227

2 (2) 95-60 engines

 MAN Energy Solutions 198 40 74-6.3

Exhaust Gas System for Main Engine

At the specified MCR of the engine, the total back-pressure in the exhaust
gas system after the turbocharger (as indicated by the static pressure meas-
ured in the piping after the turbocharger) must not exceed 350 mm WC
(0.035 bar).

In order to have a back-pressure margin for the final system, it is recommen-

ded at the design stage to initially use a value of about 300 mm WC (0.030
bar).

The actual back-pressure in the exhaust gas system at specified MCR de-
pends on the gas velocity, i.e. it is proportional to the square of the exhaust
gas velocity, and hence inversely proportional to the pipe diameter to the 4th
power. It has by now become normal practice in order to avoid too much
pressure loss in the pipings to have an exhaust gas velocity at specified MCR
of about 35 m/sec, but not higher than 50 m/sec.

For dimensioning of the external exhaust pipe connections, see the exhaust
pipe diameters for 35 m/sec, 40 m/sec, 45 m/sec and 50 m/sec respectively,
shown in Table 15.07.02.

As long as the total back-pressure of the exhaust gas system (incorporating

all resistance losses from pipes and components) complies with the above-
mentioned requirements, the pressure losses across each component may be
chosen independently, see proposed measuring points (M) in Fig. 15.05.01.
The general design guidelines for each component, described below, can be
used for guidance purposes at the initial project stage.

Exhaust Gas Piping System for main Engine

The exhaust gas piping system conveys the gas from the outlet of the tur-

15.03 Exhaust Gas System for Main Engine

bocharger(s) to the atmosphere.
The exhaust piping is shown schematically in Fig. 15.04.01.
The exhaust system for the main engine comprises:
▪ Exhaust gas pipes
▪ Exhaust gas boiler
▪ Silencer
▪ Spark arrester (if needed)
▪ Expansion joints (compensators)
▪ Pipe bracings.
2022-05-02 - en

In connection with dimensioning the exhaust gas piping system, the following
parameters must be observed:
▪ Exhaust gas flow rate
▪ Exhaust gas temperature at turbocharger outlet
▪ Maximum pressure drop through exhaust gas system
▪ Maximum noise level at gas outlet to atmosphere
▪ Maximum force from exhaust piping on turbocharger(s)
▪ Sufficient axial and lateral elongation ability of expansion joints
▪ Utilisation of the heat energy of the exhaust gas.

ME-B/ME/ME-C/-GI/-GA, MC/MC-C 1 (2)

198 40 74-6.3 MAN Energy Solutions

Items that are to be calculated or read from tables are:

▪ Exhaust gas mass flow rate, temperature and maximum back pressure at
turbocharger gas outlet
▪ Diameter of exhaust gas pipes
▪ Utilisation of the exhaust gas energy
▪ Attenuation of noise from the exhaust pipe outlet
▪ Pressure drop across the exhaust gas system
▪ Expansion joints.
9007214637469579
15.03 Exhaust Gas System for Main Engine

2022-05-02 - en

2 (2) ME-B/ME/ME-C/-GI/-GA, MC/MC-C

 MAN Energy Solutions 199 16 05-6.0

System components

Exhaust gas compensator after turbocharger

When dimensioning the compensator, option: 4 60 610, for the expansion
joint on the turbocharger gas outlet transition piece, option: 4 60 601, the ex-
haust gas piece and components, are to be so arranged that the thermal ex-
pansions are absorbed by expansion joints. The heat expansion of the pipes
and the components is to be calculated based on a temperature increase
from 20°C to 250°C. The max. expected vertical, transversal and longitudinal
heat expansion of the engine measured at the top of the exhaust gas trans-
ition piece of the turbocharger outlet are indicated in Fig. 15.06.01 and Table
15.06.01 as DA, DB and DC.
The movements stated are related to the engine seating, for DC, however, to
the engine centre. The figures indicate the axial and the lateral movements re-
lated to the orientation of the expansion joints.
The expansion joints are to be chosen with an elasticity that limits the forces
and the moments of the exhaust gas outlet flange of the turbocharger as
stated for each of the turbocharger makers in Table 15.06.02. The orientation
of the maximum permissible forces and moments on the gas outlet flange of
the turbocharger is shown in Fig. 15.06.02.

15.04 System components

2023-03-13 - en

Fig. 15.04.01a: Exhaust gas system, one turbocharger

G70ME-C9/10/-GI 1 (5)
199 16 05-6.0 MAN Energy Solutions

Exhaust gas boiler

Engine plants are usually designed for utilisation of the heat energy of the ex-
haust gas for steam production or for heating the thermal oil system. The ex-
haust gas passes an exhaust gas boiler which is usually placed near the en-
gine top or in the funnel.
It should be noted that the exhaust gas temperature and flow rate are influ-
enced by the ambient conditions, for which reason this should be considered
when the exhaust gas boiler is planned. At specified MCR, the maximum re-
commended pressure loss across the exhaust gas boiler is normally 150 mm
WC.
This pressure loss depends on the pressure losses in the rest of the system
as mentioned above. Therefore, if an exhaust gas silencer/spark arrester is
not installed, the acceptable pressure loss across the boiler may be some-
what higher than the max. of 150 mm WC, whereas, if an exhaust gas silen-
cer/spark arrester is installed, it may be necessary to reduce the maximum
pressure loss.
The above mentioned pressure loss across the exhaust gas boiler must in-
clude the pressure losses from the inlet and outlet transition pieces.
15.04 System components

Fig. 15.04.01b: Exhaust gas system, two or more TCs

2023-03-13 - en

2 (5) G70ME-C9/10/-GI
 MAN Energy Solutions 199 16 05-6.0

Exhaust Gas Silencer

The typical octave band sound pressure levels from the diesel engine’s ex-
haust gas system at a distance of one meter from the top of the exhaust gas
uptake are shown in Fig.15.04.02.
The need for an exhaust gas silencer can be decided based on the require-
ment of a maximum permissible noise level at a specific position.
The exhaust gas noise data is valid for an exhaust gas system without boiler
and silencer, etc.
The noise level is at nominal MCR at a distance of one metre from the exhaust
gas pipe outlet edge at an angle of 30° to the gas flow direction.
For each doubling of the distance, the noise level will be reduced by about 6
dB (far-field law).
When the noise level at the exhaust gas outlet to the atmosphere needs to be
silenced, a silencer can be placed in the exhaust gas piping system after the
exhaust gas boiler.
The exhaust gas silencer is usually of the absorption type and is dimensioned
for a gas velocity of approximately 35 m/s through the central tube of the si-
lencer.
An exhaust gas silencer can be designed based on the required damping of
noise from the exhaust gas given on the graph.
In the event that an exhaust gas silencer is required this depends on the ac-
tual noise level requirement on the bridge wing, which is normally maximum
60-70 dB(A) a simple flow silencer of the absorption type is recommended.
Depending on the manufacturer, this type of silencer normally has a pressure
loss of around 20 mm WC at specified MCR.

15.04 System components

2023-03-13 - en

G70ME-C9/10/-GI 3 (5)
199 16 05-6.0 MAN Energy Solutions
15.04 System components

2023-03-13 - en

Fig. 15.04.02: ISO’s NR curves and typical sound pressure levels from the en-
gine’s exhaust gas system.
The noise levels at nominal MCR and a distance of 1 metre from the edge of
the exhaust gas pipe opening at angle of 30 degrees to the gas flow and valid
for an exhaust gas system without boiler and silencer, etc. Data for a specific
engine and cylinder no. is available on request.

4 (5) G70ME-C9/10/-GI
 MAN Energy Solutions 199 16 05-6.0

Spark arrester
To prevent sparks from the exhaust gas being spread over deck houses, a
spark arrester can be fitted as the last component in the exhaust gas system.
It should be noted that a spark arrester contributes with a considerable pres-
sure drop, which is often a disadvantage.
It is recommended that the combined pressure loss across the silencer and/
or spark arrester should not be allowed to exceed 100 mm WC at specified
MCR. This depends, of course, on the pressure loss in the remaining part of
the system, thus if no exhaust gas boiler is installed, 200 mm WC might be al-
lowed.
27021651489333643

15.04 System components

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G70ME-C9/10/-GI 5 (5)
199 16 05-6.0 MAN Energy Solutions

27021651489333643
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15.04 System components

2023-03-13 - en

G70ME-C9/10/-GI
 MAN Energy Solutions 198 40 94-9.5

Calculation of exhaust gas back-pressure

The exhaust gas back pressure after the turbocharger(s) depends on the total
pressure drop in the exhaust gas piping system.
The components, exhaust gas boiler, silencer, and spark arrester, if fitted,
usually contribute with a major part of the dynamic pressure drop through the
entire exhaust gas piping system.
The components mentioned are to be specified so that the sum of the dy-
namic pressure drop through the different components should, if possible, ap-
proach 200 mm WC at an exhaust gas flow volume corresponding to the spe-
cified MCR at tropical ambient conditions. Then there will be a pressure drop
of 100 mm WC for distribution among the remaining piping system.
Fig. 15.05.01 shows some guidelines regarding resistance coefficients and
back-pressure loss calculations which can be used, if the maker’s data for
back-pressure is not available at an early stage of the project.
The pressure loss calculations have to be based on the actual exhaust gas
amount and temperature valid for specified MCR. Some general formulas and
definitions are given in the following.

Exhaust Gas Data

M: exhaust gas amount at specified MCR in kg/sec.
T: exhaust gas temperature at specified MCR in °C
Please note that the actual exhaust gas temperature is different before and
after the boiler. The exhaust gas data valid after the turbocharger may be
found in Chapter 6.

15.05 Calculation of exhaust gas back-pressure

Mass Destiny of Exhaust Gas (ρ)
ρ ≅ 1.293 x (273 / [ 273 + T ]) x 1.015 in kg/m3

The factor 1.015 refers to the average back-pressure of 150 mm WC (0.015

bar) in the exhaust gas system.

Exhaust Gas Velocity (v)

In a pipe with diameter D the exhaust gas velocity is:

V = M/ρ x (4 / [ π x D2] ) in m/s

Pressure Losses in Pipes (Δp)

2023-06-12 - en

For a pipe element, like a bend etc., with the resistance coefficient ζ, the cor-
responding pressure loss is:

Δp = (ζ x ½ ρ [v2 x 1/9.81]) in mm WC

where the expression after ζ is the dynamic pressure of the flow in the pipe.
The friction losses in the straight pipes may, as a guidance, be estimated as :
1 mm WC per 1 diameter length
whereas the positive influence of the up-draught in the vertical pipe is normally
negligible.

All engines 1 (4)

198 40 94-9.5 MAN Energy Solutions

Pressure Losses Across Components (Δp)

The pressure loss Δp across silencer, exhaust gas boiler, spark arrester, rain
water trap, etc., to be measured/ stated as shown in Fig. 15.05.01 (at spe-
cified MCR) is normally given by the relevant manufacturer.

Total Back-Pressure (ΔpM)

The total back-pressure, measured/stated as the static pressure in the pipe
after the turbocharger, is then:

ΔpM = Σ Δp
9007251239974923

where Δp incorporates all pipe elements and components etc. as described:

ΔpM has to be lower than 350 mm WC.

9007251239974923

(At design stage it is recommended to use max. 300 mm WC in order to have

some margin for fouling).

Mesuring Back Pressure

At any given position in the exhaust gas system, the total pressure of the flow
can be divided into dynamic pressure (referring to the gas velocity) and static
pressure (referring to the wall pressure, where the gas velocity is zero).
At a given total pressure of the gas flow, the combination of dynamic and
static pressure may change, depending on the actual gas velocity. The meas-
urements, in principle, give an indication of the wall pressure, i.e., the static
pressure of the gas flow.
15.05 Calculation of exhaust gas back-pressure

It is, therefore, very important that the back pressure measuring points are
located on a straight part of the exhaust gas pipe, and at some distance from
an ‘obstruction‘, i.e. at a point where the gas flow, and thereby also the static
pressure, is stable. Taking measurements, for example, in a transition piece,
may lead to an unreliable measurement of the static pressure.
In consideration of the above, therefore, the total back pressure of the system
has to be measured after the turbocharger in the circular pipe and not in the
transition piece. The same considerations apply to the measuring points be-
fore and after the exhaust gas boiler, etc.
2023-06-12 - en

2 (4) All engines

 MAN Energy Solutions 198 40 94-9.5

Pressure Losses and Coefficients of Resistance in Exhaust Pipes

Change-over valves

Change-over valves of type with constant

cross section

ζa = 0.6 to 1.2
ζb = 1.0 to 1.5
ζc = 1.5 to 2.0

Change-over valve of type with volume

ζa = ζb = about 2.0

9007251239974923

15.05 Calculation of exhaust gas back-pressure

2023-06-12 - en

All engines 3 (4)

198 40 94-9.5 MAN Energy Solutions

R=D ζ = 0.60
R = 1.5D ζ = 0.41
R = 2D ζ = 0.27
R=D ζ = 0.30
R = 1.5D ζ = 0.15
R = 2D ζ = 0.10
αo
15o ζ = 0.06
30o ζ = 0.15
45o ζ = 0.29
Outlet from top of exhaust ζ = 1.00
gas uptake

Inlet (from turbocharger) ζ = - 1.00

9007251239974923

Fig. 15.05.01: Pressure losses and coefficients of resistance in exhaust pipes

9007251239974923
15.05 Calculation of exhaust gas back-pressure

2023-06-12 - en

4 (4) All engines

 MAN Energy Solutions 198 89 05-0.6

Forces and moments at turbocharger

DA: Max. movement of the turbocharger flange in the vertical direction

DB: Max. movement of the turbocharger flange in the transversal direction
DC: Max. movement of the turbocharger flange in the longitudinal direction

Fig. 15.06.01: Vectors of thermal expansion at the turbocharger(s) exhaust

gas outlet flange

No. of cylinders 5-8 5 6 7 8

15.06 Forces and moments at turbocharger

Turbocharger DA DB DC DC DC DC
mm mm mm mm mm mm
Make Type

TCA55 8.3 1.4 1.9 2.2 2.4 2.6

TCA66 8.7 1.5 1.9 2.2 2.4 2.6

MAN
TCA77 10.0 1.6 1.9 2.2 2.4 2.6

TCA88 10.5 1.7 1.9 2.2 2.4 2.6

A165 / A265 6.9 1.5 1.9 2.2 2.4 2.6

2022-11-17 - en

A170 / A270 7.0 1.5 1.9 2.2 2.4 2.6

ABB A175 / A275 7.6 1.5 1.9 2.2 2.4 2.6

A180 / A280 8.6 1.5 1.9 2.2 2.4 2.6

A185 / A285 9.4 1.6 1.9 2.2 2.4 2.6

MET53 7.6 1.5 1.9 2.2 2.4 2.6

MET60 8.1 1.5 1.9 2.2 2.4 2.6

MHI
MET66 8.6 1.5 1.9 2.2 2.4 2.6

MET71 9.0 1.5 1.9 2.2 2.4 2.6

G70ME-C9/10-GI 1 (3)
198 89 05-0.6 MAN Energy Solutions

MET83 9.7 1.5 1.9 2.2 2.4 2.6

Table 15.06.01: Max. expected movements of the exhaust gas flange

resulting from thermal expansion
15.06 Forces and moments at turbocharger

2022-11-17 - en

2 (3) G70ME-C9/10-GI
 MAN Energy Solutions 198 89 05-0.6

Fig. 15.06.02: Forces and moments on the turbocharger(s) exhaust gas outlet
flange

Turbocharger M1 M3 F1 F2 F3
Nm Nm N N N
Make Type

TCA55 3,400 6,900 9,100 9,100 4,500

TCA66 3,700 7,500 9,900 9,900 4,900

MAN

15.06 Forces and moments at turbocharger

TCA77 4,100 8,200 10,900 10,900 5,400

TCA88 4,500 9,100 12,000 12,000 5,900

A165 / A265 1,200 1,200 2,800 1,800 1,800

A170 / A270 1,900 1,900 3,600 2,400 2,400

ABB
A175 / A275 3,300 3,300 5,400 3,500 3,500

A180 / A280 4,600 4,600 6,800 4,400 4,400

A185 / A285 6,600 6,600 8,500 5,500 5,500

MET53 4,900 2,500 7,300 2,600 2,300

2022-11-17 - en

MET60 6,000 3,000 8,300 2,900 3,000

MHI MET66 6,800 3,400 9,300 3,200 3,000

MET71 7,000 3,500 9,600 3,300 3,100

MET83 9,800 4,900 11,700 4,100 3,700

9007250287644171

Table 15.06.02: The max. permissible forces and moments on the

turbocharger(s) gas outlet flanges
Table 15.06.02 indicates the maximum permissible forces (F1, F2 and F3) and
moments (M1 and M3), on the exhaust gas outlet flange of the
turbocharger(s). Reference is made to Fig. 15.06.02.
9007250287644171

G70ME-C9/10-GI 3 (3)
198 89 05-0.6 MAN Energy Solutions

9007250287644171
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15.06 Forces and moments at turbocharger

2022-11-17 - en

G70ME-C9/10-GI
 MAN Energy Solutions 198 89 07-4.1

Diameter of exhaust gas pipes

The exhaust gas pipe diameters listed in Table 15.07.01 are based on the ex-
haust gas flow capacity according to ISO ambient conditions and an exhaust
gas temperature of 250ºC.

Fig. 15.07.01a: Exhaust pipe system, with turbocharger located on exhaust

side of engine, option: 4 59 122

15.07 Diameter of exhaust gas pipes

The exhaust gas velocities and mass flow listed apply to collector pipe D4.
The table also lists the diameters of the corresponding exhaust gas pipes D0
for various numbers of turbochargers installed.
2022-03-21 - en

G70ME-C10/9/-GI/-GA 1 (2)
198 89 07-4.1 MAN Energy Solutions

Fig. 15.07.01b: Exhaust pipe system, with single turbocharger located on aft
end of engine, option: 4 59 124

Gas velocity Exhaust gas pipe diameters

35 m/s 40 m/s 45 m/s 50 m/s D0 D4

Gas Mass Flow 1 T/C 2 T/C 3 T/C

15.07 Diameter of exhaust gas pipes

kg/s kg/s kg/s kg/s [DN] [DN] [DN] [DN]

24.5 28.0 31.5 35.1 1,150 800 650 1,150

26.7 30.5 34.3 38.2 1,200 850 700 1,200

31.4 35.8 40.3 44.8 1,300 900 750 1,300

36.4 41.6 46.8 51.9 1,400 1,000 800 1,400

2022-03-21 - en

41.7 47.7 53.7 59.6 1,500 1,050 850 1,500

47.5 54.3 61.1 67.8 1,600 1,150 900 1,600

53.6 61.3 68.9 76.6 1,700 1,200 1,000 1,700

60.1 68.7 77.3 85.9 1,800 1,300 1,050 1,800

67.0 76.5 86.1 95.7 N.A. 1,300 1,100 1,900

74.2 84.8 95.4 106.0 N.A. 1,400 1,150 2,000

9007253028113419

Table 15.07.01: Exhaust gas pipe diameters and exhaust gas mass flow at
various velocities
9007253028113419

2 (2) G70ME-C10/9/-GI/-GA
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
16 Engine Control System

18 Monitoring Systems and Instrumentation

19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395635467

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

16 Engine Control System
 MAN Energy Solutions 199 18 91-7.0

Dual-fuel engine control system

General
The ME-GA engine control system (ME-ECS) is a common control system
consisting of the ME-ECS core and the GA extension, see Fig. 16.00.01. It
controls all the functions known from the ME-engine as well as the gas admis-
sion and the additional functionality and auxiliary systems related to the hand-
ling of gas on the engine and in the machine room.
The control includes:
▪ Electronically profiled fuel oil injection
▪ Electronically controlled exhaust valve actuation
▪ Governor/speed control
▪ Start and reversing sequencing
▪ Cylinder lubrication
▪ Variable turbocharging (if applied)
▪ Electronically controlled gas admission
▪ Sequencing change over between fuel oil and dual-fuel operation
▪ Gas combustion monitoring and safety gas shutdown
▪ Double-pipe ventilation and leakage monitoring
▪ Sealing oil control
▪ Purging of gas piping with inert gas
▪ Interface to the fuel gas supply system (FGSS).

16.00 Dual-fuel engine control system

2023-03-13 - en

All ME-GA engines 1 (4)

199 18 91-7.0 MAN Energy Solutions
16.00 Dual-fuel engine control system

Fig. 16.00.01: Overview of the ME-ECS core and GA extension

For safety reasons, many functions are duplicated, and as a result of this, the
GA extension is divided in two main parts: The GA control system and the GA
safety system.
Fig. 16.00.01 illustrates how the ME-ECS core controls both the pilot injection
2023-03-13 - en

and gas admission. The GA extension handles the gas related safety control
and gas plant control, including the interface to the FGSS control system.
Fuel gas is also referred to as ‘second fuel’ and low-flashpoint fuel (LFF) in this
project guide.

Gas admission components

The gas admission is controlled by two valves in series. The window valve
sets up a timing window within which the gas admission can be performed,
and also limits the maximum admission. The gas admission valve controls the
precise timing and gas admission amount.

2 (4) All ME-GA engines

 MAN Energy Solutions 199 18 91-7.0

The gas admission valve and the window valve are both controlled by the GA
plant control and the GA safety control, respectively, as is the case for several
other systems, see Fig. 16.00.02.

Fig. 16.00.02: ME-ECS (ME-ECS-core and GA extension) with interface to

other systems and auxiliary systems

GA extension main components 16.00 Dual-fuel engine control system

The GA extension is based on Tritons, which uses the same hardware units
as used in the standard ME-ECS, and spare units can be used in any Triton
position of the ME-ECS.
The second fuel cylinder safety unit (SCSU), supervise and analyse the com-
2023-03-13 - en

bustion in real time in order to be able to cut off the gas combustion fast in
case of for example misfiring or leakage in the admission equipment.

Control units
The second fuel plant control unit (SPCU) and second fuel auxiliary control
unit (SACU1) performs the task of bringing the gas system from ‘no gas on
engine’ to ‘gas running’ and back again.

All ME-GA engines 3 (4)

199 18 91-7.0 MAN Energy Solutions

Safety units
The second fuel plant safety unit (SPSU) monitors specific gas plant safety
sensors and, in case of a failure, it carries out a gas shutdown.
The SCSU monitors the specific cylinder sensors, and every single gas admis-
sion and combustion is supervised.
In case of a failure, the window valve acts as a gas shutdown valve and
closes immediately. The electronic window valve (ELWI) controlling the win-
dow valve is electrically wired to the SCSU unit.
16.00 Dual-fuel engine control system

2023-03-13 - en

Fig. 16.00.03: ME-ECS configuration

9007260903885195

4 (4) All ME-GA engines

 MAN Energy Solutions 199 20 26-2.0

Units, layout and interfaces

The Engine Control System (ECS) for the ME engine is prepared for conven-
tional remote control, having an interface to the Bridge Control system and
the Local Operating Panel (LOP).
Control units for specific tasks described below are based on the available
module types in the Triton hardware platform.
The layout of the Engine Control System is shown in Figs. 16.01.01, the
mechanical-hydraulic system is shown in Figs. 16.01.02a and b, and the
pneumatic system, shown in Fig. 16.01.03.
The ME system has a high level of redundancy. It has been a requirement to
its design that no single failure related to the system may cause the engine to
stop. In most cases, a single failure will not affect the performance or power
availability, or only partly do so by activating a slow down.
It should be noted that any controller could be replaced without stopping the
engine, which will revert to normal operation immediately after the replace-
ment of the defective unit.

Main operating panel

Two redundant main operating panel (MOP) screens are available for the en-
gineer to carry out engine commands, adjust the engine parameters, select
the running modes, and observe the status of the control system. Both MOP
screens are located in the engine control room (ECR), one serving as back-up
unit in case of failure or to be used simultaneously, if preferred.
Both MOP screens consist of a marine approved personal computer with a
touch screen and pointing device as shown in Fig. 5.16.02.

Engine control unit

For redundancy purposes, the control system comprises two engine control
units (ECU) operating in parallel and performing the same tasks, one being a
hot stand-by for the other. If one of the ECUs fail, the other unit will take over
the control without any interruption.
The ECUs perform such tasks as: 16.01 Units, layout and interfaces
▪ Speed governor functions, start/stop sequences, timing of fuel injection,
timing of exhaust valve activation, timing of starting valves, etc.
▪ Continuous running control of auxiliary functions handled by the ACUs
▪ Alternative running modes and programs
2023-09-25 - en

Cylinder control unit

The control system includes one cylinder control unit (CCU) per cylinder. The
CCU controls the electronic control valves for fuel injection and exhaust valve
actuation as well as the starting air valves (SAV) in accordance with the com-
mands received from the ECU.
All the CCUs are identical, and in the event of a failure of the CCU for one cyl-
inder only this cylinder will automatically be cut out of operation.

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Auxiliary control unit

The control of the auxiliary equipment on the engine is normally divided
among four auxiliary control units (ACU) so that, in the event of a failure of one
unit, there is sufficient redundancy to permit continuous operation of the en-
gine.
The ACUs perform the control of the auxiliary blowers, the control of the elec-
trically and engine driven hydraulic oil pumps of the hydraulic power supply
(HPS) unit and the scavenge air control (SCU).
If applied, the ACU also controls cooling water system (LDCL/JWA) and ex-
haust gas bypass (EGB)

Engine interface control unit

The engine interface control unit (EICC) perform such tasks as interface with
the surrounding control systems, see Fig. 16.01.01a and b.
The EICC is located either in the engine control room (recommended) or in the
engine room.

Control network
The main operating panels (MOP-A & MOP-B) are connected to the control
system controllers via a redundant ehternet based control network. Due to
limitations in cobber based ethernet, the maximum cable routing distance
between the engine and the engine room is 100m.

Power supply for engine control system

The engine control system requires two separate power supplies with battery
backup, power supply A and B.
The ME-ECS power supplies must be separated from other DC systems, i.e.
only ME-ECS components must be connected to the supplies.
Power supply A
16.01 Units, layout and interfaces

System IT (Floating), DC system w. individually

isolated outputs

Voltage Input 100-240V AC, 45-65 Hz, output

24V DC

Protection Input over current, output over current,

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output high/low voltage

Alarms as potential free contacts AC power, UPS battery mode, Batteries

not available (fuse fail)

Power supply B
System IT (Floating), DC system w. individually
isolated outputs

Voltage Input 110-240 VAC, output 24V DC

Protection Input over current, output over current,

output high/low voltage

2 (10) All engines

 MAN Energy Solutions 199 20 26-2.0

Power supply B
Alarms as potential free contacts AC power, UPS battery mode, Batteries
not available (fuse fail)

Local operating panel

In normal operating the engine can be controlled from either the bridge or
from the engine control room.
Alternatively, the local operating panel (LOP) can be activated. This redundant
control is to be considered as a substitute for the previous Engine Side Con-
trol console mounted directly onto the MC engine.
The LOP is as standard placed on the engine.
From the LOP, the basic functions are available, such as starting, engine
speed control, stopping, reversing, and the most important engine data are
displayed.

Hydraulic power supply

The purpose of the hydraulic power supply (HPS) unit is to deliver the neces-
sary high pressure hydraulic oil flow to the hydraulic cylinder units (HCU) on
the engine at the required pressure during start-up as well as in normal ser-
vice.
In case of the standard mechanically driven HPS unit, at start, one of the two
electrically driven start-up pumps is activated.
The multiple pump configuration with standby pumps ensures redundancy
with regard to the hydraulic power supply. The control of the engine driven
pumps and electrical pumps are divided between the three ACUs.
The sizes and capacities of the HPS unit depend on the engine type. Further
details about the HPS and the lubricating oil/hydraulic oil system can be found
in chapter 8.

16.01 Units, layout and interfaces

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All engines 3 (10)

199 20 26-2.0 MAN Energy Solutions

Engine control system layout with cabinet for EICU

16.01 Units, layout and interfaces

2023-09-25 - en

Fig. 16.01.01: Engine control system layout with cabinet for EICU for mount-
ing in ECR or on engine, EoD: 4 65 601

4 (10) All engines

 MAN Energy Solutions 199 20 26-2.0

Mechanical-hydraulic system with mechanically driven HPS

16.01 Units, layout and interfaces

2023-09-25 - en

The letters refer to list of ‘counterflanges’

The item no. refer to ‘guidance values automation’
Fig. 16.01.02a: Mechanical-hydraulic system with mechanically driven hy-
draulic power supply, 300 bar, common supply

All engines 5 (10)

199 20 26-2.0 MAN Energy Solutions

Mechanical-hydraulic system with electrically driven HPS

16.01 Units, layout and interfaces

2023-09-25 - en

The letters refer to list of ‘counterflanges’

The item no. refer to ‘guidance values automation’
Fig. 16.01.02b: Mechanical-hydraulic system with electrically driven hydraulic
power supply, 300 bar, common supply. Example from S90/80ME-C engine

6 (10) All engines

 MAN Energy Solutions 199 20 26-2.0

Engine control system interface to surrounding systems

To support the navigator, the vessels are equipped with a ship control sys-
tem, which includes subsystems to supervise and protect the main propulsion
engine.

Alarm system
The alarm system has no direct effect on the ECS. The alarm alerts the oper-
ator of an abnormal condition.
The alarm system is an independent system, in general covering more than
the main engine itself, and its task is to monitor the service condition and to
activate the alarms if a normal service limit is exceeded.

Slow Down System

The Slowdown system receives slowdown requests from either ECS or AMS,
and if the request is not cancelled, a slowdown command will be sent to ECS.

Safety system
The engine safety system is an independent system with its respective
sensors on the main engine, fulfilling the requirements of the respective classi-
fication society and MAN Energy Solutions. If a critical value is reached for one
of the measuring points, the input signal from the safety system must cause
either a cancellable or a non-cancellable shut down signal to the ECS.
For the safety system, combined shut down and slow down panels approved
by MAN Energy Solutions are available. The following options are listed in the
Extent of Delivery:
4 75 631 Lyngsø Marine
4 75 632 Kongsberg Maritime
4 75 633 Nabtesco
4 75 636 Mitsui Zosen Systems Research.
Where separate shut down and slow down panels are installed, only panels 16.01 Units, layout and interfaces
approved by MAN Energy Solutions must be used.
In any case, the remote control system and the safety system (shut down and
slow down panel) must be compatible.

Telegraph system
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This system enables the navigator to transfer the commands of engine speed
and direction of rotation from the Bridge, the engine control room or the local
operating panel (LOP), and it provides signals for speed setting and stop to
the ECS.
The engine control room and the LOP are provided with combined telegraph
and speed setting units.

Remote control system

The remote control system normally has three alternative control stations:
▪ the bridge control

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199 20 26-2.0 MAN Energy Solutions

▪ the engine control room control

▪ local control.
The remote control system is to be delivered by a supplier approved by MAN
Energy Solutions.
Bridge control systems from suppliers approved by MAN Energy Solutions are
available. The Extent of Delivery lists the following options:
▪ for fixed pitch propeller plants, e.g.:
4 95 703 Lyngsø Marine
4 95 704 Mitsui Zosen Systems Research
4 95 705 Nabtesco
4 95 715 Kongsberg Maritime
▪ and for controllable pitch propeller plants, e.g.:
4 95 701 Lyngsø Marine
4 95 716 Kongsberg Maritime
4 95 719 MAN Alphatronic.

Power management system

The system handles the supply of electrical power onboard, i. e. the starting
and stopping of the generating sets as well as the activation / deactivation of
the main engine shaft generator (SG), if fitted.
The normal function involves starting, synchronising, phasing-in, transfer of
electrical load and stopping of the generators based on the electrical load of
the grid on board.
ECS offers a number of interface options for safe connection/dis-connection
of shaft generators

Auxiliary equipment system

The input signals for ‘Auxiliary system ready’ are given partly through the re-
mote control system based on the status for:
▪ fuel oil system
▪ lube oil system
▪ cooling water systems
16.01 Units, layout and interfaces

and partly from the ECS itself:

▪ turning gear disengaged
▪ main starting valve ‘open’
▪ control air valve for sealing air ‘open’
▪ control air valve for air spring ‘open’
2023-09-25 - en

▪ auxiliary blowers running

▪ hydraulic power supply ready.

Monitoring system
The engine control system (ECS) is supported by the engine management
services (EMS), which includes the PMI auto-tuning and the CoCoS-EDS
(Computer Controlled Surveillance-Engine Diagnostics System) applications.
A description of the EMS is found in chapter 18 of this project guide.

8 (10) All engines

 MAN Energy Solutions 199 20 26-2.0

Instrumentation
The following lists of instrumentation are included in chapter 18:
▪ the class requirements and MAN Energy Solutions' requirements for
alarms, slow down and shut down for unattended machinery spaces
▪ local instruments
▪ control devices.

16.01 Units, layout and interfaces

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All engines 9 (10)

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Pneumatic manoeuvring diagram

16.01 Units, layout and interfaces

2023-09-25 - en

Fig. 16.01.03: Pneumatic manoeuvring diagram, FPP

9007269806555787

10 (10) All engines

 MAN Energy Solutions 199 20 40-4.0

Engine control system – second fuel extensions and interfaces

General
In addition to the ME-ECS core, a dual fuel extension is installed to control the
gas supply and to monitor safety issues when the engine is operating on al-
ternative fuels, see Fig. 16.02.01.
As mentioned, the dual fuel extension is designed as an add‚on to the stand-
ard ME control system. The bridge panel, the main operating panel (MOP) and
the local operating panel (LOP) is equipped with a dual-fuel running indication
lamp. All operations in gas mode are performed solely from the engine room,
while the operation from the bridge is exactly the same whether in dual fuel or
fuel oil mode.

Dual-fuel control
The dual fuel control system consists of three parts:
▪ fuel injection control
▪ plant control
▪ safety control.
Dual fuel injection control is an additional functionality added to ECUs and

16.02 Engine control system – second fuel extensions and

CCUs of the MEECS, while plant control and safety control are handled by
additional units: the SPCU (second fuel plant control unit) and SACU (second
fuel auxiliary control unit), respectively SPSU (second fuel plant safety unit)
and SCSUs (second fuel cylinder safety units).

Dual-fuel injection control

The task of the dual fuel injection control is to determine the fuel gas index
and the pilot oil index when running in the different modes.

Dual-fuel plant control

The dual fuel plant control has the functions:
Function A – Controls the supply of dual fuel from the fuel gas supply system
(FGSS) to the engine in a safe way.
Function B – Closes down the supply of gas to the engine after end of gas
operation.
Function A:
2023-09-25 - en

▪ purges the gas pipes and gas volumes for atmospheric air before gas is
allowed
▪ starts the double-pipe ventilation system and turns on double-pipe leak-
age detection
▪ applies gas to the engine in steps and checks for leakage and correct
valve function, while the gas pressure builds up
interfaces

▪ starts the sealing oil system, when SF enters the cylinder cover.
Function B:
▪ closes the GVT (gas valve train) block valves
▪ releases the dual fuel pressure

Dual-fuel engines 1 (5)

199 20 40-4.0 MAN Energy Solutions

▪ stops the sealing oil system

▪ starts purging the gas pipes and volumes
▪ stops the double-pipe ventilation.
Furthermore, the task of the plant control is to handle the changeover
between the two stable states:
▪ Fuel oil mode (HFO only)
▪ Dual fuel mode.
The plant control can operate all the fuel gas equipment. For the plant control
to operate, it is required that the SF safety control allows it to work, otherwise
the safety control will overrule and return to a gas safe condition.
16.02 Engine control system – second fuel extensions and

2023-09-25 - en

Fig. 16.02.01: The second fuel engine control system

Dual-fuel safety control

interfaces

The task of the safety system is to monitor:

▪ manual and external automatic SF shut down
▪ engine shut down signal from the engine safety system
▪ double-pipe ventilation and leakage

2 (5) Dual-fuel engines

 MAN Energy Solutions 199 20 40-4.0

▪ sealing oil pressure

▪ SF pressure
▪ combustion pressure within normal values
▪ SF injection valve and window valve leakage.
If one of the above mentioned failures is detected, the SF safety control re-
leases the gas shut down sequence:
The GVT, main gas valve and window valve will close. The electronic gas in-
jection (ELGI) valves will be disabled. The fuel gas will be blown out by open-
ing the SF bleed valve, the blow-off valves and purge valves, and finally the
gas pipe system will be purged with inert fuels. See Fig. 7.00.01.

Safety principles of the dual fuel control system

SF mode running is not essential for the manoeuvrability of the ship, as the
engine will continue to run on fuel oil if an unintended fuel gas stop occurs.
The two fundamental safety principles of the SF equipment are, in order of pri-
ority:
▪ Safety to personnel must be at least on the same level as for a conven-
tional diesel engine
▪ A fault in the dual fuel equipment must cause stop of SF operation and
change over to fuel oil mode
which to some extent complement each other.

16.02 Engine control system – second fuel extensions and

The dual fuel control system is designed to ‘fail to safe condition’. All failures
detected during fuel gas running and failures of the control system itself will
result in a fuel gas stop or shut down and change over to fuel oil operation.
Subsequently, the control system initiates blow out and purging of high pres-
sure fuel gas pipes which releases all gas from the entire gas supply system of
the engine room.
If the failure relates to the purging system, it may be necessary to carry out
purging manually before engine repair is carried out.
The dual fuel control system itself is in general a single system without re-
dundancy or manual back-up control.

Main operating panel (MOP)

The MOP is common to both the ME-ECS core and the SF extension. All the
manual operations can be initiated from the MOP.
The MOP functions include the facilities to manually start up or to stop SF op-
eration.
2023-09-25 - en

Additionally, the change between the different running modes can be done
and the operator has the possibility to manually initiate purging of the SF pip-
ing with inert gas.

Dual-fuel function of the ECU and CCU

interfaces

The dual fuel injection control is part of the ECU which includes all facilities re-
quired for calculating the fuel gas injection and the pilot oil injection based on
the command from the ME governor function and the actual active mode.

Dual-fuel engines 3 (5)

199 20 40-4.0 MAN Energy Solutions

Based on these data and information about the fuel gas pressure, the dual
fuel injection control calculates the start and duration time of the injection,
then sends the signal to the CCU which effectuates the injection by controlling
both the electronic fuel injection valve (ELFI) (or the fuel injection valve actu-
ation (FIVA) if applied) and the ELGI valve.

Second fuel plant and second fuel auxiliary control unit

When ‘Dual Fuel Mode Start’ is initiated manually by the operator, the second
fuel plant (SPCU) will start the automatic start sequence.
The SPCU and second fuel auxiliary control unit (SACU) contain functionalities
necessary to control and monitor auxiliary systems.
The SPCU and SACU controls:
▪ start/stop of pumps, fans, and of the SF supply system
▪ sealing oil pressure set points
▪ pressure set points for the SF supply system
▪ the purging with inert gas
▪ the ACOS, if applied.
The SPCU monitors the condition of the following:
▪ SF supply system
▪ sealing oil system
16.02 Engine control system – second fuel extensions and

▪ double-pipe ventilation
▪ inert gas system
and, if a failure does occur, the SPCU will automatically interrupt SF mode
start operation and return the plant to fuel oil mode.

Second fuel plant safety unit

The central Second fuel plant safety unit (SPSU) performs safety monitoring of
the SF system and controls the SF shut down.
The SPSU monitors the following:
▪ SF leakage to the outer pipe of the double pipe
▪ pipe ventilation of the double-wall piping
▪ sealing oil pressure
▪ fuel gas pressure
▪ SCSU ready signal.
If one of the above parameters (referring to the relevant fuel gas state) differs
2023-09-25 - en

from normal service value, the SPSU overrules any other signals and SF shut
down will be released.
After the cause of the SF shut down has been corrected, the SF operation
can be manually restarted.
The SPCU main state diagram is shown in Fig. 16.02.02.
interfaces

4 (5) Dual-fuel engines

 MAN Energy Solutions 199 20 40-4.0

Fig. 16.02.02: SPCU main state diagram

Second fuel cylinder safety unit

The purpose of second fuel cylinder safety (SCSU) is to monitor if the cylin-
ders are ready for the injection of SF.
The following events are monitored by the SCSU:
▪ SF pressure variations in SF block
- SF injection valve leakage and malfunction
- window valve leakage and malfunction
- blow-off valve leakage

16.02 Engine control system – second fuel extensions and

- resume valve leakage and malfunction (if present)
- sensor supervision
▪ Cylinder pressure
- low compression pressure - too high maximum pressure
- low expansion pressure/misfiring
- too fast combustion pressure increase
▪ Fuel gas accumulator pressure drop during injection.
If one of the parameters is abnormal, the ELWI valve is closed and a shut
down of SF running is activated by the SPSU.
9007270936413323
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interfaces

Dual-fuel engines 5 (5)

199 20 40-4.0 MAN Energy Solutions

9007270936413323
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16.02 Engine control system – second fuel extensions and

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interfaces

Dual-fuel engines
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
17 Vibration Aspects

19 Dispatch Pattern, Testing, Spares and Tools

20 Project Support and Documentation
21 Appendix
61395639051

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

17 Vibration Aspects
 MAN Energy Solutions 198 41 40-5.3

Vibration aspects
The vibration characteristics of the two-stroke low speed diesel engines can
for practical purposes be split up into four categories, and if the adequate
countermeasures are considered from the early project stage, the influence of
the excitation sources can be minimised or fully compensated.
In general, the marine diesel engine may influence the hull with the following:
• External unbalanced moments These can be classified as unbalanced 1st
and 2nd order external moments, which need to be considered only for cer-
tain cylinder numbers
• Guide force moments
• Axial vibrations in the shaft system
• Torsional vibrations in the shaft system.
The external unbalanced moments and guide force moments are illustrated in
Fig. 17.01.01.
In the following, a brief description is given of their origin and of the proper
countermeasures needed to render them harmless.
51943745931

External Unbalanced Moments

The inertia forces originating from the unbalanced rotating and reciprocating
masses of the engine create unbalanced external moments although the ex-
ternal forces are zero.
Of these moments, the 1st order (one cycle per revolution) and the 2nd order
(two cycles per revolution) need to be considered for engines with a low num-
ber of cylinders. On 7-cylinder engines, also the 4th order external moment
may have to be examined. The inertia forces on engines with more than 6 cyl-
inders tend, more or less, to neutralise themselves.
Countermeasures have to be taken if hull resonance occurs in the operating
speed range, and if the vibration level leads to higher accelerations and/or ve-
locities than the guidance values given by international standards or recom-
mendations (for instance related to special agreement between shipowner
and shipyard). The natural frequency of the hull depends on the hull’s rigidity
and distribution of masses, whereas the vibration level at resonance depends
mainly on the magnitude of the external moment and the engine’s position in
relation to the vibration nodes of the ship. 17.01 Vibration aspects
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All Engines 1 (2)

198 41 40-5.3 MAN Energy Solutions
17.01 Vibration aspects

2021-09-30 - en

Fig. 17.01.01: External unbalanced moments and guide force moments

51943745931

2 (2) All Engines

 MAN Energy Solutions 199 15 71-8.0

First and second order moments

The 2nd order moment acts only in the vertical direction. Precautions need only
to be considered for 4, 5 and 6-cylinder engines in general.
Resonance with the 2nd order moment may occur in the event of hull vibrations
with more than 3 nodes. Contrary to the calculation of natural frequency with
2 and 3 nodes, the calculation of the 4 and 5-node natural frequencies for the
hull is a rather comprehensive procedure and often not very accurate, despite
advanced calculation methods.
A 2nd order moment compensator comprises two counter-rotating masses
running at twice the engine speed.

*) Frequency of engine moment

M2V = 2 x engine speed
18014451405713931

Fig. 17.02.01: Statistics of vertical hull vibrations, an example from tankers

and bulk carriers
18014451405713931

Compensator Solutions

17.02 First and second order moments

Several solutions are available to cope with the 2nd order moment, as shown
in Fig. 17.03.02, out of which the most cost efficient one can be chosen in the
individual case, e.g.:
1. No compensators, if considered unnecessary on the basis of natural fre-
quency, nodal point and size of the 2nd order moment.

2. A compensator mounted on the aft end of the engine, driven by chain,

2022-06-01 - en

option: 4 31 203.

3. A compensator mounted on the fore end, driven from the crankshaft

through a separate chain drive, option: 4 31 213.
As standard, the compensators reduce the external 2nd order moment to a
level as for a 7-cylinder engine or less.
Briefly speaking, solution 1) is applicable if the node is located far from the en-
gine, or the engine is positioned more or less between nodes. Solution 2) or 3)
should be considered where one of the engine ends is positioned in a node or
close to it, since a compensator is inefficient in a node or close to it and there-
fore superfluous.

G70ME-C/-GI/-GA, S70ME-C/-GI, S65ME-C/-GI, G60ME-C/-GI, S60ME-C/-GI 1 (3)

199 15 71-8.0 MAN Energy Solutions

Determine the Need

A decision regarding the vibrational aspects and the possible use of com-
pensators must be taken at the contract stage. If no experience is available
from sister ships, which would be the best basis for deciding whether com-
pensators are necessary or not, it is advisable to make calculations to determ-
ine which of the solutions should be applied.

Preparation for Compensators

If compensator(s) are initially omitted, the engine can be delivered prepared
for compensators to be fitted on engine fore end later on, but the decision to
prepare or not must be taken at the contract stage, option: 4 31 212. Meas-
urements taken during the sea trial, or later in service and with fully loaded
ship, will be able to show if compensator(s) have to be fitted at all.
If no calculations are available at the contract stage, we advise to make pre-
parations for the fitting of a compensator in the steering compartment, see
Section 17.03.

Basic Design Regarding Compensators

For 5 and 6-cylinder engines with mechanically driven HPS, the basic design
regarding 2nd order moment compensators is:
▪ With compensator aft, EoD: 4 31 203
▪ Prepared for compensator fore, EoD: 4 31 212
For 5 and 6-cylinder engines with electrically driven HPS, the basic design re-
garding 2nd order moment compensators is::
▪ With MAN B&W external electrically driven moment compensator, Rot-
Comp, EoD: 4 31 255
▪ Prepared for compensator fore, EoD: 4 31 212
The available options for 5 and 6-cylinder engines are listed in the Extent of
Delivery. For 4-cylinder engines, the information is available on request.
17.02 First and second order moments

1st Order Moments on 4-Cylinder Engines

1st order moments act in both vertical and horizontal direction. For our two-
stroke engines with standard balancing these are of the same magnitudes.
For engines with five cylinders or more, the 1st order moment is rarely of any
significance to the ship. It can, however, be of a disturbing magnitude in four-
cylinder engines.
2022-06-01 - en

Resonance with a 1st order moment may occur for hull vibrations with 2 and/
or 3 nodes. This resonance can be calculated with reasonable accuracy, and
the calculation will show whether a compensator is necessary or not on four-
cylinder engines.
A resonance with the vertical moment for the 2 node hull vibration can often
be critical, whereas the resonance with the horizontal moment occurs at a
higher speed than the nominal because of the higher natural frequency of ho-
rizontal hull vibrations.

2 (3) G70ME-C/-GI/-GA, S70ME-C/-GI, S65ME-C/-GI, G60ME-C/-GI, S60ME-C/-GI

 MAN Energy Solutions 199 15 71-8.0

Balancing 1st order moments

As standard, four-cylinder engines are fitted with 1st order moment balancers
in shape of adjustable counterweights, as illustrated in Fig. 17.02.02. These
can reduce the vertical moment to an insignificant value (although, increasing
correspondingly the horizontal moment), so this resonance is easily dealt with.
A solution with zero horizontal moment is also available.

1st order moment compensators

In rare cases, where the 1st order moment will cause resonance with both the
vertical and the horizontal hull vibration mode in the normal speed range of
the engine, a 1st order compensator can be introduced as an option, reducing
the 1st order moment to a harmless value.
Since resonance with both the vertical and the horizontal hull vibration mode
is rare, the standard engine is not prepared for the fitting of 1st order moment
compensators.
Data on 1st order moment compensators and preparation as well as options in
the Extent of Delivery are available on request.

17.02 First and second order moments

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Fig. 17.02.02: Examples of counterweights

18014451405713931

G70ME-C/-GI/-GA, S70ME-C/-GI, S65ME-C/-GI, G60ME-C/-GI, S60ME-C/-GI 3 (3)

199 15 71-8.0 MAN Energy Solutions

18014451405713931
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17.02 First and second order moments

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G70ME-C/-GI/-GA, S70ME-C/-GI, S65ME-C/-GI, G60ME-C/-GI, S60ME-C/-GI

 MAN Energy Solutions 198 42 22-1.6

Electrically Driven Moment Compensator

If it is decided not to use chain driven moment compensators and, further-
more, not to prepare the main engine for compensators to be fitted later, an-
other solution can be used, if annoying 2nd order vibrations should occur: An
external electrically driven moment compensator can neutralise the excitation,
synchronised to the correct phase relative to the external force or moment.
This type of compensator needs an extra seating fitted, preferably, in the
steering gear room where vibratory deflections are largest and the effect of
the compensator will therefore be greatest.
The electrically driven compensator will not give rise to distorting stresses in
the hull, but it is more expensive than the engine-mounted compensators. It
does, however, offer several advantages over the engine mounted solutions:
• When placed in the steering gear room, the compensator is not as sensitive
to the positioning of the node as the compensators 2) and 3) mentioned in
Section 17.02.

17.03 Electrically Driven Moment Compensator

2021-09-20 - en

Fig. 17.03.01: MAN B&W external electrically driven moment compensator,

RotComp, option: 4 31 255

• The decision whether or not to install compensators can be taken at a much

later stage of a project, since no special version of the engine structure has to
be ordered for the installation.
• No preparation for a later installation nor an extra chain drive for the com-
pensator on the fore end of the engine is required. This saves the cost of such
preparation, often left unused.

All Engines 1 (3)

198 42 22-1.6 MAN Energy Solutions

• Compensators could be retrofit, even on ships in service, and also be ap-

plied to engines with a higher number of cylinders than is normally considered
relevant, if found necessary.
• The compensator only needs to be active at speeds critical for the hull
girder vibration. Thus, it may be activated or deactivated at specified speeds
automatically or manually.
• Combinations with and without moment compensators are not required in
torsional and axial vibration calculations, since the electrically driven moment
compensator is not part of the mass-elastic system of the crankshaft.
Furthermore, by using the compensator as a vibration exciter a ship’s vibra-
tion pattern can easily be identified without having the engine running, e.g. on
newbuildings at an advanced stage of construction. If it is verified that a ship
does not need the compensator, it can be removed and reused on another
ship.
It is a condition for the application of the rotating force moment compensator
that no annoying longitudinal hull girder vibration modes are excited. Based
on our present knowledge, and confirmed by actual vibration measurements
onboard a ship, we do not expect such problems.
42532000011

Balancing Other Forces and Moments

Further to compensating 2nd order moments, electrically driven balancers are
also available for balancing other forces and moments. The available options
are listed in the Extent of Delivery.
17.03 Electrically Driven Moment Compensator

2021-09-20 - en

2 (3) All Engines

 MAN Energy Solutions 198 42 22-1.6

17.03 Electrically Driven Moment Compensator

2021-09-20 - en

Fig. 17.03.02: Compensation of 2nd order vertical external moments

42532000011

All Engines 3 (3)

198 42 22-1.6 MAN Energy Solutions

42532000011
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17.03 Electrically Driven Moment Compensator

2021-09-20 - en

All Engines
 MAN Energy Solutions 199 18 45-2.0

Power related unbalance

To evaluate if there is a risk that first and second order external moments will
excite disturbing hull vibrations, the concept power related unbalance (PRU)
can be used as a guidance, see table 17.04.01 below.

PRU = ( external moment/ engine power) Nm/kW

With the PRU-value, stating the external moment relative to the engine power,
it is possible to give an estimate of the risk of hull vibrations for a specific en-
gine.
Based on service experience from a great number of large ships with engines
of different types and cylinder numbers, the PRU-values have been classified
in four groups as follows:

PRU Nm/kW Need for compensator

0 - 60 Not relevant
60 - 120 Unlikely
120 - 220 Likely
220 - Most likely
18014459093954059

G70ME-C10.5/-GA – 2,830 kW/cyl at 78 r/min

5 cyl. 6 cyl.
PRU acc. to first order, Nm/kW 12 0
PRU acc. to second order, Nm/kW 157 91
18014459093954059

Based on external moments in layout point L1

Table 17.04.01: Power related unbalance (PRU) values in Nm/kW
18014459093954059

Calculation of external moments

In the table at the end of this chapter, the external moments (M1) are stated at
the speed (n1) and MCR rating in point L1 of the layout diagram. For other
17.04 Power related unbalance
speeds (nA), the corresponding external moments (MA) are calculated by
means of the formula:

MA = M1 × { nA /n1 }2 kNm
2022-05-30 - en

(The tolerance on the calculated values is 2.5%).

18014459093954059

G70ME-C10.5-GA 1 (1)
199 18 45-2.0 MAN Energy Solutions

18014459093954059
This page is intentionally left blank
17.04 Power related unbalance

2022-05-30 - en

G70ME-C10.5-GA
 MAN Energy Solutions 199 15 55-2.0

Guide force moments

The so-called guide force moments are caused by the transverse reaction
forces acting on the crossheads due to the connecting rod/crankshaft mech-
anism. These moments may excite engine vibrations, moving the engine top
athwartships and causing a rocking (excited by H-moment) or twisting (ex-
cited by X-moment) movement of the engine as illustrated in Fig. 17.05.01.
The guide force moments corresponding to the MCR rating (L1) are stated in
Table 17.07.01.

Top bracing
The guide force moments are harmless except when resonance vibrations oc-
cur in the engine/ double bottom system.
As this system is very difficult to calculate with the necessary accuracy, MAN
Energy Solutions strongly recommend, as standard, that top bracing is in-
stalled between the engine’s upper platform brackets and the casing side.
The vibration level on the engine when installed in the vessel must comply
with MAN Energy Solutions vibration limits as stated in Fig. 17.05.02.
We recommend using the hydraulic top bracing which allow adjustment to the
loading conditions of the ship. Mechanical top bracings with stiff connections
are available on request.
With both types of top bracing, the above-mentioned natural frequency will in-
crease to a level where resonance will occur above the normal engine speed.
Details of the top bracings are shown in Chapter 05.

Definition of guide force moments

Over the years it has been discussed how to define the guide force moments.
Especially now that complete FEM-models are made to predict hull/ engine
interaction, the proper definition of these moments has become increasingly
important.

17.05 Guide force moments

2022-10-12 - en

95-35ME-C/-GI/-LGI 1 (5)
199 15 55-2.0 MAN Energy Solutions

H-type guide force moment (MH)

Each cylinder unit produces a force couple consisting of:
1. A force at crankshaft level
2. Another force at crosshead guide level. The position of the force changes
over one revolution as the guide shoe reciprocates on the guide.

Fig. 17.05.01: H-type and X-type guide force moments

As the deflection shape for the H-type is equal for each cylinder, the Nth order
H-type guide force moment for an N-cylinder engine with regular firing order
is:
N × MH(one cylinder)
For modelling purposes, the size of the forces in the force couple is:
Force = MH/L [kN]
where L is the distance between crankshaft level and the middle position of
the crosshead guide (i.e. the length of the connecting rod).
As the interaction between engine and hull is at the engine seating and the
top bracing positions, this force couple may alternatively be applied in those
17.05 Guide force moments

positions with a vertical distance of (LZ). Then the force can be calculated as:
ForceZ = MH/LZ [kN]
2022-10-12 - en

Any other vertical distance may be applied so as to accomodate the actual

hull (FEM) model.
The force couple may be distributed at any number of points in the longitud-
inal direction. A reasonable way of dividing the couple is by the number of top
bracing and then applying the forces at those points.
ForceZ, one point = ForceZ, total/Ntop bracing, total [kN]

2 (5) 95-35ME-C/-GI/-LGI
 MAN Energy Solutions 199 15 55-2.0

X-type Guide Force Moment (Mx)

The X-type guide force moment is calculated based on the same force couple
as described above. However, as the deflection shape is twisting the engine,
each cylinder unit does not contribute with an equal amount. The centre units
do not contribute very much whereas the units at each end contributes much.
A so-called ‘Bi-moment’ can be calculated (Fig. 17.05.01):
‘Bi-moment’ = ∑[force-couple(cyl.X) × distX] in kNm2
The X-type guide force moment is then defined as:
MX = ‘Bi-Moment’/L kNm
For modelling purpose, the size of the four (4) forces can be calculated:
Force = MX/LX [kN]
where:
LX is the horizontal length between ‘force points’.
Similar to the situation for the H-type guide force moment, the forces may be
applied in positions suitable for the FEM model of the hull. Thus the forces
may be referred to another vertical level LZ above the crankshaft centre line.
These forces can be calculated as follows:
ForceZ, one point = (Mx X L) / (Lz X Lx) [kN]
In order to calculate the forces, it is necessary to know the lengths of the con-
necting rods = L, which are:

17.05 Guide force moments

2022-10-12 - en

95-35ME-C/-GI/-LGI 3 (5)
199 15 55-2.0 MAN Energy Solutions

Engine Type L in mm

G95ME-C10/-GI/-LGI 3,720

G90ME-C10/-GI/-LGI 3,342

S90ME-C9/10/-GI/-LGI 3,600

G80ME-C10/-GI/-LGI 3,530

S80ME-C9/-GI/-LGI 3,450

G70ME-C9/10/-GI/-LGI 3,256

S70ME-C10/-GI/-LGI 2,700

S70ME-C7/8/-GI/-LGI 2,870

S65ME-C8/-GI/-LGI 2,730

G60ME-C10/-GI/-LGI 2,790

S60ME-C10/-GI/-LGI 2,310

G50ME-C9/-GI/-LGI 2,500

S50ME-C9/-GI/-LGI 2,214

S50ME-C8/-GI/-LGI 2,050

S46ME-C8/-GI/-LGI 1,980

G45ME-C9/-GI/-LGI 2,250

S40ME-C9/-GI/-LGI 1,770

S35ME-C9/-GI/-LGI 1,550
17.05 Guide force moments

2022-10-12 - en

4 (5) 95-35ME-C/-GI/-LGI
 MAN Energy Solutions 199 15 55-2.0

Vibration limits valid for single order harmonics

17.05 Guide force moments

2022-10-12 - en

Fig. 17.05.02: Vibration limits

27021653420822923

95-35ME-C/-GI/-LGI 5 (5)
199 15 55-2.0 MAN Energy Solutions

27021653420822923
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17.05 Guide force moments

2022-10-12 - en

95-35ME-C/-GI/-LGI
 MAN Energy Solutions 199 15 32-4.0

Axial and torsional vibrations

When the crank throw is loaded by the gas pressure through the connecting
rod mechanism, the arms of the crank throw deflect in the axial direction of
the crankshaft, exciting axial vibrations. Through the thrust bearing, the sys-
tem is connected to the ship’s hull.
Generally, only zero-node axial vibrations are of interest. Thus the effect of the
additional bending stresses in the crankshaft and possible vibrations of the
ship`s structure due to the reaction force in the thrust bearing are to be con-
sideraed.
An axial damper is fitted as standard on all engines, minimising the effects of
the axial vibrations, EoD: 4 31 111.

Torsional vibrations
The reciprocating and rotating masses of the engine including the crankshaft,
the thrust shaft, the intermediate shaft(s), the propeller shaft and the propeller
are for calculation purposes considered a system of rotating masses (inertias)
interconnected by torsional springs. The gas pressure of the engine acts
through the connecting rod mechanism with a varying torque on each crank
throw, exciting torsional vibration in the system with different frequencies.
In general, only torsional vibrations with one and two nodes need to be con-
sidered. The main critical order, causing the largest extra stresses in the shaft
line, is normally the vibration with order equal to the number of cylinders, i.e.,
six cycles per revolution on a six cylinder engine. This resonance is positioned
at the engine speed corresponding to the natural torsional frequency divided
by the number of cylinders.
The torsional vibration conditions may, for certain installations require a tor-
sional vibration damper, option: 4 31 105.
Plants with 11 or 12-cylinder engines in the bore range 98-80 require a tor-
sional vibration damper.
Based on our statistics, this need may arise for the following types of installa-
tion:
• Plants with controllable pitch propeller
• Plants with unusual shafting layout and for special owner/yard requirements 17.06 Axial and torsional vibrations
• Plants with 8-cylinder engines.
The so-called QPT (Quick Passage of a barred speed range Technique), is an
alternative to a torsional vibration damper, on a plant equipped with a control-
lable pitch propeller. The QPT could be implemented in the governor in order
to limit the vibratory stresses during the passage of the barred speed range.
2023-02-07 - en

The application of the QPT, option: 4 31 108, has to be decided by the engine
maker and MAN Energy Solutions based on final torsional vibration calcula-
tions.
Six-cylinder engines, require special attention. On account of the heavy excit-
ation, the natural frequency of the system with one-node vibration should be
situated away from the normal operating speed range, to avoid its effect. This
can be achieved by changing the masses and/or the stiffness of the system
so as to give a much higher, or much lower, natural frequency, called under-
critical or overcritical running, respectively.

All Engines 1 (4)

199 15 32-4.0 MAN Energy Solutions

Owing to the very large variety of possible shafting arrangements that may be
used in combination with a specific engine, only detailed torsional vibration
calculations of the specific plant can determine whether or not a torsional vi-
bration damper is necessary.

Undercritical running
The natural frequency of the one-node vibration is so adjusted that resonance
with the main critical order occurs about 35-45% above the engine speed at
specified MCR.
Such undercritical conditions can be realised by choosing a rigid shaft sys-
tem, leading to a relatively high natural frequency.
The characteristics of an undercritical system are normally:
• Relatively short shafting system
• Probably no tuning wheel
• Turning wheel with relatively low inertia
• Large diameters of shafting, enabling the use of shafting material with a
moderate ultimate tensile strength, but requiring careful shaft alignment,(due
to relatively high bending stiffness)
• Without barred speed range.

Critical running
When running undercritical, significant varying torque at MCR conditions of
about 100-150% of the mean torque is to be expected.
This torque (propeller torsional amplitude) induces a significant varying pro-
peller thrust which, under adverse conditions, might excite annoying longitud-
inal vibrations on engine/double bottom and/or deck house.
The yard should be aware of this and ensure that the complete aft body struc-
ture of the ship, including the double bottom in the engine room, is designed
to be able to cope with the described phenomena.

Overcritical running
17.06 Axial and torsional vibrations

The natural frequency of the one node vibration is so adjusted that resonance
with the main critical order occurs at about 30-60% of the engine speed at
specified MCR. Such overcritical conditions can be realised by choosing an
elastic shaft system, leading to a relatively low natural frequency.
The characteristics of overcritical conditions are:
2023-02-07 - en

• Tuning wheel may be necessary on crankshaft fore end

• Turning wheel with relatively high inertia
• Shafts with relatively small diameters, requiring shafting material with a relat-
ively high ultimate tensile strength
• With barred speed range, EoD: 4 07 015, of about ±10% with respect to
the critical engine speed.
Torsional vibrations in overcritical conditions may, in special cases, have to be
eliminated by the use of a torsional vibration damper.
Overcritical layout is normally applied for engines with more than four cylin-
ders.

2 (4) All Engines

 MAN Energy Solutions 199 15 32-4.0

Please note:
We do not include any tuning wheel or torsional vibration damper in the
standard scope of supply, as the proper countermeasure has to be found
after torsional vibration calculations for the specific plant, and after the de-
cision has been taken if and where a barred speed range might be accept-
able.

Governor stability evaluation for special plants

On rare occasions, plant layouts are prone to engine speed instability or “en-
gine hunting”. These plant layouts usually fall within one of the three categor-
ies mentioned below. MAN Energy Solutions may require that a governor sta-
bility evaluation is carried out for plants in the risk of encountering engine
speed instability. The purpose of the governor stability evaluation is to identify
the potential risks of engine speed instability and suggest corresponding
countermeasures to the plant design. MAN Energy Solutions offers a governor
stability evaluation against a fee.

1. Torsional vibrations at low frequency

A low torsional vibration frequency of a slender shaft line may interfere with
the engine speed measurement of the engine control system (ECS). The ECS
uses the speed measurement to calculate the fuel index, and therefore it dir-
ectly affects the engine torque. The interference can in worst-case lead to
amplification of the vibrations and hunting phenomena.
If the governor stability analysis reveals a risk of interference, the solution is to
install an extra speed measurement device on the shaft line for the ECS, a so-
called dual tacho.

2. Large electrical power take-off

If the power take-off (PTO) solution includes a variable frequency drive (VFD),
which is the norm today, the PTO control system strategy is to deliver the re-
quired electrical power independent of the actual engine speed. This control
strategy reduces the stability of the engine speed, because a drop in engine
speed results in an increase in shaft generator torque to maintain a constant
electrical power output. If the destabilisation effect is large, the engine control
system is not able to compensate and properly stabilise the engine speed, 17.06 Axial and torsional vibrations
this could result in engine hunting.
The destabilisation effect is largest at low speeds and at a high level of PTO.
If the governor stability analysis shows an inadequate stability margin, the PTO
has to be limited in specific speed ranges, or turning and tuning wheels of
2023-02-07 - en

higher inertia could be installed.

Usually, it is possible to mitigate the instability by applying our extended inter-
face to the power management system (interface option C). See section 2.03
of the project guide for more information about the use of a PTO and PTO lim-
its.

All Engines 3 (4)

199 15 32-4.0 MAN Energy Solutions

3. Operation without propeller

The propeller adds inertia and damping to the system which both increases
engine speed stability and torque disturbance rejection. If the propeller is de-
tached, for example by a clutch, the reduced system becomes more volatile.
The result is an increased risk of critical speed overshoot and a reduced en-
gine speed stability margin.
Normally, an engine is only allowed to operate in a narrow speed range
without a propeller. The speed range is determined as part of the governor
stability evaluation.

Plant criteria requiring a governor stability evaluation

If a plant fulfils one of the below criteria, MAN Energy Solutions must be con-
tacted for further analysis, in case a plant fulfils one of the below mentioned
criteria. In that case, we will conduct a governor stability evaluation against a
fee. These special plants must be handled on an individual basis, preferably at
an early stage of the design.
▪ PTO output is higher than specified in project guide section 2.03
▪ The engine is operated with PTO at test bed
▪ 1st node torsional vibration frequency in the propeller shaft line is lower
than:
– 3 Hz for FPP plants
– 5 Hz for CPP plants
▪ The design includes a clutch for disconnecting the propeller
▪ The engine is for other reasons operated without a propeller, for example
during PTO tests
▪ The design deviates from known “standard” plant designs.
The governor stability evaluation can lead to changes in the control equip-
ment. This could, for example, be an increase of signals from the plant and re-
quirements to the design of engine-driven mechanical components. The eval-
uation can also result in changes in the use of the PTO.
Direct questions regarding the governor stability evaluation at RDCPH@man-
17.06 Axial and torsional vibrations

es.com.
27021650270452747

2023-02-07 - en

4 (4) All Engines

 MAN Energy Solutions 199 18 46-4.0

External forces and moments, G70ME-C10.5-GA, layout point L1

Diesel operation - Tier II

No of cylinder: 5 6

Firing type: 1-4-3-2-5 1-5-3-4-2-6

External forces [kN]:

1. order: horisontal 0 0

1. order: vertical 0 0

2. order: vertical 0 0

4. order: vertical 0 0

6. order: vertical 0 21

External moments [kNm]:

1. order: horisontal a) 193 0

1. order: vertical a) 193 0

2. order: vertical 2,430 1,690

17.07 External forces and moments, G70ME-C10.5-GA, lay-

4. order: vertical 18 137

6. order: vertical 2 0

Guide force H-moments in [kNm]:

1 x No. of cyl. 2,362 1,633

2 x No. of cyl. 137 110

3 x No. of cyl. - -

Guide force X-moments in [kNm]:

1. order: 233 0

2. order: 1,097 763

3. order: 631 1,140

4. order: 84 646

5. order: 0 0

6. order: 41 0
2022-10-18 - en

7. order: 271 0

8. order: 167 116

9. order: 8 150
out point L1

10. order: 0 32

11. order: 3 0

12. order: 31 0

13. order: 24 0

14. order: 2 18

G70ME-C10.5-GA 1 (4)
199 18 46-4.0 MAN Energy Solutions

15. order: 0 51

16. order: 2 15

a) First order moments are, as standard, balanced so as to obtain equal val-

ues for horisontal and vertical moments for all cylinder numbers.
c) 5- and 6-cylinder engines can be fitted with second order moment com-
pensators on the aft and fore end, reducing the second order external mo-
ment.
Table 17.07.01: External forces and moments

Diesel operation - Tier III

No of cylinder: 5 6

Firing type: 1-4-3-2-5 1-5-3-4-2-6

External forces [kN]:

1. order: horisontal 0 0

1. order: vertical 0 0

2. order: vertical 0 0

4. order: vertical 0 0
17.07 External forces and moments, G70ME-C10.5-GA, lay-

6. order: vertical 0 21

External moments [kNm]:

1. order: horisontal a) 193 0

1. order: vertical a) 193 0

2. order: vertical 2,430 1,690

4. order: vertical 18 137

6. order: vertical 2 0

Guide force H-moments in [kNm]:

1 x No. of cyl. 2,314 1,624

2 x No. of cyl. 170 119

3 x No. of cyl. - -

Guide force X-moments in [kNm]:

1. order: 227 0
2022-10-18 - en

2. order: 1,022 711

3. order: 582 1,052

4. order: 82 628
out point L1

5. order: 0 0

6. order: 41 0

7. order: 277 0

8. order: 171 119

2 (4) G70ME-C10.5-GA
 MAN Energy Solutions 199 18 46-4.0

9. order: 8 164

10. order: 0 40

11. order: 4 0

12. order: 33 0

13. order: 27 0

14. order: 3 20

15. order: 0 51

16. order: 2 15

a) First order moments are, as standard, balanced so as to obtain equal val-

ues for horisontal and vertical moments for all cylinder numbers.
c) 5- and 6-cylinder engines can be fitted with second order moment com-
pensators on the aft and fore end, reducing the second order external mo-
ment.
Table 17.07.01: External forces and moments

Gas operation - Tier III

No of cylinder: 5 6

17.07 External forces and moments, G70ME-C10.5-GA, lay-

Firing type: 1-4-3-2-5 1-5-3-4-2-6

External forces [kN]:

1. order: horisontal 0 0

1. order: vertical 0 0

2. order: vertical 0 0

4. order: vertical 0 0

6. order: vertical 0 21

External moments [kNm]:

1. order: horisontal a) 193 0

1. order: vertical a) 193 0

2. order: vertical 2,430 1,690

4. order: vertical 18 137

6. order: vertical 2 0
2022-10-18 - en

Guide force H-moments in [kNm]:

1 x No. of cyl. 2,156 1,703

2 x No. of cyl. 393 281

out point L1

3 x No. of cyl. - -
9007259839808395

Guide force X-moments in [kNm]:

1. order: 191 0

2. order: 592 412

G70ME-C10.5-GA 3 (4)
199 18 46-4.0 MAN Energy Solutions

3. order: 306 553

4. order: 69 536

5. order: 0 0

6. order: 43 0

7. order: 330 0

8. order: 236 164

9. order: 15 303

10. order: 0 92

11. order: 9 0

12. order: 79 0

13. order: 67 0

14. order: 5 41

15. order: 0 87

16. order: 4 29
9007259839808395

a) First order moments are, as standard, balanced so as to obtain equal val-

ues for horisontal and vertical moments for all cylinder numbers.
17.07 External forces and moments, G70ME-C10.5-GA, lay-

c) 5- and 6-cylinder engines can be fitted with second order moment com-
pensators on the aft and fore end, reducing the second order external mo-
ment.
Table 17.07.01: External forces and moments
9007259839808395

2022-10-18 - en
out point L1

4 (4) G70ME-C10.5-GA
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water

18 Monitoring Systems and Instrumentation

13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395646475

1 (1)
 MAN Energy Solutions

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18 Monitoring Systems and Instrumentation
 MAN Energy Solutions 198 85 29-9.3

Monitoring systems and instrumentation

The Engine Control System (ECS) is supported by the Engine Management
Services (EMS), which manages software, data and applications for engine
monitoring and operation.
The EMS includes the PMI and the CoCoS-EDS (Computer Controlled Sur-
veillance-Engine Diagnostics System) as applications.
In its basic design, the ME/ME-B engine instrumentation consists of:
▪ Engine Control System (ECS), see Section 16.01
▪ Shut-down sensors, EoD: 4 75 124
▪ EMS including PMI and CoCoS-EDS software and support for LAN-based
interface to the AMS, EoD: 4 75 217, see Section 18.02
▪ Sensors for alarm, slow down and remote indication according to the
classification society’s and MAN Energy Solutions' requirements for UMS,
EoD: 4 75 127, see Section 18.04.
All instruments are identified by a combination of symbols and a position num-
ber as shown in Section 18.07.
51943823115

18.01 Monitoring systems and instrumentation

2021-09-30 - en

ME/ME-C/ME-B/-GI/-GA/-LGI 1 (1)
198 85 29-9.3 MAN Energy Solutions

51943823115
This page is intentionally left blank
18.01 Monitoring systems and instrumentation

2021-09-30 - en

ME/ME-C/ME-B/-GI/-GA/-LGI
 MAN Energy Solutions 199 05 99-0.0

Engine Management Services

Engine Management Services Overview

The Engine Management Services (EMS) is used on MAN B&W engines from
MAN Energy Solutions for condition monitoring, data logging & data distribu-
tion. EMS is integrated with the ECS (Engine Control System) to allow for con-
tinuous performance tuning.
EMS is executed on the EMS MOP, an industrial type PC designed by MAN
Energy Solutions. EMS is implemented as a hardened platform, robust to
virus threats and other unauthorized use and ac-cess.
The EMS network topology is shown in Fig. 18.02.01.

18.02 Engine Management Services

Fig 18.02.01: Engine Management Services, EMS, EoD: 4 75 217

EMS Applications
EMS includes the applications PMI Auto-tuning, CoCoS-EDS and EMS man-
2021-07-20 - en

ager.

PMI Auto-tuning
▪ Online cylinder pressure monitoring
▪ Input to engine control system for closed-loop performance tuning
▪ Engine power estimation.
PMI Auto-tuning continuously measures the cylinder pressures using online
sensors mounted on each cylinder cover. Pressure measurements are
presented continuously in real time and the corresponding key performance
values are transferred to the Engine Control System.

ME/ME-C/ME-B/-GI/-GA/-LGI 1 (2)
199 05 99-0.0 MAN Energy Solutions

The Engine Control System constantly monitors and compares the measured
combustion pressures to a reference value. As such, the control system auto-
matically adjusts the fuel injection and valve timing to reduce the deviation
between the measured values and the reference. This, in turn, facilitates the
optimal combustion pressures for the next firing. Thus, the system ensures
that the engine is running at the desired maximum pressure, p(max).

CoCoS-EDS
▪ Data logging
▪ Engine condition monitoring and reporting
▪ Engine operation troubleshooting.
With CoCoS-EDS, early intervention as well as preventive maintenance, the
engine operators are able to reduce the risk of damages and failures.
CoCoS-EDS further allows for easier troubleshooting in cases where unusual
engine behavior is observed.

EMS Manager
▪ Installation and supervision of EMS applications
▪ Network and interface monitoring
▪ Optional interface for data exchange with AMS (Alarm Monitoring System).
The EMS manager provides a process for integrated installation, commission-
ing and maintenance of PMI Auto-tuning and CoCoS-EDS.
Further, the EMS Manager includes status information and functionality, e.g.
for network status, internal and external interfaces and EMS application exe-
cution.
39041011339
18.02 Engine Management Services

2021-07-20 - en

2 (2) ME/ME-C/ME-B/-GI/-GA/-LGI
 MAN Energy Solutions 198 45 82-6.9

Condition Monitoring System CoCoS-EDS

18.03 Condition Monitoring System CoCoS-EDS

2021-07-20 - en

39041661067

1 (1)
198 45 82-6.9 MAN Energy Solutions

39041661067
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18.03 Condition Monitoring System CoCoS-EDS

2021-07-20 - en
 MAN Energy Solutions 199 15 52-7.0

Slow down and shut down

The shut down system must be electrically separated from other systems by
using independent sensors, or sensors common to the alarm system and the
monitoring system but with galvanically separated electrical circuits, i.e. one
sensor with two sets of electrically independent terminals. The list of sensors
are shown in Table 18.04.04.

Basic Safety System Design and Supply

The basic safety sensors for a MAN B&W engine are designed for Unattended
Machinery Space (UMS) and comprises:
▪ the temperature sensors and pressure sensors that are specified in the
‘MAN Energy Solutions’ column for shut down in Table 18.04.04.
These sensors are included in the basic Extent of Delivery, EoD: 4 75 124.

Alarm and Slow Down System Design and Supply

The basic alarm and slow down sensors for a MAN B&W engine are designed
for Unattended Machinery Space (UMS) and comprises:
▪ The sensors for alarm and slow down.
These sensors are included in the basic Extent of Delivery, EoD: 4 75 127.
The shut down and slow down panels can be ordered as options: 4 75 630, 4
75 614 or 4 75 615 whereas the alarm panel is yard’s supply, as it normally
includes several other alarms than those for the main engine.
For practical reasons, the sensors for the engine itself are normally delivered
from the engine supplier, so they can be wired to terminal boxes on the en-
gine.
The number and position of the terminal boxes depends on the degree of dis-
mantling specified in the Dispatch Pattern for the transportation of the engine
based on the lifting capacities available at the engine maker and at the yard.

Alarm, Slow Down And Remote Indication Sensors

The International Association of Classification Societies (IACS) indicates that a
18.04 Slow down and shut down
common sensor can be used for alarm, slow down and remote indication.
A general view of the alarm, slow down and shut down systems is shown in
Fig. 18.04.01.
Tables 18.04.02 and 18.04.03 show the requirements by MAN Energy Solu-
2024-01-24 - en

tions for alarm and slow down and for UMS by the classification societies
(Class), as well as IACS’ recommendations.
The number of sensors to be applied to a specific plant is the sum of require-
ments of the classification society, the Buyer and MAN Energy Solutions.
If further analogue sensors are required, they can be ordered as option: 4 75
128.

All engines 1 (11)

199 15 52-7.0 MAN Energy Solutions

Slow Down Functions

The slow down functions are designed to safeguard the engine components
against overloading during normal service conditions and to keep the ship
manoeuvrable if fault conditions occur.
The slow down sequence must be adapted to the actual plant parameters,
such as for FPP or CPP, engine with or without shaft generator, and to the re-
quired operating mode.

Electrical System, General Outline

The figure shows the concept approved by all classification societies.
The shut down panel and slow down panel can be combined for some
makers.
The classification societies permit having common sensors for slow down,
alarm and remote indication.
One common power supply might be used, instead of the three indicated,
provided that the systems are equipped with separate fuses.
18.04 Slow down and shut down

2024-01-24 - en

2 (11) All engines

 MAN Energy Solutions 199 15 52-7.0

Alarms for UMS – Class and MAN Energy Solutions Requirements

ABS BV CCS DNV KR LR NK RINA RS IACS MAN Sensor and Point of location
ES function

Fuel oil

1 1 1 1 1 1 1 1 1 1 1 PT 8001 A Fuel oil, inlet engine

1 1 1 1 1 1 1 1 1 1 1 LS 8006 A Leakage from high pressure

pipes

Lubricating oil

1 1 1 1 1 1 1 1 1 1 1 TT 8106 A Thrust bearing segment

1 1 1 1 1 1 1 1 1 1 1 PT 8108 A Lubricating oil inlet to main en-

gine

1 1 1 1 1 1 1 1 1 1 TT 8113 A Piston cooling oil outlet/cylinder

1 1 1 1 1 1 1 1 1 1 FS 8114 A Piston cooling oil outlet/cylinder

1 TT 8117 A Turbocharger lubricating oil out-

let/turbocharger

1 TE 8123 A Main bearing oil outlet temperat-

ure/main bearing (S40/35ME-B9
only)

1 XC 8126 A Bearing wear (All types except

S40/35ME-B9); sensor common
to XC 8126/27

1 XS 8127 A Bearing wear detector failure (All

types except S40/ 35ME-B)

1 1 1 1 PDS 8140 A Lubricating oil differential pres-

sure - cross filter

1 XS 8150 A Water in lubricating oil; sensor

common to XS 8150/51/52

1 XS 8151 A Water in lubricating oil - too high

18.04 Slow down and shut down
1 XS 8152 A Water in lubricating oil sensor not
ready

MAN B&W Alpha Lubrication

2024-01-24 - en

1 TE 8202 A Cylinder lubricating oil temperat-

ure

1 LS 8212 A Small tank for heating element,

low level (Not for ACOM)

1 XC 8265 A ACOM common alarm (Only for

ACOM)

1. Indicates that the sensor is required.

The sensors in the MAN ESS and relevant Class columns are included in the
basic Extent of Delivery, EoD: 4 75 127.

All engines 3 (11)

199 15 52-7.0 MAN Energy Solutions

The sensor identification codes and functions are listed in Table 18.07.01.
The tables are liable to change without notice, and are subject to latest Class
requirements.
Table 18.04.02a: Alarm functions for UMS
18.04 Slow down and shut down

2024-01-24 - en

4 (11) All engines

 MAN Energy Solutions 199 15 52-7.0

Alarms for UMS – Class and MAN Energy Solutions’ requirements

ABS BV CCS DNV KR LR NK RINA RS IACS MAN Sensor and Point of location
ES function

Hydraulic Power
Supply

1 PT 1228 A LPS booster, oil

presure after pump
(Only if LPS pump)

1 PDS 1231 A ME (Auto) filter dif-

ferential pressure
across filter

1 TT 1310 A Lubrication oil inlet

(Only for ME/-GI
with separate oil
system to HPS in-
stalled)

Cooling water

1 1 1 1 1 1 1 1 1 1 1 PT 8401 A Jacket cooling wa-

ter inlet

1 PDT 8403 A Jacket cooling wa-

ter across engine;
to be calculated in
alarm system from
sensor no. 8402
and 8413 3)

1 PDT 8404 A Jacket cooling wa-

ter across cylinder
liners 2)

1 PDT 8405 A Jacket cooling wa-

ter across cylinder
covers and exhaust 18.04 Slow down and shut down
valves 2)

1 TT 8407 A Jacket cooling wa-

ter inlet

1 1 1 1 1 1 1 1 1 1 1 1 TT 8408 A Jacket cooling wa-

2024-01-24 - en

ter outlet, cylinder

1 TT 8410 A Cylinder cover cool-

ing water outlet,
cylinder 2)

1 PT 8413 I Jacket cooling wa-

ter outlet, common
pipe

1 1 1 1 1 1 1 1 1 1 PT 8421 A Cooling water inlet

air cooler

All engines 5 (11)

199 15 52-7.0 MAN Energy Solutions

1 TT 8422 A Cooling water inlet

air cooler/air cooler

Compressed air

1 1 1 1 1 1 1 1 1 1 PT 8501 A Starting air inlet to

main starting valve

1 1 1 1 1 1 1 1+ 1 1 1 PT 8503 A Control air inlet and

finished with engine

1 1 PT 8505 A Air inlet to air cylin-

der for exhaust
valve

Scavenge air

1 1 PS 8604 A Scavenge air, auxili-

ary blower, failure
(Only ME-B)

1 TT 8609 A Scavenge air re-

ceiver

1 1 1 1 1 1 1 1 1 TT 8610 A Scavenge air box –

fire alarm, cylinder/
cylinder

1 1 1 1 1 1 1 1 1 1 LS 8611 A Water mist catcher

– water level

1. Indicates that the sensor is required.

The sensors in the MAN ES and relevant Class columns are included in the
basic Extent of Delivery, EoD: 4 75 127.
The sensor identification codes and functions are listed in Table 18.07.01.
The tables are liable to change without notice, and are subject to latest Class
requirements.
2. Required only for engines wirh LDCL cooling water system.
3. Not applicable for engines with LDCL cooling water system.

Select one of the alternatives

18.04 Slow down and shut down

Alarm for high pressure, too

Alarm for low pressure, too

Table 18.04.02b: Alarm functions for UMS

2024-01-24 - en

6 (11) All engines

 MAN Energy Solutions 199 15 52-7.0

Alarms for UMS – Class and MAN Energy Solutions’ requirements

ABS BV CCS DNV KR LR NK RIN RS IAC MAN Sensor and Point of location
A S ES function

Exhaust gas

1 1 1 1 1 (1) 1 1 1 1 1 TT8701 A Exhaust gas before tur-

bocharger/turbocharger

1 1 1 1 1 1 1 1 1 1 TT8702 A Exhaust gas after ex-

haust valve, cylinder/cyl-
inder

1 1 1 1 1 1 1 1 1 1 TT8707 A Exhaust gas outlet tur-

bocharger/turbocharger
(Yard’s supply)

Miscellaneous

1 ZT8801 A Turbocharger speed/

turbocharger

1 WT8812 A Axial vibration monitor

2)

1 1 1 1 1 1 1 1 1 1 XS8813 A Oil mist in crankcase/

cylinder; sensor com-
mon to XS 8813/14

1 1 XS8814 A Oil mist detector failure

1 XC8816 A Shaftline earthing device

1 TT8820 A Cylinder liner monitor-

ing/cylinder 3)

Engine Control System

1 1 1 1 1 1 1 1 1 1 1 XC2201 A Power failure

1 1 1 1 1 1 1 1 1 XC2202 A ME common failure

1 XC2202-A ME common failure 18.04 Slow down and shut down

A (ME-GI only)

1 XC2213 A Double-pipe HC alarm

(ME-GI only)

Power Supply Units to

2024-01-24 - en

Alarm System

1 XC2909 Main supply failure

1 XC2910 Battery discharging

1 XC2911 Battery protective

device tripped

1. Indicates that the sensor is required.

The sensors in the MAN ES and relevant Class columns are included in the
basic Extent of Delivery, EoD: 4 75 127.

All engines 7 (11)

199 15 52-7.0 MAN Energy Solutions

The sensor identification codes and functions are listed in Table 18.07.01.
The tables are liable to change without notice, and are subject to latest Class
requirements.
(1) May be combined with TC 8702 AH where turbocharger is mounted dir-
ectly on the exhaust manifold.
2) Required for certain engines only, see the list in Section 18.06, Axial Vibra-
tion Monitor.
3) Required for: K98ME/ME-C, S90ME-C, K90ME-C and K80ME-C9 engines
incl. ME-GI variants.

Alarm for overheating of main, crank and crosshead bearings, option: 4 75

134.

Table 18.04.02c: Alarm functions for UMS

18.04 Slow down and shut down

2024-01-24 - en

8 (11) All engines

 MAN Energy Solutions 199 15 52-7.0

Slow down for UMS - Class and MAN Energy Solutions' requirements
ABS BV CCS DNV KR LR NK RINA RS IACS MAN Sensor & function Point of location
-ES
1 1 1 1 1 1 1 1 1 1 1 TT 8106 Y Thrust bearing segment

1 1 1 1 1 1 1 1 1 1 1 PT 8108 Y Lubricating oil inlet to main engine

1 1 1 1 1 1 1 1 1 1 TT 8113 Y Piston cooling oil outlet/cylinder

1 1 1 1 1 1 1 1 1 1 1 FS 8114 Y Piston cooling oil outlet/cylinder

1 1 1 1 1 1 1 1 1 TT 8117 Y Turbocharger lubricating oil outlet/

TC

1 TE 8123 Y Main bearing oil outlet temp./main

bearing

1 XC 8126 A Bearing wear

1 1 1 1 1 1 1 1 1 1 1 PT 8401 Y Jacket cooling water inlet

1 PDT 8403 Y Jacket cooling water across engine

(not LDCL)

1 PDT 8404 Y Jacket cooling water across en-

gine(only LDCL)

1 PDT 8405 Y Jacket cooling water across cyl.

covers and exhaust valves (Only
LDCL)

1 1 1 1 1 1 1 1 1 1 1 TE 8408 Y Jacket cooling water outlet

1 1 1 TE 8609 Y Scavenge air receiver

1 1 1 1 1 1 1 1 1 1 1 TE 8610 Y Scavenge air box fire alarm

1 1 1 1 TC 8701 Y Exhaust gas before TC

1 1 1 1 1 1 1 1 1 1 TT 8702 Y Exhaust gas after exhaust valve

1 1 TT 8702 Y Exhaust gas after exhaust valve,

cylinder deviation from average 18.04 Slow down and shut down
1 ZT 8801 Y Turbocharger overspeed

1 WT 8812 Y Axial vibration monitor 2)

1 1 1 1 1 1 1 1 1 1 1 XS 8813 Y Oil mist in crankcase/cylinder

1 TT 1310 Y Lubricating oil inlet (only ME-GI w.

2024-01-24 - en

separate HPS)

1. Indicates that the sensor is required.

The sensors in the MAN ES and relevant Class columns are included in the
basic Extent of Delivery, EoD: 4 75 127.
The sensor identification codes and functions are listed in Table 18.07.01.
The tables are liable to change without notice, and are subject to latest Class
requirements.
2) Required for certain engines only, see the list in Section 18.06, Axial Vibra-
tion Monitor.

All engines 9 (11)

199 15 52-7.0 MAN Energy Solutions

Table 18.04.03: Slow down functions for UMS

Shut down for AMS and UMS - Class and MAN Energy Solutions' requirements
ABS BV CCS DNV KR LR NK RINA RS IACS MAN Sensor & function Point of location
-ES
1 1 1 1 1 1 1 1 1 1 PS/PT 8109 Z Lubricating oil inlet to main engine
and thrust bearing

1 1 1 1 1 1 1 1 1 1 ZT 4020 Z Engine overspeed

1 1 1 1 1 1 1 1 TE/TS 8107 Z Thrust bearing segment

1 XS 8817 Z Turbocharger overspeed (only in

case of EGR or EGB, VT TC,
power turbine/hybrid TC, TC cut-
out and system handshake, see
table 18.06.03

1. Indicates that the sensor is required.

▪ The sensors in the MAN ES and relevant Class columns are included in
the basic Extent of Delivery, EoD: 4 75 124.
The sensor identification codes and functions are listed in Table 18.07.01.
The tables are liable to change without notice, and are subject to latest
Class requirements.
Or alarm for overheating of main, crank and crosshead bearings or slow
down, option: 4 75 134
Se also table 18.04.03: Slow down functions for UMS.

Table 18.04.04: Shut down functions for AMS and UMS, option 4 75 124
18.04 Slow down and shut down

2024-01-24 - en

10 (11) All engines

 MAN Energy Solutions 199 15 52-7.0

International Association of Classification Societies

The members of the International Association of Classification Societies, IACS,
have agreed that the stated sensors are their common recommendation,
apart from each Class' requirements.
The members of IACS are:

ABS American Bureau of Shipping

BV Bureau Veritas
CCS China Classification Society
DNV Det Norske Veritas
KR Korean Register
LR Lloyd's Register
NK Nippon Kaiji Kyokai
RINA Registro Italiano Navale
RS Russian Maritime Register of Shipping
72057655884356875

18.04 Slow down and shut down

2024-01-24 - en

All engines 11 (11)

199 15 52-7.0 MAN Energy Solutions

72057655884356875
This page is intentionally left blank
18.04 Slow down and shut down

2024-01-24 - en

All engines
 MAN Energy Solutions 198 45 86-3.13

Local instruments
The basic local instrumentation on the engine, options: 4 70 119 comprises
thermometers, pressure gauges and other indicators located on the piping or
mounted on panels on the engine. The tables 18.05.01a, b and c list those as
well as sensors for slow down, alarm and remote indication, option: 4 75 127.

Local instruments Remote sensors Point of location

Thermometer, Temperature
stem type element/switch
Hydraulic power supply
TE 1270 HPS bearing temperature (Only ME/ME-C with HPS in centre position)
Fuel oil
TI 8005 TE 8005 Fuel oil, inlet engine
Lubricating oil
TI 8106 TE 8106 Thrust bearing segment
TE/TS 8107 Thrust bearing segment
TI 8112 TE 8112 Lubricating oil inlet to main engine
TI 8113 TE 8113 Piston cooling oil outlet/cylinder
TI 8117 TE 8117 Lubricating oil outlet from turbocharger/turbocharger
(depends on turbocharger design)
TE 8123 Main bearing oil outlet temperature/main bearing (S40/35ME-B9 only)
Cylinder lubricating oil
TE 8202 Cylinder lubricating oil inlet
TS 8213 Cylinder lubricating heating
High temperature cooling water, jacket cooling water
TI 8407 TE 8407 Jacket cooling water inlet
TI 8408 TE 8408 Jacket cooling water outlet, cylinder/cylinder
TI 8409 TE 8409 Jacket cooling water outlet/turbocharger
TI 8410 TT 8410 Cylinder cover cooling water outlet, cylinder (Only for LDCL)
Low temperature cooling water, seawater or freshwater for central
cooling
TI 8422 TE 8422 Cooling water inlet, air cooler
TI 8423 TE 8423 Cooling water outlet, air cooler/air cooler
Scavenge air
TI 8605 TE 8605 Scavenge air before air cooler/air cooler
TI 8608 TE 8608 Scavenge air after air cooler/air cooler
TI 8609 TE 8609 Scavenge air receiver
TE 8610 Scavenge air box – fire alarm, cylinder/cylinder
18.05 Local instruments
2022-07-27 - en

Thermometer, Thermo couple

dial type
Exhaust gas
TI 8701 TC 8701 Exhaust gas before turbocharger/turbocharger
TI/TC 8702 Exhaust gas after exhaust valve, cylinder/cylinder
TC 8704 Exhaust gas inlet exhaust gas receiver
TI 8707 TC 8707 Exhaust gas outlet turbocharger
18014450453323019

Table 18.05.01a: Local thermometers on engine, options 4 70 119, and re-

mote indication sensors, option: 4 75 127

ME/ME-C/ME-B/-GI/-GA/-LGI 1 (3)
198 45 86-3.13 MAN Energy Solutions

Local instruments Remote sensors Point of location

Pressure gauge Pressure
(manometer) transmitter/switch
Fuel oil
PI 8001 PT 8001 Fuel oil, inlet engine
Lubricating oil
PI 8103 PT 8103 Lubricating oil inlet to turbocharger/turbocharger
PI 8108 PT 8108 Lubricating oil inlet to main engine
PS/PT 8109 Lubricating oil inlet to main engine and thrust bearing
PDS 8140 Lubricating oil differential pressure – cross filter
High temperature jacket cooling water, jacket cooling water
PI 8401 PT 8401 Jacket cooling water inlet
PS/PT 8402 Jacket cooling water inlet (Only Germanischer Lloyd)
PDT 8403 Jacket cooling water across engine (or PT 8401 and PT 8413)
(Not for LDCL)
PDT 8404 Jacket cooling water across cylinder liners (Only for LDCL)
PDT 8405 Jacket cooling water across cylinder covers and exhaust valves
(Only for LDCL)
PT 8413 Jacket cooling water outlet, common pipe
Low temperature cooling water, seawater or freshwater for central
cooling
PI 8421 PT 8421 Cooling water inlet, air cooler
Compressed air
PI 8501 PT 8501 Starting air inlet to main starting valve
PI 8503 PT 8503 Control air inlet
PT 8505 Air inlet to air cylinder for exhaust valve (Only ME-B)
Scavenge air
PI 8601 PT 8601 Scavenge air receiver (PI 8601 instrument same as PI 8706)
PDI 8606 PDT 8606 Pressure drop of air across cooler/air cooler
Exhaust gas
PI 8706 Exhaust gas receiver/Exhaust gas outlet turbocharger
Miscellaneous functions
PI 8803 Air inlet for dry cleaning of turbocharger
PI 8804 Water inlet for cleaning of turbocharger
(Not applicable for MHI turbochargers) Table
18014450453323019

Table 18.05.01b: Local pressure gauges on engine, options: 4 70 119, and

18.05 Local instruments

remote indication sensors, option: 4 75 127

2022-07-27 - en

2 (3) ME/ME-C/ME-B/-GI/-GA/-LGI
 MAN Energy Solutions 198 45 86-3.13

Local instruments Remote sensors Point of location

Other indicators Other transmitters/
switches
Hydraulic power supply
XC 1231 Automatic main lube oil filter, failure (Boll & Kirch)
LS 1235 Leakage oil from hydraulic system
Engine cylinder components
LS 4112 Leakage from hydraulic cylinder unit
Fuel oil
LS 8006 Leakage from high pressure pipes
Lubricating oil
FS 8114 Piston cooling oil outlet/cylinder
XC 8126 Bearing wear (All types except S40/35ME-B9)
XS 8127 Bearing wear detector failure (All types except S40-35ME-B9)
XS 8150 Water in lubricating oil
XS 8151 Water in lubricating oil – too high
XS 8152 Water in lubricating oil sensor not ready
Cylinder lube oil
LS 8212 Small tank for heating element, low level (Not for ACOM)
XC 8265 ACOM (Only for ACOM)
LS 8285 Level switch
Scavenge air
LS 8611 Water mist catcher – water level
Miscellaneous functions
ZT 8801 I Turbocharger speed/turbocharger
WI 8812 WT 8812 Axial vibration monitor
(For certain engines only, see note in Table 18.04.04)
(WI 8812 instrument is part of the transmitter WT 8812)
XS 8813 Oil mist in crankcase/cylinder
XS 8814 Oil mist detector failure
XC 8816 Shaftline earthing device
XS/XT 8817 Turbocharger overspeed (Only in case of EGB, VT TC, power turbine/
hybridTC, TC Cut-out, see Table 18.06.03)
18014450453323019

Table 18.05.01c: Other indicators on engine, options: 4 70 119, and remote

indication sensors, option: 4 75 127
18014450453323019
18.05 Local instruments
2022-07-27 - en

ME/ME-C/ME-B/-GI/-GA/-LGI 3 (3)
198 45 86-3.13 MAN Energy Solutions

18014450453323019
This page is intentionally left blank
18.05 Local instruments

2022-07-27 - en

ME/ME-C/ME-B/-GI/-GA/-LGI
 MAN Energy Solutions 199 15 33-6.0

Engine protection systems and alarms

Drain Box for Fuel Oil Leakage Alarm

Any leakage from the fuel oil high pressure pipes of any cylinder is drained to
a common drain box fitted with a level alarm. This is included in the basic
design of MAN B&W engines.

Bearing Condition Monitoring

Based on our experience, we decided in 1990 that all plants must include an
oil mist detector specilfied by MAN Energy SolutionsSince then an Oil Mist
Detector (OMD) and optionally some extent of Bearing Temperature Monitor-
ing (BTM) equipment have made up the warning arrangements for prevention
of crankcase explosions on two-stroke engines. Both warning systems are
approved by the classification societies.
In order to achieve a response to damage faster than possible with Oil Mist
Detection and Bearing Temperature Monitoring alone we introduce Bearing
Wear Monitoring (BWM) systems. By monitoring the actual bearing wear con-
tinuously, mechanical damage to the crank-train bearings (main-, crank- and
crosshead bearings) can be predicted in time to react and avoid damaging
the journal and bearing housing.
If the oil supply to a main bearing fails, the bearing temperature will rise and in
such a case a Bear-ing Temperature Monitoring system will trigger an alarm
before wear actually takes place. For that reason the ultimate protection
against severe bearing damage and the optimum way of providing early warn-
ing, is a combined bearing wear and temperature monitoring system.
For all types of error situations detected by the different bearing condition
monitoring systems applies that in addition to damaging the components, in

18.06 Engine protection systems and alarms

extreme cases, a risk of a crankcase explosion exists.

Oil Mist Detector

The oil mist detector system constantly measures samples of the atmosphere
in the crankcase compartments and registers the results on an optical meas-
uring track, where the opacity (degree of haziness) is compared with the opa-
city of the atmospheric air. If an increased difference is recorded, a slow down
is activated (a shut down in case of Germanischer Lloyd).
Furthermore, for shop trials only MAN Energy Solutions requires that the oil
mist detector is connected to the shut down system.
2023-01-16 - en

For personnel safety, the oil mist detectors and related equipment are located
on the manoeuvring side of the engine.
The following oil mist detectors are available:

4 75 162 Graviner Mk 7, make: Kidde Fire Protection

4 75 163 Visatron VN 215/93, make: Schaller Automation GmbH & Co. KG *)

4 75 166 MD-SX, make: Daihatsu Diesel Mfg. Co., Ltd.

4 75 167 Vision III C, make: Specs Corporation

4 75 168 GDMS-OMDN09, make: MSS AG

All engines 1 (10)

199 15 33-6.0 MAN Energy Solutions

4 75 271 Triton, make: Heinzmann GmbH & Co. KG

4 75 272 Visatron VN301plus, make: Schaller Automation GmbH & Co. KG

4 75 273 MOT-2R5M7R5MP, make: Meiyo Electric Co., Ltd.

*) Only applicable for S50ME-C8/-GI as well as MC-C and ME-B/-GI/-LGI types 50

and smaller

Examples of piping diagrams (for Visatron VN 215/93 only) and wiring dia-
grams (for all other detectors) are shown for reference in Figs. 18.06.01a and
18.06.01b.

Fig. 18.06.01a: Example of oil mist detector wiring on engine

18.06 Engine protection systems and alarms

2023-01-16 - en

Fig. 18.06.01b: Oil mist detector pipes on engine, type Visatron VN215/93
from Schaller Automation, option: 4 75 163

Bearing Wear Monitoring System

The Bearing Wear Monitoring (BWM) system monitors all three principal
crank-train bearings using two proximity sensors forward/aft per cylinder unit
and placed inside the frame box.

2 (10) All engines

 MAN Energy Solutions 199 15 33-6.0

Targeting the guide shoe bottom ends continuously, the sensors measure the
distance to the crosshead in Bottom Dead Center (BDC).
Signals are computed and digitally presented to computer hardware, from
which a useable and easily interpretable interface is presented to the user.

The measuring precision is more than adequate to obtain an alarm well before
steel-to-steel contact in the bearings occur.
Also the long-term stability of the measurements has shown to be excellent.

In fact, BWM is expected to provide long-term wear data at better precision

and reliability than the manual vertical clearance measurements normally per-
formed by the crew during regular service checks.

For the above reasons, we consider unscheduled open-up inspections of the

crank-train bearings to be superfluous, given BWM has been installed.

Two BWM ‘high wear’ alarm levels including deviation alarm apply. The first
level of the high wear / deviation alarm is indicated in the alarm panel only
while the second level also activates a slow down.

he Extent of Delivery lists the following Bearing Wear Monitoring options:

4 75 261 XTS–W (BWM), make: AMOT

4 75 262 BDMS (BW&TMS), make: Dr. E. Horn

4 75 263 BWCM, make: Kongsberg Maritime

4 75 265 B-WACS, make: Doosan Engine Co., Ltd.

4 75 266 BWCMS, make: KOMECO

18.06 Engine protection systems and alarms

4 75 267 BCM-1, make: Mitsui Zosen Systems Research Inc.

ME, ME-C/-GI/-LGI engines are as standard specified with Bearing Wear

Monitoring for which any of the above mentioned options could be chosen.

Bearing Temperature Monitoring System

The Bearing Temperature Monitoring (BTM) system continuously monitors the
temperature of the bearing. Some systems measure the temperature on the
backside of the bearing shell directly, other systems detect it by sampling a
2023-01-16 - en

small part of the return oil from each bearing in the crankcase.

In case a specified temperature is recorded, either a bearing shell/housing

temperature or bearing oil outlet temperature alarm is triggered.

In main bearings, the shell/housing temperature or the oil outlet temperature is

monitored depending on how the temperature sensor of the BTM system, op-
tion: 4 75 133, is installed.

All engines 3 (10)

199 15 33-6.0 MAN Energy Solutions

In crankpin and crosshead bearings, the shell/ housing temperature or the oil
outlet temperature is monitored depending on which BTM system is installed,
options: 4 75 134 or 4 75 135.

For shell/housing temperature in main, crankpin and crosshead bearings two

high temperature alarm levels apply. The first level alarm is indicated in the
alarm panel while the second level activates a slow down.

For oil outlet temperature in main, crankpin and crosshead bearings two high
temperature alarm levels including deviation alarm apply. The first level of the
high temperature / deviation alarm is indicated in the alarm panel while the
second level activates a slow down.

In the Extent of Delivery, there are three options:

4 75 133 Temperature sensors fitted to main bearings

4 75 134 Temperature sensors fitted to main bearings, crankpin bearings,

crosshead bearings and for moment compensator, if any

4 75 135 Temperature sensors fitted to main bearings, crankpin bearings

and crosshead bearings

Water In Oil Monitoring System

All MAN B&W engines are as standard specified with Water In Oil monitoring
system in order to detect and avoid free water in the lubricating oil.

In case the lubricating oil becomes contaminated with an amount of water ex-
ceeding our limit of 50% of the saturation point (corresponding to approx.
18.06 Engine protection systems and alarms

0.2% water content), acute corrosive wear of the crosshead bearing overlayer
may occur. The higher the water content, the faster the wear rate.

To prevent water from accumulating in the lube oil and, thereby, causing
damage to the bearings, the oil should be monitored manually or automatic-
ally by means of a Water In Oil (WIO) monitoring system connected to the en-
gine alarm and monitoring system. In case of water contamination the source
should be found and the equipment inspected and repaired accordingly.

The saturation point of the water content in the lubricating oil varies depend-
ing on the age of the lubricating oil, the degree of contamination and the tem-
2023-01-16 - en

perature. For this reason, we have chosen to specify the water activity meas-
uring principle and the aw-type sensor. Among the available methods of
measuring the water content in the lubricating oil, only the aw-type sensor
measures the relationship between the water content and the saturation point
regardless of the properties of the lubricating oil.

WIO systems with aw-type sensor measure water activity expressed in ‘aw’
on a scale from 0 to 1. Here, ‘0’ indicates oil totally free of water and ‘1’ oil
fully saturated by water.

Alarm levels are specified as follows:

4 (10) All engines

 MAN Energy Solutions 199 15 33-6.0

Engine condition Water activity, aw

High alarm level 0.5
High High alarm level 0.9

The aw = 0.5 alarm level gives sufficient margin to the satuartion point in order
to avoid free water in the lubricating oil. If the aw = 0.9 alarm level is reached
within a short time after the aw = 0.5 alarm, this may be an indication of a wa-
ter leak into the lubricating oil system.

Please note: Corrosion of the overlayer is a potential problem only for

crosshead bearings, because only crosshead bearings are designed with an
overlayer. Main, thrust and crankpin bearings may also suffer irreparable dam-
age from water contamination, but the damage mechanism would be different
and not as acute.

Liner Wall Monitoring System

The Liner Wall Monitoring (LWM) system monitors the temperature of each
cylinder liner. It is to be regarded as a tool providing the engine room crew the
possibility to react with appropriate countermeasures in case the cylinder oil
film is indicating early signs of breakdown.

In doing so, the LWM system can assist the crew in the recognition phase
and help avoid consequential scuffing of the cylinder liner and piston rings.

Signs of oil film breakdown in a cylinder liner will appear by way of increased
and fluctuating temperatures. Therefore, recording a preset max allowable ab-
solute temperature for the individual cylinder or a max allowed deviation from
a calculated average of all sensors will trigger a cylinder liner temperature

18.06 Engine protection systems and alarms

alarm.

The LWM system includes two sensors placed in the manoeuvring and ex-
haust side of the liners, near the piston skirt TDC position. The sensors are in-
terfaced to the ship alarm system which monitors the liner temperatures.

For each individual engine, the max and deviation alarm levels are optimised
by monitoring the temperature level of each sensor during normal service op-
eration and setting the levels accordingly.

The temperature data is logged on a PC for one week at least and preferably
2023-01-16 - en

for the duration of a round trip for reference of temperature development.

All types 98 and 90 ME and ME-C engines as well as K80ME-C9 are as

standard specified with Liner Wall Monitoring system. For all other engines,
the LWM system is available as an option: 4 75 136.

All engines 5 (10)

199 15 33-6.0 MAN Energy Solutions

Axial Vibration Monitor

For functional check of the vibration damper a mechanical guide is fitted,
while an electronic vibration monitor can be supplied as an option.

An Axial Vibration Monitor (AVM) with indication for condition check of the
axial vibration damper and terminals for alarm and slow down ia available as
an option: 4 31 117. It is required for the following engines:

• All ME-C9/10 engines incl. their -GI and -LGI variants

• All ME-C7/8 engines with 5 and 6 cylinders incl. their -GI and -LGI variants
• K-ME-C6/7 and K98ME6/7 engines with 11 and 14 cylinders incl. their -GI
and -LGI variants.

The requirement for AVM on 4-cylinder engines is available on request.

The alarm and slow down system should include the filtration necessary to
prevent the AVM from unintentionally activating the alarm and slow down
functions at torsional vibration resonances, i.e. in the barred speed range, and
when running Astern.

In the low speed range and when running Astern, the alarm and slow down
functions are to be disabled so that the AVM only gives an indication of the vi-
bration level.

The AVM alarm and slow down functions shall be enabled when the engine is
running Ahead and at speeds above the barred range.
18.06 Engine protection systems and alarms

To prevent rapid hunting of the engine speed in a slow down situation, a hold-
ing time function has been introduced in order to delay the automatic re-set-
ting of the slow down function.

The specification of the AVM interface to the alarm and slow down system is
available from MAN Energy Solutions Copenhagen.

(LDCL) Cooling Water System

With the Load Dependent Cylinder Liner (LDCL) cooling water system, the
cooling water outlet temperature from the cylinder liner is controlled relative to
2023-01-16 - en

the engine load, independent of the cooling water outlet from the cylinder
cover.

The interval for the liner outlet may be wide, for instance from 70 to 130 de-
gree Celsius. The cooling water outlet temperature is measured by one sensor
for each cylinder liner of the engine.

For monitoring the LDCL cooling water system the following alarm and slow
down functionality must be fulfilled:

6 (10) All engines

 MAN Energy Solutions 199 15 33-6.0

The Alarm system must be able, from one common analog sensor, to detect
two alarm limits and two slow down limits as follows:

• Upper slow down limit

• Upper alarm limit
• Load dependent slow down limit
• Load dependent alarm limit.

An example of the limits is shown in Fig. 18.06.02.

18.06 Engine protection systems and alarms

Fig. 18.06.02: Example of set points versus slow down and alarm limits for
LDCL cooling water system

The load dependent limits must include at least one break point to allow cut-
in/-out of the lower limits. The upper limits are fixed limits without breakpoints.

The values of the load dependent limits are defined as a temperature differ-
2023-01-16 - en

ence (DT) to actual cooling water temperature (which vary relative to the en-
gine load).

The cooling water temperature is plant dependent and consequently, the ac-
tual values of both upper limits and load dependent limits are defined during
commissioning of the engine.

All 95-50ME-C10/9/-GI dot 2 and higher as well as G50ME-B9.5/.3 and

S50ME-B9.5 are as standard specified with LDCL Cooling Water Monitoring
System while S50ME-B9.3 and G45ME-C9.5/-GI are prepared for the installa-
tion of it.

All engines 7 (10)

199 15 33-6.0 MAN Energy Solutions

Motor Start Method

Direct Online Start (DOL) is required for all the electric motors for the pumps
for the Load Dependent Cylinder Liner (LDCL) to ensure proper operation un-
der all conditions

Turbocharger Overspeed Protection

All engine plants fitted with turbocharger cut-out, exhaust gas bypass (EGB),
power turbine / turbo generator (PT), hybrid turbocharger or variable tur -
bocharger (VT) run the risk of experiencing turbo - charger overspeed.
To protect the turbocharger, such plants must be equipped with a turbochar-
ger overspeed alarm and slow-down function.

However, the handshake interface between the ship’s power management

system and a waste heat recovery system (WHRS) or a shaft generator (SG)
may delay the slowdown for up to 120 seconds.
Therefore, the slow-down function must be upgraded to a non-cancellable
shutdown for engine plants with handshake interface.

On engine plants designed with exhaust gas recirculation (EGR), a sudden in-
crease of energy to the turbocharger(s) will occur if the EGR system trips.
As protection, turbocharger overspeed alarm and non-cancellable slowdown
must be fitted.

Consequently, the turbocharger speed must be monitored by the ship alarm

system and the safety system(s), triggering slowdown or non-cancellable
shutdown if the turbocharger speed exceeds the defined alarm levels.
18.06 Engine protection systems and alarms

The protection applicable for individual engine plant and power management
configurations is summarised in Table 18.06.03.

Turbocharger overspeed protection

Engine plant configuration No power management system Engine with WHR or shaft generator
handshake with power management system
handshake

Traditional exhaust gas train and tur- No monitoring of turbocharger over- No monitoring of turbocharger over-
bocharger speed speed
2023-01-16 - en

Exhaust gas bypass, variable turbo Turbocharger overspeed slowdown Turbocharger overspeed shutdown
charger, power turbine or hybrid tur-
bocharger

Exhaust gas recirculation Turbocharger overspeed slowdown Turbocharger overspeed shutdown

Turbocharger cut-out Turbocharger overspeed slowdown Turbocharger overspeed shutdown

Table 18.06.03: Turbocharger overspeed protection for individual engine plant

configurations

8 (10) All engines

 MAN Energy Solutions 199 15 33-6.0

Control Devices
The control devices mainly include a position switch (ZS) or a position trans-
mitter (ZT) and solenoid valves (ZV) which are listed in Table 18.06.04 below.
The sensor identification codes are listed in Table 18.07.01.

Sensor Point of location

Manoeuvring system
ZS 1109-A/B C Turning gear – disengaged
ZS 1110-A/B C Turning gear – engaged
ZS 1111-A/B C Main starting valve – blocked
ZS 1112-A/B C Main starting valve – in service
ZV 1114 C Slow turning valve
ZS 1116-A/B C Start air distribution system – in service
ZS 1117-A/B C Start air distribution system – blocked
ZV 1120 C Activate pilot press air to starting valves
ZS 1121-A/B C Activate main starting valves - open
E 1180 Electric motor, auxiliary blower
E 1181 Electric motor, turning gear
E 1185 C LOP, Local Operator Panel
36028849521099659

Hydraulic power supply

PT 1201-1/2/3 C Hydraulic oil pressure, after non-return valve
ZV 1202-A/B C Force-driven pump bypass

18.06 Engine protection systems and alarms

PS/PT 1204-1/2/3 C Lubricating oil pressure after filter, suction side
36028849521099659

Tacho/crankshaft position
ZT 4020 Tacho for safety
36028849521099659

Engine cylinder components

XC 4108 C ELVA NC valve
ZT 4111 C Exhaust valve position
ZT 4114 C Fuel plunger, position 1
2023-01-16 - en

36028849521099659

Fuel oil
ZV 8020 Z Fuel oil cut-off at engine inlet (shut down), Germanis-
cher Lloyd only
36028849521099659

Cylinder lubricating oil, Alpha/ME lubricator

ZV 8281 C Solenoid valve, lubricator activation
ZT 8282 C Feedback sensor, lubricator feedback
36028849521099659

Cylinder lubricating oil, Alpha Mk 2 lubricator

All engines 9 (10)

199 15 33-6.0 MAN Energy Solutions

XC 8288 C Propoprtional valve

ZT 8289 C Feedback sensor
36028849521099659

Scavenge air
PS 8603 C Scavenge air receiver, auxiliary blower control
36028849521099659

ME-GI alarm system (ME-GI only)

XC 2212 External gas shut down (request)
36028849521099659

ME-GI safety system (ME-GI only)

XC 2001 Engine shut down (command)
XC 6360 Gas plant shut down (command)
36028849521099659

Table 18.06.04b: Control devices on engine

36028849521099659
18.06 Engine protection systems and alarms

2023-01-16 - en

10 (10) All engines

 MAN Energy Solutions 198 45 85-1.6

Identification of instruments
The instruments and sensors are identified by a position number which is
made up of a combination of letters and an identification number.

Measured or Indicating Variables

First letters:

DS Density switch
DT Density transmitter
E Electrical component
FS Flow switch
FT Flow transmitter
GT Gauging transmitter, index/load transmitter
LI Level indication, local
LS Level switch
LT Level transmitter
PDI Pressure difference indication, local
PDS Pressure difference switch
PDT Pressure difference transmitter
PI Pressure indication, local
PS Pressure switch
PT Pressure transmitter
ST Speed transmitter
TC Thermo couple (NiCr-Ni)
TE Temperature element (Pt 100)
TI Temperature indication, local
TS Temperature switch 18.07 Identification of instruments
TT Temperature transmitter
VS Viscosity switch
VT Viscosity transmitter
WI Vibration indication, local
2022-06-16 - en

WS Vibration switch
WT Vibration transmitter
XC Unclassified control
XS Unclassified switch
XT Unclassified transmitter
ZS Position switch (limit switch)
ZT Position transmitter (proximity sensor)
ZV Position valve (solenoid valve)

ME-B, MC/MC-C, ME/ME-C/-GI/-LGI/-GA 1 (4)

198 45 85-1.6 MAN Energy Solutions
18014450453340043

Location of Measuring Point

Ident. number; first two digits indicate the measurement point and xx the
serial number:

11xx Manoeuvring system

12xx Hydraulic power supply system (HPS)
13xx Hydraulic control oil system, separate oil to HPS
14xx Combustion pressure supervision
15xx Top bracing pressure, stand alone type
16xx Exhaust Gas Recirculation (EGR)
20xx ECS to/from safety system
21xx ECS to/from remote control system
22xx ECS to/from alarm system
24xx ME ECS outputs
29xx Power supply units to alarm system
30xx ECS miscellaneous input/output
40xx Tacho/crankshaft position system
41xx Engine cylinder components
50xx VOC, supply system
51xx VOC, sealing oil system
52xx VOC, control oil system
53xx VOC, other related systems
54xx VOC, engine related components
60xx GI-ECS to Fuel Gas Supply System (FGSS)
61xx GI-ECS to Sealing Oil System
18.07 Identification of instruments

62xx GI-ECS to Control Air System

63xx GI-ECS to other GI related systems
64xx GI engine related components
66xx Selective Catalytic Reduction (SCR) related component. Stand alone
2022-06-16 - en

80xx Fuel oil system

81xx Lubricating oil system
82xx Cylinder lubricating oil system
83xx Stuffing box drain system
84xx Cooling water systems, e.g. central, sea and jacket cooling water
85xx Compressed air supply systems, e.g. control and starting air
86xx Scavenge air system
87xx Exhaust gas system

2 (4) ME-B, MC/MC-C, ME/ME-C/-GI/-LGI/-GA

 MAN Energy Solutions 198 45 85-1.6

88xx Miscellaneous functions, e.g. axial vibration

90xx Project specific functions
A0xx Temporary sensors for projects
xxxx-A Alternative redundant sensors
xxxx-1 Cylinder/turbocharger numbers
ECS: Engine Control System
GI: Gas Injection engine
VOC: Volatile Organic Compound

Table 18.07.01a: Identification of instruments

Functions
Secondary letters:

A Alarm
C Control
H High
I Indication, remote
L Low
R Recording
S Switching
X Unclassified function
Y Slow down
Z Shut down

Repeated Signals
Signals which are repeated, for example measurements for each cylinder or
turbocharger, are provided with a suffix number indicating the location, ‘1’ for 18.07 Identification of instruments
cylinder 1, etc.
If redundant sensors are applied for the same measuring point, the suffix is a
letter: A, B, C, etc.
18014450453340043
2022-06-16 - en

Examples
indicates a local temperature indication (thermometer) in the fuel oil
system.
and indicate two redundant position switches in the
manoeuvring system, A and B, for control of the main starting air valve posi-
tion.
indicates a pressure transmitter located in the control air supply
for remote indication, alarm for low pressure and slow down for low pressure.

078 89 33-9.6.0
18014450453340043

ME-B, MC/MC-C, ME/ME-C/-GI/-LGI/-GA 3 (4)

198 45 85-1.6 MAN Energy Solutions

Table 18.07.01b: Identification of instruments

18014450453340043
18.07 Identification of instruments

2022-06-16 - en

4 (4) ME-B, MC/MC-C, ME/ME-C/-GI/-LGI/-GA

 MAN Energy Solutions 199 15 76-7.0

ME-GA safety aspects

The normal safety systems incorporated in the fuel oil systems are fully re-
tained also during dual fuel operation. However, additional safety devices will
be incorporated in order to prevent situations which might otherwise lead to
failures.

Safety Devices – External systems

Leaking valves and fractured pipes are sources of faults that may be harmful.
Such faults can be easily and quickly detected by a hydrocarbon (HC) ana-
lyser with an alarm function. An alarm is given at a gas concentration of max.
30% of the Lower Explosion Limit (LEL) in the vented duct, and a shutdown
signal is given at 60% LEL.
The safety devices that will virtually eliminate such risks are double-wall pipes
and encapsulated valves with ventilation of the intervening space. The ventila-
tion between the outer and inner walls is always to be in operation when there
is gas in the supply line, and any gas leakage will be led to the HC sensors
placed in the outer pipe discharge.
Another source of fault could be a malfunctioning sealing oil supply system. If
the gas sealing oil differential pressure becomes too low in the gas injection
valve, gas will flow into the control oil activation system and, thereby, create
unintended mixing of gas in the hydraulic oil system and create gas pockets
and prevent the ELGI valve from operating the gas injection valve. Therefore,
the sealing oil pressure is measured by a set of pressure sensors, and in the
event of a too low pressure, the engine will shut down the gas mode and start
running in the fuel oil mode.
Lack of ventilation in the double-wall piping system prevents the safety func-
tion of the HC sensors, so the system is to be equipped with a set of flow
switches. If the switches indicate no flow, the engine will be shut down on gas
mode. The switches should be of the normally open (NO) type, in order to al-
low detection of a malfunctioning switch, even in case of an electric power
failure.
As natural gas is lighter than air, non-return valves are incorporated in the gas
system’s outlet pipes to ensure that the gas system is not polluted, i.e. mixed
with air. 18.08 ME-GA safety aspects

Safety Devices – Internal systems

During normal operation, a malfunction in the pilot fuel injection system or gas
admission system may involve a risk of uncontrolled combustion in the en-
2022-07-12 - en

gine. Sources of faults are:

▪ defective gas admission valves
▪ failing ignition of admitted gas.
These aspects will be discussed in detail in the following together with the
suitable countermeasures.

ME-GA 1 (5)
199 15 76-7.0 MAN Energy Solutions

Defective gas admission valves

In case of sluggish operation or even seizure of the gas valve spindle in the
open position, which will be detected by the gas pressure transmitter in the
safe gas admission valve, a limited amount of gas may be injected into the
cylinder before the window valve closes. Therefore, when the exhaust valve
opens, a hot mixture of combustion products and gas flows out and into the
exhaust pipe and further on to the exhaust receiver.
The temperature of the mixture after the valve will increase considerably, and
it is likely that the gas will burn with a diffusion type flame (without exploding)
immediately after the valve where it is mixed with scavenge air/exhaust gas
(with approximately 15% oxygen) in the exhaust system. This may set off the
high exhaust gas temperature alarm for the cylinder in question.
In the unlikely event of larger gas amounts entering the exhaust receiver
without starting to burn immediately, a later ignition may result in violent burn-
ing and a corresponding pressure rise. Therefore, the exhaust receiver is de-
signed for the maximum pressure (around 15 bar).
However, any of the above-mentioned situations will be prevented by the de-
tection of defective gas valves, which is arranged as follows.

Valve leakage monitoring pressure sensor

The valve leakage monitoring pressure sensor, installed in the safe gas admis-
sion valve between the window/ shutdown valve and the gas admission
valves, is one unit with sensor and amplifier.
The pressure sensor measures pressure increase or decrease, concluding
whether the window/ shutdown valve or the gas admission valves are leaking,
during every cycle from when the window/ shutdown valve closes and until it
opens again.

Ignition failure of injected gas

Failing ignition of the admitted natural gas, i.e. misfiring, can have a number of
different causes, most of which, however, are the result of failure to inject pilot
oil in a cylinder:

▪ leaky joints or fractured high-pressure pipes, making the fuel oil booster
inoperative
18.08 ME-GA safety aspects

▪ seized plunger in the fuel oil booster

▪ other faults on the engine, forcing the fuel oil booster to ‘0-index’
2022-07-12 - en

Such misfiring causes a small amount of unburned gas in the exhaust receiver
to burn with a diffusion type flame as explained above. The GCSU detects
misfiring and the gas admission is stopped and a gas shutdown initiated. This
shutdown is completed within the span of one revolution, with the fuel oil sys-
tem ensuring the propulsion of the vessel is uninterrupted.

Compression and combustion pressure monitoring

The compression pressure as well as the maximum combustion pressure are
monitored. If low respectively too high, a gas shutdown is initiated.

2 (5) ME-GA
 MAN Energy Solutions 199 15 76-7.0

Test of tightness of gas pipes

During shop test of the engine as well as vessel commissioning, a tightness
test of the gas piping is conducted by means of valves installed in the gas re-
turn pipe.

Further information on tightness verification tests and gas leakage detection is

available from MAN Energy Solutions, Copenhagen.

18.08 ME-GA safety aspects

2022-07-12 - en

ME-GA 3 (5)
199 15 76-7.0 MAN Energy Solutions

Self-test of gas system

Before changing over to gas operation, the ME-GA system is fitted with an
automatic two step self-testing procedure, this procedure ensures that no
leakage are present and that the system is ready for dual fuel operation.
Step one of this procedure is pressurisation of the engine and all pipes
between the purge supply and the Gas Valve Unit (GVU), this step is carried
out using nitrogen. After ensuring that no pressure lost is experienced and
that valves operate as expected, the system is vented to the vent mast and
step 1 is complete.

Fig. 18.08.01: Pressurisation of engine side

Step two of the procedure pressurises the GVU and pipes from the supply
system, this step is carried out using LNG as these pipes are placed in gas
safe areas. After ensuring that no pressure lost is experienced and that valves
operate as expected, the engine is declared ready for operation and the sup-
ply of LNG to the engine begin.
18.08 ME-GA safety aspects

2022-07-12 - en

Fig. 18.08.02: Pressurisatoin of GVU/supply side

4 (5) ME-GA
 MAN Energy Solutions 199 15 76-7.0

Purge of gas system

To ensure that the engine and pipes are gas safe after shutdown, allowing
maintenance and work to the gas system to be carried out as needed during
standstill and fuel oil running, the engine is fitted with an automatic purge
cycle, which is completed after each engine shutdown.
The purge cycle begins by venting the LNG pressure to the vent mast, after
which the engine and pipes are pressured with nitrogen as seen in step 1 of
the self-test procedure (see figure 1). Once nitrogen pressure is build-up, the
content of the system I vented to the vent mast. This cycle of pressurasation
and depressurasation is completed several times, ensuring a gas safe system
is achieved.

Fig. 18.08.03: Depressurisation of engine side

Note that if an engine shutdown occurs, there is no safety difference between

a shutdown on gas and HFO.
53025892235

18.08 ME-GA safety aspects

2022-07-12 - en

ME-GA 5 (5)
199 15 76-7.0 MAN Energy Solutions

53025892235
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18.08 ME-GA safety aspects

2022-07-12 - en

ME-GA
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water

19 Dispatch Pattern, Testing, Spares and Tools

13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395653899

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

19 Dispatch Pattern, Testing, Spares and Tools
 MAN Energy Solutions 198 76 20-3.2

Dispatch pattern, testing, spares and tools

Painting of Main Engine

The painting specification, Section 19.02, indicates the minimum require-
ments regarding the quality and the dry film thickness of the coats of, as well
as the standard colours applied on MAN B&W engines built in accordance
with the ‘Copenhagen’ standard.
Paints according to builder’s standard may be used provided they at least ful-
fil the requirements stated.

Dispatch Pattern
The dispatch patterns are divided into two classes, see Section 19.03:
A: Short distance transportation and short term storage
B: Overseas or long distance transportation or long term storage.

Short distance transportation (A) is limited by a duration of a few days from

delivery ex works until installation, or a distance of approximately 1,000 km
and short term storage.
The duration from engine delivery until installation must not exceed 8 weeks.
Dismantling of the engine is limited as much as possible.

Overseas or long distance transportation or long term storage require a class

B dispatch pattern.

19.01 Dispatch pattern, testing, spares and tools

The duration from engine delivery until installation is assumed to be between 8
weeks and maximum 6 months.
Dismantling is effected to a certain degree with the aim of reducing the trans-
portation volume of the individual units to a suitable extent.
Note: Long term preservation and seaworthy packing are always to be used
for class B.
Furthermore, the dispatch patterns are divided into several degrees of dis-
mantling in which ‘1’ comprises the complete or almost complete engine.
Other degrees of dismantling can be agreed upon in each case.
When determining the degree of dismantling, consideration should be given to
the lifting capacities and number of crane hooks available at the engine maker
and, in particular, at the yard (purchaser).
The approximate masses of the sections appear in Section 19.04. The
2022-05-02 - en

masses can vary up to 10% depending on the design and options chosen.
Lifting tools and lifting instructions are required for all levels of dispatch pat-
tern. The lifting tools, options: 4 12 110 or 4 12 111, are to be specified when
ordering and it should be agreed whether the tools are to be returned to the
engine maker, option: 4 12 120, or not, option: 4 12 121.
MAN Energy Solutions' recommendations for preservation of disassembled /
assembled engines are available on request.
Furthermore, it must be considered whether a drying machine, option: 4 12
601, is to be installed during the transportation and/or storage period.

All engines 1 (3)

198 76 20-3.2 MAN Energy Solutions

Shop Trials/Delivery Test

Before leaving the engine maker’s works, the engine is to be carefully tested
on diesel oil in the presence of representatives of the yard, the shipowner and
the classification society.
The shop trial test is to be carried out in accordance with the requirements of
the relevant classification society, however a minimum as stated in Section
19.05.
MAN Energy Solutions' recommendations for shop trial, quay trial and sea trial
are available on request.
In connection with the shop trial test, it is required to perform a precertification
survey on engine plants with FPP or CPP, options: 4 06 201 Engine test cycle
E3 or 4 06 202 Engine test cycle E2 respectively.

Spare Parts

List of spare parts, unrestricted service

The tendency today is for the classification societies to change their rules
such that required spare parts are changed into recommended spare parts.
MAN Energy Solutions, however, has decided to keep a set of spare parts in-
cluded in the basic extent of delivery, EoD: 4 87 601, covering the require-
ments and recommendations of the major classification societies, see Section
19.06.
This amount is to be considered as minimum safety stock for emergency situ-
ations.
19.01 Dispatch pattern, testing, spares and tools

Additional Spare Parts Recommended by MAN Energy Solutions

The aboveœmentioned set of spare parts can be extended with the ‘Addi-
tional Spare Parts Recommended by MAN Energy Solutions', option: 4 87
603, which facilitates maintenance because, in that case, all the components
such as gaskets, sealings, etc. required for an overhaul will be readily avail-
able, see Section 19.07.

Wearing Parts
The consumable spare parts for a certain period are not included in the above
mentioned sets, but can be ordered for the first 1, 2, up to 10 years’ service
of a new engine, option: 4 87 629.
2022-05-02 - en

The wearing parts that, based on our service experience, are estimated to be
required, are listed with service hours in Tables 19.08.01 and 19.08.02.

Large Spare Parts, Dimensions and Masses

The approximate dimensions and masses of the larger spare parts are indic-
ated in Section 19.09. A complete list will be delivered by the engine maker.

2 (3) All engines

 MAN Energy Solutions 198 76 20-3.2

Tools

List of standard tools

The engine is delivered with the necessary special tools for overhauling pur-
poses. The extent, dimen sions and masses of the main tools is stated in Sec-
tion 19.10. A complete list will be delivered by the engine maker.

Tool Panels
Most of the tools are arranged on steel plate pan els, EoD: 4 88 660, see
Section 19.11 ‘Tool Panels’.
It is recommended to place the panels close to the location where the over-
haul is to be carried out.
9007251198617867

19.01 Dispatch pattern, testing, spares and tools

2022-05-02 - en

All engines 3 (3)

198 76 20-3.2 MAN Energy Solutions

9007251198617867
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19.01 Dispatch pattern, testing, spares and tools

2022-05-02 - en

All engines
 MAN Energy Solutions 198 45 16-9.8

Specification for Painting of main Engine

Components to be painted Type of paint No. of coats Colour: RAL 840 HR, DIN
before shipment from work- 6164, MUNSELL
shop Total Nominal Dry Film
Thickness (NDFT) μm

1. Components/surfaces, In accordance with corrosivity categories C2 Medium ISO

inside engine, exposed to 12944-5
oil and air:
Engine alkyd primer, 1 - 2 layer
Unmachined surfaces all Free
weather resistant. Total NDFT 80 μm
over. However, cast type
crank throws, main bearing Oil and acid resistant alkyd 1 layer White:
cap, crosshead bearing paint. Temperature resist- Total NDFT 40 μm RAL 9010 DIN N:0:0,5
caps, crankpin bearing cap, ant to min. 80°C. MUNSELL N-9.5
pipes inside crankcase and
chain-wheel need not be
painted but the cast surface
must be cleaned of sand
and scales and kept free of
rust. Total NDFT: 120 μm

2. Components, outside In accordance with corrosivity categories C2 Medium ISO

engine: 12944-5
Engine body, pipes, gallery Engine alkyd primer, 1 - 2 layer
brackets, etc. Free
weather resistant. Total NDFT 80 μm
Delivery standard is in a Final alkyd paint, resistant 1 layer Light green:
primed and finally painted to salt water and oil Total NDFT 40 μm RAL 6019 DIN 23:2:2
condition, unless otherwise MUNSELL 10GY 8/4
stated in the con-tract.

19.02 Specification for Painting of main Engine

See also MAN ES EN690D
Total NDFT: 120 μm
for colour marking of piping
systems

3. Low flashpoint fuels: In accordance with corrosivity categories C2 Medium ISO

See also MAN ES EN690D 12944-5
for colour marking of piping
Engine alkyd primer, 1 - 2 layer
systems. Free
weather resistant. Total NDFT 80 μm
Chain pipe, supply pipe.
Final alkyd paint, resistant 1 layer Yellow:
Spool piece. to salt water and oil Total NDFT 40 μm RAL 1021 MUNSELL 2.5Y
8/14
2021-09-20 - en

Total NDFT: 120 μm

42805002251

All Engines 1 (3)

198 45 16-9.8 MAN Energy Solutions

Components to be painted Type of paint No. of coats Colour:

before shipment from work- Total Nominal Dry Film RAL 840 HR, DIN 6164,
shop Thickness (NDFT) μm MUNSELL

4. Heat affected compon- In accordance with corrosivity categories C3 Medium ISO

ents: 12944-5
Supports for exhaust re- Ethyl silicate based zincrich 1 layer
ceiver. Air cooler housing paint, heat resistant to min. Total NDFT 80 μm
inside and outside. No sur- 300 ºC.
face may be left unpainted
in the cooler housing.
Exhaust valve housing (ex-
haust flange), (Non water
cooled only)

5. Components affected by In accordance with corrosivity categories C5-M High ISO

water, cleaning agents, and 12944-5
acid fluid below neutral Ph:
Scavenge air cooler box in-
side. (Reversing chamber).
Preparation, actual number Two component epoxy 3 layer
of coats, film thickness per phenolic Free
Total NDFT 350 μm
coat, etc. has to be accord-
ing to the paint manufac-
turer specifications.
Air flow reversing chamber See specifications from
inside and outside. product data sheet
No surfaces may be left un-
painted Supervision from
19.02 Specification for Painting of main Engine

manufacturer is recommen-
ded, in the phase of intro-
duction of the paint system.

6. Gallery plates topside: C2 medium

1 - 2 layer
Engine alkyd primer, Total NDFT 80 μm
weather resistant
42805002251

2021-09-20 - en

2 (3) All Engines

 MAN Energy Solutions 198 45 16-9.8

Components to be painted Type of paint No. of coats Colour:

before shipment from work- Total Nominal Dry Film RAL 840 HR, DIN 6164,
shop Thickness (NDFT) μm MUNSELL

7. EGR-system - Mixing
chamber *)
To be applied after Water
Mist Catcher (WMC) to
Non-return Valve at scav-
enge air reciever. See figure
2 for details.
Optional: EGR paint can be
applied from Air cooler out- Total NDFT 500 -1200 μm Free
let, (reversing chamber).
See figure 2 for details.

*) Only for engines specified

with EGR or prepared for
EGR installation Vinyl ESTER Acrylic copoly-
mer

8. Purchased equipment and instruments painted in makers colour are acceptable, unless otherwise stated in the
contract:

Tools are to be surface Electro(-) galvanised See specifications from

treated according to spe- product data sheet
cifications stated on the
drawings.
Purchased equipment
painted in markers colour is

19.02 Specification for Painting of main Engine

acceptable, unless other-
wise stated in the contract/
drawing.

Tool panels Oil resistant paint 1 - 2 layer Light grey:

Total NDFT 80 μm RAL 7038 DIN 24:1:2
MUNSELL N-7.5

9. Lifting points: Alkyd paint, resistant to wa- 1 layer Total NDFT Yellow:
Pad eyes, wholes, clamps, ter, lubricants, hydraulic oil 80 ym (my) RAL 1021 MUNSELL 2.5y
threaded wholes, eye and degreaser. 8/14
screws, eye nuts and other
lifting points
42805002251
2021-09-20 - en

All paints must be of good quality. Paints according to builder‘s standard may be
used provided they at least fulfil the above requirements.
The data stated are only to be considered as guidelines. Preparation, number of
coats, film thickness per coat, etc., must be in accordance with the paint manufac-
turer’s specifications.
074 33 57-9.21.0
42805002251

Fig. 19.02.01: Painting of main engine, option: 4 81 101, 4 81 102 or 4 81

103
42805002251

All Engines 3 (3)

198 45 16-9.8 MAN Energy Solutions

42805002251
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19.02 Specification for Painting of main Engine

2021-09-20 - en

All Engines
 MAN Energy Solutions 198 45 67-2.9

Dispatch Pattern
The relevant engine supplier is responsible for the actual execution and deliv-
ery extent. As differences may appear in the individual suppliers’ extent and
dispatch variants.
53840572683

Dispatch Pattern A – Short:

Short distance transportation limited by duration of transportation time within
a few days or a distance of approximately 1,000 km and short term storage.
Duration from engine delivery to installation must not exceed eight weeks.
Dismantling must be limited.

Dispatch Pattern B – Long:

Overseas and other long distance transportation, as well as long-term stor-
age.
Dismantling is effected to reduce the transport volume to a suitable extent.
Long-term preservation and seaworthy packing must always be used.
Note
The engine supplier is responsible for the necessary lifting tools and lifting in-
structions for transportation purposes to the yard.
The delivery extent of lifting tools, ownership and lend/lease conditions are to
be stated in the contract. (Options: 4 12 120 or 4 12 121)

Furthermore, it must be stated whether a drying machine is to be installed

during the transportation and/or storage period. (Option: 4 12 601)

19.03 Dispatch Pattern

2021-09-18 - en

G/S70-50ME-C8/9/10, G50ME-B9 1 (5)

198 45 67-2.9 MAN Energy Solutions

Dispatch Pattern Variants

A1 + B1 (option 4 12 021 + 4 12 031)
Engine complete, i.e. not disassembled
19.03 Dispatch Pattern

2021-09-18 - en

Fig. 19.03.01: Dispatch pattern, engine with turbocharger on exhaust side (4

59 123)

2 (5) G/S70-50ME-C8/9/10, G50ME-B9

 MAN Energy Solutions 198 45 67-2.9

A2 + B2 (option 4 12 022 + 4 12 032)

• Top section including cylinder frame complete, cylinder covers complete,
scavenge air receiver including cooler box and cooler insert, turbocharger(s),
piston complete and galleries with pipes, HCU units and oil filter
• Bottom section including bedplate complete, frame box complete, connect-
ing rods, turning gear, crankshaft complete and galleries
• Remaining parts including stay bolts, chains, multi-way valves, etc.

19.03 Dispatch Pattern

2021-09-18 - en

Fig. 19.03.02: Dispatch pattern, engine with turbocharger on exhaust side (4

59 123)

G/S70-50ME-C8/9/10, G50ME-B9 3 (5)

198 45 67-2.9 MAN Energy Solutions

A3 + B3 (option 4 12 023 + 4 12 033)

• Top section including cylinder frame complete, cylinder covers complete,
scavenge air receiver including cooler box and cooler insert, turbocharger(s),
piston complete and galleries with pipes, HCU Units
• Frame box section including frame box complete, chain drive, connecting
rods and galleries, gearbox for hydraulic power supply, hydraulic pump station
and oil flter
• Bedplate/crankshaft section including bedplate complete, crankshaft com-
plete with chainwheels and turning gear
• Remaining parts including stay bolts, chains, multi-way valves, etc.
19.03 Dispatch Pattern

2021-09-18 - en

Fig. 19.03.03: Dispatch pattern, engine with turbocharger on exhaust side (4

59 123)

4 (5) G/S70-50ME-C8/9/10, G50ME-B9

 MAN Energy Solutions 198 45 67-2.9

A4 + B4 (option 4 12 024 + 4 12 034)

• Top section including cylinder frame complete, cylinder covers complete,
piston complete and galleries with pipes on manoeuvring side, HCU units
• Exhaust receiver with pipes
• Scavenge air receiver with galleries and pipes
• Turbocharger
• Air cooler box with cooler insert
• Frame box section including frame box complete, chain drive, connecting
rods and galleries, gearbox for hydraulic power supply, hydraulic power sta-
tion and oil flter
• Crankshaft with chain wheels
• Bedplate with pipes and turning gear
• Remaining parts including stay bolts, auxiliary blowers, chains, multi-way
valves, etc.

19.03 Dispatch Pattern

2021-09-18 - en

Fig. 19.03.03: Dispatch pattern, engine with turbocharger on exhaust side (4

59 123)
53840572683

G/S70-50ME-C8/9/10, G50ME-B9 5 (5)

198 45 67-2.9 MAN Energy Solutions

53840572683
This page is intentionally left blank
19.03 Dispatch Pattern

2021-09-18 - en

G/S70-50ME-C8/9/10, G50ME-B9
 MAN Energy Solutions 198 47 63-6.0

Dispatch Pattern, List of Masses and Dimensions

19.04 Dispatch Pattern, List of Masses and Dimensions

2021-09-18 - en

51943897227

1 (1)
198 47 63-6.0 MAN Energy Solutions

51943897227
This page is intentionally left blank
19.04 Dispatch Pattern, List of Masses and Dimensions

2021-09-18 - en
 MAN Energy Solutions 198 87 37-2.1

Shop test
The minimum delivery test for MAN B&W two-stroke engines, EoD: 4 14 001,
involves:
▪ Starting
▪ Load test
▪ Engine to be started and run up to 50% of Specified MCR (M) in 1 hour.
and is followed by the below mentioned tests.

Load test at specific load points

The engine performance is recorded running at:
▪ 25% of specified MCR
▪ 50% of specified MCR
▪ 75% of specified MCR
▪ 90% of specified MCR or at NCR
▪ 100% of specified MCR *)
▪ 110% of specified MCR
Records are to be taken after 15 minutes or after steady conditions have been
reached, whichever is shorter.
*) Two sets of recordings are to be taken at a minimum interval of 30 minutes.

Governor test and more:

▪ Integration test of ECS
▪ Governor test
▪ Minimum speed test
▪ Overspeed test
▪ Shut down test
▪ Starting and reversing test
▪ Turning gear blocking device test
▪ Start, stop and reversing from the Local Operating Panel (LOP).

Second fuel test

Further to the minimum delivery test, in the shop test on second fuel, EoD: 4
14 041 (-GI) and 4 00 042 (-LGI), the engine is to be carefully tested on both
2022-09-01 - en

diesel oil and second fuel. The test is carried out in the presence of represent-
atives of Yard, Shipowner, Classification Society, and MAN Energy Solutions.
Fuel oil and second fuel analyses are to be presented. All load point measure-
19.05 Shop test

ments are to be carried out on diesel or gas oil as well as on second fuel and
must include:
▪ test of auto change-over to second fuel from second fuel standby condi-
tion when engine load exceeds the lowest limit for second fuel operation
▪ test of auto change-over to fuel oil when engine load falls below the low-
est limit for second fuel operation
▪ demonstration of change-over between fuel oil and second fuel at each
load stop

ME-GI/-LGI/-GA 1 (3)
198 87 37-2.1 MAN Energy Solutions

▪ second fuel shut down at 110% load, resulting in continued running of

main engine on primary fuel.
The shop tests are all carried out according to:
Factory Acceptance Test and Shipboard Trials of I.C. Engines, UR M51
by International Association of Classification Societies LTD. (IACS),
www.iacs.org.uk

Vibration aspects

Torsional vibration
The installation aspects in a shop test and on a vessel are different. As a res-
ult, the torsional vibration characteristics are also different, and special coun-
termeasures may apply during the shop test.
To reduce the stress amplitudes in the shafting system at the main critical res-
onance, a tuning wheel is commonly applied on 5-7 cylinder engines. In a
shop test, the shaft between the engine and water brake is typically short and
stiff compared to the shafting system connecting the propeller to the engine
on a vessel. Due to the different installation aspects, a torsional vibration cal-
culation of the shop test conditions is always made to ensure acceptable vi-
brations. It is common that the tuning wheel is omitted at the shop test to
avoid excessive crankshaft stresses.
Regarding SFOC, the power absorbed in the tuning wheel and main bearing
is very small. Based on elasto-hydrodynamic simulations of the foremost main
bearing, the power loss with a large tuning wheel is 0.033% of engine power
and 0.032% without a tuning wheel. Therefore, this power loss can be ig-
nored in terms of the SFOC measurement conducted in a shop test.
In some cases, a torsional vibration damper has to be applied on the water
brake side to achieve acceptable vibration conditions.

Structural vibration
In most cases, the vibration level and behaviour of the main engine is quite dif-
ferent when comparing test bed trials with sea trials. The main reason for this
is the strong influence and dynamic interaction with the surroundings, the
most important being:
1. The engine seating stiffness (foundation) is lower for the test bed com-
pared to a vessel’s double bottom. This will shift vibration resonances to
lower engine speeds, which results in significantly different vibration levels
and resonance speeds.
2. If top bracings are installed (vessel installation), this additional stiffness will
2022-09-01 - en

not be present at the shop test (due to lack of stiffness/strength of the

surrounding building). Some licensees may mount an electrically driven
moment compensator (EMC) temporarily to reduce vibration levels during
19.05 Shop test

shop tests.
The global vibration behaviour of an engine erected on a test bed cannot, and
should not, be compared to the vibration levels of a vessel-installed engine.
Local vibrations of turbochargers and exhaust gas receivers are also strongly
influenced by the dynamic interaction with the surroundings, be it a “soft test
bed” or a “stiff ship hull”.

2 (3) ME-GI/-LGI/-GA
 MAN Energy Solutions 198 87 37-2.1

EIAPP certificate
Most marine engines installed on ocean going vessels are required to have an
‘Engine International Air Pollution Prevention’ (EIAPP) Certificate, or similar.
Therefore, a pre-certification survey is to be carried out for all engines accord-
ing to the survey method described in the engine’s NOx Technical File, which
is prepared by the engine manufacturer. For MAN B&W engines, the Unified
Technical File (UTF) format is recommended.
The EIAPP certificate documents that the specific engine meets the interna-
tional NOx emission limitations specified in Regulation 13 of MARPOL Annex
VI. The basic engine ‘Economy running mode’, EoD: 4 06 200, complies with
these limitations.
The pre-certification survey for a ‘Parent’ or an ‘Individual’ engine includes
NOx measurements during the delivery test. For ‘Member’ engines, a survey
according to the group definition for the engine group is needed. This survey
should be based on the delivery test.
The applicable test cycles are:
▪ E3, marine engine, propeller law for FPP, option: 4 06 201

or
▪ E2, marine engine, constant speed for CPP, option: 4 06 202
For further options regarding shop test, see Extent of Delivery.
36028851443942795
2022-09-01 - en

19.05 Shop test

ME-GI/-LGI/-GA 3 (3)
198 87 37-2.1 MAN Energy Solutions

36028851443942795
This page is intentionally left blank

2022-09-01 - en
19.05 Shop test

ME-GI/-LGI/-GA
 MAN Energy Solutions 199 13 32-3.3

List of spare parts, unrestricted service

Spare parts are requested by the following Classification Society only: NK,
while just recommended by: ABS, DNV, CRS, KR, LR and RS, but neither re-
quested nor recommended by: BV, CCS and RINA.

The final scope of spare parts is to be agreed between the owner and engine
builder/yard.

Cylinder cover, plate 2272-0300 (901 and more)

1 Cylinder cover complete with extra holes for pilot injection equipment and In-
conel cladding, including fuel valves, micro booster injection valves, exhaust
gas and starting valves, indicator valve, cooling jacket, piping ad control
valves for pilot injection, prechamber insert for pilot injection valves and seal-
ing rings (disassembled)
½ set Studs for 1 cylinder cover

Gas pipe supply chain, plate 4272-2800 (901 and more)

1 set Double-walled fuel gas pipes for 1 cylinder
1 Repair kit for gas pipes and connection flanges for 1 engine, including gas-
kets and packings

Piston and piston rod, plates 2272-0400/0420/0500 (902)

1 Piston complete (with cooling pipe), piston rod, piston rings and stuffing box,
studs and nuts
1 set Piston rings for 1 cylinder

19.06 List of spare parts, unrestricted service

Cylinder liner, plate 2272-0600 (903)
1 Cylinder liner complete, including cooling water jacket, non-return valves,
sealing rings and gaskets (assembled)

Cylinder lubricating oil system, plates 3072-0600, 6670-0100 (903)

1 Lubricator complete
1 Inductive sensor
1 set O-rings and seals
2023-09-22 - en

2 Lubricator backup cables

Connecting rod, and crosshead bearing, plates 1472-0300, 2572-0300/0200

1 Telescopic pipe with bushing for 1 cylinder
1 Crankpin bearing shell (1 upper and 1 lower part) with studs and nuts
1 Crosshead bearing shell (lower part) with studs and nuts
2 Thrust pieces

ME-GA Engines 1 (4)

199 13 32-3.3 MAN Energy Solutions

Thrust block, plate 2572-0600 (905)

1 set Thrust pads, complete FWD set for ‘Ahead’
1 set For KR and NK also 1 set ‘Astern’ if different from ‘Ahead’

Hydraulic power supply, plates 4572-1000/0750, 4572-1100/1200/1250 1 and 2)

1 Proportional valve for hydraulic pumps
1 Leak indicator
1 Drive shaft for hydraulic pump, of each type (length)
1 Membrane and seals for accumulator
1 set Minimess for accumulator
1 Compensator, fluid type
6 Chain links. Only for ABS, LR and NK
1 set Flexible hoses, one of each size and length
1 set High-pressure gasket kit
1 Coupling for start-up pump

ME filter, plate 4572-0800

1 set Filter cartridges for oil filters. Cartridge filtration ability, minimum Beta6=16.

Engine control system, plates 4772-1500/1550, 7072-0800/1100/1250 2)

1 set Controller spares:
1 Base module
19.06 List of spare parts, unrestricted service

1 CPU module
1 Power supervision module
1 Modbus module
1 Digital I/O module (DI, DO, DRO)
1 Analog I/O module
1 Digital I/O module (DI, DO)
1 VFID modul

1 Trigger sensor for tacho system. (Only if trigger ring is installed and no an-
2023-09-22 - en

gular encoder on fore end)

1 Marker sensor for tacho system
1 Tacho signal amplifier (TCA)
1 ID-key
1 Encoder, steel compensator and bearing set

Starting valve, plates 3472-0200/0250 (907)

1 Starting valve, complete 2) (Included in "Cylinder cover complete")

2 (4) ME-GA Engines

 MAN Energy Solutions 199 13 32-3.3

1 Solenoid valve 1)

Hydraulic cylinder unit, plates 4572-0500/0100/0900, 4272-0100/0500 (906,

907, 909) 1 and 2)
1 Fuel booster top cover, complete with plunger
1 ELFI + ELVA valves complete, or FIVA if applied.
1 Suction valve complete
20% of Flexible high-pressure hoses, one of each size and length
eng. Only for DNV
1 High-pressure pipe sealing ring kit
1 set Membrane and seals for accumulator, 1 set for 1 HCU
1 Packing kit (O-rings, square seals and bonded seals)
1 Fuel booster position sensor
1 Exhaust actuator complete
1 Fuel pump/booster

Exhaust valve, plates 2272-0200/0210/0240 (908)

2 Exhaust valves complete (The second exhaust valve is included in "Cylinder
cover complete")
1 High-pressure pipe from actuator to exhaust valve
1 Exhaust valve position sensor

Fuel valve, plates 4272-0200 (909)

19.06 List of spare parts, unrestricted service

1 set Fuel valves of each size and type fitted, complete with all fittings, for 1 en-
gine
a) Engines with 1 or 2 fuel valves per cylinder: 1 set of fuel valves for all cylin-
ders on the engine
b) Engines with 3 and more fuel valves per cylinder: 2 complete fuel valves
per cylinder, and a sufficient number of valve parts, excluding the body,
which, together with the parts in the complete valves, makes up a full en-
gine set.

Micro booster injection valve, plate 4272-0210/0510

2023-09-22 - en

2 Micro booster injection valves including sealings for 1 cylinder (valves are in-
cluded in "Cylinder cover complete")

Fuel oil high-pressure pipes, plate 4272-0100 (909)

1 set High-pressure pipes, from fuel oil pressure booster to fuel valve

Turbocharger, plate 5472-0700 (910)

1 set Maker’s standard spare parts

ME-GA Engines 3 (4)

199 13 32-3.3 MAN Energy Solutions

1 a) Spare rotor for 1 turbocharger, including compressor wheel, rotor shaft with
turbine blades and partition wall, if any

Bedplate, plates 1072-0400, 2572-0400 (912)

1 Main bearing shells (1 upper and 1 lower) of each size
1 Studs and nuts for 1 main bearing
54043252996573963

1
) Spare parts required by MAN Energy Solutions.
2
) All spare parts are requested by all Classes.
a) Only required for RS. To be ordered separately as option: 4 87 660 for
other classification societies.
Note: Plate numbers refer to the Instruction Manual containing plates with
spare parts (older three-digit numbers are included for reference).
54043252996573963
19.06 List of spare parts, unrestricted service

2023-09-22 - en

4 (4) ME-GA Engines

 MAN Energy Solutions 199 20 00-9.0

Additional spares
Beyond class requirements or recommendation, for easier maintenance and
increased security in operation.
The final scope of spare parts is to be agreed between the owner and engine
builder/yard.

Cylinder cover, plate 2272-0300 (901 and more)

4 studs for exhaust valve
4 nuts for exhaust valve
½ eng O-rings for cooling jacket
½ eng sealings between cylinder cover and liner
1 set spring housings for fuel valve for 1 cylinder

Hydraulic tool for cylinder cover, plate 2272-0310/0315 (901 and more)
1 set hydraulic hoses with protectin hose, complete with couplings
8 O-rings with backup rings, upper
8 O-rings with backup rings, lower

Piston and piston rod, plates 2272-0400/0420 (902)

1 box locking wire, L=63 m
5 piston rings of each type
2 D-rings for piston skirt
2 D-rings for piston rod

Piston rod stuffing box, plate 2272-0500 (902)

15 self-locking nuts
5 O-rings
5 top spacer rings
15 sealing rings
sets
19.07 Additional spares
2024-02-21 - en

10 cover sealing rings

120 lamellas for scraper rings
30 springs top scraper and sealing rings
20 springs for scraper rings

Cylinder frame, plate 1072-0710 (903)

½ set stud for cylinder cover for 1 cyllinder
1 bushing for stuffing box

ME-GA 1 (6)
199 20 00-9.0 MAN Energy Solutions

Cylinder liner and cooling jacket, plates 2272-0600/0660/0665 (903)

4 non-return valves for 2 cylinders
1 eng O-rings for cylinder liner
½ eng gaskets for cooling water connection
½ eng O-rings for cooling water pipes
1 set cooling water pipes with blocks between liner and cover for 1 cylinder

Cylinder lubricating oil system, plate 3072-0600 (903)

1 solenoid valve
1 level switch for lubricator

Second fuel admission valve block, plates 4272-2012/2020/2302 (906)

½ eng sealing rings, gaskets and O-rings for valve block, window valve and admis-
sion valve
Pressure transducer for 1 cylinder
Non-return valves for 1 cylinder
2 proportional valves

Second fuel purge block, plates 4272-2016/2030/2032 (906)

1 set sealing rings
1 N2 filter
1 pressure transmitter
1 set sealing rings for each control valve
2 solenoid valves for control valves

Second fuel control pipes, plates 4272-2016/0048/2050 (906)

½ eng O-rings and sealing rings

Second fuel regulating unit, plates 4272-2210/2030 (906)

1 set sealing rings, O-rings and wearing rings
19.07 Additional spares

1 valve seat
2024-02-21 - en

1 proportional valve
1 pressure transducer
1 temperature sensor
1 displacement sensor
1 set sealing rings for control valve
1 solenoid valve for control valve

2 (6) ME-GA
 MAN Energy Solutions 199 20 00-9.0

Sealing oil unit (inlet) and second fuel sealing oil high-pressure pipes, plates
4272-2603/2606 (906)
1 set sealing rings and O-rings for sealing oil unit
1 set valves for sealing oil unit
1 pressure filter
½ eng sealing rings and O-rings

Second fuel inlet/outlet pipes, plates 4272-2800/2801/2900/2910 (906)

½ eng sealing rings and O-rings, inlet/outlet pipes, venting pipes and purge pipes

Jacket water recirculation system, plates 5072-0160/0165 (9XX)

1 repair kit for circulation pump in jacket water recirculation system
1 repair kit for three-way valve in jacket water recirculation system

Engine control system, plates 4772-1550, 7072-1250 (906)

1 set fuses for MPC, TSA and CNR
1 set sensors for gas system

Accumulator/safety block, plate 4572-0700 (906)

1 pressure transducer (pos. 320)
25% plug screws, shared with HPS and HCU
1 ball valve DN10
1 solenoid valve for valve pos. 310 (shut down)

Alarm and safety system, plates 4772-0100/0200 (906)

1 pressure sensor for scavenge air receiver, PT 8601
1 pressure switch for lubricating oil inlet, PS 8109
1 thrust bearing temperature sensor, TS 8107 (sensor only)
1 pressure switch for jacket cooling water inlet, PS 8402

Main starting valve, plate 3472-0300 (907)

19.07 Additional spares
2024-02-21 - en

The main starting valve parts mentioned here must be in accordance with the
supplier’s recommendation:

1 repair kit for main actuator

1 repair kit for main ball valve
1 *) repair kit for actuator, slow turning, if fitted
1 *) repair kit for ball valve, slow turning, if fitted

ME-GA 3 (6)
199 20 00-9.0 MAN Energy Solutions

Starting valve, plate 3472-0200 (907)

2 locking plates
2 pistons
2 springs
2 bushing
1 set O-rings
1 valve spindle

Exhaust valve, plates 2272-0200/0210 (908)

1 exhaust valve spindle
1 exhaust valve seat
½ eng sealing rings between exhaust valve and cylinder cover
4 piston rings
½ eng guide rings for air piston
½ eng sealing rings
½ eng safety valves
1 eng gaskets and O-rings for safety valve
1 piston complete
1 opening damper piston
1 eng O-rings and sealings between air piston and exhaust valve housing/spindle
1 spindle guide
1 eng gaskets and O-rings for cooling water connection
1 conical ring in 2/2 (only for low-force design)
1 eng O-rings for spindle/air piston
1 eng non-return valve
1 sealing oil unit (only for engines without low-force design/COL)
1 inductive sensor for exhaust valve positioning

Cooling water outlet, plate 5072-0100 (908)

19.07 Additional spares

2 ball valves
2024-02-21 - en

1 butterfly valve
1 gasket for butterfly valve
1 eng packings for cooling water compensator

Fuel valve, plate 4272-0200 (909)

½ eng springs
½ eng discs, +30 bar
3 thrust spindles

4 (6) ME-GA
 MAN Energy Solutions 199 20 00-9.0

3 non-return valves, if mounted

Fuel oil pilot injector, plates 4272-0015/0020/0190/0210/0510 (909)

½ eng sealing rings control oil high-pressure pipes
1 membrane accumulator for control oil distributor block
½ eng sealing rings fuel oil pipes
½ eng sealing rings gaskets and O-rings, fuel oil pilot injector, fuel oil pilot pressure
booster
½ eng pre-chamber nozzles
½ eng fuel oil pilot injector valve spindle guide
Multiway valves for 1 cylinder
Pump barrel fuel oil pilot pressure booster for 1 cylinder
Non-return valves for 1 cylinder
Control valves for 1 cylinder
Suction valves for 1 cylinder

Fuel oil high-pressure pipes, plate 4272-0100 (909)

1 set high-pressure pipes, from fuel oil pressure booster to fuel valve
1 set O-rings for high-pressure pipes

Fuel oil regulating valve, plate 4272-0030 (909)

1 fuel oil regulating valve, complete
1 O-ring of each type

Turbocharger, plate 5472-0700 (910)

1 set spare parts for 1 turbocharger in accordance with the supplier’s recom-
mendation

Scavenge air receiver, plates 5472-0400/0630 (910)

1 set non-return valves for turbocharger, complete
1 compensator between turbocharger and air cooler
19.07 Additional spares
2024-02-21 - en

Exhaust pipes and receiver, plates 5472-0750/0900 (910)

1 compensator between turbocharger and receiver
2 compensators between exhaust valve and receiver
1 set gaskets for each compensator
1 compensator between FWD and AFT part, if any

ME-GA 5 (6)
199 20 00-9.0 MAN Energy Solutions

Air cooler, plate 5472-0100 (910)

1 set anodes (corrosion blocks)
1 set packings (only for cooler type LKMY)

Auxiliary blower, plate 5472-0500 (910)

1 set bearings for electric motor
1 set shaft sealings
1 set bearings/belt/sealings for gearbox (only for belt-driven blowers)

Safety valve, plate 2272-0330 (911)

1 set gaskets for safety valve (only for CR and NK)
2 safety valves complete (only for CR and NK)

Arrangement of safety cap, plate 3472-0900 (911)

1 eng bursting disc

ME filter, plate 4572-0800 (912)

1 set filter cartridges for redundancy filter
Cartridge filtration ability, minimum Beta6=16
Only for filter make Boll & Kirch

Notes: In the pcs/set column, ‘engine’ means ‘engine set’, i. e. a set for one
engine, whereas ‘set’ means a set for the specific component(s).
Section numbers refer to Instruction Book, Vol. III containing plates with spare
parts.

Exhaust gas recirculation system, emission project guide

See the emission project guide, chapter 3.10
69430127755
19.07 Additional spares

2024-02-21 - en

6 (6) ME-GA
 MAN Energy Solutions 199 17 32-5.0

Wearing Parts
MAN Energy Solutions Service Letter SL2023-744 provides guiding overhaul
intervals and expected service life for key engine components.
See the latest Service Letter on
https://www.man-es.com/docs/default-source/service-letters/sl2023-744.pdf

Fig.19.08.01: Example from Service Letter

2023-08-16 - en

9007255941881483
19.08 Wearing Parts

All engines 1 (1)

199 17 32-5.0 MAN Energy Solutions

9007255941881483
This page is intentionally left blank

2023-08-16 - en
19.08 Wearing Parts

All engines
MAN Energy Solutions 199 13 38-4.0

Large spare parts, dimensions and masses

General
1. 2.

3. 4.

19.09 Large spare parts, dimensions and masses

Dimensions and masses

MAX Dimensions (mm)
Position Section description mass
kg A B C D E
1 Cylinder liner, including cooling jacket 5,900 ø987 ø945 3,510 ø789

2 Exhaust valve 1,099 1,734 878 674

3 Piston complete, with piston rod 2,430 ø950 509 ø270 4,207 ø425

4 Cylinder cover, including valves 2,415 ø1,366 611 ø922

588 98 78-4.0.0

Fig. 19.09.01: Dimensions and masses of tools

G70ME-C10.5/-GA/-GI 1 (3)
199 13 38-4.0 MAN Energy Solutions

Rotor for turbocharger

MAN

Type Max mass Dimensions (mm)

Kg A (ø) B C (ø)
TCA44 90 480 880 460

TCA55 140 570 990 515

TCA66 230 670 1,200 670

TCA77 390 800 1,380 730

TCA88 760 940 1,640 980

TCR18 24 280 469

TCR20 42 337 566

TCR22 95 440 739

561 70 21-6.1.0

Accelleron

Type Max mass Dimensions (mm)

19.09 Large spare parts, dimensions and masses

Kg A (ø) B C (ø)
A165-L 90 500 940 395

A170-L 130 580 1,080 455

A175-L 220 700 1,300 550

A180-L 330 790 1,470 620

A185-L 460 880 1,640 690

A265-L 100 500 930 395

A270-L 140 580 1,090 455

A275-L 240 700 1,320 550

A280-L 350 790 1,490 620

561 66 78-9.0.0

2 (3) G70ME-C10.5/-GA/-GI
MAN Energy Solutions 199 13 38-4.0

MHI

Type Max mass Dimensions (mm)

Kg A (ø) B C (ø)
MET33MA 45 373 662 364

MET33MB 55 373 692 364

MET42MA 69 462 807 451

MET42MB 85 462 847 451

MET48MB 155 524 954 511

MET53MA 190 586 1,035 571

MET53MB 210 586 1,068 571

MET60MA 240 652 1,188 636

MET60MB 270 652 1,185 636

MET66MA 330 730 1,271 712

MET66MB 370 730 1,327 712

MET71MA 400 790 1,318 771

MET71MB 480 790 1,410 771

MET83MA 600 924 1,555 902

MET83MB 750 924 1,608 902

MET90MA 850 1,020 1,723 996

19.09 Large spare parts, dimensions and masses

MET90MB 950 1,020 1,794 996

561 68 37-2.1.0

Fig. 19.09.02: Large spare parts, dimensions and masses

81064841496895499

G70ME-C10.5/-GA/-GI 3 (3)
199 13 38-4.0 MAN Energy Solutions

81064841496895499
This page is intentionally left blank
19.09 Large spare parts, dimensions and masses

G70ME-C10.5/-GA/-GI
MAN Energy Solutions 199 17 94-7.0

List of standard tools for maintenance

General
The engine is delivered with all necessary special tools for scheduled maintenance.
The extent of the tools is stated below. Most of the tools are arranged on steel plate
panels. It is recommended to place them close to the location where the overhaul is
to be carried out, see Section 19.11.
All measurements are for guidance only.
* Depending on the tier technology selected either of the EGR or SCR tools are
applicable, MF/SF 21-9046 and MF/SF 21-9056
Mass of the complete set of tools: Approximately 5,350 kg
27021655278249483

Cylinder cover, MF/SF-21-9010

1 pcs Tool panel including lifting chains, grinding mandrels, extractor tools etc.
1 pcs Cylinder cover rack
1 set Cylinder cover tightening tools
27021655278249483

Cylinder unit tools, MF/SF 21-9014

1 pcs Tool panel including pressure testing tool, piston ring expander, stuffing
box tools, templates etc.
1 pcs Guide ring for piston
1 pcs Lifting tool for piston
1 pcs Support iron for piston

19.10 List of standard tools for maintenance

1 pcs Crossbar for cylinder liner, piston
1 pcs Lifting tool for cylinder liner
1 pcs Measuring tool for cylinder liner
1 set Test equipment for accumulator
1 pcs ECU temporary backup cable for indicator
27021655278249483

Crosshead and connecting rod tools, MF/SF 21-9022

1 pcs Tool panel including suspension and lifting tools,
protection in crankcase etc.
1 pcs Crankpin shell, lifting tool
27021655278249483

Crankshaft and thrust bearing tools, MF/SF 21-9026

1 pcs Tool panel including lifting, testing and retaining tools etc.
1 pcs Lifting tool for crankshaft
1 pcs Lifting tool for thrust shaft
1 pcs Main bearing shell, lifting tool
27021655278249483

G70ME-C10.5-GA 1 (22)
199 17 94-7.0 MAN Energy Solutions

Control gear tools, MF/SF 21-9030

1 pcs Tool panel including pin gauges, chain assembly tools, camshaft tools,
Lifting attachments etc.
1 set Hook wrenches for accumulator
27021655278249483

Exhaust valve tools, MF/SF 21-9038

1 pcs Tool panel including grinding, lifting, adjustment and test tools etc.
27021655278249483

Gas system tools, MF/SF 21-9040

1 pcs Tool panel including grinding and lifting tools, wrenches, extractors etc.
1 pcs Test rig for Fuel Oil valve
1 pcs Test rig for gas valve
1 pcs Lifting tool for SGAV (Manoeuvre side)
1 pcs Lifting tool for SGAV (Exhaust side)
27021655278249483

Fuel oil system tools, MF/SF 21-9042 (Dual fuel)

1 pcs Tool panel including grinding, lifting, adjustment and assembly tools etc.
1 set Fuel valve nozzle tools
1 set Toolbox for mounting of fuel pump seals
1 pcs Probelight
1 pcs Test rig for fuel valve
27021655278249483

Turbocharger system tools, MF/SF 21-9046

1 set Air cooler cleaning tool
19.10 List of standard tools for maintenance

1 set EGR Tools, liftng tools and blanking plates

1 set Guide rails, air cooler element
1 pcs Compensator, dismantling tool
1 pcs Travelling trolley
1 set Blanking plates
27021655278249483

Emmision, SCR system tools, MF/SF 21-9056

1 pcs Dummy valve
1 set Blanking plate, includes packing
1 pcs Dummy seal
27021655278249483

General tools, MF/SF 21-9058

1 pcs Pump for hydraulic jacks including hydraulic
accessories
1 set Set of tackles, trolleys, eye bolts, shackles,
wire ropes
1 set Instruments including mechanical / digital measuring tools
27021655278249483

2 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 94-7.0

Maintenance support equipment, MF/SF 21-9060

1 set Working platforms including supports
27021655278249483

Hydraulic jacks, MF/SF 21-94

It is important to notice, that some jacks are used on different components on the
engine
27021655278249483

Personal safety equipment, MF/SF 21-9070

1 pcs Compulsory package of standard fall arrest equipment
1 pcs Supplemental fall arrest equipment, optional package
27021655278249483

Optional tools
1 pcs Cylinder liner inspection camera
1 pcs Collar ring for piston
1 pcs Support for tilting tool
1 pcs Wave cut machine for cylinder liner
1 pcs Wear ridge milling machine
1 pcs Honing tool for cylinder liner
1 pcs Valve seat and spindle grinder
1 pcs Work table for exhaust valve
1 pcs Digital insertable cylinder wear device
1 pcs Crankshaft deflection tool (Digital)
1 pcs Rig for large fuel valve
1 pcs Cleaning equipment

19.10 List of standard tools for maintenance

1 pcs Ferrous wear test kit, Option
1 pcs Cold corrosion test kit, Option
1 pcs Total base no. Test kit, Option
1 pcs Drip oil test kit, Option
27021655278249483

G70ME-C10.5-GA 3 (22)
199 17 94-7.0 MAN Energy Solutions

1. 2.

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C D
1 Cylinder cover rack 154 1,750 907 785 494

2 Cylinder cover tightening tools 432 1,161 2,357

27021655278249483

Fig. 19.10.01: Dimensions and masses of tools, MF/SF 21-9010

19.10 List of standard tools for maintenance

4 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 94-7.0

1. 3.

2. 4.

19.10 List of standard tools for maintenance

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C D E
1 Guide ring for piston 46 80 800

2 Lifting tool for piston 59 680 240 70 45

3 Support iron for piston 178 1,381 900 640

4 Crossbar for cylinder liner, piston 65 1,006 230 180 60 90

27021655278249483

Fig. 19.10.02: Dimensions and masses of tools, MF/SF 21-9014

G70ME-C10.5-GA 5 (22)
199 17 94-7.0 MAN Energy Solutions

1. 3.

2. 4.
19.10 List of standard tools for maintenance

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C D
1 Lifting tool for crank shaft 231 160 878 705

2 Crankpin shell, lifting tool 8 956 230 576 378

3 Lifting tool for thrust shaft 50 425 1,500 125

4 Main bearing shell, lifting tool 2 948

27021655278249483

Fig. 19.10.03: Dimensions and masses of tools, MF/SF 21-9022 and

MF/SF 21-9026

6 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 94-7.0

1.

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C
1 Hook wrenches for accumulator 77 477 506 416
27021655278249483

Fig. 19.10.04: Dimensions and masses of tools, MF/SF 21-9030

19.10 List of standard tools for maintenance

G70ME-C10.5-GA 7 (22)
199 17 94-7.0 MAN Energy Solutions

1. 3.

2. 4.
19.10 List of standard tools for maintenance

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C
1 Test rig for Fuel Oil valve 270 1,097 638 1,027

2 Test rig for gas valve 93 1,210 425 445

3 Lifting tool for SGAV (Manoeuver side) 17 2,322 384

4 Lifting tool for SGAV (Exhaust side) 26 790 237 414

27021655278249483

Fig. 19.10.05: Dimensions and masses of tools, MF/SF 21-9040

8 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 94-7.0

1. 2.

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C
1 Test rig for fuel valve - PPMI 2000 58 1,425 565 565

2 Test rig for fuel valve - Fuel valve test stand 124 972 520 1,532
27021655278249483

Fig. 19.10.06: Dimensions and masses of tools, MF/SF 21-9042

19.10 List of standard tools for maintenance

G70ME-C10.5-GA 9 (22)
199 17 94-7.0 MAN Energy Solutions

1. 3.

2.
19.10 List of standard tools for maintenance

27021655278249483

Position Description
1 Guide rails, air cooler element

2 Compensator, dismantling tool

3 Blanking plates
27021655278249483

Fig. 19.10.07: Dimensions and masses of tools, MF/SF 21-9046

10 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 94-7.0

For EGR engines only

27021655278249483

1.

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A
Engine with EGR:-

1 EGR Tools, lifting tools and blanking plates 53 605

27021655278249483

Fig. 19.10.08: Dimensions and masses of tools, MF/SF 21-9046

19.10 List of standard tools for maintenance

G70ME-C10.5-GA 11 (22)
199 17 94-7.0 MAN Energy Solutions

1. 3.

2.
19.10 List of standard tools for maintenance

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C
Engine with SCR:-

1 Dummy valve 254 1,000 194

2 Blanking plate, including packing 167 995

3 Dummy seal 36 196 300 170

27021655278249483

* Depending on the tier technology selected either of the EGR or SCR tools
are applicable

Fig. 19.10.09: Dimensions and masses of tools, MF/SF 21-9056

12 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 94-7.0

1. 2.

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C
1 Pump for hydraulic jacks including hydraulic 30 330 380 380
accessories

2 Working platforms including supports 113 948 250

27021655278249483

Fig. 19.10.10: Dimensions and masses of tools, MF/SF 21-9058 and

MF/SF 21-9060

19.10 List of standard tools for maintenance

G70ME-C10.5-GA 13 (22)
199 17 94-7.0 MAN Energy Solutions

27021655278249483

Fig. 19.10.11: Dimensions and masses of tools, MF/SF 21-94

Example of a box containing hydraulic jacks for connecting rod and end
19.10 List of standard tools for maintenance

chocks.
The exact design and dimensions will be specified by the engine builder or
subsupplier.
However, as a minimum, the boxes must be provided with the following:
▪ supports
▪ rigid handles
▪ rigid locks
▪ reinforced corners
▪ be resistant to water and oil
▪ hydraulic jacks must be secured in the box

The table indicates the scope and estimated size of boxes for hydraulic jacks.
Hydraulic jacks are often used at different locations, which is why not all fields
have been filled in.
Approx. dimensions in mm.
Size 1: 300 mm x 400 mm x 500 mm

Size 2: 500 mm x 700 mm x 500 mm

Size 3: 900 mm x 1200 mm x 500 mm

27021655278249483

14 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 94-7.0

MF-SF Hydraulic Jacks Number of Size re- MF-SF Hydraulic Jacks Number of Size re-
boxes quired boxes quired
21-9410 Cylinder cover 1 3 21-9451 Intermediate shaft

21-9420 Piston crown 21-9452 Camshaft bearing

21-9421 Piston rod 21-9453 Main Hydraulic pipe

21-9430 Crosshead 1 1 21-9454 Moment compensator

21-9431 Connecting rod 1 1 21-9460 Exhaust spindle

21-9432 Crosshead 21-9461 Exhaust valve 1 2

21-9433 Guide planes 21-9462 Exhaust valve actuator 1 1

21-9440 Main bearing 2 2 21-9463 HPU block

21-9441 Tuning wheel 21-9464 HCU block

21-9442 Turning wheel 21-9470 Fuel pump

21-9443 Chain wheel 21-9480 Stay bolts 0 1

21-9444 AVD 21-9482 Air cooler

21-9445 Segment stopper 21-9490 Holding down bolts / 1 1

End chock

21-9446 Counter weight 21-9491 End Chock 1 1

21-9447 Torsion damper

21-9448 Turning gear 1 1

Total number of boxes containing jacks 11
21-9450 Chain tightener 1 1
27021655278249483

Table 19.10.01: Dimensions and masses of tools, MF/SF 21-94xx

19.10 List of standard tools for maintenance

G70ME-C10.5-GA 15 (22)
199 17 94-7.0 MAN Energy Solutions

1. 2.

27021655278249483

Position Description
1 Compulsory package of standard fall arrest equipment
27021655278249483

Fig. 19.10.12: Dimensions and masses of tools, MF/SF 21-9070

19.10 List of standard tools for maintenance

16 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 94-7.0

1. 3.

2. 4.

19.10 List of standard tools for maintenance

27021655278249483

An optional package containing supplemental fall arrest equipment can be

ordered on request.
Position Description
1 Supplemental fall arrest equipment, optional package
27021655278249483

Fig. 19.10.13: Dimensions and masses of tools, MF/SF 21-9070

G70ME-C10.5-GA 17 (22)
199 17 94-7.0 MAN Energy Solutions

1. 2.

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C D
1 Wave cut machine for cylinder liner 210 1,050 780
19.10 List of standard tools for maintenance

2 Collar ring for piston 120 430 855 467 1,050

27021655278249483

Fig. 19.10.14: Dimensions and masses of tools, Optional tools

18 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 94-7.0

1. 3.

2. 4.

19.10 List of standard tools for maintenance

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C
1 Digital insertable cylinder wear 21 820 420 250
device

2 Wear ridge milling machine 47 780 450

3 Crankshaft deflection tool (Digital) 15 575 400

4 Cylinder liner inspection camera 2 763 92

27021655278249483

Fig. 19.10.15: Dimensions and masses of tools, Optional tools

G70ME-C10.5-GA 19 (22)
199 17 94-7.0 MAN Energy Solutions

1.
19.10 List of standard tools for maintenance

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C D
1 Valve seat and spindle grinder 550 1,050 3,040 90 600
27021655278249483

Fig. 19.10.16: Dimensions and masses of tools, Optional tools

20 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 94-7.0

1.

19.10 List of standard tools for maintenance

-
27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C D E
1 Worktable for exhaust valve 230 2,320 1,600 800 1,800 2,300
27021655278249483

Fig. 19.10.17: Dimensions and masses of tools, Optional tools

G70ME-C10.5-GA 21 (22)
199 17 94-7.0 MAN Energy Solutions

1. 3.

2.
19.10 List of standard tools for maintenance

27021655278249483

Position Description Mass Dimensions (mm)

(kg) A B C
1 Honing tool for cylinder liner 590 1,250 1,045 2,380

2 Rig for large fuel valve 75 971 700 572

3 Cleaning equipment 25 800 700 500

27021655278249483

Fig. 19.10.18: Dimensions and masses of tools, Optional tools

27021655278249483

22 (22) G70ME-C10.5-GA
MAN Energy Solutions 199 17 93-5.0

Tool panels

General

Fig. 19.11.01: Tool panels. 4 88 660

19.11 Tool panels

G70ME-C10.5-GA 1 (2)
199 17 93-5.0 MAN Energy Solutions

Mass of tools and panels

Section Tool panel Total mass of tools
and panels in kg
21-9010 Cylinder cover 88
Panel including lifting chains, grinding mandrels, extractor tools, etc.

21-9014 Cylinder unit tools, 221

Panel including pressure testing tool, piston ring expander, stuffing box tools, tem-
plates, etc.

21-9022 Crosshead and connection rod tools 173

Panel including suspension, lifting tools, protection in crank case, etc.

21-9026 Crankshaft and thrust bearing tools 129

Panel including lifting, testing and retaining tools, etc.

21-9030 Control gear tools 82

Panel including pin gauges, chain assembly tools, camshaft tools, lifting attach-
ments, etc.

21-9038 Exhaust valve tools 63

Panel including grinding, lifting, adjustment and test tools, etc.

21-9040 Gas system tools 46

Panel including grinding and lifting tools, wrenches, extractors, etc.

21-9042 Fuel oil system tools 83

Panel including grinding, lifting, adjustment and assembly tools, etc.
9007256755959435

Fig. 19.11.01: Tool panels, 4 88 660

9007256755959435
19.11 Tool panels

2 (2) G70ME-C10.5-GA
 MAN Energy Solutions 199 12 30-4.1

Tools and special tools

Standard tools
The engine is delivered with a comprehensive and extensive set of tools.
These enable normal maintenance work to be carried out.

Special tools
A wide range of special tools for on-board maintenance are available upon the
customer’s request. The optional tool serve as a supplement to the standard
set of tools specified for each engine. These are available via MAN Energy
Solutions, or directly via our co-operation agreement holders.

19.12 Tools and special tools

2023-06-23 - en

Fig. 19.12.01 Outline of tools

All engines 1 (20)

199 12 30-4.1 MAN Energy Solutions

Optional inspection tools to assist condition-based overhaul (CBO)

The objective of the Condition-Based Overhaul (CBO) strategy is to obtain the
highest number possible of safe running hours. Overhauling should only be
carried out when necessary and the most important factor in a CBO strategy
is the evaluation of the actual condition of the engine. This is done by regular
scavenge port inspections and logging of wear and hot corrosion.
MAN Energy Solutions recommends the following optional measuring tools to
assist with the CBO strategy.

Digital insertable cylinder liner measuring tool

The insertable tool facilitates liner condition monitoring. The cylinder liner trend
wear profile can be revealed and predicted by taking measurements regularly
during scavenge port inspections at engine stand-stills. The measurements
are done without removing the cylinder cover or exhaust valve housing, which
is very time saving and allows for more frequent measurements than using the
standard version of the tool. The output is digital, see Fig. 19.12.02.
19.12 Tools and special tools

2023-06-23 - en

Fig. 19.12.02 The insertable tool is available from different makers, starting
from bore size 40

2 (20) All engines

 MAN Energy Solutions 199 12 30-4.1

Liner condition camera

The liner condition camera is used for in situ photography of the cylinder liner
walls and piston ring packs in 2-stroke engines.
The photos can be used for evaluating cylinder condition parameters such as
cleanliness of ring land, size of cylinder wear edge, cylinder honing mark and
wave-cut groove extension, black lacquering from corrosive wear and bore
polish. See Fig. 19.12.03.

Fig. 19.12.03 Liner condition camera

19.12 Tools and special tools

2023-06-23 - en

All engines 3 (20)

199 12 30-4.1 MAN Energy Solutions

Digital crankshaft deflection measuring tool

Crank web deflection measurements are used to assess the alignment of the
crank throws and the main bearings. The digital crankshaft deflection tool has
a higher accuracy, easier reading and is able to store data compared to the
standard tool with mechanical dial gauge, see Fig. 19.12.04.
19.12 Tools and special tools

Fig. 19.12.04 The digital measuring tool is available for all engine bore sizes
2023-06-23 - en

Optional handling, grinding or refreshing tool

The following tools are recommended for best practice overhaul.

4 (20) All engines

 MAN Energy Solutions 199 12 30-4.1

Wear ridge milling machine

The machine is used to remove the wear ridge created in the top of the cylin-
der liner. This edge must be removed before the pulling of piston, to prevent
damage of the piston and/or lifting of the cylinder liner. The risk of damage to
piston rings when pulling piston without removing the wear ridge is especially
high for CPR rings. The wear ridge milling machine minimizes the risk of liner
damage due to un-controlled grinding. The wear ridge milling machine can
also be used to create a groove in the top of the liner to prevent the buildup of
a new wear ridge.
The wear ridge milling machine is available in two different versions: A stand-
ard milling machine and a customized milling machine for which a Hot Works
Permit is not necessary. see Fig. 19.12.05.

Fig. 19.12.05 The wear ridge milling machine is available for all engine bore
sizes
19.12 Tools and special tools
2023-06-23 - en

All engines 5 (20)

199 12 30-4.1 MAN Energy Solutions

Honing machine
Honing is the best method to remove liner ovality, which cause premature ring
breakage. Honing will also remove liner surface hardening and re-establish a
normal wear rate of a hardened liner.
The honing machine can be used on its own or combined with the wave-cut
machine, see Fig. 19.12.06.
19.12 Tools and special tools

2023-06-23 - en

Fig. 19.12.06 Cylinder liner with honing machine

6 (20) All engines

 MAN Energy Solutions 199 12 30-4.1

Wave-cut machine
The purpose of the wave-cut machine is to reestablish the wave-cut pattern
of the cylinder liner wall, which retains oil and facilitates the running-in of new
piston rings. Wave-cutting does not compensate for liner ovality. The wave-
cut machine can be used on its own or combined with honing, see Fig.
19.12.07.

19.12 Tools and special tools

2023-06-23 - en

Fig. 19.12.07 Cylinder with wave-cut machine and wave-cut pattern

All engines 7 (20)

199 12 30-4.1 MAN Energy Solutions

Worktable for exhaust valve

The worktable for exhaust valve ensures that maintenance of the complete
exhaust valve or the exhaust valve housing can be carried out safe and easy,
see Fig. 19.12.08.
19.12 Tools and special tools

Fig. 19.12.08 Worktable is available for all bore sizes

2023-06-23 - en

8 (20) All engines

 MAN Energy Solutions 199 12 30-4.1

Exhaust valve seat and spindle grinder

The exhaust valve seat and spindle grinder provides easy and accurate on-
board grinding of the exhaust valve spindle and bottom piece sealing sur-
faces. See fig. 19.12.09.
Different versions of the grinder exist and can be ordered for all engine bore
sizes.

19.12 Tools and special tools

2023-06-23 - en

Fig. 19.12.09. Exhaust valve seat and spindle grinder

All engines 9 (20)

199 12 30-4.1 MAN Energy Solutions

Dummy seal for SCR

Fig. 19.12.10 Dummy seal for SCR

Optional safety tools

Personal safety tools

Working on or inside two-stroke engines are very often connected with risk of
falling down. The risk of falling down can be mitigated by using fall protection
equipment.
The supplementary fall arrest safety equipment is CE or ANSI approved and
includes a safety harness and lanyards
Full body harness, lightweight 1,3 kg. Attack point in the back. Easy donning
and adjustment. Certified to North American, European and Russian stand-
ards. It is available in three sizes, see Fig. 19.12.11.

a)
Full body harness, lightweight 1.3 kg. At-
tack point in the back. Easy donning and
adjustment. American
n, European and Russian standards It is
available in three sizes.
19.12 Tools and special tools

2023-06-23 - en

10 (20) All engines

 MAN Energy Solutions 199 12 30-4.1

b)
Mini fall arrest block with steel hook. Ex-
tracted up to 2 m max. gives the flexibil-
ity. Th brake will arrest a free fall within
few inches. Connect it directly to harness
attach point at the hip and hook it to a
safe anchor point. It is designed to avoid
falling and must not be used as.

c)
Working positioning lanyard 2 m, ad-
justable length and a one- hand operated
steel hook. Connect it to harness attack
point at the hip and hook it to a safe an-
chor point. It is designed to avoid falling
and must not be used as.

Fig. 19.12.11 Full body harness (a), mini fall arrest block (b) and working posi-
tioning lanyard (c)

Safety ring for cylinder cover

The safety ring is used for allowing access to the cylinder liner through the ex-
haust valve bore of the cylinder cover. This option is available for bore size 90
and above. For bore sizes below the the cylinder cover are to be dismantled,
see Fig. 19.12.12.

19.12 Tools and special tools

2023-06-23 - en

All engines 11 (20)

199 12 30-4.1 MAN Energy Solutions

Optional tools for special design

Tools for reduced lifting height

The optional tool package for reduced lifting height includes a collar ring
which makes it possible to tilt the piston, hence reducing the required lifting
height of the engine room.
Engines with bore size less than 70 can be ordered with reduced lifting height
in the engine room. Engines with bore size from 70 can receive reduced lifting
height upon special request.
Tilted lift is not allowed for the cylinder liner, but by using the MAN B&W
double jib engine room crane the necessary lifting height is greatly reduced
compared to the single crane standard solution. Lifting screws for the double
jib crane is included in the tool package for reduced lifting height, see Fig.
19.12.13 and 19.12.14.
19.12 Tools and special tools

2023-06-23 - en

Fig. 19.12.13 Piston tool for reduced lifting height

12 (20) All engines

 MAN Energy Solutions 199 12 30-4.1

Fig. 19.12.14 Cylinder liner tool for reduced lifting height

Ultrasonic cleaning system

Ultrasonic cleaning system can be installed onboard to give the possibility of
cleaning of smaller engine parts such as fuel and spray nozzles, filters etc. us-
ing ultrasound waves in a specific cleaning chemical bath. The system is avail-
able in different sizes. See Fig. 19.12.15.

19.12 Tools and special tools

2023-06-23 - en

Fig. 19.12.15 Onboard ultrasonic cleaning system

All engines 13 (20)

199 12 30-4.1 MAN Energy Solutions

Rig for large fuel valve

The working rig facilitates overhaul work on large injection valves e.g. dismant-
ling and cleaning.

Fig. 19.12.16 Rig for large fuel valve.

19.12 Tools and special tools

2023-06-23 - en

14 (20) All engines

 MAN Energy Solutions 199 12 30-4.1

Tools for oil testing

Clean lubricating oil is the basis for trouble free operation of a MAN B&W en-
gine. MAN Energy Solutions recommend testing oil samples of the cylinder
lubricating oil for metal particles and determining the level of corrosive ele-
ments in order to take appropriate steps to avoid excessive cylinder liner
wear.
Contaminants in the lubricating oil may also damage the hydraulic compon-
ents in the ME system. For testing the lubricating oil, the following equipment
is available.

▪ Ferrous wear test equipment for detecting metal particles from samples of
cylinder lubricating oil
▪ Additional consumables pack for ferrous wear test equipment containing
500 test tubes and sampling pipettes.

19.12 Tools and special tools

2023-06-23 - en

Fig. 19.12.17 Ferrous wear test equipment for detecting metal particles from
samples of cylinder lubricating oil.

All engines 15 (20)

199 12 30-4.1 MAN Energy Solutions

▪ Cold corrosion test equipment for obtaining the level of corrosive ele-
ments in the cylinder lubricating oil including reagent pack for 100 tests
▪ Additional reagent pack for cold corrosion test kit containing reagents for
100 tests.

Fig. 19.12.18 Cold corrosion test eqiupment for obtaining the level of corros-
ive elements in the cylinder liner lubricating oil.
19.12 Tools and special tools

2023-06-23 - en

16 (20) All engines

 MAN Energy Solutions 199 12 30-4.1

▪ Total base number test kit for determining viscosity, total base number,
total acid number, soot and water in oil
▪ Additional reagent pack for total base number test kit containing reagents
for 50 tests.

Fig. 19.12.19 Total base number test kit for determining viscosity, total base
number, total acid number, soot and water in oil.

19.12 Tools and special tools

2023-06-23 - en

All engines 17 (20)

199 12 30-4.1 MAN Energy Solutions

▪ Drip oil analyzer for measuring the total iron content in the cylinder lubric-
ating oil which indicates the corrosive and abrasive wear.

Fig. 19.12.20 Drip analizer for measuring the total iron content in the cylinder
lubricating oil.

▪ Rack including 12 pcs. Iron testing units for drip oil analizer
19.12 Tools and special tools

2023-06-23 - en

18 (20) All engines

 MAN Energy Solutions 199 12 30-4.1

Fig. 19.12.21 Rack including 12 pcs. Iron testing units for drip oil analizer.

▪ Pipette for drip oil analizer.

19.12 Tools and special tools

2023-06-23 - en

Fig. 19.12.22 Pipette for drip oil analyzer

All engines 19 (20)

199 12 30-4.1 MAN Energy Solutions

Appendix: tool plates for optional

The tool plates of the optional tools described in ‘Optional tools’ are included
below. For ordering, please contact MAN PrimeServ and state the IMO no.,
engine type, plate no. and item no. of the tool in question.

Plate No. Description

2270-0610 Digital insertable cylinder liner measuring tool

1070-1035 Digital crankshaft deflection measuring tool

2270-0620 Wear ridge milling machine

2270-0630 Honing machine

2270-0630 Wave-cut machine

2270-0220 Worktable for exhaust valve

2270-0210 Exhaust valve seat and spindle grinder

0570-0100 Personal safety package

2270-0335 Safety ring for cylinder liner

2270-0460 Tools for reduced lifting height, bore size 50 and below

2270-0460 Tools for reduced lifting height, bore size 60 and above

4270-0240 Rig for large fuel valve

3070-0600 Ferrous wear meter test kit (FWM)

3070-0600 Consumables pac for FWM

3070-0600 Cold corrosion test kit (CCTK)

3070-0600 Reagent pack for CCTK

3070-0600 Total base number test kit (TBN)

3070-0600 Reagent pack TBN

3070-0600 DOT FAST drip oil analyzer

3070-0600 DispoRack including 12 pcs. iron testing units

3070-0600 MicroMan pipette

19.12 Tools and special tools

45036039151039755

Table. 19.12.01 Tool plates for optional tools.

45036039151039755
2023-06-23 - en

20 (20) All engines

MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas 20 Project Support and Documentation
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix
61395664523

1 (1)
 MAN Energy Solutions

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20 Project Support and Documentation
 MAN Energy Solutions 198 45 88-7.5

Project support and documentation

General
The selection of the ideal propulsion plant for a specific newbuilding is a com-
prehensive task. However, as this selection is a key factor for the profitability
of the ship, it is of the utmost importance for the end-user that the right
choice is made.
MAN Energy Solutions is able to provide a wide variety of support for the ship-
ping and shipbuilding industries all over the world.
The knowledge accumulated over many decades by MAN Energy Solutions
covering such fields as the selection of the best propulsion machinery, optim-
ization of the engine installation, choice and suitability of a Power Take Off for
a specific project, vibration aspects, environmental control etc., is available to
shipowners, shipbuilders and ship designers alike.
Part of this information can be found in the following documentation:
• Marine Engine Programme
• Turbocharger Selection
• Installation Drawings
• CEAS - Engine Room Dimensioning
• Project Guides
• Extent of Delivery (EOD)
• Technical Papers
The publications are available at:
www.marine.man-es.com--> Two-stroke.

Engine Selection Guides

The ‘Engine Selection Guides’ are intended as a tool to provide assistance at
the very initial stage of the project work. The guides give a general view of the

20.01 Project support and documentation

MAN B&W two-stroke Programme for MC as well as for ME and ME-B en-
gines and include information on the following subjects:
• Engine data
• Engine layout and load diagrams specific fuel oil consumption
• Turbocharger selection
• Electricity production, including power take off
• Installation aspects
• Auxiliary systems
• Vibration aspects.
2023-07-06 - en

After selecting the engine type on the basis of this general information, and
after making sure that the engine fits into the ship’s design, then a more de-
tailed project can be carried out based on the ‘Project Guide’ for the specific
engine type selected.

Project Guides
For each engine type of MC, ME or ME-B design a ‘Project Guide’ has been
prepared, describing the general technical features of that specific engine
type, and also including some optional features and equipment.

ME-B, ME/ME-C/-GI/-GA, MC/MC-C 1 (2)

198 45 88-7.5 MAN Energy Solutions

The information is general, and some deviations may appear in a final engine
documentation, depending on the content specified in the contract and on
the individual licensee supplying the engine. The Project Guides comprise an
extension of the general information in the Engine Selection Guide, as well as
specific information on such subjects as:
• Engine Design
• Engine Layout and Load Diagrams, SFOC
• Turbocharger Selection & Exhaust Gas By-pass
• Electricity Production
• Installation Aspects
• List of Capacities: Pumps, Coolers & Exhaust Gas
• Fuel Oil
• Lubricating Oil
• Cylinder Lubrication
• Piston Rod Stuffing Box Drain Oil
• Central Cooling Water System
• Seawater Cooling
• Starting and Control Air
• Scavenge Air
• Exhaust Gas
• Engine Control System
• Vibration Aspects
• Monitoring Systems and Instrumentation
• Dispatch Pattern, Testing, Spares and Tools
• Project Support and Documentation.
27021649708679051
20.01 Project support and documentation

2023-07-06 - en

2 (2) ME-B, ME/ME-C/-GI/-GA, MC/MC-C

 MAN Energy Solutions 198 45 90-9.3

CEAS application

General
Additional customised information can be obtained from MAN Energy Solu-
tions as project support. For this purpose, we have developed the CEAS ap-
plication, by means of which specific calculations can be made during the
project stage.

The CEAS Application

The CEAS application is found at
https://www.man-es.com-->CEAS En-gine Calculation.

On completion of the CEAS application, a report is generated covering the fol-

lowing:
• Main engine room data
• Specified main engine and ratings
• Ambient reference conditions
• Expected SFOC, lube oil consumption, air and exhaust gas data
• Necessary capacities of auxiliary machinery (SMCR)
• Starting air system, engine dimensions, tanks, etc.
• Tables of SFOC and exhaust gas data
• Heat dissipation of engine
• Water condensation separation in air coolers
• Noise – engine room, exhaust gas, structure borne
• Preheating of diesel engine
• Alternative engines and turbochargers, further reading
.
Links to related MAN Energy Solutions publications and papers are provided,
too.

Supplementary Project Data on Request

Further to the data generated by the CEAS application, the following data are
available on request at the project stage:
• Estimation of ship’s dimensions
• Propeller calculation and power prediction
• Selection of main engine
• Main engines comparison
20.02 CEAS application
2023-07-06 - en

• Maintenance and spare parts costs of the engine

• Total economy – comparison of engine rooms
• Steam and electrical power – ships’ requirement
• Utilisation of exhaust gas heat
• Utilisation of jacket cooling water heat, fresh water production
• Exhaust gas back pressure
• Layout/load diagrams of engine.

Contact MAN Energy Solutions Copenhagen in this regard.

45036048218192267

All engines 1 (1)

198 45 90-9.3 MAN Energy Solutions

45036048218192267
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20.02 CEAS application

2023-07-06 - en

All engines
 MAN Energy Solutions 198 45 91-0.7

Extent of delivery

General
MAN Energy Solutions' ‘Extent of Delivery’ (EoD) is provided to facilitate nego-
tiations between the yard, the engine maker, consultants and the customer in
specifying the scope of supply for a specific project involving MAN B&W two-
stroke engines.
We provide two different EoDs:
EoD 95-40 ME-C/-GI/-LGI Tier ll Engines
EoD 50-30 ME-B/-GI/-LGI Tier ll Engines
These publications are available in print and at: www.marine.man-es.com -->
Two-Stroke --> Extemt of Delivery (EoD).

Basic Items and Options

The ‘Extent of Delivery’ (EoD) is the basis for specifying the scope of supply
for a specific order.
The list consists of ‘Basic’ and ‘Optional’ items.
The ‘Basic’ items define the simplest engine, designed for unattended ma-
chinery space (UMS), without taking into consideration any further require-
ments from the classification society, the yard, the owner or any specific regu-
lations.
The ‘Options’ are extra items that can be alternatives to the ‘Basic’ , or addi-
tional items available to fulfil the requirements/functions for a specific project.

Copenhagen Standard Extent of Delivery

At MAN Energy Solutions Copenhagen, we base our first quotations on a
‘mostly required’ scope of supply. This is the so-called ‘Copenhagen Stand-
ard Extent of Delivery’, which is made up by options marked with an asterisk *
in the far left column in the EoD.
The Copenhagen Standard Extent of Delivery includes:
• Minimum of alarm sensors recommended by the classification societies and
MAN Energy Solutions
• Moment compensator for certain numbers of cylinders
• MAN turbochargers
• The basic engine control system
20.03 Extent of delivery

• Engine Management Services (EMS) incl. PMI software and LAN-based in-
2023-07-06 - en

terface to AMS
• Spare parts either required or recommended by the classification societies
and MAN Energy Solutions
• Tools required or recommended by the classification societies and MAN En-
ergy Solutions
MAN Energy Solutions licencees may select a differ-ent extent of delivery as
their standard.

EoD and the Final Contract

The filled-in EoD is often used as an integral part of the final contract.

All Engines 1 (2)

198 45 91-0.7 MAN Energy Solutions

The final and binding extent of delivery of MAN B&W two-stroke engines is to
be supplied by our licensee, the engine maker, who should be contacted in
order to determine the execution for the actual project.
9007251198831755
20.03 Extent of delivery

2023-07-06 - en

2 (2) All Engines

 MAN Energy Solutions 198 45 92-2.5

Installation documentation

General
When a final contract is signed, a complete set of documentation, in the fol-
lowing called ‘Installation Documentation’, will be supplied to the buyer by the
engine maker.
The extent of Installation Documentation is decided by the engine maker and
may vary from order to order.
As an example, for an engine delivered according to MAN Energy Solutions
‘Copenhagen Standard Extent of Delivery’, the Installation Documentation is
divided into the volumes ‘A’ and ‘B’:
• 4 09 602 Volume ‘A’
Mainly comprises general guiding system drawings for the engine room
• 4 09 603 Volume ‘B’
Mainly comprises specific drawings for the main engine itself.
Most of the documentation in volume ‘A’ are similar to those contained in the
respective Project Guides, but the Installation Documentation will only cover
the order-relevant designs.
The engine layout drawings in volume ‘B’ will, in each case, be customised
according to the buyer’s requirements and the engine maker’s production fa-
cilities.
A typical extent of a set of volume ‘A’ and B’ drawings is listed in the follow-
ing.
For questions concerning the actual extent of Installation Documentation,
please contact the engine maker.

Engine-relevant Documentation

Engine Data, on Engine

External forces and moments
Guide force moments 20.04 Installation documentation
Water and oil in engine
Centre of gravity
Basic symbols for piping
Instrument symbols for piping
Balancing
2023-07-06 - en

Engine Connections
Engine outline
List of flanges/counterflanges
Engine pipe connections

All engines 1 (7)

198 45 92-2.5 MAN Energy Solutions

Engine Instrumentation
List of instruments
Connections for electric components
Guidance values automation, engine
Electrical wiring

Engine Control System

Engine Control System, description
Engine Control System, diagrams
Pneumatic system
Speed correlation to telegraph
List of components
Sequence diagram

Control Equipment for Auxiliary Blower

Electric wiring diagram
Auxiliary blower
Starter for electric motors

Shaft line, on engine

Crankshaft driving end
Fitted bolts

Turning Gear
Turning gear arrangement
Turning gear, control system
Turning gear, with motor

Spare Parts
List of spare parts
20.04 Installation documentation

Engine Paint
Specification of paint

Gaskets, Sealings, O-rings

2023-07-06 - en

Instructions
Packings
Gaskets, sealings, O-rings

Engine Pipe Diagrams

Engine pipe diagrams
Bedplate drain pipes
Instrument symbols for piping
Basic symbols for piping
Lubricating oil, cooling oil and hydraulic oil piping

2 (7) All engines

 MAN Energy Solutions 198 45 92-2.5

Cylinder lubricating oil pipes

Stuffing box drain pipes
Cooling water pipes, air cooler
Jacket water cooling pipes
Fuel oil drain pipes
Fuel oil pipes
Control air pipes
Starting air pipes
Turbocharger cleaning pipe
Scavenge air space, drain pipes
Scavenge air pipes
Air cooler cleaning pipes
Exhaust gas pipes
Steam extinguishing, in scavenge air box
Oil mist detector pipes, if applicable
Pressure gauge pipes

Engine Room-relevant Documentation

Engine data, in engine room

List of capacities
Basic symbols for piping
Instrument symbols for piping

Lubricating and cooling oil

Lubricating oil bottom tank
Lubricating oil filter
Crankcase venting
Lubricating and hydraulic oil system
Lubricating oil outlet

Cylinder Lubrication
Cylinder lubricating oil system
20.04 Installation documentation
Piston Rod Stuffing Box
Stuffing box drain oil cleaning system

Seawater Cooling
2023-07-06 - en

Seawater cooling system

Jacket Water Cooling

Jacket water cooling system
Deaerating tank
Deaerating tank, alarm device

All engines 3 (7)

198 45 92-2.5 MAN Energy Solutions

Central Cooling System

Central cooling water system
Deaerating tank
Deaerating tank, alarm device

Fuel Oil System

Fuel oil heating chart
Fuel oil system
Fuel oil venting box
Fuel oil filter

Compressed Air
Starting air system

Scavenge Air
Scavenge air drain system

Air Cooler Cleaning

Air cooler cleaning system

Exhaust Gas
Exhaust pipes, bracing
Exhaust pipe system, dimensions

Engine Room Crane

Engine room crane capacity, overhauling space

Torsiograph Arrangement
Torsiograph arrangement
20.04 Installation documentation

Shaft Earthing Device

Earthing device
2023-07-06 - en

Fire Extinguishing in Scavenge air Space

Fire extinguishing in scavenge air space

Instrumentation
Axial vibration monitor

4 (7) All engines

 MAN Energy Solutions 198 45 92-2.5

Engine Seating
Profile of engine seating
Epoxy chocks
Alignment screws

Holding-Down Bolts
Holding down bolt
Round nut
Distance pipe
Spherical washer
Spherical nut
Assembly of holding down bolt
Protecting cap
Arrangement of holding down bolts

Side Chocks
Side chocks
Liner for side chocks, starboard
Liner for side chocks, port side

End Chocks
Stud for end chock bolt
End chock
Round nut
Spherical washer, concave
Spherical washer, convex
Assembly of end chock bolt
Liner for end chock
Protecting cap

Engine Top Bracing

Top bracing outline 20.04 Installation documentation
Top bracing arrangement
Friction materials
Top bracing instructions
Top bracing forces
Top bracing tension data
2023-07-06 - en

Shaft Line, in Engine Room

Static thrust shaft load
Fitted bolt

Power Take-Off
List of capacities
PTO/RCF arrangement,if fitted

All engines 5 (7)

198 45 92-2.5 MAN Energy Solutions

Large Spare Parts, Dimensions

Connecting rod studs
Cooling jacket
Crankpin bearing shell
Crosshead bearing
Cylinder cover stud
Cylinder cover
Cylinder liner
Exhaust valve
Exhaust valve bottom piece
Exhaust valve spindle
Exhaust valve studs
Fuel valve
Main bearing shell
Main bearing studs
Piston complete
Starting valve
Telescope pipe
Thrust block segment
Turbocharger rotor

Gaskets, Sealings, O-rings

Gaskets, sealings, O-rings

Material Sheets
MAN Energy Solutions Standard Sheets Nos.:
• S19R
• S45R
• S25Cr1
• S34Cr1R
• C4

Engine Production and Installation-relevant Documentation

20.04 Installation documentation

Main Engine Production Records, Engine Installation drawings

Installation of engine on board
Dispatch pattern 1, or
Dispatch pattern 2
2023-07-06 - en

Check of alignment and bearing clearances

Optical instrument or laser
Reference sag line for piano wire
Alignment of bedplate
Piano wire measurement of bedplate
Check of twist of bedplate
Crankshaft alignment reading
Bearing clearances
Check of reciprocating parts
Production schedule Inspection after shop trials
Dispatch pattern, outline
Preservation instructions

6 (7) All engines

 MAN Energy Solutions 198 45 92-2.5

Shop Trials
Shop trials, delivery test
Shop trial report

Quay Trial and Sea Trial

Stuffing box drain cleaning
Fuel oil preheating chart
Flushing of lubricating oil system
Fresh water system treatment
Fresh water system preheating
Quay trial and sea trial
Adjustment of control air system
Adjustment of fuel pump
Heavy fuel operation
Guidance values automation

Flushing Procedures
Lubricating oil system cleaning instruction

Tools
18014449789285387

Engine Tool
List of tools
Outline dimensions, main tools

List of Tools
Tool panels

Engine Seating Tools

Hydraulic jack for holding down bolts 20.04 Installation documentation
Hydraulic jack for end chock bolts

Auxiliary Equipment
Ordered auxiliary equipment
2023-07-06 - en

18014449789285387

All engines 7 (7)

198 45 92-2.5 MAN Energy Solutions

18014449789285387
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20.04 Installation documentation

2023-07-06 - en

All engines
 MAN Energy Solutions 199 18 83-4.0

ME-GA Installation documentation

General
Further to the installation documentation mentioned in Section 20.04, ME-GA
specific documentation will be supplied by the engine maker.

For an engine delivered according to MAN Energy Solutions' ‘Copenhagen

Standard Extent of Delivery’, the extent typically includes the following draw-
ings as part of volume ‘A’.
9007260650418699

Engine control system

List of Instrumentation
GA extension interface to external systems
ME-GA electric diagram (new building)
Guidance Values for Automation

Gas supply auxiliary systems’ specification

Fuel Gas Supply
Inert Gas System
Gas Ventilation System
Vent silencer
Valves
High-pressure filter
High-pressure flowmeter
Hydrocarbon (HC) sensor
Flow switch

20.05 ME-GA Installation documentation

Diagrams
GA extension interface to external systems diagram
Gas system
Ventilation system
Gas Valve Train
Hydraulic system on engine
2023-07-06 - en

Sealing oil system on engine

Approval tests
Commissioning
Factory Acceptance Test
Quay trial
Sea trial, gas operation
9007260650418699

ME-GA 1 (1)
199 18 83-4.0 MAN Energy Solutions

9007260650418699
This page is intentionally left blank
20.05 ME-GA Installation documentation

2023-07-06 - en

ME-GA
MAN Energy Solutions

01 Engine Design
02 Engine Layout and Load Diagrams, SFOC, dot 5
03 Turbocharger Selection & Exhaust Gas Bypass
04 Electricity Production
05 Installation Aspects
06 List of Capacities: Pumps, Coolers & Exhaust Gas
07 Fuel
08 Lubricating Oil
09 Cylinder Lubrication
10 Piston Rod Stuffing Box Drain Oil
11 Low-temperature Cooling Water
12 High-temperature Cooling Water
13 Starting and Control Air
14 Scavenge Air
15 Exhaust Gas
16 Engine Control System
17 Vibration Aspects
18 Monitoring Systems and Instrumentation
19 Dispatch Pattern, Testing, Spares and Tools
20 Project Support and Documentation
21 Appendix

21 Appendix
61395670027

1 (1)
 MAN Energy Solutions

This page is intentionally left blank

21 Appendix
 MAN Energy Solutions 198 38 66-2.5

Symbols for piping

Lines, Pipes etc.

Line, primary process

Line, secondary process

Control line, general type

Control line, capilar type

Lines connected

Crossing lines, connected

Crossing lines, not connected

Interruption of pipe line

Interruption of pipe line with reference indication

Pipeline or duct with thermal insulation

Pipeline with thermal insulation, heated or cooled by a separate

circuit, end

Pipeline with thermal insulation, heated or cooled by a separate

circuit

Pipeline with thermal insulation, heated or cooled by a separate

circuit, end

Jacketed (sleeved) pipeline with thermal insulated

21.00 Symbols for piping

Jacketed (sleeved) pipeline with thermal insulated, end

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Jacketed (sleeved) pipeline

Jacketed (sleeved) pipeline, end

Change of pipe diameter, pipe reducer

Pipe slope, located above pipe

All Engines 1 (11)

198 38 66-2.5 MAN Energy Solutions

Interlocked, located in interlocked line

Indication of valve normally open. With the symbol ‘function’ field

Indication of valve normally closed. With the symbol ‘function’ field

9007250534538507

Flanges, Connections and Other in-line Pipe Fittings

Flange, single

Flange coupling, flange pair, blind flange

Flange coupling, clamped

Screw joint

Quick release coupling

Quick release coupling, with automatically closing when uncoupled

End cap, threaded

End cap

Orifice

Swing blind, closed

Swing blind, open

Rupture disc
21.00 Symbols for piping

Siphon
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Boss

Boss with intersection pipe

Spray nozzle, single

Spray nozzle, multiple

2 (11) All Engines

 MAN Energy Solutions 198 38 66-2.5

Pipe Supports
Pipe support, fixation type

Pipe support, sliding type

Wall Penetrations, Drains and Vents

Wall or roof penetration, general

Wall or roof penetration, general, jacketed (sleeved) pipeline

Wall or roof penetration, sealed. * Shall be replaced with a

designation for the type of seal, e.g. fire

Drain, funnel etc.

Drain pan

Vent, outlet to atmosphere

Vent, outlet to atmosphere outside enclosure

Valve Symbols
2-way on-off valve, straight type, general

2-way on-off valve, angle type, general

3-way valve, general

4-way valve, general

21.00 Symbols for piping
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Non-return function, check function, flow left to right

Control valve, straight type, general

Control valve, angle type, general

Control valve, 3-way type, general

Pre-set control valve, e.g. flow balancing valve

All Engines 3 (11)

198 38 66-2.5 MAN Energy Solutions

Safety function, straight type general, inlet / internal side to the left

Safety function, angle type general, inlet / internal side bottom

Breather valve, straight type general, with safety function, e.g. tank
overpressure / vacuum function

Breather valve, angle type general, with safety function, e.g. tank
overpressure / vacuum function

3-way plug valve, L-bore, general

3-way plug valve, T-bore, general

4-way plug valve, double L-bore, general

Supplementary Valve Symbols

Valve, globe type

Valve, gate type

Valve, butterfly type

Valve, ball type

Valve, piston or plunger type

Valve, plug type

Valve, diaphragm type

Valve, hose type

21.00 Symbols for piping

Valve, needle type

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Manual Operators
Manually operated

Manually operated, by pushing

Manually operated, by pulling

4 (11) All Engines

 MAN Energy Solutions 198 38 66-2.5

Manually operated, by pulling and pushing

Manually operated, by a lever

Manually operated, by a pedal

Manually operated, incl. locking device

Mechanical Operators
Mechanically operated, by weight

Mechanically operated, by float

Mechanically operated, by spring

Electric Drives
Electrical motor

Electrical motor, adjustable

Automatic Operators
Actuator, without indication of type

Single-acting hydraulic actuator

Double-acting hydraulic actuator

Single-acting pneumatic actuator

21.00 Symbols for piping
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Double-acting pneumatic actuator

Single-acting diaphragm actuator

Double-acting diaphragm actuator

Single- or double-acting fluid actuator. (For double- acting, two pilot

lines are needed)

All Engines 5 (11)

198 38 66-2.5 MAN Energy Solutions

Electromagnetic actuator

Self-operated pressure sustaining control diaphragm. Upstream to

valve, right side

Self-operated pressure reducing control diaphragm. Upstream to

valve, right side

Spindle Information, e.g. Safety Operators

Fail to close

Fail to open

Quick-closing

Quick-opening

Double-acting, fail freeze

Double-acting, fail freeze, drifting against open position

Double-acting, fail freeze, drifting against closed position

Limit switch, mechanical type

Flow Meters
Flow meter, general

Flow meter, propeller, turbine and screw type

Flow meter, orifice type

21.00 Symbols for piping

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Flow meter, flow nozzle type

Flow meter, venturi type

Flow meter, pitot tube type

Flow meter, vortex type

6 (11) All Engines

 MAN Energy Solutions 198 38 66-2.5

Flow meter, ultrasonic in-line type

Flow meter, ultrasonic clamp-on type

Flow meter, magnetic type

Flow meter, Coriolis type

Flow switch, paddle type

Various
Air release valve

Condensate release valve

Restrictor, multistage type

Flow straightener

Viewing glass

Silencer

Flow restriction

Flow restriction, adjustable

Dampers
2-way on-off damper, general
21.00 Symbols for piping
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Multi-leaf damper, louvre type

3-way on-off damper, general

Non return damper, general

Safety damper, general

All Engines 7 (11)

198 38 66-2.5 MAN Energy Solutions

Safety Devices Other than Valves

Flame arrester, general

Flame arrester, explosion- proof

Flame arrester, fireresistant

Flame arrester, detonation- proof

Expansions
Expansion loop

Expansion sleeve

Expansion joint / compensator bellow

Flexible pipe, hose

Liquid Pumps
Pump, general

Pump, positive displacement type

Pump, centrifugal type

Pump, hand type

Pump, gear type

21.00 Symbols for piping

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Pump, screw type

Pump, piston type

Pump, piston radial type

Pump, membrane type

Pump, ejector type

8 (11) All Engines

 MAN Energy Solutions 198 38 66-2.5

Fans, Ventilators and Compressors

Fan, ventilator, blower, compressor. General

Fan, ventilator, blower, compressor. Rotary vane type

Fan, ventilator, blower, compressor. Impeller type

Fan, ventilator, blower, compressor. Screw type

Fan, ventilator, blower, compressor. Reciprocating piston type

Fan, ventilator, blower, compressor. Rotary reciprocating piston

type

Fan, ventilator, blower, compressor. Reciprocating diaphragm type

Fan, ventilator, blower, compressor. Turbo type

Fan, ventilator, blower, compressor. Rotary piston type, e.g. Roots

type

Turbocharger

Filters, Separators
Screen, strainer, general

Screen, strainer with pit for draining

In-line strainer, general

Cartridge filter, bag filter etc, general

21.00 Symbols for piping

Cartridge filter, bag filter etc flow direction outside - in, general
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Cartridge filter, bag filter etc, flow direction inside - out, general

Permanent magnet filter

Filter with backflush, Bernoulli type

Filter with continuous backflush

All Engines 9 (11)

198 38 66-2.5 MAN Energy Solutions

Separator, cyclone type

Separator, centrifuge type

Separator, impact type

Heat Exchangers
Heat exchanger, general

Condenser with hot well

Electrical heater, superheater

Heat exchanger with plate

Heat exchanger with tubes

Heat exchanger with ubend tubes

Heat exchanger with coil-shaped tubes

Electrical heating element

Heating or cooling coil

Finned tube

Tanks
Open tank, basin
21.00 Symbols for piping

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Closed tank

Closed tank with sloped bottom

Tank with flat bottom and conical roof

Tank with flat bottom and dished roof

Vessel with dished ends

10 (11) All Engines

 MAN Energy Solutions 198 38 66-2.5

Vessel with spherical ends

Accumulator

Gas cylinder

Instrumentation, General
Instrument with two letters, e.g. PI

Instrument with three letters, e.g. DPI

9007250534538507

079 07 70-5.5.1
9007250534538507

Fig. A.01.01: Basic symbols for pipe plants according to MAN Energy Solu-
tions
9007250534538507

21.00 Symbols for piping

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All Engines 11 (11)

198 38 66-2.5 MAN Energy Solutions

9007250534538507
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21.00 Symbols for piping

2023-07-06 - en

All Engines