Technology review

2

3

Design philosophy . . . . . . . . . . . . . . . . 4

Efficient low-emission combustion. . . . . . . . 5

Crankshaft and bearings . . . . . . . . . . . . . 5

Engine block . . . . . . . . . . . . . . . . . . . 6

Piston. . . . . . . . . . . . . . . . . . . . . . . 6

Piston rings . . . . . . . . . . . . . . . . . . . 7

Cylinder liner and anti-polishing ring . . . . . . 7

Connecting rod . . . . . . . . . . . . . . . . . 8

Cylinder head . . . . . . . . . . . . . . . . . . 8

Multiduct . . . . . . . . . . . . . . . . . . . . . 8

Fuel injection system . . . . . . . . . . . . . . . 9

Turbocharging system . . . . . . . . . . . . . 10

Cooling system . . . . . . . . . . . . . . . . . 11

Lubricating oil system . . . . . . . . . . . . . 12

Automation system . . . . . . . . . . . . . . . 12

Easy application . . . . . . . . . . . . . . . . 14

Easy maintenance. . . . . . . . . . . . . . . . 14

Main technical data . . . . . . . . . . . . . . . 15

This is a brief guide to the technical features and advantagesof the Wärtsilä 32 engine.

Design philosophy

The WÄRTSILÄ® 32 is based on the latest achievements in

combustion technology; it is designed for flexible

manufacturing methods and long maintenance-free

operating periods. The engine is fully equipped with all

essential ancillaries and a thoroughly planned interface to

external systems. The main qualities of the Wärtsilä 32 are:

� Low-NOX combustion

� Reliability and low maintenance costs

� Integrated monitoring and control or basic automation

system

� Ergonomic interface

� Minimized consumables.

4

Efficient low-emission combustion

Hydrocarbons can be burned under a wide range of

conditions. To burn them efficiently with low emissions,

in particular thermal NOX, Wärtsilä has used the

Low-NOX combustion method since 1994 in all its diesel

engines. This combustion process, which reduces thermal

NOX caused by high combustion flame temperatures, has

been further enhanced on the Wärtsilä 32 to meet not

only current IMO limits and World Bank guidelines, but

even lower NOX emission limits, such as IMO-30% and

710 ppm @ 15% O2. This also results in significantly

improved engine efficiency. The enhanced Low-NOX

combustion process features:

� High combustion air temperature at the start of

injection, which radically reduces ignition delay

� A late start of injection with short duration and

optimized injection rate to fuel the engine, avoiding

temperature peaks during combustion

� New combustion chamber optimized for low emissions

� High pressure ratio turbocharging with optimized valve

timing, which reduces flame temperature and increases

engine efficiency.

Crankshaft and bearingsThe 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 big end 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.

5

Development of engine performance

-12

-10

-8

-6

-4

-2

0

SFO

C(g

/kW

h)

0

200

400

600

800

1000

1200

NO

X

SFOC

Vasa 32 Wärtsilä 32 Wärtsilä 32economy optimized

Wärtsilä 32emission optimized

NOX

World Bank / IMO limit

New Asian limit

Fully machinedconnecting rod

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 Wärtsilä 32

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.

PistonFor years, the outstanding piston concept for highly rated

heavy fuel engines has been a composite piston with a steel

crown and nodular cast-iron skirt. Twenty 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. Wärtsilä-patented skirt

lubrication is applied to minimize frictional losses and

ensure appropriate lubrication of both piston rings and

the piston skirt.

6

Piston ringsIn Wärtsilä´s 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 underneath 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 top ring,

which bears the greatest load, is provided with a special

wear-resistant coating.

Cylinder liner andanti-polishing ringThe 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. 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. The strength of the

wear-resistant liner materials used for years in Wärtsilä

engines has been further increased to cope with the high

combustion pressures expected in the future.

7

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 is

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 Wärtsilä and used for more than 15 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 flow losses. 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 is now available.

MultiductMultiducts replace a number of individual components in

traditional engine designs. 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 air for

optimal part-load combustion

� Insulation and cooling of the exhaust transfer duct

� Support for exhaust system and its insulation.

8

Fuel injection systemThe ultimate safety in low-pressure fuel system design is

achieved with the Wärtsilä-patented multihousing

principle. With this system the fuel line consists basically

of drilled channels in cast parts clamped firmly on the

engine block. In the Wärtsilä 32 these parts are:

� The pump housing

� The tappet housing

� The fuel transfer housing

� The multicover.

For easy assembly/disassembly these parts are connected to

each other with slide connections. Since both the whole

low-pressure system and the high-pressure system are

housed in a fully covered compartment, the safety

standard is unbeatable. The high-pressure system was

designed and endurance tested at 2000 bar. Injection

pressure is around 1800 bar.

With a wear-resistant low-friction coating on the

plunger no lubricating oil is required for the pump

element. Thanks to the profiled plunger geometry the

clearance between plunger and barrel can be kept small,

thereby allowing only a minimum of oil to pass down the

plunger. This small leakage is collected and returned to

the fuel system. Any likelihood of the fuel mixing with the

lube oil is eliminated. Both nozzle holders and the nozzle

are made of high-grade hardened steel to withstand the

high injection pressures. Combined with oil cooling of the

nozzles this guarantees outstanding nozzle lifetimes.

9

Turbocharging system

Every Wärtsilä 32 engine is equipped with the

turbocharging system that best fulfils the requirements of

each specific application. The standard options are:

� Pulse system

� Spex (single pipe exhaust) system

� Spex system with exhaust waste-gate and air bypass.

The Spex system is designed for minimum flow losses on

both exhaust and air sides.

Both charging systems are designed to give high

efficiency and extremely good load acceptance. Pulse

charging is mainly intended for applications running on

variable loads. Spex is designed for the best possible

full-load performance. Spex combined with waste-gate

and bypass meets the well-known good low-load

performance of pulse charging. With its unique design its

load acceptance is close to pulse charging.

Non-cooled chargers with inboard plain bearings

lubricated from the engine´s 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

Wärtsilä 32.

10

Spex charging

Pulse charging

Exhaust waste-gate and air bypass

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.

11

Engine

62–70 °C73–80 °C

Charge aircooler

Lube oilcooler

Exp.0.7–1.5 bar

Exp.0.7–1.5 bar

35–45 °C65–70 °C

LTCcentralcooler

93–97 °C

HTCcentralcooler

Engine

Pre-heater

Charge aircooler

Optionalfor.CHP

Lubricating oil system

All Wärtsilä 32 engines are equipped with a complete lube

oil system, i.e. an engine-driven main 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. 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. This provides

the means for extraction of distant wear particles from the

system.

Automation systemThe engine automation system for the Wärtsilä 32 is

available in two versions. The two systems are optimized

to meet different customer needs. WECS is a complete

built-on automation system, including monitoring, safety

and start/stop logics. The basic engine automation system

includes only sensors, local instrumentation and a

minimum of built-on electronics, while the safety and

control logics are external to the engine.

Basic engine automation

The basic engine automation system on the Wärtsilä 32 is

specifically developed for a demanding environment. The

main properties of this system are as follows:

� Prefabricated cable modules are used instead of discrete

wiring, to minimize the risk of cabling errors and to

avoid damage to the cables in the harsh engine

environment, such as during overhaul operations.

12

FilterCooler Pump

Primingpump

� Easy plug-in connections of sensors to the cable

modules, and the use of multi-pin connectors ensure

fast and easy signal connection to the plant systems.

Optionally, terminal blocks are available.

� Use of robust sensors, specifically developed for the

engine environment.

� Instrumentation in an engine-built panel, for local

reading of engine speed, turbocharger speed, lube oil

pressure and HT water temperature. Optionally,

reading of fuel oil pressure, starting air pressure, control

air pressure, charge air pressure, HT water pressure and

LT water pressure is available.

� The control and safety system is designed for unmanned

operation and remote control. This system is external to

the engine, while sensors, cable modules and

instruments are located on engine.

� Prior to engine start, automatic checks are performed to

prevent a start under prohibited conditions. Start

blocking alarms are initiated.

� The engine speed is either controlled by a dedicated

electronic speed/load control unit, controlling an

actuator on the engine, or alternatively by a

mechanical/hydraulic governor.

� Redundant engine overspeed protection. Additionally to

a primary electrical overspeed trip, an independent

overspeed trip controls the electro-pneumatic system,

acting directly on each fuel injection pump.

� Condition monitoring of vital engine components is

provided. This monitoring is based on reliable

measurements by strategically located sensors.

WECS (only for marine engines)

Optimum use of this technology greatly simplifies both

the wiring on the engine and the whole installation. The

WECS system has the following main components:

� The Main Control Unit (MCU) Cabinet, which

comprises the MCU itself, a relay module with back-up

functions, a Local Display Unit (LDU), control buttons

and back-up instruments. The MCU handles all

communication with the external system.

� The Distributed Control Unit (DCU), which handles

signal transfer over a CAN bus to the MCU.

� The Sensor Multiplexing Units (SMU), which transfers

sensor information to the MCU.

The software loaded into the system is easily configured to

match the instrumentation, safety and control functions

required for each installation. For maximum safety, the

durability of all components is ensured by selecting only

the best available and is verified by stringent testing. Thus

temperature resistance, vibration resistance and

electromagnetic compatibility are guaranteed.

Because a diesel engine must sometimes endure pretty

rough handling the MCU cabinet is well protected and

built into the engine. The same goes for the rest of the

hardware, most of which is housed in a special electrical

compartment alongside the engine.

13

WECS cabinet

To external systems

SMUDCU

MCU and display unit

Display

Display selection buttons

Backup instruments

Local control buttons

DCU unit

Easy applicationAn important design principle of the Wärtsilä 32 is

to build as much auxiliary equipment as possible on

the engine. This goes 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 external systems. The trend is

increasingly towards standardized modules. To make

full use of this from the installation cost point of

view, the engine should support smooth interfacing.

The Wärtsilä 32 comes in a number of standard

options, e.g. a turbocharger at either end of the

engine and one- or two-stage charge air cooling,

without sacrificing the easy interfacing principle.

Easy maintenanceEfficient and easy maintenance is incorporated into

the design. In combination with the long intervals

between overhauls, the hours spent on maintenance are reduced

to a minimum. The 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 screws. The

distinctive Wärtsilä feature with individual hydraulic jacks for

each main bearing is of course adopted. The unique fuel line

design enables injection pump exchange with a minimum of

work with less risk of error.

The multiduct arrangement allows the cylinder head to be

lifted without removal of water pipes, while the slide-in

connections on the manoeuvring side allows it to be lifted

without removal of oil or air pipes. The water pumps are easy

to replace thanks to the cassette design principle and water

channel arrangement in the pump cover at the free end of the

engine. There is greater accessibility to all the above

components thanks to a minimal number of pipes and an

ergonomic component design.

14

Main technical data

Marine engines B-output B2-outputCylinder bore 320 mm 320 mmPiston stroke 400 mm 400 mmCylinder output 450, 460 kW/cyl 480, 500 kW/cylSpeed 720, 750 rpm 720, 750 rpmMean effective pressure 23.3, 22.9 bar 24.9, 24.9 barPiston speed 9.6, 10.0 m/s 9.6, 10.0 m/sVoltage 0.4 – 13.8 kV 0.4 – 13.8 kVAlternator efficiency 0.95 – 0.97 0.95 – 0.97Fuel specification:Fuel oil 730 cSt/50°C

7200 sR1/100°FISO 8217, category ISO-F-RMK 55

SFOC 180-185 g/kWh at ISO condition ± 5% tolerance

Rated power for mechanical propulsion

Engine type

750 rpm

460 kW/cyl 500 kW/cyl

kW BHP kW BHP

6L328L329L32

12V3216V3218V32

2 7603 6804 1405 5207 3608 280

3 7505 0005 6307 500

10 00011 260

3 0004 0004 5006 0008 0009 000

4 0805 4406 1208 160

10 87012 240

Principal engine dimensions (mm) and weights (tonnes)

Enginetype A* A B* B C D

6L328L329L32

12V3216V3218V32

5 1086 4786 9686 795

––

5 2676 4807 0866 4357 8908 450

2 2682 4382 4382 350

––

2 2682 4182 4182 3902 5232 523

2 2072 2072 2072 8703 2933 293

2 3452 3452 3452 1202 1202 120

E F H K N* Weight

6L328L329L32

12V3216V3218V32

500500500650650650

1 1531 1531 1531 4751 4751 475

250250250300300300

1 3501 3501 3501 5901 5901 590

8771 2941 2941 568

––

35.545.048.560.576.082.5

*Turbocharger at flywheel end.Weights with liquids (wet sump), without flywheel.

Rated power: Generating sets

Enginetype

720 rpm/60 Hz 750 rpm/50 Hz

450 kW/cyl 480 kW/cyl 460 kW/cyl 500 kW/cyl

EnginekW Gen. kW Engine

kW Gen. kW EnginekW Gen. kW Engine

kW Gen. kW

6L328L329L32

12V3216V3218V32

2 7003 6004 0505 4007 2008 100

2 5903 4603 8905 1806 9107 780

2 8803 8404 3205 7607 6808 640

2 7603 6904 1505 5307 3708 290

2 7603 6804 1405 5207 3608 280

2 6503 5303 9705 3007 0707 950

3 0004 0004 5006 0008 0009 000

2 8803 8404 3205 7607 6808 640

Principal genset dimensions (mm) and weights (tonnes)

Enginetype A* H* D L* M Weight

ton*

6L328L329L32

12V3216V3218V32

9 02910 46310 6129 992

11 69212 007

2 2902 6902 8903 0603 0603 360

2 3452 3452 3452 1202 1202 120

3 7184 0554 0254 0894 3734 373

2 2682 4252 3952 3782 4932 493

58.575.079.5

100.5115.0132.5

* Dependent on alternator type and size.The alternator outputs are calculated for an efficiency of 96%.

Power plant enginesCylinder bore 320Piston stroke 400Rated speed 720 / 750 rpmMean piston speed 9,6 / 10,0 m/sBMEP 23,3 / 22,9 barCylinder output 450 / 460 kW/cylFuel HFO

Rated power: Power generation

50 Hz/750 rpm

Engine type Power, electricalkW

Heat ratekJ/kWh

Electricalefficiency %

6L328L329L32

12V3216V3218V3220V32

2 6363 5333 9905 3277 1248 0328 924

8 2408 1978 1558 1557 9617 9447 944

43.743.944.144.145.245.345.3

60 Hz/720rpm

6L328L329L32

12V3216V3218V3220V32

3 5793 4563 9085 2116 9707 8578 730

8 1558 1128 0708 0707 8777 8607 860

44.144.444.644.645.745.845.8

Genset dimensions and weights

Engine type Length mm Width mm Height mm Weight tonne

6L328L329L32

12V3216V3218V3220V32

8 7669 750

11 20010 030

N/A11 50012 660

2 4182 4182 4103 050N/A

3 3003 670

3 7383 7403 7404 420N/A

4 2204 640

58788790

N/A128137

15

W-P

0304

/Boc

k’s

Off

ice/

Ark

med

ia

Wärtsilä Finland OyP.O.Box 252,FIN-65101 Vaasa,Finland

Tel. +358 10 709 0000Fax Ship Power +358 6 356 7188Fax Power Plants +358 6 356 9133

Wärtsilä is The Ship Power Supplier for builders, owners and operators

of vessels and offshore installations. We are the only company with a

global service network to take complete care of customers’ ship

machinery at every lifecycle stage.

Wärtsilä is a leading provider of power plants, operation and lifetime

care services in decentralized power generation.

The Wärtsilä Group includes Imatra Steel, which specializes in special

engineering steels.

For more information visit www.wartsila.com

WÄRTSILÄ ® is a registered trademark. Copyright © 2004 Wärtsilä Corporation.