Contents

Page
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Concrete Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Base Plate Alignment and Grouting . . . . . . . . . . . . . . . . . . . . . 5
Soil Conditions Compatibility with Engine Dynamics . . . . . . . 6
Quality Assurance Programme . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAN B&W Diesel Licensees . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Foundation Concept
for Stationary Low-speed Diesels
Introduction
For heavy-duty machinery, it is impera-
tive that the foundations are designed
to transmit the static and dynamic loads
to the subsoil.
The foundation concept for the MAN
B&W Diesel uniflow scavenged
two-stroke low-speed diesel engine
programme presented in this paper is
based on experience with engine foun-
dations both on board ships and in
stationary diesel power plants.
The current MAN B&W Diesel engine
programme has been continuously
developed over the past couple of
decades, and the engines which have
entered service in this period alone
represent more than 100 million bhp,
establishing a record of reliability and
providing extensive service experience.
Along with the engine design, MAN B&W
Diesel have, in close cooperation with a
joint consulting engineering company,
ISC Consulting Engineers A/S, devel-
oped a heavy-duty diesel engine/gen-
erator foundation concept adapted to
cater for the whole engine range.
The key-words for the engine/genera-
tor foundation concept are:
optimum reliability for the integrated
system
flexibility and adaptability to any
specific environmental condition
low cost thanks to a high degree of
pre-fabrication.
The foundation design can be supplied
as a complete package of construction
drawings and execution specifications,
together with a detailed inspection and
quality assurance programme.
Contracts for the delivery will then be
followed up by on-site guidance and
i nspection during the construction
period. A final inspection report con-
taining all data registered in the quality
assurance programme will be submit-
ted to the client at the delivery
hand-over.
System Concept
The most important feature of the foun-
dation concept is a built-up pre-fabri-
cated anchorage template system pro-
viding for the later installation of anchor
bolts, see Figs. 1, 2 and 3. The lattice
system is dismountable for easy trans-
port and reassembly on site to form a
torsionally-rigid lattice box beam. The
lattice beam is prepared for easy fixing
to the scaffolding system. Thus toler-
ances for the positioning of bolts are
determined by the steel workshop.
Furthermore, the oversize tubes allow
exact positioning of the anchor bolts,
even in cases of minor inaccuracies in
the position of bolt holes in the engine
base.
The anchorage system and traditional
base beam used in marine installations
have been integrated in one design,
thereby providing considerable simplifi-
cation of a complex transition to the
concrete block.
Any inaccuracies observed by inspection
of the compatibility between engine
3
Foundation Concept
for Stationary Low-speed Diesels
Fig. 1: Anchorage template systemtest mounted in the workshop Fig. 2: Anchorage template systemcompact assembled for transport
base, base beam and anchorage sys-
tem can be adjusted before shipment,
thereby avoiding costly work on site.
The concept introduced for the insertion
of anchor bolts allows for reliable pre-
stressing with a minimumof relaxation.
The system allows for replacement
of anchor bolts and any maintenance
checks of bolt pre-stressing, since
anchorage does not depend on the
cohesion strength of the concrete.
Concrete Technology
The foundation concept includes detailed
specification of concrete requirements
and casting procedures, as well as
recommendations for the selection of
cement types, aggregates, admixtures,
mixing time and plasticity requirements.
A thorough pre-investigation of envi-
ronmental conditions is part of the en-
gineering package to correlate applied
technology to available aggregates,
cement and local climatic conditions.
The foundation block should be cast in
only two continuous castings with the
construction joint positioned horizon-
tally above the base slab, see Fig. 5.
4
Fig. 3: Anchorage template systemand base beam
Fig. 4: Joint detail, engine base/base beam
1. Engine, 2. Anchor bolt, 3. Tube, 4. Washer,
5. Spherical washer, 6. Side chock, 7. Support
chock, 8. Base beam, 9. Concrete block,
10. Embeco grout, 11. Liner for side chock,
12. Protection cap
Base Plate Alignment and
Grouting
The engine foundation concept includes
base beams specifically adapted to
stationary installations dimensioned
for the purpose and for the structural
interaction with the concrete block, see
Fig. 4. The base beams are provided
with separate adjustment devices for
the easy fitting of the base beam to the
top of the anchor bolt arrangement. A
detailed recommendation for adjust-
ment and alignment of base plates
within the required tolerances is part
of the execution specification. Final
adjustment is achieved by means of
shims inserted between the base plate
and foundation, and rigid assembly
is provided by the tightening of the
anchor bolts. Grouting below the
base plate is to be executed using a
high-strength, non-shrinkable,
chemical-resistant type of grout.
5
Fig. 5: Elevation and cross section of engine mounted on the foundation
1. Engine, 2. Anchor bolt, 3. Tubular enclosure for anchor bolt, 4. Side chock, 5. Embeco grout, 6. Concrete block, 7. Generator
Soil Conditions Compatibility
with Engine Dynamics
The foundation can be adapted to suit
all subsoil conditions, allowing for direct
foundation, pile foundation or foun-
dation on an intermediate layer of
compacted gravel in cases where
vibrations may cause compaction of
the subsoil.
Verification of soil conditions, their
nature and propagation during and
after excavation, verification of any
built-up gravel layers, or verification
of the carrying capacity of piles during
the pile driving operation is a mandatory
part of the design and quality assurance
programmes.
Quality Assurance
Programme
The quality assurance programme forms
an integral part of the total design and
inspection documentation package.
The quality assurance programme
covers all aspects related to the fabrica-
tion phases of cast-in items such as
anchor bolts, template lattice girders
and base beams.
Quality Assurance also covers con-
struction on site, material properties,
concrete composition, tolerance
requirements, grouting, pre-stressing
procedure, special surface treatment,
checking of soil properties in the
excavation, etc.
6
Fig. 6: Exploded view of engine, anchorage system and foundation
1. Engine, 2. Anchor bolts, 3. Anchor bolt template box girder system, 4. Washer,
5. Spherical washer, 6. Side chock, 7. Support chock, 8. Base beam, 9. Concrete block,
10. Generator, 11. End chock
7
China, The Peoples Republic of
China Shipbuilding Trading Co. Ltd.
Dalian Marine Diesel Works
Hudong Heavy Machinery Co., Ltd.
9
Shanghai HHM
Shangchuan Diesel Co., Ltd.
Jimo Road 1,
Pudong
Shanghai 200120
Yichang Marine Diesel Engine Plant
Croatia
Brodosplit Brodogrdiliste d.o.o.
Uljanik Strojogradnja d.d.
Indonesia
P.T. Pal Indonesia
Japan
Hitachi Zosen Corporation
Machinery Division
Hitachi Zosen Nanko Bldg.
1-7-89 Manko Kita
Suminoe-ku
Osaka 559-8559
Kawasaki Heavy Industries Ltd.
World Trade Centre Bldg.
4-1 Hamamatsu-cho, 2-chome
Minato-ku
Tokyo 105-6116
Mitsui Engineering
& Shipbuilding Co., Ltd.
6-4, Tsukiji, 5-chome
Chou-ku
Tokyo 104-8439
Republic of Korea
HSD Engine Co., Ltd.
89-3, Sinchon-Dong
Changwon
Kyungnam 641-370
Hyundai Heavy Industries Co., Ltd.
Engine and Machinery Division
140-2 Kye-Dong
Chongro-ku
Seoul 110-793
Ssangyong Heavy Industries Co., Ltd.
Ssangyong Kangnam B/D
4th Floor
448-2, Dogok 2-dong
Kangnam-Ku
Seoul 135-272
Poland
H. Cegielski - Poznan S.A.
Ul. 28 Czerwca 1956
nr. 223/229
PL-60-965 Poznan
Rumania
U.C.M. Resita SA
Golului Street 1
R-1700 Resita
Russia
Bryansk Engineering Works
Ulyanova Street 26
241015 Bryansk
Spain
Manises Diesel Engine
Company S.A.
Avda. de Madrid 6 y 8
E-46930 Quart de Poblet
(Valencia)
Particulars quoted in this brochure are subject to revision without notice
MAN B&W Diesel Licensees