w32 engine technology for emergency power applications

7/31/2019 W32 Engine Technology for Emergency Power Applications

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WRTSIL 32ENGINE TECHNOLOGY

FOR EMERGENCY POWER APPLICATIONS


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DESIGN PHILOSOPHY ................................................... 4

BENEFITS .................................................................... 5

EMERGENCY APPLICATIONS ......................................... 5

CRANKSHAFT AND BEARINGS ..................................... 6

ENGINE BLOCK ............................................................ 6

PISTON ....................................................................... 6

PISTON RINGS ............................................................. 6

CYLINDER LINER AND ANTI-POLISHING RING ................. 7

CONNECTING ROD ....................................................... 7

CYLINDER HEAD .......................................................... 7

MULTIDUCT ................................................................. 8

STARTING AIR SYSTEM ................................................. 8

FUEL INJECTION SYSTEM ............................................. 8

TURBOCHARGING SYSTEM ........................................... 9

COOLING SYSTEM ....................................................... 9

LUBRICATING OIL SYSTEM ........................................... 9

MONITORING AND CONTROL ...................................... 10

EASY INSTALLATION .................................................. 10

EASY MAINTENANCE.................................................. 10

THE TOTAL SERVICE PROVIDER .................................. 11

MAIN TECHNICAL DATA .............................................. 11

This is a brie guide to the technical eatures and perormance o the

Wrtsil 32 engine, when used or emergency power applications

requiring ast and reliable start, ast loading, large load steps, and long

periods in stand-by mode.

WRTSIL 32ENGINE TECHNOLOGYFOR EMERGENCY POWER APPLICATIONS

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The submersible heavy load ship Blue Marlin is equipped with three Wrtsil 8L32 engines.

The passenger ferry Finnmarken is equipped with two Wrtsil 9L32 main

engines and two Wrtsil 6L32 auxiliary engines.

The combined heat and power plant ItalGreen is

equipped with three Wrtsil 18V32 engines running

on liquid biofuel.

The oil power plant Yue Yuen is equipped with twelve

Wrtsil 18V32LN and three Wrtsil 18V32 engines.

DESIGN PHILOSOPHY

The Wrtsil 32 is based on the latest

achievements in combustion technology; it is

designed or sae and reliable operation and

long maintenance-ree operating periods.The engine is ully equipped with all essential

ancillaries and a thoroughly planned interace

to the plant systems.

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BENEFITS

More than 1,000 engines in operation

More than 10 Million accumulated running hours

Production capacity o more than 500 engines per year

Optimized or specic project requirements

Strong engineering and project management capability

Secured spare parts and service availability Local service personel and workshops available.

EMERGENCY APPLICATIONS Diesel engines are well suited to operate in emergency applications, requiring ast and reliable

start, ast loading, large load steps and with long periods in stand-by mode.

This type o applications puts special demands on the engine and surrounding equipment and also

has certain implications or the operation and maintenance routines o the plant.

Readiness to start at any time, requires that the engine should be kept in hot stand-by position

all the time.

Testing and operating routines should be established to secure and veriy that the plant is ready to

start at any time.

Features such as slow-turning, pre-lubrication and extensive monitoring possibilities are built-in

eatures o the Wrtsil 32 engine.

The control and automation system should be designed to minimize the possibility or start

ailures, blocking o start requests or automatic shutdowns.

To secure that the engine is able to operate reliably over extended periods o time, at high load and

with a minimum o attendance, a preventive maintenance program should be put in place. This

program should cause a minimum o disturbance to the equipment and its readiness to operate.

The main qualities o the Wrtsil 32 are:

Fast and reliable start

Rapid loading

Reliability and saety

Low maintenance costs Integrated lubrication and cooling systems

Ergonomic interace

Minimized consumables.

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CRANKSHAFT ANDBEARINGSThe latest advances in combustion

development require a crank gear that

operates reliably at high cylinder pressures.The crankshat must be robust and the

specic bearing loads kept at an acceptable

level.

This is achieved by careul optimization

o crankthrow dimensions and llets. The

specic bearing loads are conservative and

the cylinder spacing, which is important or

the overall length o the engine, is minimized.

Besides low bearing loads, the other

crucial actor or sae bearing operation is

oil lm thickness. Ample oil lm thicknesses

in the main bearings are ensured by optimal

balancing o rotational masses and, in the big

end bearing, by ungrooved bearing suraces

in the critical areas. All the actors needed or

a ree choice o the most appropriate bearing

material are present.

ENGINE BLOCKNodular cast iron is the natural choice or

engine blocks today thanks to its strength andstiness properties, along with all the reedom

oered by casting. The Wrtsil 32 makes

optimum use o modern oundry technology

to integrate most oil and water channels. The

result is a virtually pipe-ree engine with a

clean outer exterior.

Resilient mounting is state-o-the-art in

many applications and requires a sti engine

rame. Integrated water and oil channels in the

engine block are designed with this in mind

and serve the double purpose o transer o

liquids and stiening o the engine block.

PISTONFor years, the outstanding piston concept

or highly rated diesel engines has been acomposite piston with a steel crown and a

nodular cast-iron skirt. More than 30 years

o experience has ne-tuned the concept.

When it comes to reliability, there is no real

alternative today or modern engines running

with high cylinder pressures and combustion

temperatures. Wrtsil-patented skirt

lubrication is applied to minimize rictional

losses and to ensure appropriate lubrication o

piston rings, the piston skirt and cylinder liner.

This design ensures proper lubrication o these

vital engine parts even ater extended periods

in stand-by mode.

PISTON RINGS

In Wrtsils three-ring concept each piston ringhas a specic task. They are dimensioned and

proled or consistent perormance throughout

their operating lives. To avoid carbon deposits

in the ring grooves, the pressure balance on

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top o and underneath each ring is crucial.

Experience has shown that this eect is most

likely achieved with a three-ring pack. Finally,

it is well-known that most rictional losses in a

reciprocating combustion engine originate rom

the piston rings. Thus a three-ring pack is the

obvious choice in this respect, too. The top ring,

which bears the greatest load, is provided with

a special wear-resistant coating.

CYLINDER LINER AND

ANTI-POLISHING RINGThe thick high-collar type cylinder lineris designed to have the stiness needed

to withstand both pre-tension orces and

combustion pressures with virtually no

deormation. Its temperature is controlled by

bore cooling o the upper part o the collar to

achieve a low thermal load and to avoid sulphuric

acid corrosion. The cooling water is distributedaround the liners with simple water distribution

rings at the lower end o the collar. At the upper

end the liner is equipped with an anti-polishing

ring to eliminate bore polishing and reduce lube

oil consumption. The unction o this ring is to

calibrate the carbon deposits ormed on the

piston top land to a thickness small enough to

prevent any contact between the liner wall and

the deposits at any piston position. Since there

is no contact between the liner and piston top

land deposits, no oil can be scraped upwards by

the piston. The other positive eect is that the

liner wear is signicantly reduced at the same

time. The strength o the wear-resistant liner

materials used or years in Wrtsil engines has

been urther increased to cope with the high

combustion pressures expected in the uture.

CONNECTING RODA three-piece connecting rod with all the highly

stressed suraces machined, is the saest designor engines o this size intended or continuous

operation at high combustion pressures. For easy

maintenance and accessibility the upper joint

ace is placed right on top o the big-end bearing

housing. A special hydraulic tool is developed or

simultaneous tensioning o all our screws.

To eliminate any risk o wear in the contact

suraces, an intermediate plate with a specialsurace treatment is placed between the main

parts.

CYLINDER HEADThe cylinder head design is based on the our-

screw concept developed by Wrtsil and used

or more than 30 years. Its internal structure

is designed or maximum stiness, which is

essential or obtaining both liner roundness

and even contact between exhaust valves and

their seats.

A our-screw cylinder head design also

provides all the reedom needed or designing

inlet and exhaust ports with a minimum o fow

losses. Computational fuid dynamics (CFD)

analysis in combination with ull-scale fow

measurements has been used or port design

optimization.

The vast amount o experience gained rom

operation o 1000s o engines all around the

world has contributed greatly to exhaust-valvedesign and development. Put together, this

means that a valve material and geometry with

superior perormance is now available.

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MULTIDUCT

Multiducts replace a number o individual

components in traditional engine designs.

Their unctions are:

Air transer rom the air receiver to the

cylinder head

Exhaust transer to the exhaust system

Cooling water outlet ater the cylinder head

Cooling water return channel rom the

engine.

Additional unctions are:

Introduction o an initial swirl to the inlet air

or optimal part-load combustion

Insulation and cooling o the exhaust transer

duct

Support or exhaust system and its

insulation.

STARTING AIR SYSTEMRapid and reliable starting is secured by the

air-over-piston starting system. Starting air

is distributed to each cylinder via air pipes and

channels, starting air valves in the cylinder

head are pneumatically controlled by air

passing through the starting air distributor at

the end o the cam shat.

The A and B-bank o the V-engines can

be tted with totally separated starting air

trains, each capable o starting the engine.

Air reciever and valves or the pneumatic

emergency shutdown system is built on the

engine.

FUEL INJECTION SYSTEMThe ultimate saety in low-pressure uel system

design is achieved with the Wrtsil-patented

multihousing principle. With this system the

uel line consists basically o drilled channels in

cast parts clamped rmly on the engine block.

In the Wrtsil 32 these parts are: The pump housing

The tappet housing

The uel transer housing

The multicover.

For ease o assembly/disassembly, these

parts are connected to each other with slide

connections. Since both the whole low-

pressure system and the high-pressure system

are housed in a ully covered compartment,

the saety standard is unbeatable. The high-

pressure system was designed and endurance

tested at 2000 bar. Injection pressure is

around 1800 bar.

With a wear-resistant low-riction coating

on the plunger, no lubricating oil is required

or the pump element. Thanks to the proled

plunger geometry the clearance between

plunger and barrel can be kept small, thereby

allowing only a minimum o oil to pass down

the plunger. This small leakage is collected and

returned to the uel system. Any likelihood o

the uel mixing with the lube oil is eliminated.

Both nozzle holders and the nozzle are madeo high-grade hardened steel to withstand

the high injection pressures. Combined with

oil cooling o the nozzles this guarantees

outstanding nozzle lietimes.

Spex charging.

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Each injection pump is equipped with an

integrated electropneumatic shutdown cylinder,

connected to the overspeed protection system.

The engine has an independent mechanical

overspeed protection system, acting directly at

the uel control rod.

The engine can be equipped with or

example, engine driven uel eed pump, uel ne

lter, electrical motor driven stand-by pump,

thus reducing installation work at site and

securing unctional and pressure interphases.

The engine can be equipped with double

shielded high pressure pipes and leak

uel alarms or early detection o possible

malunctions.

TURBOCHARGING SYSTEMThe Single Pipe Exhaust pipe (SPEX) system

is designed or minimum fow losses on bothexhaust and air sides.

The charging systems are designed to give

high eciency and extremely good start and

load acceptance.

Non-cooled turbochargers with inboard

plain bearings lubricated rom the engines

lube oil system are used. This secures

readiness to start and acceptance o rapid

loading at any time.

COOLINGSYSTEMThe cooling system is split into two separate

circuits, the high-temperature (HT) and the

low-temperature (LT) circuits. The cylinder

liner and the cylinder head temperatures are

controlled through the HT circuit. The HT water

pump and thermostatic valve are integrated

with the pump cover module at the ree end

o the engine. The complete HT circuit is thus

virtually ree o pipes.

The LT circuit cools the charge air and the

lube oil. It is ully integrated with the engine,including parts such as the LT water pump, LT

thermostatic valve and transer channels in the

engine block.

LUBRICATINGOIL SYSTEM

The Wrtsil 32 engine is equipped with a

complete engine on-built lube oil system,

including an engine-driven main pump, electrical

motor driven prelubricating pump, lubricating oil

cooler, ull fow automatic lter, centriugal lter,

thermostatic valve and pressure control valve.

The engine is tted with running-in lters beore

each main bearing, these lters are removed

ater start-up o the installation.

The lube oil ltration is based on an

automatic back-fushing lter requiring a

minimum o maintenance. The lter elements

are made o seamless sleeve abric with high

temperature resistance. A special eature

is the centriugal lter, connected to the

back-fushing line o the automatic lter. Thisprovides the means or extraction o particles

rom the system.

Engine

5763 C

Charge air

cooler

Lube oilcooler

Exp.0.71.5 bar

Exp.0.71.5 bar

LTC

centralcooler

HTC

centralcooler

Engine

Pre-

heater

Charge air

cooler

FilterCooler Pump

Prelubricating

pump

Lube oil system

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MONITORING AND CONTROLDepending on the application, the monitoring,

control and saety unctions o the engine canbe met either by utilizing a passive sensor

and actuator interace ullling class 1E

requirements or an embedded control and

management system based on Wrtsils

advanced UNIC C1 automation system.

Class 1E

In the design o class 1E sensor and actuator

interace the ocus is laid on:

Reliability

Redundancy

Diversity

Separation

Environmental, testing and maintenance

requirements.

The engine is equipped with sensors,

transducers, switches and actuators to

ulll requirements according to applicable

standards and regulations. Essential operation

and protection unctions can be realized

with diversied or redundant devices. Criticalprotection unctions such as engine over

speed, jacket cooling water temperature or

lubricating oil pressure can be provided with

sensors enabling 2-out-o-3 operation.

The operational reliability o essential

controls and signals is ensured by meanso physical separation, which is taken into

account in design o cable routing and

connections.

UNIC C1 automation system provides for:

Critical protection unctions

Basic local monitoring

Hardwired interace to plant control

Speed and load control.

Highest possible reliability is achieved with

hardwired connections and devices specically

designed or the on-engine environment. Speed

and load can be controlled with electrical or

mechanical speed regulator or alternatively

by means o electrical speed regulator with

mechanical speed regulator as a back-up.

EASY INSTALLATIONAn important design principle or the Wrtsil 32

engine is to build as much o the essential

auxiliary equipment as possible on the engine.This goes or lube oil and water pumps and

thermostatic valves, lube oil cooler and lter,

amply sized lube oil sump, engine control and

monitoring. Installation work is thus reduced

to a minimum, the systems are ully pressure

tested at actory and the interaction betweendierent components are tested and veried at

the actory.

EASY MAINTENANCEEcient and easy maintenance is incorporated

into the design. In combination with the long

intervals between overhauls, the hours spent

on maintenance are reduced to a minimum.

The lube oil ltration is one good example.

Hydraulics are used or pre-tension o the

cylinder head screws, all the connecting rod

screws and the main bearing screws. The

distinctive Wrtsil eature with individual

hydraulic jacks or each main bearing is o

course adopted. The unique uel line design

enables injection pump exchange with a

minimum o work with less risk o error.

The multiduct arrangement allows the

cylinder head to be lited without removal o

water pipes, while the slide-in connections

on the manoeuvring side allows it to be litedwithout removal o oil or air pipes. The water

pumps are easy to replace thanks to the

cassette design principle and water channel

arrangement in the pump cover at the ree

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end o the engine. There is greater accessibility to all the above

components thanks to a minimal number o pipes and an ergonomiccomponent design.

THE TOTAL SERVICE PROVIDERMore than 11 000 service proessionals employed by Wrtsil

and over 70 Wrtsil owned service centres worldwide guarantee

outstanding eld service support and ast spare parts supply

wherever the plant is located. Wrtsils total service commitment

means more than just providing a prompt supply o parts or sending a

maintenance specialist to x a problem. It means taking responsibility.

Depending on the level o partnership required, a service package

can be tailored rom round-the-clock technical support and original

parts deliveries to a comprehensive operation and maintenance

partnership on a day-to-day basis. The committed operation and

maintenance o power installations with more than 5500 MW o

installed power makes Wrtsil the largest diesel engine power plant

operator in the world. Additionally a Condition Based Maintenance

(CBM) services can be provided, which is based on remote monitoring

o the units rom CBM-centre in Wrtsil actory. Personnel o the

operator are trained by the Wrtsil Land & Sea Academy (WLSA).

This global network o training centres, with highly qualied

personnel and state-o-the-art remote learning systems, delivers athorough understanding o how to optimize the saety, reliability and

perormance o the installation. Wrtsil helps you to get the best

rom your personnel and your installation.

MAIN TECHNICAL DATA

WRTSIL 32 FOR EMERGENCY POWER APPLICATIONS

Cylinder bore 320 mm

Piston stroke 400 mm

Engine speed 720, 750 rpmPiston speed 9.6, 10.0 m/s

RATED POWER

Engine type60Hz, 720 rpm 50Hz, 750 rpm

kWm kWe kWm kWe

6L32

8L32

9L32

12V32

16V32

20V32

2 880

3 840

4 320

5 760

7 680

9 600

2 780

3 700

4 170

5 558

7 434

9 341

3 000

4 000

4 500

6 000

8 000

10 000

2 890

3 860

4 340

5 790

7 744

9 730

Acc to ISO3046 standard. 10 % overload allowed 1 hr every 12 hour.

ENGINE DIMENSIONS (MM) AND WEIGHTS (TONNES)Engine type Length Width Height Weight

6L32

8L32

9L32

12V32

16V32

20V32

5 297

6 510

7 116

6 837

8 206

9 276

2 300

2 300

2 300

2 870

3 296

3 233

3 421

3 571

3 571

3 595

3 595

4 139

30

42

44

54

63

89

GENERATING SET DIMENSIONS (MM) AND WEIGHTS (TONNES)

Engine type Length Width Height Weight

6L32

8L32

9L32

12V32

16V32

20V32

8 766

9 750

11 200

10 030

11 239

12 200

2 410

2 410

2 410

3 050

3 300

3 300

3 740

3 740

3 740

4 420

4 420

4 420

58

77

82

92

119

130

Subject to revision without notice.

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WRTSIL is a registered trademark. Copyright 2011 Wrtsil Corporation.

Wrtsil is a global leader in complete liecycle power solutions or the

marine and energy markets. By emphasising technological innovation

and total efciency, Wrtsil maximises the environmental and economic

perormance o the vessels and power plants o its customers. Wrtsil

is listed on the NASDAQ OMX Helsinki, Finland.

DBAB54096

2

08

.2011/Boc

ksOfce

/Waasa

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w32 engine technology for emergency power applications

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