Generation X Engines - WinGD · PDF fileGeneration X Engines The X Concept X-tra efficiency by...

Generation X EnginesConcept, testing and first service experienceMarc Spahni, Beat Schumacher

- The X concept- Latest updates- Service experience

Generation X EnginesAgenda

Generation X EnginesX Concept

Generation X EnginesThe X Concept

X-tra environmentally-friendly by…

Optimised fuel efficiency- Energy Efficiency Design Index

(EEDI) to quantify the total efficiencyof a vessel

Emission control- Dual-Fuel (DF)- Selective Catalytic Reduction (SCR)- Exhaust Gas Recirculation (EGR)


X-tra efficiency by…

Advanced flexible fuel injection system

Low engine speed for increasedengine & propeller efficiency- Bigger stroke-to-bore ratio

Focus on de-rated engines- Extension of rating fields- Optimisation of tunings

Tunings adapted to vessel operation- Four tuning options

- Standard Tuning- Delta Tuning- Delta Bypass Tuning- Low-load Tuning

84rpm4750 kW

76 rpm4750 kW

58 rpm3625 kW

58 rpm2765 kW

76 rpm3620 kW

84 rpm3620 kW

50%

60%

70%

80%

90%

100%

60% 70% 80% 90% 100%

R1+R1

R2+R3

R4

R2

W-X82-B

65 rpm

RT-flex96C W-X92

Engine power [%]

X-tra compact and manufacturing friendly by…

Minimised dimensions and weights- Long strokes needed to achieve efficiency- Concept with 2 cm bigger bore and

reduced stroke- Applied on X52/62/72/82- Weight advantage ~15%

- X35/40 “me too”- X92 optimized for BSFC and engine speed

- Dual cylinder distance

Optimized manufacturing cost- Close cooperation with engine builders- Manufacturing Engineering team- Commonality wherever possible



X-tra reliability by…

Application of proven conceptswherever possible- Many concepts were already applied

on RT-flex50 or RT-flex82T

Use of state-of-the-art simulation toolsFEM (stress, temperatures), CFD (flow),

vibrations, hydraulic simulation,bearing calculation

Intensive testing of new equipment(e.g. fuel injection valves)- Rig testing- Field testing


Technical implementationof the X conceptAs far as possible the same technicalconcepts were selected for all X engines

Certain adaptations were necessary- Engine power, speed & size

- 4’350 – 73’560 kW @ R1- 167 – 76 rpm @ R1- 74 – 2’140 tons

- Engine and vessel segment- E.g. turbocharger location

- Availability of technical solutions- E.g. fuel injection system

© WinGD, 25 August 2015, M. Spahni & B. Schumacher9


X35/40 X52 X62/72 X82 X92

Generation X EnginesLatest Updates

Extended layout field- R3 & R4 speed reduced to 58 rpm

- Based on market requirementsto further reduce absolute fuelconsumption

- Wider layout field allowsoptimum selection of the wholepropulsion system

Generation X EnginesLatest Updates – X82 Version B

84rpm4750 kW

76 rpm4750 kW

58 rpm3625 kW

58 rpm2765 kW

76 rpm3620 kW

84 rpm3620 kW

50%

60%

70%

80%

90%

100%

60% 70% 80% 90% 100%

R1+R1

R2+R3

R4

R2

W-X82-B

65 rpm


84rpm4750 kW

76 rpm4750 kW

58 rpm3625 kW

58 rpm2765 kW

76 rpm3620 kW

84 rpm3620 kW

50%

60%

70%

80%

90%

100%

60% 70% 80% 90% 100%

R1+R1

R2+R3

R4

R2

W-X82-B

65 rpm

Withoutpumps

Modifications for extended layout field- Crosshead booster pumps only for low CMCR speeds below 65 rpm

Additional improvements- Bypass liner cooling system

- Increased liner surfacetemperatures to prevent corrosiveattack on liner and piston rings

- Two yard connections- „Warm water“ for liner- „Cold water“ for cylinder cover

and exhaust valve- Introduced on X62/72


Extended layout field of X35-B- X35-B

- R3 & R4 speed reducedto 118 rpm

- X40-B- R3 & R4 speed reduced

to 104 rpm

General remarks- Extension is based on market

requirements- Wider layout field allows

optimum selection ofthe entire propulsion system

Generation X EnginesLatest Updates – X35/40 Version B

Improvements from X62/72- Flex system

- Implementation of FAST fuel injectornozzles as standard(FAST = Fuel Actuated Sacless Technology)- Better BSFC- Cleaner combustion


FAST

Improvements from X62/72- Harmonization of UNIC control

system with X62/72- Hardware & software

- ICC available as option(Intelligent Combustion Control)


Example 6X72

Improvements based on X35 experience- Redesign of the cylinder jacket, liners and covers

- Measure against issues with gas sealing andwater leakages

- Possibility to increase combustion pressures forfurther reduced BSFC


- Developed as DF-ready- First X52 will run in Q3/2016

Generation X EnginesLatest Updates – X52

X52 X52DF

Bore [mm] 520 520

Stroke [mm] 2315 2315

Cylinder number 4 – 8 5 – 8

Cylinder output [kW] @ R1 1810 1490

Engine speed [1/min] @ R1 / R3 105 / 79 105 / 82

BMEP [bar] @ R1 21.0 17.3

Design concept- X62 scaled down to 520 mm bore,

with some adaptations- Stroke-to-bore ratio- 4,29à 4,45

- Two instead of three fuelinjection valves

- Slim-type cylinder liner- Application of

RT-flex50 supply unit

Generation X EnginesLatest Updates – X52

Supply unit RT-flex50

Generation X EnginesService Experience

Target- Optimisation- Verification

Areas- Performance Optimisation- Control system Optimisation- Temperature measurements- Stress & strain measurements- Vibration measurements- Component inspection

Generation X EnginesPrototype Testing

Examples 6X72

Engines on Order and in Service – June 2015- More than 3 Mio. running hours achieved with very good service experience- More than 35 % market share in 82 bore segment

Generation X EnginesService Experience X82

Summary # Engines onorder

# Engines aftershop test

# Engines inservice

Max. runninghours

Accumulatedrunning hours

RTA82C 18 18 ~41‘000 ~598‘700

RT-flex82C 37 1 36 ~35‘100 ~879‘300

RT-flex82T 92 1 91 ~37‘600 ~1‘403‘500

RTA82T 5 5 ~27‘400 ~106‘900

X82 67 9 15 ~6‘500 ~54‘800

Total 219 11 165 – ~3‘043‘200

8RTA82CMain bearing #5 – 5’491 h- Shell in good condition- Rear side without fretting marks

8RTA82CBottom end bearing – 7’975 h- Bearing shell in good condition

10RT-flex82CCrosshead bearing – 29’008 h- 8 units inspected- All bearing shells in good condition


Injection Control Unit (ICU)- The ICU had been further developed

to reach longer lifetime- Since 2012 service experience has been

very good- Less sensitivity to HFO impurities- Maintenance on-board by the crew

is possibleà lower OPEX

- Similar concept also used forRT-flex50 and X92


1. Valve seat,2. Valve sleeve,3. Valve spindle

ICV(Inject. Control Valve)

FAST fuel injectors- RT-flex82T- Inspection at 12’600 h

- Nozzle found in goodworking condition

- Nozzle tip inside and outsidein good condition

- No cavitation on spring andinside spring chamber

- Needle and needle seatwithout wear


W9X82 – unit #6 – 5’101 h

Generation X EnginesService Experience X82 – piston running

All piston rings Chromium Ceramic type

Top piston ring B piston ring C piston ring

Engine configurations delivered- W5X35, W6X35, W7X35, W6X40- FPP and CPP- With / without PTO shaft generators

Total accumulated running hourson all engines: > 125’000 hrs(June 2015)-3 engines > 12’000 hrs-5 engines > 10’000 hrs

Generation X EnginesService Experience X35/40

- Very good fuel consumption at all loads

- Positive feedback about L’Orange Injectorslifetime and performance- Initial estimate of 8000 hrs TBO

(time between overhaul) has beenconfirmed

- Issues with gas sealing betweencylinder liners and covers at higher loads -solutions ready


X72- 40 engines on order- Of which 10 engines in service (6X72)


X62- 20 engines on order- Of which 4 engines in service (6X62)

6X72 6X62

- Most of the sea-trials and maiden voyagesattended by Wärtsilä and/or WinGDservice engineers

- General feedback- Good piston running behaviour- Reliable cylinder lubrication- Positive experience with fuel injection

and servo system- Spotless condition of gear wheels- Superb engine performance


Issues solved or under implementation- Starting and crash manoeuvres

- Parameters optimized(cannot be done on test bed)

Fuel injectors sticking afterchangeover from HFOà MDO- Clearance at pilot valve increased- Cooling/lubrication of fuel injectors

restricted by orifice


Four 8X92 engines tested at HHI-EMD- Extensive prototype testing on first

engine-All stress, temperature and vibrationvalues within permissible limits-BSFC figures well within published values-Good condition of inspected parts

- TAT successfully passed on fourthengine at HHI, 27 Aug. 2015


The X concept-Environmentally-friendly-Efficient-Compact & manufacturing-friendly-Reliable

Latest updates-Versions B of X82 and X35/X40-New X52

Generally good service experience

Generation X EnginesSummary

Generation X Engines - WinGD · PDF fileGeneration X Engines The X Concept X-tra efficiency by...

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