wartsila 38
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38
Technology Review
Setting new standards for economical power productions 4
Design Philosophy 6
Low NOx combustion 7
World Bank Guide Lines Compliance 8
Engine block / Crankshaft 10
Main bearings / Connecting rod 11
Camshaft / Cylinder head 12
Cylinder liner / Anti-polishing ring 13
Piston and piston rings / Fuel system 14
Fuel injection system / Air and exhaust gas system 15
Hot box design / Air cooler / Lubricating system 16
Control, alarm and monitoring system 17
Maintenance 18
Service solutions to optimize profitability 19
Daily round-the-clock service, wherever it is needed 20
Main data marine 21
Main data power 22
Technology Review Contents
3Technology Review Wärtsilä 38
38
Setting new standards for economical power productions
5Technology Review Wärtsilä 384Technology Review Wärtsilä 38
38
Elation, cruise ship,
equipped with six Wärtsilä 12V38 engines Diesel Electric.
Wärtsilä 38 offers an outstanding total economy concept
adding up to numerous valuable benefits for the customer.
Volvox TerraNova, T.S. hopper dredger,
equipped with two Wärtsilä 18V38 engines.
Sea Nordica, containership,
equipped with two Wärtsilä 8L38 engines.
De Vechtborg, multipurpose,
equipped with a Wärtsilä 6L38 engine.
Power Plant Tapal,
equipped with twelve Wärtsilä 18V38 engines (120 MW), Karachi, Pakistan.
IMO NOx Compliance
The best trade-off between low NOx and low SFC is obtained through a low NOx com-
bustion system. The combination of high compression ratio and a fast, controlled heat
release, ensured by optimized fuel injection and combustion process, achieves this goal.
High injection pressures and a well designed combustion chamber also contribute to this.
Gas exchange losses are minimized, thanks to optimized inlet and exhaust channels in
the cylinder head as well as adequate valve seat and valve lift dimensions. Furthermore the
turbocharger system contributes to this optimization process.
When talking about Power Plant stack emissions nitrogen oxides (NOx), sulphur dioxides
(Sox) and particles (as dry dust) are in focus. World Bank Guidelines 1998 for ‘Thermal
Power: Guidelines for New Plants’ take into account the air quality in the surrounding of
the power plant when defining the applicable stack limits.
Low NOx combustion
Responding to a need in the market for an engine in the 400 mm cylinder bore class, the
Wärtsilä 38 was developed. The Wärtsilä 38 is a technologically advanced engine in its
class – a product that sets standards. The compactness of the Wärtsilä 38 and its light
weight contribute to easy and space-saving power plant installations. The high level of
technology incorporated in this engine, its design, and the power plant that is built around
it, are all focused on achieving the lowest possible kWh production cost. With fewer parts,
lower maintenance requirements, low fuel consumption, lower emissions and the ability to
run reliably on a variety of fuels, the Wärtsilä 38 is unquestionably the state-of-the-art in
power generation.
Design Philosophy
38
7Technology Review Wärtsilä 386Technology Review Wärtsilä 38
State-of-the-art plant of Tapal Energy Ltd., Karachi, Pakistan.
Engine type: 12 x Wärtsilä 18V38, total electric output: 126 MW.
9L38B Diesel generator set
Specific NOx emissions
weighted (g/kWh)
20
18
16
14
12
10
8
6
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Rated engine speed (rpm)Regulation 13 of annex VI of MARPOL 73/78
IMO NOx limit for new engines
Wärtsilä 38Blow NOx combustion
Wärtsilä 38B with Direct Water Injection
38
9Technology Review Wärtsilä 388Technology Review Wärtsilä 38
World Bank Guide Lines Compliance
The 38-engine is designed for minimum NOx emissions at an optimum fuel consumption.
The engine fulfills the new (from 1.7.2000) World Bank NOx stack limit for ‘non-
degraded areas’. In a ‘degraded area’, which might be the case for a big city with heavy
car traffic, etc. the stack limit for NOx is lower and a SCR catalyst has to be applied.
Emissions of sulphur dioxides and particles are fuel related (mainly dependent on sulphur
and ash content of the fuel).
1700 1750 1800 1850 1900 1950 2000
350
330
310
290
270
ppvm
Greenhouse Effect and Global Warming
Atmospheric concentrations
of carbon dioxide since 1750
Ice core measurement(siple station, West Antarctia)
Direct measurement (Mauna Loa, Hawaii)
CFC 24%
Carbon dioxide concentrationsGreenhouse Gases
N2O 6%
CO2 55%
Methane 15%
1999 2000 2001
200
400
600
800
1000
1200World Bank (non-degraded airshed):2300 ng/nm3 (dry, 15 vol-% O2, 0 ˚C)
World Bank (non-degraded airshed):2000 ng/nm3 (dry, 15 vol-% O2, 0 ˚C)
Appying for FundingAfter 1.7.2000
NOx Emmission limits/World Bank 1998 Guide Lines
200
400
600
800
1000
1200
Coal fired power plant Diesel engine HFO
g/kW
he
CO2 EmmissionsSou
rce:
Env
ironm
enta
l Dat
a R
epor
t, U
NE
P 1
990
World Bank (degraded airshed): 400 mg/nm3 (dry, 15 vol-% O2, 0 ˚C)
pp
m-v
(dry
, at
15 v
ol-%
O2)
In the future the carbon dioxide (CO2 ) emission will be in focus due to its’ expected
impact on the global warming. An efficient diesel power plant has relatively low CO2
emissions. The Kyoto Protocol provisions allow for a Clean Development Mechanism
(CDM) under which carbon offsets trading between certain countries will become
possible in the future, the mechanism is still however under development.
The moderate bearing load and rigid design of the main bearing cap ensure reliable
operation. The geometry of the bearing creates an oil film thickness which greatly exceeds
the safety margins required by bearing manufacturers; all in
accordance with the Wärtsilä ‘Thick Pad’
philosophy. Bolt connections are
hydraulically tightened, and the main
bearing oil supply pipe is combined
with a hydraulic jack for lowering
the main bearing cap.
Crankshaft
Engine block Main bearings
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11Technology Review Wärtsilä 3810Technology Review Wärtsilä 38
The combination of design elements such as
under slung crankshaft, integrated air receivers,
short cylinder distances and material choice has
resulted in a very rigid engine block. The
camshaft bearing environment forms an
integrated part of the engine block,
contributing to the overall stiffness of the
block. The rigidity of the engine block ensures
easy flexible mounting. Cast-on feet of the V-
type block and bolted-on feet on the in-line
engine offer a simple solution to accommodate
resilient elastic mountings to isolate structure-
borne noise.
In the design process of the W38 engine, special attention was given to optimizing the
various geometric characteristics such as cylinder distance and high combustion pressure in
order to achieve a space-saving solution. By using FE (Finite Element) calculation
methods, an optimal crankshaft design was achieved resulting in maximum
overall rigidity while maintaining moderate bearing loads. The design
of the crankshaft is such that even with higher combustion
pressures, all criteria of classification societies are met.
Under slung crankshaft. Hydraulic Tensioned
bearing studs and side bolts.
Connecting rod
The ‘marine head’ design of the connecting rod is carefully optimized with regard to stress
levels using 3-D FE analysis. Dismantling height of the piston/connection rod assembly is
shorter than any other engine in this output range. The ‘marine head’ design makes it
possible to remove the piston-connecting rod assembly without removing the big-end
bearing, significantly reducing maintenance down-time and cost.
Wärtsilä ’s long-term experience and extensive research and
development resulted in the high collar cylinder liner design. This
design ensures ideal roundness of the liner, a precondition for
optimal ring-liner contact. Furthermore, the straightness of the liner
is maintained during operation, and interference from adjacent
cylinders is prevented. By optimizing the design of the vertical
cooling bores, the correct temperature range is maintained on the
inner liner surface - high enough to prevent cold corrosion and low
enough to ensure good lubrication.
■ The cylinder head has been redesigned to maximise thermal efficiency (by
incorporating the largest possible air/gas channels). It is also adapted to the higher
load of the W38B engine.
■ The use of four cylinder head studs
facilitates easy maintenance.
■ The valve design guarantees excellent
component operational behaviour,
especially with heavy fuel.
■ Rigidity of the cylinder head design
ensures adequate and uniform sealing
between cylinder head and liner.
■ Rigidity of the construction allows no
deformation of the valve seat
environment.
■ All connections to the cylinder head are
easy to reach and disconnect.
13Technology Review Wärtsilä 38Technology Review Wärtsilä 38 12Technology Review Wärtsilä 38
The camshaft consists of individual one-cylinder camshaft units, flange connected to separate
bearing journals. Built-in valve tappet modules screwed onto the engine block ensure easy
maintenance and reliable operation. The overall design ensures reliable operation, easy
maintenance and inspection.
Cylinder head
Cylinder liner Camshaft
The anti-polishing ring removes the carbon from the piston top,
thus preventing liner polishing. This system results in a drastic
reduction of cylinder wear, lower and constant lubricating oil
consumption, and a clean piston.
Anti-polishing ring
Cylinder head
Camshaft
38
Cylinder liner
■ The Wärtsilä 38 fuel injection system achieves the optimum trade-off between
performance parameters – fast injection together with good injection quality
with respect to the fuel spray pattern and droplet size.
Air and exhaust gas system
■ The new generation turbochargers, applied on the W38B series, allow not
only improved performance but also a compact installation with less piping
(water cooling is not needed).
■ Special attention is paid to the integration of the by-pass and waste gate valves,
becoming essential parts of the engine. The position of the valves and their
controls is selected based on the requirements of low vibration levels, low local
temperatures and short piping.
■ Simple reliable manual controlled cleaning device is standard. Besides the system
full automatically controlled cleaning device can be delivered. A cast turbocharger
bracket provides the housing of a revised two-stage air cooler and supports the
turbo charging system.
■ The charge air receiver is designed for minimum pressure variation and good
engine ‘breathing’.
■ The inlet bends between the air receiver and the cylinder head for the L-engine
are designed with additional functionality in mind:
- support of the exhaust system (rigid mounted isolation box and single
pipe exhaust [SPEX])
- support of the cooling water return channel from the engine
■ This multifunctional solution allows a compact installation.
■ The exhaust system contributes to the efficiency of the
turbochargers thanks to its flow-optimised design.
The system is modular for easy assembly and can handle
such factors as gas exchange dynamics, high temperatures,
thermal expansion, etc.
■ Insulation of the exhaust system is achieved by stainless
steel insulating panels, which are easily removable for
inspection access.
Piston and piston rings
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14Technology Review Wärtsilä 38
■ The piston design, based on the extensive experience of the
Wärtsilä Corporation, consists of a steel crown, nodular cast
iron skirt and pressurised skirt lubrication.
■ The three-ring pack consists of two compression and one
oil scraper ring located at the crown. This ring pack
ensures optimal pressure distribution and lowers
lubricating oil consumption.
■ The shape of the combustion chamber is such that it ensures efficient
combustion at all loads, while the component temperatures are kept low.
Fuel system
■ Fuel feed and return lines are integrated in the fuel pump housing. This offers a
‘clean’ cylinder head environment for easy access and maintenance. It also means
fewer part connections resulting in high reliability.
■ Shielded high-pressure lines as well as the ‘hot box’ contribute to safety – especially
for HFO operation.
■ The design of the fuel system is such that pressure pulses in the low-pressure system
are very low.
■ Proper dimensioning of the camshaft, camshaft bearings and rollers ensures a
controlled mechanical load on all driving parts, ensuring long lifetime and low
maintenance costs.
15Technology Review Wärtsilä 38
Fuel injection
system
Fuel system Air and exhaust gas system
Piston
Fuel injection system
■ Externally there are swinging ‘hot box’ covers and cylinder head covers closing the
hot box area. Internally, a fuel system is designed based on state of the art fuel
pumps resulting in a simple and very reliable system.
■ Multi-channel extrusion profiles are selected (a) for the main starting air supply
and (b) the transport of some fluids. The latter is also used as a back cover for the
special space created for the components of the control system.
Air cooler
The Wärtsilä 38 is equipped with a two-stage air cooler, making it highly
suitable for combined heat and power application, due to a high degree
of waste heat recovery. Housing of the two-stage air cooler forms an integral
part of the turbo-charger support, creating a compact, economic, and rigid
design.
Lubrication system
The lubrication system of the in-line engines includes a complete lubrication
oil module with a cooler, an automatic backflush filter, a centrifugal filter in
the backflush line, and thermostatic valves. The main and the pre-lubrication
oil pumps and the regulating valve are part of the total system. The
lubrication oil flow through the engine is revised based on optimised bearing
clearances allowing great safety margins. The new three piston ring package
together with the anti-polishing ring assure very low lubrication oil
consumption.
Engine-driven pumps
Engine-driven lubricating oil and cooling water pumps are an integral part
of the Wärtsilä 38 design. All engine-driven pumps are located on the free
end of the engine. For the eighteen-cylinder Wärtsilä 38 all pipe
connections are grouped together allowing easy connection to the power
plant’s auxiliary systems. Use of the engine-driven pumps considerably
simplifies the whole power plant design and lowers investment costs.
Cooling water system
The LT and HT cooling water systems are integrated in the engine, including built-on
pumps and thermostatic valves. This guarantees maximum protection of the engine under
all circumstances.
Control, alarm and monitoring system
The Wärtsilä 38B includes several advancing features in the field of automation. A new
generation engine-integrated system, the WECS 7000, is introduced on the engine. WECS
stands for Wärtsilä Engine Control System and 7000 is the version for medium speed
diesel engine applications. It incorporates all past experience of the Wärtsilä in electronics
development based on new generation control units. It is the new standard in the Wärtsilä
electronics, to be used by all Wärtsilä medium-speed engines in the near future.
The main components are:
■ The WECS cabinet on the right of the operating side
of the engine. It included the heart of the system, the
main control module MCM700, the Relay Module for
back-up functionality. The WECS communicates with
the external systems through a Mod- or Profi-bus
(Marine/Power Plants); the connectors are located on
the WECS cabinet.
■ The cylinder control units located at a special room
underneath the hotbox, grouping the signals from the
cylinder related sensors (one cylinder control unit per
three cylinders).
■ Control of by-pass and waste-gate valves (if applicable)
is an integrated part of the WECS 7000.
The software can be very easily reconfigured to match
installation needs.
As a common Wärtsilä system based on identical hardware
(control units) and basic software, the WECS 7000 will allow
unique serviceability and customer satisfaction.
‘Hot box’ design
17Technology Review Wärtsilä 3816Technology Review Wärtsilä 38
Engine-driven pumps
38
WECS 7000
WECS 7000
Assembly hall, Zwolle, The Netherlands
■ The Wärtsilä 38 overall design resulted in a considerably
lower number of parts compared to other engines in its
class, which results in reduced maintenance costs and less
down-time.
■ All parts, both internal and external, are easily accessible for
quick and easy servicing.
■ Advanced computer-based maintenance software designed
to support all aspects
of maintenance is available.
Maintenance
18Technology Review Wärtsilä 38 19Technology Review Wärtsilä 38
Service solutions to optimize profitability
Wärtsilä is committed to keeping your investment productive and profitable throughout
the equipment lifecycle, whether you are operating a land-based power plant or marine
power system.
This calls for proactive services including performance optimization, modernization and
comprehensive operation support.
Wärtsilä provides separate service packages for its power plant and marine customers:
Energy Partner and Marine Partner, which are tailored to the specific needs and operating
conditions of these customers. In both cases, however, our aim is yours – to find a service
solution you can adapt to your needs in the most cost-efficient way.
Energy Partner and Marine Partner services cover all aspects of plant support to help you
to optimize the lifecycle costs of your equipment in the way you consider most
appropriate. Our approach is two-fold. You can either use them individually on a daily
basis. Or you can use them in combinations predefined by one of our service agreements.
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21Technology Review Wärtsilä 3820Technology Review Wärtsilä 38
Main data marineDaily round-the-clock service, wherever it is needed
Parts
Top-quality original parts covering all Wärtsilä and Sulzer engines, including
all previous engine brands with first-class response times and first-class global
logistics support.
Field Service
Competent, regularly trained field professionals available round the clock
anywhere in the world through Wärtsilä’s global service network, backed up
by product specialists.
Workshop Services
Restoration of full functionality, safety and reliability with OEM (Original
Equipment Manufacturer) quality.
Technical Support
Full technical support for trouble-shooting and equipment optimization by local
dedicated contact people and specialized product company experts.
Operation Support
Full Operation and Maintenance documentation support and sophisticated
software applications to ensure continuous operational reliability and cost control.
Training
Standardized and tailor-made courses worldwide on all Wärtsilä and Sulzer products.
Service AgreementsWärtsilä service agreements cover all aspects of lifecycle optimization from parts
supply and daily assistance, to inspection, maintenance and even implementation
of agreed performance targets. Though comprehensive in scope, Wärtsilä service
agreements are designed to allow you to tailor them to your exact needs.
■ Parts supply agreement
■ Support agreement
■ Inspection agreement
■ Maintenance support agreement
■ Maintenance agreement
■ Management support agreement
■ Performance agreement
■ Operation & Maintenance
agreement
C
K
D BFE
H
N M
I
O M
IK
DE F
B
C
A*
GA
H
N
38
Main data
Cylinder bore 380 mm
Piston stroke 475 mm
Speed 600 rpm
Mean effective pressure A-version: 24.5 bar
B-version: 26.9 bar
Piston speed 9.5 m/s
Fuel specification
Fuel oil 730 cSt/50°C
7 200 sRI/100°F
ISO 8217, category ISO-F-RMK 55
Rated power: Propulsion engines
EngineType A-Output * B-output *
kW BHP kW BHP
6L38 3 960 5 385 4 350 5 915
8L38 5 280 7 180 5 800 7 885
9L38 5 940 8 075 6 525 8 870
12V38 7 920 10 770 8 700 11 830
16V38 10 560 14 360 11 600 15 770
18V38 11 880 16 155 13 050 17 745
* Output at 600 rpm
Wärtsila 38B – Principal engine dimensions (mm) and weight (tonnes)
EngineType A* A B C D E F G
6L38B 6 235 6 291 2 637 2 186 3 520 560 1 115 4 455
8L38B 7 912 7 491 2 782 2 352 3 520 560 1 115 5 655
9L38B 8 512 8 091 2 782 2 352 3 520 560 1 115 6 255
12V38B 7 578 7 320 2 900 3 028 3 000 720 1 435 5 165
16V38B 9 175 8 917 3 067 3 028 3 000 720 1 435 6 565
18V38B 9 875 9 617 3 067 3 028 3 000 720 1 435 6 265
H I K M N O Weight
6L38B 270 1 110 1 500 1 205 1 471 - 50.0
8L38B 270 1 110 1 500 1 205 1 471 - 66.0
9L38B 270 1 110 1 500 1 205 1 471 - 74.0
12V38B 240 1 382 2 150 1 514 1 738 1 020 -
16V38B 240 1 382 2 150 1 514 1 935 1 020 -
18V38B 240 1 382 2 150 1 514 1 935 1 020 -
Our company, as a manufacturer and
supplier of high-quality diesel engines
is certified according to ISO 9001.
The Wärtsilä 38 is the result of systematic
efforts, and its manufacture is
certified under the Lloyd’s Register
Quality Assurance scheme.
Main data power
23Technology Review Wärtsilä 3822Technology Review Wärtsilä 38
C
B
Main data
Cylinder bore 380 mm
Piston stroke 475 mm
Cylinder output 675 kW/cyl.
Engine speed 600 rpm
Piston speed 9.5 m/s
Mean effective pressure 25.1 bar
Fuel specification
Fuel oil 730 cSt/50°C
7200 sRi/100°E
ISO 8217, category ISO-F-RMK 55
Natural gas
Rated power
Engine 50Hz and 60HzType Eng. kW Gen. kW
18V38 12 150 11 820
Principal engine dimensions (mm) and weight
(tonnes)
EngineType A B C Weight
18V38 14 175 4790 4900 176
38
Wärtsilä Corporation is the leading global ship power supplier and a major provider
of solutions for decentralized power generation and of supporting services.
In addition Wärtsilä operates a Nordic engineering steel company and manages
substantial share holdings to support the development of its core business.
Telephone: +31 (0)38 425 32 53Fax (marine):+31 (0)38 425 33 52
Wärtsilä NSD Nederland B.V.P.O. Box 10608, 8000 GB Zwolle Hanzelaan 95, 8017 JE ZwolleThe Netherlands
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