Wartsila 16 and 20v34sg Engine Technology Brochure PDF

Enginetechnology16and20V34SG

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Engine technology
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Design philosophy. . . . . . . . . . . . . . . . . . . . . . . .5The lean-burn concept. . . . . . . . . . . . . . . . . . . . .6Low emissions. . . . . . . . . . . . . . . . . . . . . . . . . . .6Gas admission system. . . . . . . . . . . . . . . . . . . . .7Gas supply system. . . . . . . . . . . . . . . . . . . . . . . .7Prechamber. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Ignition system. . . . . . . . . . . . . . . . . . . . . . . . . . .8 Air-fuel ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . .9Lubricating oil system. . . . . . . . . . . . . . . . . . . . . .9Starting system. . . . . . . . . . . . . . . . . . . . . . . . . .10Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Piston ring set. . . . . . . . . . . . . . . . . . . . . . . . . . .10Cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . .10Connecting rod and big-end bearings. . . . . . . .11Engine block. . . . . . . . . . . . . . . . . . . . . . . . . . . .11Crankshaft and bearings. . . . . . . . . . . . . . . . . .12Cylinder liner and anti-polishing ring. . . . . . . . .12Turbocharging system. . . . . . . . . . . . . . . . . . . .12Multiduct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Automation system. . . . . . . . . . . . . . . . . . . . . . .13Easy maintenance. . . . . . . . . . . . . . . . . . . . . . . .14Main technical data. . . . . . . . . . . . . . . . . . . . . .15

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In 1992, Wärtsilä started the development of lean-burn,spark-ignited Otto gas engines. The first 34SG engine wasreleased in 1995 and now the product range of lean-burngas engines has been expanded by introducing the new WÄRTSILÄ
®
34SG. These engines take the poweroutput of the 34SG series up to 9 MW.The Wärtsilä 34SG is a four-stroke, spark-ignited gasengine that works according to the Otto process and thelean-burn principle. The engine has ported gas admissionand a prechamber with a spark plug for ignition.The engine runs at 720 or 750 rpm for 60 or 50 Hzapplications and produces 6950 to 9000 kW of mechanical power, respectively. The efficiency of the Wärtsilä 34SG is the highest of any spark-ignited gasengines today. The natural gas fuelled, lean-burn,medium-speed engine is a reliable, high-efficiency andlow-pollution power source for co-generation plants.
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Ringköping, Denmark Engine type: 1 x Wärtsilä 20V34SGTotal electrical output: 7.9 MWTotal heat output: 9.7 MWTotal efficiency: >95%.
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Design philosophy
The Wärtsilä 34SG was developed in response to themarket need for bigger gas engines. Its design principlesare based on the well-proven technology of the 18V version but with substantial improvements. The Wärtsilä 34SG lean-burn gas engine utilizes the frame of the new Wärtsilä 32 diesel/heavy fuel engine with its advancedintegrated lube oil and cooling water channels. The borehas been increased to 340 mm to fully utilize the powerpotential of this engine block.The Wärtsilä 34SG meets current and futurerequirements for overall cost of ownership. It is designedfor 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 Wärtsilä 34SG combines high efficiency with low emissions. This is achieved applying state-of-the-arttechnology with features including:

use of a lean gas mixture for clean combustion

individual combustion control and monitoring,providing even load on all cylinders

stable combustion, ensured by a high-energy ignitionsystem and pre-combustion chamber

self-learning and self-adjustable functions in the controlsystem

efficient heat recovery design

minimal consumables.
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The lean-burn concept
In a lean-burn gas engine, the mixture of air and gas in thecylinder is lean, i.e. more air is present in the cylinder thanis needed for complete combustion. With leanercombustion, the peak temperature is reduced and lessNO
X
is produced. Higher output can be reached whileavoiding knocking and the efficiency is increased as well,although a too lean mixture will cause misfiring.Ignition of the lean air-fuel mixture is initiated with a spark plug located in the prechamber, giving a high-energy ignition source for the main fuel charge in thecylinder. To obtain the best efficiency and lowestemissions, every cylinder is individually controlled toensure operation at the correct air-fuel ratio and with thecorrect timing of the ignition.Stable and well-controlled combustion also contributesto less mechanical and thermal load on enginecomponents. The specially developed Engine ControlSystem is designed to control the combustion process ineach cylinder, and to keep the engine within the operating window, by optimizing the efficiency and emissions levelof each cylinder under all conditions.
Low emissions
The main parameters governing the rate of NO
X
formation in internal combustion engines are peak temperature and residence time. The temperature isreduced by the combustion chamber air-fuel ratios: thehigher the air-fuel ratio the lower the temperature andconsequently the lower the NO
X
emissions.In the Wärtsilä 34SG engine, the air-fuel ratio is very high and is uniform throughout the cylinder, due topremixing of the fuel and air before introduction into thecylinders. Maximum temperatures and subsequent NO
X
formation are therefore low, since the same specific heatquantity released by combustion is used to heat up a larger
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Input:- rpm- kW- air/ fuel- etc.Main gasadmission valveCamshaft controlledprechamber valvePrechamberGas pipe forprechamber valveGas pipe formain gas valveEngine Control System
T h e r m a l e f f i c i e n c y ( % ) N O x ( g / k W h )
Air/fuel ratio
0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2
Detonation
B M E P ( b a r )
2.62.4
M i s f i r i n g
Operatingwindow
45%
< 1 g/kWh

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mass of air. Benefiting from this unique feature of thelean-burn principle, the NO
X
emissions from the Wärtsilä 34SG are extremely low, and comply with the moststringent existing NO
X
legislation.
Gas admission system
The Wärtsilä 34SG engine fully controls the combustionprocess in each cylinder. The “brain” for controlling thecombustion process and the whole engine is the EngineControl System.The gas admission valves located immediately upstreamof the inlet valve are electronically actuated and controlledto feed the correct amount of gas to each cylinder. Sincethe gas valve is timed independently of the inlet valve, thecylinder can be scavenged without risk of the gas escaping directly from the inlet to the exhaust. Various parameterslike engine load, speed and cylinder exhaust temperaturesare monitored and work as inputs to the Engine ControlSystem. With this arrangement, each cylinder alwaysworks within the operating window for the best efficiency at the lowest emission levels.
The ported gas admission concept gives:

high efficiency

good load response

lower thermal loading of engine components

no risk of backfire to the air inlet manifold.
Gas supply system
Before the natural gas is supplied to the engine it passesthrough a gas-regulating unit, including filter, pressureregulators, shut off valves and ventilating valves. Theexternal pressure regulator regulates the gas pressure to thecorrect value under different loads; however, themaximum pressure needed is not more than 4.5 bar(a)under full load.In the engine, the gas is supplied through commonpipes running along the engine, continuing withindividual feed pipes to each main gas admission valvelocated on each cylinder head. There are two commonpipes per bank, one for the main and one for theprechamber gas supply. A filter is placed before every gasadmission valve to prevent particles from entering thevalve.
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Gas admission valvesLoadSpeedPLCEngineMechanical operated pre-chamber valvesGas regulating unit
EPEP
P r e s s u r e G a s v e n t i l a t i o n

Engine ControlSystem

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Prechamber
The prechamber is the ignition source for the mainfuel charge and is one of the essential components of a lean-burn spark-ignited gas engine.The prechamber should be as small as possible togive low NO
X
values, but big enough to give rapidand reliable combustion. Some of the designparameters considered are:

shape and size

mixing of air and fuel

gas velocities and turbulence at the spark plug

cooling of the prechamber and the spark plug

choice of material.The prechamber of the Wärtsilä 34SG is already optimized at the design stage using advancedthree-dimensional, computerized fluid dynamics. Inpractice, the results can be seen as:

reliable and powerful ignition

high combustion efficiency and stability

extended spark plug life

very low NO
X
levels.Gas is admitted to the prechamber through a mechanical,camshaft-driven valve. This solution has proved to beextremely reliable and gives an excellent mixture into theprechamber.
Ignition system
The Wärtsilä 34SG ignition system is tailor-madefor the engine type and integrated in the EngineControl System. The ignition modulecommunicates with the main control module,which determines the global ignition timing. Theignition module controls the cylinder-specificignition timing based on the combustion quality.The cylinder-specific control ensures theoptimum combustion in every cylinder withrespect to reliability and efficiency.The ignition coil is located in the cylindercover and is integrated in the spark plug extension. The coil-on-plug design ensures a reliable solution with a minimum of jointsbetween the spark plug and the ignition coil. Thespark plug has been especially developed for long lifetime and to withstand the high cylinderpressure and temperature related to the high engineoutput.
Air-fuel ratio
To always ensure correct performance of the engine, itis essential to have the correct air-fuel ratio under all typesof conditions. The Wärtsilä 34SG uses an exhaust gaswastegate valve to adjust the air-fuel ratio. Part of theexhaust gases bypasses the turbocharger through thewaste-gate valve. This valve adjusts the air-fuel ratio to thecorrect value regardless of varying site conditions underany load.
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Prechambervalve push rodPrechambervalve camRocker arm Valve integratedin prechamber

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Cooling system
The Wärtsilä 34SG engine is designed with a Wärtsilä open-interface cooling system for optimal cooling andheat recovery. The system has four cooling circuits: thecylinder cooling circuit (Jacket), the charge airlow-temperature (LTCA) and high-temperature (HTCA)cooling circuits, and the circuit for the lube oil cooler(LO) built on the engine.The LTCA cooling circuit and Jacket cooling circuithave water pumps integrated in the cover module at thefree end of the engine. The LO circuit has its ownthermostatic valve built on the engine. The watertemperature into the LTCA cooler and the watertemperature out from the Jacket cooling circuit arecontrolled by external thermostatic valves.The default cooling system is a single-circuit radiatorcooling system where the cooling circuits on the engineare connected in series. For heat recovery applications eachcooler can be individually connected to an externalcooling system. The open interface allows full freedom incooling and heat recovery system design.
Lubricating oil system
The Wärtsilä 34SG is equipped with a wet oil sump, anengine-driven main pump, electrically drivenpre-lubricating pump, cooler, full flow filter andcentrifugal filter. The pumps, pressure regulation valvesand safety valves are integrated into one module fitted atthe free end of the engine. Filter, cooler and thermostaticvalves make up another module.The lube oil filtration is based on an automaticback-flushing filter requiring a minimum of maintenance.The filter elements are made of a seamless sleeve fabricwith high temperature resistance. A centrifugal filter ismounted in the back-flushing line, acting as an indicatorfor excessive dirt in the lube oil. The engine uses a pre-lubricating system before starting to avoid wear of engine parts. For running in, provision has been made formounting special running-in filters in front of each mainbearing.
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JACKETHTCALTCALO

AIRINTAKE

AIRINTAKE
EngineFrontal Piping
Radiator
FilterCooler PumpPrimingpump

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Starting system
The Wärtsilä 34SG engine is provided with pneumaticstarting valves in the cylinder heads of one bank. Thevalves are operated by air from a distributor at the end of the camshaft. A starting limiter valve prevents the enginefrom starting if the turning gear is engaged.
Piston
Pistons are of the low-friction, composite type with forgedsteel top and aluminium skirt. The design itself is tailoredfor an engine of this size and includes a number of innovative approaches. Long lifetime is obtained throughthe use of Wärtsilä’s patented skirt-lubrication system, a piston crown cooled by “cocktail-shaker” cooling,induction hardened piston ring grooves and thelow-friction piston ring.
Piston ring set
The two compression rings and the oil control ring arelocated in the piston crown. This three-ring concept hasproved its efficiency in all Wärtsilä engines. In a three-pack, every ring is dimensioned and profiled for thetask it must perform. Most of the frictional loss in a reciprocating combustion engine originates from thepiston rings. A three-ring pack is thus optimal with respectto both function and efficiency.
Cylinder head
Wärtsilä successfully employs four-screw cylinder headtechnology. At high cylinder pressure it has proved itssuperiority, especially when liner roundness and dynamicbehaviour are considered. In addition to easiermaintenance and reliability, it provides freedom to employ the most efficient air inlet and exhaust outlet channel portconfiguration. A distributed water flow pattern is used for propercooling of the exhaust valves, cylinder head flame plateand the prechamber. This minimizes thermal stress levelsand guarantees a sufficiently low exhaust valvetemperature. Both inlet and exhaust valves are fitted withrotators for even thermal and mechanical loading.
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Connecting rod andbig-end bearings
The connecting rod is designed for optimum bearing performance. It is a three-piece design, in whichcombustion forces are distributed over a maximumbearing area and relative movements between mating surfaces are minimized. Piston overhaul is possiblewithout touching the big-end bearing and the big-endbearing can be inspected without removing the piston.The three-piece design also reduces the height requiredfor piston overhauling. The big-end bearing housing ishydraulically tightened, resulting in a distortion-free borefor the corrosion-resistant precision bearing. Thethree-piece connecting rod design allows variation of thecompression ratio to suit gases with different knocking resistance.
Engine block
Nodular cast iron is the natural choice for engine blockstoday due to its strength and stiffness properties. The Wärtsilä 34SG makes optimum use of modern foundry technology to integrate most oil and water channels. Theresult is a virtually pipe-free engine with a clean outerexterior. The engine has an underslung crankshaft, whichimparts very high stiffness to the engine block, providing excellent conditions for main bearing performance. Theengine block has large crankcase doors allowing easy maintenance.
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Crankshaft and bearings
The latest advance in combustion development requires a crank gear that can operate reliably at high cylinderpressures. The crankshaft must be robust and the specificbearing loads maintained at acceptable levels. Carefuloptimization of crankthrow dimensions and fillets achievethis.The specific bearing loads are conservative, and thecylinder spacing, which is important for the overall lengthof the engine, is minimized. In addition to low bearing loads, the other crucial factor for safe bearing operation isoil film thickness. Ample oil film thickness in the mainbearings is ensured by optimal balancing of rotationalmasses and, in the big-end bearing, by ungrooved bearing surfaces in the critical areas.
Cylinder liner andanti-polishing ring
The cylinder liner and piston designs are based on Wärtsilä’s extensive expertise in tribology and wearresistance acquired over many years of pioneering work inheavy-duty diesel engine design. An integral feature is theanti-polishing ring, which reduces lube oil consumptionand wear. The bore-cooled collar design of the linerensures minimum deformation and efficient cooling. Eachcylinder liner is equipped with two temperature sensorsfor continuous monitoring of piston and cylinder linerbehaviour.
Turbocharging system
Every Wärtsilä 34SG is equipped with the Spex turbocharging system. The system is designed forminimum flow losses on both the exhaust and air sides.The interface between the engine and turbocharger isstreamlined to avoid all the adaptation pieces and piping frequently used in the past. The Wärtsilä 34SG engineuses high-efficiency turbochargers with inboard plainbearings, and the engine lube oil is used for theturbocharger.
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Multiduct
The multiduct replaces a number of individualcomponents in traditional engine designs. These include:

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

gas fuel mixing into the combustion air. Additional functions are:

introduction of an initial swirl to the inlet air foroptimal part-load combustion

insulation / cooling of the exhaust transfer duct

support for the exhaust system and its insulation.
Automation system
The Engine Control System is an engine-mounteddistributed system. The various electronic modules arededicated to different functions and communicate witheach other via a CAN databus. All parameters handled by the Engine Control System are transferred to the operatorinterface and the plant control system. Its features are:

easy maintenance and high reliability due to ruggedengine-dedicated connectors, CIB´s (cabling interfaceboxes) and high quality cables

less cabling on and around the engine

easy interfacing with external system via a databus

digitized signals giving immunity from electromagneticdisturbance

built-in diagnosis for easy troubleshooting.
Main control module
The main control module, the core of the Engine ControlSystem, reads the information sent by all the othermodules. Using this information it determines referencevalues for the main gas admission to control the engine’sspeed and load.The main control module also uses the informationsent from the different distributed modules to control theglobal air-fuel ratio and global ignition timing in order toobtain the best performance and reliable operation indifferent site conditions, such as varying ambienttemperature and methane number.The main control module automatically controls thestart and stop sequences of the engine and the enginesafety. It also communicates with the plant control system(PLC).
Cylinder control module
Each cylinder control module monitors and controls threecylinders. The cylinder control module controls thecylinder-specific air-fuel ratio by adjusting the gasadmission individually for all cylinders. This ensuresoptimal combustion in all cylinders.The cylinder control module also measures the knock intensity i.e. uncontrolled combustion in all cylinders.Information on knock intensity is used to adjust thecylinder-specific ignition timing by the cylinder controlmodule. Light knocking leads to automatic adjustment of the ignition timing and air-fuel ratio. Heavy knocking leads to load reduction and ultimately to shut-down of theengine if heavy knocking does not disappear.
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The cylinder control module also monitors the exhaust gas andcylinder liner temperatures of all cylinders.

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Monitoring modules
Several monitoring modules are located close to groups of sensors, which reduces cabling harness on the engine. Themonitored signals are transmitted to the main controlmodule and used for the engine control or safety system.The monitored values are also transferred to the operatorinterface and the plant control system. The cylindercontrol module also monitors the exhaust gas and cylinderliner temperatures of all cylinders.
Easy maintenance
The service life of Wärtsilä 34SG engine components andthe time between overhauls are very long due to the purity of the gas. The design incorporates efficient and easy maintenance. In combination with the long intervalsbetween overhauls, the hours spent on maintenance arereduced to a minimum. There is greater accessibility to allthe components because the number of pipes is minimizedand the components are ergonomically designed.For ease of maintenance, the engine block has largeopenings to the crankcase and camshaft. All boltsrequiring high tension are hydraulically tightened.Hydraulics is extensively used for many other operationsas well. Since the main bearing caps are relatively heavy,each bearing cap is equipped with a permanently fittedhydraulic jack for easy manoeuvring of the cap. During delivery test runs, a running-in filter is installed to preventthe bearings from being scratched by any particles left inthe oil system.

The multiduct arrangement allows the cylinder head tobe lifted without having to remove gas pipes or waterpipes. The slide-in connections allow lifting of thecylinder head without the need to remove oil or airpipes.
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ensors connectedto monitoring moduleMonitoring moduleylinder control moduleCANMain control moduleProfibusto externalsystems

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
The water pumps are easy to replace thanks to thecassette design principle and water channel arrangementin the pump cover at the free end of the engine.

A rigid and tight but easily removable insulating box surrounds the exhaust system.

Easy access to the piping system is obtained by removing the insulating panels.

The camshaft is built of identical cylinder segmentsbolted to intermediate bearing pieces.

A wide range of special tools and measuring equipmentspecifically designed to facilitate service work are alsoavailable.

Access to and maintenance of the spark plug andprechamber gas valve in the prechamber is easy. Theprechamber does not need to be removed. For spark plug replacement, the valve cover does not need to beremoved.

Use of electrically controlled gas admission valves meansfew mechanical parts and less need for periodicadjustments.

The three-piece connecting rod allows inspection of thebig-end bearing without removal of the piston, andpiston overhaul without dismantling the big-endbearing.
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A BCDE
Main technical data
Cylinder bore340 mmPiston stroke400 mmSpeed720 / 750 rpmMean effective pressure20.0 / 19.8 barPiston speed9.6 / 10 m/sNatural gas specification for nominal loadLower heating value

28 MJ/m
3N
Technical data
Unit 16V34SG 20V34SGCompression ratio 12Speed/HzNO
X
mg/Nm
3
at 5 % O
2
500 250 500 250Methane number >80 >70 >80 >70720 rpm60 HzElectrical power kW 6751 6751 8439 8439Electrical efficiency % 46.5 45.1 46.5 45.1750 rpm50 HzElectrical power kW 6984 6984 8730 8730Electrical efficiency % 46.5 45.1 46.5 45.1
Technical data
Unit 16V34SG 20V34SGCompression ratio 11Speed/HzNO
X
mg/Nm
3
at 5 % O
2
500 250 500 250Methane number >65 >55 >65 >55720 rpm60 HzElectrical power kW 6751 6751 8439 8439Electrical efficiency % 45.5 44.1 45.5 44.1750 rpm50 HzElectrical power kW 6984 6984 8730 8730Electrical efficiency % 45.5 44.1 45.5 44.1
Electrical power at generator terminals, including engine-driven pumps, ISO 3046 conditionsand LHV. Tolerance + 5%. Power factor 0.8.
Principal genset dimensions (mm) and weights (tonnes)
Engine type A B C D E EngineweightGensetweight16V34SG 11692 3233 4348 1998 2648 66.5 11520V34SG 12466 3233 4348 1998 2648 76.4 137.5
For more specific information, please contact Wärtsilä.
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0 6 . 2 0 0 5 / B o c k ´ s o f f i c e / W a a s a G r a p h i c s
Wärtsilä Finland Oy
P.O.Box 252,FIN-65101 Vaasa, FinlandTel:+358 10 709 0000Fax:+358 6 356 9133Wärtsilä is a leading provider of power plants, operation and lifetimecare services in decentralized power generation.Wärtsilä is The Ship Power Supplier for builders, owners and operatorsof vessels and offshore installations. Our own global service networktakescompletecareofcustomers’shipmachineryateverylifecyclestage.For more information visit www.wartsila.com
WÄRTSILÄ
®
is a registered trademark. Copyright © 2005 Wärtsilä Corporation.

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