WÄRTSILÄ WÄRTSILÄ 50DF User manual

WÄRTSILÄ 50DF

PRODUCT GUIDE

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CONSEQUENTIAL DAMAGES OR OTHER LOSS, OR ANY OTHER DAMAGE OR INJURY, SUFFERED BY ANY

PARTY MAKING USE OF THIS PUBLICATION OR THE INFORMATION CONTAINED HEREIN.

Introduction

This Product Guide provides data and system proposals for the early design phase of marine

engine installations. For contracted projects specific instructions for planning the installation

are always delivered. Any data and information herein is subject to revision without notice.

This 2/2016 issue replaces all previous issues of the Wärtsilä 50DF Project Guides.

UpdatesPublishedIssue

Technical data updated09.09.20162/2016

Fuel sharing added. Other minor updates30.06.20161/2016

Chapter Technical data and numerous updates throughout the project guide13.06.20141/2014

Minor updates throughout the product guide03.12.20121/2012

Wärtsilä, Marine Solutions

Vaasa, September 2016

Wärtsilä 50DF Product Guide - a16 - 9 September 2016 iii

IntroductionWärtsilä 50DF Product Guide

Table of contents

1-11. Main Data and Outputs .......................................................................................................................

1-11.1 Maximum continuous output .......................................................................................................

1-21.2 Output limitations in gas mode ....................................................................................................

1-41.3 Reference conditions ...................................................................................................................

1-41.4 Operation in inclined position ......................................................................................................

1-51.5 Dimensions and weights .............................................................................................................

2-12. Operating Ranges ................................................................................................................................

2-12.1 Engine operating range ...............................................................................................................

2-22.2 Loading capacity .........................................................................................................................

2-62.3 Operation at low load and idling ..................................................................................................

2-62.4 Low air temperature ....................................................................................................................

3-13. Technical Data ......................................................................................................................................

3-13.1 Introduction ..................................................................................................................................

3-23.2 Wärtsilä 6L50DF ..........................................................................................................................

3-53.3 Wärtsilä 8L50DF ..........................................................................................................................

3-83.4 Wärtsilä 9L50DF ..........................................................................................................................

3-113.5 Wärtsilä 12V50DF ........................................................................................................................

3-143.6 Wärtsilä 16V50DF ........................................................................................................................

3-173.7 Wärtsilä 18V50DF ........................................................................................................................

4-14. Description of the Engine ....................................................................................................................

4-14.1 Definitions ....................................................................................................................................

4-14.2 Main components and systems ..................................................................................................

4-74.3 Cross section of the engine .........................................................................................................

4-94.4 Free end cover .............................................................................................................................

4-104.5 Overhaul intervals and expected life times ..................................................................................

4-104.6 Engine storage .............................................................................................................................

5-15. Piping Design, Treatment and Installation .........................................................................................

5-15.1 Pipe dimensions ..........................................................................................................................

5-25.2 Trace heating ...............................................................................................................................

5-25.3 Pressure class ..............................................................................................................................

5-35.4 Pipe class ....................................................................................................................................

5-45.5 Insulation .....................................................................................................................................

5-45.6 Local gauges ...............................................................................................................................

5-45.7 Cleaning procedures ...................................................................................................................

5-55.8 Flexible pipe connections ............................................................................................................

5-65.9 Clamping of pipes ........................................................................................................................

6-16. Fuel System ..........................................................................................................................................

6-16.1 Acceptable fuel characteristics ...................................................................................................

6-76.2 Operating principles ....................................................................................................................

6-86.3 Fuel gas system ...........................................................................................................................

6-206.4 Fuel oil system .............................................................................................................................

7-17. Lubricating Oil System ........................................................................................................................

7-17.1 Lubricating oil requirements ........................................................................................................

7-37.2 Internal lubricating oil system ......................................................................................................

7-67.3 External lubricating oil system .....................................................................................................

7-147.4 Crankcase ventilation system ......................................................................................................

7-167.5 Flushing instructions ....................................................................................................................

iv Wärtsilä 50DF Product Guide - a16 - 9 September 2016

Wärtsilä 50DF Product GuideTable of contents

8-18. Compressed Air System ......................................................................................................................

8-18.1 Instrument air quality ...................................................................................................................

8-18.2 Internal compressed air system ..................................................................................................

8-48.3 External compressed air system .................................................................................................

9-19. Cooling Water System .........................................................................................................................

9-19.1 Water quality ...............................................................................................................................

9-29.2 Internal cooling water system ......................................................................................................

9-69.3 External cooling water system ....................................................................................................

10-110. Combustion Air System .......................................................................................................................

10-110.1 Engine room ventilation ...............................................................................................................

10-210.2 Combustion air system design ....................................................................................................

11-111. Exhaust Gas System ............................................................................................................................

11-111.1 Internal exhaust gas system ........................................................................................................

11-311.2 Exhaust gas outlet .......................................................................................................................

11-511.3 External exhaust gas system .......................................................................................................

12-112. Turbocharger Cleaning ........................................................................................................................

12-112.1 Napier turbochargers ...................................................................................................................

12-212.2 ABB turbochargers ......................................................................................................................

12-512.3 Turbocharger cleaning system ....................................................................................................

12-612.4 Wärtsilä control unit for four engines, UNIC C2 & C3 ................................................................

13-113. Exhaust Emissions ...............................................................................................................................

13-113.1 Dual fuel engine exhaust components ........................................................................................

13-113.2 Marine exhaust emissions legislation ..........................................................................................

13-513.3 Methods to reduce exhaust emissions ........................................................................................

14-114. Automation System .............................................................................................................................

14-114.1 UNIC C3 .......................................................................................................................................

14-714.2 Functions ....................................................................................................................................

14-1214.3 Alarm and monitoring signals ......................................................................................................

14-1314.4 Electrical consumers ...................................................................................................................

15-115. Foundation ............................................................................................................................................

15-115.1 Steel structure design ..................................................................................................................

15-115.2 Engine mounting ..........................................................................................................................

15-1415.3 Flexible pipe connections ............................................................................................................

16-116. Vibration and Noise ..............................................................................................................................

16-116.1 External forces and couples ........................................................................................................

16-216.2 Torque variations .........................................................................................................................

16-216.3 Mass moment of inertia ...............................................................................................................

16-316.4 Structure borne noise ..................................................................................................................

16-416.5 Air borne noise .............................................................................................................................

16-516.6 Exhaust noise ..............................................................................................................................

17-117. Power Transmission ............................................................................................................................

17-117.1 Flexible coupling ..........................................................................................................................

17-117.2 Torque flange ...............................................................................................................................

17-117.3 Clutch ..........................................................................................................................................

17-117.4 Shaft locking device ....................................................................................................................

17-217.5 Input data for torsional vibration calculations .............................................................................

17-317.6 Turning gear .................................................................................................................................

Wärtsilä 50DF Product Guide - a16 - 9 September 2016 v

Table of contentsWärtsilä 50DF Product Guide

18-118. Engine Room Layout ...........................................................................................................................

18-118.1 Crankshaft distances ...................................................................................................................

18-218.2 Space requirements for maintenance .........................................................................................

18-418.3 Transportation and storage of spare parts and tools ..................................................................

18-418.4 Required deck area for service work ...........................................................................................

19-119. Transport Dimensions and Weights ...................................................................................................

19-119.1 Lifting of engines .........................................................................................................................

19-519.2 Engine components .....................................................................................................................

20-120. Product Guide Attachments ...............................................................................................................

21-121. ANNEX ...................................................................................................................................................

21-121.1 Unit conversion tables .................................................................................................................

21-221.2 Collection of drawing symbols used in drawings ........................................................................

vi Wärtsilä 50DF Product Guide - a16 - 9 September 2016

Wärtsilä 50DF Product GuideTable of contents

1. Main Data and Outputs

The Wärtsilä 50DF is a 4-stroke, non-reversible, turbocharged and inter-cooled dual fuel engine

with direct injection of liquid fuel and indirect injection of gas fuel. The engine can be operated

in gas mode or in diesel mode.

500 mmCylinder bore ........................

580 mmStroke ...................................

113.9 l/cylPiston displacement .............

2 inlet valves and 2 exhaust valvesNumber of valves .................

6, 8 and 9 in-line; 12, 16 and 18 in V-formCylinder configuration ..........

45°V-angle .................................

clockwiseDirection of rotation ..............

500, 514 rpmSpeed ...................................

9.7, 9.9 m/sMean piston speed ...............

1.1 Maximum continuous output

Table 1-1 Rating table for Wärtsilä 50DF

Diesel electric applicationsMain engines 514

rpm

Cylinder

configuration

514 rpm500 rpm

BHPkWBHPkWEngine [kW]

79505850775057005850W 6L50DF

1060078001034076007800W 8L50DF

1193087751163085508775W 9L50DF

1591011700155001140011700W 12V50DF

2121015600206701520015600W 16V50DF

23860175502326017100N/AW 18V50DF

Nominal speed 514 rpm is recommended for mechanical propulsion engines.

The mean effective pressure P

e

can be calculated using the following formula:

where:

mean effective pressure [bar]P

e

=

output per cylinder [kW]P =

engine speed [r/min]n =

cylinder diameter [mm]D =

length of piston stroke [mm]L =

operating cycle (4)c =

Wärtsilä 50DF Product Guide - a16 - 9 September 2016 1-1

1. Main Data and OutputsWärtsilä 50DF Product Guide

1.2 Output limitations in gas mode

1.2.1 Output limitations due to methane number

Fig 1-1 Output limitations due to methane number

Notes:

The dew point shall be calculated for the specific

site conditions. The minimum charge air temperat-

ure shall be above the dew point, otherwise con-

densation will occur in the charge air cooler.

Compensating a low methane number gas by

lowering the receiver temperature below 45°C is

not allowed.

Compensating a higher charge air temperature

than 45°C by a high methane number gas is not

allowed.

The charge air temperature is approximately 5°C

higher than the charge air coolant temperature at

rated load.

The engine can be optimized for a lower methane

number but that will affect the performance.

1-2 Wärtsilä 50DF Product Guide - a16 - 9 September 2016

Wärtsilä 50DF Product Guide1. Main Data and Outputs

1.2.2 Output limitations due to gas feed pressure and lower

heating value

Fig 1-2 Output limitation factor due to gas feed pressure / LHV

Notes:

No compensation (uprating) of the engine output

is allowed, neither for gas feed pressure higher

than required in the graph above nor lower heating

value above 36 MJ/m

3

N

.

The above given values for gas feed pressure

(absolute pressure) are at engine inlet. The pres-

sure drop over the gas valve unit (GVU) is approx.

80 kPa.

Values given in m

3

N

are at 0°C and 101.3 kPa.

Wärtsilä 50DF Product Guide - a16 - 9 September 2016 1-3

1. Main Data and OutputsWärtsilä 50DF Product Guide

1.3 Reference conditions

The output is available within a range of ambient conditions and coolant temperatures specified

in the chapter Technical Data. The required fuel quality for maximum output is specified in the

section Fuel characteristics. For ambient conditions or fuel qualities outside the specification,

the output may have to be reduced.

The specific fuel consumption is stated in the chapter Technical Data. The statement applies

to engines operating in ambient conditions according to ISO 3046-1:2002 (E).

100 kPatotal barometric pressure

25°Cair temperature

30%relative humidity

25°Ccharge air coolant temperature

Correction factors for the fuel oil consumption in other ambient conditions are given in standard

ISO 3046-1:2002.

1.4 Operation in inclined position

Max. inclination angles at which the engine will operate satisfactorily.

15.0°

● Transverse inclination, permanent (list)

22.5°

● Transverse inclination, momentary (roll)

10.0°

● Permanent fore-and-aft inclinations

1-4 Wärtsilä 50DF Product Guide - a16 - 9 September 2016

Wärtsilä 50DF Product Guide1. Main Data and Outputs

1.5 Dimensions and weights

Fig 1-3 In-line engines (DAAE000316d)

HE2HE1LE5*LE5LE4LE3*LE3LE2LE1*LE1TCEngine

4000358016055546012951295617083108205NA357W 6L50DF

4000347523055546012951295617083108120TPL71

40003920-700460-17757810-10270TPL76W 8L50DF

40003920-700460-17758630-11140TPL76W 9L50DF

WeightWE6WE5WE3WE2WE1HE6HE5HE4HE3TCEngine

96395189514451940327092526556501455NA357W 6L50DF

96420189514451940327079026856501455TPL71

1283402100144519403505110028206501455TPL76W 8L50DF

137.53402100144519403505110028206501455TPL76W 9L50DF

* TC in driving end

All dimensions in mm. Weights are dry engines, in metric tons, of rigidly mounted engines

without flywheel.

Wärtsilä 50DF Product Guide - a16 - 9 September 2016 1-5

1. Main Data and OutputsWärtsilä 50DF Product Guide

Fig 1-4 V-engines (DAAE000413c)

HE4HE3HE2HE1LE5*LE5LE4LE3*LE3LE2LE1*LE1TCEngine

8001500360040555005004601840184078501054010410NA357W 12V50DF

8001500360042404354354601840184078501054010425TPL71

80015003600440068068046023002300100501320013830TPL76W 16V50DF

800150036004400-680460-230011150-14180TPL76W 18V50DF

WeightWE6WE5WE4**WE4WE3WE2WE1ΔWE1HE6HE5TCEngine

17576522201300149518002290452038109253080NA357W 12V50DF

175770222013001495180022904525405511403100TPL71

224930222013001495180022905325473011003300TPL76W 16V50DF

244930222013001495180022905325473011003300TPL76W 18V50DF

* TC in driving end

** With monospex (exhaust manifold)

Δ With air suction branches

All dimensions in mm. Weights are dry engines, in metric tons, of rigidly mounted engines

without flywheel.

1-6 Wärtsilä 50DF Product Guide - a16 - 9 September 2016

Wärtsilä 50DF Product Guide1. Main Data and Outputs

Fig 1-5 Example of total installation lengths, in-line engines (DAAE000489)

Fig 1-6 Example of total installation lengths, V-engines (DAAE000489)

Genset weight [ton]DCBAEngine

13810902235494012940W 6L50DF

17110202825506015060W 8L50DF

18510202825506015910W 9L50DF

23913652593525315475W 12V50DF

28815902050469017540W 16V50DF

31515902050469018500W 18V50DF

Values are indicative only and are based on Wärtsilä 50DF engine with built-on pumps and

turbocharger at free end of the engine.

Generator make and type will effect width, length, height and weight.

[All dimensions are in mm]

Wärtsilä 50DF Product Guide - a16 - 9 September 2016 1-7

1. Main Data and OutputsWärtsilä 50DF Product Guide

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2. Operating Ranges

2.1 Engine operating range

Below nominal speed the load must be limited according to the diagrams in this chapter in

order to maintain engine operating parameters within acceptable limits. Operation in the

shaded area is permitted only temporarily during transients. Minimum speed is indicated in

the diagram, but project specific limitations may apply.

2.1.1 Controllable pitch propellers

An automatic load control system is required to protect the engine from overload. The load

control reduces the propeller pitch automatically, when a pre-programmed load versus speed

curve (“engine limit curve”) is exceeded, overriding the combinator curve if necessary. Engine

load is determined from measured shaft power and actual engine speed. The shaft power

meter is Wärtsilä supply.

The propulsion control must also include automatic limitation of the load increase rate.

Maximum loading rates can be found later in this chapter.

The propeller efficiency is highest at design pitch. It is common practice to dimension the

propeller so that the specified ship speed is attained with design pitch, nominal engine speed

and 85% output in the specified loading condition. The power demand from a possible shaft

generator or PTO must be taken into account. The 15% margin is a provision for weather

conditions and fouling of hull and propeller. An additional engine margin can be applied for

most economical operation of the engine, or to have reserve power.

Wärtsilä 50DF Product Guide - a16 - 9 September 2016 2-1

2. Operating RangesWärtsilä 50DF Product Guide

Fig 2-1 Operating field for CP-propeller, 975 kW/cyl, rated speed 514 rpm

Remarks: The maximum output may have to be reduced depending on gas properties and

gas pressure, refer to section "Derating of output in gas mode". The permissible output will

in such case be reduced with same percentage at all revolution speeds.

Restrictions for low load operation to be observed.

2.2 Loading capacity

Controlled load increase is essential for highly supercharged engines, because the turbocharger

needs time to accelerate before it can deliver the required amount of air. Sufficient time to

achieve even temperature distribution in engine components must also be ensured. Dual fuel

engines operating in gas mode require precise control of the air/fuel ratio, which makes

controlled load increase absolutely decisive for proper operation on gas fuel.

The loading ramp “preheated, normal gas” (see figures) can be used as the default loading

rate for both diesel and gas mode. If the control system has only one load increase ramp, then

the ramp for a preheated engine must be used. The HT-water temperature in a preheated

engine must be at least 60ºC, preferably 70ºC, and the lubricating oil temperature must be at

least 40ºC.

The loading ramp “max. capacity gas” indicates the maximum capability of the engine in gas

mode. Faster loading may result in alarms, knock and undesired trips to diesel. This ramp can

also be used as normal loading rate in diesel mode once the engine has attained normal

operating temperature.

The maximum loading rate “emergency diesel” is close to the maximum capability of the

engine in diesel mode. It shall not be used as the normal loading rate in diesel mode.

Emergency loading may only be possible by activating an emergency function, which generates

visual and audible alarms in the control room and on the bridge.

2-2 Wärtsilä 50DF Product Guide - a16 - 9 September 2016

Wärtsilä 50DF Product Guide2. Operating Ranges

The load should always be applied gradually in normal operation. Acceptable load increments

are smaller in gas mode than in diesel mode and also smaller at high load, which must be

taken into account in applications with sudden load changes. The time between load increments

must be such that the maximum loading rate is not exceeded. In the case of electric power

generation, the classification society shall be contacted at an early stage in the project regarding

system specifications and engine loading capacity.

Electric generators must be capable of 10% overload. The maximum engine output is 110%

in diesel mode and 100% in gas mode. Transfer to diesel mode takes place automatically in

case of overload. Lower than specified methane number may also result in automatic transfer

to diesel when operating close to 100% output. Expected variations in gas fuel quality and

momentary load level must be taken into account to ensure that gas operation can be

maintained in normal operation.

2.2.1 Mechanical propulsion, controllable pitch propeller (CPP)

Fig 2-2 Maximum load increase rates for variable speed engines

The propulsion control must not permit faster load reduction than 20 s from 100% to 0%

without automatic transfer to diesel first.

Wärtsilä 50DF Product Guide - a16 - 9 September 2016 2-3

2. Operating RangesWärtsilä 50DF Product Guide

2.2.2 Constant speed applications

Fig 2-3 Maximum load increase rates for engines operating at nominal speed

The propulsion control and the power management system must not permit faster load

reduction than 20 s from 100% to 0% without automatic transfer to diesel first.

In electric propulsion applications loading ramps are implemented both in the propulsion

control and in the power management system, or in the engine speed control in case

isochronous load sharing is applied. When the load sharing is based on speed droop, it must

be taken into account that the load increase rate of a recently connected generator is the sum

of the load transfer performed by the power management system and the load increase

performed by the propulsion control.

Maximum instant load steps

The electrical system must be designed so that tripping of breakers can be safely handled.

This requires that the engines are protected from load steps exceeding their maximum load

acceptance capability. If fast load shedding is complicated to implement or undesired, the

instant load step capacity can be increased with a fast acting signal that requests transfer to

diesel mode.

2-4 Wärtsilä 50DF Product Guide - a16 - 9 September 2016

Wärtsilä 50DF Product Guide2. Operating Ranges

Gas mode

Fig 2-4 Maximum instant load steps in % of MCR in gas mode

● Maximum step-wise load increases according to figure

● Steady-state frequency band ≤ 1.5 %

● Maximum speed drop 10 %

● Recovery time ≤ 10 s

● Time between load steps ≥ 30 s

● Maximum step-wise load reductions: 100-75-45-0%

Diesel mode

● Maximum step-wise load increase 33% of MCR

● Steady-state frequency band ≤ 1.0 %

● Maximum speed drop 10 %

● Recovery time ≤ 5 s

● Time between load steps ≥ 10 s

Start-up

A stand-by generator reaches nominal speed in 50-70 seconds after the start signal (check

of pilot fuel injection is always performed during a normal start).

With black-out start active nominal speed is reached in about 25 s (pilot fuel injection disabled).

The engine can be started with gas mode selected provided that the engine is preheated and

the air receiver temperature is at required level. It will then start on MDF and gas fuel will be

used as soon as the pilot check is completed and the gas supply system is ready.

Start and stop on heavy fuel is not restricted.

Wärtsilä 50DF Product Guide - a16 - 9 September 2016 2-5

2. Operating RangesWärtsilä 50DF Product Guide

2.3 Operation at low load and idling

Absolute idling (declutched main engine, disconnected generator):

● Maximum 10 minutes if the engine is to be stopped after the idling. 3-5 minutes idling

before stop is recommended.

● Maximum 2 hours on HFO if the engine is to be loaded after the idling.

● Maximum 8 hours on MDF or gas if the engine is to be loaded after the idling.

Operation below 20 % load on HFO or below 10 % load on MDF or gas:

● Maximum 100 hours continuous operation. At intervals of 100 operating hours the engine

must be loaded to min. 70% of the rated output for 1 hour.

● If operated longer than 30h in liquid fuel mode, the engine must be loaded to minimum

70% of rated output for 1 hour before transfer to gas.

● Before operating below 10% in gas mode the engine must run above 10% load for at least

10 minutes. It is however acceptable to change to gas mode directly after the engine has

started, provided that the charge air temperature is above 55°C.

Operation above 20 % load on HFO or above 10 % load on MDF or gas:

● No restrictions.

2.4 Low air temperature

The minimum inlet air temperature of 5°C applies, when the inlet air is taken from the engine

room.

Engines can run in colder conditions at high loads (suction air lower than 5°C) provided that

special provisions are considered to prevent too low HT-water temperature and T/C surge.

For start, idling and low load operations (Ch 2.3), suction air temperature shall be maintained

at 5°C.

If necessary, the preheating arrangement can be designed to heat the running engine (capacity

to be checked).

For further guidelines, see chapter Combustion air system design.

2-6 Wärtsilä 50DF Product Guide - a16 - 9 September 2016

Wärtsilä 50DF Product Guide2. Operating Ranges

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WÄRTSILÄ WÄRTSILÄ 50DF User manual

WÄRTSILÄ WÄRTSILÄ 50DF User manual

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