Technical File D3*GL*E3 According to Revised MARPOL Annex VI and NOx Technical Code 2008 Manufacturer: Engine Family: GL family approval no. Engine Type: AB Volvo Penta D3 14252-10 HH D3-200I-D, D3-200A-D Engine Serial no.: 14339 Date of Manufacture: 2009 Rated Power: 147 Rated Speed: 4000 Contents 1. Components, setting and operating values of the engine which influence NOx emissions 2. On board verification procedure 3. Test report of parent engine, E3. 4. Specification of spare parts D3(Tier II)*GL*E3*05 1 / 12
1. Components, setting and operating values of the engine that influence NOx emissions Sheet 1/5 D3-220I-D, D3-220A-D D3-220I-E, D3-220A-E D3-150I-D, D3-150I-E Common components of engine types: D3-200I-D, D3-200A-D D3-200I-E, D3-200A-E D3-170I-D, D3-170A-D D3-170I-E, D3-170A-E D3-140I-D, D3-140A-D D3-110I-D, D3-110I-E D3-140I-E, D3-140A-E ID-no. on component Volvo Penta part No. Remarks Cylinder Head 30777363 30777363 Inlet Camshaft 30777262 30777262 Exhaust Camshaft 31216227 31216227 Piston 31303100 31303100 Turbo Charger 21354008 21354008 Charge Air Cooler 21378472 21378472 Injector 31272690 31272690 Injector nozzle 31272690 31272690 Common Rail Pump 31272896 31272896 Common Rail 30777759 30777759 Engine Electronic Control Unit 21092158 21092158 Specific Settings Engine type D3-220I-D, D3-220A-D, D3-200I-D, D3-200A-D, D3-170I-D, D3-170A-D, D3-220I-E, D3-220A-E D3-200I-E, D3-200A-E D3-170I-E, D3-170A-E Power kw 162 147 125 Speed rpm 4000 4000 4000 Application(s) E3 E3 E3 Dataset, part no. 21454101 21454102 21480632 21480639 21518521 21532005 21532009 21576743 21650910 21650917 21400501 21400605 21480631 21480638 21518518 21533117 21533123 21576742 21650909 21650916 21400500 21400604 21480629 21480636 21518515 21533115 21533121 21576740 21650907 21650914 Engine type D3-150I-D, D3-150I-E D3-140I-D, D3-140A-D, D3-140I-E, D3-140A-E D3-110I-D, D3-110I-E Power kw 110 103 81 Speed rpm 3000 4000 3000 Application(s) E3 E3 E3 Dataset, part no. 21400499 21400498 21400496 21400603 21400602 21400601 21480628 21480627 21480626 21480635 21480634 21480633 21518512 21518506 21518503 21533114 21533113 21533112 21533120 21533119 21533118 21576739 21576738 21576737 21650906 21650905 21650904 21650913 21650912 21650911 D3(Tier II)*GL*E3*05 2 / 12
Sheet 2/5 Common components of engine types: D3-190 / D3-185 ID-no. on component Volvo Penta part No. Remarks Cylinder Head 30731986 Piston 30731890 Inlet Camshaft Exhaust Camshaft Turbo Charger 8699506 30677509 30750758 30731132 30750759 3819920 3847393 3819920 3847393 Charge Air Cooler 3812610 3812610 Common Rail Pump 3817389 3817389 Common Rail 3809500 3809500 Injector A 445 110 251 Injector nozzle 1497 Engine Electronic Control Unit 3586930 Specific Settings Engine type D3-190 D3-185 Power kw 140 136 Speed rpm 4000 4000 Application(s) E3 E3 ID-no. on component Volvo Penta part No. Dataset 1 3842195 21178354 21386821 3842195 21178354 D3(Tier II)*GL*E3*05 3 / 12
Common components within the engine family Sheet 3/5 D3-220I-F, D3-220A-F D3-200I-F, D3-200A-F D3-170I-F, D3-170A-F D3-150I-F D3-140I-F, D3-140A-F D3-110I-F ID-no. on component Volvo Penta part No. Remarks Cylinder Head 30777363 31359839 30777363 31359839 Inlet Camshaft 31258094 31258094 Exhaust Camshaft 31216227 31216227 Piston 31339220 31339220 Turbo Charger 21354008 21354008 Charge Air Cooler 21378472 21378472 Injector 31272690 31272690 Injector nozzle 31272690 31272690 Common Rail Pump 31272896 31272896 Common Rail 30777759 30777759 Engine Electronic Control Unit 21092158 21092158 Setting specific components Engine type D3-220I-F, D3-220A-F D3-200I-F, D3-200A-F D3-170I-F, D3-170A-F Power kw 162 147 125 Speed rpm 4000 4000 4000 Application(s) E3 E3 E3 Dataset, part no. 21693689 21693765 21848234 21848244 21930215 21693687 21693764 21848233 21848243 21930214 21693683 21693762 21848232 21848241 21930212 Engine type D3-150I-F D3-140I-F, D3-140A-F D3-110I-F Power kw 110 103 81 Speed rpm 3000 4000 3000 Application(s) E3 E3 E3 Dataset, part no. 21693682 21693760 21848231 21848239 21930210 21693673 21693758 21848229 21848238 21930209 21693666 21693751 21848227 21848237 21930207 D3(Tier II)*GL*E3*05 4 / 12
Common components within the engine family Sheet 4/5 D3-220I-G, D3-220A-G D3-200I-G, D3-200A-G D3-170I-G, D3-170A-G D3-150I-G D3-140I-G, D3-140A-G D3-110I-G ID-no. on component Volvo Penta part No. Remarks Cylinder Head 30777363 31359839 30777363 31359839 Inlet Camshaft 31258094 31258094 Exhaust Camshaft 31216227 31216227 Piston 31339220 31339220 Turbo Charger 21354008 21354008 Charge Air Cooler 21928775 21378472 21928775 21378472 Injector 31272690 31272690 Injector nozzle 31272690 31272690 Common Rail Pump 31272896 31272896 Common Rail 30777759 30777759 Engine Electronic Control Unit 21092158 21092158 Setting specific components Engine type D3-220I-G, D3-220A-G D3-200I-G, D3-200A-G D3-170I-G, D3-170A-G Power kw 162 147 125 Speed rpm 4000 4000 4000 Application(s) E3 E3 E3 Dataset, part no. 21848234 21930215 21848233 21930214 21848232 21930212 Engine type D3-150I-G D3-140I-G, D3-140A-G D3-110I-G Power kw 110 103 81 Speed rpm 3000 4000 3000 Application(s) E3 E3 E3 Dataset, part no. 21848231 21930210 21848229 21930209 21848227 21930207 D3(Tier II)*GL*E3*05 5 / 12
Settings Sheet 5/5 Maximum sea water temp D3I-D & D3I-E, D3A-I & D3A-D, if applicable 30 C Maximum sea water temp D3I-F & D3A-F, D3I-G & D3A-G if applicable 25 C Maximum charge air temperature 40 C Maximum charge air temperature (D3-190/D3-185) Maximum fresh water temp. from Keel Cooler, if applicable Low / high temp. cooling system set points Maximum inlet depression (D3-220/D3-200/D3-190/D3-170/ D3-150/D3-140/D3-110) Maximum exhaust back pressure (D3-220/D3-200/D3-190/D3-170/ D3-150/D3-140/D3-110) Fuel oil specification 45 C N/A N/A / 98 C 3,0 / 2,7 / 3,0 / 2,5 / 1,5 / 2,0 / 1,0 30 / 27 / 30/ 25 / 15 / 20 / 10 According to owner's manual Fuel oil temp. 40 C Lubricating oil specification According to owner's manual Please see section 3 Test report of parent engine for design details of the engine family. D3(Tier II)*GL*E3*05 6 / 12
2. On board verification procedure Component Procedure / location of ID-nos. Remarks Cylinder head The ID-no is located on the cylinder head at the glow plug side between glow plug 3-4, counting from the front of the engine Piston Check ID-no on piston crown. Inspection is recommended at overhaul when cylinder head is removed. Turbocharger Check ID-no on metal plate on compressor house. Injector Check Id-no on top of the injector. Injector nozzle Electronic control unit and data set Charge air cooler Compression ratio Camshaft Check the ID-no in the nozzle. The ID numbers can be checked by using a service shop diagnostic tool. Check the ID-number on the charge air cooler housing in the front. Determined by the correct piston and cylinder head combination. Inspection is recommended at overhaul when cylinder head is removed. The ID-no. is located at the end of the camshaft. Inspection is recommended at overhaul when valve cover is removed and the camshaft is visible.! Important! The ID-numbers that can not be controlled unless the engine is taken apart shall only be checked at regular overhaul when the engine is taken out of service and dismantled for maintenance. Check only if considerable doubt of the correctness of the ID-no exist. D3(Tier II)*GL*E3*05 7 / 12
3. Test report of parent engine Emission Test Report Sheet 1 of 4 Engine Information Manufacturer AB Volvo Penta Engine type D3-200I-D, D3-200A-D Family identification D3 Serial number 14339 Rated speed 4000 rpm Rated power 147 kw Intermediate speed N/A Maximum torque at intermediate speed N/A Static injection timing N/A Electronic injection control no: yes: X Variable injection timing no: yes: X Variable turbocharger geometry no: yes: X Bore 81 mm Stroke 93,2 mm Nominal compression ratio 16,5:1 Mean effective pressure, at rated power 1,84 MPa Maximum cylinder pressure, at rated power N/A Cylinder number and configuration Number: 5 V: In-line: X Auxiliaries None Specified Ambient Conditions Maximum inlet cooling water temperature 30 C Maximum charge air temperature, if applicable 40 C Cooling system spec. intermediate cooler no: yes: X Cooling system spec. charge air stages Single stage High temperature cooling system set points 98 C Maximum inlet depression 2,7 kpa Maximum exhaust back pressure 27 kpa Fuel oil specification VSD 10 (acc. to ISO 8217, ISO-F-DMA) Fuel oil temperature 40 C Lubricating oil specification VDS2 SAE 15W-40 Emissions Test Results Cycle NOx (g/kwh) Test number E3 7 28003695 Date/time 2009-06-17 Test site/bench Volvo Penta/Testcell 28 Surveyor Pierre Nordin, Germanischer Lloyd Date and Place of report Signature 2009-06-24, Gothenburg D3(Tier II)*GL*E3*05 8 / 12
Common Features Within the Engine Family Sheet 2 of 4 Family identification D3 Electronic injection control Yes Variable injection timing Yes Variable turbocharger geometry Yes Bore 81 mm Stroke 93,2 mm Nominal compression ratio 16,5:1 Nominal compression ratio (D3-190/D3-185) 17,3:1 Cylinder configuration 5, in-line Combustion cycle 4-stroke, compression ignition Cooling medium 50/50 glycol/water Method of aspiration Pressure charged Fuel type to be used on board Distillate fuel Combustion chamber Open chamber Valve and porting configuration 2 inlet valves Ø = 28 mm 2 exhaust valves Ø = 26 mm All valves are located in the cylinderhead Fuel system type Common rail Auxiliaries None Miscellaneous features Exhaust gas recirculation No Water injection / emulsion No Air injection No Charge cooling system Single stage, water to air Exhaust aftertreatment No Exhaust aftertreatment type N/A Dual fuel No Engine Family Information (selection of parent engine for test bed test) Family identification Method of pressure charging Charge air cooling system Criteria of the Selection (specify) D3 Turbo charger Single stage, water to air Maximum NOx cycle emission (g/kwh) Engine D3-220I-D, D3-220A-D D3-220I-E, D3-220A-E D3-220I-F, D3-220A-F D3-220I-G, D3-220A-G D3-200I-D, D3-200A-D D3-200I-E, D3-200A-E D3-200I-F, D3-200A-F D3-200I-G, D3-200A-G D3-170I-D, D3-170A-D D3-170I-E, D3-170A-E D3-170I-F, D3-170A-F D3-170I-G, D3-170A-G D3-150I-D D3-150I-E D3-150I-F D3-150I-G Number of cylinder 5 5 5 5 Max. rated power per cyl. 32,4 29,4 25 22 Rated speed 4000 4000 4000 3000 Injection timing (range) Variable Variable Variable Variable Max. fuel parent engine 57 Selected parent engine X Application(s) E3 E3 E3 E3 Engine D3-140I-D, D3-140A-D D3-140I-E, D3-140A-E D3-140I-F, D3-140A-F D3-140I-G, D3-140A-G D3-110I-D D3-110I-E D3-110I-F D3-110I-G D3-190 D3-185 Number of cylinder 5 5 5 5 Max. rated power per cyl. 20,6 16,2 28 27,2 Rated speed 4000 3000 4000 4000 Injection timing (range) Variable Variable Variable Variable Max. fuel parent engine Selected parent engine Application(s) E3 E3 E3 E3 D3(Tier II)*GL*E3*05 9 / 12
Emission Test Report Sheet 3 of 4 Exhaust Pipe Diameter 150 mm Length 7 m Insulation no: yes: X Probe location 2 m Remark Measurement Equipment Manufacturer Model Measurement ranges Analyser Span gas conc. Calibration Deviation NOx Analyser Horiba CLA-755A 0-2000 ppm 1863 < ±2% or 0.3% of full scale 0-500 ppm 490 < ±2% or 0.3% of full scale CO Analyser Horiba AIA-721A 0-300 ppm 298 < ±2% or 0.3% of full scale 0-100 ppm 99,5 < ±2% or 0.3% of full scale CO 2 Analyser Horiba AIA-722 0-15 % 14,81 < ±2% or 0.3% of full scale O 2 Analyser Horiba MPA-720 25 % 24,64 < ±2% or 0.3% of full scale HC Analyser Horiba FIA-725A 0-1000 ppm 973,8 < ±2% or 0.3% of full scale 0-100 ppm 94,2 < ±2% or 0.3% of full scale Speed Schenck WT2-380 0-7500 rpm <± 2% of reading or ± 1% of engines maximum value Torque Schenck D1200 0-5500 Nm <± 2% of reading or ± 1% of engines maximum value Power, if applicable calculated Fuel flow ASE Xact-2000 1-350 lit/h < ± 2% Air flow Westwind 6" 167-2548 m³/h < ± 2% of reading or ± 1% of engines maximum value Exhaust flow calculated Temperatures Coolant Heraeus type-k 0-150 C < ± 2K absolute Exhaust gas Heraeus type-k 0-800 C < ± 1 % absolute Inlet air Pentronic type-pt100 0-100 C < ± 2 C absolute Intercooled air Heraeus type-k 0-150 C < ± 2K absolute Fuel Heraeus type-k 0-150 C < ± 2K absolute Pressures Exhaust gas WIKA -10-45 kpa < ± 0,2 kpa Absolute Inlet manifold WIKA -10-0 kpa < 5% Atmospheric Druck Ltd. 0-1,6 bar < ± 0,1 kpa Absolute Vapour pressure Intake air Intake air Fuel type General Eastern DEW-10-0A2 calculated Humidity Fuel Characteristics CEC: VSD 10 (acc. to ISO 8217, ISO-F-DMA) Fuel Properties 0-100 % < ±1% of point Fuel Elemental Analysis Density, at 15 C ISO 12185 835,4 kg/m3 Carbon 86,5 % mass Viscosity, at 40 C ISO 3104 2,761 mm2/s Hydrogen 13,5 % mass Water 32 mg/kg Nitrogen <0,01 % mass Oxygen < 0,1 % mass Sulphur 0,07 % mass LHV/Hu 42,93 MJ/kg D3(Tier II)*GL*E3*05 10 / 12
Emission test report of parent engine, E3-cycle E3-cycle Emission Test Report Sheet 4 of 4 Mode 1 2 3 4 Power/Torque % 100 75 50 25 Speed % 100 91 80 63 Time at beginning of mode Ambient Data Atmospheric pressure kpa 101,7 101,7 101,7 101,7 Intake air temperature C 26 26 26 26 Intake air humidity g/kg 7,5 7,5 7,5 7,8 Rel. Hum % 37,4 37,2 37,6 39,5 Air temp at rel. h sensor C 25,3 25,5 25,3 25,2 Atmospheric factor (f a) 0,99 0,99 0,99 0,99 Gaseous Emission Data NOx concentration dry/wet ppm 1023 884 679 513 CO concentration dry/wet ppm 240 55 67 142 CO 2 concentration dry/wet % 10,7 8,4 7,7 7,1 O 2 concentration dry/wet % 6 9,2 10,1 10,9 HC concentration dry/wet ppm 21 31 37 54 NOx humidity correction factor 0,95 0,95 0,95 0,96 Dry/wet correction factor 0,91 0,93 0,93 0,94 NOx mass flow g/h 1032 810 446 193 CO mass flow g/h 154 32 28 34 CO 2 mass flow kg/h 108 77 50,8 26,8 O 2 mass flow kg/h 44,2 61,4 48,2 30,1 HC mass flow g/h 7 10 8 7 NOx specific g/kwh 7 7,4 6,1 5,3 CO specific g/kwh 1,1 0,3 0,4 0,9 CO 2 specific g/kwh 738 702 692 731 HC specific g/kwh 0,1 0,1 0,1 0,2 Engine Data Speed rpm 4000 3640 3200 2520 Auxiliary power kw 0 0 0 0 Dynamometer setting kw 147 110,2 73,4 36,7 Power kw 147 110 73 37 Mean effective pressure MPa 1,84 1,51 1,15 0,73 Fuel rack mm - - - - Uncorrected specific fuel consumption g/kwh 234 221 221 233 Fuel flow kg/h 35 24 16 9 Air flow kg/h 702 634 450 259 Exhaust flow (gexhw) kg/h 738 659 468 266 Exhaust temperature C 582 439 403 379 Exhaust back pressure kpa 26,7 17,5 8,7 3 Charge air coolant in C - - - - Charge air coolant out C - - - - Charge air temp C 39 37 34 31 Charge air ref temp C 34 32 29 26 Inlet depression kpa -2,6-2,1-1 -0,2 Charge air pressure kpa 147 135 91 39 Fuel oil temp C 40 40 40 40 D3(Tier II)*GL*E3*05 11 / 12
4. Specification of spare parts Ship owners or persons responsible for ships required to undergo an engine parameter check method shall maintain on board a record book of engine parameters for recording of all the changes made relative to an engine s components and settings. If any adjustments or modifications are made to any engine after its delivery from Volvo Penta, a full record of such adjustments or modifications shall be recorded in the engine s record book of engine parameters. Any changes or modifications of the approved parameters and components of this engine that are not allowed by Volvo Penta may result in that the engine no longer complies with the approved specification. Volvo Penta has no responsibility for compliance if parts and components are used other than those authorized by Volvo Penta. D3(Tier II)*GL*E3*05 12 / 12