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Wartsila-O-E-W-64-TR - 28 Pages

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Catalogue excerpts

Technology Review This is a brief guide to the technical features and advantages of the Wartsila 64 engine. Design Philosophy Cylinder Liner and Anti-Polishing Ring Cylinder Head Fuel Injection System Turbocharging System Cooling System Automation System Macro Modules

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Design Philosophy The Wärtsilä 64 is based on the latest achievements in combustion technology; it is designed for flexible manufacturing methods and long maintenance-free operating periods. All the essential ancillaries, precisely sized and matched, are built onto the standard engine and the engine has a thoroughly planned interface to external systems. The main qualities of the Wärtsilä 64 are: World’s most powerful medium-speed engine, 2 MW / cylinder High efficiency combustion with low emissions High reliability with low maintenance costs, built in experience from Wärtsilä engines Compact...

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Low Emissions Hydrocarbons can be burnt under a wide range of conditions. To burn them efficiently with the lowest possible emissions, in particular of NOx, Wärtsilä developed a Low NOx combustion process which reduces the NOx level by up to 25-35 % without compromising on thermal efficiency. Low NOx combustion is based on: An high compression ratio that therefore gives an higher combustion air temperature at the start of injection, which drastically reduces the ignition delay A late start of injection and shorter injection duration to place combustion at the optimal point of the cycle with respect...

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Crankshaft and Bearings The latest advances in combustion development require a crank gear which can operate reliably at high cylinder pressures. The crankshaft must be robust and the specific bearing loads kept at an acceptable level. This is achieved by careful optimization of crankthrow dimensions and fillets. The specific bearing loads are conservative and the cylinder spacing, which is important for the overall length of the engine, is minimized. Besides low bearing loads, the other crucial factor for safe bearing operation is oil film thickness. Ample oil film thicknesses in the main bearings...

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Engine Block Nodular cast iron is the natural choice for engine blocks today thanks to its strength and stiffness properties and all the freedom that casting offers. The Wärtsilä 64 makes optimum use of modern foundry technology to integrate most oil and water channels. The result is a virtually pipe-free engine with a clean outer exterior. Resilient mounting is state-of-the-art in many applications and requires a stiff engine frame. Integrated channels designed with this in mind thus serve a dual purpose. 7

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Piston and Piston Rings For years, the outstanding piston concept for highly rated heavy fuel engines has been a rigid composite piston with a steel crown and nodular cast-iron skirt. More than twenty years of experience has fine-tuned the concept. When it comes to reliability, there is no real alternative today for modern engines with high cylinder pressures and combustion temperatures. Wärtsilä-patented skirt lubrication is applied to minimize frictional losses and ensure appropriate lubrication of both piston rings and the piston skirt. In Wärtsilä’s three-ring concept each ring has a specific...

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Induction Cr-plated Cr-ceramic Hardened Cr-ceramic engine, the pressure balance above and below each ring is crucial. Experience has shown that this effect is most likely achieved with a three-ring pack. Finally, it is well known that most frictional losses in a reciprocating combustion engine originate from the rings. Thus a three-ring pack is the obvious choice in this respect, too. The piston ring package and ring grooves are optimized for long lifetime by special wear-resistant coating and groove treatment. 9

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Cylinder Liner and Anti-Polishing Ring The thick high-collar type cylinder liner is designed to have the stiffness needed to withstand both pre-tension forces and combustion pressures with virtually no deformation. Its temperature is controlled by bore cooling of the upper part of the collar to achieve a low thermal load and to avoid sulphuric acid corrosion. The cooling water is distributed around the liners with simple water distribution rings at the lower end of the collar. In the upper end the liner is equipped with an anti-polishing ring to eliminate bore polishing and reduce lube oil consumption....

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Connecting Rod A three-piece connecting rod with all the highly stressed surfaces machined is the safest design for engines of this size intended for continuous operation at high combustion pressures. For easy maintenance and accessibility the upper joint face is placed right on top of the big-end bearing housing. A special hydraulic tool has been developed for simultaneous tensioning of all four screws. To eliminate any risk of wear in the contact surfaces, an intermediate plate with a special surface treatment is placed between the main parts. 11

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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. Wärtsilä’s vast amount of 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 carefully controlled cooling and a separate seat cooling circuit, which ensures...

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The cylinder head design is based on the four-screw concept developed by Wärtsilä and used for almost 20 years. A four-screw cylinder head design also provides all the freedom needed for designing inlet and exhaust ports with a minimum of flow losses. The port design has been optimized using computational fluid dynamics (CFD) analysis in combination with full-scale flow measurements. 13

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Fuel Injection System The split pump technology, firstly introduced on the W64, offers unique advantages in terms of operating flexibility, mechanical strength and cost effectiveness. Injection timing can be freely adjusted independently of the injected quantity. Tuning of the injection parameters according to the engine’s operational conditions improves engine performance and reduces exhaust emissions. Smaller closed-type pump elements reduce mechanical stresses and increase reliability. Reduced loads on rollers, tappets and cams improve pump driving reliability. The pump elements are adapted...

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