1 © Wärtsilä

DESING AND FUNCTIONW46

2 © Wärtsilä

– Wärtsilä 46 engine has excellent combustion properties over the entire load range with a wide variety fuels - from low grade heavy fuels to Marine diesel oils and natural gas

W46 ENGINE

3 © Wärtsilä

TERMINOLOGY

B1A2

A3A4

A5A6

A7A8

B3B2

B4B5

B6B7

B8

A1

REAR SIDE

FREE END

MANOUVERING SIDE

FLYWHEEL END

4 © Wärtsilä

Terminology - Designation of Bearings

0

000

0 1 2 3 4 5 6 7 8 9 10

10

00-4v

1 2 3 4 5 6 7 8 9

5 © Wärtsilä

Core Values

– Real reliability– Low fuel consumption– Low lube oil consumption– Low NOx emissions– Easy and cost-effective installation– Proven flexible mounting technology– Low maintenance cost

6 © Wärtsilä

Wärtsilä 46 Milestones

– Development start 85– Prototype 6L46 87– First deliveries 88

• Marine– M/S Polaris

• 6L46/450 rpm• 5100 kW = 850 kW/cylinder

• Power Plant– St’ Marten

• 9R46/514 rpm• 8145 kW = 905 kW/cylinder

– First 4L46 and 18V46 engines 90– Integrated air receiver L46 94– Reversible engine L46 94– DWI-engine 98– D-output 99– Compression ratio 16:1 00– W50DF-engine 01– Common Rail engine 02

7 © Wärtsilä

Technical Data Marine engines

W 46A W 46B W 46C W 46D

Cylinder bore (mm) 460 460 460 460

P iston stroke (mm) 580 580 580 580

Cylinder output (kW ) 905 975 1050 1155

Nominal speed (rpm) 450 500 514 500 514 500 514 500 514

M ean piston speed (m/s) 8,7 9,7 9,9 9,7 9,9 9,7 9,9 9,7 9,9

M ean effective pressure (bar) 25,0 22,5 21,9 24,3 23,6 26,1 25,4 28,8 28,0

M ax. cylinder pressure (bar) 180 190 200 210

Turbocharging SPEX (S ingle P ipe Exhaust system)

Cylinder numbers 6L, 8L, 9L, 12V, 16V, 18V

Fuel specification ISO 8271, class F, DMX-DMC, RMA10- RML55

8 © Wärtsilä

Technical Data Power Plant engines

Cylinder bore 460 mmPiston stroke 580mmMechanical output 975 kW / Cylinder

Ambient temperature 35 °CLT-water temperature 45 °CBarometric pressure 100 kPaDe-rating based on ISO 3046-1 rules

Speed 500 rpm (50 Hz), 514 rpm (60Hz)Mean effective pressure 24,3 bar (500 rpm), 23,6 bar (514 rpm)Mean piston speed 9,7 m/s (500 rpm) 9,9 m/s (514 prm)

Fuel specification ISO 8271, class F, DMX-DMC, RMA10- RML55

Crude oilOrimulsion

9 © Wärtsilä

Wärtsilä L46

10 © Wärtsilä

Wärtsilä V46

11 © Wärtsilä

Engine Block - State of the art technology

– Nodular cast iron and closed box design provides rigidity for flexible mounting

– Under slung main bearing cups– All bolts hydraulically tightened– Integrated charge air receiver

12 © Wärtsilä

Engine Block - State of the art technology

– Nodular cast iron and closed box design provides rigidity for flexible mounting

– Under slung main bearing cups– All bolts hydraulically tightened

13 © Wärtsilä

Engine block - W46

14 © Wärtsilä

Engine Block - L46

15 © Wärtsilä

Engine Block - L46

16 © Wärtsilä

Crankcase Doors with Safety Valves

– Number of valves depend on the crankcase volume

DON’T USE AIRGUN

FORTIGHTENING

17 © Wärtsilä

Crankcase breather

END OF THE PIPE TO LEAD THE DIRTY OIL GROVE

INTO THE HOT BOX

18 © Wärtsilä

Dry Oil Sump

RUNNING-IN FILTER

OIL DISTRIBUTION PIPE

LIFTING AND LOWERING JACK

DRY OIL SUMP

BY-PASS VALVE

CONNECTION FLANGE TO MAIN BEARING GAP

SUMP O-RING SEALING

19 © Wärtsilä

Dry oil sump of low type

LUBE OIL DISTRIBUTION PIPE

20 © Wärtsilä

Wet Oil Sump (used in power plant engines)

TO SEPARATOR

FROMSEPARATOR

OIL INLET

OIL RETURNFROM

ALTERNATOR

AB

AB

21 © Wärtsilä

Wet oil sump

– Suction pipe of floating design

– Without welded supports

STRAINER

22 © Wärtsilä

Wet oil sump

ADJUSTABLEORIFICES

FLEXIPLE HOSES ON PIPELINES

ADDITIONAL SUPPORT IN FREE END

23 © Wärtsilä

Hydraulic Jack

Up Down

24 © Wärtsilä

Running-in Filter

– Maximum 500 operating hours

PAPERCARTRIDGE

BY-PASS VALVE

CONNECTION FLANGE TOWARDS TO THE MAINBEARING CAP

LUBE OIL FROM LUBE OIL DISTRIBUTION PIPE

LUBE OIL TO THE MAIN BEARING

25 © Wärtsilä

Main Bearings - State of the art technology

– Reliable Thick-Pad bearing technology– Big crankshaft journals and pin diameters ensure low bearing loads– Low bearing loads allow softer bearing materials– Results in virtually seizure-free bearings– 2004-> alternative AlSn bearings

26 © Wärtsilä

Dismantling/assembling of the main bearing

27 © Wärtsilä

Dismantling/assembling of the main bearing

WIEW A

UP DOWN

CLICK TO CD1

28 © Wärtsilä

Crankshaft W9L46

GEISLINGER VIBRATION DAMPER

SPLIT GEAR WHEEL

FLYWHEEL

– Crankshaft 9L46• Constant speed = tuning mass

• Variable speed = Geislinger vibration damper

29 © Wärtsilä

Crankshaft - Counterweight Mounting

– Location of each counterweight is optimized for optimum balancing

30 © Wärtsilä

Crankshaft deflection measurement tool

31 © Wärtsilä

Crankshaft - torsion vibration damper

– W18V46 engines• Geislinger damper at the free end + the balancing mass

• Two holes in fly wheel

– W9L46 engines• Mechanical propulsion installations

– Geislinger damper at the free end of the crankshaft

• Diesel electric installations

– Tuning mass at the free end of the crankshaft

– Other cylinder configurations• Typically no dampers at the crankshaft

32 © Wärtsilä

Flywheel

– Hydraulically tightened nuts at flywheel

33 © Wärtsilä

Vulcan Rato coupling

34 © Wärtsilä

Flywheel and coupling

• Geislinger coupling between engine and generator on W18V46

35 © Wärtsilä

Turning gear for V-engines

– Will activate shut down function if leaver is moved

– Manual turning of crank shaft• By electrical motor

• By hand

– Blocking the starting air to the solenoid starting valve when it is engaged

– Position indication to the PLC system

36 © Wärtsilä

Driving gear of the pumps

– W18V46 • Geislinger damper at free

end of crankshaft

• Driving gear of the pumps

37 © Wärtsilä

Driving gear of the pumps

38 © Wärtsilä

Stampings on Flywheel

– W18V46 has the alternating firing order (405°)– W12V46 and W16V46 have the consecutive firing order (45°)

39 © Wärtsilä

End cover with crankshaft sealing

– Crankshaft seal fitted on the end cover, lip against the crankshaft• Improved sealing

– No oil lock

– Repair kit available

40 © Wärtsilä

Cylinder Liner - State of the art technology

– Small deformations due to high collar to stroke ratio– Anti-polishing ring eliminates the risk of bore polishing– Designed for optimal temperature distribution– Special grey cast iron for excellent wear resistance and high strength

41 © Wärtsilä

Anti-Polishing Ring Arrangement

– APR doesn’t touch to the piston

ANTI-POLISHINGRING

42 © Wärtsilä

Function of Anti-polishing

SHARP CORNER

43 © Wärtsilä

Anti-polishing ring design

COMPRESSION RATIO

ANTI-POLISHING RING HIGH

14:1 14:1 16:1

85MM 79MM 72,5MM

DEVELOPMENT

44 © Wärtsilä

Assembling/Removing of cylinder liner

A

10-27v-3

45 © Wärtsilä

Assembling/Removing of cylinder liner

46 © Wärtsilä

Assembling/Removing of cylinder liner

A

CLICK TO CD2

47 © Wärtsilä

Connecting Rod - State of the art technology

– Three-piece design– Combustion forces are distributed over a maximum bearing area– Easy maintenance– Low piston overhauling height– Tri-metal big end bearing

• Oil groove over whole shell in 6L46 lower half to lower pressure pulses

• Maximum ovality 0,1mm

48 © Wärtsilä

Connecting Rod

– Improved surface quality• scratches not allowed

– Tri-metal piston pin bearing• weight point on the outer edge of bushing

SHIM THICKNESS

12,5:1 5mm

14:1 11mm

16:1 17mm

COMPRESSIONRATIO

SHIMTHICKNESS

SHIM

49 © Wärtsilä

View A

A

11-4

Removing/Dismantling of the Piston

ANTI-POLISHING RING REMOVING TOOL

50 © Wärtsilä

Removing/dismantling of the piston

the cylinder wall

Pay attention to

Lift with care

11-7

LIFTING POINTS

TO IN-LINE ENGINE TO V-ENGINE

CLICK TO CD2

51 © Wärtsilä

Removing/Dismantling of the Piston

134

11-8

M10

11-10

500

11-11

52 © Wärtsilä

Removing/Mounting of the Big End Bearing

11

A

View ViewA B

11-21v

B

836004

836006

836007

836027

CLICK TO CD2

53 © Wärtsilä

Gudgeon Pin

PLUG

OIL FROMCONNECTING ROD

OIL TO THE PISTONOIL TO THE PISTON

54 © Wärtsilä

Piston - State of the art technology– Composite low-friction piston– Design assures efficient cooling and high rigidity– Hardened top ring groove assures long lifetime– Low friction by skirt lubrication– Well distributed oil film eliminates risk of ring scuffing– Cleaner rings and grooves– Tilting movements damped by the oil film

55 © Wärtsilä

KS-Piston Top assembly

• Threads and support surface to be lubricated by machine oil

• Screws to be tightened 100 Nm

• Screws to be loosened

• Screws to be cross pre tightened 20 Nm

• Screws to be cross tightened 90°

• Test for the right tightness

– Screw should not move when tightening by 75 Nm torque

56 © Wärtsilä

Mahle-Piston Top assembly

1. Threads and support surface of nut to be lubricated by Machine oil

2. Screws to be tightened 10 Nm

3. Nuts to be cross pre tightened 60 Nm

4. Nuts to be cross tightened 120°

ASSEMBLY INSTRUCTIONS

ASSEMBLY INSTRUCTIONS FOR NEW SREWS AND NUTS

57 © Wärtsilä

Kolben Smith wave type of piston crown cooling gallery

IMO ID NUMBER

IMO ID NUMBER

58 © Wärtsilä

Connecting Rod with Piston

OIL FLOW TO THE PISTON

CLICK TO CD1

59 © Wärtsilä

Piston Rings - State of the art technology

– Low friction three-ring set– Special wear resistant coating for compression rings– Geometry optimized for maximum sealing and pressure balance– The first ring has both sides chromium coated– Different gap between the first and the second ring

60 © Wärtsilä

Wärtsilä 46 Piston Ring Set

• Designs:Designs:• Standard set:

• 1. ring: C103 + revision letter + m/y

• 2. ring: C 109 + revision letter + m/y

• 3. ring: C 83 + revision letter + m/y

– running surface cr-ceramic on all rings

– top ring flanks cr-coated– scraper ring radial

pressure:1N/mm2

SPECIAL CHROMIUM

61 © Wärtsilä

Cylinder Head - State of the art technology

– Rigid box design for even contact pressure– Four fixing bolts for easy maintenance– No valve cages leads to improved reliability and optimized flow

characteristics– Water cooled exhaust valve seat rings– Valve rotators on both exhaust and inlet vales

62 © Wärtsilä

Cylinder Head with Valves

63 © Wärtsilä

Cylinder Head development

Pilot valve

Previous (Year 2000)

Marine engine

Power plant engine

Marine and power plant engine

64 © Wärtsilä

Valve house cover

O-ringgrooveatthecap

Old New

65 © Wärtsilä

Inlet and Exhaust clamp

– Four piece clamp connected together with three bolts– Important to tighten the bolts to stated torque in steps– Use heat resistant paste in the clamp and the bolts

66 © Wärtsilä

Cylinder Head Equipment

67 © Wärtsilä

Gasket ring for cylinder cover

SIXSPIGOTS

ø487±0.5

492±0.5

120°

12

0°

A

A

– Material:• stainless steel

68 © Wärtsilä

Valve guide

• Evaluate possible corrosion• Measure the wear from sliding surfaces

69 © Wärtsilä

Removing the Cylinder Head

• Hydraulic tightening pressure 450 bar

B 41

A

12 12

View X:

C

X

12-3

12-4

861143

834045

860170

A:

A

83200112-5

70 © Wärtsilä

Dismantling of the Valves

40

AIRIN

EXHOUT

00-3

A D

B C

CLICK TO CD2

71 © Wärtsilä

Fitting/Removing the Seat Rings

12-14

34

33

3231

31

34

12-19

– For fitting• Head +60 °C• Seat ring -18°C…-24°C• One O-ring • Use Wärtsilä standard lubricants

72 © Wärtsilä

Pressure test

• Test pressure 10 bar

73 © Wärtsilä

Puller for central sleeve

74 © Wärtsilä

Turning device for cylinder head

CLICK TO CD1

75 © Wärtsilä

Safety valve

– Opening pressure 275±bar– Marked with opening pressure as well as running lot number and year– Mild steel sealing casket material towards to the cylinder head

COMRESSION SRING

PLUG

HOUSING

SPINDEL

76 © Wärtsilä

Exhaust Valve

– Valves Ø 160m and Ø 170mm– Fully Nimonic 80A-valve up to cotters– Top part of the valve is harder material– Cr-coating on stem of the valve– In LFO and Gas installations valve has Stellite-armoured seat

30 degrees

ISte llit

IIN im o n ic

v a lv e d isc d ia m . 1 6 0

IIIN im o n ic

v a lv e d isc d ia m . 1 7 0

ø160 ø160 ø170

S T E L L IT

77 © Wärtsilä

Exhaust Valve for 16:1 compression ratio engines

– All W46 engines specified for HFO operation with compression ratio16:1– Connection rod shim thickness 17 mm

• (Compression plate)

– Valve disk is 2mm thinner

(Y ) m in im u m

(Y ) n om in a l

S ea t face in n er d iam eter(X ) m in im u m

(Z ) m ax im u m

In let va lve E xh au st va lve

ISte llit

IIN im on ic Ø 160

IIIN im on ic Ø 170

1 3 m m

1 4 .5 m m

1 3 3 m m

2 m m

1 2 .5 m m

1 4 m m

1 4 0 m m

2 m m

1 2 .5 m m

1 4 m m

1 3 3 .5 m m

2 m m

1 3 m m

1 4 .5 m m

1 3 1 .5 m m

2 m m

78 © Wärtsilä

Exhaust and Inlet Valves/Seat Rings

COOLED EXHAUST GASVALVE SEAT RING

79 © Wärtsilä

Inlet Valve

20 degrees

– Cr-coating on stem of the valve

– Stellite-coat armoured disc

80 © Wärtsilä

Contact Area with new Valves and Seats

Note! Both contacts areas must be in inner edge of seat rings

81 © Wärtsilä

Exhaust gas seat ring

– Only one O-ring– Assembly

• Seat -18…-25ºC• Cylinder head +50...+60ºC• Locking with Loctite 620 locking fluid to bore• Use only one O-ring• Use Wärtsilä standard 337.0014 based

lubricant lubricant to bore• 0,5, 1, 1,5 and 2mm oversize• Dry and clean seat ring surfaces before

assembly• Fit as fast as possible

82 © Wärtsilä

Over size exhaust gas seat ring

• Four over size seat rings• 0,5, 1, 1,5 and 2mm

Used with exhaust valve

Seat angle and tolerances

Outer seat diameter, nominal

Outer seat diameter, maximum

I and II

manual chapter 12.

160 0/-0.2 mm

164 mm

III

173 ±0.1 mm

177 mm

A B

manual chapter 12.

83 © Wärtsilä

Inlet valve seat ring

Old

Contact area

New

Contact area

84 © Wärtsilä

Camshaft Drive

85 © Wärtsilä

Camshaft Driving Gears

• No guiding pin between bigger and smaller intermediate gear

86 © Wärtsilä

Camshaft - State of the art technology– Uniform one cylinder camshaft pieces for the complete engine range– Easy maintenance– Cam/roller optimized for even contact pressures– Fully machined surfaces

87 © Wärtsilä

Camshaft

88 © Wärtsilä

Valve Tappet

COTTERS

89 © Wärtsilä

Tappet for Injection Pump

• Ball washers• High quality bolts

USED IN W46C2 ENGINES WITHØ40 mm FUEL PUMP PLUNGERS

90 © Wärtsilä

Locking for tappet adjusting

– Locking plate to pump tappet

– Spring

– With Ø40 mm fuel injection pumps

91 © Wärtsilä

Camshaft torsional Vibration Dampers

ASK 1949 VISCOUS HASSE & VREDE DAMPERD49/1 GEISLINGER DAMPERC63/6.5 15U GEISLINGER FLEXIBLE COUPLING

CONSTANT SPEED VARIABLE SPEED6L46 A

BC

8L46 A ASK1949B ASK1949C ASK1949 ASK1949

9L46 AB ASK1949 ASK1949C ASK1949 ASK1949

12V46 AB ASK1949 ASK1949C ASK1949 ASK1949

16V46 A ASK1949 D49/1B ASK1949 D49/1C ASK1949 D49/1

18V46 A C63/6.5 15UB C63/6.5 15UC C63/6.5 15U

ENGINE

92 © Wärtsilä

Fuel Injection- and Valve timing

BDC

TDC50 44

26 53°

E(1996)

10°

BDC

TDC4440

53°

Compression ratio16:1

BDC

TDC4646

D(1995)

22 50°

(2001)

93 © Wärtsilä

Injection pump cam profile to 16:1 timing

14:1 16:1

94 © Wärtsilä

Removing/mounting of camshaft

A

A

95 © Wärtsilä

Fuel System - State of the art technology– Components in a Hot Box provide maximum safety and high pre-heating

temperature– Outside fuel pipes carefully shielded– All leakage's collected to a closed system– Sealed-off compartment between pump and tappet

96 © Wärtsilä

Injection Pump - State of the art technology

– Distortion-free mono-element– Constant pressure relief valve– Sealed-off compartment between pump and tappet– Interchangeable pumps

97 © Wärtsilä

Turbo charging System - State of the art technology

– Application optimized, SPEX or pulse system– SPEX combines the advantages of both pulse and constant pressure

charging– Ejector effect provides high efficiency at partial load– Even exhaust gas temperatures– Designed for high pressure rations and thermal expansions

98 © Wärtsilä

Exhaust pipe supports

– Support plates 4x2,5mm

– Stainless steel plates

99 © Wärtsilä

Exhaust gas bellows

– Long design 160mm– Allowable movements from fitted

length• Axial±15mm

• Radial ±1,4mm

100 © Wärtsilä

W18V46 Charge air receiver

– Charge air resonator inside of receiver

– Damping charge air pulses

– 18V46C2 engines

101 © Wärtsilä

Assembling of Charge Air cooler/ V-engine

102 © Wärtsilä

Air cooler and water trap arrangement

HT LT

103 © Wärtsilä

L/Water Separator After Charge Air Cooler

HT-WATER INLET

WATERSEPARATOR

104 © Wärtsilä

Charge air cooler

TWO FAST COUPLINGS– Pressure different measurement over charge air cooler

– Portable charge air cooler differential pressure gauge

105 © Wärtsilä

Charge air cooler pressure different meter

– High accuracy, electronic pressure meter– Dust and waterproof to IP67 (BS EN 60529, IEC529) standards– Selectable pressure units, PSI, mbar, inH2O, inHg, mmHg, torr, KPa,

cmH2O, Kgcm-2– Twin inputs for gauge or differential pressure measurement– Adjustable zero value– Maximum, minimum pressure and hold function– Selectable auto switch off

106 © Wärtsilä

Waste-gate and By-pass arrangement

• All surfaces must be < 220ºC (SOLAS)

107 © Wärtsilä

Waste-gate and By-pass arrangement

• Waste gate (WG)– Charge air waste gate for SCR– Exhaust WG reduce the maximum firing pressure and turbo charger

speed– Against too cold suction air in Power Plant installations

• By pass (PB)– Always in CPP installations– <60% load for smoke reduction in DG installations

108 © Wärtsilä

Control Mechanism/ V-engine

109 © Wärtsilä

Mechanical Over speed Trip Device

B

B

A

A

C

A - A

110 © Wärtsilä

Governor Drive