Wartsila 38 Ship Diesel Engine Service Manual

186 Pages·020.229 MB·English

by  Wartsila

Multiprint
Office /
Wärtsilä enhances the business of its customers by providing them with Bock´s W
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with products and solutions as well as services. Through innovative products
S WÄRTSILÄ 38
and services, Wärtsilä sets out to be the most valued business partner of all I
L PROJECT GUIDE
its customers. This is achieved by the dedication of over 18,000 professionals Ä
manning 160 locations in 70 countries around the world. Wärtsilä is listed on
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the Nordic Exchange in Helsinki, Finland. 8

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WÄRTSILÄ® is a registered trademark. Copyright © 2008 Wärtsilä Corporation.
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Wärtsilä38-Projectguide
Introduction
Introduction
ThisProjectGuideprovidesdataandsystemproposalsfortheearlydesignphaseofmarineengineinstall-
ations.Forcontractedprojectsspecificinstructionsforplanningtheinstallationarealwaysdelivered.Any
data and information herein is subject to revision without notice. This 2/2008 issue replaces all previous
issuesoftheWärtsilä38ProjectGuides.
Issue Published Updates
2/2008 11.11.2008 CompactSilencerSystemaddedandotherminorupdates
1/2008 02.07.2008 GeneralPGupdate
1/2007 31.10.2007 GeneralPGupdate
WärtsiläShipPower
Technology,ProductSupport
Trieste,November2008
THISPUBLICATIONISDESIGNEDTOPROVIDEASACCURATEANDAUTHORITATIVEINFORMATIONREGARDINGTHESUBJECTSCOVEREDAS
WASAVAILABLEATTHETIMEOFWRITING.HOWEVER,THEPUBLICATIONDEALSWITHCOMPLICATEDTECHNICALMATTERSANDTHEDESIGN
OFTHESUBJECTANDPRODUCTSISSUBJECTTOREGULARIMPROVEMENTS,MODIFICATIONSANDCHANGES.CONSEQUENTLY,THEPUB-
LISHERANDCOPYRIGHTOWNEROFTHISPUBLICATIONCANNOTTAKEANYRESPONSIBILITYORLIABILITYFORANYERRORSOROMISSIONS
INTHISPUBLICATIONORFORDISCREPANCIESARISINGFROMTHEFEATURESOFANYACTUALITEMINTHERESPECTIVEPRODUCTBEING
DIFFERENTFROMTHOSESHOWNINTHISPUBLICATION.THEPUBLISHERANDCOPYRIGHTOWNERSHALLNOTBELIABLEUNDERANYCIR-
CUMSTANCES, FOR ANY CONSEQUENTIAL, SPECIAL, CONTINGENT, OR INCIDENTAL DAMAGES OR INJURY, FINANCIAL OR OTHERWISE,
SUFFEREDBYANYPARTARISINGOUTOF,CONNECTEDWITH,ORRESULTINGFROMTHEUSEOFTHISPUBLICATIONORTHEINFORMATION
CONTAINEDTHEREIN.
COPYRIGHT©2008BYWÄRTSILÄITALYS.p.A.
ALLRIGHTSRESERVED.NOPARTOFTHISPUBLICATIONMAYBEREPRODUCEDORCOPIEDINANYFORMORBYANYMEANS,WITHOUTPRIOR
WRITTENPERMISSIONOFTHECOPYRIGHTOWNER.
ProjectGuideW38-2/2008 iii
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Wärtsilä38-Projectguide
TableofContents
Table of Contents
1. General data and outputs............................................................................................................................ 1
1.1 Technical main data............................................................................................................................. 1
1.2 Maximum continuous output................................................................................................................ 1
1.3 Reference conditions........................................................................................................................... 2
1.4 Principal engine dimensions and weights............................................................................................ 2
1.5 Principal generating set dimensions.................................................................................................... 4
2. Operating ranges.......................................................................................................................................... 5
2.1 Engine operating range........................................................................................................................ 5
2.2 Loading capacity.................................................................................................................................. 6
2.3 Low air temperature ............................................................................................................................ 8
2.4 Operationatlowloadandidling........................................................................................................... 9
3. Technical data............................................................................................................................................... 10
3.1 Introduction.......................................................................................................................................... 10
3.2 Technicaldatatables............................................................................................................................ 11
3.3 Exhaustgasandheatbalancediagrams............................................................................................. 22
4. Descriptionoftheengine............................................................................................................................. 28
4.1 Definitions............................................................................................................................................ 28
4.2 Engineblock......................................................................................................................................... 28
4.3 Crankshaft............................................................................................................................................ 29
4.4 Connecting rod..................................................................................................................................... 29
4.5 Mainbearingsandbigendbearings.................................................................................................... 29
4.6 Cylinder liner........................................................................................................................................ 29
4.7 Piston................................................................................................................................................... 29
4.8 Piston rings.......................................................................................................................................... 29
4.9 Cylinder head....................................................................................................................................... 29
4.10 Camshaft and valve mechanism.......................................................................................................... 30
4.11 Camshaft drive..................................................................................................................................... 30
4.12 Turbocharging and charge air cooling.................................................................................................. 30
4.13 Injection equipment.............................................................................................................................. 30
4.14 Exhaust pipes...................................................................................................................................... 30
4.15 Cooling system.................................................................................................................................... 31
4.16 Fuel system.......................................................................................................................................... 31
4.17 CommonRail,optional......................................................................................................................... 31
4.18 Lubricating oil system.......................................................................................................................... 31
4.19 Starting air system............................................................................................................................... 31
5. Piping design, treatment and installation.................................................................................................. 34
5.1 Pipe dimensions................................................................................................................................... 34
5.2 Trace heating....................................................................................................................................... 35
5.3 Operatinganddesignpressure............................................................................................................ 35
5.4 Pipe class............................................................................................................................................. 35
5.5 Insulation.............................................................................................................................................. 36
5.6 Local gauges........................................................................................................................................ 36
5.7 Cleaning procedures............................................................................................................................ 36
5.8 Flexible pipe connections..................................................................................................................... 37
5.9 Clamping of pipes................................................................................................................................ 38
6. Fuel oil system.............................................................................................................................................. 40
6.1 Acceptable fuel characteristics............................................................................................................ 40
6.2 Internal fuel oil system......................................................................................................................... 43
6.3 External fuel oil system........................................................................................................................ 46
7. Lubricatingoilsystem.................................................................................................................................. 65
7.1 Lubricating oil requirements................................................................................................................. 65
7.2 Internal lubricating oil system.............................................................................................................. 66
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TableofContents
7.3 External lubricating oil system............................................................................................................. 69
7.4 Crankcase ventilation system.............................................................................................................. 78
7.5 Flushing instructions............................................................................................................................ 79
8. Compressed air system............................................................................................................................... 80
8.1 Instrumentairquality............................................................................................................................ 80
8.2 Internal compressed air system........................................................................................................... 80
8.3 Externalcompressedairsystem.......................................................................................................... 82
9. Coolingwatersystem................................................................................................................................... 87
9.1 Water quality ....................................................................................................................................... 87
9.2 Internal cooling water system.............................................................................................................. 88
9.3 External cooling water system............................................................................................................. 91
10. Combustion air system................................................................................................................................ 103
10.1 Engine room ventilation....................................................................................................................... 103
10.2 Combustion air system design............................................................................................................. 104
11. Exhaust gas system..................................................................................................................................... 106
11.1 Internal exhaust gas system................................................................................................................ 106
11.2 Exhaust gas outlet............................................................................................................................... 108
11.3 External exhaust gas system............................................................................................................... 110
12. Turbocharger cleaning................................................................................................................................. 115
12.1 Turbine cleaning system...................................................................................................................... 115
12.2 Compressorcleaningsystem............................................................................................................... 116
13. Exhaust emissions....................................................................................................................................... 117
13.1 General................................................................................................................................................ 117
13.2 Diesel engine exhaust components..................................................................................................... 117
13.3 Marine exhaust emissions legislation.................................................................................................. 118
13.4 Methodstoreduceexhaustemissions................................................................................................. 119
14. Automationsystem....................................................................................................................................... 121
14.1 UNICC1 .............................................................................................................................................. 121
14.2 UNIC C2............................................................................................................................................... 127
14.3 UNIC C3............................................................................................................................................... 132
14.4 Functions............................................................................................................................................. 132
14.5 Alarm and monitoring signals.............................................................................................................. 134
14.6 Electrical consumers............................................................................................................................ 135
14.7 System requirements and guidelines for diesel-electric propulsion..................................................... 137
15. Foundation.................................................................................................................................................... 138
15.1 General................................................................................................................................................ 138
15.2 Rigid mounting..................................................................................................................................... 138
15.3 Resilient mounting............................................................................................................................... 149
15.4 Mountingofgeneratingsets................................................................................................................. 151
16. Vibration and noise...................................................................................................................................... 154
16.1 General................................................................................................................................................ 154
16.2 ExternalfreecouplesandforcesactingonW38B............................................................................... 154
16.3 Torque variations.................................................................................................................................. 154
16.4 Massmomentsofinertia...................................................................................................................... 155
16.5 Structure borne noise.......................................................................................................................... 155
16.6 Air borne noise..................................................................................................................................... 156
16.7 Exhaust noise...................................................................................................................................... 157
17. Power transmission...................................................................................................................................... 158
17.1 Flexible coupling.................................................................................................................................. 158
17.2 Clutch................................................................................................................................................... 158
17.3 Shaft locking device............................................................................................................................. 158
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TableofContents
17.4 Power-take-offfromthefreeend.......................................................................................................... 158
17.5 Input data for torsional vibration calculations....................................................................................... 159
17.6 Turning gear......................................................................................................................................... 160
18. Engine room layout...................................................................................................................................... 161
18.1 Crankshaft distances........................................................................................................................... 161
18.2 Four-enginearrangements................................................................................................................... 162
18.3 Fatherandsonarrangement................................................................................................................ 164
18.4 Space requirements for maintenance.................................................................................................. 166
18.5 Platforms.............................................................................................................................................. 170
18.6 Engine room maintenance hatch......................................................................................................... 171
19. Transport dimensions and weights............................................................................................................ 172
19.1 Dimensions and weights of engine parts............................................................................................. 174
20. Project guide attachments........................................................................................................................... 176
21. ANNEX........................................................................................................................................................... 177
21.1 Unit conversion tables.......................................................................................................................... 177
21.2 Collectionofdrawingsymbolsusedindrawings.................................................................................. 178
vi ProjectGuideW38-2/2008
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1.Generaldataandoutputs
1. General data and outputs
1.1 Technical main data
TheWärtsilä38isa4-stroke,turbochargedandintercooleddieselenginewithdirectinjectionoffuel.
Cylinderbore 380[mm]
Stroke 475[mm]
Pistondiplacement 53.9[l/cyl]
Numberofvalves 2inletvalvesand2exhaustvalves
Cylinderconfiguration 6,8,9,in-line12,16inV-form
V-angle 50°
Directionofrotation Clockwiseorcounter-clockwise
Max.Cylinderpressure 21[MPa](210bar)
Speed 600[rpm]
Meaneffectivepressure 2.69[MPa](26.9bar)
Meanpistonspeed 9.5[m/s]
1.2 Maximum continuous output
Nominalspeedis600rpmforpropulsionengines.Themeaneffectivepressurecanbecalculatedasfollows:
where:
p = Meaneffectivepressure[MPa]
e
P= Outputpercylinder[kW]
c= Operatingcycle(2)
D= Cylinderbore[mm]
S= Stroke[mm]
n= Enginespeed[rpm]
Table1.1Maximumcontinuousoutput
Enginetype DieselElectric[kW] CPP[kW] FPP[kW]
6L 4350 4350 4050
8L 5800 5800 5400
9L 6525 6525 6075
12V 8700 8700 8100
16V 11600 11600 10800
ProjectGuideW38-2/2008 1
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1.Generaldataandoutputs
1.3 Reference conditions
Theoutputisavailableuptoachargeaircoolanttemperatureofmax.38°Candanairtemperatureofmax.
45°C.Forhighertemperatures,theoutputhastobereducedaccordingtotheformulastatedinISO3046-
1:2002(E).
The specific fuel oil consumption is stated in the chapter Technical data. The stated specific fuel oil con-
sumptionappliestoengineswithenginedrivenpumps,operatinginambientconditionsaccordingtoISO
15550:2002(E).TheISOstandardreferenceconditionsare:
totalbarometricpressure 100kPa
airtemperature 25°C
relativehumidity 30%
chargeaircoolanttemperature 25°C
CorrectionfactorsforthefueloilconsumptioninotherambientconditionsaregiveninstandardISO3046-
1:2002.
1.4 Principal engine dimensions and weights
Figure1.1In-lineengines(DAAE042634a)
Figure1.2V-engines(DAAE042635)
2 ProjectGuideW38-2/2008
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1.Generaldataandoutputs
A Totallengthoftheengine
B Heightfromthecrankshaftcenterlinetothehighestpoint
C Totalwidthoftheengine
D** Minimumheightwhenremovingapiston
E Heightfromthecrankshaftcenterlinetotheenginefeet
F Dimensionfromthecrankshaftcenterlinetothebottomoftheoilsump
G Lengthoftheengineblock
H Dimensionfromtheendoftheengineblocktotheendofthecrankshaft
I Widthoftheoilsump
K Widthoftheengineblockattheenginefeet
M Distancefromthecenterofthecrankshafttotheoutermostendoftheengine
N Lengthfromtheengineblocktotheoutermostpointoftheturbocharger
O Minimumwidthwhenremovingapiston(Venginesonly)
Table1.2In-lineenginesdimensions
Engine A*[mm] A[mm] B*[mm] B[mm] C[mm] D**[mm] E[mm] F[mm]
6L 6345 6220 2830 2830 2190 3135 560 1115
(2210*)
8L 7925 7545 2820 2770 2445 3135 560 1115
(7875") (7495") (2735") (2690") (2185")
9L 8525 8145 2820 2770 2445 3135 560 1115
Engine G[mm] H[mm] I[mm] K[mm] M[mm] N*[mm] N[mm] Weight1)
[tons]
6L 4455 240 1110 1500 1205 1295 1345 51
8L 5655 240 1110 1500 1240(980") 1680 1470 63(62")
(1635") (1420")
9L 6255 240 1110 1500 1240 1680 1470 72
Table1.3V-enginesdimensions
Engine A*[mm] A[mm] B=B*[mm] C[mm] D**[mm] E[mm] F[mm] G[mm]
12V 7615 7385 2930 3030 2855 720 1435 5165
16V 9130 8945 3105 3030 2855 720 1435 6565
Engine H[mm] I[mm] K[mm] M[mm] N*[mm] N[mm] O**[mm] Weight1)
[tons]
12V 240 1382 2150 1515 1775 1775 1490 88
16V 240 1382 2150 1515 1890 1935 1490 110
*Dimensionvalidwhenturbochargerislocatedatflywheelend
**Dismantlingdimension
"Dimensionvalidfor8L,FPPapplicationonly
1)Tolerance5%,themassesarewetweightsofrigidlymountedengineswithflywheelandbuilt-onpumps
andwithoutadditional;e.g.hoistingtools,packing,torsionalelasticcouplingetc.
Table1.4Additionalmass
Item 6L 8L 9L 12V 16V
Flexiblemounting(withoutlimiters)[tons] 4 5.5 6 4 4.5
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1.Generaldataandoutputs
1.5 Principal generating set dimensions
Theenginecanalsobedeliveredascompletegeneratingset.Anengineandgeneratormountedtogether
on a common base frame, which can be flexible mounted. For indicative main dimensions see figure 1.3
andtables1.5and1.6.
Figure1.3Generatingset(DAAE042636)
Table1.5Generatingsetsdimensions
Engine A*[mm] A[mm] E[mm] I[mm] K[mm] L[mm] L*[mm] Weigth
[tons]
6L 9100 9600 2900 1655 3135 4485 4485 90
8L 11500 12000 2900 1705 3135 4475 4525 110
9L 11800 12300 3100 1805 3135 4575 4625 130
12V 11100 11900 3600 2015 2855 4945 4945 160
16V 12500 13300 3800 2015 2855 5120 5120 200
Table1.6CommonBaseframedimensions
LenghtL* LenghtL WidthW HeigthH W.mounts H.mounts
B B
[mm] [mm] [mm] [mm] W [mm] H [mm]
BM BM
6L 8300 8000 2200 1100 2600 1350
8L 10500 10000 2200 1150 2600 1350
9L 11000 10500 2400 1250 2800 1350
12V 9800 9600 2800 1300 3200 1550
16V 11200 11000 3000 1300 3400 1550
Indicativedimensionsandwetweights(finalvaluesdependongeneratortypeandsize)
*T/Catflywheelend
4 ProjectGuideW38-2/2008
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