Leakage Detection !!!!!!!!!!!!!

MAN B&W
Page 1 of 13
Leakage Detection Ident No.: 0744836-6

How to detect for leakage on the ME-GA-system
This document is valid for existing engine Production Recommendation

types on order as of the date of this docu-
ment: 0744836-6.1
Engine types: January 2022

All ME-GA engine types
Info No: 7P2001
Structure No: 21-5402
Replaces:
Scope and Field of Application

This Production Recommendation describes
of how to locate a leakage on the assembled
ME-GA engine. It covers the gas system com-
ponents, such as: Spool piece, Gas Regulating
Unit, Flange connections, Safe Gas Admission
Valve, Connection piece, Nitrogen Purge Block.
It applies to complete engine at engine builder

facilities, shipyard or engine in service.
Document history
Date Designer Checked AC Revision change Revision
2021-05-11 VAFI PYB 0
2022-01-31 VAFI ABH Z3 General update 1
2
3
Copyright © 2022 MAN Energy Solutions, branch of MAN Energy Solutions SE, Germany MAN Energy Solutions
Registered with the Danish Commerce and Companies Agency under CVR-no. 31611792 (referred to as “MAN Energy Solutions”). Teglholmsgade 41, 2450 Copenhagen SV, Denmark
This document is the property of MAN Energy Solutions and is to be treated as confidential by the party to whom it has been submitted by MAN Phone +45 33 85 11 00
Energy Solutions, and may not be disclosed to any third party without the specific prior written permission of MAN Energy Solutions. E-mail info-cph@man-es.com
This document may be a translation of an original English language document. In case of any discrepancy between the original English Web www.man-es.com
language document and this translation, it is always the original English language document which shall prevail.
The original English language document may have been replaced by a later version, in which case only such later version shall be valid.
Production Recommendation 0744836-6.1
Page 2 of 13
Contents Changes in this revision:

1. Introduction��3 General update
2. References��3
3. Abbreviations��3
4. Tools��3
5. Safety precautions��4
6. Description of the leakage detection principles��4
6.1. How to pressurize the supply system with nitrogen (N2)4
6.2. Gas leakage detection tool 5
7. ME-GA Components��6
7.1. Gas Regulating Unit (GRU) 7
7.2. Flange connection 8
7.3. Safe Gas Admission Valve (SGAV) 9
7.4. Nitrogen purge block and connection piece 10
8. Replacing a leaking component�� 13
9. Concluding leaking search�� 13

Copyright © 2022 MAN Energy Solutions, branch of MAN Energy Solutions SE, Germany 0744836-6. How to detect for leakage on the ME-GA-system
Page 3 of 13
1. Introduction
The purpose of this procedure is to describe of how to locate a leakage on the assembled engine,
when the hydrocarbon system has registered unacceptably high levels of gas in the ventilation
channel. The design of engine components may vary, therefore the illustrations in this procedure
are examples for guidance only.
2. References
MAN B&W Quality Specification:
No. 0743525-7; Pressure and Functional Test of Components.
MAN B&W Production Specification:

No. 0743827-7; Tightness Verification of Supply System before Engine Running on Second Fuel.
MAN B&W Safety Regulation:

No. 0743742-5; Safety Precautions while Working in an Engine Room.
No. 0743874-3; Safety Precautions while Working in a Workshop.
3. Abbreviations
GRU: Gas Regulating Unit.
SGAV: Safe Gas Admission Valve.
4. Tools
Equipment:
1. Hose, airtight sealing, cup and water.
2. Tools for leakage search, request design spec. specific tools with MAN Energy Solutions.
3. Supply of N2 at 14 barG.
4. Extra spare sealing rings.

Page 4 of 13
5. Safety precautions
All local safety requirements must be followed.
Please acquire Safety Data Sheets for all components handled during production. Please also see
MAN B&W Safety Regulation No. 0743742-5; Safety Precautions while Working in an Engine Room.
It is under no circumstances allowed to detect for second fuel leakage by removing detection plugs
while there is second fuel on the system. Detection is only allowed after purging with N2.
Note! If there is a leakage of second fuel from inner to outer pipe while a detection plug is not in
place, it will leak into the engine room. Therefore always remember to replace detection
plug after removal. Engine room must be in accordance with Class rules/IMO IGF code.
Furthermore it is assumed that the engine is evacuated from all personnel not relevant to the test.
The turning gear must be disengaged and the indicator cocks must be open.
6. Description of the leakage detection principles

When a leakage is detected by the HC sensor:
Shut down fuel supply.
Empty fuel supply line.
Purge with N2 as per maintenance protocol.
Note! Before a leakage search can be performed the system must be fully operational, mean-
ing that all valves shall be connected and functioning with correct supply of control oil,
LPS and sealing oil.
6.1. How to pressurize the supply system with nitrogen (N2)

Before proceeding with the leakage detection the system must be pressurized with N2 via the
purge block. This procedure is described into details in 0744836-6.

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6.2. Gas leakage detection tool

The leakage detection concept is easy to use and straight forward. Basically one just have to
loosen and remove the plug screw and mount the gas leakage detection tool into the hole. After
that, place the hose into a water container and observe whether the connection is leaking or not.
Figure 1: Gas leakage tool.

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7. ME-GA Components
For new build it is recommended to start by checking if the leakage is coming from the engine side
of the GRU or the supply side of the GRU.
Note! If the leakage is coming from supply side of GRU this recommendation does not apply.
If the leakage is coming from the engine side, please check following connections/parts:
1. GRU (Gas Regulating Unit).
2. Flange connections.
3. SGAV (Safety Gas Admission Valve).
4. Connection piece.
5. Purge block.
4
Figure 2: General overview of the gas supply system.

Page 7 of 13
7.1. Gas Regulating Unit (GRU)

For gas leakage detection of GRU follow these steps:
1. Remove the plug screw for each of the five Gas Detection points (A to E).
2. Mount the leakage detection tool.
3. Place the clear hose inside a cup of water and count the bubbles.
4. Acceptance criteria is 5 bubbles in 5 min.
Each of the bellow mentioned plug screws (A to E) can be unscrewed in order to measure gas
leakage.
C) Gas Detection D) Gas Detection

PCV (piston GRU) outlet flange
RIGHT
B) Gas Detection E) Gas Detection

outlet flange BPV
LEFT (Bypass valve)
A) Gas Detection
Inlet flange
Figure 3: Overview of GRU’s gas leakage detection ports.

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7.2. Flange connection

The flange connection is equipped with an double o-ring system. If the inner o-ring is damaged
the gas leakage will flow into the outer ventilation pipe because of the gap between the plug screw
and the bottom of the hole. HC sensor will trigger an alarm if to high levels of hydrocarbons oc-
curs. Basically the gas leakage detection is to be done by removing the plug screw and mounting
the leakage tool as shown below.
Step 1: Remove the plug screw from the gas Step 2: Mount gas detection tool in the gas
detection hole. detection hole.
Example of a
damaged O-ring
Outer gas pipe
Inner gas pipe

(Ventilation)
(Gas inlet)
Plug screw depth

Step 3: Place the hose into a water container and start testing for leakage.

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7.3. Safe Gas Admission Valve (SGAV)

D1 to detect gas leakage from SPINDLE GUIDE (Window Valve).
D2 to detect gas leakage from SPINDLE GUIDE.
D3 to detect gas leakage and PT 6449/1.
D4 to detect gas leakage from SPINDLE GUIDE.
D1 &
SPINDLE
GUIDE
D4 &
SPINDLE
GUIDE
D3 & PT
6449/1
D2 & SPINDLE GUIDE

Page 10 of 13
7.4. Nitrogen purge block and connection piece

These two components are used for N2 purging in following situations: Engine shut-down and
start-up, gas leakage during engine running.
C

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7.4.1. Nitrogen purge block
D1 to detect gas leakage from side High pressure gas flange (right), close to valve 806.
D2 to detect gas leakage from Valve 806 (NO in order to avoid pressure build up between
806 and 809).
D3 to detect gas leakage from Valve 808 (NC).
D6 to detect gas leakage from side High pressure gas flange (left), close to valve 820.
7.4.1.1. Gas Detection when engine running (Gas running state)

If the HC sensor detects gas leakage in the outer pipe. In order to determine whether the leakage
is coming from the Nitrogen purge block, the following detection hole should be used:
D5 to detect from valve 820.

Page 12 of 13
7.4.1.2. Only to be used in special cases if N2 line is leaking. Tightness check of the other
valves on Nitrogen block
In order to check the tightness of the valves following sequence should be used.
Starting from N2 supply side, and continue as illustrated bellow:

To check 806: all valves closed.
To check 808: 806 open.
To check 809: 806, 808 open.
To check 820: 806, 808, 809 open.
N2 supply side 806 808 809 820 CH4 supply side
Close Close Close Close

Open Close Close Close
Open Open Close Close
Open Open Open Close
7.4.2. Connection piece

D1
D2
D3
D1 to detect gas leakage from Top flange connection.

D2 to detect gas leakage from Left side flange connection.
D3 to detect gas leakage from Right side flange connection.

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8. Replacing a leaking component

When replacing a leaking component:
Depressurize the system.
Ensure the system is completely depressurized, either by checking the MOP or an analogue
pressure gauge.
Replace component, re-assemble using correct assembly instruction (torque etc).
Re-Pressurize system with N2 at 11-14 bar(g).
Check the replaced component is not leaking.
Proceed with leakage search if there is still a leakage.
9. Concluding leaking search

When all leakages are amended, proceed to perform tightness test of engine with N2 at 11-14
bar(g). When the pressure is stabilized, leave the system pressurized for 1 hour. Acceptance cri-
teria: Pressure drop of maximum 0.3-0.4 bar(g).


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MAN B&W

Leakage Detection Ident No.: 0744836-6

This document is valid for existing engine Production Recommendation

Engine types: January 2022

Structure No: 21-5402

Scope and Field of Application

It applies to complete engine at engine builder

Contents Changes in this revision:

Date Designer Checked AC Revision change Revision

MAN B&W Production Specification:

MAN B&W Safety Regulation:

Date Designer Checked AC Revision change Revision

6. Description of the leakage detection principles

6.1. How to pressurize the supply system with nitrogen (N2)

Date Designer Checked AC Revision change Revision

6.2. Gas leakage detection tool

Figure 1: Gas leakage tool.

Date Designer Checked AC Revision change Revision

Figure 2: General overview of the gas supply system.

Date Designer Checked AC Revision change Revision

7.1. Gas Regulating Unit (GRU)

C) Gas Detection D) Gas Detection

B) Gas Detection E) Gas Detection

Figure 3: Overview of GRU’s gas leakage detection ports.

Date Designer Checked AC Revision change Revision

7.2. Flange connection

Outer gas pipe

Inner gas pipe

Plug screw depth

Date Designer Checked AC Revision change Revision

7.3. Safe Gas Admission Valve (SGAV)

D2 & SPINDLE GUIDE

Date Designer Checked AC Revision change Revision

7.4. Nitrogen purge block and connection piece

Date Designer Checked AC Revision change Revision

7.4.1. Nitrogen purge block

7.4.1.1. Gas Detection when engine running (Gas running state)

Date Designer Checked AC Revision change Revision

Starting from N2 supply side, and continue as illustrated bellow:

N2 supply side 806 808 809 820 CH4 supply side

Close Close Close Close

7.4.2. Connection piece

 D1 to detect gas leakage from Top flange connection.

Date Designer Checked AC Revision change Revision

8. Replacing a leaking component

9. Concluding leaking search

Date Designer Checked AC Revision change Revision

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D1 to detect gas leakage from Top flange connection.