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TECHNOLOGY REVIEW
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WÄRTSILÄ 46
TECHNOLOGY REVIEW
This is a summary of Wärtsilä’s approach to design and
technology in the Wärtsilä 46 engine.
DESIGN PHILOSOPHY................................................... 4
DEVELOPMENT POLICY................................................ 4
EXHAUST EMISSIONS................................................... 5
FUEL SYSTEM.............................................................. 7
FUELS ......................................................................... 7
TURBOCHARGING SYSTEM........................................... 8
PISTON ...................................................................... 9
CONNECTING ROD..................................................... 11
CRANKSHAFT ............................................................ 11
BEARINGS ................................................................. 12
RESILIENT MOUNTING................................................ 14
AUTOMATION SYSTEM............................................... 16
MAINTENANCE .......................................................... 19
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DESIGN PHILOSOPHY DEVELOPMENT POLICY
Wärtsilä engine designs are based on The Wärtsilä 46 is a medium-speed engine
generations of know-how combined with for which reliability and total economy have
innovations in response to customer needs. been the guiding principles.
The WÄRTSILÄ® 46 engine offers Extensive testing in our modern diesel
customers the following core values: laboratory backed up by several thousand
• Real reliability running hours have made the Wärtsilä 46
• Low operating costs a really reliable diesel engine. Laboratory
• Low exhaust gas emissions testing is full-scale engine testing: it
Due to its excellent combustion performance and
reliability level the Wärtsilä 46 has become the most • Easy and cost-effective installation covers various types of endurance testing,
popular engine for power generation onboard new • Proven flexible mounting technology and also combustion measurements and
cruise vessels. Liberty of the Seas is equipped with • Easy maintenance system optimizations. All these confirm
six 12-cylinder Wärtsilä 46 V-engines with a total
theoretical calculations, simulations as well
output of 75,600 kW.
as performance mapping of such factors as
heat balance, fuel and lube oil consumption,
exhaust emission, noise and vibration level.
Wärtsilä works in close co-operation with
the customer in conducting field tests and
follow-ups of selected test components. Data
on wear rates, maintenance intervals and
consumption rates are collected regularly.
This activity is part of a long-term customer
relationship creating an even better product.
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Low NOX combustion NOX emissions compliance with Wärtsilä engines
1200
Pressure rise
induced from 1000
compression 800 Degraded airshed:
400 mg/nm3 (dry, 15 vol-% O2, 0 °C)
600
Compliance using
400 SCR techniques
and proper fuel
-90 -60 -30 0 30 60 90 120 200
choice
TDC
induced from 16
combustion 14
Standard
Wärtsilä 46
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Pressure rise 10 Low NOX combustion
induced from
8
compression Direct Water Injection or Wetpac humidification
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4
Selective Catalytic Reduction (SCR)
2
Low-speed Medium-speed High-speed
0
-90 -60 -30 0 30 60 90 120 0 200 400 600 800 1000 1200 1400 1600 1800
TDC rpm
EXHAUST EMISSIONS
The emphasis on environmental issues has common rail fuel injection, which maintains Wetpac humidification, which briefly
steadily grown and it is expected to grow an optimum fuel injection pressure also described means that pressurized water
further in the future. The main focus has been at low load and reduced speed. The ash is injected directly after the compressor of
on nitrogen oxides (NOX) emissions, sulphur content of the fuel strongly affects both the turbocharger. Less water is required if
oxides (SOX) and particulate emissions. Lately smoke and particulates. it is injected directly into the cylinder. The
much attention has been paid to CO2 due to • The factor that has the most significant Wärtsilä 46 is available also with Direct
the Kyoto Protocol and in the marine sector influence on NOX formation is the Water Injection (DWI) (only for marine
smokeless operation has become important temperature. Therefore the most successful applications). Direct water injection is
especially for cruise ships. approach to lower NOX emissions is to an option for low sulphur fuel. Wetpac
• CO2 and SOX emissions are practically reduce the peak temperatures during the humidification and DWI can be applied in
directly proportional to the carbon and combustion. The available means to achieve addition to the dry methods already utilised
sulphur content of the fuel and the fuel stable and low combustion temperatures to achieve further NOX reduction.
consumption. The superior fuel efficiency can be divided into dry methods and wet • Selective catalytic reduction (SCR), which is
of diesel engines therefore gives lower CO2 methods. external from the engine, offers the highest
and SOX emissions than most other power • Dry methods involve of optimum shape of possible NOX reduction.
sources, when comparing operation on the the combustion chamber, high compression The standard engine meets the NOX level set
same fuel. ratio, sophisticated fuel injection equipment by IMO (International Maritime Organisation) in
• Generally diesel engines have very low CO and adapted cam profile, optimised Annex VI to MARPOL 73/78, and the World Bank
and THC (Total HydroCarbon) emissions turbocharging system for correct air to fuel Group specified in “Thermal Power: Guidelines
compared to other power sources thanks to ratio and internal cooling of the cylinder by for New Plants, 1998” for engine driven power
the efficient combustion. earlier closing of the air intake valves (Miller plants in “non-degraded air sheds”. All marine
• Smoke is by definition visible. In the exhaust concept). engines are delivered with an EIAPP (Engine
from a diesel engine smoke consists of soot • The principle of wet methods is to International Air Pollution Prevention) certificate,
particles that are large and concentrated introduce water into the combustion technical file and marked engine components as
enough to become visible. Smokeless chamber. Wärtsilä has developed a new required by the NOX Technical Code in MARPOL
operation at any load is achieved with technology for addition of water named 73/78 Annex VI.
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Compressor
Water mist catcher
Heat
Accumulator
Flow fuse
DWI valve
Water to
DWI valve
Water inlet
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FUEL SYSTEM
The Wärtsilä 46 is available with conventional and electronically controlled fuel injectors. The HIGH VISCOSITY HFOS
fuel injection, or optionally with common rail fuel pumps are driven by the camshaft and each Among the recently approved fuels, there are
fuel injection for smokeless operation also at pump and accumulator serve two cylinders. varieties of high-viscosity mineral oils that can
low load. Adjacent accumulators are connected with be found either naturally in e.g. oil-sand or as
The entire fuel system is enclosed in a fully small bore piping in order to reduce the risk of heavy residues from oil refineries.
covered compartment for maximum safety. pulsation in the rail. The engine can operate CRUDE OILS
All leakages from injection valves, pumps and with one or two fuel pumps disconnected, Crude oils are especially suitable for pumping
pipes are collected in closed system. should this ever be necessary. A safety feature stations along crude oil pipelines and for
of the system is that there is no pressure on the electricity production at oil fields. Crude oils
CONVENTIONAL FUEL INJECTION injection nozzles between injections. All functions have been in frequent use as fuels for Wärtsilä
• The monoelement injection pump design are controlled by the embedded control system engines at power plants and oil pumping
is a rigid a distortion-free solution for high on the engine. stations since mid 1990-ties.
injection pressures. The main advantage of the common rail system EMULSIFIED FUELS
• A constant pressure relief valve in the is that the injection pressure can be kept at a Emulsification offers means of utilising
injection pump eliminates the risk of sufficiently high level over the while load range, fuels with even higher viscosity. Among the
cavitation erosion by maintaining a residual which gives smokeless operation also at low load. emulsified fuels, the Venezuelan Orimulsion®
pressure, which is on a safe level over the is already in commercial use and other
whole operating field. FUELS qualities are being evaluated. The high
• A drained and sealed-off compartment water contents in these fuels facilitate the
between the pump and the tappet prevents The Wärtsilä 46 engine is designed and handling of these fuels almost in the same
leakage fuel from mixing with lubricating oil. developed for continuous operation on fuels with way as conventional fuel oils and they have
• Precalibrated pumps are interchangeable. the following properties: advantageous effects on the exhaust gas
• The injection valve is designed to have a DIESEL OIL & HFO emissions. These fuels will be of importance in
small heat absorbing surface facing the Diesel oils (distillate oils) have traditionally been the future.
combustion space. Together with efficient the fuels for diesel engines. Heavy fuel oils (HFO) LIQUID BIO FUEL
heat transfer to the cooling water this have been used in Wärtsilä engines since the Vegetable based bio oils have been accepted
eliminates the need for a separate nozzle 1970’s. During the recent years, oil refineries for Wärtsilä engines since 1996 and they have
temperature control system. have developed processes to increase the yield of found commercial use for diesel power plants.
high-revenue products resulting in poorer quality Olive oil, palm oil, soy bean oil and rape seed
COMMON RAIL FUEL INJECTION residues. This means higher sulphur content, oil are some of the main qualities among the
The common rail system comprises higher ash content and worse combustion bio oils, all usable as diesel fuel. Biodiesel,
pressurizing fuel pumps, fuel accumulators properties. transesterified bio oil, can also be used.
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TURBOCHARGING SYSTEM
Wärtsilä 46 is provided with Spex (Single • The modular-built exhaust gas systems are
pipe exhaust) system and with high efficiency durable enough to handle high pressure
turbocharger. ratios and pulse levels, but at the same
• The Spex turbocharging system is an time elastic enough to cope with thermal
exhaust gas system that combines the expansion in the system.
advantages of both pulse and constant • The turbocharger has the highest available
pressure charging. efficiency.
• Compared with a constant pressure system, • The turbocharger is equipped with plain
the ejector effect of the gas pulses will bearings and there is no cooling water.
provide better turbine efficiency at partial • The turbocharger is fitted with cleaning
loads. devices for both the compressor and the
• The Spex system is practically free from turbine side.
interference. This means very small • Exhaust waste-gate and air by-pass are
deviations in the scavenging between the used to obtain specific requirements on the
cylinders and consequently an even exhaust operating range, load response or partial
gas temperature. load.
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PISTON PISTON RING SET
• A composite low-friction piston with a • Low friction three-ring set in the upper part. The purpose of this ring
nodular cast iron skirt and a steel top. • Special wear resistant coating for the is to “calibrate” the carbon deposits on the
• The special cooling gallery design assures compression rings piston top land to a thickness small enough to
efficient cooling and high rigidity for • Dimensioned and profiled for maximum prevent contact between the liner inner wall
the piston top. The design can handle sealing and pressure balance and the deposits on the piston top land. “Bore
combustion pressures beyond 200 bar. polishing” can lead to local liner wear and
• Hardened top ring grooves assure a long CYLINDER LINER AND
increased lube oil consumption.
lifetime.
• Low friction is ensured by the skirt
ANTI-POLISHING RING
The temperature distribution in the cylinder
liner is important not only in terms of stress
lubrication system featuring: Cylinder liner deformations are normally and deformation but also decisive for the
• A well distributed clean oil film that caused by cylinder head clamping, thermal cylinder liner wear rate. The temperature
eliminates the risk of piston ring scuffing and mechanical load. Thanks to a special must remain above the sulphuric acid dew
and reduces the wear rate. design with a high collar-to-stroke ratio, the point to avoid corrosion, but at the same time
• Cleaner rings and grooves free from deformations in this liner are very small. A remain sufficiently low to avoid lubricating oil
corrosive ombustion products. round liner bore in combination with excellent breakdown.
• Hydraulically damped tilting movements lubrication improves conditions for the piston The material composition is based on long
provided by an oil pad between the liner rings and reduces wear. experience with the special grey cast iron alloy
and the piston, resulting in less noise and To eliminate the risk of bore polishing, the developed for excellent wear resistance and
wear. liner is provided with an anti-polishing ring high strength.
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CONNECTING ROD
CRANKSHAFT
The crankshaft design allows for use of high
CYLINDER HEAD
The cylinder head design is based on reliability
and easy maintenance.
• A rigid box like design for even
circumferential contact pressure between
the cylinder head and the cylinder liner.
• Four cylinder head fixing bolts are used,
which simplifies maintenance.
• No valve cages are used; this improves
reliability and provides greater scope
for optimization of the exhaust port flow
characteristics.
• Efficient water-cooled exhaust valve seat
rings.
• Valve rotators on both exhaust as well as
inlet valves guarantee an even thermal and
mechanical load on the valves.
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CAMSHAFT AND VALVE GEAR BEARINGS
The camshaft is built of single cylinder sections • The valve mechanism includes rocker arms The Thick-Pad bearing design emphasizes
with integrated cams. working on yokes guided by pins. one key concept: Reliability.
• The camshaft sections are connected • Both exhaust and inlet valves receive a The bearing loads have been reduced
through separate bearing journals, which forced rotation from Rotocaps during every by increasing crankshaft journal and pin
makes it possible to remove the shaft opening cycle. This forced rotation provides diameters as well as length.
sections sideways from the camshaft for even temperature distribution and wear • Low bearing loads allow for softer
compartment. of the valves, and keeps the sealing surface bearing materials with greater
• The valve follower is of the roller tappet free from deposits. Good heat conduction is comformability and adaptability. This
type, where the roller profile is slightly the result. makes the bearing virtually seizure-free.
convex for good load distribution.
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ENGINE BLOCK
• The engine block is manufactured of nodular
cast iron in order to achieve the rigid and durable
construction needed for resilient mounting.
• The main bearings are of the underslung type,
with hydraulically tightened bolts.
• Side bolts add further rigidity to the main bearing
housing.
• In-line engines are equipped with an integrated
air receiver featuring increased rigidity, simplicity
and cleaness.
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RESILIENT MOUNTING
Engine foot
Fixing rail
Resilient element
Foundation
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COOLING SYSTEMS
• The fresh water cooling system is devided • For obtaining maximum heat recovery the
into high temperature and low temperature charge air cooler is split into a high and low
cooling system. temperature section.
• The high temperature cooling water system • Engine driven pumps can be provided as an
operates constantly at a high temperature option for marine application. In power plant
level to make the temperature fluctuations application, these are standard.
in the cylinder components as small as
possible and preventing from corrosion due
to undercooling.
• Marine engines have dry sump and power • For the purpose of running-in, provision has
plant engines wet sump. The lube oil is been made for mounting special running-in
treated outside the engine by continuous filters in the crankcase in front of each main
separating. bearing.
• On the way to the engine, the oil passes • Engine driven lube oil pump can be
through a lube oil cooler, a full flow provided as an option for marine
automatic filter unit and a safety filter for application. In power plant application this
final protection. is standard.
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AUTOMATION SYSTEM
UNIC C1 • Basic local monitoring
In the UNIC C1 engine automation system, the • Hardwired interface to external alarm and
The Wärtsilä 46 is equipped with a fundamental aspects of the engine control and monitoring systems
modular embedded automation system, safety are handled by the embedded control • Speed and load control
Wärtsilä unified controls - UNIC, which and management system. This includes engine
is available in three different versions. speed and load control as well as overspeed The engine control system
The basic functionality is the same in all protection, lube oil pressure and cooling water is designed to:
versions, but the functionality can be easily temperature protection. For the other parts, • Achieve the highest possible reliability,
expanded to cover different applications. the design requires the majority of the sensors with components, e.g. sensors, designed
UNIC C1 and UNIC C2 are versions to be hardwired to an external alarm and specifically for the on-engine environment,
applicable for engines with conventional monitoring system. • Reduce cabling on and around the engine,
fuel injection, whereas UNIC C3 additionally with a clear point of interconnection and a
includes fuel injection control for engines The following functionality is provided: standardized interface, and
with common-rail fuel injection. • Fundamental safety (overspeed, LO • Provide high performance with optimized
pressure, cooling water temp.) and pre-tested controls.
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Hardwired
connections
Loadsh.
CAN
LCP
AUTOMATION SYSTEM COMPONENTS
TCM
TCM Thermocouple Module
MCM
IOM Input Output Module
Hardwired
connections
Loadsh.
CAN
Ethernet
LCP
ESM
IOM
MCM
PDM
UNIC C2
Hardwired
connections
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and the need for off-engine systems is
considerably reduced.
The system meets the highest requirements
for reliability, with selective redundancy and
fault-tolerant designs, and can be applied to
single main engine operation.
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WÄRTSILÄ 46
MAIN TECHNICAL DATA
Ship Power and Ship Power
Power Plant engines engines
Cylinder bore 460 mm 460 mm
Piston stroke 580 mm 580 mm
Cylinder output 975 kW/cyl 1050 kW/cyl
Engine speed 500, 514 rpm 500, 514 rpm
Mean effective 25.4, 26.1 bar
pressure 24.3, 23.6 bar 28.0, 28.8 bar
Piston speed 9.7, 9.9 m/s 9.7, 9.9 m/s
Fuel specification:
Fuel oil 730 cSt/50°C
7200 sR1/100°F
ISO 8217, category ISO-F-RMK 55
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05.2008 / Bock´s Office / Waasa Graphics
Wärtsilä enhances the business of its customers by providing them
with complete lifecycle power solutions. When creating better and
environmentally compatible technologies, Wärtsilä focuses on the
marine and energy markets with products and solutions as well as
services. Through innovative products and services, Wärtsilä sets out
to be the most valued business partner of all its customers. This is
achieved by the dedication of more than 17,000 professionals manning
160 Wärtsilä locations in 70 countries around the world. Wärtsilä is
listed on The Nordic Exchange in Helsinki, Finland.