WARTSILA 46 F Engine PDF
WARTSILA 46 F Engine PDF
WARTSILA 46 F Engine PDF
Technology review
This is a summary of the technicall features and performance
of the Wrtsil 46F engine.
Design philosophy . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine performance . . . . . . . . . . . . . . . . . . . . . . . 5
CASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crankshaft and bearings . . . . . . . . . . . . . . . . . . . 7
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Piston & piston rings. . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder liner and antipolishing ring . . . . . . . . . . . 9
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft and valve gear . . . . . . . . . . . . . . . . . . 10
Fuel injection system . . . . . . . . . . . . . . . . . . . . . 12
Turbocharging system . . . . . . . . . . . . . . . . . . . . 14
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lubrication oil system. . . . . . . . . . . . . . . . . . . . . 16
Automation system . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Main technical data . . . . . . . . . . . . . . . . . . . . . . 19
Design philosophy
n
n
n
n
n
n
LT-water pump
HT-water pump
LT-water, outlet
HT pump
HT thermostat
LT pump
LT thermostat
LO pump
LO module*
Pre-lube pump
HT-water, outlet
HT-water, inlet
HT-water, from standby pump
Leak oil drain
Engine performance
The engine output has been achieved by increasing engine
speed instead of mean effective pressure, and the latest
developments in turbocharging technology have been fully
available to make wider use of the Miller concept.
At full-load operation, early closure of the inlet valves
gives room for a low effective compression ratio, and
thereby comparatively low temperatures at the end of the
compression stroke. The charge air, being both somewhat
expanded and cooled on its way through the receiver into
the cylinders, contributes to creating the initial conditions
favourable to an environmentally friendly combustion
process, i.e. a low global temperature that is still high
enough to guarantee reliable and stable ignition of the
fuel-air mixture in the combustion chamber.
In the Wrtsil 46F engine, these advantageous initial
conditions are combined with a higher engine speed and a
high expansion ratio, i.e. with design parameters that
make the combustion chamber expand quickly when the
combustion process has started. Due to the quick
expansion of the combustion gases, the temperatures most
critical to intensive NOx formation in the combustion
chamber are limited to the shortest time possible. This
combination makes the combustion process not only
environmentally friendly but efficient as well, since the
high expansion ratio also creates the required conditions
for efficient utilization of the heat energy released by
combustion at the beginning of the power stroke.
However, it is not only the choice of the
compression/expansion ratio that makes the Wrtsil 46F
engine highly efficient. All versions of the engine are
equipped with a fuel injection system that allows the
operator to adjust the injection characteristics to the
prevailing load conditions, fuel in use, etc. For example,
the operator can freely fine-tune the injection process to
enable full use of the engine loading potential over a wide
power range in order to reach the best possible fuel
economy. Alternatively, the operator can of course use the
degrees of freedom offered by the flexible fuel injection
equipment to adjust the engine to the existing limitations
of exhaust gas emissions, to minimize smoke formation.
Thermal load and mechanical stress levels are kept
within the safety margins established by Wrtsil over
decades of engine development.
CASS
Engine block
Compressor
Water mist catcher
Saturated air
70...90C
Water
injection
Heat
Principle of CASS.
Engine foot
Fixing rail
Resilient element
Foundation
Resilient mounting.
Connecting rod
The three-piece connecting rod is of the marine type,
where combustion forces are distributed over a maximum
bearing area and the relative movements between mating
surfaces are minimized. The connecting rod is optimized
for both strength and weight. The shank is fully
machined. The three-piece design reduces the piston
overhauling height as piston overhauling is possible
without touching the big end bearing. The big end
bearing can also be inspected without removing the
piston.
Main features of the connecting rod design:
n Three-piece marine type design
n Fully machined shank
n Hydraulically tightened bolts
n Strength- and weight-optimized
n Easy maintenance.
Cylinder head
The cylinder head design features high reliability and easy
maintenance. A stiff cone- / box-like design can cope with
high combustion pressure, and is essential for obtaining
both liner roundness and even contact between the
exhaust valves and their seats. Wrtsils vast experience
gained from heavy fuel operation all around the world has
contributed greatly to exhaust valve design and
development.
The basic criterion for the exhaust valve design is
correct temperature. This is achieved by optimized cooling
and closed seat ring technology, which ensures long
lifetimes for the valves and seats.
The cylinder head design is based on the four-screw
concept developed by Wrtsil and used for many years. A
four-screw cylinder head design also provides all the
freedom needed for designing the inlet and exhaust ports
with a minimum of flow losses. The port design has been
optimized using computational fluid dynamics analysis in
combination with full-scale flow measurements.
Main features of the cylinder head design:
n Four cylinder head screws only, giving space for
flow-efficient ports
n Inlet and exhaust gas ports on the same side
n Height and rigid design ensure even and sufficient
surface pressure on the cylinder head gasket
n Bore-cooled flame plate for optimum temperature
distribution
n Two inlet valves and two exhaust gas valves, all with
valve rotators.
VIC on engine.
flexibility to apply early inlet valve closure at high load for lowest
NOx levels, while good part-load performance is ensured by
Valve lift
VIC air
bleed valve
between the valve tappet and the pushrod. Briefly, the device
can be described as two hydraulic cylinders connected through
Crank angle
VIC valve
VIC control valve
12
injector
delivery valve
1.
timing
plunger
2.
3.
4.
quantity
plunger
- tappets on cam
base circle
- filling of injection pump
Turbocharging system
Turbocharger technology has undergone intense design
and performance development in recent years, resulting in
high performance and high reliability. Only the best
available charger technology is used on the Wrtsil 46F.
The engine is equipped with a one-stage turbocharging
system that best fulfils the requirements of each
application.
The standard is a single-pipe exhaust gas (SPEX)
system, with the option of exhaust wastegate or air bypass
according to the application. The SPEX system is designed
to apply the benefits of both pulse charging and constant
pressure charging. SPEX is able to utilize the pressure
pulses without disturbing the cylinder scavenging. Lube
oil cooled chargers are used with inboard plain bearings
lubricated from the engines lube oil system. All this
makes for longer intervals between overhauls and reduced
maintenance.
The charge air receiver is integrated into the engine
block. The two-stage self-supporting charge air cooler
consists of separate HT and LT water sections, which
gives an advantage for heat recovery applications. The
charge air temperature is controlled by an LT water
temperature control valve (bypass valve). The engine has a
water mist catcher as standard, enabling humidification of
the air for reduced NOx emissions.
SPEX.
14
Turbocharger.
Cooling system
The cooling system on the engine is split into two separate
circuits: high-temperature (HT) and a low-temperature
(LT). The cylinder liner, the cylinder head and the first
stage in the charge air cooler are connected to the HT
Lubricating
oil
cooler
Charge
air cooler
LT
LT
stand-by
pump
LT
pump
Water pumps.
Charge
air cooler
HT
Heat recovery
Cyl.
Central
cooler
HT
pump
Preheater
HT
stand-by
pump
Oil cooler
Automatic filter
Centrifugal filter
Oil pump
Electric
pre-lube
oil pump
Suction
strainer
16
Electric
stand-by
oil pump
Automation system
The Wrtsil 46F engine is equipped with a scaleable
embedded control system that can cover a wide range of
engine applications. Reliability and serviceability were the
main cornerstones of this systems design.
The on-engine electronics are designed to match the
harsh environment on a large diesel engine, while also
allowing fault tracing and maintenance on board with
commonly available tools. A non-repairable harness design
is not used. The system is designed for use with common
marine type cables. For fault tracing all connections points
in the systems are easily accessible, and replacing the
electronics is easy.
LCP
(Local control panel)
Ethernet to
external
systems
CCM
(Cylinder control module)
MCM
(Speed controller)
IOM
(Input output
module)
ESM
(Engine safety module)
MCM
(additional I/O)
Hardwired measurements
to external systems
MCM
(Speed controller)
ESM
(Engine safety module)
18
Maintenance
During design and development the engine manufacturer
emphasizes the necessity for easy maintenance by
including tooling and easy access in the basic design and
by providing easy-to-understand instructions.
The Wrtsil 46F maintenance principle is substantiated
by the following:
n A cylinder head with four fixing studs and simultaneous
hydraulic tightening of all four studs
n A hydraulic jack for overhaul of the main bearing
n Uniform one-cylinder camshaft pieces
n Slip-on fittings wherever possible
n Exhaust gas system insulation using easy-to remove
panels on an engine-mounted frame
n The three-piece connecting rod allows inspection of the
big end bearing without removal of the piston, and
piston overhaul without dismantling the big end
bearing
n Weight-optimized and user-friendly maintenance tools
Cylinder
configuration
kW*
BHP*
6L46F
7500
10200
7L46F
8750
11900
8L46F
10000
13600
9L46F
11250
15300
*At flywheel
Weight (dry)
6L46F
8300
2830
4850
97
7L46F
9120
2830
4850
113
8L46F
10000
3080
5100
124
9L46F
10820
3180
5100
140
19
Wrtsil is The Ship Power Supplier for builders, owners and operators
of vessels and offshore installations. We are the only company with a
global service network to take complete care of customers ship
machinery at every lifecycle stage.
Wrtsil is a leading provider of power plants, operation and lifetime
care services in decentralized power generation.
The Wrtsil Group includes Imatra Steel, which specializes in special
engineering steels.
For more information visit www.wartsila.com
Wrtsil Corporation
P.O.Box 196
FIN-00531 Helsinki