Wartsila 38

38

Technology Review

Setting new standards for economical power productions 4

Design Philosophy 6

Low NOx combustion 7

World Bank Guide Lines Compliance 8

Engine block / Crankshaft 10

Main bearings / Connecting rod 11

Camshaft / Cylinder head 12

Cylinder liner / Anti-polishing ring 13

Piston and piston rings / Fuel system 14

Fuel injection system / Air and exhaust gas system 15

Hot box design / Air cooler / Lubricating system 16

Control, alarm and monitoring system 17

Maintenance 18

Service solutions to optimize profitability 19

Daily round-the-clock service, wherever it is needed 20

Main data marine 21

Main data power 22

Technology Review Contents

3Technology Review Wärtsilä 38

38

Setting new standards for economical power productions

5Technology Review Wärtsilä 384Technology Review Wärtsilä 38

38

Elation, cruise ship,

equipped with six Wärtsilä 12V38 engines Diesel Electric.

Wärtsilä 38 offers an outstanding total economy concept

adding up to numerous valuable benefits for the customer.

Volvox TerraNova, T.S. hopper dredger,

equipped with two Wärtsilä 18V38 engines.

Sea Nordica, containership,

equipped with two Wärtsilä 8L38 engines.

De Vechtborg, multipurpose,

equipped with a Wärtsilä 6L38 engine.

Power Plant Tapal,

equipped with twelve Wärtsilä 18V38 engines (120 MW), Karachi, Pakistan.

IMO NOx Compliance

The best trade-off between low NOx and low SFC is obtained through a low NOx com-

bustion system. The combination of high compression ratio and a fast, controlled heat

release, ensured by optimized fuel injection and combustion process, achieves this goal.

High injection pressures and a well designed combustion chamber also contribute to this.

Gas exchange losses are minimized, thanks to optimized inlet and exhaust channels in

the cylinder head as well as adequate valve seat and valve lift dimensions. Furthermore the

turbocharger system contributes to this optimization process.

When talking about Power Plant stack emissions nitrogen oxides (NOx), sulphur dioxides

(Sox) and particles (as dry dust) are in focus. World Bank Guidelines 1998 for ‘Thermal

Power: Guidelines for New Plants’ take into account the air quality in the surrounding of

the power plant when defining the applicable stack limits.

Low NOx combustion

Responding to a need in the market for an engine in the 400 mm cylinder bore class, the

Wärtsilä 38 was developed. The Wärtsilä 38 is a technologically advanced engine in its

class – a product that sets standards. The compactness of the Wärtsilä 38 and its light

weight contribute to easy and space-saving power plant installations. The high level of

technology incorporated in this engine, its design, and the power plant that is built around

it, are all focused on achieving the lowest possible kWh production cost. With fewer parts,

lower maintenance requirements, low fuel consumption, lower emissions and the ability to

run reliably on a variety of fuels, the Wärtsilä 38 is unquestionably the state-of-the-art in

power generation.

Design Philosophy

38


State-of-the-art plant of Tapal Energy Ltd., Karachi, Pakistan.

Engine type: 12 x Wärtsilä 18V38, total electric output: 126 MW.

9L38B Diesel generator set

Specific NOx emissions

weighted (g/kWh)

20

18

16

14

12

10

8

6

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Rated engine speed (rpm)Regulation 13 of annex VI of MARPOL 73/78

IMO NOx limit for new engines

Wärtsilä 38Blow NOx combustion

Wärtsilä 38B with Direct Water Injection

38


World Bank Guide Lines Compliance

The 38-engine is designed for minimum NOx emissions at an optimum fuel consumption.

The engine fulfills the new (from 1.7.2000) World Bank NOx stack limit for ‘non-

degraded areas’. In a ‘degraded area’, which might be the case for a big city with heavy

car traffic, etc. the stack limit for NOx is lower and a SCR catalyst has to be applied.

Emissions of sulphur dioxides and particles are fuel related (mainly dependent on sulphur

and ash content of the fuel).

1700 1750 1800 1850 1900 1950 2000

350

330

310

290

270

ppvm

Greenhouse Effect and Global Warming

Atmospheric concentrations

of carbon dioxide since 1750

Ice core measurement(siple station, West Antarctia)

Direct measurement (Mauna Loa, Hawaii)

CFC 24%

Carbon dioxide concentrationsGreenhouse Gases

N2O 6%

CO2 55%

Methane 15%

1999 2000 2001

200

400

600

800

1000

1200World Bank (non-degraded airshed):2300 ng/nm3 (dry, 15 vol-% O2, 0 ˚C)

World Bank (non-degraded airshed):2000 ng/nm3 (dry, 15 vol-% O2, 0 ˚C)

Appying for FundingAfter 1.7.2000

NOx Emmission limits/World Bank 1998 Guide Lines

200

400

600

800

1000

1200

Coal fired power plant Diesel engine HFO

g/kW

he

CO2 EmmissionsSou

rce:

Env

ironm

enta

l Dat

a R

epor

t, U

NE

P 1

990

World Bank (degraded airshed): 400 mg/nm3 (dry, 15 vol-% O2, 0 ˚C)

pp

m-v

(dry

, at

15 v

ol-%

O2)

In the future the carbon dioxide (CO2 ) emission will be in focus due to its’ expected

impact on the global warming. An efficient diesel power plant has relatively low CO2

emissions. The Kyoto Protocol provisions allow for a Clean Development Mechanism

(CDM) under which carbon offsets trading between certain countries will become

possible in the future, the mechanism is still however under development.

The moderate bearing load and rigid design of the main bearing cap ensure reliable

operation. The geometry of the bearing creates an oil film thickness which greatly exceeds

the safety margins required by bearing manufacturers; all in

accordance with the Wärtsilä ‘Thick Pad’

philosophy. Bolt connections are

hydraulically tightened, and the main

bearing oil supply pipe is combined

with a hydraulic jack for lowering

the main bearing cap.

Crankshaft

Engine block Main bearings

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The combination of design elements such as

under slung crankshaft, integrated air receivers,

short cylinder distances and material choice has

resulted in a very rigid engine block. The

camshaft bearing environment forms an

integrated part of the engine block,

contributing to the overall stiffness of the

block. The rigidity of the engine block ensures

easy flexible mounting. Cast-on feet of the V-

type block and bolted-on feet on the in-line

engine offer a simple solution to accommodate

resilient elastic mountings to isolate structure-

borne noise.

In the design process of the W38 engine, special attention was given to optimizing the

various geometric characteristics such as cylinder distance and high combustion pressure in

order to achieve a space-saving solution. By using FE (Finite Element) calculation

methods, an optimal crankshaft design was achieved resulting in maximum

overall rigidity while maintaining moderate bearing loads. The design

of the crankshaft is such that even with higher combustion

pressures, all criteria of classification societies are met.

Under slung crankshaft. Hydraulic Tensioned

bearing studs and side bolts.

Connecting rod

The ‘marine head’ design of the connecting rod is carefully optimized with regard to stress

levels using 3-D FE analysis. Dismantling height of the piston/connection rod assembly is

shorter than any other engine in this output range. The ‘marine head’ design makes it

possible to remove the piston-connecting rod assembly without removing the big-end

bearing, significantly reducing maintenance down-time and cost.

Wärtsilä ’s long-term experience and extensive research and

development resulted in the high collar cylinder liner design. This

design ensures ideal roundness of the liner, a precondition for

optimal ring-liner contact. Furthermore, the straightness of the liner

is maintained during operation, and interference from adjacent

cylinders is prevented. By optimizing the design of the vertical

cooling bores, the correct temperature range is maintained on the

inner liner surface - high enough to prevent cold corrosion and low

enough to ensure good lubrication.

■ The cylinder head has been redesigned to maximise thermal efficiency (by

incorporating the largest possible air/gas channels). It is also adapted to the higher

load of the W38B engine.

■ The use of four cylinder head studs

facilitates easy maintenance.

■ The valve design guarantees excellent

component operational behaviour,

especially with heavy fuel.

■ Rigidity of the cylinder head design

ensures adequate and uniform sealing

between cylinder head and liner.

■ Rigidity of the construction allows no

deformation of the valve seat

environment.

■ All connections to the cylinder head are

easy to reach and disconnect.

13Technology Review Wärtsilä 38Technology Review Wärtsilä 38 12Technology Review Wärtsilä 38

The camshaft consists of individual one-cylinder camshaft units, flange connected to separate

bearing journals. Built-in valve tappet modules screwed onto the engine block ensure easy

maintenance and reliable operation. The overall design ensures reliable operation, easy

maintenance and inspection.

Cylinder head

Cylinder liner Camshaft

The anti-polishing ring removes the carbon from the piston top,

thus preventing liner polishing. This system results in a drastic

reduction of cylinder wear, lower and constant lubricating oil

consumption, and a clean piston.

Anti-polishing ring

Cylinder head

Camshaft

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Cylinder liner

■ The Wärtsilä 38 fuel injection system achieves the optimum trade-off between

performance parameters – fast injection together with good injection quality

with respect to the fuel spray pattern and droplet size.

Air and exhaust gas system

■ The new generation turbochargers, applied on the W38B series, allow not

only improved performance but also a compact installation with less piping

(water cooling is not needed).

■ Special attention is paid to the integration of the by-pass and waste gate valves,

becoming essential parts of the engine. The position of the valves and their

controls is selected based on the requirements of low vibration levels, low local

temperatures and short piping.

■ Simple reliable manual controlled cleaning device is standard. Besides the system

full automatically controlled cleaning device can be delivered. A cast turbocharger

bracket provides the housing of a revised two-stage air cooler and supports the

turbo charging system.

■ The charge air receiver is designed for minimum pressure variation and good

engine ‘breathing’.

■ The inlet bends between the air receiver and the cylinder head for the L-engine

are designed with additional functionality in mind:

- support of the exhaust system (rigid mounted isolation box and single

pipe exhaust [SPEX])

- support of the cooling water return channel from the engine

■ This multifunctional solution allows a compact installation.

■ The exhaust system contributes to the efficiency of the

turbochargers thanks to its flow-optimised design.

The system is modular for easy assembly and can handle

such factors as gas exchange dynamics, high temperatures,

thermal expansion, etc.

■ Insulation of the exhaust system is achieved by stainless

steel insulating panels, which are easily removable for

inspection access.

Piston and piston rings

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■ The piston design, based on the extensive experience of the

Wärtsilä Corporation, consists of a steel crown, nodular cast

iron skirt and pressurised skirt lubrication.

■ The three-ring pack consists of two compression and one

oil scraper ring located at the crown. This ring pack

ensures optimal pressure distribution and lowers

lubricating oil consumption.

■ The shape of the combustion chamber is such that it ensures efficient

combustion at all loads, while the component temperatures are kept low.

Fuel system

■ Fuel feed and return lines are integrated in the fuel pump housing. This offers a

‘clean’ cylinder head environment for easy access and maintenance. It also means

fewer part connections resulting in high reliability.

■ Shielded high-pressure lines as well as the ‘hot box’ contribute to safety – especially

for HFO operation.

■ The design of the fuel system is such that pressure pulses in the low-pressure system

are very low.

■ Proper dimensioning of the camshaft, camshaft bearings and rollers ensures a

controlled mechanical load on all driving parts, ensuring long lifetime and low

maintenance costs.


Fuel injection

system

Fuel system Air and exhaust gas system

Piston

Fuel injection system

■ Externally there are swinging ‘hot box’ covers and cylinder head covers closing the

hot box area. Internally, a fuel system is designed based on state of the art fuel

pumps resulting in a simple and very reliable system.

■ Multi-channel extrusion profiles are selected (a) for the main starting air supply

and (b) the transport of some fluids. The latter is also used as a back cover for the

special space created for the components of the control system.

Air cooler

The Wärtsilä 38 is equipped with a two-stage air cooler, making it highly

suitable for combined heat and power application, due to a high degree

of waste heat recovery. Housing of the two-stage air cooler forms an integral

part of the turbo-charger support, creating a compact, economic, and rigid

design.

Lubrication system

The lubrication system of the in-line engines includes a complete lubrication

oil module with a cooler, an automatic backflush filter, a centrifugal filter in

the backflush line, and thermostatic valves. The main and the pre-lubrication

oil pumps and the regulating valve are part of the total system. The

lubrication oil flow through the engine is revised based on optimised bearing

clearances allowing great safety margins. The new three piston ring package

together with the anti-polishing ring assure very low lubrication oil

consumption.

Engine-driven pumps

Engine-driven lubricating oil and cooling water pumps are an integral part

of the Wärtsilä 38 design. All engine-driven pumps are located on the free

end of the engine. For the eighteen-cylinder Wärtsilä 38 all pipe

connections are grouped together allowing easy connection to the power

plant’s auxiliary systems. Use of the engine-driven pumps considerably

simplifies the whole power plant design and lowers investment costs.

Cooling water system

The LT and HT cooling water systems are integrated in the engine, including built-on

pumps and thermostatic valves. This guarantees maximum protection of the engine under

all circumstances.

Control, alarm and monitoring system

The Wärtsilä 38B includes several advancing features in the field of automation. A new

generation engine-integrated system, the WECS 7000, is introduced on the engine. WECS

stands for Wärtsilä Engine Control System and 7000 is the version for medium speed

diesel engine applications. It incorporates all past experience of the Wärtsilä in electronics

development based on new generation control units. It is the new standard in the Wärtsilä

electronics, to be used by all Wärtsilä medium-speed engines in the near future.

The main components are:

■ The WECS cabinet on the right of the operating side

of the engine. It included the heart of the system, the

main control module MCM700, the Relay Module for

back-up functionality. The WECS communicates with

the external systems through a Mod- or Profi-bus

(Marine/Power Plants); the connectors are located on

the WECS cabinet.

■ The cylinder control units located at a special room

underneath the hotbox, grouping the signals from the

cylinder related sensors (one cylinder control unit per

three cylinders).

■ Control of by-pass and waste-gate valves (if applicable)

is an integrated part of the WECS 7000.

The software can be very easily reconfigured to match

installation needs.

As a common Wärtsilä system based on identical hardware

(control units) and basic software, the WECS 7000 will allow

unique serviceability and customer satisfaction.

‘Hot box’ design


Engine-driven pumps

38

WECS 7000

WECS 7000

Assembly hall, Zwolle, The Netherlands

■ The Wärtsilä 38 overall design resulted in a considerably

lower number of parts compared to other engines in its

class, which results in reduced maintenance costs and less

down-time.

■ All parts, both internal and external, are easily accessible for

quick and easy servicing.

■ Advanced computer-based maintenance software designed

to support all aspects

of maintenance is available.

Maintenance

18Technology Review Wärtsilä 38 19Technology Review Wärtsilä 38

Service solutions to optimize profitability

Wärtsilä is committed to keeping your investment productive and profitable throughout

the equipment lifecycle, whether you are operating a land-based power plant or marine

power system.

This calls for proactive services including performance optimization, modernization and

comprehensive operation support.

Wärtsilä provides separate service packages for its power plant and marine customers:

Energy Partner and Marine Partner, which are tailored to the specific needs and operating

conditions of these customers. In both cases, however, our aim is yours – to find a service

solution you can adapt to your needs in the most cost-efficient way.

Energy Partner and Marine Partner services cover all aspects of plant support to help you

to optimize the lifecycle costs of your equipment in the way you consider most

appropriate. Our approach is two-fold. You can either use them individually on a daily

basis. Or you can use them in combinations predefined by one of our service agreements.

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Main data marineDaily round-the-clock service, wherever it is needed

Parts

Top-quality original parts covering all Wärtsilä and Sulzer engines, including

all previous engine brands with first-class response times and first-class global

logistics support.

Field Service

Competent, regularly trained field professionals available round the clock

anywhere in the world through Wärtsilä’s global service network, backed up

by product specialists.

Workshop Services

Restoration of full functionality, safety and reliability with OEM (Original

Equipment Manufacturer) quality.

Technical Support

Full technical support for trouble-shooting and equipment optimization by local

dedicated contact people and specialized product company experts.

Operation Support

Full Operation and Maintenance documentation support and sophisticated

software applications to ensure continuous operational reliability and cost control.

Training

Standardized and tailor-made courses worldwide on all Wärtsilä and Sulzer products.

Service AgreementsWärtsilä service agreements cover all aspects of lifecycle optimization from parts

supply and daily assistance, to inspection, maintenance and even implementation

of agreed performance targets. Though comprehensive in scope, Wärtsilä service

agreements are designed to allow you to tailor them to your exact needs.

■ Parts supply agreement

■ Support agreement

■ Inspection agreement

■ Maintenance support agreement

■ Maintenance agreement

■ Management support agreement

■ Performance agreement

■ Operation & Maintenance

agreement

C

K

D BFE

H

N M

I

O M

IK

DE F

B

C

A*

GA

H

N

38

Main data

Cylinder bore 380 mm

Piston stroke 475 mm

Speed 600 rpm

Mean effective pressure A-version: 24.5 bar

B-version: 26.9 bar

Piston speed 9.5 m/s

Fuel specification

Fuel oil 730 cSt/50°C

7 200 sRI/100°F

ISO 8217, category ISO-F-RMK 55

Rated power: Propulsion engines

EngineType A-Output * B-output *

kW BHP kW BHP

6L38 3 960 5 385 4 350 5 915

8L38 5 280 7 180 5 800 7 885

9L38 5 940 8 075 6 525 8 870

12V38 7 920 10 770 8 700 11 830

16V38 10 560 14 360 11 600 15 770

18V38 11 880 16 155 13 050 17 745

* Output at 600 rpm

Wärtsila 38B – Principal engine dimensions (mm) and weight (tonnes)

EngineType A* A B C D E F G

6L38B 6 235 6 291 2 637 2 186 3 520 560 1 115 4 455

8L38B 7 912 7 491 2 782 2 352 3 520 560 1 115 5 655

9L38B 8 512 8 091 2 782 2 352 3 520 560 1 115 6 255

12V38B 7 578 7 320 2 900 3 028 3 000 720 1 435 5 165

16V38B 9 175 8 917 3 067 3 028 3 000 720 1 435 6 565

18V38B 9 875 9 617 3 067 3 028 3 000 720 1 435 6 265

H I K M N O Weight

6L38B 270 1 110 1 500 1 205 1 471 - 50.0

8L38B 270 1 110 1 500 1 205 1 471 - 66.0

9L38B 270 1 110 1 500 1 205 1 471 - 74.0

12V38B 240 1 382 2 150 1 514 1 738 1 020 -

16V38B 240 1 382 2 150 1 514 1 935 1 020 -

18V38B 240 1 382 2 150 1 514 1 935 1 020 -

Our company, as a manufacturer and

supplier of high-quality diesel engines

is certified according to ISO 9001.

The Wärtsilä 38 is the result of systematic

efforts, and its manufacture is

certified under the Lloyd’s Register

Quality Assurance scheme.

Main data power


C

B

Main data

Cylinder bore 380 mm

Piston stroke 475 mm

Cylinder output 675 kW/cyl.

Engine speed 600 rpm

Piston speed 9.5 m/s

Mean effective pressure 25.1 bar

Fuel specification

Fuel oil 730 cSt/50°C

7200 sRi/100°E

ISO 8217, category ISO-F-RMK 55

Natural gas

Rated power

Engine 50Hz and 60HzType Eng. kW Gen. kW

18V38 12 150 11 820

Principal engine dimensions (mm) and weight

(tonnes)

EngineType A B C Weight

18V38 14 175 4790 4900 176

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Wärtsilä Corporation is the leading global ship power supplier and a major provider

of solutions for decentralized power generation and of supporting services.

In addition Wärtsilä operates a Nordic engineering steel company and manages

substantial share holdings to support the development of its core business.

Telephone: +31 (0)38 425 32 53Fax (marine):+31 (0)38 425 33 52

Wärtsilä NSD Nederland B.V.P.O. Box 10608, 8000 GB Zwolle Hanzelaan 95, 8017 JE ZwolleThe Netherlands

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Wartsila 38

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