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Wartsila Medium Speed Engines PDF
Wartsila Medium Speed Engines PDF
MEDIUM-SPEED ENGINES
Medium-speed diesel and dual-fuel
engines for reliability
and total economy .................................3
Compliance with environmental
regulations and other standards............4
Main features.........................................4
Engine performance ..............................5
Engine design ........................................6
Engine block......................................6 The Thetis, equipped with a Wärtsilä 20 engine. The submersible heavy load ship Blue Marlin is
Crankshaft and bearings.....................6 equipped with three Wärtsilä 8L32 engines.
Connecting rod ..................................7
Cylinder liner and antipolishing ring.....7
POWER RANGE FOR WÄRTSILÄ MEDIUMSPEED ENGINES
Piston & piston rings ..........................8
DIESEL ENGINES
Cylinder head.....................................8
Wärtsilä 20
Multiduct ...........................................9
Wärtsilä 26
Camshaft and valve gear ....................9
Wärtsilä 32
Operational systems
Wärtsilä 38
Fuel injection system........................10
Wärtsilä 46
Turbocharging system ......................11
Cooling system ................................12 Wärtsilä 46F
The Naval vessel De Zeven Provincien is equipped with The tanker Bitflower is equipped with a
two Wärtsilä 16V26 engines. Wärtsilä 6L38 engine.
3
COMPLIANCE WITH ENVIRONMENTAL REGULATIONS AND OTHER STANDARDS
Environmental issues, especially emissions NOx emissions, g/kWh
reduction and fuel consumption, have 20
become increasingly important in the 18
shipping sector where enforcement of 16
IMO Tier I, 2000
environmental regulations, at both global 14
4
ENGINE PERFORMANCE
Wärtsilä 4-stroke engines utilize the latest
developments in turbo-charging technology, which
enables Miller valve timing and the Variable Inlet
Valve Closing (VIC) system to be employed.
At full-load operation, early closure of the
inlet valves enables a low effective compression
ratio, and as a result, comparatively low
temperatures at the end of the compression
stroke. The charge air, being both somewhat
expanded and cooled on its way through the
receiver into the cylinders, has a low global
temperature that is still high enough to
guarantee reliable and stable ignition of the
fuel/air mixture in the combustion chamber.
This contributes to the creation of favourable
conditions for an environmentally friendly
combustion process.
In Wärtsilä engines, these advantageous
initial conditions are combined with a higher
engine speed and a high expansion ratio,
i.e. with design parameters that make the
combustion chamber expand quickly when
the combustion process has started. Due to
the quick expansion of the combustion gases,
high temperatures that are most critical to the
formation of intensive NOX within the combustion
chamber are rapidly abated. This combination
creates a combustion process that is not only
environmentally friendly, but also extremely
efficient as the high expansion ratio produces
the conditions needed for efficient utilization of
the heat energy released by combustion at the
beginning of the power stroke.
However, it is not only the choice of the
compression/expansion ratio that makes
Wärtsilä engines highly efficient. All versions
of the engine are equipped with fuel injection
systems that allow adjustment of the injection
characteristics to the prevailing load conditions.
The advanced common-rail fuel injection
system offers the freedom to control and fine-
tune the injection process. This enables full use
of the engine’s loading potential over a wide
power range in order to achieve optimum fuel
economy. Similarly, this freedom offered by the
flexible fuel injection equipment can be utilized
to adjust the engine to the existing limitations
of exhaust gas emissions, to minimize smoke
formation. Thermal load and mechanical stress
levels are kept within the safety margins
established by Wärtsilä over decades of engine
development.
5
ENGINE DESIGN
ENGINE BLOCK
Nodular cast iron is the natural choice for This is achieved by careful optimization of the A crankshaft line assembled from three
engine blocks today because of its strength crankshaft’s throw dimensions and fillets. The elements: the crankshaft, gear and end
and stiffness properties. Wärtsilä engine mono- specific bearing loads are conservative and piece. The crankshaft itself is forged in one
block designs are based on modern foundry the cylinder spacing, which is important to piece
technology to integrate most oil and water the overall length of the engine, is minimized. Each throw is fully balanced individually for
channels, as well as the charge air receiver. Besides low bearing loads, the other crucial safe bearing function
The result is a virtually pipe-free engine with a factor for safe bearing operation is oil film Main bearing temperature monitoring
clean outer exterior. thickness. Ample oil film thickness in the main Patented crankpin bearing temperature
Resilient mounting, available as an option, bearings is ensured by optimal balancing of the monitoring
is required in many application types. The rotational masses and, in the big end bearing, Modest bearing loads thanks to generous
engine block has been designed especially for by ungrooved bearing surfaces in the critical bearing dimensions.
this purpose. Integrated channels designed areas. All the factors needed for a free choice
with this in mind serve a double purpose. of the most appropriate bearing material are CONNECTING ROD
present.. The three-piece connecting rod is of the
CRANKSHAFT AND BEARINGS marine type used in Wärtsilä engines having
The latest advances in combustion The main features of the crankshaft and a cylinder power of more than 400 kW, where
development require a crank gear that can bearings design are: the combustion forces are distributed over
operate reliably at high cylinder pressures. Clean steel technology to minimize the a maximum bearing area, and the relative
The crankshaft must be robust and the amount of slag forming elements, and to movements between mating surfaces are
specific bearing loads kept at a safe level. guarantee superior material properties minimized. The connecting rod is optimized for
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both strength and weight. The shank is fully CYLINDER LINER AND ANTIPOLISHING RING position of the piston. The absence of contact
machined. The three-piece design simplifies The cylinder liner is designed to have the between the liner and piston top land deposits
piston overhauling, as this can be carried out stiffness needed to withstand both pretension eliminates the risk of bore polishing. Nor can
without touching the big end bearing. The big forces and combustion pressures with virtually oil be scraped upwards by the piston. This
end bearing can also be inspected without no deformation. This gives the best cylinder significantly reduces liner wear and keeps the
removing the piston. function and ensures good basics for the lube oil consumption stable for long periods of
The two-piece design is used for smaller tightness of the cylinder head gasket. The time.
engines having a cylinder power of less than temperature is controlled by optimizing the
400 kW. The design offers the maximum pin cooling water flow in the upper part of the The main features of the cylinder liner
diameter while still making it possible to pull collar to achieve a low thermal load, and to design are:
the connecting rod through the cylinder liner. avoid sulphuric acid corrosion. Centrifugal casting with high strength and
The liner is made of wear-resistant material good wear resistance
The main features of the connecting rod developed from a dedicated and long-term Cooling of the bore for optimum wall
design are: R&D programme. To eliminate the risk of bore temperatures
Two/three-piece type design depending on polishing, the liner is provided with an anti- High-collar technology to ensure good
engine size polishing ring on the upper part. The purpose cylinder head gasket tightness
Hydraulically tightened bolts of this ring is to limit the carbon deposits Anti-polishing ring removes deposits from
Both strength and weight are optimized built up on the piston top land to a thickness the piston top land, ensuring proper cylinder
Easy maintenance small enough to prevent contact between function, no bore polishing, stable lube oil
the inner liner wall and the deposits on any consumption, and low wear to the liner.
7
PISTON & PISTON RINGS ring package and ring grooves are optimized achieved through optimized cooling and closed
For years, the outstanding piston concept for long life by a special wear-resistant coating seat ring technology, which extend the life of
for highly rated heavy fuel engines has been and groove treatment. the valves and seats.
a rigid composite piston with a steel crown The cylinder head design is based on the
and nodular cast-iron skirt. More than twenty The main features of the piston design are: four-screw concept developed and used by
years of experience has fine-tuned this A two-piece composite structure Wärtsilä for many years. A four-screw cylinder
concept. When it comes to reliability, there is A steel crown and nodular cast-iron skirt head design also provides the possibility
no real alternative today for modern engines Two compression rings and one oil scraper for having inlet and exhaust ports with a
with high cylinder pressures and combustion ring, which in combination with a pressure minimum of flow losses. The port design
temperatures. lubricated piston skirt, achieve low friction has been optimized using a combination of
Wärtsilä’s patented skirt lubrication and high seizure resistance computational fluid dynamics analysis and full-
minimizes frictional losses, and ensures the Optimized piston ring groove temperature to scale flow measurements.
appropriate lubrication of both piston rings and prevent cold corrosion.
the piston skirt. In Wärtsilä’s three-ring concept The main features of the cylinder head design
each ring has a specific task. The rings are CYLINDER HEAD are:
dimensioned and profiled for consistent The cylinder head design features high Four cylinder head screws only, giving
performance throughout their operating lives. reliability and easy maintenance. A stiff cone- / space for flow-efficient ports
To avoid carbon deposits in the ring box-like design can cope with high combustion Inlet and exhaust gas ports that are on the
grooves of a heavy fuel engine, the pressure pressures, and is essential for obtaining both same side
balance above and below each ring is crucial. liner roundness and even contact between the The height and rigid design, which ensure
Experience has shown that this effect is most exhaust valves and their seats. Wärtsilä’s vast even and sufficient surface pressure on the
likely achieved with a three-ring pack. Finally, global experience of heavy fuel operation has cylinder head gasket
it is well known that most frictional losses in contributed greatly to the efficient design and A bore-cooled flame plate for optimum
a reciprocating combustion engine originate development of exhaust valves. temperature distribution
from the rings. Thus a three-ring pack is the The basic criterion in exhaust valve design Two inlet valves and two exhaust gas
obvious choice in this respect, too. The piston is having the correct temperature. This is valves, all with valve rotators.
8
MULTI-DUCT The valve follower is of the roller tappet thermal load reduction. The variation of inlet
A multifunctional duct is connected to the type, where the roller profile is slightly valve closing timing is achieved through the
cylinder head. The functions of this multi-duct convex for good load distribution. The valve addition of a hydraulic chamber between
are as follows: mechanism includes rocker arms working on the inlet valve tappet and the push rod.
Air transfer from air receiver to cylinder head yokes guided by pins. Adjustability of the inlet valve movement is
Introduction of an initial swirl to the inlet air Both exhaust and inlet valves are equipped achieved by controlling the oil flow into and out
for optimal part load combustion with valve rotators to ensure a safe valve and the hydraulic chamber.
Exhaust transfer to the exhaust system seat function. The rotation means that the
Cooling water transfer from the cylinder temperature distribution and wear to the valves The main features of the VIC system are:
head to the return channel in the engine is even, and that the sealing surface is kept Inlet valve closing timing that can be
block free of deposits. adjusted
Insulation/cooling of the exhaust transfer With VIC employed, the inlet valve is open
duct The main features of the camshaft and valve longer
Support for the exhaust system, including design are:
insulation Each cylinder section of the camshaft is As compared to the standard valve train, the
forged in one piece with integrated cams VIC system comprises the following additional
CAMSHAFT AND VALVE GEAR Separate bearing journals parts:
The engine is available with either traditional The valve follower is of the roller tappet type Pressure accumulator
mechanical valve actuation, or variable inlet Traditional valve actuation Piston and oil supply
valve closing actuation. Variable Inlet Valve Closing (VIC) for Non-return valve
The camshaft is built of single cylinder IMO Tier II compliance.
sections with integrated cams. The camshaft The VIC system is designed to improve the
sections are connected through separate engine’s partial load performance by enabling
bearing journals, which make it possible to alternative inlet valve closing timings. The
remove the shaft sections sideways from the major advantages are a reduction in visible
camshaft compartment. smoke, load application improvement, and
9
OPERATIONAL SYSTEMS
FUEL INJECTION SYSTEM An unmatched level of safety is achieved connected to a fuel accumulator that evens
The patented Wärtsilä multi-housing principle through housing both the entire low-pressure out the pressure and feeds the two cylinders.
ensures outstanding safety of the low-pressure and high-pressure systems in a fully covered The accumulators are connected to each other
fuel system. The fuel line consists of channels compartment. through double-walled pipes, a detail that
drilled in cast parts, which are clamped firmly Common-rail technology offers almost both guarantees continuously even pressure
to the engine block. For easy assembly and unlimited possibilities to adjust the fuel in all accumulators, and that allows the engine
disassembly, these parts are connected to injection process to the prevailing engine to operate with one or two disconnected
each other using slide connections. operating conditions, fuel characteristics, high-pressure pumps, should this ever be
Wärtsilä 4-stroke engines are available and to achieve emission levels. The main necessary.
with three alternative fuel injection systems components of the common-rail injection From the accumulators, fuel is supplied
depending on configuration: a conventional system that are designed especially for at the required pressure into the cylinders
fuel injection system, with either single- or Wärtsilä engines are the high-pressure pumps, through injection valves controlled by electro-
twin plunger injection pumps, and common- the balance accumulators, the fuel injection hydraulic actuators. The individual, and
rail fuel injection. High injection pressures valves, and the built-on control oil pump. The therefore cylinder-specific, control of injection
giving low smoke emissions characterize all control oil is engine oil with additional filtration. timing and duration is an important feature that
three systems. The common-rail technology The system’s high-pressure pumps are is made possible by this injection equipment.
in particular, enables operation at any load camshaft-driven and amply dimensioned for One significant safety detail is that the
without visible smoke. supplying fuel to two cylinders. Each pump is injection valves are designed to ensure that the
10
injection nozzles are totally unloaded between charger technology is used on Wärtsilä A single-pipe exhaust gas system (SPEX)
injection periods. This feature eliminates the engines. or pulse charging, depending on engine
risk of unintended fuel supply into the cylinders configuration
caused, for example, by incomplete closure of The main features of the turbocharging The SPEX system is designed for minimum
the nozzle needle at the end of injection. system are: flow losses on both the exhaust and air sides.
The twin-pump system, likewise, offers the One-stage turbocharging The charging systems are designed to give
possibility to optimize the prevailing engine An oil-cooled turbocharger with plain high efficiency and good load acceptance.
operating conditions, fuel characteristics and bearings lubricated by engine oil SPEX is designed for best possible full-load
emission levels, thanks to twin plunger pump A two-stage charge air cooler depending on performance. SPEX, combined with the
elements. One plunger controls the quantity engine configuration exhaust waste gate and air bypass, meets
of fuel while the other controls the injection An LT water bypass valve for charge air the established low load performance of
timing. temperature control pulse charging. With its unique design, the
The charge air receiver is integrated into load acceptance is close to that of pulse
TURBOCHARGING SYSTEM the engine block charging. Non-cooled chargers, with inboard
Turbocharger technology has undergone A water mist catcher as a standard option plain bearings lubricated by the engine’s lube
intense design and performance development Air and exhaust waste gate functions for oil system, are used. The end result is that
in recent years, resulting in higher performance best engine performance, depending on intervals between overhauls are reduced, as is
and greater reliability. Only the best available engine configuration maintenance.
11
Lubricating
oil
cooler Heat recovery
Charge
air cooler
HT
Charge
air cooler
LT Cyl. Central
cooler
HT
LT pump Pre
standby LT heater
pump pump HT
standby
pump
Oil cooler
Automatic filter
Electric
Oil pump standby
oil pump
Centrifugal filter
Electric
prelube
oil pump
Suction
Dry oil sump strainer
System oil tank
12
Hardwired
connections
Loadsh.
CAN
Ethernet
LCP
ESM
IOM
MCM
PDM
UNIC
for engines with common-rail fuel injection. minimal commissioning or installation work
AUTOMATION SYSTEM COMPONENTS
UNIC C3 automation is also used in gas is needed before the engine or generating
engines. set is operational. The critical parts of the ESM Engine Safety Module
The Wärtsilä UNIC is a flexible and fully UNIC system are either redundant or very MCM Main Control Module
scalable control system for large reciprocating fault-tolerant to guarantee high safety and TCM Thermocouple Module
diesel and gas engines. availability in all circumstances. In particular,
IOM Input Output Module
The UNIC system is designed to fulfill the parts like the communication and power supply
PDM Power Distribution Module
long lifetime expectations for large marine are fully redundant to allow single failures
diesel and gas engines operating in the without interruptions in engine operation. LCP Local Control Panel
toughest of conditions. The system is based The electronic control enables the engine to LDU Local Display Unit
on a high degree of commonalities and be adapted to different operating conditions. CCM Cylinder Control Module
standard interfaces, covering different engine
sizes and fuel systems in a modular way. The main features of the UNIC system are:
A modular, standardized interface provides A complete engine safety system
an easily reusable design for off-engine Local monitoring
automation systems. It allows, for example, Speed control with load sharing Start/stop sequencing and load reduction
diesel engines to be converted to dual fuel or Fuel injection request
common rail with a minimum of modifications. Timing control and knock detection System diagnostics and a fieldbus interface
Thanks to the pre-tested configuration, Alarm signal acquisition applicable to each engine’s configuration.
13
Operating
Knocking
Misfiring
window
45%
BMEP (bar)
Thermal efficiency (%)
NOX (g/kWh)
2 g/kWh
0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6
Air/fuel ratio
DUAL-FUEL TECHNOLOGY
14
FUEL INJECTION PUMPS FOR
LIQUID FUEL OPERATION INJECTION VALVES
RETURN FUEL
Control
COMMON RAIL FOR HIGH
RETURN FUEL
PRESSURE PILOT FUEL
system
PRESSURE
PRESSURE
PRESSURE
BOOSTER BOOSTER M
PUMP PUMP
UNIT UNIT
15
GAS ADMISSION VALVE at all times and will switch over from gas to
Gas is admitted to the cylinders just before fuel oil if necessary. The plunger is equipped
the air inlet valve. The gas admission valves with a wear-resistant coating.
are electronically actuated and controlled by
the engine control system to give exactly the PILOT PUMP
correct amount of gas to each cylinder. In this The pilot fuel pump is engine-driven. It receives
way, the combustion in each cylinder can be the signal for correct outgoing fuel pressure
fully and individually controlled. Since the valve specially selected materials, thus providing low from the engine control unit and independently
can be timed independently of the inlet valves, wear and long maintenance intervals. sets and maintains the pressure at the required
the cylinder can be scavenged without risk of level. It transmits the prevailing fuel pressure to
gas being fed directly to the exhaust system. INJECTION PUMP the engine control system.
Independent gas admission ensures the The Wärtsilä dual-fuel engine utilizes the well- High-pressure fuel is delivered to each
correct air-fuel ratio and optimal operating proven monoblock injection pump developed injection valve through a common-rail pipe,
point with respect to efficiency and emissions. by Wärtsilä. This pump withstands the high which acts as a pressure accumulator and
It also enables reliable performance without pressures involved in fuel injection and has damper against pressure pulses in the system.
shutdowns, knocking or misfiring. The gas a constant-pressure relief valve to avoid The fuel system has a double wall design with
admission valves have a short stroke and cavitation. The fuel pump is ready for operation alarm for leakage.
16
“INSTANT” CHANGE OVER FROM GAS TO LIQUID FUEL MODE OPERATION MODE TRANSFER
WITH THE DUAL-FUEL SOLUTION The engine can be switched automatically
gas to liquid fuel liquid fuel to gas from liquid fuel oil to gas operation at loads
100 % * below 80% of the full load. Transfer takes place
~80% automatically after the operator’s command
Instant ~0,5 h ~0,5 h without load changes. During switchover, which
~0,1 h
lasts about one minute, the fuel oil is gradually
substituted by gas.
In the event of for instance a gas supply
interruption, the engine converts from gas to
liquid fuel operation at any load instantaneously
and automatically. Futhermore, the separate
Gas LFO HFO Gas LFO HFO
liquid fuel system makes it possible to switch
In the dual-fuel solution the twin injection nozzles are used also for HFO operation. over from LFO to HFO without power reduction.
The LFO pilot is in use also during the HFO operation.
* The time needed to reach full load on gas depends on the duration of HFO-mode operation. The pilot fuel is in operation at liquid fuel mode to
ensure nozzle cooling. The pilot fuel consumption
is less than 1% of full load fuel consumption.
Switching over to LFO from HFO operation can
Engine control Load also be done without load reduction. From LFO
Exhaust wastegate system Speed
to gas operation, the switch can be made as
described above. This operation flexibility is the
real advantage of the dual-fuel system.
P
I
AIR-FUEL RATIO CONTROL
T The correct air-fuel ratio under any operating
conditions is essential to optimum performance
and emissions. For this function, Wärtsilä dual-
Exhaust fuel engines are equipped with an exhaust gas
TC
waste-gate valve.
Part of the exhaust gases bypasses the
Air
turbocharger through the waste-gate valve. The
valve adjusts the air-fuel ratio to the correct value
independent of the varying site conditions under
P
high engine loads.
17
MAINTENANCE FEATURES SERVICES
During design and development, engine Several customers have recognized us as These services cover everything from basic
manufacturers typically emphasize ease of their preferred service supplier to ensure the support with parts, field service and technical
maintenance by including tooling and easy availability and cost-efficient operation of their support to service agreements and condition
access in the basic design, and by providing installations. They benefit from having their based maintenance; from installation and
easy-to-understand instructions. entire power system fully serviced by one commissioning, performance optimization,
Wärtsilä´s maintenance principle is global supplier. Wärtsilä Services provides full including upgrades and conversions, to
substantiated by the following: service throughout the product lifecycle for environmental solutions, technical information
A cylinder head with four fixing studs and both marine and power plant customers, and is and online support.
simultaneous hydraulic tightening of all four constantly developing its network worldwide. The choice available to you extends from
studs Additionally we are continually broadening parts and maintenance services to a variety
Uniform one-cylinder camshaft pieces our range of services by adding valuable of comprehensive, customized long-term
Slip-on fittings wherever possible products and specialist services to our service agreements, including performance
Exhaust gas system insulation using easy- portfolio. In this way we also support and operations & management agreements.
to remove panels on an engine mounted equipment onboard your vessel or at your Our Services organization currently features
frame installation and in our numerous workshops more than 11,000 dedicated professionals in
A hydraulic jack for the overhaul of the main around the globe and in key ports, regardless 70 countries.
bearing where applicable of equipment make. Wärtsilä adds value to your business at
A three-piece connecting rod in bigger We offer lifecycle efficiency solutions in the every stage in the lifecycle of your installations.
engines, allowing inspection of the big end following services product lines: With us as your service partner, you receive
bearing without removal of the piston, and Engine Services many measurable benefits such as availability
piston overhaul without dismantling the big Propulsion Services and performance, productivity gains and
end bearing Electrical & Automation Services cost benefits. Above all, peace of mind in
Weight-optimized and user-friendly Boiler Services the knowledge that your installation is being
maintenance tools Operations & Management Services serviced by the most experienced partner you
Training Services could have – Wärtsilä.
Environmental Services
18
06.2010 / Bock´s Office / Waasa Graphics
Wärtsilä is a global leader in complete lifecycle power solutions for the marine
and energy markets. By emphasising technological innovation and total
efficiency, Wärtsilä maximises the environmental and economic performance
of the vessels and power plants of its customers. Wärtsilä is listed on the
NASDAQ OMX Helsinki, Finland.