Technology Review

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Technology Review

Design philosophy 4

Wärtsilä 200 for marine andland-based applications 5

Main features of the compact heavy-duty design 6

Compliance with emission regulations 7

Component features 8

Engine block 9

Piston and liner 10

Crank mechanism 11

Fuel system 12

Camshafts and timing gear 14

Engine driven pumps. Power take-off. 15

Exhaust gas and turbocharging system 16

Starting motor and pneumatic system 17

Engine cooling 18

Engine lubrication 20

Engine automation 21

Maintenance 22

Main technical data 23

This is a summary of Wärtsiläs approach to design and technologyin the Wärtsilä 200 engine.

Design philosophy

The Wärtsilä 200 engine design is based on generations of know-how

combined with innovations in response to market needs.

The design of the Wärtsilä 200 combines the requirements of heavy

duty and compactness in a unique way.

The development of this engine type is based on the following core

values:

� Continuous heavy-duty operation

� High power density

� Modern technology

� Operational economy

� Environmental friendliness

� Easy and cost-effective installation

� Easy maintenance

� Superior load pick-up

4

Wärtsilä 200 for marine and land-based applications

Typical land-based applications

� Baseload for remote sites

� Large standby

� Turbine black-start

� Baseload plants up to 50 MW

Typical marine applications

� Offshore

� Diesel-electric ships

� Navy vessels

� Workboats

� Ferries

� Yachts

5

Main features of the compact heavy-duty design

The Wärtsilä 200 compact, heavy-duty engine has been developed to

combine:

� High power density,

� Durability in continuous heavy-duty applications,

� Cost effectiveness,

� Excellent load pick-up performance,

� Easy maintenance.

Compact design means 40% fewer parts than in conventional engines.

Integrated design:

� complete lubrication oil system

� complete fuel oil system

� cooling water pump, pre-heating and

temperature control.

� engine control system

6

Compliance with emission regulations

Wärtsilä has developed the Low NOx combustion concept to ensure

compliance with NOx emission demands. The concept features a higher

compression ratio, higher fuel injection pressure, optimized valve timing

and an optimized combustion chamber.

The Wärtsilä 200 engines meet the requirements of the IMO and World

Bank guidelines.

Wärtsilä 200 marine engines are delivered with an EIAPP certificate

according to IMO MARPOL’97 Annex VI requirements.

Lower level NOx emissions can be achieved by secondary reduction

methods; a compact SCR catalytic converter is able to reduce NOx

emissions by 90% to a level of < 2 g/kWh.

7

Component features

Cylinder head

The “easy to service” cylinder head is

mounted by four hydraulically tensioned

stud screws.Each cylinder head has two

inlet valves and two exhaust valves with

valve rotators.

A distributed water flow pattern is used

for efficient cooling of the exhaust valve

seats and the flame plate.

Multiduct

A multifunctional connection piece is

located between the cylinder head, engine

block and exhaust manifold. This

“multiduct” has the following functions:

� Combustion air transfer from charge air

receiver to cylinder head

� Introduction of an initial swirl to the

inlet air for optimal part load

combustion

� Exhaust gas transfer to the exhaust system

� Cooling water transfer from the cylinder head to the return channel in the

engine block

� Insulation/cooling of the exhaust transfer port

� Support for the exhaust manifold and insulation

� Inclined face towards the cylinder head facilitates easy

removal/remounting of the cylinder head

8

Engine block

The Wärtsilä 200 engine block has been designed for optimal compactness

and rigidity. The monobloc structure incorporates the following functional

features:

� Timing gear housing

� Camshaft bearing housings

� Charge air receiver

� Cooling water and lube oil distribution channels

� Lubricating oil main distribution.

There is an extra support and axial guide bearing in the flywheel end of the

block. The main bearing caps are hydraulically fastened to the engine block

and can be accessed through the inspection doors of the engine block.

The engine block is cast in nodular iron, which provides the best

resistance against mechanical forces and shock.

The engine support feet are bolted on each side of the block and

enable both rigid and elastic mounting.

9

Piston and liner

Piston and piston ring

The piston is a composite, low-friction

piston with steel top and aluminium

skirt.

The piston is lubricated by an oil jet.

The same jet supplies oil to the cooling

oil gallery in the piston top.

The piston ring set

consists of two hard

chromium plated

compression rings and

one spring-loaded oil

scraper ring.

Cylinder liner

The special cast iron cylinder liners are fitted with anti- polishing rings at

the liner top.

The anti-polishing ring limits the build-up of carbon deposit on the

piston top.

The anti-polishing ring offers following benefits:

� Reduced lube oil consumption

� Reduced particle emissions

� Reduced thermal stress on the piston and cylinder liner top

� Reduced piston and liner wear

� Reduced risk of piston seizure

10

Crank mechanism

Connecting rod

The connecting rod is of forged

high-tensile steel, fully machined and

balanced for low vibration running.

The big end has a diagonal split with

serration teeth.

Two stud screws are hydraulically

tensioned and can be accessed through the

inspection doors at the engine sides.

The off-set split makes it possible to overhaul the

piston and connecting rod assembly through the

cylinder liner.

Crankshaft and bearings

The monobloc crankshaft is forged of high-tensile steel. The

running surfaces of the crankpin and main journal are hardened.

The crankshaft is fitted with counterweights and is fully balanced.

The crankshaft oil seal can be changed without removing the

crankshaft.

The conrod big end bearings and

main bearings are of CuPb type.

11

Fuel system

The fuel system of the Wärtsilä 200 is integrated in the engine.

The main components of the fuel system are:

� Strainer

� Engine driven or optional electrically driven fuel feed pump

� Main filters, pressure regulation & relief valve

� Supply/return piping

� Injection system

� Leak oil collection.

The individual unit injection pumps incorporate several functions and are

easy to maintain.

The high injection pressure provides the conditions for efficient

combustion with low emission levels.

Easy access, quick pipe removal/refitting and an ample-sized filter

minimize maintenance time and cost.

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Leakage recovery, an isolated “hot box”

compartment for the injection system and

optional double-skin injection pipes ensure a high

level of safety in unmanned installations.

The injection pumps are equipped with

pneumatic emergency stop pistons which are

activated to switch the fuel racks to the 0-position

by a signal from the engine overspeed detector or

safety stop contacts.

A rack position transmitter and smoke limiter

options are available for marine propulsion

engines.

Wärtsilä 200 direct injection engines are

designed to run with ISO 8217 DMX, DMA and

DMB or similar quality diesel fuels .

13

Camshafts and timing gear

The camshafts are assembled from 2- or 3-cylinder modular sections and are

dimensioned for high injection pressures.

The cams are surface-hardened for wear resistance and long lifetime.

The camshaft sections can be removed axially from the engine block.

The timing gear is located in the flywheel end of the engine. The timing

gear compartment is incorporated in the engine block casting, which

provides the best rigidity, a small number of parts and minimum risk of oil

leakage.

The timing gear wheels are dimensioned, surface-hardened and

precision-finished for long lifetime.

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Engine driven pumps. Power take-off.

Engine-driven pumps for the lube oil, jacket water, fuel oil and an optional

sea water pump are located in the free end of the engine with an easy

access for pipe connections and maintenance.

The engine can be equipped with connections for stand-by pumps.

A maximum of 2400 kW power can be transmitted from the free end of

the engine using an optional power take-off (PTO) shaft from the

crankshaft. This option is available on the 12V200 and 16V200 models.

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Exhaust gas and turbocharging system

Wärtsilä 200 engines are single-stage

turbocharged and are all equipped with

two latest-generation turbochargers to

provide high efficiency and excellent load

response. The turbochargers are located

in the free end of the engine.

The charge air is cooled by the

engine cooling water and then distributed

to the cylinders through the charge air

receiver in the Vee of the cylinder block

casting.

Exhaust gas temperature sensors are fitted at each cylinder outlet for

monitoring of the engine condition.

The exhaust system is multi-pulse configured for all cylinder numbers to

ensure good load response at all load situations.

The exhaust gas manifold consists of pipe sections of a high

temperature resistant cast alloy. The sections are fixed together with robust

clamps and compensators to avoid gas leaks and manifold distortions.

The exhaust manifold and hot parts of the turbochargers are equipped

with thermal protection which can be quickly removed for maintenance or

inspection.

16

Starting motor and pneumatic system

Wärtsilä 200 engines have a

pneumatic starting motor. A

second pneumatic starting

motor is available as an

option.

The starting system

functions with 30 or 40 bar

compressed air. The starting

motor unit has a built-on

main valve and pressure

reducer to provide a

working pressure of 10 bar

to the starting motor.

The starting sequence is

programmed into the

control system. The starting motor pinion drives the toothed rim of the

flywheel.

The same pneumatic system supplies air to the control and safety stop

system through solenoid valves and an air bottle.

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Engine cooling

The cooling system is built on the engine and comprises:

� Preheating module

� Double impeller cooling water pump for LT/HT circuits

� Thermostatic valves and LT/HT water mixing

� Charge air cooler

� Lube oil cooler

� Seawater pump (optional)

� Cooling circuitry mostly incorporated in the engine block casting

The LT/HT (low temperature/high temperature) circuits can be configured

to a single circuit with an HT outlet from the engine and return to the LT

side or they can be configured to two circuits with separate outlets and

inlets for the HT and LT sides.

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Engine cooling system with separate LT/HT circuits

The external system normally comprises a plate-type heat exchanger for

cooling the engine water and another smaller plate heat exchanger for fuel

cooling.

Fan radiators are used for engine cooling in stationary power plants and

in marine emergency genset installations.

Box cooling systems can be used in marine installations.

Heat recovery is possible from the HT circuit.

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Engine cooling system with mixed LT/HT circuits

Engine lubrication

The lubricating oil system of Wärtsilä 200 is built on the engine.

The main parts of the lubricating oil system are:

� Wet oil sump

� Lube oil pump module comprising the engine-driven oil pump and the

electrically driven pre-lubrication pump

� Lube oil module comprising the thermostatically controlled lube oil

cooler and main filters

� Centrifugal filter

� Distribution channels integrated in the engine block

� Oil jet nozzles for piston cooling and

lubrication

� Instrumentation.

The main filters can be changed quickly and

safely thanks to the easy location of the filter

module.

Pre-lubrication can be controlled

automatically or manually.

Wärtsilä 200 engines can use SAE 40 mineral

or synthetic oils.

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Engine automation

Land-based power plant applications:

Wärtsilä 200 engines are equipped with the

WECS 7000 engine control and monitoring

system.

Marine applications:

Wärtsilä 200 engines are delivered with a

PLC-based engine control and monitoring

system comprising the following system

components :

� Sensors and instrumentation according to the

classification rules

� Wiring harness fully finished for quick and

easy hook-up

� Control cabinet with IP55 steel enclosure

� Tachometer system for speed display , speed

relays and overspeed detection

� PLC unit for processing the displays, alarms

and safety stops

� MODBUS communication interface

(optional)

� Electronic speed control unit

� Control buttons, switches and displays

The engine control and monitoring system is fully tested before delivery

according to the classification society rules

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Maintenance

The Wärtsilä 200 is designed to ensure easy maintenance.

� Reduced number of parts thanks to incorporated fluid

channels, multiducts and other integrated functions

� Possibility to change the main bearings through the

access doors in the engine block without removing the

engine from its seating

� Professionally designed maintenance tools

� Hydraulic tensioning of the stud bolts of cylinder head,

connecting rod and main bearings

� The exhaust gas piping and insulation box, supported by

the multiduct, stays in place when removing the cylinder

head

The Wärtsilä 200 is designed for:

� Over 20 000 hours for engine top overhaul interval

� Over 40 000 hours for engine bottom overhaul interval.

Wärtsilä’s worldwide service network at your disposal: Own

network offices in more than fifty countries and numerous

service points worldwide:

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Main technical data:

Cylinder bore 200 mm

Piston speed 9.6-12 m/s

Piston stroke 240 mm

Speed 1200-1500rpm

Swept volume 7.5 l/cyl

Mean effective pressure 21.2-23.2 bar

Fuel specification: Marine diesel oil ISO 8217 category

ISO-F-DMX-DMA-DMB

Rated power: Marine engines

Engine typeMCR output in kW/ BHP, mechanical

1200 rpm 1500 rpmkW BHP kW BHP

12V20016V20018V200

210028003150

285038004280

240032003600

326043504890

Marine generator sets:

Engine type

Output in kWe at generator terminals1200 rpm/ 60 Hz 1500 rpm/50Hz

Continuous Stand by Continuous Stand bykWe kWe kWe kWe

12V20016V20018V200

200027003000

220029703300

230030503500

256033503860

Land-based generator sets:

Engine type

Output in kWe at generator terminals1200 rpm/ 60 Hz 1500 rpm/50Hz

COP/PRP LTP COP/PRP LTPkWe kWe kWe kWe

12V20018V200

20003000

22003300

23003500

25603860

COP= Continuous duty, PRP= Prime power output, LTP= Standby duty

Principal dimensions (mm) and weights (tons)A B C E Weight

12V20016V20018V200

392045104810

166018301830

179018401840

102010251025

14.617.519.1

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Genset dimensions are available

in Marine and Power Plant

project guides

For power plant applications:

Wärtsilä France S.A.S.1, rue de la Fonderie, B.P. 121068054 Mulhouse Cedex - France

Tel. + 33 3 89 66 68 68Fax + 33 3 89 66 68 40

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Wärtsilä Corporation is a global engineering company focusing on marine

propulsion, power generation and industrial applications.

Wärtsilä designs, manufactures, licenses, markets, and services Wärtsilä

and Sulzer engines from 0.5 to 80 MW. The company engineers and

provides complete propulsion systems for all vessel types and turnkey

power plants from 1 to 300 MW.

With its global sales and service network and licensees in all major

markets, Wärtsilä is your local partner who can deliver the optimum

solution to meet your present and future power needs.

For more information, please visit: www.wartsila.com

For marine applications:

Wärtsilä Finland OyP.O. Box 252FIN 65101 Vaasa

Tel. +358 10 709 0000Fax +358 6 356 7188

Please contact:

WÄRTSILÄ® and SULZER® are registered trademarks.