THE MOST EFFICIENT ENGINE IN THE WORLD Risto Lejon, Product Management, Wärtsilä 31 Wärtsilä Marine Solutions, Business Line Engines 2017
WHAT HAS BEEN THE DRIVERS FOR THIS ENGINE DEVELOPMENT ENERGY EFFICIENCY & TOTAL COST OF OWNERSHIP RELIABILITY FUEL & OPERATIONAL FLEXIBILITY EMISSION REDUCTION & LEGISLATION 2
IT S A V-ENGINE, IN ALL IT S COMBINATIONS PM Gen. as installed in lab Main parameters Diesel Dual Fuel (DF) Spark ignited Gas (SG) Bore (mm) 310 Stroke (mm) 430 Nom. Speed (rpm) 720 / 750 720 / 750 720 / 750 Max. cyl. output (kw) 590 / 610 530 / 550 580 / 600 Cyl. configurations 8V31 10V31 12V31 14V31 16V31 20V31 Weight (tonnes) 56,7 62,0 73,0 81,0 89,0 110,5 Size L x W x H (m) 6,2 x 3,1 x 4,7 6,8 x 3,1 x 4,7 7,8 x 3,5 x 4,1 8,5 x 3,5 x 4,2 9,1 x 3,5 x 4,2 10,0 x 3,8 x 4,7 3
DIESEL, DF & SG SAME BORE & SAME STROKE EXPONENTIAL BENEFITS The Power-Pack PowerPack = cylinder head, liner, piston, exhaust pipe and connecting rod unit Cross-flow cylinder head, for stiffness and low stress concentration Same basic cylinder head for all fuels Semi-hydraulic valve system Drill cooled flame plate and cylinder liner Can be assembled or replaced as a unit 4
MAKE THE FOUNDATION SOLID & STRONG Engine Structure & Power Systems Engine block The block has been given a stiff and durable design to absorb internal forces One piece nodular cast iron Including water and charge air channels and camshaft bearing housings Equipped with crankcase explosion relief valve with flame arrester 5
ALL EXPERIENCE & COMPETENCE GATHERED IS BUILT INTO THE CORE Crankshaft Constant main & big end bearing temperature monitoring Power take out from both ends Connecting rod 3-piece design, for minimum dismantling height New designed connecting rod for low weight and increased stiffness Forged alloy steel, partially machined All studs are hydraulically tightened Crankshaft bearings Tri-metal design with steel back, lead-bronze lining and a soft running layer Sn-flash for corrosion protection Excellent loading capacity 6
IMPROVED OPERATING FLEXIBILITY, PERFORMANCE & SERVICE-ABILITY BY ADJUSTABLE VALVE ACTUATION Fully adjustable semi-hydraulic valve actuation Variable inlet valve closing enables right air-fuel ratio at any operating condition Variable exhaust valve closing enables lower component thermal load at any conditions No need to adjust valve clearance every 1000 hrs Exhaust valve with variable closing Inlet valve with variable closing 7
VARIABLE VALVE TRAIN Stepless VIC - Fully adjustable inlet valve closing -> Optimized performance at all loads! VEC Stepless VIC VEC - Variable scavenging Validated in Valvetrain Rig - 15 000 hours - Components tested in extreme conditions. Fast solenoid valve Valve spring validation Additional to normal stress measurements high speed camera has been used. 8
EXPERIENCE CREATES ULTIMATE PERFORMANCE & RELIABILITY Pressure, features and performance Common Rail >2000 bar injection pressure; Timing and pressure adjustability; Part load optimization; Rate shaping; Multiple injection; Pilot in gas mode (DF engines); Twin Common Jerk Pump Rail Twin 21 Needle LFO Optimised >1500 1800 2200 bar injection pressure; Timing High power adjustability; and pressure density; adj.; Small adjustability; Multiple needle: injection; low load. Big Multiple Fast needle: and injections; accurate; high Rate load. shaping; Jerk Pump Twin Pump CR2 Common Rail TP/TN CR2+ W31 CR & CRDF The new Wärtsilä 31 engine family represents the synthesis of all the previous experiences. The Wärtsilä 31 CR results in a unique package fitting a large spectrum of diesel and gas applications designed around the todays and future expected customer values. 1998 2015 9
SYSTEM ARCHITECTURE The current trend in fuel system development is to increase injection pressure. The fewer high pressure joints, the less the possibilities for fuel leakages. Clean and safe layout. A smart safety valve, the CUBE, with an additional function enabling pressure holding and control without automation. 10
Smoke [FSN] SMOKE EMISSIONS COMMON RAIL 1 Already good: Smoke and particulate emissions of the CR1 are low. Practically invisible smoke is achieved over load range 25-100%. Smoke as FSN with HFO CR1 is better than jerk pump at low loads. Jerk pump is better than CR1 at loads above 60%. CR2 brings a clear improvement in smoke over the whole load range. JERK PUMP Visibility limit COMMON RAIL 2 - Even better thanks to: CR2 CR1 Nozzle design Higher injection pressure capability. 0% 20% 40% 60% 80% 100% Smoke with different CR stages versus engine load 11
GAS ADMISSION VALVE ON WÄRTSILÄ 31DF Easy & fast installation Easy to service Service pack available Coated valve plates Ensures expected life time with LNG Unchanged internal design Vast experience from W32DF/W34DF Extensive CFD simulation: Optimum gas flow to the gas admission valve Balanced gas feed Minimum losses 12
SIMPLICITY MULTIPLIED FOR OUTSTANDING PERFORMANCE AND RELIABILITY 2-stage turbocharging enabler for high efficiency Serviceability and uptime improved by cartridge concept for compressor and turbine removal and overhaul 2nd generation two-stage turbocharging Validated on 2-stage rig and engines June 2017 50000 45000 40000 35000 30000 25000 20000 W20V32TS field Low pressure turbocharger High pressure turbocharger 15000 W31 10000 W6L46TS 5000 W6L20 W20V32TS 0 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 13
2-STAGE TURBO CHARGING SYSTEM Fast, Accurate, Reliable; Real time valve position feedback signal standard on W31 engines. W31 engine is equipped with 2-3 control valves depending on application. 14
SOUND AND VIBRATION INSULATION Sound intensity level, A-weighted, ref. 1 pw/m^2 [db] Proper noise insulation on engine top part to reduce engine noise emission. Latest noise insulation reduced 10dB noise resulting sound pressure level at 1m distance from the engine top part to be ~105dB(A). 10 db 800 Hz With cover Without cover 100 1000 1/3 octave band frequency [Hz] 15
ENGINE AUTOMATION SYSTEM FOR THE NEW AGE 16 INTERNAL [CIMAC 2016_91 / Tomi Vuollet] Document ID DBAE182233 Revision -.27
INCREASED DATA MANAGEMENT & SYSTEM CAPABILITY IS A REALITY Air/fuel ratio control Speed / load control Thermal management Fuel & Gas injection control Self tuning Engine balancing Load sharing Prognostics/diagnostics High performance engines require high performance controls Knock control Valve control Ignition control Start/stop management Safety Cylinder wise trip & transfer Plant/vessel communication Redundancy (virtual sensors) 17 Wärtsilä_4-stroke_RD_Vaasa_Plant_130215.pptx
ACCUMULATED UPFRONT EXPERIENCE FOR HIGHEST RELIABILITY DOWN STREAMS Close to 50 000 h accumulated experience gathered by 2017 end 50,000 40,000 30,000 20,000 10,000 0 2011 2012 2013 2014 2015 2016 2017 Virtual Validation Rig Testing Engine validation 18 Document ID DBAE182233 Revision -.27
Brake efficiency [%]* IN AVERAGE >9 G/KWH FUEL SAVING OVER THE WHOLE LOAD RANGE g/kwh 220 SFOC Diesel-Electric constant speed 720 rpm 210 2 %-unit Wärtsilä 31 Market best practise W31 200 190 180 1995 2000 2005 2010 2015 Year 170 25 50 75 100 At ambient conditions according to ISO 15550. HFO as fuel. With engine driven pumps (two cooling water + one lubricating oil pump). Acc. to ISO 3046. IMO Tier II, without SCR. MCR % 19
SOLD ENGINES Type: Icebreaker Owner: FSUE Atomflot Yard: Vyborg 3 x W8V31 Type: RoPax Owner: MolsLinien Yard: RMC 2 x W8V31 Type: Fishing vessel Owner: P. Hepsö Rederi Yard: Karstensen Shipyard 1 x W8V31 Type: Fishing vessel Owner: - Yard: - 1 x W10V31 Type: Fish prosessing vessel Owner: Hav Line Yard: Balenciaga 1 x W10V31 Type: Fishing Vessel Owner: Strand Senior AS Yard: Karstensen Shipyard 1 x W8V31 Type: Fishing Vessel Owner: Research Fishing Yard: Vard 1 x W12V31 Type: Engine power plants Owner: - 75MW (W20V31SG) 20 INTERNAL Document ID DBAE182233 Revision -.27
Over 10 years ago the seeds of development were planted Now our customers can harvest the fruits of our work. Marine engine award 21 Document ID DBAE182233 Revision -.27