ENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Fuel system arrangement - Internal 1032) (io joes) 08 o «CA os 4 06 o7 06 Click the figure ae heENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Fuel system arrangement - Internal tase Tr on + of & ca of mA lip a re wae PRP eee YY a oh io ims Y 2 ii Click the figure fo zoom in oi o7 8 ng ft a ‘ool ref oe 1 Oo 06 oe The engine is designed for continuous operation on heavy fuel oil (HFO) or light fuel oil (LFO). The design of the extemal fuel system may vary from ‘one installation to another, every system will supply the engine with fuel at the correct temperature and pressure. It is most important that solid particles and water are properly cleaned from the fuel. The purity of fuel and the fuel quality directly influences the lifetime of the injection pumps and other components in the injection line and hence the performance of the engine. Filters and cleaning equipment are therefore very important. Fuel that has not been treated properly, may cause harm to the engine. e.g. resulting in excessive bearing wear in fuel pump tappet bearings, cavitations damage in fuel system components or leakage. A high water content may also cause operational problems for the fuel feed system.ENGINE W32 BASIC - Built-On Systems Fuel System Cc WARTSII Fuel system arrangement - Internal ey t an yeas: (1039) Click the figure to zoom in 01 Injection pump 02 Injection valve 03 Pressure control valve 04 Fuel rack Fuel oil leakage collector 06 Camshaft O7 Flywheel 08 Pulse damper 09 Onfice o a Pipe connections 101 Fuel inlet 102 Fuel outlet 1031 Clean fuel leakage outlet 1032 Clean fuel leakage outlet 1033 Clean fuel leakage outlet 1034 Clean fuel leakage outlet 1041 Dirty fuel leakage outlet 1042 Dirty fuel leakage outlet 1043 Dirty fuel leakage outlet 1044 Dirty fuel leakage outletENGINE W32 BASIC - Builf-On Systems Fuel System WARTSILA Fuel system on engine The arrangement on the engine consists of a covering system, low pressure system, injection system with control devices. System Components « 01 Covering system e 02 Low pressure system e 03 Injection system I XFO2K0154_OlenENGINE W32 BASIC - Built-On Systems Fuel System Covering system rT } XFCDNOIBS_Oten WARTSILA Covers on engine, A-bank The Hot-box covering system can be divided into four categories, cover for fuel piping, end covers, side covers and covers between the cylinder heads. Sys components 01 Covers for fuel piping 02 Side covers, upper part 03 Side covers, lower part 04 End cover FE, lower part 05 End cover FE, upper part 06 End cover FE, end part 07 Top cover 08 Cover for air container 09 End cover DE, upper part 10 Cover 11 Top cover 12 Splash guard for pipe connectionENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Covering system Hot-box side covers System components « 01 Hot-box side covers, upper part *® 02 Hot-box side covers, lower part The Hot-box side covers are made of Al-profile, which at the lower end are retained by means of screws onto the lower side cover profile. The lower side cover profile in turn is attached onto the side surface of the engine block. At the upper end, the covers is attached to the cylinder head The Hot-box covers are designed to form an retained area. The covers are giving even higher protection for the same area by preventing direct pressunzed fuel injection to hot surfaces. In addition, heat is sealed in this area, thereby eliminating the need for pre heating system to operating temperature.ENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Low pressure system 02 Fuel delivery system The low pressure fuel oil system on the engine consists of the fuel delivery piping and leak fuel system. The low pressure system transfers clean fuel oil to the injection pump and exces fuel oil back for reuse. The pressure of the circulating system is kept correct and constant by the pressure regulating valve mounted on the engine. System components e Of Fuel delivery piping «* 02 Leak fuel system e 03 Pressure regulating valve e 04 Pulse damperENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Low pressure system HPOZXO1EI_Olen Fuel supply line to Hot-box and from A-bank to B-bank System components * O01 Fuel delivery piping * 02 Fuel return piping « 03 End cover Pipe connections « A Supply line « 6 Return line Due to safety consideration, the maintenance schedule respect to the fuel lines cross connecting the fuel systems, must be followed. Failure to do so may result in a potentially dangerous situation. NOTE: The fuel pipes between A- and B-bank has to be replaced at 12 000 h.ENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Low pressure system Fuel supply line in Hot-box, A-bank System components 01 Fuel pipe housing 02 Guide block for injection pump 03 Fuel pipe end housing 04 Locking plate 05 Sleeve 06 Housing Of Fuel pipe 08 O-ting 09 O-ring 11 Pulse damper 12 Connection piece 13 Onffice Pipe connections XFOZKO079_Oten + A Supply line + B Retum lineENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Low pressure system The fuel supply line consists of drilled channels in cast parts assembled on the engine block. These parts are the pump housing, the tappet housing. the fuel pipe housings and the “multicover"end cover. Complete arrangement is called “multihousing’. ‘The functions of the multihousing are: + Housing for the injection pump element, + Fuel supply channel along the whele engine, + Fuel return channel from each injection pump, + Lubricating oil supply to the valve mechanism. The arrangement with the multihousing represents XFO2K0079_O1en the ultimate in safe fuel system. It also gives'a compact design without fuel piping and with easy maintenance operations_ENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Low pressure system the fuel pipe housings and the “multicaver’end cover Complete arrangement is called “multihousing’. The functions of the multihousing are: * Housing for the injection pump element, + Fuel supply channel along the whole engine, + Fuel return channel from each injection pump. Lubricating oil supply to the valve mechanism. ‘The arrangement with the multihousing represents. ‘the ultimate in safe fuel system. It also gives a compact design without fuel piping and with easy maintenance operations. XFORKOOTS_Oten The multihousing arrangement ensure maximum possible safety with the fuel system. Itis compact design that allows easy maintenance operationENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Dampers for fuel line The silicone filled dampers are used to eliminate the possible pressure pulses in the fuel delivery and o4 05 oT retum lines. System components 04 Connector kit 02 Name plate 03 Nut 04 Bladder 05 Silicon elements 06 Gnd 07 Accumulator shell 08 Tension ring 09 O-ring Pipe connections e =A Fuel leakage 06. 08 i] Damper consists of silicon elements containing in the steel shell. Connector is connected with pipe for contro! of bladder of leaking XFO2K9048_O1en Aconnection allows the correct fitting of the damper without fuel leakage-ENGINE W32 BASIC - Built-On Systems Fuel System Leak fuel system © WARTSILA Leak fuel system on engine, A-bank At the A-side leak fuel system consist of piping in XFOQXO1SE_O1en the Hot-box, leak oil channels in the aluminium manifold and end covers in the side cover lower part and leakage piping at free end and driving end of the engine. System components 01 Clean fuel leakage 02 Dirty fuel leakage 03 Fuel leakage from injection pump 04 Fuel leakage from high pressure pipe 05 Fuel leakage from injection valveENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Leak fuel system XPOaXO19_O1en Leak fuel system on engine, B-bank At the B-side leak fuel system consist of piping in the Hot-box, leak oil channels in the aluminium manifold and end covers in the side cover lower part and leakage piping at free end and driving end of the engine. System components * 01 Clean fuel leakage 02 Dirty fuel leakage 03 Fuel leakage from injection pump 04 Fuel leakage from high pressure pipe 05 Fuel leakage from injection valveENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Leak fuel system Leak fuel system in Hot-box, A-bank Leak fuel from the injection system is collected in a leak fuel manifold on the Hot-box. The manifold is divided in two sections to collect the leakage. One is for leakage from pumps and cylinder heads and the other is for leakage from the high pressure pipes. Pipe connections + A Clean fuel leakage + 6 Dirty fuel leakage + € Fuel leakage from injection pump + D Fuel leakage from high pressure pipe + F Leakage oil from injection valve XFO2X00R1_Cten Clean leak fuel is collected and drained through the same leak pipes, to the clean fuel leak tank for reuse. A level switch on the leak fuel outlet channel monitors the leakage and will initiate an alarm from an abnormally high backflow or from + a leak in an injection pipeENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Leak fuel system cylinder heads and the other is for leakage from the high pressure pipes. Pipe connections A Clean fuel leakage B Dirty fuel leakage C Fuel leakage from injection pump D Fuel leakage from high pressure pipe + F Leakage oil from injection valve Clean leak fuel is collected and drained through the same leak pipes, to the clean fuel leak tank for reuse. A level switch on the leak fuel outlet channel monitors the leakage and will initiate an alarm from an abnormally high backflow or from a leak in an injection pipe. XFO2XO08t_Oten Dirty leak fuel, lubricating oil and water are collected to a separate leak pipe system situated at driving end or both ends of the engine and are returned to a separate waste fuel oil collection tank.ENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Leak fuel system Leak fuel system in Hot-box, B-bank Leak fuel from the injection system is collected in a leak fuel manifold on the Hot-box. The manifold is divided in two sections to collect the leakage. One is for leakage from pumps and cylinder heads and the other is for leakage from the high pressure pipes Pipe connections + A Clean fuel leakage B Dirty fuel leakage C Fuel leakage from injection pump D Fuel leakage from high pressure pipe F Leakage ail from injection valve XF02X0082_01enENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Leak fuel system Leak fuel system in Hot-box Pipe connections « C Fuel leakage from injection pump « D Fuel leakage from high pressure pipe « F Leakage oil from injection valve xFazxo0s1_oten _!ENGINE W232 BASIC - Built-On Systems Fuel System WARTSILA Pressure regulating valve The valve is a directly controlled pressure 10 limiting valve which is installed at the outlet of each engine to maintain the pressure of the os circulating system at the correct and constant 08 value. o7 Components + 01 Housing 06 + 02 Sliding piston + 03 Cover o3 + 04 Spring guide 1 + 05 Spring 06 Protecting cap O7 Set screw 08 Nut 09 Sealing ring + 10 Venting screw A XFO2X0048_Oten + 41 O-ing Pipe connections A Fuel outlet 4ENGINE W32 BASIC - Built-On Systems Fuel System WARTSILA Pressure regulating valve » 08 Nut + 09 Sealing ning 04 10 + 10 Venting screw 05 09 + 44 O-ring 08 o7 Pipe connections + A Fuel outlet 06 03 The sliding piston (poppet) is pressed against Pr the sealing face by a compression spring and separates the inlet connection of the valve from outlet connection while also sealing the bore As soon as the operation pressure is adjusted by the adjusting screw, the sliding piston - XFO2N0O48_OTen (poppet) releases the oil flow to the outlel. As the inlet pressure falls below the set pressure value, the valve closes. The sping chamber is pressure compensated by a borehole to the outlet. During valve start-up, the spring chamber must be expelled from possible air by releasing the venting screw.ENGINE W32 BASIC - BuiltOn Systems Lubricating Oil System WARTSILA Lubricating oil system arrangement - Internal System components * 01 Lubricating oil pump 02 Pressure regulating valve 03 Pre-lubricating oil pump 04 Pressure regulating valve 05 Oil cooler 06 Thermostatic valve Q7 Automatic filter 08 Centrifugal fitter 09 Turbocharger 11 Gil strainer 12 Oil sump Pipe connections * 243 Lubricating oil inlet from separator and filling «® 214 Lubricating oil outlet to separator and filling * 215 Lubricating oil filling . . ee ee 4 216 Lubricating oil draining 12 ote 701 Crankease ventilation + «A Lubricating oil to upper parts of the ne xS03K00 engine « 6 Lubricating oil to main moving parts « C Lubricating oil to engine oil sumpENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Lubricating oil system on engine 04 04 The arrangement on the engine consist of lubricating 4 system at free end, lubricating oil system at driving end, storage system, delivery system, lubricating oil control devices and oil condition monitoring systems. System components * 01 Lubricating oil system at free end * 02 Lubricating oil system at driving end * 03 Lubricating oil storage system * 04 Lubricating oll delivery system « 05 Running-in filter (for commissioning and maintenance)ENGINE W32 BASIC - Built-On Systems ce Lubricating Oil System WARTSILA Lubricating oil system at free end System components «* 01 Lubricating oil pump * 02 Pre-lubricating oil pump « 03 Oil sump Pipe connections G Lubricating oil inlet from separator and filling K Lubricating oil outlet to separator and draining L Lubricating oil filling M Lubricating oil draining onENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Lubricating oil sump The ail sump (D1) of the engine is wet type, Le. a separate system oil tank is not needed. The main function of the wet sump Is to collect lubricating ail after circulation through the engine Suction pipes to the lubricating oil pump and if used, for the separater, as well as for the main lubricating oil distributing pipe for crankshaft bearings, are incorporated in the oil sump. System components « 07 Oilsump ® 02 Hydraulic jack e 03 Lubricating oil delivery pipe XFU3<0086_O1enENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Hydraulic jack 01 The hydraulic jack with integrated lubricating oil q delivery pipe is a maintenance tool for the main bearing caps. Components 03 01 End flange + 2 Fastening flange 04 + 03 Cylinder + 04 Oilpipe 4 t 05 + 05 Piston + 06 Outer cylinder t 4 + O7 Inner cylinder 8 A 06 + 08 Fastening flange oT Connections 08 + A Pressure connection, when lowering 02 + 6 Pressure connection, when lifting + —€ Lubricating oil inlet The lubricating oil is led up from the lubricating oilENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Hydraulic jack The lubricating oil is led up from the lubricating oil delivery pipe to the main bearings through the centre of the hydraulic jack. Lifting and lowering function for bearing caps 03 provides an operational environment when inspecting the bearings. Hydraulic jack contains an Operating cylinder which is controlled by o4 pressurized oil connection. 4 05 The hydraulic jack operating oil circuit is separate from the engine circulation oil supply. t A low pressure hand pump is used for lifting with B 06 hydraulic jack. o7 Norma! engine oil, which is used in the engine lubricating system (sump) must be used in this pump because the drain oil from the tools is led to 08 the sump of the engine. Lowering the main bearing cap: + Connect the hoses of the hydraulic pump and to the side marked AENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Hydraulic jack (DOWN) on the hydraulic jack. Connect the return hose to the side marked B (UP) and an additional quick coupling male part to the free end of the return hose and place it in the 03 crankcase. + Lower the main bearing cap by pumping oil to the hydraulic jack with 04 the hydraulic pump 05 Lifting the main bearing cap: 06 + Remove the quick coupling from the retum hose and reverse the oil feed to 07 the hydraulic jack by connecting the pump to the side marked B (UP). Mount the quick coupling male part to the free 08 end of the hose, connected into the side marked A (DOWN). and place it in the crankcase. + Lift the main bearing cap by pumping oil to the hydraulic jack with the hydraulic pump.ENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Lubricating oil delivery system 05 XFOSXO122_Oten System components Lubricating oil pipit 01 Oil suction piping from oil sump 02 Oil suction piping for lubricating oil pump 03 Oil suction piping for preubricating oil pump 04 Oil piping for lubricating oil cooler 05 Oil piping for lubricating oil delivery line 06 Lubricating oil delivery line Of Oil piping for main moving parts 08 Oil piping for gear wheels and built- on pumps 09 Oil piping for upper parts of the engine 40 Oil channels for tappets 41 Oil piping for turbocharger 12 Oil connection to turbocharger 13 Oil piping for cylinder head 14 Oil piping for centrifugal filter is made of seamless carbon stee] and seamless precision tubes in carbon orENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Lubricating oil delivery system + 03 Qil suction piping for pre-lubricating 14 ‘oil pump + 04 Qil piping for lubricating oil cooler 12 0a 05 Oil piping for lubricating oil delivery line + 06 Lubricating oil delivery line 09 + 07 Gil piping for main moving parts + 08 Gil piping for gear wheels and built- ‘on 04 + 09 Oil piping for upper parts of the engine 10 Qil channels for tappets + 11 Qil piping for turbocharger * 42 Qil connection to turbocharger * 13 Qil piping for cylinder head os * 44 Oil piping for centrifugal filter o2 Lubricating oil piping is made of seamless carbon steel and seamless precision tubes in carbon or stainless steel. Engine block and other cast constructions contain oil channels which are used for lubrication cil delivering and collecting. Lubricating oil delivery piping can be divided into sub-systems as follows. 08 07 01 \06 xrosxotz2_otenENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Splash guards at driving end Covers are designed to shield the connections and thus meet the SOLAS requirements (4). Components * 01-07 Splash guard for pipe connection NOTE: All of these to be replaced after maintenanceENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Lubricating oil to main moving parts Oil flow in the engine is divided to following lubricating oil circuits: To main moving parts. To camshaft bearings and gear wheels at driving end. To actuator and drive gear. To valves, valve tappet mechanism and fuel nozzle cooling To gear wheels and built-on pumps at free end_ To turbocharger bearings. From driving end oil flows in to distribution channel at the bottom of the oil sump (01). From distribution channel oil flows through hydraulic jack (02) to main bearings (03), through crankshaft (04), to connecting rod bearings (05), up through connecting rod (06) to gudgeon pin bearings (07) and further to piston skirts’ cooling space (08)ENGINE W32 BASIC - Built-On Systems Cc Lubricating Oil System WARTSILA Lubricating oil flow in piston Part of the lubricating oil through connecting rod (01) 1 flows out from piston skirt through the special a2 BS! nozzles (02) to cylinder liner, forming an oil film Ph — r between piston and cylinder liner surfaces. From the cylinder liner oil flows back to.oil sump. - oe The rest of the oil is used to cool the piston top with : nozzles and “shaker effect. 01 XFOaX0072_O1enENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Lubricating oil flow at driving end The oil circuit consists of lubricating oil module and lubricating oil pipe to lubricating oil delivery pipe; lubricating oil channels to intermediate gear wheel, camshaft drive gear, camshaft oil channels and camshaft bearings. Components * 01 Lubricating oil module a « 02 Lubricating oil nozzle for gear \ « 03 Lubricating oil nozzle plug * 04 Lubricating oil connection pipe for nozzles & * 05 Suction oil pipe for lubricating oil cooler » 06 Return oil pipe for lubricating oll delivery pipe oz Connections « A Lubricating oil to lubricating oil cooler 05 » B Lubricating oil to lubricating oil deliver pipe Part of the lubricating oil flow is branched for lubrication of the gear wheels by special lubricating oil nozzle channels and pipes (04). The nozzle pipes include small nozzle holes where a lubricating oil jet lubricates the gear wheels. Through channels in the end cover and gear assembly the oil flows fo bearings and back to oil sump.ENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Lubricating oil flow at driving end Components. * O01 Automatic filter * 02 Centrifugal fitter « 03 Lubricating olf cooler » 04 Thermostatic valve Connections « = ALubncating oil to lubricating oil cooler * B Lubricating oil to lubricating oil delivery pipe * C _ Lubncatng oil to upper parts of the engine in A-bank « D Lubricating oil to upper parts of the engine in B-bank * N_ Lubricating oil to sump Lubricating oil module consists of lubricating oil cooler, thermostatic valves, centrifugal filter and full flow automatic filter. Module housing is attached into engine driving end with bracket with channels for LT water and lubricating oil.ENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Oil flow to intermediate gear wheel bearing System components ee - o1 « 01 Bigger intermediate gear wheel . = « (02 Smaller intermediate gear wheel 02 « 03 Thrust bearing piece 06 « 08 = Intermediate gear beanng 03 « 46 Thrust bearing * OF Office Connections 05 se A Qil flaw to bearing o7 « B Oilflow tosump The lubrication for the intermediate gear wheel bearings is arranged through channels in the crankshaft, engine block, end cover and for the gear wheels from a distributing pipe through nozzles. Through the intermediate gear, oil flows back to oil sump. | XFO3X0075_O1enENGINE W32 BASIC - Built-On Systems Lubricating Oil System Oil flow to camshaft drive gear bearing on A-bank FO8X0078_D100 WARTSILA System components: * 01 Camshaft drive gear wheel * 02 Ofifice « 03 Thrust bearing * 04 Camshaft drive gear bearing « 05 Thrust bearing piece * 06 Extension piece « O07 Gear wheel Connections * A Gil flow to bearing « B Oil flow to sump The oil supply is arranged for the axial bearing from the driving end of the engine. From lubricating oil channels oil flows through channels in the cover for bearing and camshaft end. The oil returns to the sump via channels. Lubricating oil is supplied to every camshaft bearing through drillings in the engine block.ENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Oil flow to camshaft drive gear bearing on B-bank System somponients o * 01 Camshaft drive gear wheel 02 * 02 Orifice * 03 Thrust bearing 03 * 04 Camshaft drive gear bearing «+ 05 Thrust bearing piece Connections « A Oil flow to bearing « B Oil flow to sumpENGINE W32 BASIC - Built-On Systems ec Lubricating Oil System WARTSILA Oil flow to camshaft bearing For lubrication of the camshaft bearing the oil is branched from lubricating oil cooler through the lubricating oil channels. The aluminium profile manifold in the Hot-box side cover lower part at provides lubricating oil for the upper parts of the engine. System components « 01 Lower part of side cover Connections « A Oil flow to camshaft bearings « B Lubricating flow to upper parts of the engine XFOSX0012_OtenENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Oil flow to actuator drive The oil supply for actuator drive is arranged from the thrust bearing of camshaft lubricating channel. From lubricating oil channels oil flows through channels in actuator housing for bearings and gear wheel Through channels in engine block and actuator housing the oil flows back to oil sump. Connections * A Qil flow to bearings * B Oil spray to gear wheel e C Oilflow to sump XFO3KO092_O1enENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Oil flow to valve tappets Lubrication to valve tappets is arranged through oil channels in Hot-box. From tappet guide the ail is led to cylinder head via lubricating oil pipe connection. Lubrication for tappets is provided through ail channels. The lubricating oil from the rocker arm bracket returns through a pipe to the valve tappet guide. After circulation the oil then returns to the oil sump. Connections e A Oil flow to valve tappets * B Gil flow to cylinder head tneE —_— XFO3X0081_O1enENGINE W232 BASIC - Built-On Systems Cc Lubricating Oil System WARTSILA Oil flow to injection tappets and pump Lubrication to injection tappet is arranged through oil channels in Hot-box. From tappet base the ail is led to injection pump via oil channels. Lubrication for tappet is provided through oil channels After circulation the oil then returns to the oil sump. ‘Connections e C€ Oil flow to injection tappet and injection pump push rodENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Oil flow to valve mechanism bees 5 o) eee The oil flows from the tappets through a connection on the side of the cylinder head. Inside the cylinder head, oil flows through bores continuing up through the internal channels in the rocker arms arrangement. System components 01 Rocker arm G2 Push rod 03 Yoke O04 Valve rotator 05 Valve and valve guide Pipe connections + B Oilinlet connection Lubricating oil lubricates the yoke pins and further on also the valve rotaters. The rocker arm supplies oil only when it is in the “open valve” pesition. When the rocker arm is in "valve closed” position, the surface between rocker arm and theENGINE W32 BASIC - Built-On Systems Lubricating Oil System 01 03 04 05 | | | 4 r XFOGKO11S_Oten WARTSILA Oil flow to valve mechanism system components Pipe connections 01 Rocker arm 02 Push rod 03 Yoke 04 Valve rotator 05 Valve and valve guide + B Oilinlet connection Lubricating oil lubricates the yoke pins and further ‘on also the valve rotators. The rocker arm ‘supplies oil only when itis in the “open valve” position. When the rocker arm is in “valve closed” position, the surface between rocker arm and the shaft is lubneated_ The lubricating oil is returned via the push rod covering pipe through the valve tappets assemblies and back to the oil sump as a free flow.ENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Lubricating oil flow to gear wheels and built-on pumps at free end The system consists of the oil piping from lubricating ail delivery pipe (02), lubricating oil distributor and oil channels in the inner side of pump cover. The lubricating oil distributor delivers oil to built-on LT- and HT-pumps and the drive gear wheels. System components « O01 — Lubricating oil distributor « 02 Oil piping for gear wheels and built-on oa pumpsENGINE W32 BASIC - Built-On Systems Cc Lubricating Oil System WARTSILA Lubricating oil to turbocharger bearings The lubrication for turbocharger bearings is arranged with pipe and the channel connection and connection piece in TC bracket. From the turbocharger, the lubricating oil returned to the sump through oil channels. System components « 01 Connection piece Pipe connections 2« A Lubricating oil flow to upper parts of the engine .« B Lubricating oil to turbocharger c Lubricating oil return flow »* D Lubncating oil back flow to sumpENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Lubricating oil to turbocharger bearings Connection piece \ ‘Components e 1 ring 03 « 02 Connection outlet pipe = = © 03 Onfice 02 « 04 O-tin: 05 e 05 Connection inlet pipe 06 « 06 O-ring e Q7 O-ring 08 07 * 08 Connection piece e 09 GOting e 10 O-ring 09 e 11 Locking plate | | i Connections | | I « B Lubricating ail to turbacharger / | 4 10 e ¢ Lubricating oil return flaw venyei2a ManENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Lubricating oil pump arrangement System components . Electric motor o1 . e Flexible coupling es = # 03 Pressure regulating valve « 04 Pre-lubricating pump 08 « 05 Pressure regulating valve — 02 * 06 Lubricating oil pump ype eee - * Of Suction pipe for lubncating oil pump « 08 Suction pipe for pretubricating oil pump o7 F _03 Connections. = * A Suction connection « B Pressure connection > 04 The system consist of a preubricating oil pump and a main lubricating oil pump. The pre-ubricating oil pump is powered by an electric motor through a flexible coupling. The lubricating oil pump is powered by the drive gear wheel at the end of crankshaft, which rotates the pump mechanism XxFOaxO018_OtenENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Pre-lubricating oil pump The pump is an of gear-type with two gears, diving and driven gear, powered by an electric motor. The pump is also provided with an adjustable pressure: control valve. Components + 01 Pump bracket + 02 Shaft 03 Shaft seal + 04 Bearing bush + 05 Distance sleeve + 06 O+ing + 07 Driving gear + 08 Driven gear 09 Pump housing Connections FOIMDOTE_O1En A Pressure connection + B Suction connection The pre-lubnicating oil pump fills the engineENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Pre-lubricating oil pump 01 Pump bracket 02 Shaft 03 Shaft seal 04 Bearing bush 05 Distance sleeve 06 O-nng 07 Driving gear 03 Driven gear 03 Pump housing Connections + A Pressure connection + B Suction connection The pre-lubricating oil pump fills the engine lubricating oll system before starting, e.g. when the engine has been out of operation for a long time. It also provides continuous pre-ubrication of a stopped engine through which fuel oil is circulating and continuous pre-lubnication of stopped engine (s) in a multi-engine installation, when one of the other engines is running. XFOLXDOTE_OtenENGINE W32 BASIC - Built-On Systems Lubricating Oil System Pre-lubricating oil pump WARTSILA Pressure regulating valve Components a1 02 03 04 05 06 o7 038 09 10 The pressure regulating valve is integrated in the pre-lubricating oil pump housing and it regulates the oil pressure before the engine by retuming the surplus oil directly from the pressure side of the pump to the suction side. O-ring Retaining ring Non-retum valve Piston Spring Spring retainer O-ring End cover Screw Adjusting screw Outlet pressure actuates the regulating piston and the spring is tensioned to balance this force at the required pressure. By tensioning the spring withENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Pre-lubricating oil pump pump to the suction side. Components 01 O-+ing 02 Retaining ring 03 Non-retum valve 04 Piston 05 Spring 06 Spring retainer O07 O-nng 08 End cover 09 Screw 10 Adjusting screw Outlet pressure actuates the regulating piston and the spring is tensioned to balance this force at the required pressure. By tensioning the spring with the screw a higher oil pressure is obtained. The pressure shall be limited to the recommended operation value by unscrewing the adjusting screw to the end position in order to prevent the electric motor from being overloaded when running with very cold oilENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Drive gear for lubricating oil pump The lubneating oil pump is driven by a drive gear wheel at the end of the crankshaft which rotates the pump mechanism. Pump is correctly located with the pump housing and fastened by screws. Components e 01 Drive gear wheel ® 02 Gear wheel » 03 ScrewENGINE W32 BASIC - Built-On Systems Lubricating Oil System Lubricating oil pump Components cH 02 63 04 05 06 or 08 09 10 ab 12 13 14 15 16 WARTSILA The lubricating oil pump is a gear-type pump with two gears, driving and driven gear. The pump is dimensioned for actual lubricating oil viscosity. Pump housing Side flange Bottom flange Gear wheel Drive shaft Screw Pressure plate Pair of friction rings Bearing bush Pressure regulating valve Pump cover Distance sleeve Driving gear Driven gear Distance sleeve O-ringENGINE W32 BASIC - Built-On Systems Lubricating Oil System Lubricating oil pump 09 10 1 12 - = 414 = 15 » 16 Connections HFOINONEAOter WARTSILA Bearing bush Pressure regulating valve Pump cover Distance sleeve Driving gear Driven gear Distance sleeve O-ring A. Suction connection B Pressure connection © Pressure from pre-lubricating oil pump The pump has a built-in pressure regulating valve, which functions as a safety valve for the pump. Pressure control regulating valve of lubricating oil system is integrated into pump housing. The pump lubrication is supplied by the pumped lubricating oil.ENGINE W32 BASIC - Built-On Systems Cc Lubricating Oil System WARTSILA Pressure regulating valve 02 The lubricating oil system is equipped with a pressure regulating valve to maintain the oil ata constant pressure to the engine lubrication ail 06 system under variable conditions. The pressure regulating valve is designed for the maximum lubricating oil flow of the pump. Components o 01 Adjusting piston + 02 Onfice 02 + 03 Spool + 04 Orifice 03 + 05 Onffice + D6 Spring (external) + 7 Cone (external) 04 o1 05 oy Connections at X1 Control pressure after lube oil pump A A. -xe03x0022_02en + X2. Control pressure at delivery piping * L Ollta sumpENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Pressure regulating valve 02 o7 az 03 4 A A xF0350022,02en + 06 Spring (external) + 07 Cone (external) ‘Connections « X1 Control pressure after lube oil pump + X2 Control pressure at delivery piping ek Oil to sump When pressure exceeds the adjusted values on the pressure side, the valve cone lifts from the seat and the lubricating oil circulates into the suction side of the pump housing. The opening pressure is adjusted by compressing the valve spring with the adjusting screw at the factory. For engines running at varying speeds, the valve is arranged to maintain a speed dependent pressure, according to the operating pressures recommended at various speeds. If the pressure significantly increases in the pressure pipe, the ball will open and admit oil fo pass onte the regulating piston. This serves as a safety valve operation.ENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA, Thermostatic valve for lubricating oil a In principle, the thermostatic valve is a three-way valve FOOXONZS_ FH 01 a2 Q3 o4 05 06 Al RREGS with a built-in thermal element. A self-acting thermostatic valve is installed to keep the lubricating ai! temperature constant for filtration and delivery. The thermostatic valve is designed to act for a specified 02 temperature range. This temperature range cannot be adjusted Components. Tube housing Tube bundle Bracket Thermosiatic valve Thermostatic element assembly O-ring Connections Lubricating ail to cooler Lubricating oil delivery (uncooled) Lubricating oil delivery (cooled) Lubricating oil to filtration and delivery Lubricating oil to upper parts of the engine Lubricating oil flow back to cil sumpENGINE W32 BASIC - Built-On Systems Lubricating Oil System WARTSILA Thermostatic valve for lubricating oil Function of thermostatic valve i _- 307 ) oe He 8 “ Late 02 — © OOGos =O) (}—+-a ot a - - B - bank Click the figure to zoom in System components. « O01 Air fitter 02 Compressor 03 Charge air cooler (HT) 04 Charge air cooler (LT) 05 Cylinders 06 Turbine O07 Waste gate valve Pipe connections »* 501 Exhaust outlet »* 507 Cleaning water to turbine and compressor * 601 Charge air inlet General An exhaust gas system guides waste exhaust gases away from a controlled combustion. The exhaust gases flow through turbocharger to increase engine power. The air intake system provides the ambient air (charge air) to engine’s combustion process in combustion chamber. The filtered air is compressed in turbocharger and cooled in the charge air cooler. The ambient air needs to be free from sea water. dust, fumes, etc.ENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Exhaust gas and air intake system on engine 04 Click the figure to zocENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Exhaust gas and air intake system on engine Delivers compressed air to the combustion chamber and channels the exhaust gases out from the combustion chamber to exhaust manifold. The system can be split up into an intake section and an exhaust section System components * O01 Turbocharger * 02 Charge air cooler * 03 Water cleaning system * 04 Multiduct » 05 Waste gateENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System Turbocharger a re ie it ‘XS06X0003_O1e9 WARTSILA System components * 01 Compressor « 02 Charge air cooler « 03 Turbine « 04 Waste gate valve System connections e A Airintake » B Exhaust outlet Basic settings of turbocharging Power Plant application Waste gale. YES By pass: NO Marine diesel electric Waste gate. YES By pass: NO Marine CPP propulsion Waste gate: YES By pass: YESENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Turbocharger Converts the thermal and kinetic energy of the exhaust gases in to air pressure that can be fed in to the cylinders of an engine. A turbocharger consists of an exhaust driven turbine and a compressor wheel which are mounted on the same shaft. The turbine uses the waste energy of the exhaust gases.as a power source. The rotational speed of a turbocharger is usually in the range 10.000 mpm to 30.000 mpm depending on the size of the unit. Turbocharger increases specific power over naturally aspirated engine. This means a turbocharged engine can achieve more power from same engine volume.ENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System Turbocharger WARTSILA Depending on installation, a filter! silencer or an air suction branch can be used in ambient air connection. Components « 01 Cartridge group « 02 Gas inlet casing « 03 Nozzle ring * 04 Gas outlet casing « O08 Turbine diffuser « 06 Foot « O07 Compressor casing, external part « 08 Compressor casing, internal part » 09 Wall insert » 10 Diffuser a The housings fitted around the compressor and turbine collect and direct the gas flow through the 08 wheels as they spin. The size and shape can dictate some performance characteristics of the o7 overall turbocharger. XFOGX1068_OlenENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Turbocharger 24 16 me 1 we w Sate aren Components 11 Turbine wheel (shaft) 42 Compressor wheel 13. Thrust bearing 14 Radial plain bearing, comp. end 15 Radial plain bearing, turbine end 16 Axial thrust bearing 17 Floating disc 18 Auxiliary bearing 19 Bearing bush 20 Bearing casing Hood WY * 22 Sealing cover + 23 Gasket + 24 Partition wall « 25 Speed sensor The turbine and compressor wheels are each contained within their own folded conical housing, the cartridge group, on opposite sides. XFOSX1069_01en ‘The turbine and compressor wheel sizes dictate the amount of air or exhaust that can be flowed through theENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Turbocharger 16 Axial thrust bearing 17 Floating disc 48 Auxiliary bearing 48 Bearing bush 20 Bearing casing 21 Hood 22 Sealing cover 23. Gasket 24 Partition wall 25 Speed sensor ‘The turbine and compressor wheels are each contained within their own folded conical housing, the Cartridge group, on opposite sides. ‘The turbine and compressor wheel sizes diciaie the amount of air or exhaust that can be flowed through the sysiem and the relative efficiency at which they operate. This normally means that the lamer the turbine wheel and compressor wheel the larger the fiow capacity. XFOSX1069_O1en The cartridge design of the turbocharger allows all normal service work to be done from the compressor ‘side of the turbocharger without removing the whole unit from the engine. aqENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Turbocharger Operation System connections + A Exhaust gas inlet + B Exhaust outlet * C Ambient air inlet * D Charge air outlet The turbocharger turbine is driven by exhaust gases coming from cylinders through opened exhaust valves. The compressor is driven by the turbine. The eneray of the exhaust gases is used. to compress the intake air of ambient pressure to higher level. The charged air enlarges the air quantity fed into the combustion space and thus makes it possible to burn a bigger amount of fuel in the cylinder space. ‘The combustion air is taken outside of engine to the compressor side of the turbocharger. Passing through the compressor side, the air pressure and density increases as well as the temperature. The heated air is cooled down in the charge air cooler.ENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Turbocharger + B Exhaust outlet * C Ambient air inlet + D Charge air outlet The turbocharger turbine is driven by exhaust gases coming from cylinders through opened exhaust valves. The compressor is driven by the turbine. The energy of the exhaust gases is used to compress the intake air of ambient pressure to higher level. The charged air enlarges the air quantity fed into the combustion space and thus makes it possible to bum a bigger amount of fuel in the cylinder space The combustion air is taken outside of engine to the compressor side of the turbocharger. Passing through the compressor side. the air pressure and density increases as well as the temperature. The XFOGR1087_Oten heated air is cooled down in the charge air cocler. The turbocharger can either have its own built on cil system or it can be connected to the engine lubricating oil system. Oil inlet and outlet normally located at bottom.ENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Charge air system System components e 01 Bellows 02 Arr inlet box 03 Charge air cooler 04 Charge air cooler housing Charge air receiver 06 Charge air supply pipe (multiduct) 07 Turbocharger adapter plate eeeee = mH 01 System connections « A Ambient air e B Charge air to cooler « € Charge air to receiver « OD Condensate water after charge air cooler 02 The engine is equipped with air cooler(s) to cool down the compressed and thus heated air after turbochargers. The outlets are connected to the charge air receiver (05) through air inlet box(s) (02) te ‘ 5 a a and charge air cooler housing (04). 03 The charge air cooler(s) is of ngid frame type and mounted to charge air cooler housing.ENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Charge air cooler Components © 01 Charge air cooler Connections e =A Airflow « B HT water inlet « C HT water outlet « D LT water inlet e« E LT water outlet The purpose of the charge air cooler is to reduce the temperature of charge air before it enters the cylinders. Air temperatures can reach levels which are above 200 °C depending on the charge air pressure. The charge air temperature is kept at the correct level by high temperature and low temperature cooling water flows. The cooling water is circulated through the tubes while the charge air passes between the fins outside the tubes. By lowering the temperature of the charge air it becomes more dense and therefore contains more oxygen per unit volume. This allows for more fuel and aN oxygen to react in the combustion chamber generating ee more combustion pressure and thus power to be produced.ENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Water cleaning system Cleaning water dosing unit Components 01 Cleaning water pipe 02 Ball valve for water dosing 03 Cleaning water pipe 04 Flow meter 05 Cleaning water pipe 06 Reduction piece 07 Cleaning water hose 08 Bracket Connections e A Cleaning water inlet * B Cleaning water to turbine and compressor The cleaning water dosing unit is located outside of the engine. It consists of ball valve for water dosing, flow meter and connection piping. Cleaning water for turbine and compressor is led through cleaning water ~ XFOEX1004_Oten hoseENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Water cleaning system Compressor side Components « 01 Ball valve, A- bank * 02 Ball valve, B- bank « 05 Pipeline, A-bank e 04 Pipeline, B-bank Connections « € Cleaning water inlet ‘The compressor cleaning system consists of pipeline {s) (03 and 04) and ball valve(s) (01 and 02) for ‘compressor washing. Depesits in the compressor stage (compressor wheel and diffuser) and the deposit of dirt in the flow ducts are cleaned up with an amount of clean water which is injected with air pressure. The cleaning water and air are provided from extemal water and air systems. Compressor washing is normally performed with the highest engine load. i.e. at high compressor speed.ENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Water cleaning system Turbine side Connections e C Cleaning water inlet The exhaust gas inlet of the turbocharger is equipped with a water cleaning system. Cleaning water to turbine side is delivered through ball valve (s) and pipeline(s) (03 and 04). Dirty turbines cause higher temperatures of the exhaust gas and higher stress to the bearings due to imbalance. Deposits on the turbine side can be reduced by periodic washing during operation. The turbine washing is performed with reduced engine load Click the area in between C-C to see more detailsENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Water cleaning system Turbine side Connections « € Cleaning water inlet lg “ The exhaust gas inlet of the turbocharger is equipped with a water cleaning system. Cleaning water to turbine side is delivered through ball valve (s) and pipeline(s) (03 and 04). If Dirty turbines cause higher temperatures of the exhaust gas and higher stress to the bearings due to imbalance. Deposits on the turbine side can be reduced by periodic washing dunng operation. The 02 turbine washing is performed with reduced engine = load.ENGINE W32 BASIC - Built-On Systems Ce Exhaust Gas and Air Intake System WARTSILA Intake & Exhaust manifolds 06 04 05 o4 03 02 OF Components 01 Multiduct 02 Exhaust pipe 03 Bellows Sealing ring 05 Exhaust pipe 06 Bellows OF End flange eee eee 2 & i In Spex (single pipe exhaust) system the exhaust 1 manifold is divided into sections to facilitate easy i maintenance, Each section consists of branched exhaust pipe (02) connected to the cylinder head through a multiduet (01). 01," xFO6K1000_o1en The exhaust pipe manifolds are provided with flexible expansion bellows (03 and 06) in order to eliminate the forces caused by thermal deformations. The bellows are fitted to the pipes with screws and sealed with sealing rings.ENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Intake & Exhaust manifolds Components * 01 Exhaust pipe Q2 Insulation box . « 03 Multiduct « 04 Charge air receiver * 0&8 Cylinder head © 06 = Cylinder liner * OF Cooling water Connections « A Charge air flow to cylinder * 6B Exhaust gas flow from cylinder Charge air is delivered from charge air receiver (05) to cylinder head through multiduct (03). The cylinder head in tum connects to exhaust manifold with multiduct and exhaust pipe (01). XFOBK1040_Olen The exhaust manifold is covered with insulation box (02). The exhaust manifold and insulations are supported with multiducts.ENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Waste gate system System components e O01 Turbocharger, B-bank « 02 Exhaust pipe » 03 Waste gate valve * 04 Exhaust pipe after waste gate valve O14 eS System connections « A Exhaust gas inlet « B Exhaust gas from turbine inlet « © Exhaust outlet The waste gate system consists of the waste gate valve and an exhaust pipe system The waste gate valve is mounted near the turbocharger above the charge air cooler housing. The waste gate valve is working as a requlator and adjusts the air-fuel ratio to the correct value by opening to limit the exhaust gas flow to the XFOBNTD61_Ofen turbocharger turbine. It reduces the charge air pressure and firing pressure to suitable level in whole scale of the power output range. The waste gate system is contralled by engine automation system.ENGINE W32 BASIC - Built-On Systems ce Exhaust Gas and Air Intake System WARTSILA Waste gate system Waste gate connections Waste gate valve is connected to exhaust system with exhaust pipes and also supported with brackets. The waste gate connections from the turbocharger are provided with flexible expansion bellows in order to eliminate the forces caused by thermal deformations. oF Components * 01 Bellows * 02 Exhaust pipe « 03 Waste gate valve 04 « 04 Exhaust pipe after waste gate valve « 5 End flange « 06 Bracket « Of Bracket Connections * 6 Exhaust gas from turbine inlet 02 RFOGK1062_O1en « D Exhaust to turbine outletENGINE W32 BASIC - Built-On Systems Cc Exhaust Gas and Air Intake System WARTSILA Waste gate system Waste gate valve The waste gate valve is situated in a pipeline between exhaust inlet to turbocharger and exhaust outlet to stack. The valve is controlled electronically and operated pneumatically. The waste gate control system takes compressed air from the instrument air system. ‘Components « Of Butterfly valve * 2 Actuator (pneumatic power cylinder) * 03 Positioner 031 Pilot valve in positioner 032 Lever 033 Cam 034 Adjusting screw 035 Adjusting screw ‘Connections « A Control air from external system * B Connections to and from actuator « € Control air from W/P converter Click the area in between AAENGINE W32 BASIC - Built-On Systems Exhaust Gas and Air Intake System WARTSILA Waste gate system Waste gate valve The waste gate valve is situated in a pipeline between exhaust inlet to turbocharger and exhaust outlet to stack. The valve is controlled electronically and operated pneumatically. The waste gate control system takes compressed air from the instrument air system. Components. « 071 Butterfly valve » 02 Actuator (pneumatic power cylinder) * 03 Positioner 031 Pilot valve in positioner 032 Lever 033 Cam 034 Adjusting screw 035 Adjusting screw se eee Connections * A Control air from external system « B Connections to and from actuator « © Control air from I/P converter