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Simulator Module Systems

System of Circulation Lubrication and Piston Cooling (LO Page)


Purpose
The system is designed for lubrication of bearings and cooling of diesel pistons (main
system), for lubrication of camshaft bearings, fuel pump drive cam faces and exhaust
valve cam faces (camshaft lubrication system), and for lubrication of diesel cylinders.
In the main system, lube oil of certain temperature is supplied under certain pressure
to circulation lubrication points, including:

Main bearings and connecting-rod bearings;

Crosshead bearings and crosshead guides;

Thrust bearing;

Bearings and camshaft drive;

Other drives and attached mechanisms.

Part of lube oil supplied to the crosshead bearings is directed for cooling the pistons,
from where it drains to the collecting tank via pipes equipped with sight glasses,
which allow the cooling oil flow to be checked.
In the camshaft lubrication system, lube oil of certain temperature is supplied under
certain pressure to circulation lubrication points, including:

Camshaft bearings;

Valve tappet guides.

Lube oil is collected in the camshaft crankcase oil pan, where it is maintained at
a level sufficient for being caught by rotating cams for the purpose of lubricating
the cam working face; then lube oil is directed to the camshaft lubrication tank.
In the diesel cylinder lubrication system, lube oil is supplied via special nipples
directly to the bushing work face.
Thus, the system page includes three subsystems:

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Circulation lubrication of ME bearings and piston cooling (Main Circulation


System). The devices and mechanisms of the main system are in the right-hand
part of the mnemonic diagram, while the controls/indicators thereof are located
in the upper part of the control panel;

Camshaft Lubricating Oil System. Components of the system are presented


in the left-hand part of the mnemonic diagram, while the controls/indicators
thereof are in the lower part of the control panel;

Diesel cylinder lubrication (Lubricators).

ENGINE ROOM SIMULATOR ERS 4000.


Vessel Model Tanker LCC. Trainee Manual

Simulator Module Systems

System Components
See Fig. 12 for a system schematic diagram.

Fig. 12

See Fig. 13 for the system scheme realized in the simulator, i.e. the system
mnemonic diagram.

Fig. 13

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Simulator Module Systems

The system includes the following components modelled by the simulator:


Main Circulation System

The tank of circulating oil is a collecting reservoir located under the diesel, where
lube oil drains by gravity from the lubrication points. The receiver pipe connects
the tank to the circulation pumps. The overflow pipe drains to the spill tank;

The circulating oil stock tank for replenishment of the circulating oil tank and
the camshaft lubrication tank;

The circulating oil pumps 1 and 2 (one Stand-by) create required pressure in
the lubrication system. These are electrically driven pumps of, usually, the gear
type or the screw type. The constant pressure at the charging side is maintained
by a bypass valve;

Lube oil cooler 1 and 2. These are heat exchangers of the shell-and-tube type
or plate type, pumped through with water. They maintain lube oil temperature at
a specified level, which is necessary for keeping lube oil under certain pressure.
Temperature rise results in reduction of lube oil viscosity, which, in turn, effects
pressure reduction in the circulation lubrication points impairing tribological situation;

Temperature controller and the three-way valve (controlled automatically by the


temperature controller or manually), which maintains lube oil temperature
constant before ME by partial or full bypassing the oil cooler. The temperature
controller setting can be changed within the range of 3550 . There are
similar thermostatic valves installed at the diesel-generator;

A duplex lube oil filter for removal of particles greater than 50 m from lube
oil is installed directly before diesel;

The lube oil separator removes water and mechanical particles from lube oil.
Lube oil is drawn by the separator pump from the circulating oil tank, to where
it subsequently returns after treatment;

The settling tank or the used-lube oil tank. Lube oil is pumped from
the circulating oil tank to the settling tank by the separator pump. Lube oil
in the settling tank can also be treated by the separator;

The pump for dirty lube oil transfer;

Stuffing box drain collection tank;

Drains from all tanks and separation waste are directed to the separator; tank
(sludge tank).

ME Camshaft Lubrication System

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Lube oil tank, which is a collecting reservoir, to where lube oil drains by gravity
from the lubrication points. The receiver pipe connects the tank to the pumps;

Circulation oil pumps 1 and 2 (one Stand-by) create required pressure in the
lubrication system. These are electrically driven pumps of, usually, the gear type or
the screw type. The necessary discharge pressure is controlled by a diverter valve;

Lube oil cooler represented by a heat exchanger of the shell-and-tube type or plate
type, pumped through with water (the simulator models a plate-type exchanger). It
helps to maintain lube oil temperature at a level of 40 to 50 , which is
necessary for maintaining required lube oil viscosity and working pressure in the
lubrication system. At lower oil temperature, its circulation is performed at a partially
or fully opened bypass valve of the oil cooler. Temperature can be controlled
manually with the aid of the bypass valve;

ENGINE ROOM SIMULATOR ERS 4000.


Vessel Model Tanker LCC. Trainee Manual

Simulator Module Systems

A duplex lube oil filter for removal of particles greater than 50 m from lube
oil is installed directly before the camshaft;

A fine filter removes water and mechanical particles of 1m and bigger from
lube oil. Lube oil is drawn by the filter pump from the circulating oil tank,
to where it subsequently returns again after treatment;

A magnetic filter at the engine oil outlet for removal of metal particles from lube oil.

Cylinder Lubrication System

The cylinder oil tank is located under the diesel. The oil flows by gravity to
the lubricating pumps. The tank is replenished from the stock tank using a special
hand pump that directs oil through a filter. The tank volume is usually equal to twoday cylinder oil consumption. A overflow pipe runs to the stock tank;

Cylinder oil stock tank;

Hand pump for cylinder oil tank replenishment;

Lubricating pumps (one per cylinder). These are special pumps to lubricate
the cylinders; they are provided with a main drive from the diesel and
an additional manual drive designed for pumping oil to the cylinder before
starting the diesel. The lubricating pumps are equipped with transparent
tubes for visual control over oil flow to each and every lubrication point.
There is a possibility to adjust volume of oil feed per revolution depending
on the load and diesel operation conditions.

Control Panel
Main Circulation System
The upper part of the control panel features the lubrication system pressure
adjustment module. This function is performed by circulation oil pumps 1 and 2
(operating in the Stand-by regime). Oil is supplied to the pumps from the tank via
a receiver pipe.
The switch of pump control mode allows for selection of MANUAL or AUTO mode.
In the AUTO mode, the system turns on pump 1 automatically, if the pressure in
the system drops too low. If the system pressure doesnt rise, it will turn on pump 2.
Use PUMP 1 and PUMP 2 button to turn on/off the circulation oil pumps.
The PUMP 1 and PUMP 2 buttons are active only in case the pump control
mode switch is in the MANUAL position.
The oil pressure at the suction/discharge side of the pumps is monitored by
the analog/digital SUCTION/DISCHARGE pressure indicators.
Maximum pump discharge pressure is determined by the PRESSURE LIMIT diverter
valve using the controller (setpoint in bar). The rate of diverter valve opening is
shown in % (0 to 100) on the diverter valve digital indicator located in the mnemonic
diagram under the pumps. Note that the valve 100%-opening corresponds to
the lowest controller setting.

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Simulator Module Systems

The temperature controller and the three-way valve are used to maintain oil
temperature at the ME inlet at a constant level by way of full or partial bypassing
the oil cooler. The controller sensor is installed at the oil cooler exit.
The oil temperature adjustment valve is controlled with the aid of the
TEMPERATURE CONTROL module.

It includes:

MANUAL/AUTO valve control mode switch;

SET POINT rotating knob for setting the value oil temperature in the Auto mode
of controller operation. The temperature controller setting can be changed within
the range of 35 to 50C;

COOLER FLOW controller, operating in the Manual mode.


The controller setpoint is shown in the mnemonic diagram digital
indicator to the right of the coolers (see Figure). The 0 position
corresponds to full bypassing the cooler, the 100 position
corresponding to full flow of oil through the cooler.

Oil temperature before the cooler and before ME is shown by the COOLER INLET
and ENGINE INLET temperature indicators, respectively, calibrated 0 to 80 .
Lube oil goes through a duplex filter installed directly before the engine (it catches
foreign particles larger that 50 m). Clean filter pressure drop doesnt exceed
0.2 bar. If the filter pressure drop is more that 0.5 bar, it should be switched over to
the clean section.
The control panel houses the FILTER switch for toggling between filters 1 and 2
of the circulation oil system, as well as analog/digital indicators: oil pressure before diesel
(ENGINE INLET), and filter pressure drop (FILTER DROP) (above the filter switch).

An oil separator is used to remove water and mechanical particles from oil. Lube oil
is drawn by the separator pump from the circulating oil tank, to where it comes back
again after treatment. Turning the oil separator on/off is performed by the
SEPARATOR button.
Besides, the panel houses the following control buttons:

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ENGINE ROOM SIMULATOR ERS 4000.


Vessel Model Tanker LCC. Trainee Manual

Simulator Module Systems

MAKE UP the valve for replenishment of the circulation oil tank from
the oil stock tank;

COOLER 1 the cutoff valve of oil cooler 1;

COOLER 2 the cutoff valve of oil cooler 2.

The left-hand part of the screen page contains a mnemonic diagram, which shows
the current status of devices, oil level in the tanks, and system parameter values.
In particular, the two-stroke diesel has (from the top down):

Lubricating pump operation indicators (one per cylinder);

Digital indicators of oil temperature at piston cooling outlet (one per cylinder);

Indicators of oil flow at piston cooling outlet (one per cylinder);

Digital indicators of diesel main bearing temperature.

Lubricating Pumps
The graphical representation of a two-stroke diesel in the mnemonic diagram
has 6 buttons for manual rotation of lubricating pumps, which are used specially
for lubricating cylinders (one per cylinder) numbered 1 to 6. In addition, the diagram
has lubricating pump operation indicators (one per cylinder). See figure above.
ME Camshaft Lubrication System
The circulation lubrication system provided for the camshaft is controlled from
the lower part of the control panel, this is CAMSHAFT LO SYSTEM control module.

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59

Simulator Module Systems

Just like in the main lubrication system, the function of oil pressure adjustment in
the lubrication system is performed by two circulation oil pumps: pump 1 and pump 2
(one Stand-by). Oil is supplied to the pumps via the receiver pipe from lube oil tank,
where it flows to from the lubrication points by gravity. The pumps are controlled in
the same way as for the main system, i.e. using the MANUAL/AUTO switch of
control mode and the PUMP 1 and PUMP 2 buttons.
Oil pressure at lube oil discharge side is shown by analog/digital DISCHARGE indicator.
Control of lube oil working temperature (4050 ) is provided by the oil cooler.
The COOLER button controls then cutoff valve of the oil cooler.
If the button is pressed (highlighted), the valve is open: the valve indicator
in the mnemonic diagram comes on.

At lower oil temperatures, circulation is performed at a partially or fully opened


bypass valve of the oil cooler. Temperature can be controlled manually with the aid
of the bypass valve in the Manual mode using the COOLER BYPASS controller.

The oil temperature before the cooler, before diesel, and after the diesel is shown by
the COOLER INLET, ENGINE INLET ENGINE OUTLET temperature indicators,
respectively, calibrated 0 to 80.
Oil goes through a duplex filter installed directly before the engine. It
serves for removal of particles greater than 50 m from lube oil. The filter
is installed directly before ME, before camshaft. Clean filter pressure
drop doesnt exceed 0.2 bar. If the filter pressure drop is more than
0.5 bar, it should be switched over to the clean section. The control
panel houses the FILTER switch for toggling between filters 1 and 2 of
the camshaft circulation lubrication with position indications 1 and 2,
as well as the ENGINE INLET and FILTER DROP analog/digital
indicators of oil pressure before diesel and of filter pressure drop,
respectively.

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ENGINE ROOM SIMULATOR ERS 4000.


Vessel Model Tanker LCC. Trainee Manual

Simulator Module Systems

For the purpose of removal of water and mechanical particles larger than 1 m from
oil, the system includes a fine oil filter. Lube oil is drawn by the filter pump from
the camshaft circulating oil tank, to where it subsequently returns again after
treatment. The level of lube oil in the tank can be checked on the scaleplate and
digital indicator (see fig. below). The fine filter pump can be started/stopped using
the FINE FILTR. button. To open/close the valve for replenishing the tanks with
lube oil from the stock tank, the MAKE UP button is used.

The buttons on the control panel and valve indicators in the mnemonic diagram
are highlighted, when the valves are in the open state.

Alarm Signals

PUMP AUTOSTART automatic start of the Stand-by circulation pump


following a system low pressure signal;

FILTER DIRTY fouled filter, increased filter pressure drop;

LEVEL LO TANK low/high level in the circulation oil tank;

LOW PRESS. ME INLET low pressure of circulation oil before ME;

T ME INLET high/low temperature of circulation oil before ME;

OIL MIST actuation of oil mist sensor in the ME crankcase;

LEVEL CAM. TANK low/high level in the camshaft oil tank;

LOW PRESS. CAM. INLET low pressure of oil before the camshaft lubrication
system;

CAM. FILTER DIRTY fouled filter of the camshaft lubrication system;

CAM. PUMP AUTOSTART automatic start of the stand-by pump of the


camshaft lubrication system by a signal of low pressure in the system;

HIGH T CAM. INLET high temperature of oil before camshaft lubrication


system;

LEVEL CYL. OIL low/high level in the cylinder oil tank;

HIGH T PIST. OUTLET high temperature of piston cooling oil;

LOW PRESS. PISTON low temperature of piston cooling oil.

ME Safety System

Actuation of the Shut Down system (ME stopping) by low oil pressure (1.8 Bar)
before diesel;

Actuation of the Shut Down system (ME stopping) by low oil pressure (1.8 Bar)
in the camshaft lubrication system;

Actuation of the Slow Down system (ME slowing down) by a high temperature
(85 ) of the piston cooling oil at exit;

Actuation of the Slow Down system (ME slowing down) by oil mist in the diesel
crankcase.

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Simulator Module Systems

System Faults Introduced by the Instructor

Pump 1 Breakdown emergency stop of pump 1;

Pump 2 Breakdown emergency stop of pump 2;

Cooler 1 Fouling fouling of cooler 2;

Cooler 2 Fouling fouling of cooler 2;

Oil Leakage oil leakage in the system;

Filter 1 Fouling fouling of filter 1;

Filter 2 Fouling fouling of filter 2;

Temperature Controller Breakdown temperature controller failure;

Camshaft Oil Leakage oil leakage from the camshaft lubrication system;

Camshaft Oil Pump 1 Breakdown emergency stop of pump 1 of the camshaft


lubrication system;

Camshaft Oil Pump 2 Breakdown emergency stop of pump 2 of the camshaft


lubrication system;

Camshaft Oil Filter 1 Fouling fouling of filter 1 of the camshaft lubrication system;

Camshaft Oil Filter 2 Fouling fouling of filter 2 of the camshaft lubrication system;

Camshaft Oil Cooler Fouling fouling of the camshaft lubrication system cooler.

System Operation
System Preparation and Putting in Operation
1. Check the level of circulation oil in the collecting tank. If replenishment is
required, use the MAKE UP valve.
2. Check the level of cylinder oil in the tank.
3. Set the PRESSURE LIMIT valve of pressure adjustment to the position that
ensures the minimum pressure in the system.
4. Switch to the AUTO mode of thermostatic valve control.
5. Specify the SET POINT for the temperature controller.
6. Open the valve of a cooler: COOLER 1 or COOLER 2.
7. Select the MANUAL mode for the circulation oil pumps and start of them
(the PUMP 1 or PUMP 2 button). Make sure there is pressure in the system.
8. Adjust pressure before diesel using the PRESSURE LIMIT valve.
9. Set the circulation oil pump control to the Auto mode.

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10.

Check the level of oil in the camshaft lubrication tank. If replenishment is


needed, use the MAKE UP valve.

11.

Set the COOLER BYPASS valve to the 100 position (fully open).

12.

Start a pump of the camshaft lubrication system using the Manual mode. Make sure
the oil is under required pressure.

13.

Set the control of camshaft lubrication system pumps to AUTO.

14.

Open the COOLER valve of the camshaft oil cooler. Adjust oil temperature using
the COOLER BYPASS valve.

15.

Make sure there is no alarm signals in the LO system.

ENGINE ROOM SIMULATOR ERS 4000.


Vessel Model Tanker LCC. Trainee Manual

Simulator Module Systems

Control Over System Operation


1. Before starting the diesel, rotate the lubricate pumps (of 1 to 6 button in
the mnemonic diagram).
2. Check the pressure of oil before diesel and for camshaft lubrication.
3. Check the level of circulation oil in the collecting tank and the camshaft
lubrication tank. If replenishment is required, use the MAKE UP valve.
4. Check pressure drop through the filter; change over to the filter Stand-by
section, if necessary.
5. Check the temperature oil before diesel and oil used for camshaft lubrication.
6. Check flow and temperature of oil at its exit after picture cooling, for each cylinder.
7. Check for correctness of temperature controller operation maintaining
the proper temperature value.
8. Start the oil treatment separator regularly.
9. Start the camshaft oil pump through the FINE FILTER.
10.

Control over operation of the lubricating pumps.

11.

Check for alarm signals in the LO system.

Setting the System to the In-Port Mode


1. Maintain the system running mode for 60 to 80 min after stopping ME.
2. Switch over to the Manual mode of circulation oil pump control and camshaft
lubrication control.
3. Set the PRESSURE LIMIT valve of pressure adjustment for minimum pressure.
4. Stop the running pumps: the circulation one and the camshaft lubrication one
(the PUMP 1 and PUMP 2 buttons in the Manual mode).

Chapter 1. Ship Diesel Propulsion Plant

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