abs rules part 4: craft systems and machinery

GUIDE FOR BUILDING AND CLASSING

HIGH SPEED NAVAL CRAFT2002

PART 4CRAFT SYSTEMS AND MACHINERY

American Bureau of ShippingIncorporated by Act of Legislature ofthe State of New York 1862

Copyright 2002American Bureau of ShippingABS Plaza16855 Northchase DriveHouston, TX 77060 USA

This Page Intentionally Left Blank

ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT . 2002 iii

P A R T

4Craft Systems and Machinery

CONTENTSCHAPTER 1 General .................................................................................. 1

Section 1 Classification of Machinery................................ 3

CHAPTER 2 Prime Movers...................................................................... 19

Section 1 Diesel Engines................................................. 23

Section 2 Turbochargers ................................................. 65

Section 3 Gas Turbines ................................................... 71

Section 4 Craft Less Than 24 meters (79 feet) inLength.............................................................. 81

Section 1 Appendix 1 Plans and Data for DieselEngines............................................................ 57

CHAPTER 3 Propulsion & Maneuvering Machinery.............................. 83

Section 1 Gears ............................................................... 91

Section 2 Propulsion Shafting........................................ 169

Section 3 Propellers....................................................... 189

Section 4 Steering Gears............................................... 203

Section 5 Thrusters........................................................ 219

Section 6 Waterjets........................................................ 229

Section 7 Propulsion and Lift Devices for Air CushionCraft ............................................................... 231

Section 8 Craft less than 24 meters (79 feet) inLength............................................................ 233

Section 1 Appendix 1 Rating of Cylindrical andBevel Gears ................................................... 101

Section 1 Appendix 2 Gear Parameters ..................... 159

CHAPTER 4 Pressure Vessels.............................................................. 237

Section 1 Pressure Vessels........................................... 241

Section 1 Appendix 1 Rules for Design ...................... 249

iv ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT . 2002

CHAPTER 5 Deck and Other Machinery................................................ 281 Section 1 Mooring Machinery.........................................283 Section 2 Boat Handling and Stowage...........................287

CHAPTER 6 Piping Systems .................................................................. 291

Section 1 General Provisions .........................................297 Section 2 Metallic Piping ................................................307 Section 3 Plastic Piping..................................................331 Section 4 Piping Systems and Tanks.............................345 Section 5 Piping Systems for Internal Combustion

Engines...........................................................375 Section 6 Other Piping Systems.....................................391

CHAPTER 7 Fire Safety Systems........................................................... 399

Section 1 Fire-extinguishing Systems and Equipment...403 Section 2 Craft Less Than 24 meters (79 feet) in

Length.............................................................429 CHAPTER 8 Electrical Systems ............................................................. 433

Section 1 General Provisions .........................................441 Section 2 System Design ...............................................447 Section 3 Electrical Equipment.......................................483 Section 4 Shipboard Installation andTests.....................523 Section 5 Special Systems.............................................549

CHAPTER 9 Remote Propulsion Control and Automation.................. 567

Section 1 General Provisions .........................................573 Section 2 Remote Propulsion Control ............................583 Section 3 ACCU Notation...............................................593 Section 4 Craft Classed with ABCU Notation ................607 Section 5 Craft Less than 500 GT Having a Length

Greater Than 24 meters (79 feet) ..................609 Section 6 Craft Less Than 24 meters (79 feet) in

Length.............................................................613 Section 7 Installation, Tests and Trials...........................615 Section 8 Computerized Systems ..................................617

ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT . 2002 1

P A R T

4C H A P T E R 1 General

CONTENTSSECTION 1 Classification of Machinery ................................................. 3

1 General.................................................................................. 3

1.1 Organization of Part 4........................................................3

1.3 Requirements for Classification.........................................3

1.5 Classification Notations .....................................................4

1.7 Alternative Standards ........................................................5

1.9 Definitions..........................................................................5

3 Certification of Machinery...................................................... 7

3.1 Basic Requirements ..........................................................7

3.3 Type Approval Program.....................................................7

3.5 Non-mass Produced Machinery ........................................7

3.7 Details of Certification of Some RepresentativeProducts ............................................................................8

5 Machinery Plans.................................................................... 8

5.1 Submission of Plans..........................................................8

5.3 Plans .................................................................................8

7 Miscellaneous Requirements for Machinery ......................... 8

7.1 Construction Survey Notification .......................................8

7.3 Machinery Equations .........................................................9

7.5 Astern Propulsion Power ...................................................9

7.7 Dead Ship Start .................................................................9

7.9 Inclinations ........................................................................9

7.11 Ambient Temperature........................................................9

7.13 Machinery Space Ventilation .............................................9

9 Sea Trials .............................................................................. 9

TABLE 1 Certification Details Prime Movers ......................... 11

TABLE 2 Certification Details Propulsion, Maneuvering andMooring Machinery.................................................... 12

TABLE 3 Certification Details Electrical and ControlEquipment ................................................................. 13

TABLE 4 Certification Details Fire Safety Equipment............ 14

TABLE 5 Certification Details Pressure Vessels and FiredEquipment ................................................................. 15

2 ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT . 2002

TABLE 6 Certification Details Piping SystemComponents .............................................................. 16

TABLE 7 Design Angles of Inclination ...................................... 17

TABLE 8 Ambient Temperatures for Unrestricted Service ....... 17

FIGURE 1 Organization of Part 4 ................................................. 3


P A R T

4C H A P T E R 1 General

S E C T I O N 1 Classification of Machinery 4-1-1

1 General 4-1-1/1

1.1 Organization of Part 4 4-1-1/1.1

Part 4 contains classification requirements for machinery. These requirements are organized in twobroad segments: that specific to equipment, and that specific to systems. 4-1-1/Figure 1 shows theoverall organization of Part 4.

FIGURE 1Organization of Part 4

Chapter 1CLASSIFICATION OF

MACHINERY

Chapter 2PRIME

MOVERS

Chapter 3PROPULSION &MANEUVERING

MACHINERY

Chapter 4PRESSURE VESSELS

& EQUIPMENT

Chapter 5DECK AND OTHER

MACHINERY

EQUIPMENTREQUIREMENTS

Chapter 6PIPING

SYSTEMS

Chapter 7FIRE SAFETY

SYSTEMS

Chapter 8ELECTRICAL

SYSTEMS

Chapter 9REMOTE

PROPULSION CONTROL & AUTOMATION

SYSTEMREQUIREMENTS

PART 4RULES FOR MACHINERY

1.3 Requirements for Classification 4-1-1/1.3

1.3.1 Scope 4-1-1/1.3.1

Part 4 provides the minimum requirements for machinery of self-propelled high-speed navalcraft. Compliance with Part 4 is a condition for classification of all such craft, and forassigning the appropriate machinery class notations indicated in 4-1-1/1.5.

Part 4 Craft Systems and MachineryChapter 1 GeneralSection 1 Classification of Machinery 4-1-1


1.3.2 Fundamental Intent of Machinery Requirements 4-1-1/1.3.2

1.3.2(a) Propulsion and maneuvering capability. Part 4 of this Guide is intended to assurethe propulsion and maneuvering capability of the craft through specification of pertinentdesign, testing, and certification requirements for propulsion, maneuvering and otherequipment and their associated systems. See 4-1-1/Figure 1 for equipment and systemsincluded in the scope.

1.3.2(b) Machinery hazards. Part 4 of this Guide is also intended to identify and addresshazards associated with machinery aboard a craft, particularly those hazards which arecapable of causing personal injury, flooding, fire or pollution.

1.3.3 Application 4-1-1/1.3.3

Requirements in Part 4 are intended for craft under construction; but they are to be applied toalterations made to existing craft, as far as practicable.

1.5 Classification Notations 4-1-1/1.5

Classification notations are assigned to a craft to indicate compliance with particular portions of thisGuide. The following classification notations define compliance with specific requirements of thisGuide for machinery:

AMS indicates that a craft complies with all machinery requirements in Part 4 other than therequirements associated with the other classification notations below. AMS is mandatory for all self-propelled craft.

HSC indicates that the craft has a speed to length ratio of Vkn > 2.36 mL , with no limit to the

displacement.

ACCU Where it is intended that the propulsion machinery space and the centralized control andmonitoring station be periodically unattended, and that the propulsion machinery be controlled andmonitored from the navigation bridge, the provisions of Section 4-9-3 are to be complied with. Uponverification of compliance, ACCU will be assigned.

ABCU For craft capable of operating as ACCU, but because of their compact propulsionmachinery space design, are not fitted with the means to control the propulsion machinery from acentralized control station, but rather the propulsion machinery is controlled and primarily monitoredfrom the navigation bridge, the provisions of Section 4-9-4 are to be complied with. Upon verificationof compliance, ABCU will be assigned.

APS indicates that a craft is fitted with athwartship thrusters. APS is optional for craft fitted withsuch thrusters and signifies compliance with applicable requirements of Section 4-3-5.

The above class notations, where preceded by the symbol (Maltese cross; e.g. AMS), signify thatcompliance with this Guide was verified by the Bureau during construction of the craft. This includessurvey of the machinery at the manufacturers plant (where required), during installation on board thecraft and during trials.

Where an existing craft, not previously classed by the Bureau, is accepted for class, these classnotations are assigned without .



1.7 Alternative Standards

Equipment, components and systems for which there are specific requirements in Part 4 may complywith requirements of an alternative standard, in lieu of the requirements in this Guide. This, however,is subject to such standards being determined by the Bureau as being not less effective than thisGuide. Where applicable, requirements may be imposed by the Bureau in addition to those containedin the alternative standard to assure that the intent of this Guide is met. In all cases, the equipment,component, or system is subject to design review, survey during construction, tests, and trials, asapplicable, by the Bureau for purposes of verification of its compliance with the alternative standard.The verification process is to be to the extent as intended by this Guide. See also 1-1-1/1.

1.9 Definitions 4-1-1/1.9

Definitions of terms used are defined in the chapter, sections or subsections where they appear. Thefollowing are terms that are used throughout Part 4.

1.9.1 Control Station 4-1-1/1.9.1

A location where controllers or actuator are fitted, with monitoring devices, as appropriate,for purposes of effecting desired operation of specific machinery.

Control Station is defined exclusively for purposes of Part 4, Chapter 7 Fire SafetySystems,

Centralized Control Station is used in Part 4, Chapter 9 Remote Propulsion Control andAutomation to refer to the space or the location where the following functions arecentralized:

controlling propulsion and auxiliary machinery,

monitoring propulsion and auxiliary machinery, and

monitoring the propulsion machinery space.

1.9.2 Machinery Space and Machinery Compartment 4-1-1/1.9.2

1.9.2(a) Machinery space is any space that contains propulsion machinery, oil fuel units, andinternal combustion engines, generators and major electrical machinery, oil filling stations,air conditioning and ventilation machinery, refrigerating machinery, stabilizing machinery, orother similar machinery, including the trunks to the space. Machinery space is to includemachinery space of category A, which is a space and trunks to that space which contains:

internal combustion machinery used for main propulsion; or

internal combustion machinery used for purposes other than main propulsion wheresuch machinery has in the aggregate a total power output of not less than 375 kW(500 hp); or

any oil fuel unit [the equipment used for the preparation of oil fuel for delivery to anoil-fired boiler, or equipment used for the preparation for delivery of heated or non-heated oil to an internal combustion engine, and includes any oil pressure pumps,filters and heaters dealing with oil at a pressure of more than 1.8 bar (1.8 kg/cm2,26 psi)].

1.9.2(b) Machinery compartment is the same as above except that only room for themachinery is provided. All machinery is accessed through hatches, doors, or panels and is tobe fully accessible for maintenance through these access openings. Machinery accesses are tobe suitably protected such that machinery can be accessed under all operational and weatherconditions.



1.9.3 Essential Services 4-1-1/1.9.3

Essential services are those considered necessary for:

navigation, propulsion and maneuvering of the craft;

maintaining a minimum level of safety, such as providing for lighting, ventilation ofpropulsion machinery space, interior and radio communications, manually operatedalarms, fire protection, bilge and ballast services; and

maintaining a minimum level of safety with regard to the cargoes carried, forinstance, the ventilation of ro-ro space, ammunition stowage, etc.

maintaining a minimum level of safety with regard to the mission of the craft, e.g.,power for the self-defense systems.

1.9.4 Hazardous Area 4-1-1/1.9.4

Areas where flammable or explosive gases, vapors, dust or cargo are normally present orlikely to be present are known as hazardous areas. Hazardous areas are however morespecifically defined for certain machinery installations, storage spaces and cargo spaces thatpresent such hazard, e.g.:

helicopter refueling facilities

paint stores

ammunition/weapons storage

1.9.5 Toxic or Corrosive Substances 4-1-1/1.9.5

Toxic substances (solid, liquid or gas) are those that possess the common property of beingliable to cause death or serious injury or to harm human health if swallowed or inhaled, or byskin contact.

Corrosive Substances (solid or liquid) are those, excluding saltwater, that possess in theiroriginal stage the common property of being able through chemical action to cause damageby coming into contact with living tissues, the craft or its cargoes, when escaped from theircontainment.

1.9.6 Redundancy

Where plants are installed in separate machinery spaces or compartments, each plant is to beself-sufficient so that malopertion of one plant will not affect operation of any other plant.System flexibility incorporating cross-connections between plants and by-passes aroundcomponents are to be provided, as specified in the applicable sections covering piping andelectrical systems, to permit warm-up and continued operation under conditions whenspecified components are inoperative.

1.9.7 Loss of Power

Loss of power by one propulsion unit while underway and the resultant free turning of itspropulsion shafting is to not cause bearing damage to the propulsion unit. Continuedlubrication to free-turning propulsion shafts and machinery is to be provided.

1.9.8 Flooding damage

Continued operation of a propulsion plant is to not be affected by the flooding of the bilgeregions in which the plant or a portion of the plant is located.



3 Certification of Machinery 4-1-1/3

3.1 Basic Requirements 4-1-1/3.1

This Guide defines, to varying degrees, the extent of evaluation required for products, machinery,equipment, and their components based on the level of criticality of each of those items. There arethree basic evaluation constituents:

design review; prototype testing;

survey during construction and testing at the plant of manufacture; and

survey during installation on board the craft and at trials.

Where design review is required by this Guide, a letter will be issued by the Bureau upon satisfactoryreview of the plans to evidence the acceptance of the design. In addition to, or independent of, designreview, ABS may require survey and testing of forgings, castings, and component parts at the variousmanufacturers plants as well as survey and testing of the finished product. A certificate or report willbe issued upon satisfactory completion of each survey to evidence acceptance of the forging, casting,component or finished product. Design review, survey and the issuance of reports or certificatesconstitute the certification of machinery.

Based on the intended service and application, some products do not require certification because theyare not directly related to the scope of classification or because normal practices for their constructionwithin the industry are considered adequate. Such products may be accepted based on themanufacturers documentation on design and quality.

In general, surveys during installation on board the craft and at trials are required for all items ofmachinery. This is not considered a part of the product certification process. There may be instances,however, where letters or certificates issued for items of machinery contain conditions which must beverified during installation, tests, or trials.

3.3 Type Approval Program 4-1-1/3.3

Products that can be consistently manufactured to the same design and specification may be TypeApproved under the ABS Type Approval Program. The ABS Type Approval Program is a voluntaryoption for the demonstration of the compliance of a product with this Guide or other recognizedstandards. It may be applied at the request of the designer or manufacturer. The ABS Type ApprovalProgram generally covers Product Type Approval (1-1-4/3.9.3), but is also applicable for a moreexpeditious procedure towards Unit-Certification as specified in 1-1-4/3.9.2.

See the ABS Type Approval Program in Appendix 1-1-A1.

3.5 Non-mass Produced Machinery

Non-mass produced critical machinery, such as propulsion boilers, slow speed diesel engines,turbines, steering gears, and similar critical items are to be individually unit certified in accordancewith the procedure described in 4-1-1/3.1. However, consideration will be given to granting TypeApproval to such machinery in the categories of Acceptable Quality System (AQS) and RecognizedQuality System (RQS). The category of Product Quality Assurance (PQA) will not normally beavailable for all products and such limitations will be indicated in 4-1-1/Table 1 through 4-1-1/Table6. In each instant where Type Approval is granted, in addition to quality assurance and quality controlassessment of the manufacturing facilities, the Bureau will require some degree of product specificsurvey during manufacture.



3.7 Details of Certification of Some Representative Products

4-1-1/Table 1 through 4-1-1/Table 6 provide abbreviated certification requirements of representativemachinery based on the basic requirements of this Guide for machinery. The tables also provide theapplicability of the Type Approval Program for each of these machinery items.

For easy reference, the tables contain six product categories as follows:

Prime movers

Propulsion, maneuvering and mooring machinery

Electrical and control equipment

Fire safety equipment

Pressure vessels and fired equipment

Piping system components

5 Machinery Plans 4-1-1/5

5.1 Submission of Plans 4-1-1/5.1

Machinery and systems plans required by this Guide are to be submitted by the manufacturer,designer, or shipbuilder, in triplicate, to the Bureau. After review and approval of the plans, one copywill be returned to the submitter, one copy will be retained for the use of the Bureaus Surveyor, andone copy will be retained by the Bureau for record. It may be necessary to submit additional copies ofplans when attendance by the Bureaus Surveyor is anticipated at more than one location. Where sostated in the shipbuilding contract, the Owner may require the builder to provide it with copies ofapproved plans and related correspondence, in which case the total number of copies of each plan tobe submitted to the Bureau is to be increased correspondingly. A fee will be charged for the reviewof plans which are not covered by a contract of classification with the shipbuilder.

In general, all plans are to be submitted and approved before proceeding with the work.

5.3 Plans 4-1-1/5.3

Machinery plans required to be submitted for review and approval by the Bureau are listed in each ofthe Sections in Part 4. In general, equipment plans are to contain performance data and operationalparticulars; standard of compliance where standards are used in addition to, or in lieu of, this Guide;construction details such as dimensions, tolerances, welding details, welding procedures, materialspecifications, etc.; and engineering calculations or analyses in support of the design. System plansare to contain a bill of material with material specifications or particulars, a legend of symbols used,system design parameters, and are to be in a schematic format. Booklets containing standard shipyardpractices of piping and electrical installations are generally required to supplement schematic systemplans.

7 Miscellaneous Requirements for Machinery 4-1-1/7

7.1 Construction Survey Notification 4-1-1/7.1

Before proceeding with the manufacture of machinery requiring test and inspection, the Bureau is tobe notified that survey is desired during construction. Such notice is to contain all the necessaryinformation for the identification of the items to be surveyed.



7.3 Machinery Equations 4-1-1/7.3

The equations for rotating parts of the machinery in Part 4 of this Guide are based upon strengthconsiderations only and their application does not relieve the manufacturer from responsibility for thepresence of dangerous vibrations and other considerations in the installation at speeds within theoperating range.

7.5 Astern Propulsion Power 4-1-1/7.5

Sufficient power for going astern is to be provided to secure proper control of the craft in all normalcircumstances. The astern power of the main propelling machinery is to be capable of at least 30minutes of astern operation at 70% of the ahead rpm corresponding to the maximum continuous aheadpower. For main propulsion systems with reversing gears, controllable pitch propellers or electricpropulsion drive, running astern is not to lead to overload of the propulsion machinery. The ability ofthe machinery to reverse the direction of thrust of the propeller in sufficient time, and so to bring thecraft to rest within a reasonable distance from maximum ahead service speed, is to be demonstratedand recorded.

7.7 Dead Ship Start 4-1-1/7.7

Means are to be provided, such as starting batteries, compressed air or emergency generator, to bringthe machinery into operation from a dead ship condition (e.g., a condition under which the mainpropulsion plant, boilers and auxiliaries are not in operation due to the absence of the main source ofpower). See 4-8-2/3.1.3 for the required starting arrangements.

Note: For the purpose of this requirement, dead ship and blackout are both to be understood to mean the same.

7.9 Inclinations 4-1-1/7.9

Machinery installations are to be designed such as to ensure proper operations under the conditions asshown in 4-1-1/Table 7. Lower angles may be accepted by the Naval Administration taking intoaccount the hull shape and service limitations of the craft.

7.11 Ambient Temperature 4-1-1/7.11

Ambient temperature as indicated in 4-1-1/Table 8 is to be considered in the selection and installationof machinery, equipment and appliances. For craft of special service, the ambient temperatureappropriate to the special nature may be required by the Naval Administration.

7.13 Machinery Space Ventilation 4-1-1/7.13

Suitable ventilation is to be provided for machinery spaces so as to allow simultaneously for crewattendance and for engines and other machinery to operate at rated power in all weather conditions,including heavy weather.

9 Sea Trials 4-1-1/9A final under-way trial is to be made of all machinery, steering gear, anchor windlass, stopping andmaneuvering capability, including supplementary means for maneuvering, if any. Insofar aspracticable, the craft is to be ballasted or otherwise arranged to simulate fully laden condition so as toallow propulsion machinery to discharge its rated power. The entire machinery installation is to beoperated in the presence of the Surveyor to demonstrate its reliability and sufficiency to functionsatisfactorily under operating conditions and its freedom from dangerous vibration and otherdetrimental operating phenomena at speeds within the operating range. All automatic controls,including tripping of all safety protective devices that affect the crafts propulsion system, are to betested underway or alongside the pier, to the satisfaction of the Surveyor. References are also to bemade to the following for more detail requirements:



Steering gear trial: 4-3-4/21.7.

Anchor windlass trial: 4-5-1/9.

Remote propulsion control and automation trial: 4-9-5/5.

Based on the sea trials, the following information is to be provided on board:

stopping time (see also 4-1-1/7.5),

craft headings and distances recorded on sea trials, and

for craft with multiple propellers, ability to navigate and maneuver with one or morepropellers inoperative.

Reference may be made to IMO Resolution A.209(VII) Recommendation on Information to beIncluded in the Maneuvering Booklet and IMO Resolution A.601(15) Recommendation on theProvision and the Display of Maneuvering Information on board ships.



TABLE 1Certification Details Prime Movers

Type Approval Program (3)

Product design assessment1-1-A1/5.1

Manufacturing Assessment1-1-A1/5.3

Prime movers (1)Individual unit

Certification (2) (a)Designreview

(b)Typeexam.

(b)

Type test

(a)

AQS

(b)

RQS

(d)

PQA.

1. Diesel engines with cylinder bore;> 300 mm

d, m, s, t, x x x o o NA

2. Diesel engines; steam turbines; gasturbines; 100 kW (135 hp)

d, m, s, t x x x o o o

3. Diesel engines; steam turbines; gasturbines, < 100 kW (135 hp)

g x o x o o o

4. Turbochargers for engines 100kW (135 hp) and bore 300 mm(11.8 in)

d, m, s, t x x x o o o

5. Turbochargers for engines 100kW (135 hp) and bore



TABLE 2Certification Details Propulsion, Maneuvering

and Mooring Machinery


Product design assessment

1-1-A1/5.1

Manufacturing Assessment

1-1-A1/5.3Propulsion, maneuvering

and mooring machinery (1)Individual

unitcertification (2)

(a)Designreview

(b)Typeexam.

(b)

Type test

(a)

AQS

(b)

RQS

(d)

PQA.

1. Propulsion shafts, couplings,coupling bolts (4)

d, m, s x NA NA o o NA

2. Cardan shafts, standard couplingsand coupling bolts

d, m, s x x x o o o

3. Gears and Clutches 1120 kW(1500 hp)

d, m, s x x x o o NA

4. Gears and clutches, 100 kW(135 hp)

d, m, s x x x o o o

5. Gears and clutches,



TABLE 3Certification Details Electrical and Control Equipment



Manufacturing Assessment1-1-A1/5.3Electrical and control

Equipment (1)Individual

unitcertification (2)

(a)Designreview

(b)Typeexam

(b)

Type test

(a)

AQS

(b)

RQS

(d)

PQA.

1. Generators and motors foressential services 100 kW(135 hp)

d, s, t x x x o o o

2. Generators and motors foressential services



TABLE 4Certification Details Fire Safety Equipment



Manufacturing Assessment1-1-A1/5.3

Fire safety equipment (1)Individual unit

Certification (2) (a)Designreview

(b)Typeexam.

(b)

Type test

(a)

AQS

(b)

RQS

(d)

PQA

1. Fire detection and alarm systemcomponents

d, t x x x o o o

2. Fixed fire extinguishing systemcomponents

d, t x x x o o o

3. Firemans outfit t x x x o o o

4. Fire hoses t x x x o o o

5. Portable fire extinguishers t x x x o o o

Notes1 For certification details, see Section 4-7-3.

2 See also 4-1-1/3.1. Notations used in this column are:

d design review by ABS.

s survey at the plant of manufacture and witness acceptance tests of production unit.

t type test, conducted on a sample or a prototype is required; or type approval by Flag Administration.

3 For description of Type Approval Program, see 1-1-A1/5. Notations used in these columns are:

x indicates the particular element of the program is applicable.

o indicates the particular element of the program is optional.



TABLE 5Certification Details Pressure Vessels

and Fired Equipment


Product design assessment

1-1-A1/5.1

Manufacturing Assessment

1-1-A1/5.3Pressure vessels

and fired equipment (1)Individual unit

certification (2) (a)Designreview

(b)Typeexam.

(b)

Type test

(a)

AQS

(b)

RQS

(d)

PQA.

1. Group I pressure vessels d, m, s x x NA o o NA

2. Group II pressure vessels d, s x x NA o o o

3. Inert gas generators, incinerators d x x x o o o

Notes1 For grouping of pressure vessels, see 4-4-1/1.7 and 4-4-1/1.9.


d design review by ABS.

m material tests to be witnessed by Surveyor.

s survey at the plant of manufacture and witness acceptance tests of production unit.

3 For description of Type Approval Program, see 1-1-A1/5. Type Approval Programs are applicable generally tomass produced boilers and pressure vessels (See 4-4-1/1.11.2). Notations used in these columns are:

x indicates the particular element of the program is applicable.

o indicates the particular element of the program is optional.

NA indicates the particular element of the program is not applicable.



TABLE 6Certification Details Piping System Components



Manufacturing Assessment1-1-A1/5.3Piping system

components (1)Individual

unit

Certification(2)

(a)Designreview

(b)Typeexam.

(b)

Type test

(a)

AQS

(b)

RQS

(d)

PQA.

1. Pumps related to propulsion dieselengines (bore >300mm) (11.8 in)and gas turbines and gearsfuel,cooling water, lube. Oil services

s, t x x x o o o

2. Pumps related to propulsion steamplant and gearsfuel oil, lube. Oil,condensate, main circulating, feedwater services

s, t x x x o o o

3. Hydraulic pumps of steering gears,controllable pitch propellers,anchor windlass

s, t x x x o o o

4. Pumps for fire main, ballast, bilge,liquid cargoes

s, t x x x o o o

5. Air compressors g x x x o o o

6. Steel pipes, classes I and II m, s x NA NA o o o

7. Steel pipes, class III g x NA NA x x x

8. Pipe fittingsflanges, elbows,tees, flexible joints, etc., andvalves; classes I & II

d-1 x NA NA o o o

9. Pipe fittingsflanges, elbows,tees, flexible joints, etc., andvalves; class III

g x NA NA o o o

10. Plastic pipes and pipe joints d-2, t, s x x x o o o

11. Hoses d-2, t x x x o o o

12. Vent heads, pressure vacuumvalves

d-2, t x x x o o o

13. Gauges, detectors and transmitters d-2 x x x o o o

14. Fluid power cylinders and systems,including valve actuators (4)

d-1 x x x o o o

Notes1 For full certification details, see 4-6-1/7 and Section 4-6-2 for metallic piping and Section 4-6-3 for plastic

piping.


d-1 verification for compliance with recognized standard or design review by ABS.

d-2 reviewed for suitability for proposed installation.

m material tests witnessed by Surveyor.

s survey at the plant of manufacture, including witnessing acceptance tests of production unit.

t type test, conducted on a sample or a prototype is required.

g certification by ABS not required; acceptance is based on manufacturers documentation.

3 For description of Type Approval Program, see 1-1-A1/5. Notations used in these columns are:

x - indicates the particular element of the program is applicable.

o - indicates the particular element of the program is optional.

NA - indicates the particular element of the program is not applicable.

4 Other than steering gear actuators.



TABLE 7Design Angles of Inclination

Angle of inclination, degrees (1)

Athwartship Fore-and-aft

Installations, components Static Dynamic Static Dynamic

Propulsion and auxiliary machinery 15 22.5 5 7.5

Safety equipment

Emergency power installation 22.5 22.5 10 10

Emergency fire pumps and their drives 22.5 22.5 10 10

Switchgear

Electrical and electronic appliances and control systems 22.5 (2) 22.5 (2) 10 10

Notes1 Athwartship and fore-and-aft inclinations occur simultaneously.

2 Up to an angle of inclination of 45 degrees, switches and controls are to remain in their last set position.

3 The Naval Administration may require higher static and dynamic angles of inclination.

TABLE 8Ambient Temperatures for Unrestricted Service

Location Temperature

Atmospheric Enclosed spaces (1), (2) 0 to 45C

Open deck (1)25 to 45C

Seawater All 32C

Notes:1 Electronic equipment is to be suitable for operations up to 55C.

2 Electrical equipment in machinery spaces is to be designed for 45C, except that electric generators and motorsare to be designed for 50C. Electrical equipment outside machinery space may be designed for 40C.

3 The Naval Administration may require higher and/or lower ambient temperatures.

This Page Intentionally Left Blank


P A R T

4C H A P T E R 2 Prime Movers

CONTENTSSECTION 1 Diesel Engines.................................................................... 23

1 General................................................................................ 23

1.1 Application.......................................................................23

1.3 Definitions........................................................................23

1.5 Increased Power Rating ..................................................24

1.7 Ambient Reference Conditions........................................24

1.9 Plans and Particulars to be Submitted.............................24

3 Materials.............................................................................. 27

3.1 Material Specifications and Tests....................................27

3.3 Alternative Materials and Tests .......................................27

5 Design ................................................................................. 28

5.1 Bedplate/Crankcase ........................................................28

5.3 Crankcase Doors.............................................................28

5.5 Cylinders and Covers, Liners and Pistons.......................28

5.7 Securing of Nuts ..............................................................28

5.9 Crankshafts .....................................................................28

5.11 Shaft Couplings and Clutches .........................................39

7 Engine Appurtenances........................................................ 39

7.1 Explosion Relief Valves ...................................................39

7.3 Governors and Overspeed Protection .............................40

7.5 Governors and Overspeed Protection for EnginesDriving Generators ..........................................................40

7.7 Cylinder Overpressure Monitoring...................................41

7.9 Scavenging Blowers ........................................................42

7.11 Warning Notices ..............................................................42

7.13 Jacket Drain and Over-pressure Protection.....................42

7.15 Monitoring........................................................................42

9 Piping Systems for Diesel Engines ..................................... 42

11 Installation of Diesel Engines .............................................. 43

11.1 Seating Arrangements for Diesel Engines.......................43

11.3 Metal Chocks...................................................................43

11.5 Cast Resin Chocks..........................................................43

11.7 Resilient Mountings .........................................................43

11.9 Hot Surfaces....................................................................43


13 Testing, Inspection and Certification of Diesel Engines...... 43

13.1 Material and Nondestructive Tests ................................. 43

13.3 Hydrostatic Tests of Diesel Engine Components............ 43

13.5 Relief and Safety Valves................................................. 43

13.7 Manufacturers Quality Control ....................................... 44

13.9 Type Tests of Diesel Engines ......................................... 46

13.11 Shop Tests of Each Produced Diesel Engine ................. 49

13.13 Type Tests of Mass-produced Diesel Engines................ 51

13.15 Certification of Diesel Engine.......................................... 52

15 Shipboard Trials of Diesel Engines ..................................... 53

15.1 Engines Driving Fixed Pitch Propellers........................... 53

15.3 Engines Driving Controllable Pitch Propellers................. 54

15.5 Engines Driving Propulsion Generators.......................... 54

15.7 Engines Driving Generators............................................ 54

15.9 Engines Burning Residual Fuel Oil ................................. 54

15.11 Torsional Vibration Barred Speed Range ....................... 54

17 Spare Parts ......................................................................... 54

TABLE 1 Required Material and Nondestructive Tests ofDiesel Engine Parts................................................... 55

TABLE 2 Test Pressures for Parts of Internal-combustionEngines...................................................................... 56

FIGURE 1 Crank Throw for In-line Engine.................................. 29

FIGURE 2 Crank Throw for Engine with Adjacent ConnectingRods .......................................................................... 29

FIGURE 3 Crank Dimensions for the Calculation of StressConcentration Factors ............................................... 29

FIGURE 4 Crank Throw for Semi-built Crankshaft ..................... 29

FIGURE 5 Limiting Curves for Loading 4-stroke DieselEngines Step by Step from No-load to RatedPower as Function of the Brake MeanEffective Pressure ..................................................... 41

FIGURE 6 Type Test Power/Speed Diagram ............................. 49

SECTION 1 Appendix 1 - Plans and Data for Diesel Engines ..............57

SECTION 2 Turbochargers.....................................................................65

1 General................................................................................ 65

1.1 Application ...................................................................... 65

1.3 Definitions....................................................................... 65

1.5 Plans and Particulars to be Submitted............................ 65

3 Materials .............................................................................. 67

3.1 Material Specifications and Purchase Orders ................. 67

3.3 Engines with Cylinder Bore 300 mm (11.8 in.)............. 67

3.5 Engines with Cylinder Bore >300 mm (11.8 in.).............. 67

3.7 Alternative Material Test Requirements.......................... 67


5 Design ................................................................................. 67

5.1 Engines with Cylinder Bores 300 mm (11.8 in.)............67

5.3 Engines with Cylinder Bores > 300 mm (11.8 in.)............68

7 Piping Systems for Turbochargers...................................... 68

9 Installation of Turbochargers............................................... 68

9.1 Air Inlet ............................................................................68

9.3 Hot Surfaces....................................................................68

9.5 Pipe and Duct Connections .............................................68

11 Testing, Inspection and Certification of Turbochargers ...... 69

11.1 Shop Inspection and Tests ..............................................69

11.3 Certification of Turbochargers .........................................69

11.5 Engine and Shipboard Trials ...........................................70

13 Spare Parts ......................................................................... 70

SECTION 3 Gas Turbines ...................................................................... 71

1 General................................................................................ 71

1.1 Application.......................................................................71

1.3 Definitions........................................................................71

1.5 Plans and Particulars to be Submitted.............................72

3 Materials.............................................................................. 73

3.1 Material Specifications and Tests....................................73

3.3 Alternative Materials and Tests .......................................73

5 Design ................................................................................. 74

5.1 Rotors and Blades...........................................................74

5.3 Operation Above the Rated Speed and Power................74

5.5 Overhaul Interval .............................................................74

5.7 Type Test Data................................................................74

7 Gas Turbine Appurtenances ............................................... 75

7.1 Overspeed Protective Devices ........................................75

7.3 Operating Governors for Propulsion Gas Turbines .........75

7.5 Operating Governors for Turbines Driving ElectricGenerators ......................................................................75

7.7 Safety Systems and Devices...........................................76

7.9 Hand Trip Gear................................................................77

7.11 Air-intake Filters and Anti-icing........................................77

7.13 Silencers..........................................................................77

9 Piping Systems for Gas Turbines........................................ 78

11 Installation of Gas Turbines ................................................ 78

11.1 Pipe and Duct Connections .............................................78

11.3 Intake and Exhaust..........................................................78

11.5 Hot Surfaces....................................................................78

13 Testing, Inspection and Certification of Gas Turbines ........ 78

13.1 Shop Inspection and Tests ..............................................78

13.3 Certification of Gas Turbines ...........................................79

13.5 Shipboard Trials ..............................................................80

15 Spare Parts ......................................................................... 80


TABLE 1 List of Alarms and Shutdowns................................... 77

SECTION 4 Craft less than 24 meters (79 feet) in Length ....................81

1 Diesel Engines .................................................................... 81

3 Turbochargers ..................................................................... 81

5 Gas Turbines....................................................................... 81

7 Gasoline Engines (inboard and outboard) .......................... 81


P A R T

4C H A P T E R 2 Prime Movers

S E C T I O N 1 Diesel Engines 4-2-1

1 General 4-2-1/1

1.1 Application 4-2-1/1.1

Diesel engines having a rated power of 100 kW (135 hp) and over intended for propulsion and forauxiliary services essential for propulsion, maneuvering and safety (see 4-1-1/1.3) of the craft are tobe designed, constructed, tested, certified, and installed in accordance with the requirements of thissection.

Diesel engines having a rated power of less than 100 kW (135 hp) are not required to comply with theprovisions of this section but are to be designed, constructed and equipped in accordance with goodcommercial and marine practice. Acceptance of such engines will be based on manufacturersaffidavit, verification of engine nameplate data, and subject to a satisfactory performance test afterinstallation conducted in the presence of the Surveyor.

Diesel engines having a rated power of 100 kW (135 hp) and over intended for services considerednot essential for propulsion, maneuvering and safety are not required to be designed, constructed, andcertified by the Bureau in accordance with the requirements of this Section. They are to comply withsafety features, such as crankcase explosion relief valve, overspeed protection, etc., as provided in4-2-1/7, as applicable. After installation they are subject to a satisfactory performance test conductedin the presence of the Surveyor.

Piping systems serving diesel engines, such as fuel oil, lubricating oil, cooling water, starting air,crankcase ventilation and exhaust gas systems are addressed in Section 4-6-5; hydraulic andpneumatic systems are addressed in Section 4-6-7.

Requirements for turbochargers are provided in Section 4-2-2.

1.3 Definitions 4-2-1/1.3

For the purpose of this section the following definitions apply:

1.3.1 Medium-, High-speed Diesel Engines 4-2-1/1.3.1

Medium Speed Engines means trunk piston type diesel engines having a rated speed of 400rpm and above but less than 1400 rpm.

High-Speed Engines means trunk piston type diesel engines having a rated speed of 1400 rpmor above.

Part 4 Craft Systems and MachineryChapter 2 Prime MoversSection 1 Diesel Engines 4-2-1


1.3.2 Rated Power 4-2-1/1.3.2

The Rated Power is the maximum power output at which the engine is designed to runcontinuously at its rated speed between the normal maintenance intervals recommended bythe manufacturer.

1.5 Increased Power Rating 4-2-1/1.5

The rated power of an engine, which has been type tested as specified in 4-2-1/13.9 or 4-2-1/13.13and which has proven reliability in service, may be increased by not more than 10% of the type testedpower rating without performing any new type test, subject to prior approval of relevant plans andparticulars.

1.7 Ambient Reference Conditions 4-2-1/1.7

The following ambient reference conditions are to be applied by the engine manufacturer for thepurpose of determining the rated power of diesel engines used on craft with unrestricted service.However, the engine manufacturer is not expected to provide simulated ambient reference conditionsat any test.

Barometric pressure: 1 bar (1 kgf/cm2, 15 psi)

Air temperature: 45C (113F)

Relative air humidity: 60%

Seawater Temperature (Charging air coolant inlet): 32C (90F)

1.9 Plans and Particulars to be Submitted 4-2-1/1.9

For a tabulated listing, see Appendix 4-2-A1.

1.9.1 Engine Construction 4-2-1/1.9.1

Engine transverse cross-section

Engine longitudinal section

Bedplate with welding details and procedures; frame/column with welding details andprocedures; crankcase with welding details and procedures

Structural supporting and seating arrangements

Arrangement of foundation bolts (for main engines only)

Thrust bearing assembly

Thrust bearing bedplate

Tie rod

Cylinder cover, assembly or cylinder head

Cylinder jacket or engine block

Cylinder liner

Crankshaft, details

Crankshaft, assembly

Thrust shaft or intermediate shaft (if integral with engine)

Coupling bolts

Counterweights (if not integral with crankshaft)



Connecting rod, assembly and details

Piston rod, assembly and details

Piston, assembly and details

Camshaft drive, assembly

Arrangement of crankcase explosion relief valve and breather arrangement (only for engineshaving a cylinder bore of 200 mm (8 in.) and above)

1.9.2 Engine Systems and Appurtenances 4-2-1/1.9.2

Starting air system

Fuel oil system

Lubricating oil system

Cooling water system

Governor arrangements

Schematic diagram of the engine control and safety system

Shielding and insulation of exhaust pipes, assembly

Shielding of high pressure fuel pipes, assembly as applicable

Turbochargers and superchargers, see 4-2-2/1.5

Couplings and clutches

Vibration damper assembly

Engine driven pump assembly

Scavenging pump and blower assemblies

1.9.3 Data 4-2-1/1.9.3

Type designation of engine and combustion cycle

Number of cylinders

Rated power, kW (PS, hp)

Rated engine speed, (rpm)

Sense of rotation (clockwise/counter-clockwise)

Firing order with the respective ignition intervals and, where necessary, V-angle, v

Cylinder diameter, mm (in.)

Stroke, mm (in.)

Maximum cylinder pressure pmax, bar (kgf/mm2, psi)

Mean effective pressure, bar (kgf/mm2, psi)

Mean indicated pressure, bar (kgf/mm2, psi)

Charge air pressure, bar (kgf/mm2, psi), (before inlet valves or scavenge ports, whicheverapplies)

Nominal compression ratio

Connecting rod length LH, mm (in.)



Oscillating mass of one crank gear, kg (lb.), (in case of V-type engines, where necessary, alsofor the cylinder unit with master and articulated type connecting rod or forked and innerconnecting rod)

Mass of reciprocating parts, kg (lb.)

Digitalized gas pressure curve presented at equidistant intervals, bar (kgf/mm2, psi) versuscrank angle, (intervals equidistant and integrally divisible by the V-angle, but not more than 5degrees CA)

1.9.4 Materials 4-2-1/1.9.4

Crankshaft material:

Material designation

Mechanical properties of material (tensile strength, yield strength, elongation (withlength of specimen), reduction of area, impact energy)

Type of forging (open die forged (free form), continuous grain flow forged, close dieforged (drop-forged), etc.; with description of the forging process)

Crankshaft heat treatment

Crankshaft surface treatment

Surface treatment of fillets, journals and pins (induction hardened, flame hardened,nitrided, rolled, shot peened, etc. with full details concerning hardening)

Hardness at surface

Hardness as a function of depth, mm (in.)

Extension of surface hardening

Material specifications of other main parts

1.9.5 Calculations and Analyses 4-2-1/1.9.5

Strength analysis for crankshaft and other reciprocating parts.

Strength analysis for engine supports and seating arrangements.

Torsional vibration analysis for all modes of operation including the condition of one cylindermisfiring.

Calculation demonstrating the adequacy of the bolting arrangement attaching tuning wheelsor vibration dampers to the propulsion system to withstand all anticipated torsional vibrationand operating loads.

1.9.6 Submittals by Licensee 4-2-1/1.9.6

1.9.6(a) Plans lists. For each diesel engine manufactured under license, the licensee is tosubmit two listings of plans and data to be used in the construction of the engine:

one list is to contain drawing numbers and titles (including revision status) of thelicensers plans and data of the engine as approved by the Bureau (including approvalinformation such as location and date at which they are approved); and

a second list, which is to contain the drawing numbers and titles (including revisionstatus) of the licensees plans and data insofar as they are relevant to the constructionof the engine. In the event that construction is based solely on licensers plans, thislist will not be required.



1.9.6(b) Plans for approval. Any design change made by the licensee is to be documentedand relevant plans and data are to be submitted by the licensee for approval or forinformation, as appropriate. The licensers statement of acceptance of the modifications is tobe included in the submittal.

1.9.6(c) Plans for surveyor. A complete set of the licensers or the licensees plans and data,as approved by the Bureau, is to be made available to the Surveyor attending the licenseesplant.

3 Materials 4-2-1/3

3.1 Material Specifications and Tests 4-2-1/3.1

Material specifications are to be in accordance with that in Chapter 3 of the Rule Requirements forMaterials and Welding Part 2 or other specifications approved under 4-2-1/3.3.1. Except as noted in4-2-1/3.3, materials intended for engines required to be constructed under survey are to be tested andinspected in accordance with 4-2-1/Table 1. The material tests, where so indicated in the table, are tobe witnessed by the Surveyor. Nondestructive tests in 4-2-1/Table 1 are to be carried out by themanufacturer whose test records may be accepted by the Bureau.

Copies of material specifications or purchase orders are to be submitted to the Surveyor forinformation.

3.3 Alternative Materials and Tests 4-2-1/3.3

3.3.1 Alternative Specifications 4-2-1/3.3.1

Material manufactured to specifications other than those given in Chapter 3 of the RuleRequirements for Materials and Welding Part 2 may be accepted, provided that suchspecifications are approved in connection with the design and that they are verified or testedin the presence of a Surveyor, as applicable, as complying with the specifications.

3.3.2 Steel-bar Stock 4-2-1/3.3.2

Hot-rolled steel bars up to 305 mm (12 in.) in diameter may be used when approved for anyof the items indicated in 4-2-1/Table 1, subject to the conditions specified in Section 2-3-8 ofthe Rule Requirements for Materials and Welding Part 2

3.3.3 Material for Engines of 375 kW (500 hp) Rated Power or Less 4-2-1/3.3.3

Material for engines having a rated power of 375 kW (500 hp) or less, including shafting,couplings, and coupling bolts will be accepted on the basis of the material manufacturerscertified test reports and a satisfactory surface inspection and hardness check witnessed by theSurveyor. Coupling bolts manufactured to a recognized bolt standard will not require materialtesting.

3.3.4 Engines Certified Under Quality Assurance Approval 4-2-1/3.3.4

For diesel engines certified under quality assurance assessment as provided for in4-2-1/13.15.2(b), material tests required by 4-2-1/3.1 need not be witnessed by the Surveyor;such tests are to be conducted by the engine manufacturer whose certified test reports may beaccepted instead.



5 Design 4-2-1/5

5.1 Bedplate/Crankcase 4-2-1/5.1

The bedplate or crankcase is to be of rigid construction, oiltight, and provided with a sufficientnumber of bolts to secure the same to the crafts structure. See also 4-2-1/11.1 for seating of dieselengines.

5.3 Crankcase Doors 4-2-1/5.3

Crankcase doors are to be constructed and securely fastened so that they will not be readily displacedby an explosion.

5.5 Cylinders and Covers, Liners and Pistons 4-2-1/5.5

Cylinders, liners, cylinder covers, and pistons, which are subjected to high temperatures or pressures,are to be of materials suitable for the stresses and temperatures to which they are exposed.

5.7 Securing of Nuts 4-2-1/5.7

All nuts of main bearings and of connecting-rod bolts and all other moving parts are to be secured bysplit pins or other effective locking means.

5.9 Crankshafts 4-2-1/5.9

5.9.1 General 4-2-1/5.9.1

Crankshafts are to be designed in accordance with the following requirements. Theserequirements are intended for diesel engines for propulsion and auxiliary purposes where theengines are being so designed as to be capable of continuous operation at their rated powerwhen running at rated speed.

Alternatively, the design may be substantiated by means of a more detailed stress analysisand/or direct stress (strain) measurement. In such instances details of the method, results andanalysis are to be submitted, including reliability data.

In addition to the criteria given hereunder, torsional vibration stresses in propulsion enginecrankshafts, and associated gears where applicable, are to be evaluated based on criteriaprovided in 4-3-2/7.5.

5.9.2 Bending Moments and Shearing Forces 4-2-1/5.9.2

The journals are considered supported in the center of adjacent bearings and subjected tocylinder pressure and inertia forces. The bending length is taken as the length between the twomain bearings (distance L3), see 4-2-1/Figure 1 and 4-2-1/Figure 2.

The nominal bending moment is taken as the bending moment in the crank web cross-sectionin the center of the solid web (distance L1) based on a triangular bending moment load due tothe radial components of the connecting rod force. For crank throws with two connecting rodsacting upon one crankpin the nominal bending moment is taken as a bending momentobtained by superimposition of the two triangular bending moment loads according to phase.



FIGURE 1Crank Throw for In-line Engine

DE

DG

L1 L1

L2 L2

L3

FIGURE 2Crank Throw for Engine withAdjacent Connecting Rods

D

EDG

L1 L1

L2 L2

L3

cent

erlin

e of

conn

ecti

ng r

od

FIGURE 3Crank Dimensions for the

Calculation of StressConcentration Factors

W

D

DG - S2

DBH

RH

A

A

W

RG

DBG

DG

S

TG TH

B

DG - S2

E

A - A

FIGURE 4Crank Throw for

Semi-built Crankshaft

DSDG

D

LS

A

A

DBGy

RG

DA

x

A - A

The nominal alternating stresses due to bending moments and shearing forces are to be relatedto the cross-sectional area of the crank web. This reference area of cross-section results fromthe web thickness W and the web width B in the center of the overlap of the pins or, ifappropriate, at the center of the adjacent generating lines of the two pins if they do notoverlap, see 4-2-1/Figure 3.

5.9.2(a) Calculation of nominal alternating bending and shearing stresses. In general, thecalculation is carried out in such a way that the individual radial forces acting upon the crankpin owing to cylinder pressure and inertia forces will be calculated and considered for allcrank positions within one working cycle. The nominal alternating bending moment is to bedetermined by the following equation.

MBN = 0.5(MBmax MBmin)

where

MBN = nominal alternating bending moment; Nmm (kgf-mm, lbf-in)

MBmax = maximum bending moment during one working cycle; Nmm (kgf-mm,lbf-in)



MBmin = minimum bending moment during one working cycle; Nmm (kgf-mm,lbf-in)

The nominal alternating bending stress is to be modified by the empirical factor Ke whichconsiders the influence of adjacent cranks and bearing restraint.

eq

eBNBN W

KM =

6

2WBWeq

=

where

BN = nominal alternating bending stress; N/mm2 (kgf/mm2, psi)

Weq = equatorial moment of resistance related to cross-sectional area of web

(section modulus); mm3 (mm3, in3)

B, W = see 4-2-1/Figure 3; mm (mm, in.)

Ke = 0.8 for crosshead engines; 1.0 for other engines

In case of V-type engines, the bending moments calculated from the cylinder pressure andinertia forces of the two cylinders acting on one crank throw are to be superimposedaccording to phase.

Where there are cranks of different geometrical configuration (e.g., asymmetric cranks) in onecrankshaft, the calculation is to cover all crank variants. The nominal alternating shearingstress is to be determined by the following equation:

F

KQ eNQN

=

QN = 0.5 (Qmax Qmin)

WBF =

where

QN = nominal alternating stress due to shearing force; N/mm2 (kgf/mm2,

lbf/in2)

QN = nominal alternating shearing force; N (kgf, lbf)

Qmax = maximum shear force during one working cycle; N (kgf, lbf)

Qmin = minimum shear force during one working cycle; N (kgf, lbf)

F = area related to cross-section of web; mm2 (mm2, in2)

B, W = see 4-2-1/Figure 3

5.9.2(b) Calculation of alternating bending stresses in fillets. The alternating bendingstresses are to be determined for the crankpin fillet as well as for the journal fillet.

For the crankpin fillet:

BH = B BN

where



BH = alternating bending stress in crankpin fillet; N/mm2 (kgf/mm2, lbf/in2)

B = stress concentration factor for bending in crankpin fillet

For the journal fillet:

BG = (B BN + Q QN)where

BG = alternating stresses in journal fillet; N/mm2 (kgf/mm2, lbf/in2)

B = stress concentration factor for bending in journal filletQ = stress concentration factor for shearing

5.9.2(c) Calculation of alternating torsional stresses. The calculation for nominal alternatingtorsional stresses is to be determined by the engine manufacturer as indicated below.

The maximum value obtained will be used when determining the equivalent alternating stress.In the absence of such a maximum value (such as when a prototype design is submittedwithout an actual installation), it will be necessary to incorporate a fixed value based on theallowable vibratory stresses from 4-3-2/7.5.1 in the calculation for the crankshaft dimensionson the basis of an estimation.

5.9.2(d) Calculation of nominal alternating torsional stresses. The maximum and minimumalternating torques are to be ascertained for every mass point of the system and for the entirespeed range by means of a harmonic synthesis of the forced vibrations:

for 2-stroke cycle engines, from the first order up to and including the 15th order; and

for 4-stroke cycle engines from the 0.5th order up to and including the 12th order.

Allowance must be made for the dampings that exist in the system and for unfavorableconditions (misfiring in one of the cylinders).

The nominal alternating torsional stress in every mass point, which is essential to theassessment, is to be determined from the following equations.

p

TN W

M=

MT = 0.5(MTmax MTmin)

D

DDW BHp

16

)( 44 =

or

G

BGG

D

DD

16

)( 44

where

N = nominal alternating torsional stress referred to crankpin or journal;

N/mm2 (kgf/mm2, lbf/in2)

MT = nominal alternating torque; N-mm (kgf-mm, lbf-in)

Wp = polar moment of resistance related to cross-sectional area of bored

crankpin or bored journal; mm3 (mm3, in3)

MTmax = maximum torsional moment during one working cycle with considerationof mean torque; N-mm (kgf-mm, lbf-in)



MTmin = minimum torsional moment during one working cycle with considerationof mean torque; N-mm (kgf-mm, lbf-in)

D, DG, DBH, DBG, = see 4-2-1/Figure 3; mm (mm, in.)

The assessment of the crankshaft is based on the alternating torsional stress which inconjunction with the associated bending stress, results in the lowest acceptability factor (see4-2-1/5.9.8). Where barred speed ranges are necessary, the torsional stresses within theseranges are to be neglected in the calculation of the acceptability factor.

Barred speed ranges are to be so arranged that satisfactory operation is possible despite theirexistence.

5.9.2(e) Calculation of alternating torsional stress in fillets. The alternating torsionalstresses are to be determined for both the crankpin and the journal fillets by the followingequations:


H = T N

where

H = alternating torsional stress in crankpin fillet; N/mm2, (kgf/mm2, lbf/in2)

T = stress concentration factor for torsion in crankpin fillet or pins

N = nominal alternating torsional stress referred to crankpin or journal;

N/mm2 (kgf/mm2, lbf/in2)


G = T Nwhere

G = alternating torsional stress in journal fillet; N/mm2, (kgf/mm2, lbf/in2)

T = stress concentration factor for torsion in journal filletN = nominal alternating torsional stress referred to crankpin or journal;

N/mm2, (kgf/mm2, lbf/in2)

5.9.2(f) Calculations of nominal torsional stress for the crankpin/journal centers. Thenominal torsional stresses are to be determined at the neutral axis for consideration of the oilholes. If the oil holes are not on the neutral axis, calculations are to be submitted consideringthe additional bending load on the section.

The corresponding alternating torsional stress is to be determined from the followingequations:

p

TTNM W

MM )(5.0 minmax =

D

DDW BHp

16

)( 44 =

where

= stress concentration factor for torsion at the oil hole



NM = alternating torsional stress in the oil holes; N/ mm2, (kgf/mm2, lbf/in2)

MTmax = maximum torsional moment during one working cycle with theconsideration of the mean torque

MTmin = minimum torsional moment during one working cycle with theconsideration of the mean torque

D, DBH = see 4-2-1/Figure 3; mm (mm, in.)

5.9.3 Calculation of Stress Concentration Factors 4-2-1/5.9.3

Where the stress concentration factors cannot be furnished by actual measurements, thevalues may be evaluated by means of the equations below which are applicable to the filletsof solid-forged web-type crankshafts and to the crankpin fillets of semi-built crankshafts only.

Crank dimensions for calculation of stress concentration factors are shown in 4-2-1/Figure 3.

5.9.3(a) Actual dimensions and ratios

B = web width; mm (mm, in.)

D = crankpin diameter; mm (mm, in.)

DBG = diameter of bore in journal; mm (mm, in.)

DBH = diameter of bore in crankpin; mm (mm, in.)

DG = journal diameter; mm (mm, in.)

E = pin eccentricity; mm (mm, in.)

L1, L2, L3 = see 4-2-1/5.9.2 and 4-2-1/Figure 1 and 4-2-1/Figure 2; mm (mm, in.)

RG = fillet radius of journal; mm (mm, in.)

RH = fillet radius of crankpin; mm (mm, in.)

S = pin overlap = [(D + DG)/2] E; mm (mm, in.)

TG = recess of journal; mm (mm, in.)

TH = recess of crankpin; mm (mm, in.)

W = web thickness; mm (mm, in.)

The following ratios of dimensions will apply for the calculation of stress concentrationfactors:

rp = crankpin fillets = RH /D

rj = journal fillets = RG /D

s = S/D

w = W/D

b = B/D

dG = DBG /D

dH = DBH /D

tH = TH /D

tG = TG /D



The stress concentration factor calculations are valid only if ratios of dimensions are withinthe following limits:

0.5 s 0.7

0.2 w 0.8

1.2 b 2.2

0.03 r, rp, rj 0.13

0 dG 0.8

0 dH 0.8

The factor, f(recess) which accounts for the influence of a recess in the fillets is valid if

tH RH /D, tG RG /D

and is to be applied within the range

0.3 s 0.5

5.9.3(b) Crankpin fillet. The stress concentration factor for bending (B) is to be determinedfrom the following equation:

B = 2.7 (s, w) (w) (b) (r) (dG) (dH) (recess)f(s,w) = 4.19 + 29.2w 77.59w2 + 91.95w3 40.05w4 + (1 s) (9.54 58.35w

+ 159.35w2 192.58w3 + 85.29w4) + (1 s)2 ( 3.84 + 25.04w 70.56w2

+ 87.04w3 39.18w4)

f(w) = 2.18w0.72

f(b) = 0.68 0.01b + 0.15b2

f(r) = 0.21rp0.52

f(dG) = 1.0 + 0.27dG 1.02dG2+ 0.53dG

3

f(dH) = 1 + 0.31dH 1.52dH2+ 2.41dH

3

f(recess) = 1 + (tH + tG) (1.8 + 3.2s)

The stress concentration factor for torsion (T) is to be determined from the following

equations.

T = 0.8 fT(r,s) fT(b) fT(w)

[ ])1(1.032.0),( spT rsrf +=

fT(b) = 7.9 10.65b+ 5.35b2 0.86b3

fT(w) = w0.15

5.9.3(c) Journal fillet. The stress concentration factor for bending B is to be determinedfrom the following equations:

B = 2.7 fB(s,w) fB(w) fB(b) fB(r) fB(dG) fB(dH) f(recess)fB(s,w) = 1.76 + 2.99w 1.53w

2 + (1 s) (5.12 5.81w + 3.12w2) + (1 s)2

( 2.16 + 2.33w 1.3w2)



fB(w) = 2.24w0.75

fB(b) = 0.56 + 0.12 b + 0.12 b2

fB(r) = 0.19rj0.56

fB(dG) = 1.0 0.64dG + 1.23dG2

fB(dH) = 1.0 0.19dH + 0.01dH2

f(recess) = 1 + (tH + tG) (1.8 + 3.2s)

The stress concentration factor for shearing Q, is to be determined from the followingequation:

Q = 3.01 fQ (s) fQ (w) fQ (b) fQ (r) fQ (dH) f(recess)fQ (s) = 0.44 + 2.16 (1 s) 1.52 (1 s)

2

fQ (w) = w/(0.06 + 0.94w)

fQ (b) = 0.5 + b

fQ (r) = 0.53 rj0.2

fQ (dH) = 1.0 1.19dH + 1.74dH2

f(recess) = 1 + (tH + tG) (1.8 + 3.2s)

The stress concentration factor for alternating torsion T is:T = T

if the diameters and fillet radii of crankpin and journal are the same, or

T = 0.8 fT(r,s) fT(b) fT(w)if crankpin and journal diameters and/or radii are of different sizes. fT(r,s), fT(b) and fT(w) are

to be determined in accordance with the calculations of T, however, the radius of the journalfillet is to be related to the journal diameter,

r = RG /DG

and used in lieu of rp in determining fT(r, s) above for T.5.9.3(d) Oil hole. The stress concentration factor for torsion is

= 1.65.

The oil hole diameter is to be in the range up to 25 percent of D and the edge radius is not tobe less than 1/3 of the oil hole diameter. The oil holes are assumed to be positioned near theneutral axis. If this is not the case the effects of bending moment is to be included in theanalysis. Stress concentration data for the oil hole will be required for other units.

5.9.4 Additional Bending Stresses 4-2-1/5.9.4

In addition to the alternating bending stresses in fillets (see 4-2-1/5.9.2), further bendingstresses due to misalignment and bedplate deformation as well as due to axial and bendingvibrations are to be considered by applying add as given by the table below.



add

N/mm2 kgf/mm2 psi

Crosshead engines 30 3 4350Trunk piston engines 10 1 1450

5.9.5 Calculation of Equivalent Alternating Stress 4-2-1/5.9.5

The equivalent alternating stress is to be calculated for the crankpin fillet as well as for thejournal fillet. In this it is assumed that the maximum alternating bending stresses andmaximum alternating torsional stresses within a crankshaft occur simultaneously and at thesame point.

The equivalent alternating stress is to be determined in accordance with the followingequations.


22 3 HaddBHv + ) +( =


22 3 GaddBGv + ) +( =

For the oil hole:

( )23 NMv =where v = equivalent alternating stress; N/mm

2 (kgf/mm2, lbf/in2)

5.9.6 Calculation of Fatigue Strength 4-2-1/5.9.6

The fatigue strength is that value of alternating bending stress which a crankshaft canpermanently withstand at the most highly stressed points of the fillets.

Where the fatigue strength for a crankshaft cannot be furnished by reliable measurements, thefatigue strength may be determined by means of the following equations.

Related to the crankpin diameter:

}{

+

+++=

B

HBBDW

Rc

c

cDccK

/126.042.0 5

4

32.021

Related to the journal diameter:

}{

+

+++=

B

GBGBDW

Rc

c

cDccK

/126.042.0 5

4

32.0

21

Related to the pin oil hole:

}{

+++=

4

32.021 26.042.0 c

cDccK BBDW



where

DW = calculated fatigue strength of crankshaft; N/mm2 (kgf/mm2, lbf/in2)

K = factor for different type of forged and cast crankshafts without surfacetreatment

= 1.05 for continuous grain flow forged or closed die crankshafts

= 1.0 for open die forged crankshafts

= 0.93 for cast steel crankshafts

B = minimum tensile strength of crankshaft material; N/mm2 (kgf/mm2,

lbf/in2)

c1, c2, c3, c4, c5 are given in the table below.

SI units MKS units US units

c1 39.3 4 5700

c2 1.1 1.1 0.576

c3 785 80 113850

c4 4900 500 711000

c5 196 20 5640

It is to be considered that for calculations purposes RH and RG are not to be taken less than2 mm (0.08 in).

Surface strengthened crankshaft strength will be subject to special consideration. Whereresults of fatigue tests conducted on full size crank throws or crankshafts which have beensubjected to surface treatment are not available, the K-factors for crankshafts without surfacetreatment are to be used and strength is to be taken as that of the untreated materials.

In each case the experimental values of fatigue strength carried out with full size crank throwsor crankshafts are subject to special consideration.

The survival probability for fatigue strength values derived from testing is to be in principlenot less than 80%.

5.9.7 Calculation of Shrink-fits of Semi-built Crankshafts 4-2-1/5.9.7

Crank dimensions for the calculation of the shrink-fit are shown in 4-2-1/Figure 4.

DS = shrink diameter; mm (mm, in)

LS = length of shrink-fit; mm (mm, in)

DA = outside diameter of web; mm (mm, in), or twice the minimum distance xbetween centerline of journals and outer contour of web, whichever isless

y = distance between the adjacent generating lines of journal and pin; mm(mm, in)

y 0.05DS

Where y is less than 0.1DS special consideration is to be given to the effect of the stress due tothe shrink-fit on the fatigue strength at the crankpin fillet. For other parameters see4-2-1/Figure 3.



Respecting the radius of the transition from the journal to the shrink diameter, the followingshould be complied with,

RG 0.015 DG and RG 0.5 (DS DG)

where the greater value is to be considered.

The actual oversize Z of the shrink-fit must be within the limits Zmin and Zmax calculated bythe following equations.

5.9.7(a) Minimum oversize of shrink-fit. The minimum oversize of the shrink-fit is to bedetermined by the following equations.

The calculation of the minimum oversize is to be carried out for the crank throw with theabsolute maximum torque Mmax. The torque Mmax corresponds to the maximum value of thetorque MTmax used to calculate the nominal alternating torsional stress for the various masspoints of the crankshaft.

( )( )

=22

22

22

maxmin

11

124

SA

SA

m QQ

QQ

LDE

MZ

A

SA D

DQ = ,

S

BGS D

DQ =

= 0.20 for LS /DS 0.40

where

Zmin = minimum oversize of shrink-fit; mm (mm, in)

QA,QS = ratio of different diameters

= coefficient for static frictionEm = Youngs modulus; N/mm

2, kgf/mm2, lbf/in2)

5.9.7(b) Maximum permissible oversize of shrink-fit. The maximum permissible oversize ofthe shrink-fit is calculated in accordance with the following formula.

1000

8.0max

S

m

SS D

E

DZ +

=

where

Zmax = maximum oversize of shrink-fit; mm (mm, in)

S = minimum yield strength of material for crank web; N/mm2, kgf/mm2,

lbf/in2)

5.9.8 Acceptability Criteria 4-2-1/5.9.8

The crankshaft is to have an acceptability factor of at least 1.15. The acceptability factor is tobe determined for the crankpin fillet, the journal fillet and the oil hole in the crankpin, and isto be in accordance with the following equation.

v

DWQ

=

where Q = acceptability factor.



5.9.9 Other Reciprocating Components 4-2-1/5.9.9

All other reciprocating components (e.g., connecting rod) are to have acceptability factors ofat least 1.15. Tightening torques are to be submitted for pretensioned bolts/studs.

5.11 Shaft Couplings and Clutches 4-2-1/5.11

The design and construction of fitted bolt and non-fitted bolt couplings, flexible couplings andclutches is to be in accordance with the provisions of 4-3-2/5.19.

7 Engine Appurtenances 4-2-1/7

7.1 Explosion Relief Valves 4-2-1/7.1

7.1.1 Application 4-2-1/7.1.1

Explosion relief valves of an approved type are to be installed on enclosed crankcases of allengines having a cylinder bore of 200 mm (8 in.) or above or having a crankcase grossvolume of 0.6 m3 (21 ft3) or above.

7.1.2 Valve Construction and Sizing 4-2-1/7.1.2

The free area of each explosion relief valve is not to be less than 45 cm2 (7 in2), and the totalfree area of all relief valves is to be not less than 115 cm2 for each cubic meter (1 in2 for each2 ft3) of crankcase gross volume. The volume of the fixed parts in the crankcase may bededucted in estimating gross volume.

The explosion relief valves are to be of the return-seating type, are to relieve the pressure readily atnot more than 0.2 bar (0.2 kgf/cm2, 2.85 lbf/in2), and are to close quickly in order to prevent an in-rush of air.

In the arrangement and location of valves, consideration is to be given to minimizing thedanger from emission of flame.

7.1.3 Location of Valves 4-2-1/7.1.3

Engines having a bore of 200 mm (8 in.) and above, but not exceeding 250 mm (10 in.), are tohave at least one valve near each end. However for engines with more than 8 crank throws, anadditional valve is to be fitted near the middle of the engine.

Engines having a bore exceeding 250 mm (10 in.), but not exceeding 300 mm (11.8 in.), areto have at least one valve in way of each alternate crank throw, with a minimum of twovalves.

Engines having a bore exceeding 300 mm (11.8 in.) are to have at least one valve in way ofeach main crank throw.

7.1.4 Other Compartments of Crankcase 4-2-1/7.1.4

Additional relief valves are to be fitted on separate spaces of the crankcase such as gear orchain cases for camshaft or similar drives when the gross volume of such spaces is 0.6 m3

(21 ft3) and above.

7.1.5 Scavenge Spaces 4-2-1/7.1.5

Explosion relief valves are to be fitted in scavenge spaces which are in open connection to thecylinders for engines having a cylinder diameter greater than 230 mm (91/16 in.).



7.3 Governors and Overspeed Protection 4-2-1/7.3

7.3.1 Governors 4-2-1/7.3.1

All diesel engines, except those driving electric generators (see 4-2-1/7.5), are to be fittedwith governors which will prevent the engines from exceeding the rated speed by more than15%.

7.3.2 Overspeed Protective Device 4-2-1/7.3.2

In addition to the governor, each main propulsion engine having

abs rules part 4: craft systems and machinery

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