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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
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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
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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
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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
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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
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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.
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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
.
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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.
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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.
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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.
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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.
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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:
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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.
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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
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TABLE 2Certification Details Propulsion, Maneuvering
and Mooring Machinery
Type Approval Program (3)
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,
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TABLE 3Certification Details Electrical and Control
Equipment
Type Approval Program (3)
Product design assessment1-1-A1/5.1
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
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TABLE 4Certification Details Fire Safety Equipment
Type Approval Program (3)
Product design assessment1-1-A1/5.1
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.
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ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT .
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TABLE 5Certification Details Pressure Vessels
and Fired Equipment
Type Approval Program (3)
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.
2 See also 4-1-1/3.1. Notations used in this column are:
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.
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Part 4 Craft Systems and MachineryChapter 1 GeneralSection 1
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16 ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT .
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TABLE 6Certification Details Piping System Components
Type Approval Program (3)
Product design assessment1-1-A1/5.1
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.
2 See also 4-1-1/3.1. Notations used in this column are:
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.
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ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT .
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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.
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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
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20 ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT .
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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
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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
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22 ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT .
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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
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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.
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24 ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT .
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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)
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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.)
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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.
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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.
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28 ABS GUIDE FOR BUILDING AND CLASSING HIGH-SPEED NAVAL CRAFT .
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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.
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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)
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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
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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)
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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:
For the crankpin fillet:
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)
For the journal fillet:
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
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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
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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)
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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.
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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.
For the crankpin fillet:
22 3 HaddBHv + ) +( =
For the journal fillet:
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
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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.
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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.
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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.).
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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