WRTSIL 32 ENGINE TECHNOLOGY FOR EMERGENCY POWER APPLICATIONS

WRTSIL 32 ENGINE TECHNOLOGY FOR EMERGENCY POWER APPLICATIONS

This is a brief guide to the technical features and performance of the Wrtsil 32 engine, when used for emergency power applications requiring fast and reliable start, fast loading, large load steps, and long periods in stand-by mode.

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
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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 for safe and reliable operation and long maintenance-free operating periods. The engine is fully equipped with all essential ancillaries and a thoroughly planned interface to the plant systems.
The submersible heavy load ship Blue Marlin is equipped with three Wrtsil 8L32 engines. 4

BENEFITS
More than 1,000 engines in operation More than 10 Million accumulated running hours Production capacity of more than 500 engines per year Optimized for specific 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 fast and reliable start, fast loading, large load steps and with long periods in stand-by mode. This type of applications puts special demands on the engine and surrounding equipment and also has certain implications for the operation and maintenance routines of 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 verify that the plant is ready to start at any time. Features such as slow-turning, pre-lubrication and extensive monitoring possibilities are built-in features of the Wrtsil 32 engine. The control and automation system should be designed to minimize the possibility for start failures, blocking of start requests or automatic shutdowns. To secure that the engine is able to operate reliably over extended periods of time, at high load and with a minimum of attendance, a preventive maintenance program should be put in place. This program should cause a minimum of disturbance to the equipment and its readiness to operate.

The main qualities of the Wrtsil 32 are: Fast and reliable start Rapid loading Reliability and safety Low maintenance costs Integrated lubrication and cooling systems Ergonomic interface Minimized consumables.

CRANKSHAFT AND BEARINGS

The latest advances in combustion development require a crank gear that operates reliably at high cylinder pressures. The crankshaft must be robust and the specific bearing loads kept at an acceptable level. This is achieved by careful optimization of crankthrow dimensions and fillets. The specific bearing loads are conservative and the cylinder spacing, which is important for the overall length of the engine, is minimized. Besides low bearing loads, the other crucial factor for safe bearing operation is oil film thickness. Ample oil film thicknesses in the main bearings are ensured by optimal balancing of rotational masses and, in the big end bearing, by ungrooved bearing surfaces in the critical areas. All the factors needed for a free choice of the most appropriate bearing material are present.

result is a virtually pipe-free engine with a clean outer exterior. Resilient mounting is state-of-the-art in many applications and requires a stiff engine frame. Integrated water and oil channels in the engine block are designed with this in mind and serve the double purpose of transfer of liquids and stiffening of the engine block.

ENGINE BLOCK
Nodular cast iron is the natural choice for engine blocks today thanks to its strength and stiffness properties, along with all the freedom offered by casting. The Wrtsil 32 makes optimum use of modern foundry technology to integrate most oil and water channels. The
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PISTON
For years, the outstanding piston concept for highly rated diesel engines has been a composite piston with a steel crown and a nodular cast-iron skirt. More than 30 years of experience has fine-tuned the concept. When it comes to reliability, there is no real

alternative today for modern engines running with high cylinder pressures and combustion temperatures. Wrtsil-patented skirt lubrication is applied to minimize frictional losses and to ensure appropriate lubrication of piston rings, the piston skirt and cylinder liner. This design ensures proper lubrication of these vital engine parts even after extended periods in stand-by mode.

PISTON RINGS
In Wrtsils three-ring concept each piston ring has a specific task. They are dimensioned and profiled for consistent performance throughout their operating lives. To avoid carbon deposits in the ring grooves, the pressure balance on

top of and underneath each ring is crucial. Experience has shown that this effect is most likely achieved with a three-ring pack. Finally, it is well-known that most frictional losses in a reciprocating combustion engine originate from 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.

deformation. Its temperature is controlled by bore cooling of the upper part of the collar to achieve a low thermal load and to avoid sulphuric acid corrosion. The cooling water is distributed around the liners with simple water distribution rings at the lower end of 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 function of this ring is to calibrate the carbon deposits formed 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 effect is that the liner wear is significantly reduced at the same time. The strength of the wear-resistant liner materials used for years in Wrtsil engines has been further increased to cope with the high combustion pressures expected in the future.

housing. A special hydraulic tool is developed for simultaneous tensioning of all four screws. To eliminate any risk of wear in the contact surfaces, an intermediate plate with a special surface treatment is placed between the main parts.

CYLINDER HEAD
The cylinder head design is based on the fourscrew concept developed by Wrtsil and used for more than 30 years. Its internal structure is designed for maximum stiffness, which is essential for obtaining both liner roundness and even contact between exhaust valves and their seats. A four-screw cylinder head design also provides all the freedom needed for designing inlet and exhaust ports with a minimum of flow losses. Computational fluid dynamics (CFD) analysis in combination with full-scale flow measurements has been used for port design optimization. The vast amount of experience gained from operation of 1000s of engines all around the world has contributed greatly to exhaust-valve design and development. Put together, this means that a valve material and geometry with superior performance is now available.

CYLINDER LINER AND ANTI-POLISHING RING

The thick high-collar type cylinder liner is designed to have the stiffness needed to withstand both pre-tension forces and combustion pressures with virtually no

CONNECTING ROD
A three-piece connecting rod with all the highly stressed surfaces machined, is the safest design for engines of this size intended for continuous operation at high combustion pressures. For easy maintenance and accessibility the upper joint face is placed right on top of the big-end bearing

Spex charging.

MULTIDUCT
Multiducts replace a number of individual components in traditional engine designs. Their functions are: Air transfer from the air receiver to the cylinder head Exhaust transfer to the exhaust system Cooling water outlet after the cylinder head Cooling water return channel from the engine. Additional functions are: Introduction of an initial swirl to the inlet air for optimal part-load combustion Insulation and cooling of the exhaust transfer duct Support for exhaust system and its insulation.

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 of the cam shaft. The A and B-bank of the V-engines can be fitted with totally separated starting air trains, each capable of starting the engine. Air reciever and valves for the pneumatic emergency shutdown system is built on the engine.

FUEL INJECTION SYSTEM

The ultimate safety in low-pressure fuel system design is achieved with the Wrtsil-patented multihousing principle. With this system the fuel line consists basically of drilled channels in cast parts clamped firmly on the engine block. In the Wrtsil 32 these parts are: The pump housing The tappet housing The fuel transfer housing The multicover.

STARTING AIR SYSTEM

Rapid and reliable starting is secured by the air-over-piston starting system. Starting air
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For ease of assembly/disassembly, these parts are connected to each other with slide connections. Since both the whole lowpressure system and the high-pressure system are housed in a fully covered compartment, the safety standard is unbeatable. The highpressure system was designed and endurance tested at 2000 bar. Injection pressure is around 1800 bar. With a wear-resistant low-friction coating on the plunger, no lubricating oil is required for the pump element. Thanks to the profiled plunger geometry the clearance between plunger and barrel can be kept small, thereby allowing only a minimum of oil to pass down the plunger. This small leakage is collected and returned to the fuel system. Any likelihood of the fuel mixing with the lube oil is eliminated. Both nozzle holders and the nozzle are made of high-grade hardened steel to withstand the high injection pressures. Combined with oil cooling of the nozzles this guarantees outstanding nozzle lifetimes.

Engine

5763 C

Charge air cooler

Lube oil cooler

Exp. 0.71.5 bar

LTC central cooler

Lube oil system Filter Cooler Pump

Charge air cooler

Prelubricating pump
Exp. 0.71.5 bar HTC central cooler

Engine Pr eheater

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 fuel control rod. The engine can be equipped with for example, engine driven fuel feed pump, fuel fine filter, electrical motor driven stand-by pump, thus reducing installation work at site and securing functional and pressure interphases. The engine can be equipped with double shielded high pressure pipes and leak fuel alarms for early detection of possible malfunctions.

Non-cooled turbochargers with inboard plain bearings lubricated from the engines lube oil system are used. This secures readiness to start and acceptance of rapid loading at any time.

LUBRICATING OIL 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, full flow automatic filter, centrifugal filter, thermostatic valve and pressure control valve. The engine is fitted with running-in filters before each main bearing, these filters are removed after start-up of the installation. The lube oil filtration is based on an automatic back-flushing filter requiring a minimum of maintenance. The filter elements are made of seamless sleeve fabric with high temperature resistance. A special feature is the centrifugal filter, connected to the back-flushing line of the automatic filter. This provides the means for extraction of particles from the system.

COOLING SYSTEM
The 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 free end of the engine. The complete HT circuit is thus virtually free of pipes. The LT circuit cools the charge air and the lube oil. It is fully integrated with the engine, including parts such as the LT water pump, LT thermostatic valve and transfer channels in the engine block.

TURBOCHARGING SYSTEM
The Single Pipe Exhaust pipe (SPEX) system is designed for minimum flow losses on both exhaust and air sides. The charging systems are designed to give high efficiency and extremely good start and load acceptance.

MONITORING AND CONTROL

Depending on the application, the monitoring, control and safety functions of the engine can be met either by utilizing a passive sensor and actuator interface fulfilling class 1E requirements or an embedded control and management system based on Wrtsils advanced UNIC C1 automation system. Class 1E In the design of class 1E sensor and actuator interface the focus is laid on: Reliability Redundancy Diversity Separation Environmental, testing and maintenance requirements. The engine is equipped with sensors, transducers, switches and actuators to fulfill requirements according to applicable standards and regulations. Essential operation and protection functions can be realized with diversified or redundant devices. Critical protection functions such as engine over speed, jacket cooling water temperature or lubricating oil pressure can be provided with sensors enabling 2-out-of-3 operation.
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The operational reliability of essential controls and signals is ensured by means of physical separation, which is taken into account in design of cable routing and connections. UNIC C1 automation system provides for: Critical protection functions Basic local monitoring Hardwired interface to plant control Speed and load control. Highest possible reliability is achieved with hardwired connections and devices specifically designed for the on-engine environment. Speed and load can be controlled with electrical or mechanical speed regulator or alternatively by means of electrical speed regulator with mechanical speed regulator as a back-up.

to a minimum, the systems are fully pressure tested at factory and the interaction between different components are tested and verified at the factory.

EASY MAINTENANCE
Efficient 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 filtration is one good example. Hydraulics are used for pre-tension of the cylinder head screws, all the connecting rod screws and the main bearing screws. The distinctive Wrtsil feature with individual hydraulic jacks for each main bearing is of course adopted. The unique fuel line design enables injection pump exchange with a minimum of work with less risk of error. The multiduct arrangement allows the cylinder head to be lifted without removal of water pipes, while the slide-in connections on the manoeuvring side allows it to be lifted without removal of 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 free

EASY INSTALLATION
An important design principle for the Wrtsil 32 engine is to build as much of the essential auxiliary equipment as possible on the engine. This goes for lube oil and water pumps and thermostatic valves, lube oil cooler and filter, amply sized lube oil sump, engine control and monitoring. Installation work is thus reduced

MAIN TECHNICAL DATA WRTSIL 32 FOR EMERGENCY POWER APPLICATIONS end of the engine. There is greater accessibility to all the above components thanks to a minimal number of pipes and an ergonomic component design.
Cylinder bore Piston stroke Engine speed Piston speed RATED POWER
Engine type 6L32 8L32 9L32 12V32 16V32 20V32 60Hz, 720 rpm kWm 2 880 3 840 4 320 5 760 7 680 9 600 kWe 2 780 3 700 4 170 5 558 7 434 9 341 kWm 3 000 4 000 4 500 6 000 8 000 10 000 50Hz, 750 rpm kWe 2 890 3 860 4 340 5 790 7 744 9 730

320 mm 400 mm 720, 750 rpm 9.6, 10.0 m/s

THE TOTAL SERVICE PROVIDER

More than 11 000 service professionals employed by Wrtsil and over 70 Wrtsil owned service centres worldwide guarantee outstanding field service support and fast spare parts supply wherever the plant is located. Wrtsils total service commitment means more than just providing a prompt supply of parts or sending a maintenance specialist to fix a problem. It means taking responsibility. Depending on the level of partnership required, a service package can be tailored from 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 of power installations with more than 5500 MW of 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 of the units from CBM-centre in Wrtsil factory. Personnel of the operator are trained by the Wrtsil Land & Sea Academy (WLSA). This global network of training centres, with highly qualified personnel and state-of-the-art remote learning systems, delivers a thorough understanding of how to optimize the safety, reliability and performance of the installation. Wrtsil helps you to get the best from your personnel and your installation.

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

ENGINE DIMENSIONS (MM) AND WEIGHTS (TONNES)

Engine type 6L32 8L32 9L32 12V32 16V32 20V32 Length 5 297 6 510 7 116 6 837 8 206 9 276 Width 2 300 2 300 2 300 2 870 3 296 3 233 Height 3 421 3 571 3 571 3 595 3 595 4 139 Weight 30 42 44 54 63 89

GENERATING SET DIMENSIONS (MM) AND WEIGHTS (TONNES)

Engine type 6L32 8L32 9L32 12V32 16V32 20V32 Length 8 766 9 750 11 200 10 030 11 239 12 200 Width 2 410 2 410 2 410 3 050 3 300 3 300 Height 3 740 3 740 3 740 4 420 4 420 4 420 Weight 58 77 82 92 119 130

Subject to revision without notice.

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Wrtsil is a global leader in complete lifecycle power solutions for the marine and energy markets. By emphasising technological innovation and total efficiency, Wrtsil maximises the environmental and economic performance of the vessels and power plants of its customers. Wrtsil is listed on the NASDAQ OMX Helsinki, Finland.
DBAB540962 08.2011 / Bocks Office / Waasa Graphics

WRTSIL is a registered trademark. Copyright 2011 Wrtsil Corporation.