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Generation X EnginesConcept, testing and first service experienceMarc Spahni, Beat Schumacher
- The X concept- Latest updates- Service experience
Generation X EnginesAgenda
Generation X EnginesX Concept
Generation X EnginesThe X Concept
X-tra environmentally-friendly by…
Optimised fuel efficiency- Energy Efficiency Design Index
(EEDI) to quantify the total efficiencyof a vessel
Emission control- Dual-Fuel (DF)- Selective Catalytic Reduction (SCR)- Exhaust Gas Recirculation (EGR)
Generation X EnginesThe X Concept
X-tra efficiency by…
Advanced flexible fuel injection system
Low engine speed for increasedengine & propeller efficiency- Bigger stroke-to-bore ratio
Focus on de-rated engines- Extension of rating fields- Optimisation of tunings
Tunings adapted to vessel operation- Four tuning options
- Standard Tuning- Delta Tuning- Delta Bypass Tuning- Low-load Tuning
84rpm4750 kW
76 rpm4750 kW
58 rpm3625 kW
58 rpm2765 kW
76 rpm3620 kW
84 rpm3620 kW
50%
60%
70%
80%
90%
100%
60% 70% 80% 90% 100%
R1+R1
R2+R3
R4
R2
W-X82-B
65 rpm
RT-flex96C W-X92
Engine power [%]
X-tra compact and manufacturing friendly by…
Minimised dimensions and weights- Long strokes needed to achieve efficiency- Concept with 2 cm bigger bore and
reduced stroke- Applied on X52/62/72/82- Weight advantage ~15%
- X35/40 “me too”- X92 optimized for BSFC and engine speed
- Dual cylinder distance
Optimized manufacturing cost- Close cooperation with engine builders- Manufacturing Engineering team- Commonality wherever possible
Generation X EnginesThe X Concept
Generation X EnginesThe X Concept
X-tra reliability by…
Application of proven conceptswherever possible- Many concepts were already applied
on RT-flex50 or RT-flex82T
Use of state-of-the-art simulation toolsFEM (stress, temperatures), CFD (flow),
vibrations, hydraulic simulation,bearing calculation
Intensive testing of new equipment(e.g. fuel injection valves)- Rig testing- Field testing
Generation X EnginesThe X Concept
Technical implementationof the X conceptAs far as possible the same technicalconcepts were selected for all X engines
Certain adaptations were necessary- Engine power, speed & size
- 4’350 – 73’560 kW @ R1- 167 – 76 rpm @ R1- 74 – 2’140 tons
- Engine and vessel segment- E.g. turbocharger location
- Availability of technical solutions- E.g. fuel injection system
© WinGD, 25 August 2015, M. Spahni & B. Schumacher9
Generation X EnginesThe X Concept
X35/40 X52 X62/72 X82 X92
Generation X EnginesLatest Updates
Extended layout field- R3 & R4 speed reduced to 58 rpm
- Based on market requirementsto further reduce absolute fuelconsumption
- Wider layout field allowsoptimum selection of the wholepropulsion system
Generation X EnginesLatest Updates – X82 Version B
84rpm4750 kW
76 rpm4750 kW
58 rpm3625 kW
58 rpm2765 kW
76 rpm3620 kW
84 rpm3620 kW
50%
60%
70%
80%
90%
100%
60% 70% 80% 90% 100%
R1+R1
R2+R3
R4
R2
W-X82-B
65 rpm
Generation X EnginesLatest Updates – X82 Version B
84rpm4750 kW
76 rpm4750 kW
58 rpm3625 kW
58 rpm2765 kW
76 rpm3620 kW
84 rpm3620 kW
50%
60%
70%
80%
90%
100%
60% 70% 80% 90% 100%
R1+R1
R2+R3
R4
R2
W-X82-B
65 rpm
Withoutpumps
Modifications for extended layout field- Crosshead booster pumps only for low CMCR speeds below 65 rpm
Additional improvements- Bypass liner cooling system
- Increased liner surfacetemperatures to prevent corrosiveattack on liner and piston rings
- Two yard connections- „Warm water“ for liner- „Cold water“ for cylinder cover
and exhaust valve- Introduced on X62/72
Generation X EnginesLatest Updates – X82 Version B
Extended layout field of X35-B- X35-B
- R3 & R4 speed reducedto 118 rpm
- X40-B- R3 & R4 speed reduced
to 104 rpm
General remarks- Extension is based on market
requirements- Wider layout field allows
optimum selection ofthe entire propulsion system
Generation X EnginesLatest Updates – X35/40 Version B
Improvements from X62/72- Flex system
- Implementation of FAST fuel injectornozzles as standard(FAST = Fuel Actuated Sacless Technology)- Better BSFC- Cleaner combustion
Generation X EnginesLatest Updates – X35/40 Version B
FAST
Improvements from X62/72- Harmonization of UNIC control
system with X62/72- Hardware & software
- ICC available as option(Intelligent Combustion Control)
Generation X EnginesLatest Updates – X35/40 Version B
Example 6X72
Improvements based on X35 experience- Redesign of the cylinder jacket, liners and covers
- Measure against issues with gas sealing andwater leakages
- Possibility to increase combustion pressures forfurther reduced BSFC
Generation X EnginesLatest Updates – X35/40 Version B
- Developed as DF-ready- First X52 will run in Q3/2016
Generation X EnginesLatest Updates – X52
X52 X52DF
Bore [mm] 520 520
Stroke [mm] 2315 2315
Cylinder number 4 – 8 5 – 8
Cylinder output [kW] @ R1 1810 1490
Engine speed [1/min] @ R1 / R3 105 / 79 105 / 82
BMEP [bar] @ R1 21.0 17.3
Design concept- X62 scaled down to 520 mm bore,
with some adaptations- Stroke-to-bore ratio- 4,29à 4,45
- Two instead of three fuelinjection valves
- Slim-type cylinder liner- Application of
RT-flex50 supply unit
Generation X EnginesLatest Updates – X52
Supply unit RT-flex50
Generation X EnginesService Experience
Target- Optimisation- Verification
Areas- Performance Optimisation- Control system Optimisation- Temperature measurements- Stress & strain measurements- Vibration measurements- Component inspection
Generation X EnginesPrototype Testing
Examples 6X72
Engines on Order and in Service – June 2015- More than 3 Mio. running hours achieved with very good service experience- More than 35 % market share in 82 bore segment
Generation X EnginesService Experience X82
Summary # Engines onorder
# Engines aftershop test
# Engines inservice
Max. runninghours
Accumulatedrunning hours
RTA82C 18 18 ~41‘000 ~598‘700
RT-flex82C 37 1 36 ~35‘100 ~879‘300
RT-flex82T 92 1 91 ~37‘600 ~1‘403‘500
RTA82T 5 5 ~27‘400 ~106‘900
X82 67 9 15 ~6‘500 ~54‘800
Total 219 11 165 – ~3‘043‘200
8RTA82CMain bearing #5 – 5’491 h- Shell in good condition- Rear side without fretting marks
8RTA82CBottom end bearing – 7’975 h- Bearing shell in good condition
10RT-flex82CCrosshead bearing – 29’008 h- 8 units inspected- All bearing shells in good condition
Generation X EnginesService Experience X82
Injection Control Unit (ICU)- The ICU had been further developed
to reach longer lifetime- Since 2012 service experience has been
very good- Less sensitivity to HFO impurities- Maintenance on-board by the crew
is possibleà lower OPEX
- Similar concept also used forRT-flex50 and X92
Generation X EnginesService Experience X82
1. Valve seat,2. Valve sleeve,3. Valve spindle
ICV(Inject. Control Valve)
FAST fuel injectors- RT-flex82T- Inspection at 12’600 h
- Nozzle found in goodworking condition
- Nozzle tip inside and outsidein good condition
- No cavitation on spring andinside spring chamber
- Needle and needle seatwithout wear
Generation X EnginesService Experience X82
W9X82 – unit #6 – 5’101 h
Generation X EnginesService Experience X82 – piston running
All piston rings Chromium Ceramic type
Top piston ring B piston ring C piston ring
Engine configurations delivered- W5X35, W6X35, W7X35, W6X40- FPP and CPP- With / without PTO shaft generators
Total accumulated running hourson all engines: > 125’000 hrs(June 2015)-3 engines > 12’000 hrs-5 engines > 10’000 hrs
Generation X EnginesService Experience X35/40
- Very good fuel consumption at all loads
- Positive feedback about L’Orange Injectorslifetime and performance- Initial estimate of 8000 hrs TBO
(time between overhaul) has beenconfirmed
- Issues with gas sealing betweencylinder liners and covers at higher loads -solutions ready
Generation X EnginesService Experience X35/40
X72- 40 engines on order- Of which 10 engines in service (6X72)
Generation X EnginesService Experience X62/72
X62- 20 engines on order- Of which 4 engines in service (6X62)
6X72 6X62
- Most of the sea-trials and maiden voyagesattended by Wärtsilä and/or WinGDservice engineers
- General feedback- Good piston running behaviour- Reliable cylinder lubrication- Positive experience with fuel injection
and servo system- Spotless condition of gear wheels- Superb engine performance
Generation X EnginesService Experience X62/72
Issues solved or under implementation- Starting and crash manoeuvres
- Parameters optimized(cannot be done on test bed)
Fuel injectors sticking afterchangeover from HFOà MDO- Clearance at pilot valve increased- Cooling/lubrication of fuel injectors
restricted by orifice
Generation X EnginesService Experience X62/72
Four 8X92 engines tested at HHI-EMD- Extensive prototype testing on first
engine-All stress, temperature and vibrationvalues within permissible limits-BSFC figures well within published values-Good condition of inspected parts
- TAT successfully passed on fourthengine at HHI, 27 Aug. 2015
Generation X EnginesService Experience X92
The X concept-Environmentally-friendly-Efficient-Compact & manufacturing-friendly-Reliable
Latest updates-Versions B of X82 and X35/X40-New X52
Generally good service experience
Generation X EnginesSummary