Wartsila o e w 32gd Tr

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WRTSIL 32GDTECHNOLOGY REVIEW


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INTRODUCTION ............................................................ 5

DESIGN PHILOSOPHY ................................................... 5

CRANKSHAFT AND BEARINGS ...................................... 6

FUEL INJECTION SYSTEM ............................................. 6

ENGINE BLOCK ............................................................ 7

PISTON ....................................................................... 7

PISTON RINGS ............................................................. 7

CYLINDER LINER AND ANTI-POLISHING RING ................. 7

CONNECTING ROD ....................................................... 8

CYLINDER HEAD .......................................................... 8

MULTIDUCT ................................................................. 8

EFFICIENT GAS-DIESEL COMBUSTION ........................... 9

TURBOCHARGING SYSTEM ......................................... 11

COOLING SYSTEM ..................................................... 11

LUBRICATING OIL SYSTEM ......................................... 11

AUTOMATION SYSTEM ............................................... 13

EASY APPLICATION .................................................... 14

EASY MAINTENANCE.................................................. 14

This is a brief guide to the technical features and performance

of the Wrtsil 32GD engine.

WRTSIL 32GDTECHNOLOGY REVIEW

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INTRODUCTIONThe Wrtsil 32GD has been developed to

set new standards in the market for high

performance, fuel-flexible engines. The

Wrtsil 32GD is a four-stroke, gas-diesel

engine, which means that the engine can run

on either gas or fuel oil according to the dieselcycle. Switching from one fuel to the other

can be done under all operating conditions.

The Wrtsil 32GD covers a power range of

2520 8400 kW. The engine runs at 720 or

750 rpm for use with 50 or 60 Hz generators

and produces 405 420 kW per cylinder.

Benefitting from the unique properties of the

gas-diesel combustion principle, the Wrtsil

32GD is a very reliable and fuel-flexible

engine. The Wrtsil gas-diesel concept for

onshore and offshore installations utilizes

efficient engine technology in combination

with state-of-the-art controls and auxiliaries,

forming a total power generation solution that

substantially exceeds the plant efficiency of

conventional solutions. Wrtsil gas-diesel

technology is the solution for the needs of the

oil and gas industry. Thanks to the unique pilot

fuel injection method for initiating combustion,

associated gas can be used for power

generation or mechanical drive applications atthe oil field. And if the supply of gas varies in

quantity and quality, the answer is fuel sharing

the Wrtsil innovation that revolutionizes

the concept of fuel flexibility. What was once

considered an expense, is now an asset.

DESIGN PHILOSOPHY

The Wrtsil 32GD is an engine that meets

present and future requirements for the

life cycle cost of ownership. The engine

design is based on the well-tried Wrtsil

32GD HFO engine. The Wrtsil 32GD is a

technically advanced engine for fuel economy

and low emission rates. It is designed for

flexible manufacturing methods and long

maintenance-free operating periods. The

engine is equipped with all essential ancillaries

and a carefully planned interface to the plant or

ship control system.

The main features of the Wrtsil 32GD are:

Low-NOXcombustion

Reliability and low maintenance costs

Integrated monitoring and control or basic

automation system

Ergonomic interface

Minimized consumables

Unique fuel flexibility

The optimized fuel injection system contributes to complete

combustion of all fuels over the entire load range.

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CRANKSHAFT ANDBEARINGSThe latest advances in combustion

development require a crank gear that

operates 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 are ensured by optimal

balancing of rotational masses and, in the bigend bearing, by ungrooved bearing surfaces

in the critical areas. All the factors needed for

a free choice of the most appropriate bearing

material are present.

The fuel injection system utilizes a high

pressure gas injector combined with a dieselinjector. The gaseous fuel is injected at

350 bar through three nozzles located at the

vertices of the triangle at the injector end.

Each nozzle has three holes, so altogether

nine jets of gas are formed during gas

injection. The oil fuel is injected before gasinjection starts. The oil fuel nozzle is located

in the injector axis and has nine holes

which deliver oil fuel jets between gaseous

ones.

FUEL INJECTION SYSTEM

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ENGINE BLOCKNodular cast iron is the natural choice for

engine blocks today thanks to its strength and

stiffness properties, along with all the freedom

offered by casting. The Wrtsil 32GD 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 can serve a double purpose.

PISTON

For years, the outstanding piston conceptfor highly rated heavy fuel engines has been

a composite piston with a steel crown and

nodular cast-iron skirt. More than 20 years

of experience has fine-tuned the concept.

When it comes to reliability, there is no real

alternative today for modern engines running

with high cylinder pressures and combustion

temperatures. Wrtsil-patented skirt

lubrication is applied to minimize frictional

losses and ensure appropriate lubrication of

both piston rings and the piston skirt.

PISTON RINGS

In Wrtsils three-ring concept each ring has

a specific task. They are dimensioned and

profiled for consistent performance throughout

their operating lives. To avoid carbon deposits

in the ring grooves of a heavy fuel engine, the

pressure balance on top of and underneatheach 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 top ring, which bears the greatest

load, is provided with a special wear-resistant

coating.

CYLINDER LINER ANDANTI-POLISHING RING

The thick high-collar type cylinder lineris 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.

At the upper end the liner is equipped with an

anti-polishing ring to eliminate bore polishing

and reduce lube oil consumption. The function

of this ring is to calibrate the carbon deposits

formed on the piston top land to a thickness

small enough to prevent any contact between

the liner wall and the deposits at any piston

position. Since there is no contact between

the liner and piston top land deposits no oil

can be scraped upwards by the piston. The

other positive effect is that the liner wear is

significantly reduced at the same time. Thestrength of the wear-resistant liner materials

used for years in Wrtsil engines has been

further increased to cope with the high

combustion pressures expected in the future.

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CONNECTING RODA 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.

CYLINDER HEADThe cylinder head design is based on the four-

screw concept developed by Wrtsil and used

for more than 25 years. Its internal structure is

designed for maximum stiffness, which is essential

for obtaining both liner roundness and even contact

between exhaust valves and their seats.

A four-screw cylinder head design also

provides all the freedom needed for designing

inlet and exhaust ports with a minimum of flowlosses. Computational fluid dynamics (CFD)

analysis in combination with full-scale flow

measurements has been used for port design

optimization.

The vast amount of experience gained from

heavy fuel operation all around the world has

contributed greatly to exhaust-valve design

and development. Put together, this means that

a valve material and geometry with superior

performance are now available.

MULTIDUCTMultiducts replace a number of individual

components in conventional engine designs.

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Their functions are:

Air transfer from the air receiver to the

cylinder head

Exhaust transfer to the exhaust system

Cooling water outlet after the cylinder head

Cooling water return channel from the

engine.

Additional functions are:

Introduction of an initial swirl to the inlet airfor optimal part-load combustion

Insulation and cooling of the exhaust transfer

duct

Support for exhaust system and its insulation.

Hydrocarbons can be burned under a wide

range of conditions. Today, CO2emissions

are also much in focus due to climate change

issues, so it is essential to to optimize the fuel

oil consumption while meeting other emission

reduction targets. Wrtsil has developed the

gas-diesel combustion concept since 1987 andraised the fuel efficiency of gas-diesel engines

substantially without a simultaneous increase

in NOXemissions. The Wrtsil 32GD was the

first gas engine in the Wrtsil portfolio and its

technology makes it possible to run a power

plant on either associated gas or crude oil,

giving the operator fuel versatility and security

against disruptions in gas supply. The system

accommodates variations in gas quality. Gas-

diesels use the diesel combustion cycle in

both gas and liquid fuel operation, which gives

them the characteristics of a diesel engine with

uncompromized output and derating. In the gas

mode, a small amount of pilot fuel oil injection is

used to initiate combustion.

The fuel sharing system allows the engine

to run on gas and liquid fuel in different

proportions, in order to optimize plant operation

according to the availability of the fuels. For

example, if with the gas available only 30% of

the rated output can be achieved, the engine willuse fuel oil for the remaining 70%. The operator

can freely change the set point of the fuel share,

and the control system will ensure that the

actual operating point is within the specified

operating windows. Of course, the operator has

the choice of running the engine in conventional

GD or fuel oil operation mode as well.

FUEL OIL OPERATION

Fuel oil operation is based on the use of

normal fuel oil injection pumps and the system

operates just like any diesel engine. The engine

can run on crude oil, light fuel oil or heavy fuel

oil as the main and pilot injection fuel, without

any changes to the fuel injection system. Fueloil operation is available within the full load

range from zero to the rated load of the engine.

GD OPERATION

GD is the original gas-diesel operation mode,

where gas is the main source of energy, and

pilot fuel oil injection of approximately 5% is

used to ignite the combustion. GD operation is

available at any point between 30% and 100%

of the rated load and the plant can transfer to

and from GD operation within this same range.

FUEL SHARING OPERATION

The fuel sharing option is available between

35% and 87.5% of rated load. This mode

allows combustion of gaseous and liquid fuel

at the same time, and the ratio between the

fuels can be adjusted flexibly. The fuel share

set point can be adjusted on-line from the

WOIS (Wrtsil Operators Interface System).

The operator may, for example, want to runwith 40% gas, so he selects the fuel sharing

mode and both fuels will be delivered at the set

ratio. If at any time the engine load is too low

to achieve the selected set point, the control

system will automatically adjust the set point to

the minimum or maximum limit. The operator

may also change the set point at any time

during operation.

EFFICIENT GAS-DIESEL COMBUSTION

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60 70 80 90 100

Fuel Sharing

0

10

20

30

40

50

60

70

80

90

100 Fuel oil operation

Engine load%

as

share %

Diesel

share %

GD operation

Transfer window

Fuel Sharing

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Fuel sharing technology

FUEL SHARING CONTROL SYSTEM

The fuel sharing system is essentially a

combination of the GD engine and a new

control system and control principle. The system

controls both gas and oil injection simultaneously

and allows both to be used within the allowed

operating window limits. The new control system

is integrated into the programmable logic control(PLC) of the Wrtsil extended level automation

system using the WOIS platform.

Since the control system is now integrated

into the Wrtsil standard extended level

automation system, gas conversion applications

or future gas conversions are now much more

attractive than with the original GD system.

The main advantages of the fuel sharing system

are:

Flexible operation with variable proportions of

gas and oil

Flexibility in fuel oils, for example LFO, HFO

and crude oil can be used as main and pilot

fuel

The system can operate on low methane

number gas

The system can use both low and high heat

value gas

CONVERSION OF EXISTING ENGINES

If conditions at the field change and it becomesmore economical to use gas as the main fuel for

field energy production, Wrtsil diesel engines

can be converted to gas-diesel operation.

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Engine

5763 C

Charge air

cooler

Lube oil

cooler

Exp.

0.71.5 bar

Exp.

0.71.5 bar

3847 C

LTCcentral

cooler

93102 C

HTC

central

cooler

Engine

Pre-

heater

Optional

for.CHP

Charge air

cooler

Spex charging.

TURBOCHARGINGSYSTEM

Every Wrtsil 32GD engine is equipped with

the turbocharging system that best fulfils the

requirements of each specific application. The

standard alternatives are:

Spex (single pipe exhaust) system with

exhaust waste gate

Spex system with exhaust waste gate and

air bypass for variable speed engines.

The Spex system is designed for minimum flow

losses on both exhaust and air sides.

The charging systems are designed to

give high efficiency and extremely good load

acceptance. Spex is designed for the best

possible full-load performance. Spex combined

with exhaust waste gate and air bypass meets

the well-known good low-load performance ofpulse charging. With its unique design its load

acceptance is close to pulse charging.

Non-cooled chargers with inboard plain

bearings lubricated from the engines lube

oil system are used. All this makes for longer

intervals between overhauls and reduced

maintenance.

The turbocharger technology is going

through a period of intense design and

performance development. Only the best

available charger technology will be used on

the Wrtsil 32GD.

COOLING SYSTEM

The cooling system is split into two separate

circuits, the high-temperature (HT) and the

low-temperature (LT) circuits. The cylinder

liner and the cylinder head temperatures

are controlled through the HT circuit. The

system temperature is kept at a high level,

about 95 C, for safe ignition/combustion

of low-quality heavy fuels, also at low loads.An additional advantage is maximum heat

recovery and total efficiency in cogeneration

plants. To further increase the recoverable

heat from this circuit, it is connected to the

high-temperature part of the double-stage

charge air cooler. The HT water pump and

thermostatic valve are integrated with the

pump cover module at the free end of the

engine. The complete HT circuit is thus virtually

free of pipes.

The LT circuit serves the low-temperature

part of the charge air cooler and the built-on

lube oil cooler. It is fully integrated with engine

parts such as the LT water pump with pump

cover module, the LT thermostatic valve with

the lube oil module and transfer channels in

the engine block.

LUBRICATING OILSYSTEMAll Wrtsil 32GD engines are equipped with a

complete lube oil system, i.e. an engine-drivenmain pump, electrically driven prelubricating

pump, cooler, full flow filter and centrifugal

filter. The engine may also be fitted with special

running-in filters before each main bearing.

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Filter Cooler Pump

Primingpump

The pumps, pressure regulation and

safety valves are integrated into one

module fitted at the free end of the

engine. Filter, cooler and thermostatic

valves make up another module. On

in-line engines this is always located

neatly on the back side of the engine

whereas on V-engines it is either at the

flywheel or free end, depending on the

turbocharger position.

The lube oil filtration is based on an

automatic back-flushing filter requiring

a minimum of maintenance. The filter

elements are made of seamless sleeve

fabric with high temperature resistance.

An overhaul interval of one year is

recommended. The expected lifetime

is four years. A special feature is the

centrifugal filter, connected to the back-

flushing line of the automatic filter. Thisprovides the means for extracting distant

wear particles from the system.

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AUTOMATION SYSTEM

The Wrtsil 32GD engine is equipped with

the Wrtsil unified controls (UNIC) engine

automation system. The different systems

available for Wrtsil 32GD engine are UNIC

C1 and C2, described below.

UNIC system components

ESM Engine Safety Module

MCM Main Control Module

TCM Thermocouple Module

IOM Input Output Module

PDM Power Distribution Module

LCP Local Control Panel

LDU Local Display Unit

UNIC C1

In the UNIC C1 engine automation system, the

fundamental aspects of engine control andsafety are handled by the embedded control

and management system. This includes engine

speed and load control as well as overspeed

protection, lube oil pressure and cooling water

temperature protection. For the other parts,

the design requires the majority of the sensors

to be hardwired to a plant or ship control and

monitoring system.

The UNIC C1 system provides the following

functionality:

Fundamental safety (overspeed, LO

pressure, cooling water temp.)

Basic local monitoring

Hardwired interface to plant or ship control

system.

Speed and load control (electronic speed

control by MCM if engine equipped with

actuator, otherwise by mechanical governor)

Start/stop management.

The engine control system is designed to:

Achieve the highest possible reliability,

with components, e.g. sensors, designed

specifically for the on-engine environment

Reduce cabling on and around the engine,

with a clear point of interconnection and a

standardized interface

Provide high performance with optimized

and pre-tested controls.

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EASY APPLICATIONAn important design principle of the

Wrtsil 32GD is to build as much auxiliary

equipment as possible on the engine. Thisgoes for lube oil and water pumps, lube

oil cooler and filter, engine control and

monitoring. Application work is thus reduced

to a minimum. However, the engine still needs

connections to the plant or ship control system.

The trend is increasingly towards standardized

modules. To take full advantage of this and

keep installation costs to a minimum, the

engine should support smooth interfacing. The

Wrtsil 32GD comes in a number of standard

options, e.g. with a turbocharger at either end

of the engine and one- or two-stage charge air

cooling, without sacrificing the easy interfacing

principle.

EASY MAINTENANCE

Efficient and easy maintenance is incorporated

into the design. As well as intervals between

overhauls, the hours spent on maintenance avebeen reduced to a minimum. Lube oil filtration

is one good example. Hydraulics are used for

pre-tension of the cylinder head screws, all the

connecting rod screws, and the main bearing

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MAIN TECHNICAL DATACylinder bore 320 mmPiston stroke 400 mm

Speed range 720 and 750 rpm

Mean piston speed 9.6 / 10 m/s

BMEP 22.9 bar

Cylinder output 405 / 420 kW

Firing pressure 150 bar

The Wrtsil 32GD engine is manufactured

in cylinder configurations from 6L to 20V.

Technical data 50 Hz/750 rpm Unit 16V32GD 20V32GD

Power, electrical kW 6505 8148

Heat rate kJ/kWh 8200 (7843)* 8181 (7813)*

Electrical efficiency % 43.9 (45.9)* 44.0 (46.0)*

Technical data 60 Hz/720rpm

Power, electrical kW 6273 7857

Heat rate kJ/kWh 8200 (7843)* 8181 (7813)*

Electrical efficiency % 43.9 (45.9)* 44.0 (46.0)*

Dimensions and dry weight with generating set

Length mm 11303 12890

Width mm 3300 3300

Height mm 4472 4243

Weight tonne 120 132

Heat rate and electrical efficiency at generator terminals, including engine-driven pumps, ISO 3046 conditions and LHV

> 36 MJ/m3. Tolerance 5%. Power factor 0.8. Gas pressure at engine inlet 350 bar.*in liquid mode.

GAS FUEL QUALITY

The Wrtsil 32GD can cope with most available gas qualities and can

be operated on gases with lower methane numbers. The Wrtsil 32GD

has been designed and developed for continuous operation, without

reduction in the rated output, on gas qualities that meet the following

specifications:

Lower heating value (LHV) MJ/Nm3 > 30

Methane content, CH4 %-vol. > 60

Hydrogen sulphide, H2S %-vol. < 0.05

Hydrogen, H2 %-vol. < 5

Condense %-vol. 0

Chlorine + fluorines %-vol. < 0.005Particles or solids size m < 10

Gas temperature C 0-50

Gas pressure bar (g) 350 5

Other fuels must be considered on a case by case basis.

screws. The distinctive Wrtsil feature with individual hydraulic jacks

for each main bearing has of course been applied. The unique fuel line

design minimizes the work in replacing the injection pump, with less

risk of error.The multiduct arrangement allows the cylinder head to be lifted

without removing the water pipes, while the slide-in connections on

the manoeuvring side allows it to be lifted without removing the oil or

air pipes. The water pumps are easy to replace thanks to the cassette

design principle and the water channel arrangement in the pump cover

at the free end of the engine. Access to all the above components is

simplified thanks to the minimum number of pipes and the ergonomic

component design.

Technical data 750 rpm 6L32GD 8L32GD 9L32GD

Shaft power kW 2520 3360 3780

Shaft power hp 3378 4504 5067

Heat rate kJ/kWh 7912 (7580)* 7912 (7580)* 7912 (7580)*

Shaft efficiency % 45.5 (47.5)* 45.5 (47.5)* 45.5 (47.5)*

Dimensions and dry weight

Length mm 5297 6245 7116

Width mm 2300 2300 2300

Height mm 3421 3450 3571

Weight tonne 30 42 44

Technical data 750 rpm 12V32GD 16V32GD 18V32GD 20V32GD

Shaft power kW 5040 6720 7560 8400

Shaft power hp 6757 9009 10135 11261

Heat rate kJ/kWh 7912 (7580)* 7912 (7580)* 7912 (7580)* 7912 (7580)*

Shaft efficiency % 45.5 (47.5)* 45.5 (47.5)* 45.5 (47.5)* 45.5 (47.5)*

Dimensions and dry weight

Length mm 6837 8206 8766 9276

Width mm 2870 3296 3296 3233

Height mm 3595 3595 3595 4139

Weight tonne 54 63 70 89

Technical data is based on mechanical output at shaft, including engine-driven pumps, ISO conditions and LHV > 36HJ/m3. Tolerance 5%. Gas pressure at engine inlet 350 bar. * In liquid mode.

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WRTSILis a registered trademark. Copyright 200 Wrtsil Corporation.

Wrtsil enhances the business of its customers by providing them with

complete lifecycle power solutions. When creating better and environmentally

compatible technologies, Wrtsil focuses on the marine and energy markets

with products and solutions as well as services. Through innovative products

and services, Wrtsil sets out to be the most valued business partner

of all its customers. This is achieved by the dedication of close to 19,000

professionals manning 160 locations in 70 countries around the world.

Wrtsil is listed on the Nordic Exchange in Helsinki, Finland.

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Wartsila o e w 32gd Tr